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Honda GoldWing GL1000 1975, Shop Manual

The Honda GoldWing GL1000 1975 Shop Manual is a comprehensive user guide designed for owners of this iconic motorcycle. Packed with detailed instructions, diagrams, and specifications, this manual is a must-have for any GoldWing enthusiast. Download your free copy at manualshive.com and unlock the knowledge to maintain and repair your bike with confidence.

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Summary of Contents for GoldWing GL1000 1975

Page 1: ... SPBCff IC8 IOI3S O OP Vei UPS Vvof kl Ag p 8C ICBS tOAIS ITI8tPViels BAd SBI VfCB pf OCPGGt BS fo h8t SVSIBA3 The fft 8 pegB Qf BBCA SBClfof t hes 8 Teble G f COA Bt f S th f ifVBS f 38ge Bfel Bt 3CBS VVI hlf I the SBCt l 3I1 3 TV ME UP 7 LU 8 R ICATIOM 8 tl STEM 6 EMGIIME TOP EMD REPAIR 8 COOLIMG SYSTEM SPECIAL NOTES ROT E pt OVfdBS Spe CIBI IAfof A38 fQA fo i AO B BffIC BA 8Ad CQAVBAIBI3 Se t V...

Page 2: ...f3 L l GGQ SfdtjP IVi AN f IA I 1 9 t 6 A fTf t l tt tttf f f Qtfffct Miff Dt t G l tf t P f lt fat f f tf U S A 7 t 8 ...

Page 3: ... sfcje iei tjse c Bnkcese j jfe cef jBle I 8 Qf fdel ff fficB fiQIB f 1UITicff f js jQCBI ecj QQ kj18 IQp Qf l jj 8 8 8 I b f f I 81 0f 8 0 tI f I 41 Qg tjBFIg8 j he fjf Bj drive Sef iej f ffccbef fs Qcejed Qv tjse jerk side ut i jie ff BI Qf IV8 CBS8 ffeef tj fe j 1 A IQI 1 jBQge VIRAL DBIVE SEBIAL MOVBEB o Pf i 900 8 i i 8 M A N L A L 2 1978 Ao o jodo twonea Mom e C lo s ...

Page 4: ...ff L Br gtt 0 5 t I f r Ea I g 0 rf I r I P fa fvi BtP r f P rifts i rider f r B Ifead Matei I I H r fee f Pa if f fef t if f 5t f j taf N if it P s Iseals 0 f ir gs Ia af ff Igs Btc l RC N I A l I1 I3U 1 SEAL F i iCt i Of yf p I l B ta i I I f f t3Br Pr0dU rt I i if L I A I Ief B h f st ifserII t a S Sl fC af i0ii V af i i acrl f p f 91251 300 003 Special f l frfhef s f 00f f ii ierchaf geahle l ...

Page 5: ...turP Cef1 i grede Co Ftfhl Brfl 1Pft Cep ecit j I ter if i tpi j i i Lfuer iicl I Geilftn isel Vciiuftfe C u f f f c c e I itfr11P iPf f ccf Ci bfc irfc 1esicu fn i Aefglit 0 2642 Gello n gel t 0568 Quert qt 0 9463 Liter I 3 785 Liter I Feet ft Inches in Mieter m Mi lliifneter mm Mile mi Kilometer km t 4 22 Pounds Sq inch psi 0 0703 Kilog rem Sq centimeter kg cm2 I oot pounds ft lb Inch pounds fn ...

Page 6: ...ith the tools listed in this section New tuals required tu maintain thfs fT10torcycfe Bre I A I30ld face type BAd tl38se special tools Bf P I equifed fot many opet atfons If ctiistornef cumplaints are described Gn the wurk order and they Bre Unfa Ailiar refer tu the tn3ubleshuuting sections 0 f t i ils manUBI Always replace gask8ts 0 f Ings Bncl cottef pins with new ones When assembling make sure ...

Page 7: ...AINTI TV 6 5 x I 5 mm oil ot ifice 1 per side 1 per side 21 9 x 2 3 4 12 5 x 2 2 1 13 5 x 1 4 1 15 5 x 1 4 21 9 x 2 3 2 37 2 x 2 3 1 46x2 1 56 x 2 4 1 15 x 2 5 1 89 x 4 5 1 17 0 x 2 5 1 29 x 2 2 1 33 5 x 3 1 30 8 x 3 2 1 5 2 x 4 1 42 5 x 2 1 23x2 1 9 5 x 1 7 1 18x 3 1 27 x 2 7 26 x 2 2 1 17 0 x 2 5 1 Bx 1 9 l 40 x 2 6 4 15 x 2 5 28 x 2 3 2 45 x 2 4 2 63x 3 0 1 30 8 x 3 2 1 20 8 x 2 1 96 5 x 2 1 F ...

Page 8: ... m m OIL SEALS G D I I D w I Right Hand Cylinder Head 27 x 43 x 9 Left Hand Cylinder Head 7 achorneter D f ive Gill Pump Soav engePU f Ap Clutch Cover Pear Case Left Case Crankshaft Front Fol k F inal Drive Assembl y I DUST SEALS LOCATION F f ont Wheel 8 ear 8 he e I Svvlng Af A l I G l 1 0 D O S H G P M A N t Al c 1976 American ffnrr fn M otnr Cn lnrn N 7 P rtnted in Vl s fn 7 7 8 ...

Page 9: ...P t Sx9mm Open EI1d Wrench Screw Driver Stubby Screw Driver Wr encf1 100min Wood Handle 1 0X1 2A1tnl Op8tl EI ld Wrench Screw Driver WI PACh 9tnl ri S ockp1 W tel tel t f AIAAI Socket Drench 10x14ntfn Open EAd I I 150mm Wood Heridfe Screw Dr ver Ro 2 Phil ips Head 1719 O E d P iel 8 Wrench I lx13mm Open End IISOI External Snap BiAQ Wtench Pliers Wrench 19x22mm Open Ettd ISO fntenial Snap Bing Wren...

Page 10: ...RCf fASF Timittg Light LQCAI PURCHASE I CQAtt 1uttpi Tc ate LQ AI PURCHASE 3 j 9 8 52 X Cyfinder Leak Teeter 40047 j ft I976 X 023 X X X X X Draft t Co 1 to net TcetP Cooft 1g St stem r8attery Hydro Pter Wheel Afignment Fixture Geeol tAB CQAttttnel t f C LOCA I P UB C I I AS E LOCAL PURCf fASE Pfeatic Two G a l lon CQ 1talll1BI I Anti FreezeI 1 Funnel Auto Trans Type LQCAL PUBCI fASE Electric Hot ...

Page 11: ... Conlpressor l HMM SHOP TOOLS I 40046 ff 1975A 023 XXXXX Erigirle Removal Stand 64431 J IVf9259 999 6443 I Fngine Stand IVlobile Base I I OCAL PUBCHASF LOCAL PURCHASF LOCAf PLIBCHASE Hole Giauge Spring Pressure Tester Spring Prill Scale grams ounces f 1 884 1 7 7343 0f330000 Crr fir fei GBUge Set 35 80riirn frlagne tie Stand L 25 40 0 7345 00 0000 4129 I 07140 999 l4 V Block i inch 2 pcs I LOCAI P...

Page 12: ...25 0 947 3 71 0200 Df iver Qil Seal 67mm QD For pfA tot gee l sf aft ol sPBI fsfae 32X67XBITI TI 07965 371 0 t 00 41332 Driver Rtnq Gertr Bearint and Qil Seal Con ail ed in Set 0 965 3710000 I BIBB Guicfe Refnover and fr stellar Tool AI 64768 07946 3 f0600 Bearinq Driver and IOWBI beat tAg 07946 3710500 Race Removal Tool Uppet at lft I owet steel fAg I BcPB 64 766 I ower Race did d L F tt 64767 07...

Page 13: ...0 respectivefy Remover Bear Fork Pivot Bashing Use witft fiaAdfe alld weight 41311 07936 3710100 and 4 f 315 07930 3 710500 41312 07936 3710200 i espective v 413 I 9 07945 371040I3 Remover 8earinq Fork pivot needle bearing remover 07948 3710100 Remover A Oil Seal 48mrn OD For fiorlt fork seal slee 37x48x11mrnf I 3 26 4 l327 07948 3 71 MQQ Remover B Oil Seal Fof pinioli gear shaft seal Use vvith ha...

Page 14: ...r Tf n1fng TDDIs 63068 07999 37 I 0000 Ttmtl g tnspectiott Pfug VjIF8nch8s andI Spann8Fs I Wrench Fli Ial Ret tinct Wt ei left f6mm socket far assetnbling anrj d isassemb l ing cl ut ch Wrench Lack 5I3mm Fat tttel ttntt cftsassel nttltng 61076 07920 6340001 t OCAL PURCHASE Holfovv Wrench Set 061 55 0 7902 001 0000 36f33m Pill Spa Il fet 54 765 079 15 3 7 I 0 I 00 Steering Stem Sncf et 37828 07908 ...

Page 15: ...13te LOCAL PURCHIASE 10xL5mm 25mm ODI 1 QCA L PIER CHASE 12x f 2mrrf 25rnm QD I Dte LOCAL PURCHASE 12x1 5mm 25mm LID Die 12xl i5rnm 25rnn QIQI Die I QCAL PURCHASE ff x L 5mn0 38mm 0 D Die f QCAL PURCHASE 14X2 0IYtrrt 38ITtt ff QD LOCAL PURCHASE Die 568 j 00t 0t I 0 0 00 00000 HPtt0PI f Der 10fnn I Spat k Ping Terminal Kit Valve Seat Gri frier 5243 0 i 692 0010000 I 0 GO I Ir P f 3 A I I I A f 9 ra...

Page 16: ... Camshaft Bearings G AL PUB HASE Molybdenum Disulfide Cam Followers Fuel Pump LOCAL PUfBCHASE Molybdenum Disul ide Cylindiei Head Bolts LOCAI PUP CHASE Sif icon Sprrry Oil Seals I OCAf PUBCHASE Muftipurpose grease NLG I 2 LOCA PUBCHASE Multipurpuse Greatse Nf G 2M i GCAL PUBCHASE A ttomattc Traffsmtsstot1 Ffuid IF I orft Fot k LOCAL PLIBCHASE Ethylene Glycof Antifreeze 394 9 M I894X 278 i 00IL Hor...

Page 17: ...ng tln1es and dfistances that can be relet of exceeded by the Honda 5 L 1000 I Aotorcycle The Iow speed pass assumes an initial speed of 20 MPH and a limiting speed cf 35 MPH The high speed pass assUftnes an tnftlal speed of 50 MtPH af1d a IIA1 lt speecl of 80 MPH ISO IICE The infnrmation presented represents resuits obtained by skilled drivers under controlled road and vehfcle coAdltfoAs and th6 ...

Page 18: ...I d t I re p ress I es I i i f o 90 7 ki ng i 200 lb load I Pont 2 0 k g cnl2 i28 psf 2 28 kg c ni2 32 psi l roni 2 0 k j crn2 28 psf H eer 2 8Ikg crn2 l40 psf f It O V 8 IliCI 6l 08pecIty IOdd I ron I Beer S per Speed 21 F 2 l8 idgestone F6 lounlop Sffpef SpPed 23 R 2 8 idgestone 87 Merk I iounlop 8 op I I ENGINE I Aeter Cooled 4 Sboke C y Ifndef A fenge Tle lt Bcif P Bnd Stf ok8 l3 sp Idee l ent...

Page 19: ...IBUst the tPchBician s abflfty to fulcf ly isoiaitP apv QrobiPAqs hat A ay occur 3r peCilIC SyStefA t QubieshQQtirhg Su f gestiOrfs reier tQ tl ae appf opf fate SeCtion Q thfS r r naf luai Ea shtroubieshoQti Bg I ist shou id be Used as 8 guide wheA trying to isQiate a prob afar ii fs i fid Q It to fQllQw a basic rule Qt truubieshootirfg Never overiQQk the bv IO l S G L I I06 r lOP 4 tr 0 t I ra ta...

Page 20: ...G I 1 0 0 0 H 0 P M A I N I0A I r t9 CIt American Hartria Maror Ca Inc P t tttrt CI Ill 0 S A t H ...

Page 21: ... e3 9 CONTACT BREAKER PC lfs T S i I I I I I I I I I I Page 3 13 I J 6 1 DRIVE SHAFT IOiNT L L L Pa ge 122 0 f jj 1 BRAKJ SYSTEM I I I I Sect tO I I l4 BRAKE PAD WEAR I I I I I I Pa e 14 9 14 17 BR WKE I IGHT S ftjf fCH I I I I I I Pag e 17 3 HEADLIGHT AIM f I I I I Pag e17 19 CLLITCH FBFE PLAY I I I i I I I I Pau e10 6 SUSPFni SIGN I I I I I I Pag e13 6 STEERING HEAD BEARING l I I I Pa e 13 16 I ...

Page 22: ...5 Hex f o I 8 x l fex hvft 10 x 28 Pf rtqe buit 10 x 80 l f inqe holt 10 x 120 Fiarlge bolt 10 x 166 Flange f7olt 8 x 175 Fl inqebolt 8 x 70 Fl lnge bolt 6 x 1 12 Flaiige bolt 6 x I IO Fl 1 gP t olt 6 x 35 Oif drain bolt 150 200 l1 I4 180 25ig 13 I 8 530 570 r5 0 570 2 7 5 30 4 24 27 I 8 21 1 8 21 7 f f 7 10 7 0 25 29 AI Pri1ato ffywhePI else lbly Cfu toft center Alta natu be lring holder F4nge bo...

Page 23: ...0 x 40 Hex Alit 1 0 1 IAs Hex baft 6 x 40 Stop switch oil baft H e x A o t 8 I A IA Brake pipe Hex bait 10 x 50 Aheuf axle flex balt 8 x 1 t 3 U 6 6 A o t 8 IA ITI Wheel axle Aut Rear wheel axfe Reur fork pivot lack Lock nut 23 mm Hex bolt 12 x 60 Al lt Bee bra k eI el I per Bear shock ebsal bel s Be le muster cylinder Be fr brake hoses Spokes Fr oni brake It laster cyfinde holder BPaf fufuke fIAP...

Page 24: ...fr BI Drive IHIUb Oil CAPACfTV API GL 5 Hypoid Gear Oil Above 5 C I41 F SAE 90 Beiow 5 C I41 F SAE 80 FIPont FOrk Oii Betiil 1 7 5 cc D ry 200 c c Automatic Tt anstYlission Ffutd 8f Bke FIIU ill TyPE Camshaft Followet s f ucl Pump Acftuator Cvlinder Head Bolts Carnsha t Bearings Oil Seats and 0 rinqs Molybdenum Disui fide fylofybdenutn Disul fide Iyfolybdenuftt Dtsuft de Lubriplate Assembly Grease...

Page 25: ... 3L 1000 5I I QP VAPI U r t I i 97 ra l rnerirtur IIan rlrr V iatar Ca I ric P rinted rn U S A 7 7 8 ...

Page 26: ......

Page 27: ...C L I 0 a Ci 5 H Q P M A IN U A L 1976 Afnef Icon Hnndn Mntnf Cn Inc M 3 P vintnd in U S A 7 7 8 ...

Page 28: ... t 1 ustif1 Buts I 20 to 160 kg cfn 104 139 In lb Rear ll lb Df all l Bolt I00 to I40 kg cln 87 122 Ifl Ib BliP t 3 i I18 I dpi I BxpaAsloA of all PAglAB parts duf lf1g opef ation the BAglne IAust l38 cGIcl ofurff1 I AiGst tLffsic up checks an 1 adILIst rfents Cold means f GGAI 1ef11pef atufe Qf less I I 8 1 p 3ssfbIB schedule tLfine Up sPrvfcPs atter aff Overnight CQQI dovvn Une Up sPfvlces af 8 ...

Page 29: ...f CIOgged Giber fuel SySten i prGblemS 6 f riel ceja vefat cIogged Engiine cranks but vviilll not start coldl vveather ChGke i set tff 1g toG leafi 2 Ice lri fuel lines GarburetGrs fuel tank Gr fuel filter Battery weak d1ie to IGw tefTfperature 4 I ACOf f PCI BAgfAP Oil yyater primp lanif r niPcl vvfth lce I fncof rec t af ftf ff eezB ratfoI Engirfe cranks but vvfll not start engine hot Fuf l flQv...

Page 30: ... atffty spark Gluqs 2 Incorfect fgnf tfon tfn1fng 3 Lovv BAgf Aecon1Pressfon 4 Love ftfel pun1p pressure 5 rr Ilafopef Iv ad Usted throttle IIAkage 6 If1cofrPct valve tin1fng 8ackfires Kicl backs Explosions in Muffler i l i Igf fft IOI I IS too taf adVBACed prernatf3f e spark rf18y occuf A hen tl Ie BAgfAB fs cf af1ked 2 R P ta I fled f gn It I 0 A t If1fI I Ig EatP valve tf A11ng 4 I Baf1 fTfixtU...

Page 31: ...f 5 ff Gm tfie eff fflIBf cGvef i end cefnov6 4l ie CGVef KlOT E 4 f f Bf t novP tihie eff l iliPf BlPfAPA t end cl 86 A vv f t h cG f npff 8ss Bd 6 f8 t heck i he condftfGA ot fliP Bif i i 48 i 8 i 8 fTi 8f iL s83I0 6 A d f 6 i A st ci l l f lect f the 6 ff filtef clef Gent eftef 6 000 kilGAfelefs I3 750 fni fesl end feplece evict 12 000 k flomete s I7 500 fwfflesI MGie ffeqGBA se icP end feplece...

Page 32: ... coii ItBfii fP A10 I Iflng bo t R el Ove ti 8 storege col lteilf el if orn ti ie ITIGfol cycie p ii f STORAGE n 1 VV i COMTAIIMER Rei 10 jel l1P tlo rest le 0f f r o f n f hP c AtBf Acr Bf 1 i drBIA tife con tell fpr i sert ttiP I loiv re trf tGf BA i einst lii the cor teiner STORAGE STORAGE r Tl J BE C L AIMS i ONTnllXIER r 4 F f OVV R F S IrRI TOR he elnp I fin i 81 er y i QQQ k II merel S I 3 ...

Page 33: ...e 3 PPet Clea atfCes When the I 1 t fm f ngmai k Blfgns 3tter thP Ir take valvP orf 0 2 cylinder lett fl GAtl closes rr 2 pfston Is 3 I TDC top dead centerI Gf tile cGm pf ssiGA stf oke Ch8ck Bnd Bdlust tl fe foilovvfng valvP tappe I clearancPs I fi i i e I I I lght ri f i I i tet i i i ii i h iI r i I I I aII it 3 I i i I I i i I e I i 6 x I 3 I I s I 4 4 i if I 6 n i i 1 i t i 6 Valves whir l i ...

Page 34: ...TBPPPT BPIjUs 1 ling scf evv lock AUL Bfnd tU n the TBppe B I Ustfng sc evv to Bc IPvP kf fe cof I eel cleB Bnce Hol j tIIP teppeT B I US fng scf evV Bnd fetfgI ten fI P Iock nut Recheck vBIve f Bppet cleef BncP 4 R P IAS 8 I TII8 I fTllng fTfBf k CBp g8 n 8 I 81 0 I f f f11c p 8 I I I c V I I I 8I IPB l COVef S AID JUSTfMGSCREW LOCK MUT FEEI ER GAUGE RlGHT SIDE LOCK MUT 4 H C 26250 P M 07908 3230...

Page 35: ...pPBt this procedUre t of ecch cyi inde ifioAAB cofnpfessioii p essUle is 2 kg CITl2 i l 71 pSI COi Apl 8SsfOA piessU 8 Bt ove l4 kg CITI2 199 psi iff icetes f inet CBf bon deposits heve BccUITIU Bte f Iff the coPnbUstfof1 c IBwibev ot on the pfston Dfsessefn OfP BA decef bon fze i f the ccin ipfessfoA p ssIJI6 fs beiow lO kq cfn2 l42 psi or it there is 3 i i f kci cfog l i psl vei IBtfofi betwfeen...

Page 36: ...Bv c t B cI e cio I c h I ppPci f sUieko s Re T 3ve fc Ui feg ie OS f S V ti I SBA lit ps Speck IUg t I i t P i l l eek i lect o e jtfpt vvf I I 3CIPB Bfsce geclge B wf i e t pe cieBI Ace gBUgc will A ieesUce elect od e gep ictot Bci I I Bf I B ilH 0 jUgP Tl c A e t Piect odP gep fs 0 6 0 7 mA3 I0 024 0 028 lf A d Ust gi p i ICCp S SB V 3V CB ell f l g i eACifA f ti e Sl P eleCtf Oi 3 i I t s eii ...

Page 37: ... O A S i iiVP OD8A r j i 0 i P if At L L it 8 U Ti 0 jCBF BACP I j8BSU f8 81 1 AfBC1 j O 1 A1 0 8 j i j V F S8 1 IA B C 8BFB 8 Bi tg8 jrBFVV8 f 1 I 18 0 F BC Sf i i BC BS 1 j COi f PCt ij IBC Off L gBj i iS 0 3 0 4 1 if 1 t 2 0 016 i i I i Bil USS F 8 T S 1 8CPSS V I OSPA i f8 CC i AC b 8 l F F jIBt j IOCjL Arg Fr tr PF i IBf p F B j cof tr cj o t f s t 1 j Bc8s v rr 1 I 1 B r r 18 j CBj 1 Of IBC ...

Page 38: ...I Ae gAI IQA swffcI I f 1 60gfA6 s tJ vffch AU81 foe I UiA1teGI 0 A 0 8 ct I v B le fi I P c fI 6 I I f tvC fa PQ e g Q j t 7 t CONTACT POINT LEADS MUST 8E COI IRECTED COMTIMUlll Y ILIIGIHT D Q63 3 SERIES HOOK UP I I the cof t AU tp Ifghf Is coAAecIed IA BP7 8 Wftk OA8 Of Zhe COACBCt pOIAt SB tS the IfghI v II cGIAe Qin wheA the pof Ats opeA Pe fQ f A hte foIIQvvf fq steps 0 Aeke 8 S6tf j eS f OQk...

Page 39: ...ews Bnd CP i heck Point qrlP an I timing C 0 A A 8 c t t f I 8 c 0 i I I If 1 u I t y I f g f1t t0 tile if ght j 3 4 1ylfndef j i Qntact I oint set aAG uri f thP gP f1P f BtGf f Qlt cfpckwise u tif the F 2 I lnih g f 13f k Gn the ffywflBPf 3 llgns iiwltf I t f 8 fncfex cn if k of the tfmfng f f statf t fn1lfig IS COf f ect tf e COA In ulty Ifgf1t wl ff fndlcatP that Ih8 cQf1tac f pQints Gpei I wf ...

Page 40: ...I A 0 f 3 pi rt f Q flow t hp 3 IIustf lent prDce Iu I 6 descriI3ed fA Sfep 1 f age 3 15 3 I fl 3ITIOIM TIIVIIN 3 FOR 3 W4 I V LINL IE RS i Connect 3 strOlaoscopfc tifTflng light 10 il36 o3 Ql t 4 c3 Ifndef spark plug lead Oh Ck Idle fgf I IGA tff AIAg witf 3 llfp PrlglAB ref AAIAg 3 t 950 100 rpn Idle ignition t if Affrfg ls cGrf Pct lt thP F 2 f f I 311 tg i Asai k 01 the fl I Wheel aligns with ...

Page 41: ...t le cables Replace worn darrtBIgted Qr bfrtclfng cables Acljustrnent Veasfare thf ottle grfp free play QA thP I r UfP Bien P Gf IP gt fp flangei hP airIOunt Qt freP play fS 2 6 rt 1ni I I 8 1 4in If Bdjustf11ent is required loosen the Bdluster IQck Aut Bf 1 jtUf r f tl 18 Bd jusler Retighten the IQck Aut FREEPLAy EL It 8 1 14IAI EOCK M0 F FREE PLAN ADJUSTER FREE PLAy 2 6 mr I INCREASE IDLE SPEED ...

Page 42: ...f si Insteli vecUUA I hQ58 BdeptOt Si Bnd B ttBCh thP VBCUUIA fBUge Set 2 S t BI I h6 engll ie Blid BdjUst idle speP I to 950 100 I pfTI Check vBcUlint gBUge I PBdlngs Ail cViindef 5 shoUid I 6Bd ImftiilA 50 rnn Hg i2 fn Hg ot ecch Qthef it tihie diitef en 8 betvveen cyfindef BBd ff1gs fs g eBtef theni 90 AilTii tq i 2 in H f f BdlUstfnent is i 6 Uif e l Bs descf 1 ed lnf steps 4 7 I 0 I t Si ii t...

Page 43: ... 3S f13Bf17fSCO f33 it P f 1Ck f U f 3 1 O O SP CI If 3BCjjUS fA SCCPVVIOCk 1 I f if fj C I flkB jB j ct f 8ji ff1Cj hP CBI 3 3 I PT I r3A j tU f Tj P SCI P iiV O Si l I I Qrt 7P err f Pf16 I Irji f CV ICICIPI PBICS Pi jjUS ITfdl T IS CO II CT P 3 df1 Bjf C f IA jPI 5 Sj3OW 3 f i f i I Q X f A I d t P j j P SB A i P V B 1 U Ui I I cj 3 3 i r B 3 I t i jS P 8 I j 1 P f f f j 3 jO rr i i lt k I i BC...

Page 44: ...G L 1 006 SI Of MAN LIA 1 CI 19 76 l w l A B I iCHt I f Ol i68 M O f Ol C Q I l1 Printer rt LJ S s 1 8 ...

Page 45: ...abIP Supp01 f Is rer u re tQ support Lfr f f narfeuver ihe Pf gine TI P lower left fraf 38 fUI3P fs IBITIGvabIB tG Bssfst BAg AP rerr oval The carl Lfretor Bssefffb r ma y be detacI ed BA 3 left in tbe fI tain 8 I 3 speecf PAguae I BA Oval jtj 3 I E Pt wa y s c P anit 3P Off pick up screP A vvlaen he enfgfAP fs ren OvP f cf ss tu the scf BPI3 fs t trOU ltl tl if Iot ver i lg t t Ilail i sf 8 of t ...

Page 46: ...ENCE OAoA1 CBB IUf 5 8x 6 B i 2 8F A r r r err p r r Ut r 6 0 x 298 3 2 rr 66 B l 2 x 80 l L 7 10 x 6 0 B 8r L 4 2 x 274 8 Gx45 B6 L l 3 0 4 0 l g rr r r 22 29 ft 6 pq l 22 29 f jW 3 0 4 0 q wi 2 8 9 k eg m 22 20 ft4b l I j I pi r 40 re t lbr 40 43 f b ...

Page 47: ... BI Pic g Bf J f BCj BtOI Cj I O jf I A ti i COOj ff S 5 LBI f I BA I I aV i O l ff I if O B j P if IBBA 9 6 A i iCi I I P IB I I I 3 l O W j i 2 I I I 8 i Pi i ii B fi l I V PI O l j IC i j if iBjLI i Bf Cj lj IP Of j j Ij f V H Bi I IOUB j P Oi j il l Pi tO I i B If OI j f I Of I I iP CI ELIS f g R j ji CP tA f tlj L f Cj BIII fj lLf t Ii i C i I f j i i L ENGiiME oils ORAjlM jj 106 Torque 360 4...

Page 48: ...r L rSI j H IT Uf jlB fT UI If g l f f S j il jf1 I J fj0f ASSAI bj 0 Ql Aj j I I 0j V IT V f0 I I f I f H X j I S I fST I I j eS j ll rOoor ff o j rl d j r I Pffj I0 fr UIS ff I Srj S r r li j j r UI rfpqo oner j fr lf I o gp I I 000 ri M Aik LrP I r S Or irrrr ic ns I on u lslo or Co i nrr 5 r r nrrrc irr 0 r rX r ...

Page 49: ...I i i I J I b P i I P g q f VP CO I I I IPC O S 8 i I I I I I5OI OI 8 0 I PL Ii PS VVf S CIP I O f P IT O 3f CA BO I tt i I i P I f A f l it w i S I i ti i P I i IP t I OS f I I P I 8 tl 1 if I OS 8 COV I f j I lC I OVVB I OSe f P I I I VV tQP I I P CQV ef ...

Page 50: ...be dBrABged Wiring I I Bruess UAcu piiug i i l tl tP IP f t ts I8 cu ApB t 7 P At BAd ci I 5 t Aec t t I 8 8 3 g l 385tJLf vvlI lI g I PrA 5 Pull the herA 55 CIBB uf the t t 3 te I tP rr uv6 the sr B K p rig cBps frurA hie S PtB i k r 8 I 5 l38tBcht ti 8 ligh tens A cBI I 5 fl G T I te Cl pS GA tI1 3 CBl b t etul BSSP Ahlp MQ IE I f the cert returs Bre left A the frBA38 lt ls Aut r ecessBrp to lle...

Page 51: ...8Oft BQd I 81 QV8 fh8 tOOI JB y Bl Id lt 8 Bll CI8BQBI COV8f R8QIOV8 tl 8 Blf t flt8f SPIT 8Q i DBtBCh fhP Cf BflkCBS8 t f 8B f i8f I IOS8 RPI l V fl 8 bOI fS Q ding g l lB Bfj C 8BI I l CBSB kO TA8 3 lf CI I BI f PI R8f OV8 f fQ8 ChOk8 CBf 18 ff Of I h8 C f 8 I iP 8 I d d I S COBIf8C i l t18 C 8 b l 8 8 I d I OfQ 2 18 CBlf bflf 8tOI llf l k ...

Page 52: ...e throttle c iles tit the Iovvei ecllustei enu i i nove tlie ct i 3IP ends ftoin tihe hellcrenI Fuel Putnp Outlet Hose Reiittovel Hei the tliel cocl in the OF F posf tioif enicl Jptdch ihe two hoses Bt tlie fuel ...

Page 53: ......

Page 54: ...iove the Sffb fven e tube ItNGER I v rl U W l u UPPER ENGiNE HANGER BOLT iCrf q Q REAR MOUNT BOf TS f t q CAUTIO N Jeck height vnust be cGntinUGUsiy edIUsted dUving BAgfA8 vevnGvei end AsteiietfGA tG PveveAt devnege tG vnGUnting boit ti veeds wive hevneSSesend cebies Ben rru he upper engine henge balt IBV q VIGVBCketS fr R 5 f I fnr SUB F RAME TUBE NUTS G L I 00 0 S H 0 P M re hf I 3 AL I97 r i me...

Page 55: ...noUAts in tl fe follcvvlng sequeAce Rear fl amP tube Aut 2 F frint arid reer frame tube cap nuts 3 Right reBI engine mcunting belt LPft real englAP mouriting bolt 4 Fl Qnt Bngfne IAQUAtfng bolt Uppel AglnP brackPt rnQUntlAg belts 6 Upper engine hanger belt 7 Lovver shroud belts H Upper shroud bolts 1 QI que t fBfTI In the sBITiesec uence 3 0 tc 4 0 kg m 22 to 29 ft lb 2 2 5 to 2 9 kg m 18 tc 2t ft...

Page 56: ... g Ii4 Alt lrrfat sr connP ct or Breaker pulnt vvfres Ex faust systPA I blQI i Cf BllkCBS8 tf afn pl fg a fry B faf r I df BIA plLIg af 8 IAStalled an cl t or II fed i9 Ra tlator I esPf vP tBnk cap Bn t 16 Negative battery teftninal l8 BP su ie that tl le uil filter center Ur n Iinp A tlust tlTe clutch Bs descl l bed lrl BPctlon 10 Throttle Free Play Adjustment A just the tllruttle cable tG prcvid...

Page 57: ...Clamp 10 Clutch Cable 11 Taehometet Cable 12 Throttle Cable 13 Choke Cable 14 Speedometer Cable 1b Breather Tube A 1978 1979 16 Breathe Tube 8 1978 1979 17 Front Brake Wire 18 Switch Wires l Contact Breaker Lead 2 Starter Motor Cable 3 A C Generator Cable 4 Fuel Filler Overflow Tube lb Hatter Over F low Tube 0 Fan Motor l ead ...

Page 58: ...A L I 000 S H 0 Fr M wr I rI 0 A I c r I9ir6 Arnocican Handle Macac Ccr Inc P crnis a rn Ll S A 7 7 A ...

Page 59: ... clea ance 040 to 077 f Tm 0 0015 0 0030 in Jr orna OD 24 954 to 24 970 n m 0 982 0 983 in Sefvice limit 24 91 Asm 980 if i 8earing lD 25 00 to 25 021 mn 0 984 Q 985 in Service limit 25 05 mm 0 986 in 8f ai nq clearance 0 5 0 t o 0 8 7 AIIT 0 0019 0 0034 fnl 0 ITfshaft cei tei Rocker Arms and Shafts Rocker arrri lD 14 00 to 14 018 n nn 0 551 0 552 in Rocker shaft OD 13 966 to 13 984 mm 0 550 0 551...

Page 60: ...0 i i060 SHOP MPg U p i t 976 A a s r i r a n H o n d a M o o i o Inc Printed in U S A 7 78 ...

Page 61: ...in gef VIC I I ftl r fj 08 il li il i 0 0 31 if i I xbB fs t 0 05 U 0 0 ftffl I 0 0020 0 0028 in 8 f v ce tini I 0 10 f li n I Q rJ039 fn I j pf rr 38 00 l fitl 496 rfg 9 Xrufi St 32 00 i nil I 1 260 fn vr lv i sPB r viclth 4 i if I 0 05b i I V BI Ve I f B giB lre f Cylindet HBBd Vip pi Ip rle i USS I err r 8PI vice limit 0 0 Pirl l I0 0039 in CBrnsP B t I f fve BBIts Tre Btfli I il ft t r i r f P...

Page 62: ... I 55 tl al I 26 n fit Q taVOI pQ sf ie rde ife Of th ff 381 g aSS IT atel fa dive Qtf I tt I d CQI fspr Pssof i jC 40963 Valve G f ie Ref over nstaiiec HC 4872 V f V i I 8 P 8 IBP 1 j C 48 26 Vati ti i 8 iar c tI ff f Pf I rtp tt 8 t Acif f str ef t k ll elfc l HC 2 62 0 I if f nir g PQI rty ic i Pf i C 4 307 T I oe Vref i 0 38 U kg cn 0 300 In ibi Tetr i Ie Nf er ch 0 2 I k ji n 0 j 6 0 t i h I ...

Page 63: ... g SkP i ll l P ili c 2 k f C lA O Ii i3d i i A i i A i I g P I l A l l A g I PIl OOse i ill i or J e kPy lP C CA ii L1ln 3gP I I Clt LPAS OAi l U lP l AOA lo w A U AI IP T is P Pc lon 4 C OA PSS OA TOC I igI I O Bi 4 Kik Sg CA I 99 OS I r C SSiiiE i r OA hii k h U P Ol U SlO l hCB f 3 ln I iU 5 i 0 A iA ihoF 3 t Si l iI l l l ii f PS i iCO l PC l j 3P i I l l l inl I l ii Ck l lg lJ i P Oi Br Ok ...

Page 64: ... V et Gj rs 3 fr le C 3VBI fft It X A ef ks Vf t 4 BBCi j Acts Ail jilt ef I I t 3 i iii giG itl Cete fl 8 di l BC l II Gt if 3tet GA et jr I i iettP l 0 II3dlce 8 I jI t Gl tP t Ide IAel k Sftfe Cf eftkS 8 If j UIIB tr rtirtf I I i 8 l 8 0 I rt I k t i I j 3 I 8 t 3 If ess 3i Get 9 i c y i i de I t 3OSFM fe tS OMEf 8 S PUILILEY ARROW i i r jest i i i f ip Pj i vr iVI Tt JSI Aif F R 3t l R AN A F ...

Page 65: ...13gB tG BI1gIAB COI7IPOABAtS IAOVB PIStGAS 6IIIIBQfI OITI T D C bg I Ot6tlAg th6 CIBBkS48ft 90 fA B f t hBI i II BCtIGA fi OAI T D C BS IACllCBtBd bg tlll8 t8p8 OI Ch6lk ItIBI k OA th8 CI 6AkSI46ft pGIIBQ USB thB gBAPVBtOI I GtGI bOIt tG I Ot6tB th8 BAgIAB IA BfthBI dA BCtlOA DO AOt USB th8 l I 6 IkSh6ft pGIIBQ LfGIt ...

Page 66: ......

Page 67: ... i OVBACC f B hBffflSfAi Bf l J hAO Sl A 8BCk Gi f fB VBlVB B 4 fS BVSCf BVVS tO CIfBVB VBIVB SP IAg BSSOf B f O ff tIfB CB l lShB i t RB GVB t 3B SfX BAfSI O I t I fOIdB bGI Bnd ref AOVB I fB f fOI jB BSSBmb aV P B TfGVB kA B i OCkBf Bl f A ShBf S MOTE ...

Page 68: ...es fof scorff lg scratches of Bvfderfce of Irfs1fftfcIPAt luff feat oA Make sure the oil passages are clear CBAIfshaft 8earI Ag C leaf 8Ace 8olt the carrfshaft holder iAto place aAd tol slue the bolts VeasfarB arfd record the l D Qf Bach bear I Ag SBP Page 5 1 2 0 000 I IGP MIAN 0 6 i I 70 An idiczn Ba nd a MOtov Co I nt i tinted i n U S A 7 78 ...

Page 69: ...38Bf lflg IS tile Cieef BACe CENTER 8EARIIMG CLEARANCE 050 tn 087 nffn f 0019 0034 in Check O Bci1 eel A iG 3P I of vveBf vvfth B A1icfo Aeter Repiece the CBIA if iGbe vv 8BK exceeds the sef vice if i Af ts Reftfove the IAtek8 IABAffGld bolts ex lBUst PfPP BUTs BA i cooIBAt f ffPe i oosef1 thfe exhfBUst ciBfTilp BAd f 8A 1GvP the ex iecfst pfpe tf GA1 the heel j scvevvs ...

Page 70: ...el 7 O VLllf49ER I HEA D SOIL FS SUf3 JOI f T IC ipCBkre l i irjt 1iTO ICr ritlQ r Bf l1OVB C ply tdPI hPB J a f i f AOVi l i 0 f i69 d guSkP t dOWQIS etrlQ lt e Q I c fi e i l L f300 SHOt IVIES NI AL i 76 Arnerieen iknn le Mainr Cn Irle M 1 3 p riin erj i n U S e r n 78 ...

Page 71: ... 4 BBII 8 3 3 I dP 3 3SI IS OITf I3B IITIt8IIS t I if3 h8 f3bBI fiBBk i fB SP8f k 3itfq 301B 8ffd VBIVB if 385 B8 B II II p 3 Cf 8CkS f f 8fi IIB II 8 jdSkP SUf 8CBS l3 Bi I g85kf3 fTI8tBI I8 QOTE I IBCk 1B Chjlff I fBI iB8C 3 VV8f 38 jB VVf 3 8 Sl 8fg I 8 g 8 3d 8 BBIP g800B ...

Page 72: ...Gf d ecch v v ive gufL fe i D LisiAg 6 beii geugP GP I 1Lf t f f L f 0 A i 6 6f 4 ubtf ffct iecI I verve stetf I 3 D if GLA fhP CQf PBSpGAdfff g VeiVB gLfid6 hD EG f TftviA the stefA tG gUide I lee Bf166 stBAl tG gu idP ciBi Ii BAce st fii exceeds tftP sPf vice ifftfits vvfth AevIA guides f Bp 1 fce thIB ve ives BAf i gu f d es G I 1OACl SHOP M A AIUA I oi I 9 pe ATDDTiaan Honda MD TDTco I no Hafn...

Page 73: ...VALVE GUII3E REPLACEMENT 1 lect cylinder heed fry rn 80 to i 00oC Use heevy gloves when her dlinq the het cylinder heed F een i the new velve 0 Ide5 Bftef i ns te I let eni ...

Page 74: ... even rneti fftlfsi I Bround ti e seB t Indlce les gGod veive contect 1f the seel fs Qo vvfde 4GG nerf GA cfr 1fBs iovv spots he seek Aust l36 groUAd QI DSEAT WIDTH OLD SEAT Wf DTH I 63 50 cGrnpiefe con Bct After cur ing the sect Bppiy iepping cofnpGurld to veive face Bnd 1Bp the veive usiing light pressure Afrer ieppfng vvesh the cgifnder heed Bnd veivP cieBA Gt resfcluel compound Check vBive sec...

Page 75: ...flgS I f jSI f I i f 6 VBIVBS SI f jf fqS i f64 BjfiBVS If lf l BI lB I flf VB IV jBl l l gB f I IV VVj f I i 3 OG If Bf 6 8 l 6 I I j I f j I VSBBt Bf J f8f g f f fiick 1 fp Ipf i f f t8f 6 tIlp CAUTION I SfjppOf k th6 CYIIAd8f h68d BbOVB kh8 VVOf k I36ffCh S f f 466 tO pf BVBOt pOSSf DIP VBIVB d8Af8g8 ...

Page 76: ...tne tl I f fl g ftfBI k off fhe c I 8 nk sI 8ft tn be c 6 t 8 I n t I dt f ufTibe t cglflnde Is 8 f TDC on the cofTII ressfon stf oke then otdte It g o See CAUTION note on bottom Of f ge 5 8 lnsiBII the oil oi ffice Using fee I figs Bf d inset t thP heeo geskPt lov e ls Codt tl 6 c llnclef Block Bl f Ileed sul fdci s vvftl f If u f I sPBIPv Bno instBII thl heBd geskets ol f oth SldPS ...

Page 77: ...A 8BChi I feed I fsstBII the cBmsheft with the teclfGmPtef fly Ive gee fA the vfght 8 Ifn let hBB l Bi p p i fr s i8 I 6 V t 0 t I I P C8mh G Id8i 8 Ad tG c gifAdef heB j con Bet sU f fecPs I nstBfl the CBmshett BAO hOIdPI Bf1fd G I lfe fff tl fc SB AP X pet tef A Bs thP CQ hf f je I Iee 3 I 000 I I fi I M A I i I Xi B rin r I I i 1 i S 7 70 2O i 1 snf I i inririnrin Har i n ii M v o r Cii In 5 ...

Page 78: ... the pun Ifp shaft fotate the drive assembly until the fuel pump shaft cleaf s the cern cl ive lobe and the asseft bly will seat int the head 1 n st 8f1 l1 P 1 88tshIe1 3s i ve sf f 6 Ae P ft BI wff P L Ph nd tf fe tfght 1 aff l t QBt sf fel M 8 k8 s l IFe t h 8 t b t 1 t i M I n g h PItd I I 0P p hl feys Bne f fgtft KEywAv ...

Page 79: ... T D C so the T mark is centered Looser the tensioneI bolts and install the timing belts TEMSIONER BOLTS VAI VE TIIMlNG MARKS I P QIQ fwnnlv I r ss Ire coI I Ite clockwISB on he camshaft pulley so the belt vvIll be slack at the tensIoner v l t t ie Pr IsI ner bol ts loosened I he sp II lg pressure a ur o n t a tI c a llypos ItIons the tensIoner TIgl ten h e i in ii ot Br l olt Re hBck vaIVB tf TIi...

Page 80: ... thie Cef A Loosen the polAt gep Bd ustfnef ft scf evvs to set poifits At check gep Bftef tightening Rote te the engine Bnd f ep8et the Isf ocess OA tlhe riglht point Aefef t0 tune up Sectf0A 3 fof tfftf fng Bd UstfAent usiIAg 6 sti Obe light POINT GAP 0 3 to 0 4 fVIM I f 4spP ct the conclitlof i of tl 1P i ockef covef seBI lnstell tire vBlvP covef s ex itBUst pipes Bnd t f iinif Ag4 8It c 0 v P f...

Page 81: ...1 Kf 0 ii H Cl t IVf A I 0 l l i 1978 At n e i i c rn Ho n i ls o t a l Co I n i 9 ...

Page 82: ...1 5 fnrni I 0 006 in i rl Gn I tin diBI tielPI 1 7 000 I 003 n irn Pis t Gn I tifl L tGfe l 7 010 tG 7 01tt rttf11 I tnii t D Bi sl tf1 71 945 rG 71 97 rrif it 2 8325 Seit ce lift Il 1 85 iTtfA 2 8288 IA istutt ra cy int e er I leerence 0 03 tG 0 07 mfn 0 8 e r yfc e I I fAIf G 1 5 f rl f n 006 I f I ing ei trf fgep Gf Bf tr seccrtfj 0 25 tG Q 40 rrirq I O I I 0 0 016 n SefVice litnit G 70 i r nrn...

Page 83: ... 3 wQ j t e r p g 1978 1979 e C 4 G 7 r i C q 1 4 I Q I ip i ...

Page 84: ...lubrication Piston Supports set of two HC 41329 Piston Ring Compressors Adjustable Ratchet 2 P ston Pin Tool Set HC 57307 Case Supports HC 41334 Drive Shaft Bearing Remover HC 48429 Driver Attachment HC 41328 Bearing Drive O HC 41316 Bearing Drive O HC 413 17 17 mm Bearing Remover Set HC 41313 Torque Damper Compressor HC 41331 Torque Nlrench 0 300 in Ib Torque Wrench 0 150 ft Ib IFeeler Gauge Set ...

Page 85: ...ngine 8 Bpf Of Stend FGf PngfAB f B f fGVBI Pf SCedUf S f Beef tQ Se tfQff 4 Erfgiine Ccvef Fle AQvet fkefTfQve cfoÃtcn cQvef ef f J f Bef enqfne COVB7 ENGifME COVER Ui P f tffe kick stef tcf 1 etc fe BA 3 Pfnf til feetn Tof vveev Pf f ffOK TEETH 1 000 l l 0 7 f N r 778 7 neer i7an ldll d Ma rv y u e tc M 5 I ttlf 6i I fB U 7 7 ...

Page 86: ...Il NL l I 2 g 8388 R83SS ff bIP V 8 pBVS USlOg 3 O8 IOCk 435 ill s8I LIl8 gO ldP I OIX GUIDE EfDLT KICK STARTER vtcv sT svss seas PIf fllGR RETURN SHAIF Tf CASE SPRIIMG WASHER sswvs Qg I CDLLAR LQ S T A Rl E R PI BIOPS Y ifsS B lf O8 kiCk St3 8 BD l dfl I if CIIP Ol I 8 kICk S IBf C SllBft l OIB lCB LI 8 SIBf L8 BV B klCk lOj OL SfO f BOd SOB f BOO f f S731l lh8 j St S83IS KfCf lOiflt Bf d Cl l CI...

Page 87: ... Reri love I I le lef l cg illider I leBdBAd 5 Bl el See SPctIQA 3 F emuve the three riqht cBBe boite p r 8 v iiP I 9 lPf i ise 4QIts NIOT F Th8l Br 8 8Aglr 8 CBBP IBQItB behlA I the pter ter BA I lli tIBpflee j olI feft BKIe QAIQ r i I J e c Qr I I RIGHT CASiE 80 TS l I 0 0 i iso 0 0 O 0 8 0 1 00 r3 S H O P M r r ill Cr L 19i 6 rnrrr i crrn Ha rid a Mcrrnr Co in c r fl lrr ii iri 3 a rr r ...

Page 88: ...op tow8lls uAdet the pistoAs to pf eveAt thefA ftoftf fellingQAto the tvBAswissioA when the lett cese fs Ye oved Fief i e ve the lett ces PISTO A RO RE OVAL Check coAAectf I ig I oci sfde cieef BAce it ciPBf ef i 6 Pxcee js he sef v fee lif Af t r epiece the cad l faspe t the c BAkshett QI Q I t t I SPOtS Of dBITIBge BPA fove ilfe lPft side o ls Bfl l pi stQffs PAil Af A theA1 tO IAdIPBte tffe O V...

Page 89: ...Q tt I f f3dBC I3BBi l SBB SBCCfQf3 f YLI DER REAR RIDGE RBif ft3VB0 f gI3 4 I l g f i i ii f Q d S Pf f CI Vf4TQCfS 3f fQ fT fBCk f IfBfA 3Q ftQdfQfftB Q IlCf 3BPI3QSI f fQf3 807E i l l i3 OO 5 H0 P M A i J l3 4 f l9 6 A m e r i c i n f i en d Malt v Qe tne Pl in 8d lti U B i 8 ...

Page 90: ... PILOT COLLAR f f i i gi Ii f I I SPIN REMOVAI TOOL j iHC48723 Meescf f B t fe 3fston tfffi ik pfs IGn p f3 to cjetecfTfff1B pifi GIPBPBnee SERVICE LIIMIT 0 050 fnn1 0 0008 in DRIVFR PILOT TG lf istBII i h e plf i i j nsPc I t B pi cft Go Bc l fside the PfstQn Bcicf BGinnBGtfng f oci P IBBB tf iP pfstGn end I c3cI BssefTf 3 iiI Gn i I1B pii 1 f BfÃovel ioo A lgn t iP I f fVBC PilQt Bl1G 3IStGn Pff...

Page 91: ... ASpBC I I fe 1 lf ig IBAds 0f ebAof ITfel wedf BAd pfsIGA Ihf Qst feces fOI scl etcI fes THRUST FACE Meesef 8 BecI i pfstGf l cffefTfefef et I he Sk ff f If tl18 pfSiQAS SI OVV VJBBfbeyOAd Ill Aft s cepfecefTfBA f fs Aecessef y Check cyIIf ef cIIf AeAsIQAS cef efUIIy vvI ffeA pfstGAs shovv excessive vveef Mejof cyIIndef sefvice ffAey be f BqUfrecI 3 f 1 D f 0 S f i 0 P k f n Li l i n in sr in i I...

Page 92: ... i GT G f 3 I BCk TOt BI B 3O if t BI f fgi l B 1 jIBS B 1d PB Bll BI 0 f 8 B f 1B i V I l i f B I ffB CVIif sB S IG l O UBqU B 3 B g fB f 4 h B l f l BC B OO Ot I Od l S tG i 8 f q f f CX fn lf f lite O IBl BBif f j l S Gi f f f f i fO fG 1 C fl 1GB Off I f S BC I1B BO f C B ...

Page 93: ...ing insteiicition CaietUiiy inStciii the Piston i inqS 20 mm OR VORE Do not diign tie gBps in ti1e Qii Angs t 20 mm OR VORE i G L 1GGG SCOP MANUA l tcg i976 Artterican Honda Mo to r Co inc Printon itt U S A 78 ...

Page 94: ...UB g 0 Bi 3 Sd tI 8 0l I SBPB 340 i if4 Sf i i f 83 fS 0 SSf0 3 iT Bff fSI 3 7 3fid I f ffTiBf j d fV8f f g83 Bfld 8 fQV8 l t f f l 30 h t t8 Pf ffT Bt V hBff f R8 T GV8 t f38 FBf fI S f fI t F f310 b83 fPg BPS Bl Q fl i t f I 8 0 BPl ShBfk ff 0 Tf kh8 0BS f ...

Page 95: ... ABI SERVICE LIMIT 0 05 mm iI 0019 ifrfi i CTUAL RUffIOUT 1 2 TOTAL NDICATOR f I j I IASpBCf th8 Ct BAkSi fBft fTfBIA IOUI ABIS BACI CCBAkpiAS LOP tBp8f Vvith 8 iflA I Cf OfTf8 tB f I ASpBCt th8 Cf Bl ikShiBtf AfBfA IOUCABIS Bffd Cf BflkpfAS fOf OUt Of f OU lid VVfth 8 f i AiiCi Of f etBf MOTE G i f 0 00 S H G P M A N U A i P rinfed in V S A 7 7 8 ic 1976 A IMBrfcGn fdnnd8 MQ for Qn f nr 1 5 ...

Page 96: ...stBII the cf BAkshett PUt B piece Gt plestfgBUge Bcf Gss ecch IGUf ABI BvoldlAg the olI hole ii stBI l Ulei fABfA heel fAg ceps GA the cGf f ect lGf f f ABIs BAcf tof qefe tlleFA eveAI y HPf AGve tfie ceps Bli J fvleesUf e I he coftipfessed pIBstlgBUge GA ecch IOUf l BI ...

Page 97: ... OSS 8BCI i POd Cf Bf fkpfA MOTE I AS IBII 8BCh COBA8Ctf Ag i OCI OA h8 0 0 f r 8Sp0 ffj f f f g 0 f 80 k I f ff f 8 A f 0 q U8 0 Sfp8CfI 1CBtfGAS R8fACW 8 I I il CBpS BA I FA8BSUf 8 f I f8 PIBSr igBUgP G 0 L f GOO SHQP MAN VA i i f 978 Arrreri en Hvncfa Mater Co i nc Printer in if S A 78 ...

Page 98: ...lfl fB BA I BCOI d BBCI COI ABCtfAg I OG I i AC 8 f UA bBf I 8 Bf f lf 8 Bf f BCGl thB CGf PBSpGf dlA 3 Cf Bflkl ff O L CGC P IBttP I S Cl GSS f 8 tBf Bf CB tI18 Cf BA k BACI f Gd CGC BS tC 8 tPI fA IIHB t 8 I PpIBCPA fBAt BBf l I COIOI 3 8RO f f 8LA C K 8ILU E I 2 G R EEK 8R OIN N 8 ACK F ELLOW G R E E N 8R OW K ...

Page 99: ... P f f AfpiP 3Ad f BCOt 4 TI iP cof rBspoft jff fg ff fist A IVL I ABI 3 D COEfiB Alt f A l P f MO 1 MAIM S f fstsl jcPrr P j I 4Bdr ir fg ciBIor CrQSS f 8 Bt PAcB thE bPEff lf g sf fppor1 ttf1il Cf BAK COCIBS 40 CIB Bf A If fiP tAB 3 rrt MA I N 8E A R I M6 8 EILECTIOM C er 111 8 FIOWN BLA CK 8LUE 2 Xl fTI 8 or 11 GRE E M 8RO AN 8ILA C K A tt tf Q fT rtt A or 1 VELL OVIf GREEN 8R O fffM f I f j 3 ...

Page 100: ...tG the beef if1g sLfppGI ts Ley the crenksheft erfd prifnery chein cere I Lflly it piece l nstell tl e Gppef beerfng Inser ts QQ vvef pfns end beer fng ceps MOTE TGrqLI ti Ie frfefn c3p bGIts I OOU B 0 I g A nf Li A L I 976 Am e Ia n Banda iV a Ia Ca na 6 2A IL in ed In LI S 7 7 8 ...

Page 101: ...isfl set r fngs I ft fn tfae rf nt fnand case Bf fd i I fe n fafnshaft 368 lng Qla fef 18Ces 7til fgrf tAe f r nafASha tt Qfl PdSSBgP IQcatnr tab with I he cyIindef bl QcI gr Qnv 6 Instaif tlute right I land Qd Bssernbiies AtQ the Iiffders 1 Bffd 3 vvitlf tffe f r Q 3 01I I lQIP s Iaclftg 1 I le elfgifle tQF I Qr 16 f Qd caps 250 290 kq cft 1 I I 8 2 I tt lb i Qi fL1 Sll i M i 4 l i 1 f 7 F X li I...

Page 102: ...gagff lg tl 8 Sl ift aim intQ the drum MOTE The left cyIinders have B large chamfer that BIIQ ws the rings tQ enter the I IIAdel 5 jifJIthoot UsIAg 8 rIAg Re AQve tI 8 pfstQA bases and seat the casP P P S cofnpressor 0al all casP bolt tI f eads Bn 3 the IJt I sfdP Qf tl fe Pa js WIth A I 0 f jJ d 8 I I f A d i 50 I f f II8 g I8asP a 0Ij nr IUP thef I I Bs IIQvfj NOTE 1 0 mm 330 370 kg fj I I24 2 g...

Page 103: ...E 6x85 FRONT ENGINE COVER Q CLOT CH COVER 6 x 66 SCREWS 6 x 35SCREWS Qi 3 3 3 333 REINS I Q cge r 3 3 3 3 3 3tNS rtt 3 3 St RFlltfS SSR ri tt l09333 WATER POMP 6 8 0 SF R r r OOBSZ9 IQGO S IS OP MAIOLII ft I Iia t3 SNliiaij a Rn H a n t 3 M a t a n C a Ina M 2 Q I t ltttRij tt t L t a A 8 ...

Page 104: ... i L 1 0 0 0 S I I i P V A iX I i A t 1 8 s i rlr 1 Ho t i a M Q Q f C A I l C g Prii er ir Ll S A 7 VR ...

Page 105: ...f f f I I f I f it I i lt I g iBI US SpiPCI ii Ql I B ICff IV BS IS i ill IP PS iB BA VV II Ol I if CVPBS 0 Cf I IAg PXpPASPS Iiil lt t IP Pfl f V i P i BIB i BS f I ifSP J f BCIII Qf S Bl P AQ I PCQff IT PI fdP 3 3CABTB IBi T l B IQT S AE t0 1 t49 Qr 20 0 jO t t I t I I Vt S i G t B c t 30 Ft l V OQi t i 2 SAF f I V O C Q Q f 59QF j SP E 20 n T 20A I p i p B I p I p I p i i IAP I SS li P C B i t ...

Page 106: ...OR I F I CE OII PRESSURE i QP NIARNING SR ITCH J FRONT i j i IVIAIN OI PUMP FILTER ELEMENT SPRAY RAR FOR CILUTCH SCAVENGE PUVP PUMP DRIVE SHAFT DR AI N8OLT j OIL STRAINER Fll TER 8VPASS VAL VE PRESSURF BELIEF VAI VE ...

Page 107: ...in lb Oil pressure warning switch 150 to 200 kg cm l3 1 174 in lb 6mm Case bolts 100 to 140 kg cm 87 I 22 in lb 8mm Case bolts 180 to 220 kg crn 157 191 in Ib Working Practice The pumps at the front and rear of the engine are driven by a chain from the clutch and coupled by a shaft runnirfg the length of the engine Sir ce the drive spf ocket fn the f ear engfne covef is bolted to the pump shaft th...

Page 108: ...il Defective vvarffing light svvitch High M BIA Qfl pu tTI I i VVQI A Oil Pressure Pressuf B I elle l velve stuck clQsed Plilgged oil filter gellel y Qf rnetef ing orifice I I leo rect oil hefng ised 3 No Oil Pressure 2 D f ive pin sl 1BBIPd of IAIssfng trQI f meff t ofl pUI np 3 0 f l p l fnp df lve Cl IBI A broken Dil pump drive sheft Lfroken Dil I vel t00 lovv Oll IA COOIBAt li DPfPCtlVP heed g...

Page 109: ......

Page 110: ... Bn l Bf low I t tQ idi6 lo f Bfew rnff Utes Check to i e sUIC there Bfe n j oil leaks tQp t 16 engine Bnrl check the Gil level see Gl L LF EL CHECK ISBge 7 5AI l f tne Oil levPl fs IOvv B j li Qif TG hrf I f tl 18 level tG t 16 pp f fr BI k CRANKCASE DRAIN PLUG Perform jfl filter replacement in con UActfGA with the et1giA6oil chBAgP ReplecP t h6 fill ef B ftef orBIAIAg Bnd efQIP I e iiilirig tf1e...

Page 111: ... P 3j3 RB 33 V l i3f i i 3 lip 3 3 i 0 SVS B 3 i F i i V ii B 3 3 BTO S jBSC j3BC i i iB i 3 i Hi i i iB i l SV fp v i i j p 33OVp gl3B t i B iiC3VB j B T 3 t i3B CgVB 3 SBSSB 33 jB tf p T Bii i Oil l3 i ip j T C VB i P B g 3 iS BSC jbB 3 RB 3 iVP i B BB B l 3B C 3 SBT Cl TCl3 l BSS f 3j V S VB jp j i i 3j3 i V P B ii 3 Sl l JCk p i iS BSC i 3 d i i Tf Q 3 i f ...

Page 112: ... INSPECTION RBff OVB f I B pU f ffp COVBt S I f lhpBC I fB pL if ipB 70 Bf f fnj IB d fd MBBBUf B if 1P I IP CI i 3 Bf fCi3 PiP Bf 5 IP Bgfif f f f fTfP Cf V IBBf BifCP MEASURE PUMP BOD ff Cl EARARCF HERE f QG HI3P Vfh f AC i 978 ne ican I fan 0 K fatn Cn Inn g 9 P inf n i n l i Cn A 7 B ...

Page 113: ...vPf the l UA I St tBlt Brf l r e BSSPA i ttr IVBSI i I I f v P Ct I fi ROTOR OUTER Olk POMP ROTOR ORHAVESPROCKET Q QLftP i f t rQf inc I I IB 0f SCAVENGE PUMP ICAUTION I SCA AVENGE PtOOV PUMP fi Un if COVef I l ti i r i P Tile punCh merkS UA the mein Uil pun fp QUter f otor s i n fist be tBcfr 3 out vvhen the rotors Bre instBIIed in tl e pump body I rlstBI tI lPrtoI les fr l df fve chB r Bf s BI Q...

Page 114: ...Pf snoU fd bfa leaned and irfspected Also the Qil jiitef shQQld be replafced and the Qfj shQuld be changed I t i ie oil strainer is to lae f P T fQved fifth tf fe engfne ff f the trafne ioI low th p QcPd ffe o ftjfned fn SectfQrf i 0 OIL PRESSURE WARNING SWITCH j estlAg ot tj f s ofl pressnre warrilng svlffc f s descrfbe fn SectfQA l i ...

Page 115: ... lf aIA the cGGIBAt BAd I Blnove the cGf 6 plugs Appfg Per latex gasket sealef ol silicGAe to seal the threads and re install the cere plugs e T Sg Wherf ofl coAtarnlAa tfoA fs present c 0 rA rA6IcI8IgU A18AdsIudge r 8rA 0 v6r can be sadfo pUrge 8 Agfne Gf cnntarnfnants SBB Page 7 4 fof suggPsted l3ranfd I DG nGt breathe sludge remnver fumes PrGvide adequate ventilatiGn while the engine is running...

Page 116: ...t L 1000 SHt0P M A N U A L r i 978 A tn at i t ttt H t7tttfa Ma l ot u ttc Ptit ttnd tl I t i S A 7 7 8 ...

Page 117: ... wiftec 45 fi ethylene glycol 32OC 25QF leod Aq Pcfint with 50 50 ITfixtuf e c npf Bssuf Ized l 07 7 C 226 F I Crap on ocessUtized 125 6 C 258 FI Raclfratfal CBP i B Ie facessuce 0 75 to 1 05 kg scl QA 10 7 to 14 9 psi l Pic to 1 yne 2 V D C rkotatifaff Countef Blookwise vfewed lf off BAqIAB side Cucceclti spBPcl ancl loau 1A max at 2300 cpm without blade 3 5 0 4A 1900 250 I pm with blade I an bwi...

Page 118: ...FAM OM AT 38O TO i02 C THE R MOS TAT GAUGE SEMSOR AMD F AM SWITCH j i f MO FLOW TMROUGH ts A Di A f OP UMTI s7 TO Oi EM 80 TO 84 C i BYPASS FLOW UM WATEI PUMP THERMOSTAT OP ...

Page 119: ... coolfng system perts LJSB only distilled vveter end ethylene glycol in the cooling system Du NOT Use e coho based entitreeze Add cuolent iet ceip oi I resPrve tel fk Do not f Pmove I edfetor cep except to refill of dreflf the systBIA C ylnfdef leek tcstPf Geske screper FI Ishing compQUI1d Any blend I Bcomfnended tof BIUffffnUnf block PAgff ies i4ff cifetof pl QssU rB ti Pster H C 41 033 TIferviof...

Page 120: ... fot hoiG IAg Pl essL ff 8 Bif Aot VVQ Ii Il fg d IDeteCtlVB thPI AG itetlc SWItC4 ld Detective I Bff AO 0 ABtl I PLf TIP Aot Qttitfng VPBtef PLIITIP Ii BPPliets GBi IBge 3 incofs BCt Cooidnt VVBte I Bt 0 Detective teinpPI BtUI 8 gBUgP sensof inSUtf iciest CGGIBnt 2 HBi d tor cBP notholding PvessLI 8 3 CGG i d flt Iedklfig Iflto Oi 4 D e f i ctlve heBLI geskPt Biiowlf fg c Boient IAto cViin ilefs ...

Page 121: ... Rerf1ove tliP I edfetQf CPp BS deSCI jfied QA pege 8 7 StPP 2 04Sef Ve SteP 2 I en dI CA t j I l OM Q F ill f hP I Bdfet0f 3 l I PBPI V8 tenk BS jeSC lt ed QA pBge 8 1 St P P S7 5 8 000IBI1t shoU Id be 3f Biinecl Bftd I I pleceu evef y 36 000 kfllOf r neters 22 D00 I fi leS P egBI djeSS 0 r f i n I leBge the cQQlffig sV sterf I sliQUld f te jliished i t tfiere IS PVf fCACP Qf lime SCBie Or rust F...

Page 122: ... engine for 10 minutes at normal operating temperature then drain repeating steps l tfirou fh 4 6 Fi I the radiator with plain water Run the engine then d ragon repeati g steps I throuqh 4 Perform this stef twice to ensU 8 that Bll flUsl ing compound I as L een rinsed fi o T tf P coo lling systeiTi 7 Iff the radiator with a 50 50 mixture of distilled water Br d ethylene qlycol antifreeze Run the e...

Page 123: ...ace the I Bdletof cap lf lt iQ s not i fQid pvpssUfp of ff vpilef pvpssUvp fs tQQ I fgh of tQQ low l SUR IFACE DQ Aot ioosPA ov l efvf ve the vedfB tov cep whiie the engine is hot Scei ing hot coolent mey be ve ieBse j when the cBP Is iooseAed Bn 3 vevvfoved lCAUTIO 8i if theve is cocient in the vesevve t ienk do AQt ioosen ov vefnove the vB liietov cefp befove vef Aovinq the vesefve teel fiiiev C...

Page 124: ... ih taf f tfle ellglfie Plf d 3il 3vv If fc Iuf1 cintfi ff rPaci Ps Qpef BI if g tenfi3Pf atU 8 itl ef A10stat opens OI3sP ve i 8 3i essUCP rPadirlg Gf1 thP festef ga 3 je Jt prPssule does f10t ib i lid Up vvhfle the PAg AP Is I Uf 1f1 fig Use the tester pur ip to bring the qauge re ding to 0 9 1 05 kg cm2 I12 8 14 9 ps I Do not aliovv pressure I 0 8 cPP f 1 12 f q c A1 5 9 p sI h f api i pressure...

Page 125: ...RABlATGR ANG FAN QSE RESERVE TANK H RADIATOR CAP X RE SE R f E TANK BAD A i QR T P FAN WIRE CONNECTOR HOSE l 1 l9 L l l f g SHROUD P j t I IFAR MOTOR I R RAD ATQ SHROUD IFAR FWQ 8QLTS 80 TGI vl HOSE ...

Page 126: ... I 3Bf 1 f BO fii O ff fiS LISIAq VV 3 SC BVVCII fVBf S BS SISOVVI I f f I t hB C C 3AiP IA Vf Aq Il IIISt iITI Qfi RB tBCB tfIB BdfB OI lf Bll tlOA fS I BS f ICTBd OVBI I AO B hBI I 20 i Of thB f B J IBit li 1 f SO I iCB FAN MGTGR TESTING O il fBCf fB Bf AIO Of t 3 Bi i 2 VOl I iBI I I Bi i I C hOCk OpBI it iOIl I LIB fiA O I ShOuld r in tr Bly ...

Page 127: ... 1P ff OI3 BAgfAB 1381V I IN SIDF i NT ERO COV f f I S P V8 t I1 8 I 3CBtI0A O f I l I 0 1 f A g S CO I I i91 S81Ad I A O CKI3fAS WATER PUMP EIOLTS RBfjAOVB tI 18 VVBtB p ffjAp BA IASpBCt ft 1 Of A 3l A l388t lAOS iOOSB St18ft Ol d8 f 1 18gB I I f13 p8II8f DO AOt i3ttB APt tO f BPBl tl tiP VVBtB pOfTip IT i lS VVOI A Of dB tf f IB t I3 I 3 8 81t f IfBA 8 iS BIIIAg th8 VSQtBt f3lgff3I3 HSB i iBVV f...

Page 128: ... g 0 THERMOSTAT I ASp8C tf76 A8l IAOStBt VISGBII 43 f Bf i ABg8 SGSp8ACI th8 th8f ITIOStB f If I h0 t Vi BI 6f tQ Ch8Ck Op fBtfQA THERMOMETER THERIVIOSTAT WATER R8plBC8 th8f IAOStBt I I VBIV8 StB S Op80 Bt f 00 7 t6f IP8f BtfJ 8 7 f t lt f 8SPQAdS Bt t 6 tp6I BtIJf 85 Gt h8 tl IBA tki058 SPPCI fi8d R 68558 AQI6 fSfAg 8 APVV 0 I ff g QA th8 ti I8f AQSIBt CGV8f HEAT APPLIED MOTE iS 0 l000 56 O P M A...

Page 129: ...i0 L i 000 S H O i M A iN Li A L 19 PR Arnei ivan Ho nda Mo t o r o in l P rinted in U S A 7 a 8 ...

Page 130: ... Maxirfiufn throftle lever operating force I k q Air F fltel Replaceable paper alert ent F Bl F ifter Rel3laceable in line filter F uel Puf nfP 1 yf 8 cafrl elaerratecl d lal3hr am PufnP I ress fre 0 1 7 kg cfn2 2 4 psl at cf Bnklngspeed 0 16 kg crn2 2 3 psi at 1100 rpm idle 0 14 kg ci i2 2 0 psi at 5000 rpm 13 ur 18 350 nI 12 oz per 3 nute Bt 600 rpm 450 ml 15 ez per minute at 3000 rpm 500 n l I ...

Page 131: ... 75 WIQBFf GRAY Q 9K q i 4 oW y Qe e e Q 5 y p I j 0 l i J J i 1 tlH Ill 4 ...

Page 132: ...e 6 Air cleaner clogged 7 Air leakirig into man fold 8 Fuel contaminated 9 Carbutetors llot synchtonizecl Lean Mixture lnsufficiient Fuel to the Cylinders 1 Carburetoi fuel jets clogqed 2 Vacuum piston stuck closed 3 Defective fuel pump or fuel pump cam lobe 4 Fuel cap vent blocked 5 Fuel fiiter clogged 6 Fuel line kinked or restricted 7 Fuel line blocked 8 Carburetor fuel inlet filter screen clog...

Page 133: ...FUEL LEVEL SENSOR AIR C EANER ASSEMBL V w E L l F OAT 3 I AIR CUT OFF VALVE FLOAT BOA L DRAIN Pl UG iÃANl FOLDS ...

Page 134: ...P 4 I w I i I SECOR DAB V Ail B CI B CUIT f VALVE 8 f ASS POBTS 8 I t E l Pg P p K a PI I OT SCBEV F i l 4 7 I IIVIITEB CAP I HEI I vIAIN KC ZZIi F PBIMABV MAIN FUEL JE I EC 34 iDAB d i v IAIN FUEI JET ...

Page 135: ... SI OW AIR JET f EMGIME SLOW SPEED FUEL IS IM TROD UC ED TO T HE SLOW FUEL IET CHAMBER THBU I HE PBIVAB tr MAIM iET PI I O T SCREW vrrcuuv L EAK H O L E wrrew r THROUG CBEATIM PREVEM DECEI E C 1 000 8 id D P tti AN U A I 1 976 American Hcrrda itrictor Cc i n c Printed in U S A 7 1 8 ...

Page 136: ...PRIMARY FUEI CIRCUIT I O TO I 2 OPER THROTTLE VALVE VACLIOM PISTON VOWS PRIMAR jt AIR CIRCUIT JET ME THROTTLE VALVE MAIR NOZZLE PRIMARY MAIM FUEL JET ...

Page 137: ...DARV FUEI CIRCUIT I 2 TO PUI L GPEM TRRGTTEE i ACUUMI PIST GM RAISED SECOMDARY AIR CIRCUIT PRIIIi IARV AIR CIRCUIT 3 fg 0 g g H i 3F Vi A N 0 A i 19 6 p inenicon Hando unior 6 o Ino 9 P rintea in V S A 7 7 8 ...

Page 138: ...LEFT CHOKE IEVER RIGHT CHOKE LEVER ...

Page 139: ...et fei ff tel D e ket B f 3U f fe t l tef OUt tO A let B t le Pit Sl B Ot th Bi fgf fe 4 i Goser t the tuel L f 3B c BFA 3 GA t t f e C G A A BCUASft 3P t f f tt y el tAP ti Bi tiube t fSCCif APCt t 3B f P I t H 3 L f ouNT MG Mt T FUEL F LTER Ff EL POMP E F t f e i t i Gv Fet f lP k fftBf b Bc B t i o l 3 the Use tf te Bfi f 3 itt lt oil t e Fte ttV t t tP t f e t Eff AB A vTJt t if pf BAc c 3 T f...

Page 140: ...lABGSi P ti 6 VOIUA 6 PU APBd dUf fA g 8 SPBCfflC PB fOd If f 6 tUBf f UfT P dOBS AO iT 684 SPBCff fCB fOAS l BfT OVP TAB bOd g COVB BAfj SBB If Of Blgff A 8 6 iS CIOggfAg f 6 VBfVBS BA d PQ S JO E DB BC fS S tJCh BS 8 fBBkfffg dlBPhfBgfTf i 6 3U VB B 31GCBAlB t 0 f hB PU AP BS Bf t BSSP i I lQ Df APHRAGM i t O Ot S tt F I A vU 5 t 9 i t 6 Atttttr iaan ia t ta iVla at Pt itttet itt U S A 7 7 9 ...

Page 141: ... cB 3U etol Ink Dfs QAI feet the tUel UITfp QUtpUt I IQse t I l le 3LI f np I30 y Ref Qv Ile efgi lf TI B nf Q I 3 t0 I IPBU I Qfts T a fh CBThU Pt r ssllmbly P l l 3 I U l I38t ffani if fl I tQ lo 3sef lf CAU7 OM Do nct pty I3etvveef the menitolcIS BA0 tl e heed oeceffsP tl fls mey 3BIAB ge the A IOUAt Ag SUif fBC8 I fl i tl 38 ce bUI etQTS B cfd Blf cllan t3P B S 8 is B SS 8ltl h I V t I 0 I I3 ...

Page 142: ...en3oved Rote fts pQslltfoA for plf oper re 3ssernbig Disco IAB ft he Iols I chQke IIA I 83 A 3rftfJBI 4 caf I3UÃretof BO I 1 CEN I ER t t alii k 30 I I E Is P f NS R f f IOV 8 Cl IOI E L liN HERE I978 1979 MODE SHO fff N f I S I 3TTEE L I NK 8 E R 8 NI 0 V EIQ tdt sPGAI3 c fi tP sinw a tv I t 3 sPs Bf thP dl chdfni3Pf and el I tQvB the f we scf Bws IIQllilng tf38 alf chan be ttQget Ier S ectaf dte...

Page 143: ...S f 8t i I fC I f f I Ifl tf Pd C I I O f C f I i f VP I O S l O I Ie f lP f tt Ot8f 8 I i P HCl l S 8ff OI CBf hU f Cf Of S Ã tIlC V ll cli IP i fv ik tff d t I t e CIROkP I fBk 38 Clif 6 II I I IO iC SSP l IB S Pf fig I Id Ced I tl tVftPPfl I P I f I O i i IC i OI LS Ol f I P Cf iOk S I i I k I O f I I tP t C i 0 f C 8 l 8 I I SHOP tttf IS O I Pi tA t tt ti t It S 7 7 8 97 8 tt tt t It tit I Iet...

Page 144: ...GV8 t i8 SCf 8VV f Bt I O IQS tI P 8CGA 33t g l 8 I8 l IBCP I Sif C I 8 VBCU fA if fStQA BAd CB f f 8 G i3O V fOT SfgAS Qf VVBB f f kS SCf BtCf 8 Of Ot 8f BA B I8 i ABIi SU f 8 tAB f th8 GlStGf fTAOV8 UP Bi I VN f i i 88IP lA I 8 CBf k f f 8tOf SECONDARY NEEQLE CV VM Pl STON iMOTE O AOt Ifft8 Cl BAg8 VBCUUTT P StG 3 8 V BCUUft ChBA b8 COV8 A8tQV88A B iBU f P tOi I 8 f T OV 8 t 8 8 f l 8 t CGV 8 8 ...

Page 145: ...oet bovvl tG f h bodp RB 17ovethe flGet LtGVt l 8AG g8Sket GBAtlg pOll GA fife A 6 tel teb io f Brr fGvP tl f6 prffA8rV efld seeoAdertf f A8 f Ai f 6 tS FLOAT ReA Gve the robber c fp Over the slGvv le t 6 t 0 0 0 8 H O P fttf P i N O A L P t it tt if fti tJ S 7t 7 7 8 t I978 A t tit rit ittt f tOtt83 M t t 1Dt CD f i l e 9 iiti 3 7 ...

Page 146: ...i TBii out TG ceA ovethe pcffABf ttt f fozzie tpf ess f l ou l cef efui i V ff ofTf the cef buf etof thf GBt side usiflg 8 SOt l VvOGd Of f3iBS lfC tOGi SQ lhBJ the bf Bss is AQ4 defTfeged P PARQvefhe fioel p vol fBiA BAd iffy oui lhe t iQB4 Bssef Ab id e BAG A8PdiP Ref l fQve he P8 Bfflfffg pieiP Btfd the lioel APedfe seel ...

Page 147: ...3 bolt the 8 f f 3 i f i t 0 f S t 0 l f Ch 8 f i 8 f j l 8 Ij s sel i I3 I 8 t A 8 3 l I i 8 n I38 f I BfvP fn j 3 3fnf ect thl sfovv elf hosPs f 3 Ae cf thie IOng chOk P Ill f Bt f ilf iif et 4 Ce 3 if BtO i AP i el tji f i k e Bl ti if f ttje sj if n f Ac jink e je cente I lojt InsteIf t i 8 if j s Ot OttPf I if is 0A lfiP I fi l ege ft tl 8 i U T 3ci 3 ff d l ti l 8 f 0 f 8 j 3j ovvf U BesseiT...

Page 148: ... V IV 36 36 BI 6 I i I i0 i 6 Bi 6 fj 6 i cfSC 8 I fI 6 6 6 IBIZI 8 t IBk8 Si f 3 f i f 8 VBIV6 i BV8 S ft 81 j f S 38C l i 3 ff f iOS6S BOCf 6 f ll IC6 COVER SCREWS SPRING MOUNTING SCREWS S I lE 084 i CI f it 3 iBi l3 B f f f 0l C BCkS B 0 3 I f 6SS D APHRAGM O IBCI fit Btf f I SBI t S i 3 ff IB g f t f f i i t ASS8 3 3I8 t 6 COli l 30 36f3 S BS QI I VVfl tt lBk6 S I f 8 Tf P 3 I I ftqg S8 3 P I3...

Page 149: ...pl lel s 2l MM BOTTOM OIF IFILGAT RBBssemble the cBfbutetor Bsseftfbly on thle eAgf ne ROTF 88 sute the A3BAffolcl 0 tfngs 13te Aot ctlf33pMil of fnfs BllgAed Recf3nnect the fuel hf les thfOttle lfnkege cl 10ke cBble Bf3d Bff cleBAef Col Acct tf 8 cf BnkcBse bf eethef to tl38 f3lf cleBAef ...

Page 150: ...t 1Pcessary tG ad Ust Id P inix tule unless the pilot screws i lave been ref 10ved ias during carburetGr overhaui 1 Turn jhe piiot screws in iciQckvvise Untii they lightly seat then back them oui ICQUAZBIC Qckwise fh6 specfffeG Aurnher Qf turns Thts Is a pfelfrnlnary settlf1g pi for to the ffAai adIuslnlenk procedufes 2 7 cjescl ibad beiGw grief t Qntze calbuf etols iPg 3 b 3 i j 16ck Idiin spec j...

Page 151: ...idie speen ot 950 iprn Repeat step 4 foi Bacl i of tlie remrainiflg carbuifetoi s iii tui A 6 i nstall the piiot screw caps positioning thenr so the lug on the carburetor body fits between the lugs on thP cap 7 Reacljust engine idle speed to 950 100 rpm The carbur etor idle speecl may have to be readjusted for high altitude operaticr above 2 000 M 6 500 ft Tl re speci f iPd idle spPcd is 950 100 i...

Page 152: ...G I 1 000 0 H G P M A iN U A L C I 9 6 A P Y1PI Ic813 HQfldiIM O I Q i C o I f f c P i illg iI fii I I S A 7 7 8 ...

Page 153: ...0 1 2t ln 5 f iiigs S ix coil spi ir gs Spring tree length 3b b mm 1 398 in se Mce Iimiit 34 2 ir ini 1 346 in Spring foicP 9 corrfpressed length 23 8 kg 5 23 mm 52 4 Ib O 0 903 iri servi e limit 21 8 kg I 23 inm 48 lb 6 0 905 in f orgue VBIUes r iuicl enter nut 380 to 420 kg cm 27 to 30 ft lb 6 inm case bolts 100 to 140 kg cm 87 to 121 in lb the engine in the frarrie t I i tcl i plate i eiTioval ...

Page 154: ...LlFTER Pl A TE 80l T 6 i ce cvvcts sisitsc ts I Lesse seasiwa CI UTCH CENTER MU l LOCK TA8 WASHER CLUTCH CEIs ITE B I CUPPFD WASHER Cl UTCH COVER LIFTER COVER gg i i i 1 GOO S I S Q P M Sk sc ej A j II I js fs 1P l I ssuesIIl 311 IsMcleod Co Ice 3 0 PeIAss J fvl LI S s J sB ...

Page 155: ... If fh i of clue Vf ef ci 1 0 tt Ib TQ que vvf ev ch TROUBL ESHOOTWG y l ef d f f caf I Lfsf faiiy be Qf f pcted by a Ustf ng thP tf eP pi ay Ciutci Siips i hen Acceletatfng 2 Di scs vvol n 3 5 f I gs V eak Clutch Aiii Not Disengage Too much i P play i l B t PSVVBIf C C i Ni I f eP I iay MQtQvcycie Creeps Wfth Ciutch Difsengage jl Tc Pf Ucii f I e play i f Ps vva I l e l Excpssfve 3 evet Ptessuf e...

Page 156: ...Bate Alax If7furA caffle free play at the lifter LESS FREE PLAy RBIAOVB tflP lit tBI CGVBI IOQSefl the IQck f fuI aflG tuf ri the adIUstef scf Bw In CIGckwise until resistance is felt Theta back it cut IcGuntercIGckwise three Quarters of a turA Tighten the luck flut TUrn the fGwPr ad UstBf QLI t Lfntil the I equired amuunt of Ievef free play iis a ttaineQ TightBA the IowPr aclIListef leek nut and ...

Page 157: ...e Cf lPck thi r BIPesPt 383rf Ag for cgf rtf tiGri BACI tf BBGGrA ot operetfoA COVER 01888 p I Lefte Re AGve lfttef pIEirite I30Its if strfell iAcieit1 BAts 811terAetfAg bofts lt 3 ct fss cross PetterA tG evGfd bt eek fAg BfTfove tt 8 I it ter p BIB BAcl 6 cltttch st rfAgs Li P TER PLATE 1 e Cerftef Rut Removel St r 3 1gA t 8A thi8 I oc k te b h 0 I d 1 1 1 g th8 Aut1 C i 1 1 OB 3 S 11 Di M Af 0 e...

Page 158: ...moveI RBFlOVB tIRB CIUtCh CBAtBf I ASpBCt fof CVBCkS Dj BXCBSSlVB WBBi QA t hB SPI fABS CLU ll Cll I CENTER LARGER TANGS DAMPER PLATE I RBAluVB the CIUtCh PIBtBS dISCD BAd tt tP 3t B SO t P A I cj tP t PRESSURE PI ATE DRUM arm ttL rr QQg t t L 0 000 SHt tP MUSNUD L Pl IOt d It 0 8 I t 7 7 8 PC t976 A IVIDttCDO HOIIOR M O tOt C O I A C I M 7 ...

Page 159: ...ee Iength Piete end Disc Inspection HepIBce t he cIutch I Ietes encJ discs ff tile yi show sfgns Qf scot Ing ot d I sc 0 I oreticin Ki eesure riisc thickness Check fGt pIMe viier pageon 3 surfece p4te using a feeIet geuge CLUTCH PLATE ...

Page 160: ...NGINE FLUSHING PROCEDURE icauTfowg 1 Clean the clutch outer drum with 6 I I At free solvent soakecl I ag 3 Remove the right head pipe 4 Loosen the bottom engine mounting bolt next to the oil 2 l3rain the oil scl Ben cover 5 Remove tl 16 foul olll scf Ben covef 6 Use an offset sc ewdrive or a chisel to remove the front oil scl BBA cover secuf Ing scl Bw secul Ing scf Bws ...

Page 161: ...he drain plug 14 Clean and install the oil screen 15 Install the oil screen cove 16 Replace the front oil screen cover screw with a hex head bolt approximately 3 mm shorter thaA the or Iglnal securIAg scl ew to facjl jtatB futuf 8 I emoval and installation of the oil screen cover mounting bolt to 550 to 650 kg cm 40 47 ft lb 17 Retorque the lower engine 18 Install the muffler and head pipe 19 Fill...

Page 162: ...f Ot the CIUtCh QUt6f Pen fQve the scavenge pU np SOf OCket SBCLI 0 i ig t Qlt MP SPROCKET BOILT Ise specfeI pUIIB tQ f PMovP ti P cIUtci f QUtef df UM chain end spf Gcket tegethef Examine the chai end spf ockets iQt vveaf FIBplace ff fxcessfveIV wQ f 1 PULLER HC 4 l308 Iii si li the tGIIQwing O 0 t I I UIi c h 6 f f 1 6 Ad sp t 0c k 8 t Spl Ocket hQit OI I C IIIa Si I f net VVeshBI New gasket Ree...

Page 163: ...h ceolel IBecI i cuIBpei WBshet i ock t BIB wBshec IBeciBI flUt PRESSURE PLATE DAMPER LARGER TANGS PLATE g IGAUT ON GROOVES CLOCKWISE The ft ctIoA dIscs MUst be IAstBIIecl Arith the cUI grooves fBdIBtillflg M 8 cIockwlse dfÃectloo Bs IIIUstif Bt d 7 go Q CLOTCH CEN IER ...

Page 164: ...O B i f C f g i Bp j i f Li f f i f i Cf J i i B i f i g f lii C i i Ci j if Off j H f i i i i f il J CIB CCf bB i i B jlO Bfg B P i B 0 O f i f i i I i B f ff B BS f BBf f BF O jBG B i C i i f B B f j f f B i f I BC f i f f A fi f i i i B j f q i B PB O i B f B i f Ci ii B BO i B B S C jB f B B B f Jj f I B i i f f B f f lB Bf f I i B i3 iO BC O Bfd fC f i f l f f i Dl BI IC I iv j X C A t j A H ...

Page 165: ...5 1 1000 Sl IQP MANU p 1 Pl l lk8 f fi f U 5 h l 376 AITICt ICBlt IHOI Md Me t a l CCl I r IC 4 1 ...

Page 166: ... Shift DrfffB Iv e or Dierfleter lCD 35 959 lo 35 980 Alftf 1 4157 tn 1 4165 In Sf Aft rDrUA I off frior Dfenieter IOD 1 i 966 te 1 984 mfA i0 47 I 1 to 9 4718 IA Sli tt f frIJrrt Carvove t Vfdth 7 95 te 7 15 ITIA I 0 278 to 0 282 fn 8 I ck l Bish 1ist Geef 9 944 tnt 0 121 ITIAI I 9 00 l7 to 0 9048 in Service Lirrfit 9 2 mes 9 0078 inl 2AII C eer 0 044 to 0 988 mm 0 0017 to 0 0055 in ye vf ce I fr...

Page 167: ...34T 40T 3 3 T OVTPVT GEARS OVTPVT SHAFT COVRTERSHAFT f OVERALIL RA TlO ...

Page 168: ...rQ fewrench 0 150 kg m l0 150 In Ib Mlcrcrnjeter 0 25 fr In HC 11885 Vernier celipPr V icrQmeter 25 50 i m H C 1 1 886 TRGUBLE SHGGTING Henri to Slhift I fjto Ge r I rnl jrgp I cIUtch BQI Ustfjjent ti00 f nUcl i rrs BPle y 2 S I I I f t i 0 I Ir S b P I j r 3 Shit t slneft bent 4 Shift cl vv berft 5 Shift sf irjdIB belt lc 0se Sl lf t jf Ilrtf stQpl Bf bent 7 Sl rift df Un Cenj gf CIQVBS Perneged ...

Page 169: ...ief1t BBd f eB rove the adietof Dfrfin the eii femove the oii ff ftef BAd ti fe tf QBt eBgff fe cove tI t f rr jj l C f L DRAfM 80LT VVAWER PUMiP COVER l MOTE O l f 00 0 S HO P M A N U A r lr07rf r rmr r rrr r lar fa Mvtor Co fr r re r d rr U S A 7 r 8 ...

Page 170: ...1 f5j BQ I Bl I 0 fjA pQf1t tB f01 iVBBf Bid C B fAfff C SHf IF DRUM STOPPER FQ1 fAQF B BX fBABfVB fAtBf ABID E 11 Bf fSff ff3SffBff f BpBff I f fB BffCff AB fAff Sf lfB f BfjAQVB d BACII t46 BAgfAB CBSBS B p ff Bf fff3 NEUTRAL STOPPER Q N qy HBfjAQVQ tl f6 BTfCjff 1B Bfi dBSCf 1IQB d Bf 11 0f 1 4 POSil T I V E STOPPER ...

Page 171: ...ei ovPT the sceveoge I of 1I bolt ti f l S p r O f et kgaMaa PP ft OVPr T l e If OOI ehgfOP COVE I R f OVP ihP lPTt C rrfiO def I eefusBO I ster T P SPP SP Tfofi f 0 RINGS Reft ove f l e fg lett fkf T L G i 1 000 3 OP MAL L A O 9 e a mariran Hnnda Mnrnr Cn Inc Prin far in O e a n78 ...

Page 172: ...SE SUPPORT CASE SUPPORT HC 41334 SHIFT SHAFT het tove if It sl ief t it t s tert tf t e shlf shB t sh lf I B A Br Q s t i le for wee or dBmBqts I f there is e t cesstve sl if t I i t er rrtovrir er t I tel ot e tr e shBft ster ts to rotete v I tlBc the shift Brrr or sptrtdle I OCK TA8 AI ID 80iLT SHIFT SHAF T Re ristell lhe sh ft slieit ARM SPINDLE SPRIM6 EMDS EACH SIDE OP TA8 801T PIPJS ARM TO SH...

Page 173: ... gal fP i i j l OC t I P i k Sl 18 7 Ai f 3 f f qp Q P t j p pp p 1 f I i l f f f Qp fQ f a 5I i 6 i lI l f l l i l B i l i f3 3I f1 t f 1 6 f S 3V f i I DOG t l C P Vis i A L l9 i i P i rl a tier J Mala Co ft c 3 g Q P l i AC tel U S A 7 7 R ...

Page 174: ...fuf kS V IBCk th8 fO kS fOt bUI f IBCJ Bff JS Of OthBf BVfdBACB H BbAOIITIBI COAtBCt it lBITIBg8 3 IASlfBC I lihB g88i S FORK l D 13 0 TG 13 018mm SERVICE LIIMlT l3 04mm L J i I L SHAFT O D 12 966 TO 12 984mm SERVlCE LIMlT 12 90mm lffS BCt t 8 Clf O A gVOOVBS Th8 ShOII id fB SA100tlf Bfl 3 ff 88 Of CI I PS Ci I 8 C k d I 8 I A SI0A S Of I off I S GROOVE WIDTH 7 05 TG 7 15mm ...

Page 175: ...IBPeplfff13f j CI18fi1 FQf Clf ACI1 AfSBSSBfTlI3I ql SBB SBCTIGA 1 0 ChPCK t 16 QBBf S fOV ff PB6OAi Qf fTiOVBf AHAT OP f GKBifOfi QA khB SI13 tl FXBfAif13 I13 gPBf fjOgS fOf BViCIBACB Q f Bl A df ff13I VVBBi i Gf 8 lI1P Bl fgAfTfPf14 Q f f t 9Cddf 3hff1g3ffCISf13ft 0 i I h 0 IPeS G f 1 000 SHOP MAR LiA L e fn76 A m evfeen Hande Moses Cu i nc I 3 P rinted in U S A 7 7 8 ...

Page 176: ...CGUAtef ShBf i R8f AOV fI 8 A f W ffAfe CO l Af f fl f f f be kf f fig CAP f ffjQV f hf OLlf ft fit f op gP jt fA i f I q f P f A a qtP P qqOVP f Sffd f AD hf f A ff f f f fg f g f f i ff sf fI i Ci Q ...

Page 177: ...H81 0val RBA fGve the vf ftfaPy df fve geaf t3 8 aP fBfg lespeet the if side f vlles beef iffq and the shaft 4all laeaf ing BEARINGS 8 L 1 DOG SHOP MAN fJA L cf f 9 8 Amr riced Honda fffiofor Co fnc P l 1Ar8rf fB O S A 7 78 ...

Page 178: ...OfdgI f Th8 BCC8SS AQI8 8 JtfSBS tS8fTfI 3I8 fh8 QUTPUf ShBTT t CQfTfPf 8SS f h8 SPf fffg 8AQffgh f Q f 8f AQVP gl f8 t Q t 8f S Cf f8Ck Tf f8 SPf fAg ff 88 IBAgTIf l ASP8CT Ttf8 GBfTftt08f fffT 8ÃfGV BbAQt f ABf tttVCBf C f8Cf Th8 Sl fBf f SPftf t i8S tGf dBf ABq8 C t f 000 S f 0 P M A t 3 Ut t L f 9 t6 A t t tt Ic8 t t PfGttBtt Vft TGt 0 0 ...

Page 179: ...ft danfpef engage Gfnpleteilf SPf f ng SHAFT GEAR TRANSMISSION REASSEMBLY MAIMSHAFT Assef Able the geocs on tI le ftfafnsI jaft ancI cGuntevshaft Check the geafs fcf fceedQf l Gf rnGveinrent Gn thB shatts Check that all the clcclfps f it secU elf fn tl jeff grooves Cl RCLlP E USHI MG SPACER C P Vr C 3UMTERSHAFT CIRCLIP If I 4 SPACERS E USHfRG Cf R CLIPS r i j j Vj3 SHOP MA N UA i P rjn ed jn I S A...

Page 180: ... fB8 if g SPf f f fgS OSf8il tl B COU f tBf SI B ent 8 8 3 f ffB r3 8 i 1q tfOI 3Bf QP Sf if B I fB 0 03SS8 gB fS IB8 f Pf BSS tf B ffOI IB f0 f PVSfkf00 b y f B l f fIi BE fhB SC f A S BVPO IP I f80d 0 8I1 8 Sh f t PL f f 8 f j ffBfgt f 8l S 8 it Cl lf l f IIfiB f BIBB f fBUf 8I SBCU fl fg 0 f t 8 8 3 0 S k8 I t V BUD ll VVff 8 ...

Page 181: ...nsert the shBft pin 4th n IIAIINSHA F 1 FORK lAstBIl the Atetnsheft Qfl seperetor Brfd cI fein olfe r LrtgBge the shift fork Into the geer BPid seel the 46Brfngs tnto the set n f tgs CHAIIN Ol IVER Ai l gA the met Ashe f t of I pBssege locetor tBb wftI f the c ttl fnrler blQcl groove 6 l OOI3 HOP M NUT t P FlHl86 tn LI S A 7 78 t l9 6 nvnnnn l anna Magna 6 fnc 3 17 ...

Page 182: ... f m SHl FT The lPtt c Iff1det 5 Reve B IBvge chem fet thet Bllows the rings to enter the col fnclers wfti1ofilt Usfng 8 ffng compvessov Reffsove thP pfston bB565 Bnfj seBt the cese 4 feet Bll cese bolts encl thP Undef sff36 ot t 16 bort heeds wfth mol ffDclenUm dfsUltfdP gveese Bnc tof gU8 tl fef1 f Bs DRUM shown 16 m f 330 to 370 kg cm 24 27 tt Ib 8 f fm 250 to 2gfo kg cm f236 252 in lbf 6 mm 10...

Page 183: ... j3 ImpPi ief She ft vvi j the drive tfeif j Asteij Bli 0 riAgs BAf i the tf Of it COVBf fij E U T RP I S I OPPF R Q Q For cpiiAfier he8d BAid bAifAg 13eit IASteijetiOII SPBSBCtitfA 5 Bee SBCtIGfi f 0 tOf Cief tCjf rsSSBfTIbjp F Oi 6 A CjIsf6 I I f St6 l i t f O A S66 BC tIO A4 6 L I 000 6 fa 0 PM A i e i i ra i I976 American Honda Vloror Co iric I l 1 9 f rinfed iif LJ S A 7 7 8 ...

Page 184: ...1 0 I 10 x 166 6 x 1 IO p 0 0 C Q LE 6x 36 REAR ENGINE CASE k fU 1 CLO1CH COVER P F BOPJT EN GINE COVE R 6 x 55 SCREWS f ps j s sc rws t I OIE FILTER Q e x 22 SCREVVS TO 6 3 Sl REWS SER tL 1M9 3 M 6 x 22 BOiLTS AIFTEB WA1ER POMP 6 x g0 Z ER Is e339 0 ...

Page 185: ...6 l 1QQO SHOP MAN UA 1 C f 3T B I t tl t I CBt t PiCPlifg 3 gl tgtCB t t3 l a 1 2 P lan ed i i U S A i 8 ...

Page 186: ...76 in Gz Hub Assemb iy Pre Gad Puil Scale MethGd 1140 tG 2100 grams 2 51 tG 4 63 lb TGrque Wrench MethQd 5 7 tQ 10 5 kg cm 80 tG 146 in Gz Torr1llle Values RIAg gear 8eai ing retainer 400 kg cm 29 f t lb 8It m flange belts 230 tv 280 kg cm 200 tG 243 in lb Swm g arm pivet adlusters EH 100 kg cm 87 in lb back Gff Pivet lGck nuts 8 0 to 12 0 kg m 58 tG 87 tt lb Huh at ta hing nuts 350 tQ 450 kg cm 2...

Page 187: ...REAR I HEEL HUB r QJ x i t i MD r i PROPELLER SHAFT PROPELiLER SHAFT JOINT i r neiow soier GL tooggHOP MANUAL g 9 iV ip 3976 A t n erfoen Honde Motnr C o ino 5 w 3 P rinted in U S A 7 7 8 ...

Page 188: ... 0 HC 06277 St r HC 41301 HC 41333 HC 41332 I lC 4 l327 HC 41312 HC 4131 I HC 4 305 I IC 41325 HC 41318 HC 41314 0 25 kg cm I0 300 in oz 0 25 kg m 0 150 ft lb irclip Pilaf Cif c I 3 Pl fef I etaff er A rencI P a I T 00 rive 5P BI P ef 1QVer 5 idirf Weight H f310VPI I Iandlc P r off I 10 der I frlv8f i rI VP f Hear If fg Ren 10ve i f cf r 3 8 A r 8 I1c h TGrque Wrench Pcfil SCB P I IBI I Ad lca tOI...

Page 189: ... e block uAder tile leer tf e to pf eveAt the axle ff om fAteffetriAg with the exheost systefT I tBA ove t P ottP f f ff AUt ef f d f Be l B X IP 5 lt Rtf lee tI B CRI l ptUf Ovef the SVVf Ag ef lA t3AO 0ot O I f AP wev t0 pfevBAt t leA BgB tv BA tl lP wl eel fs f BA oved DisBAgege tif P i Bef wl feel tf ofTl tI B I f k jl ive spliAP BA 3 BfTfove tI te Wl teel 0 L l OQQ Sl tQP MA a tJ L 6 a t a t ...

Page 190: ...ai id slide the hllb fr88 Pnng Gear Carr er RernovBI Reinuve the ring gear bearing preIuad luck tab and the dIs tance cul Iai PREL OAD AETAIMER ILOOK TAB Rernuve tiie rII Ig geai beat ing IsreIuadi i Bta incr RKTAIIiIIF AR k P i Q QQsi i u v A 8 Q 4 i 2 i 976 Anklet i a t Honda Mown Qn I nn 6 F fnted in Q s 7 78 ...

Page 191: ...f if sI e f I he hl ia vent holes t ot ISil IIC IQn GEAR CASE COVER CONTR01 I f I c BicI lf l ofsBsseft 4 heBt thP geBf c isecovet to BooC I 76oF 0r JVP thP f iflg gPB t of the geef r BSe CO ref rvith B PIBStfC h IVj ftlP Of USe B t IBSS A vvB y s tepIBce thle seBI Bf tel th fs Of ef Bt iof L 00 0 S I I O P tr I A N Id r I r 76 J nrer radn Hands Motor I o f no Prir r1 in J 8 A 7 8 ...

Page 192: ...I pf 088CIIL V8 CIBMBgeS tf e beBCIAg Replace the beering With B ABW OAB NOTE I ASCBII tIIB f BW beaf fAg Of f the I IAg graf shBff with the I casing driver if ll icI GIT ti 8 stake Qftfofa c f hP I af fA f II Qf pf 9 t 18 staked BI ea fop CAUTIONS D f iAg thlS Opef Bt OA be CBYeft I AOt tV AIBA Bge the thfeadS Ot tl 8 ClC V8 PI A OA ...

Page 193: ...Tfooth rGtetiof Check the piniori geer fof evidence of ffveer SPACE Ps Do not remove the reer beefing from tihe sheft lf the piniGn geer ofr beerfAQSere 4A18 d the drive hub must be veplleced es en essembly j PlkfON GEAR I hredd tine seel f BfTiGvef toGI lAtG tile pfnfoff Sedl Irlslefl the rPrnGvef hendle dr i use the sliding weight IO f BfTfOVB th e SPBI Do Aot f B use the sPBI Ref AGve the f f o...

Page 194: ... y on tif8 if1nef Pece Spree j tI38 pevvIs l3 y tUf AfAg the shett cIockvvise Use the siiding vveiglnt to l Bntove ti l8 beef lng DG Aot tf Use thP cese beef fAg Do Aot denlege tI38 tiff Beds in the IDUN vvhlIB fjlfvf Ag Qcf t tI fP Qf I seei Do f ot Pe Use the sPBI G4 i 600 SII OP MA QUA I Prfnte f in U A 78 0 2 3 c 1 976 Ameffcen Hon dv Matnr Cn Inc ...

Page 195: ...I I IS43lf f18 I QAt Pfff3f 3At IQBBI flfg lff h8 CBS8 BffQ j IV8 t t8 ff8 v SBBl lA l 3 PQSII IGA iC UT O LGI 2 gf 8BS8 b8fOI 8 IAMB fBtIOA tO PV8V8At RBAIBg8 L 04f ICBf 8 8 8 S88 Brf6 ShBff I kh I ISIBll f 38 SI3IIA8 IhP CQ IPffAq A BSh8 BAD f3 fl TQt 308 AtO4 hi SP8CI ICBtfQAS HOCDFR Hc 4 306 3 C I 000 8 f IQP M Af I 44 f 9 i 6 it N t t fti tt t ff itt tit t Mtt lot Ct t Pt ittfed itt f t S A f...

Page 196: ...BI i S i i lGVV j P i jf AG t I 3 i I P i i I f i GP 8 f I 0 l d 8 I 8 A I PINION PRELOAO 700 100 6 1 54 43 tbi O 8 l t Gf 7 t tf I C BS VB i i t S I 8 f PAIBCP I i l TE Btt 81 g A 8 8 A 8 llO l 07 ChBCkfftg l A OA Bt d f fb BSSB Abler p BlOBd IS 8 I 8 f I 0 I 8 l 0 ii 0 kI8t l f8 k 0 S I A g P 0 DUO f A OZ kOI q 8 W BAC i BAd 8 24 AA S CUBI ObSB VB tl 8 Ot l 8 8 IGICB tO 0 8 8 AB p AIGA I tf f I ...

Page 197: ...r slack Is t8kerl Up I Ulf n the pfnfGA Gack and forth tG read ilaac kIash it ihP laacklash Is toG gre8t ose 8 fhlnrler spacer I f the backlash is toG lfttIB UsP8 thicker spacef Assernl le the drive hob ar d check assembly prelGad as described L I fder plnfOf ll prelOad 1 2 1 2 I f co iI Pc preload cafinot be obfafrfed chPck t fe Gfl sPQI fit oi pl BIGad I Btal neil torqoe If necessarY I Bplafce f...

Page 198: ......

Page 199: ...VBFS KA6 Ff BFI f6 RPA IOVPI tF 6 CfFCI fP BAi l th6 dFIV6 SI IBI f COUP i I g RBFA fV6tf36 Sl IBFt f Of A FAI6 SVVIFIC BI TA I IISP6CF 16 Ijl IIVBFSBI jOIF1t LIAIV FSBI IOIAF b68FIAQS RCI FB f6 FFI6 SF IB fF BAd OIF1t lfl OPPOSft6 31FPCFIOAS l f F 16F6 fS Bf IV PVfd6AC6 0 f Sfd6 PIB j Ft i6 SAB i FIUSF b6 FBPiBC6d SlfOif g 06 AO p BY fff t f 6 ICffu TfONj P inzea j n O S A 7 7 8 ...

Page 200: ...eck ies 1 MAXIMUM 8ACKLASH 0 3All CI elk tIie beekIesh Iii the UnivereeI loiiIK BBd f IIIBI df Ive sABf MUI TIP URPGSE GREASE NIL GI Pf 2 MoS2 ADDITIVE g 3 L UI3f Icete eI ees IPclfcele6 t3Q Bf rovvs pi ioi t0 Be SeAibIY MULTIPURPOSE GREASE i7 Q MlLGI 2 2 Pg k ...

Page 201: ...f IBBF R 800T CPBi lS if i it SfT IOf I i tSt BQ i i i i Vi K bOI I t 0 dBfi fii BO I C B Ifj Sfil IB SBS Of fjf i BC tS i i ii 30f I t VC 4S I j j t I Of V f A t0 i I ff BBdS 0 P t jt t f f Qtj I I 8 iAP I Vlf S tV t BQQ l I P f C BQk l Cj CI i 8 CO I f l jI PCiI tI 8 St V fj I BCIT jQf i Bij jl i 0 f tI QV 0 P f tt I I bffjCjff i f Oi I I IBP i f fjj V if I fgO i 0 qtO Cf I i tv I i i i pp IV bt...

Page 202: ...B BAd f CI PCk 4t fP 8 fAg Bf O G fVBPd 3 lf 3 f AGVB APBt If fB Bl f tO B L AfVPf SBI QfAX Cff Cl fP f f8 Bf I f f8 i BBf GUPPY ffg BAd ff Cf fP P B Cf f I t P CG f 3f fAgVVf fh 0C f 40 gf Bf ASI 9 f AUIIIf3U POSIES qABBBP fQ ...

Page 203: ...f 8 the caliper stBy Dolt I nstalii Bnd torque the Iowel shock abisorber mounting bol ts Reattach the starter cable battery vent hose Bnd rear Drake ifne to the swing BrrA TOrque tlfe BXle t ut arid fnfstaII 8 n i aw Goiterpin Brir g the oil level to the bottom thiead of the tiller hole Cnecl or ree rotation o f the wheel EA 0 Pl l ihtl a ii 1 u 8 A 8 ...

Page 204: ...center sf Bf 1cl on B libel sUf fBCP f ef Anve the ail f lier cep The oil level should i PBcf1 tlfe flllPr neck l i the ievel is helm the filler neck Bdd the f ecof PifAPAGed lubrfcef1l until ft reecl les tile filler APck threeds Reirfstell the filler cep ic if 0fff 1 6 I 1 QUG SI un i i 4 l fn f 2 r 2O f e78 Arn I n ladon Matn Ca e rfnxnrd fn f S A 7 i 8 ...

Page 205: ...Paf vvi e ff to cirafrf Br Psi isa fO oic c r c re 2oo 22o i6 8 7 5 z Vake S Jf P ti e A ashen is ff gOOd i r r 6itiOr Br f 1 f efostali ti e draff P lU i F ill the gear caseto the filler rfeck vvith clean f f ricarft o r the recom f A ef rJ e fgf B de R e f f stBlfthe 7 flte r CBP Se CO f el rr G r t P P C i 1 000 H Q r M r N U I 19 78 r o crjcco f onno IVfo for Co f n Prir io i jr Ll S r 7 8 ...

Page 206: ...C I 1 00 0 BI IQP VIA N V A L c i97 8 D nnerlcan Ho nnn M a ser Co in n 3 P rinte 3 in I I S A 7 7 8 ...

Page 207: ...te 39 2 kg i33 227 5nlrn 94 to 106 kg i23 194 8rnm ervfce llnisf 39 2 kg fl3222 9rrffn 94 kg foi 190 2mm Reef sl iQck spf I ig 1978 1979 I ee IBITgtlf 38 r5nlfrf 2 70 ff3 178 2mfTI 7 02 fA Service lir iit 67 0mm 2 64 ir3 174 9mrrl 6 89 in 8 Tfte 39 I kgT58 0mrn 39 1kg 167 6n3m 40 Plus I Ainus 100 Plus Minus 6kg 2 4 kg 57 8mn I 151mm Service limI t 39 I kg 56 8mm 39 1 kg 1 64 2mm 3 7 6kg 56 6ASA l ...

Page 208: ...FRAME AMD SUSPEMSIOM ...

Page 209: ... I I 8 I f c I GI I 6 I 8F I ofi f fe wten h 0 25 kg m I0 150 tt it j t Q iiU6 wf f fCI 0 350 kg Cn i0 300 I I lbI 6ptin f pUli sicaie gtan s QUncp 5 I la it If g i31fe S 76 f le caifpets t 0 20657 Vf U tf IIIpose g t t as M 1 i 2 t 1 tOI I at IC t I tan sf I ssfOi i ti f i t He ftfl ig f en Gve HC 4 I319 plv 3t nlft I efT 3vP HC 4 i3 I 5 t eatfl lg i liaOVPI Wefght H 4 1 3 i 2 Healingi ef Qvef il...

Page 210: ...n fGik legs 4 8 Bf swff fg Bf fTi bfncllng 5 RPB SIIGCk 1 Gds IVBA t 0 blffCjft Ig 6 Defective I Bet sf ocks Soft Suspensfon 2 7 GG iftuch cleef BncP Insfde tiof ks Bf okpn fof k sptiftgfs 4 BIGkefs feet sp inq SI Dei ective I Pel sffocks I I cof Beet weight fl u fd fn f ofit fG ks L lncorr ect fluid level in fo ks 2 B Gkef0 pe ts if fGIks 3 Steel fnig stevA nlft too IoosB 4 LOGSB Bxle I ff Ont Ot...

Page 211: ...4 I PP f t l i P Sf i ii IQ i 8 P f P 5 SPPC 5 O t BSSP ff I tl OC tpf lp jP f i5 O gt A A ppf Aq ua gf f t g i3 il it i 15 Ct SD C f f C l f i3 f f5 ii PP A ft St TO Cf pCk Iip S pp fA j l ip O f pp l GS l lpf l r P l OAlf V APPl j A f OUAd O5 l l t C t P C l f ClPl l 8 f3 f j i t P tf tfA i I P Cij Itpp AiP it f k SIfVP 5 CI tP f t 5f lp lf OA t i P Pf tf 5 O A f f JII IPi t i C f j l i f Cl f l...

Page 212: ... plug PjBce B pen t3elow the tGt k f efnQve the df Bin plffg Bnd Bil oxi thefQf k tO df Bfn RPplece fr je d VBf n pl tfg Retill the fovk Bnd ceplece the tf lier plug Bnd fQtk cep Repeet thfs QpevetfQn rof the f efneff jfng fQPk lP g OlL FILLER PLVG ...

Page 213: ......

Page 214: ...fQrk iegs PQU Gf3t Bf1 y PefTfe fnfFfg tO k Fi id end n1ou 1t the Gf k ieg in B vfse Remove the bottom sncket UO i t 3isessen bie the tock Gmponents Bs si o A ff QA Pege f 3 9 I Aspect GA D1eck ti1B tf BB iengti 1 Q f the tQ k SPA ng RBPieCB ft 1 i ft dOBS AOt i ne t spec ticeti Gn EREE LENGTH ...

Page 215: ...RING FORK CASE ISLI DER OI IL SPRING CKET j FORK PIPE ILT SERVICE LIMIT 36 900IPA M AXLE HOLDER Dip the nev f I k seel in ATF end instell it IA the sIIder Using the foI k Ieg es 6 gUIde foI the tool I nstell the fork Iegl SI into the ste A BAD cI owe I TIghten the Uppef end loA 6I pIACI l bolts secUI elf FIil tlI8 fOÃks With gOOd queiit y ATF i 000 si i Q P M ANUAL 3 0 3 0 A c f978 0 t iet ivan Ho...

Page 216: ...tla dan age f IP l3 fke 3 3 fs i f Is a i I I hi c if fpef I rioenti f g 30 its i lgllte i alfie rig It a i hOidef f Jets speedr meeter side l l thP specitfed t 3 r f I8 starting w ft l t h 8 t 0 r w 8 r 3 f Uts Veascfrr tiie c Bare tee betwee I thP left brafke disc al d the real Ot the led t Il fp r Olde wi i h 8 feeiP r ga U je I I t 8 gaf ge can lot t e Inscf ted pU f tl fB I f t fork BIO twas ...

Page 217: ...B the f fght I fdAd SVVftCh Br frl rerAove the cebles trorA the throttle pfpe Urfscrew the cel3IB go ides tf of A the lower heII oI the switch UpBA tf fe Ieft slfje covef BrfQ discof Acct the wires I or the h 8 f fdl ebef sw ftch Bs Refoove the clUtch ceble and s ffety swifch sterter ...

Page 218: ...ovvn CLAMPS PuIl the svvitch wirIAg thIu th6 f18 IIdlebeI V PULL WIRE HROUG WITH ILOOM FGRK BRiDGE RE OVAL DIsconAect the tachometeI aAd speedometeI cabbies fI om the InstI umeIlts Remove the tvvo IetaIAIAg Auts and IIfI the plate instIuIAents and light panel of f as an asseml3l G L I DOG SHOP MANU L C 9 6 P IT dd t QA H O A d d M d t O f C O t A C Pi tgtPd ft U S A 7 78 ...

Page 219: ...nu rentRQvethe steef Ing stefTf STEERIMG STEM CAP caf i STEERIMG STEM CAP Jack up the engine until the frQnt wheel is Qff the grQund Reff IQve the steel fffg steIYI Ifut and vvasher and lift the fQrk bridge BIear Qf Ihe stein and fQrk tubes REM0VE MUT WITH PIN SPANNER T00iL STEERING STEM NuT WASI IER G L 1 fief tlti P M A NQ u 3 sa3 4 l I7 3 f4 I St tt 8tt t tiit ll18 ViO fat ...

Page 220: ... NT ASSEMBLY MOUNT N BOLTS RBI QQVB lf B h83dIBI IP SiNBI 3 i O k C QV P I S 3 S 3 1 1 QIt P N Sf ANNER 700L HC 06152 OR STEEWVG 8 EQQOCKET HC Q f65 I t I PM i VP 13P S BP l G Q83 d OP fl l4 1 j i i SU fSQf I 8 StB Q fQ j BVBf t I t I QITI f3III g 3Qd B T OVB LIQBQPI 8 Cl 118 x CB 3f 3 I33 f 3 3f IQgS Top ffI M f 8 000 S HOP MANQ A I Pt tnt d in I I S A 8 Cn 9 R Arnarlean Honda Pintos Co Inn 3 3 I...

Page 221: ...ACE lB BALLS LOWER RACE 19 BALLS LftWEB COfftE BABE OUST SEAL T STEM OUST SEAIL WASHIER 0 QR EQU i 1 OR VE OUT UPPER RACE i P IILQT IN i I LOWER RACE Pl LQT IM UPPER BORE i STEERINC i HEAO i OR liVE OUT i ILOWER RACIE E i i i 6 L t OCtO r 8 0 P fft fL tft U A L P l jffSBfl t f l L Lt A 7 7 8 3 ffA 3 Q Cf 978 1 Llf BEtCBD t f D D ft B M D SDECD t D C ...

Page 222: ...j DRIVE IN UPPER RACE P ILOT IN UPPER RACE f I PII OT IN L OWER 8ORE lnslBIi II B I IBw IGwBr I BcB DRIVE IN LOWER RACE AssBPll IB tI1B sI Brn wII I I fhP deist sBBI vs sh Br dns l sBBI Bnd IGwBI cGIIB I BcP 4 r tiI OWER 8AILLS rr t LOWER CONE RACE DUST SEAL DUST SEAL WASHER ...

Page 223: ...vef tfcBI AfovefAeflt Bf IJ fhe stefA I Q exes t6 88I y TOPIVUT TOP R CE l Q TO BA L 18 RUT CAP STEM fiifUT ST 6 V NUT AS iH E 8 3 fASfefI thie bVfdge BAd SteA AQt IAStBII the foeks heel heBdIight Bnc hBAdle bB I S f Ref AIQVP tile 4 VVBV JQIAt BSSPA fbi y R ieA iQv8 the l IPBdIGIAp BssPIAb V BAd thP lAtP ABf W I fAg Refeeve he vvheef Bf id fQI ks 4 WA V JOf MT R 8 ITIOV8fhiP h8BdfB TIp Sh8IfBAdf ...

Page 224: ...i s iEO ER UPPER I RACE RACF LOWER gygifa HEARING BEAR ING i lll jQ oust sr r c ICAU OX jteerfrlg hear i f38arfAgs BAN f aces dre s Lf p p f Ifa I I I Tf at c i 86 s 8 is t 0 8 A s o re a Pl BCISiOia It B e fTfpt re arfrj IAStali cQfTI f lete sets rfQ Aot rtffx rPpiace f APAI 4 eaf frfqs Ql ra Bs wfti I orfgfABI parts T BEARfftfa DRIVER HefTiOVB trf8 tff3pPf bean Ag OQtPr laCP Qsirfg bearing ofrfv...

Page 225: ...BVIAgS l AStBll tf18 Upp8V b8BVIAg OUt8f VdC8 IUSIAg b8BVIAg dnVBV HC 29824 BI3Q VBC8 AStBllBtlOA BttBCi ffTf6At H f 64767 C I AstBll tk 8 lovv8v b6BFIAg of ft8v I Bc6 USIAg l3CBVIAg dF lv6v lC 29824 dAd I BC8 IAStBl iBtfOI I BttBChFABAt Hf 64767 PlBCC th8 JUSt S8Bl Of I th6 St68f IAg St8F 6 IVIStBll th8 lOVVPf b8BVIAg BA 1 AA8 I d P US f AOb8BI IAg df VBV HC 64768 BEABIIVG I3BIVEB ATTACHMENT HC 6...

Page 226: ... I I I I Q e I O I U I VB I l l B Ot 3 4 k g I I 2 2 28 t tc sect tl fe L p If f gs 1 I PA IQQ Bl the I U l ffo d I ei gl fPI i I I tQ d ll If i OA tie V IUP Q 1 5 i 7 k j f BEABI IG DBIVER LOIIIIEB BEABff IO P Df ST SE L t i S t d I I I f B 0 t k I I I gB f 0 I k 5 Pl hed liight d cl Iidf 3 IBI I ff s SOCKET HC 64765 REAR SUSPENSION Pe c 1ve ttfe Uppe Bnd I of fef sl ocI dt ov Pl f EIU tf I bO ls...

Page 227: ... GV iF P OCK f 4UT frfS SSS l iP L P f f f MP St f 8 P ffBP Pffft i f lhP Sf ffi f fASI P CI P SI Ck C f PV deaf CP i C ff IBPkS PA NG S t i e SPRfMG ADJUSTER f REAR WHEEL EMOVAL I 8 Tf0 P I P f P8 V JI i S1 ff d S A ff g RSf f 3S PS f D 3 f SPC f f f I f f ...

Page 228: ...3OV8 th8 dUSt COV 8P PIVOt C 3lIBf Bf f j tlf tI if fJSt I3USI if fig THOUS 7 IEIUSHIIRG f fiSI38Ct i t t8 f f88 l8 tL Ã df fflgS NEEDLE BEAR tNG I f tf t8 f L388f IBqS 8f 8 U ff Tf E3g8L I 8 IHQV8 t f8f I t O it3t ti38 QI3 3OSft8 Sf 38 ...

Page 229: ......

Page 230: ...VOT COLILAR PO fCfStBIlBXIOfcf Of IhB df fVB Sl Bft I fB tBI COUPlfAg BOd SVVf fig Bfc I SBP SBCssfOO l 2 I fft Q i sttocst 8USHIItt IG REAR SWING ARM BEARING stvos susan susttttrto PIVOT COLLAR DUST COVER PIIVOT NUT I PI VOT EIOLT I OCK NUT Qg ctrs O ft tQGU StfA P M c N t f t s t ll I t ll t o l t d V tr l rt t t 0 I 1 I 3 ...

Page 231: ...r cvfilndef avvap if Dm the ue tank vvlt 1Qfut dlscoflffectfng ttfle 131 r3ke If nte RP Y1Qv t f 1 te tuPI tal tk dralrf plutl and rafn t t le tuel RP f 1 1Gvc tne t fBl pP tc 3ck RPrn 3tJB 13Qtl 1 Seat b 3lts and f cfnfove tile seat 3fscQnrfect the tall light and turn ignal vvfrets RefnDVB the r r r ill bGlts the r tall and turn sfg t fls a5 a unf t ...

Page 232: ...vf res thB tenk I ol fsncI crossplete Herr nv p r ie to0 f ref vfcp corY1pdrtn ien rnof Atfng t ol ts RPf i iove if ie bettPr y Br d tl 8 bBt tery box rnoof ftfng bolts Pertieliy slide the be tery box out ot tne treftie L IevBte the servfce cort pef trnent enotfgr to cIBBr tI ie ges tenk filter neck Bnd slide the teink toiverd trie f eei or tl e fnoti f cvcIP Burl OUtOk t he f r eni P ...

Page 233: ...nd ight in off le TnoUntln I bolts foot pegs encl it iffIe Iy PIPE CLAMP 89LT Rei inove the pivot pipe cottPP pii i Loosen th pinch bolts Bnd emove ihe stBn l 89ii TS I nspF Ct ii iP Sten j fot c BCks of othe 6BfT Bge Luh icetP hP pivot sheft Bn 1 i Pii istei tl e sten i IVIA IN STAND LU8RICATE WITH NiLGI 2 F2 GREASE ...

Page 234: ...ntf Ag ho t and spring Aspect thP rUbher pacI and repiace it i it is worn beyond the wear tine STEERING HEAD FRAME I N 8 PECTION f Aspect t Ie If ernovabIB frame sectfon for cracks ol darnagP Inspect the stPerlng head area arfcl BAglAB rnoont PiatP COAdltlOA ENGINE MOUNT ...

Page 235: ...GL OOOO SHOP MA EQUAL c inr78 4 rnericnn Honde Motor Co lnri I 4 P rinted in U S ih 7 P ...

Page 236: ...o 38 148 ITim I 1i 5005 tc 1 5018 in service Iifzlit 38 245 mm 1 5057 in F f Qnt Bnd rf Br dfscs ruf loof staf idaf I 0 to 0 05 rnnl 0 0 002 in service limit 0 3 mm 0 012 in hick ss s tandard front f 9 t o 6 1 m m f0 2322 to 0 2401 in sef vf 8 lfrnft ff ontf 5 0 ITII Tf 0 1968 fA Bear tire size 4 50H 17A Front tire size 3 50H 19 IAflatfoA pf essuf 8 2 0 kg cfTi2 28 psi inflation pressure 2 25 kglc...

Page 237: ...87 to 1 689 in service limit 42 915 mm 1 690 in Real caliperpiston 0IIBmetel stal1dard 42 772 to I2 822 mftf l 684 to 1 686 in sef vice limit 42 757 mm 1 683 in r0 n t B ncl f eB f clIscs runout standard 0 to 0 05 mm 0 0 0019 in service limit 0 3 mm 0 0118 in thickness standard front 4 8 to 5 2 mm 0 189 to 0 205 in service liimit front 4 0 mm 0 157 in thick iaess staflcIBf d II eal 6 9 to 7 1 fTll...

Page 238: ...I c I j I I F i j j I G i 1 0 0 0 H 3 A i F vi e i i n 4 5 f F s ...

Page 239: ...R FRONl MASl ER CYLINDER P cll o PII1 PISlON CUPS AND SPRING ci i Ir OIL 801T BRAKE 1EVER RUBBER BOOT FOUR WAX JOINT DISC SUPPOR T BRACKET g GAL tc f ocr BO LT CS i I GOI3 SHOP MA rci U A I 144 1 976 Acneriown Honcfa Motor Co I neo PI Into 3 cft US A 7 8 ...

Page 240: ...ve pvessure gaUge Circlip pliers HC 4 823 8 lee er I iose I f lside rntcl ometef 3utsldP At IcrotTPtPf Tot que vvt ench 0 25 kg vn 0 l50 ft Ib Tcrque wrench 0 3vo0 kg ctn 0 300 in lb Brake fluid DOT 3 Ul tl purpose gf Base NLG I 2 Si I CGASeal fn g gt ease TROUBLESHOOT MG Bvak8 Lever Pedal Soft ov SpoAgy Aiv bubbles Its hydraulic system 2 Insufficient fluid tn hydraulic system 3 Extef Aal leak ivt...

Page 241: ...I Ie f k tillthe I 858I velv vvIth Dol 3 I3BAI E I LUID I u the I pe level LONIER LEVEL MARK 8 elk l iutinil F ROP4T MASTER CVLIMOEB I BRAKE HOSES 3 VVAV JOINT g7 v 388 slil 8 tl te I f ke h0888 ef IO 1ttlBge et 8 1 ot elefel Il3Ietetl Gf eeke 3 Fe j lv I 88k I ji t l I t I 0 f l t 8 f elv88 1 i 8 k 8 s V 5 I 881 8 t l I 8 8k8 I8 5 y g CAI IPEB i i BEAR MASTER CYI IRI3ER I CALIPER ll 8BAKE PIPE 8R...

Page 242: ...B Bi fd t3UA1P thB I3VBk6 IBVB S Gr t OPPi 8 iAg fh6 IBVBi VVI BA Ai 3 iU ld tIGVVS GU I Of I18 bIBBdBr VBIVB CiGSB lh8 b 68dBFVBIVB fIll 1I 1P BSBi VGi BA t AStBI 016 dIBPf i Bgm FGIIOVV HRAKE BLEEDING p GCB 5 i 8 DIAPHRAGM BRAKE BLEEDING BRAKE FLUID RESERVOIR IS 1 QQ 0 S ki 8 P M A ttt 8 A I i 8 6 A I t tBPIGGII H of fdG iVivtdr Co I n o I Printed in O S rA 78 ...

Page 243: ...hendleber grip wheri bleeding the front breke system 15mm SPARER PREVENTS OVERTRAVEL l3 LI RIN6THE 8 LEE DINGPR0 CE9 0RE Pump up the spsten l pi essure ivlth the lever or pedel j until it becomes herQ Open thP celiper blePd velve Close tlie bleed velve just befnre the IQvet lo pedeII reecl les tl ie et id of its tr evPi Continue this procPdure on both front celipers until the breke Ipver fepls sol...

Page 244: ......

Page 245: ...en ove the pBG spf fng BL 05 CI fP PISTON BOOT Pemuve the pis ton bGGt clip pistGn boGt etld piston it I t ep be necesse if V tO Bppl 8 SlIght BA 00nt Gt eft pPBSSUre tG the cellpef floid ff let tG I emove the Pfston I f BIP Pf BssLI 8 fs fJsed t0 f Bn fove the pfStGA pleCB 8 ShOp Peg GP Othe ClOth In the CelfpeP BS ShOWA tG pf BVBAt fhe pfstoA ff GIT becomfng defTfeged vvhen it is expelled t LAID...

Page 246: ... 58t 5 ta I l ec31 r f li spect the pistoo seat Replace it h reed BFIP I 01 jetef fof efe 3 SEAL t fbntcett the l lst00 vvf th 8 Ff fee t ILIPOI gf 8 18 hfglf te TII BFBILOIB sfllcOf1P glf Pese eteil P r SSBI I hi rntti it 800T t t tec tceiiipel I ff s to he s IFB the Tfove rfBeirut l fr tl18 IT 000tf t 1 I bf BCkBt t10IPS I t ICdt 00 t I pI P rttlth I O IPO ILIA I I 8 38 h fgI I teftfpet retpt B ...

Page 247: ... the buut Ifp teeing QU f Insta l thP buul BAd Clip QA thP piston Irtstalf the pa 3 springin the ca lpP Plac8 the bf Bke pads Bfacl uf Bke pad shfn I OA tI I8 PAQU At ng b acket Bnu install he caliper Tighten the 8 x 25 mrn caliper bolts tu 350 2 00 kg cut Il 1 14 ft b CQAAect t 18 hydraUU IIne tu he caliper Pill the reservuir with trash DOT 3 brake tlUid frum B sealeu curitafner 8 lePd the brake ...

Page 248: ...r the BA 3o I tl t8 hose tG preveAt con tert off tet Ion BAd secore the Ifose to tl fP f Gf k Fluid Reservoir ReiAove thie boot frorA the Afester c y t fAGer body Me stet Cylinde Body HP t Aove the cfrciip tl ofA fhe PAfester cyll AdPl IQocly Usif l 4 elf clip pllef s Circlip Pliers 07914 323000 I HC 41823 Mester Cyli nder 8ody O l tQQQ Steep MA SlU A i 1876 rtlT16r crt ldortrl3 fvfofrtttQe Irttv ...

Page 249: ...e te BAd f esef voff Check t ie condfifoA OT g he O f fng PRIMARY CUP MBBSOfe the f ASide CtfefTfetef Gf the fABS ef CQIIAdef pfSlOfl l3OI B SQA DARD t l 460 2 603 i nm MASTER CVI INDE R I0 6874 0 6891 in SERVICE I lf IIT I STAIV DAR D 5 8 70 l 6 913 mm I 0 6248 0 6265 in SERVICE I 16 926 mm IMIT I l0 6270 in PISTON 8OR E G I QQQ 8 f i OP M A N U A i 8 irited f n LJ S A 7 7 8 4 4 c 3978 fL A IBVfC...

Page 250: ...TCH CYI IH ff tS CA UTlt ON fI AheA fAstallfAg the cups do Aot allow the lips t o turA fAsifde out 88 certaiin the circlip is seated firmly fn th8 gf Oov8 Install the 3oot wasifer Bnd clip Install the reservoir o I t emaster cyiiffder making sure that the 0 ring fs If I good fcond f tfon PIBCP the p ate fA tlfe resPrvoff Bnd Iffstall he two platf3 s rews f 975 1 978 Place the mastef cylinder on th...

Page 251: ...FLOID RESERVOIR BRAKE I IME TO 8RAKE HOSE I Y 1 PRIMARY CIJP RECDRDARY CUP RU88ER 8OO F 8RAKE PEDAL CALIPFR DISC 8LEEDER REAR AXLE f STAT 8OLT Y ...

Page 252: ... paGs dnd shfir ns Iitstaf I Ppiacelne tt pads lfl I PvPf sP I3rdef Qf cifsassernbfhj HP sLIf 6 lf Ie arrcfvvs On the brake pad shims pOffft dGwf ward PBGSa Id shfl As mUst be propPf lV ai fgneci before Inst fiilng the pfns I t Yfa f b I iece ssal y IQ pUsh bGrh alf per pfstoAs iaack iritQ tifeff cvff fdPf 6 0 pfOvfde Bdeq fate cledrancB to pad I I fstai la I I Qn PAD SPR NG Pj PPER PAD PIN L s i ...

Page 253: ...g B i Bnci secLJIte It R move the cBli perstey boit Remove the cottef pjn fl on the Bxie AUt Bnd K ove the AUt BAd Bxie t i t Op OA the bteke CBi per BAd pUII ft OfJt Ovet the f AUf fiel FIBMOV8 the breke iine fm n the celipet Bnd pIBce B ci8BA conte net Undel the I Ac ROTE ...

Page 254: ... the eel ipef hBIves eligove the PBds Pies BGd sPI ling Bs BA BSSBFAblg SPRING Reilkove The l3GGt clips Brid the LQGGts on botl celiper sides Remove both pistGAs It ITIB y be I IecessBI to Bpplp 8 slight BA 3GUGt Gf Bil pl essUi 8 to the beck of the PistoA tG i 8AAGve lt CAL I PER A CALIPER 8 ...

Page 255: ...I 683i in MBkP s f i 6 8Bcln plstoA Is 8IAstB 8d in t 6 SBAt 6 CB fp8l Sl 6 thBt lt W BS CYI INDER BORE 6 ITt QV 6 I I fO I VPBSO 8 t I6 iASi 8 IIBIA6tCI Of th6 CB Ip6 C t t tffAd6 S CALIPER I D II975 1977 6 AI If AP I0 I 38 8 0 38 23 nim I 5031 1 5051 in SE P V ICF 38 245 n m LilVIIT 1 5007 iri STAN 0AI10 42 85 0 42 900 mm i 6870 6890 its PfSTON SEAL SF F t7IC E Ijgf I PISTON BOOT t tASP8Ct th8 P...

Page 256: ...3VFOWS Qn tI18 ShffAS IALtSt t38 pOflftifig CIOWti W hen the cBIfpet i5 posftfQffed of the fTfotf3tcVcIB I he 5PBI betvvePA the tvvQ cBIipet halve shQI3ld be repIBrceCI Wfth ii ABW Se tiI AI gf3 bGth calipec I lives Blitt ff tStBII tl IP tWG bQIts 3AO tightPA tI tefTI I flstel t tf38 brake I inc 3f d position the calipet install the leaf 3xIP axle AUt Bnd thte CBIipet stey bQI T ighten the st3ftf ...

Page 257: ...ii pi t Q f lp i g 1 fQ jpf l ATTACHING 80I TS CAUTION Avo d spiIIIAg b58k8 fluid or pei pd ij v4cez MAS CYLIW ISASSEM LY i i i i i p i lp i 0d p y p 3Bpl pi l pd c4 Jc i p p ii p pii i i p i l li i ip teke l w i i v I i p i toii i pili s i l i J t 3 Clip 4 V B Jp li iiP i c 5 iiii y t G 3 l il Y ii ifgl ft r y ppq if p gQ f p fi ii k iJ lp il pi ij p i i i p sl oi i gii PUSH BOD Pl TQl l A i SP C...

Page 258: ...betote Bssen16IQ I tlstBII tI18check vBIve on life spl Inq I f IstBIItile sptlf1g i l O RIN G I F L oto REBERvoIR Bnd velve Bs B unit MASTER cvuwo aa I r VALVE Pl PF SPRING CUPS wsroa f tE CIRCILIIP 0 3 cusaaoo IAster ti le pf ftAB Q cup BAd plstof 1 I f1stBIi tne pushtod Bn clt cI fp InstBII the hoot Aut Bnd tod eye aooT RQD f I O I I000 S H O P iVi i liIUAC c I 9 7 8American I I o nd a M ooar C ...

Page 259: ...nd instell the moonting belts rod eye pin wvsheI Bnd cottet pIn ThBII Instell the bI eke line I III tbe tesBI voit to tbe oppef IeveI end bIeed tbe bleke spsteITI eccGcdIng to pege 14 8 4 1099 SHO P t A w ll Xj 4 2 i I 9 7i olo oooo r looOB 4 foldo C I o P l p c gP ...

Page 260: ...G otsrtttcoe ot ttrte e e A e ttito DISC FINAL DRIVE FLANGE FLANGE FIXING eEtte wtteet AND TIRE BEAR ING 6304r W DUST SEAL g ecrttttttee DISTANCE COLLAR COLLAR uo soi r D I SC AXLE 0 NUT l to L 1000 8 idtdP Mrt t EQUAL 8 197 8 A tn e r f o ittl I i o t td e M o t o r 0 0 It t o P rinted in U S A 7 7 8 ...

Page 261: ...G p i 8EARING DUST SEAL FLANGE F XII NG8O LT RE A R VVH EEL AND TIRE e 3 j E pe DISTANCE tt r 8EAR MG t Pi BE A RING Oi LAR I R 6 E i i oi h H D E t IVt t t GE3Pt t 4 2 G t 9 t A t Gt ttiBV1 ti t i i i tR M t t t l C G t I i i i E P i Ntt Rt t I U B E t i 7c ...

Page 262: ...l I iee I i t n I r pr t l tip Iei ie lei r Ite I IYI f ii 4 l ej i e f t l e i tl fcf el I r jei I li te j ii I rf i if e i TORQUiE INREI ICR ei I tef I iit e I Ie R I tr tr I e e I I l I 5 jn t 4 IOIt i Ai f e i I e fr J f i i5 f t r I i ereeSS 3 i 2 r i f c t i i e I I To f I eeet i I j I t l I tr i Ie i r II I e K i I I i I i R I j i iI Ie sj rf r ni ii l I e tr f e el I R I Ir e e 8 f I 0j e ...

Page 263: ...e IocatIGA of the heaviest Brea I f the wheel is prcperly balanced it will not stop consistantly in the same position I3BIance the wheel by installing wheel vveights Install weights on the hi hest side of The r irn directly opposite the heavy spot you have marked after spinning the wheel Install just enough balance weight so the wheel WIII no longer stop consistently in the same position when it i...

Page 264: ......

Page 265: ...ve the neeI disc RemGVB the I etBIGBI Ueilng the Bf38cIBI toGI ReniGve the finBI I Ive fIenge bQ Iifting it GUt of the hUb Then PBPAove the beer Ings end distecIce coI IBI C RIMG F IMAI FLAMGF g COLl AR EI EAR IMQ t j g DR IVE 3 DISTAMCE g 62O4 SEAnmG p DUST SEAL RETAIMER C LLAR ...

Page 266: ...sc MeesUf P tl fe thlicknjPss o the I roAt Brfd reer discs Using 8 micrometer MeesUre tne thickness in the midd e Ol the diSC SUI tBC8 I975 1979 RPBf DISC I hfCkneSS 6 9 t 0 7 m rr n 0 27 ii6 to 0 2795 jn Serif ice L im it 6 0 m jn 0 2362 in I 9j75 977 F runt Disc T hickrfess 5 9 to 6 1 mm 0 232 to 0 240 iff 6 P I V fCe L f r A If I 978 j 979 Front Disc Thickness 4 8 to 5 2 mnf 0 I 89 0 205 i rf S...

Page 267: ...ed to f B f Aove it Astell thP seel BAG the i eerfng I eteii 16r end peeA the edge of th8 I eteIAer I AsteII the 0 I Ing Brouf1CI th6 right side of the hfjb then Instell the dIsc gesket retefner reteiner eever end the disc bolts InstBII the left disc end disc nuts lnstell the left side coller BAO BXIB Lubrfcete tl IB speedonheter geef x with NLGI 2 No 2 Align the speedorrfeter geef box tengs vvfti...

Page 268: ...n fe t00f the t wes usecl t0 ten fOve it Peen it to the huh lnstell the bf 8ke clisc 8nd nuts lns 8ll the t IABIdrive flenge 8nd 0 f fng Luff fc8te th6 tl8Age splines with MultlpuvpOSB gf 68se R LG I 2 f MOS2 8dditives Ins t8ll the t 68f vvheeI 8ccOt ding t0 Pege 12 19 30 4g m fA 24 ftgglf 6 f 000 SHGP MANU f c j f978 A let fcsA HoncIB Motot Co fl ic P vfnted jn U S A 7 7 8 ...

Page 269: ... to veI flcIP CBpecftp IOB 3 BC ltt 360 ibs l63 kg C heck the tires for OUts I Abe ded rfefls or other slferp ob ects Replece the tlf es before tl 18 treBd leplh Bt the ceAte of the tire reeches thP tO IOtrVf tg IfAfft 8Ater treB depth servfce If A1 t F roAt I I 6 1Ach 5 A t 1 Reef 3 32 fACh r I2 0 AA ll Pr in i crt io 8 Sr t 78 ...

Page 270: ...ovnstav w Ieeis because the innev tube does Aot veoufve pvotectfon oA CQIAstav wlllee s Rivvf bands ave f Ised AA y on w I ve spoked 4vhee s to p vo tact th8 iffnef tube tvovn abvasion by wive spoke feiPP 8S GL OOO 78 79 Tffe SIZ8 T II 8 bvand 6 L 1000 Sf I OP M A NUA l 8 infed is U S A 7 7 8 f 19 i 8 Pi l i IcBA HGA08 Mo f 0 1 0 0 f fth m 3 4 ea35 ...

Page 271: ... i I 76 American Ho ilcig Isola Qo i nc P rinted in U S A 7 7 8 ...

Page 272: ... t i t f t t t f i j t l I Iffy i I t f iB t f BI it Q i twpig s t f t Ct 7 g t I Ctit i I P I i fi t if i 4 I 4 Q gf I t ff i PBBS I C L j f t ft t k I Cl I I t t i 2 2 i Cf lb t ift i t Bl iiCI Clt t B i ltB i f ijf Pt f B f I Bf f Cj f 3l BI i t l40 l t f CPB 8l l i tf I f j B t t f f i Ci f I t 0 B f l f i t B I B It H j V I j l I t P P t g I I I P l f t t Bi t i i t ttt t tf I i t f it tCP f ...

Page 273: ...SWIITCH VIAGNE TS y P g W R IXIEUTRAL LIGHT I srrtrce FIIE L D COI LS RELAX WINDIINGS G R I NEUTRAL DIODE CLUTCH SWl TCIH G AC GENERATOR RO TOR STARTli MG CLUTCH Q AC GENERATOR SHAFT I J STARTER MOTOR 3 I I 000 SHrdP MANUAL Printed in U S A i 78 19 76 American Honda Motor Co Irtc 1 5 3 ...

Page 274: ... 2 E cessivef eslstaflce iA ci el it 3 B l n ffhg IA staff tef I Botof dl fve cl aff I of df lvP s y stefn Statute MotQ T fvf s BUt Engine Dces Not Token i Biff e in iD f I v e c I Ia A 0 I s I f 0if kels D fve si B ff 0 Qvef f UA Aing clUtci f 3 Sfa f tef VAotof I IBI eta V j B s 4 A C aje Ie atof lf Ive geaf s Stattel Motor and Engine Tutn But Engine Does NQt Staft ow I at lef v f Ag AP Pl 0 I A...

Page 275: ...etteif Y cBI3IB Bt the ster ter terrAfABI RBA fove the Afro stei ter AfouAtfAg bolts Brfd pull the rAotor out of the 8Agifse cese The sprocket will stey fri the hofjsff fg ArrABtuire RewovBI REMOVE ARMATURE 6 L i OOG SHOP MAN UA L P rinted in U S A 7 78 f9 6 Arnerfoan Honda Motor Co inc lI 5 ...

Page 276: ...suletiGA 8Bvs discoIGved IA peiivs Indiicete gf Gunded Gv Open Bvmeture coils MOTE DG AGt us8 eifvIGvp Gv sBAcl pepef GA the CGA mutetGV SHAFT P eplece stel tef mGtGi ff Bvf AB tUve coils Bf 8 Open or shGI tevj tQ Bl metuve shef f NO I ONTINUl7 f NORMAIL CONTINUITY SHORTIED WllNO NG Eield CQII InspectiQA Check fQV CGntinuity fvQm the ceble tei I Ainel tQ the motor cese BAd I vovn the ceble terminB...

Page 277: ... UP QN rHE MQT QR f iSE AND ENDS THRQUGH BQI T s RECONNECT the baitery calale at ooth ends If jith the ef gine STOP switch OFF t est the starter for proper oppf Btfof Rt INSTALL the shfft lever exhaUst st Id and Pxhf ffst pfpP Remove the three rullers from the esse Ably Bnd inspect them for flat spots 488 that they IT ovefreelyUp BA j down theif f BA ps See Section 14j OTE Worn of corroded rollers...

Page 278: ... cQI Pet I eslstBnce I S 3 teSt l Qr sf Orts fram eitiaer Ql ill idf y iead to ti fe f eiay case ReplBCe the relay i tile primary itQli bas af I opeA cfrc 3ft skorte 3 r Qfis 3r fs sborted t 3 the case Connect 2 voit sQLfr 8 across I3l lniary feads Reiay sboff Ir make ar I BQciible click t pst fQr cQAI IAQfty dcrQSStf fe lar je tefcnilAdis vvf3efl fbe reiay f s 6Aei c IZPd ff f hPre fs dray f esfs...

Page 279: ...l I 3000 Sf IOP VIAI C UAi 19 78 America I lerrda Mater C e Inc ari ate A in U S A 7 78 ...

Page 280: ...rlaf ks F 1 fttdfcatoi or cvlff fders 1 and 2 F 2 IA f catOI for cylfndPI s 3 and 4 I gnf I Iof I tll A l ag F M ark fof statfc ot Idle speed tfmff lg 50 8T DC 1975 1977 100 8TDC 1978 1979 F ull Advtfnce Mark 370 8 T D C Ac vance Starts 1 450 I pfn Mat tfti If Advance 2 600 rpm Torrlue Values Spark riluqs 120 to 190 kg cm 104 to 165 in Ib 9 t0 14 ft Ib WOrk lrfg Practllce 8e su B that the battery ...

Page 281: ...OIL ENGINE STOP S WiiTCH T q Bk Bv Bk W I 3 I tl Bk W CAPACITOR l BALL S RESISTOR J I t I 8 V BREAKER r COMI A C T y R PLUGS BK Rj qn FMGINE START ii i BUTTON LEF I COIL WIRES TO STARTER SOI EMOI D COIL i I tjMtttN FusE R j PLUGS Bk V TO BAT T ERV HEADLI GHT CI RCUIT Ct f 1 000 SHOP MA NU I P t ilt et t R 0 I A 7 7 8 I 1 9 i 6 m e t i t Sn ida t t da M O t a t C O It tt I 3 ...

Page 282: ...IBs Dpen f38IIBSt I Bslstof GAP col I vveek or fnoperistfve D A 6 se t 0 f 01 f3 t8 b u f A8d g r 0 Urid8d 0 r I I 0 t 0 p 8 A fAg 3 DefP tive cepecltof 4 One plug wire I 3 3se Qr discGAAe ted Engine Sterts Input Runs POGrlly 1 Ignlt iGA pf ifTIef y clf elf lt P iirlts dirty Gr fouled 0 I Acof I PC I polf lt gep A eek Gr defective coil d DefeCAVI3 CBI3BCI tof GGSP Ol bef i W iif 8 I r i tel ITiftt...

Page 283: ...to igf ftfon test dial our the electrodes afad ohserve the spaf k gap Check the output ot the remaining coil by switching aii coil leads Hepcat the spark gap test CQf L I ee 8kiw 7 OR 8k 8r 8 V 8QTH COIES IVIOST 3QIVIP 8m 0 GAP V I SERVICE TESTER Bl T R 8k R ESI STQR 8AI I ST RESISTOR A4 4A 8k t 8k 8 BALLAST RESISTOR f i f ispPctfor Zero tlie ohn frrieter a Ad test f pslstance I I the f esisfance ...

Page 284: ...APACITOR The cepecitur Ioceted Gn the trent Gf trie I ettery bereft e ft ey bP tPstPG vvfthQUt I Pn GvIAg It frQm the I 1 8 tOi CyC I B MOTE It mey be f ecessery to remcve ti e bettery end ti iie bettery fr a T 8 to f Bn QvP tI 8 cepecftGr CI eck CepeCftf ACB GA BA BIBCtl 1CBI tCStef FOIIOA the ff IStf UCtIGI fs Vvfti the tBster Ior specific fprGce UrPs Svvftch Iesref IBBG tG the rer efnff fg cePB...

Page 285: ...L 1 l 000 h H C3 P M A Kl L A f l978 An erican flan a Mo o Cc Ir c 3 7 Pronto rs Ll S A 7 7R ...

Page 286: ...B ier t i ical circuits Bre off Engine cannot be s fa ted The key can be Qi Elect r i cal cifcuits Bre cin Headlight teil light funnirig lights and stai ted I iP key can be I el ni over refAoved Steeriffr Is nor locked instrurnefit lighfs Bra oA otlief lights cali be opel Btecl The eAgine can be started The key cannot be removed PARK T h r r aII light is An bij all Ath r circuits are off T h e key...

Page 287: ...X AuX L ARV 76 76 77 yg OL TAG E I FLAS H ER l 76 76 77 SINITCH LIGHT HORN S STARTERS ij TURN SIGNAL IGNITIGN CLUTCH LEVER SINITCH FUEl LEVEL SENSOR 7 F E 8BAKE TURN S GNAL 8UZZER 76 76 77 IY MAIN FUSE REAR 8RAKE SWlTCH TEMPERA URE SENSOR ANID FAN SW TC 8ATTERV A NEUTRAL SW TCH 1 000 S FE L T P FV EEIN Sl I 1 EI 6 I I ITII I IC I I j I OIILJU MU jIBI I G BIC 3 7 3 I I I I I y I N ...

Page 288: ... jfJ FUSE 8OX TERM MAL ACCESSORY 78 79 8OX 78 79 ii 8UZZER RELAX 78 79 TURM S GMAiL 8OX i FLASH ER 79 79 ...

Page 289: ... t rii sigrt il switch is I eked in f ll left of full right position arIQ igni tfoA sv Itch Is ol i Resef ve ll ghtfng resfstor P nk to Blue 1 9 oh m s Black Blue to Green VBIIow 3 3 oh ms Reserve Lighting Unit Black W BIIovv to Blue Wliite 0 ohms Brovvn Blue to Blue Brown 0 ohms Gf Bef I r Bllow to I ft ovv jf BBA 0 ohms 0 I pressure warning svvitch 150 to 200 kq cm 130 to 173 in Ib I of lt bf ak...

Page 290: ... B 3 ight Blue Fellow lri fde tu isolate an electrical failure check the continuity of the electrical path through the part A cc fitinuity cher k can usually be made without removing the part from the motorcycle by simply disconnectiffg the wires and connecting a continuity tester of vol QhfTI t eter to thP tel minais QI conAections A continuity tester is useful vvhen Checking to find out vvhether...

Page 291: ...tfvP 4 Main fuse defective 30 empI 5 Wlrfffg defective IGGSP of I 3rokeA Ailt l ights Come On hut Dimly When llgnitiGn Switch Is T frned OM Battery luw 2 W ring 3f svvitch has PxcPssfve l esfstance Headlight Beaims DG MGt Slhift When Hll LO Switch Is Operated Beanf f ilanlPAt buf fl ed out 2 Headlight svvi itch defective 3 Stal tBl buttef l dBfPctlvP fn fl ee pGsltlGrl HEAD Indicator D 3es MGt Lig...

Page 292: ... buf l led ou t 2 Taf frfstf fffTfent lamp fUs P burfiecI out 3 Reserve lighting systenf switching uni f fetectiive Stop iqht Does Rot Light When Teil Light Is Bun ed Out Bulb burned ouf 2 Tafli fffstf Ufnent lan fp tffse burned out 3 Bserve ifghtfng s ffstefTfswftchfrfg U Aft deaf ctfve 4 Reserve ligITfing spstern l Psfstof has open cfrcUft Component Does Rot Function r ofTfponen cIB fectfve 2 SW...

Page 293: ... fTCH REAR BRAKE SQf l TCHI MOTE Check Swftcl I IGf cnf ftff fU fty l38tween swftclf tevn final Iwfve ven fGvedf and gvotf Ad fvftl tvansfTffSsfGf ln n64tval BAQwith tvansvnissiGff fn arly g eaf L TG veplace the Aefjtval switch ten ove thP R H Bxhaost pipe Gll Scveen covev iowev Bnglne nlGGAtlAg bolt and nel i tval swiitch vetainev bGlt Flex thB fvavne 65 d85cvibed GA page 1 0 3 0 3nd vevvfGve the...

Page 294: ... tG 8 A LQ 8 f A tn 8 A TL DMi H8 l 8 HEADLIIGHT I Ill I 0 LEFT 2 I Bv zz e r f le i sher G f tO 8 f 6 I 0 Q Br 0 to LB A I I fesher vniiy gl tG Q fBr W tpi LB iA i TR l 8 fT l RT TURN SI GNA L HI HT I I F i esf3Pr Qf3 Ifi Bf TG Qi yy 8 I G I ll 2 B 3zzPr I leshef Gf Io Br 6 fG LB Br yy tG Q y J 4f tG LB 8 f 8 I O L8 S FA R T 80TTOFd EffiIGIME 8 TOP Syf ITCH Bk tG Bk PI vlf t h 3Lf ttGi3 rP IBBser...

Page 295: ...witch fn ecch swf tch POSit IOA SWITCH PGSlTlGM LOCK Gf F QfN INo continuity No cr3ntfnufty R tOHk BF W tO BF 8 R tO BF 6 ff If OFF oil C rifo IIAti IG I ti i Fi r ff CLUTCH SWITCH i cLUTOHappr iED coNTiNuirv Check continuity cf clutch lever setety switch with clutch f eleesBd BAO Bppl leo lfBplece ff ffecessety CILUTCH RELEASED NO CORTIRUITV Ufiplug the vvites Remove the clutch IeveF end eble Pry...

Page 296: ...A of felse reecfiAgs vviii resUit Ol L THERMOM ETER I DlODES i de I tf f tive dlo 38 cfl cUft bV 0 fre CGIof cGde Aii 4 diodes 3re fdeAtic3i If f dBSIgA 3ACj ffjActfGff Check diG ies fGr cGrftiAUitg vvith 3 VG f fifA Ii ffP Pr Gf POf tIAUftg tBStef Discerd the oid diode 3Ad iAsteii3 fledge 33rt I i thef P Is AG coAtfAUftg IIR tive Aof IA3i dfrectfoA Gf I i cGf itiAUft Pxfsts IA he I Bverse ilfrect...

Page 297: ...UIBtor thet f edLfces v oitege frGm I 2v to 7v VO LT OHIMIVlE TER BefBGve the BUxiiief V vGitege teguletof tf GfTf OAdef the iett side cGAApBctf ABAt BAci test lt vvfth B 4Bttef j BAd B voi tfTfetef Bs showA 6 TERWNAC WIR TERMI IMAL 12V GL 1000 SffOP VIAiNGA L Ptieff96 fA O S A 7 78 78 Af A BI IcRA H GABLE Mof Of Co l t lc 7 0 3 ...

Page 298: ...to check opef atfoA above l 00 C c p gOF I TEMPERATVRE GAUGE G GK Teftfpetatuf 8 68Uge F VACtfGA Test CQAAPct 8 tested seAsQP GAd auxfiiaf fi vGItage f egulatol as showff to the gauge to be testBcl W R The tefTfpef Gtufi 8 g8Uge opef ates OA 7 vGllts DO AOt apply ll2 vOIts dff ectIQ to gauge SuspeAd the SBAsol fA 8 paA of ofl as IA tl fe tPst above DQ f lot Iet the sPAsGf of thef fAQAfeter touch t...

Page 299: ...UEl LEVEL SEMSQR Fuel GBUge FGActfGA Test Test thfe opef BtfGf I of the feel gBUge wIth 8 t ested seAsGt BAd BtfxflfBf p v Mtege f egf lBtGI Bs shGff JA FUEI GAUGE FUEl SEMSQR T ll2 V BATTER ff FLOAT IS L 1000 SHQP MAN GAL C I 9 78 A r I IAI I BA HOFi69 M C t Of C D If lC PI IBt CI IA U S A 7 7 8 ...

Page 300: ... belevv 10 V Qr above 16 V f Plica Ps B n Bl U ctfOA fr the 8 L ic t r t 8 I s y s18 r A 0 8 t 8 r r 1I1 88f d cQ lect the CB lse ct f the n altLlnctjQfl fe VC l f fr np tp f Can t p CA8Ck8d l y Qt f tp l nq ft tO 8 k tQVVA VQItdge SOU f Ce Bf f Ohsef Vfl g the gaUge read fng imhef t ps i ff lg vvf 6 8 ii Bfl 6 8 voltagP soi ff ce start dt 6 V B ALl raise the vQltdqe tu 16 V T h e gal tg slfQLfld ...

Page 301: ... q t Lf 4 S d t 3 I f g t bUlbS R e T QVe iT P f t t S C 0nfl tli t i i SC Vt S t f iVS f Lnl T f t d l S L P f f QV i f G f G jdO IP 1 2 w L d Ct SSOi 6S BOf td CPPC fld 60 VVd S di T pS HI i Pf Lfn 2 ff LIeA d iAS Ti d V QVV f h q f I f SP L i Cf SCI l q rgb L I P d L fy Q GAP dC PSS 3f y L Cf f fCdl IPddS S L f I li IZ tt L t Pkdff lf L f PS 1QCdkPCI Of f hP CiQ ii h t Sf i i i f QL Lt f t f td...

Page 302: ......

Page 303: ...1AMP ASSEM81y SCREWS SCREW UI IIT SPR III IG IPS 7gl REFEECTOR Heedlight Aim I he hBBGI ght cBA l B adjusted verticeliy end ho izontally A jjust ve ticeIIy by removing the side ref lectof s Bf fd ref lectof b f3ses Loosen the heedlight mounting bolts end re positior the heedIight Tighter the mount g bolts end reinstBII the ref ee tors Adjust horizonteI y vvith the ed lustf Ag Screffv KiQT E A just...

Page 304: ...TAGE REGVLATOR I I EV8F 8Oy 8OX CVRRENT l IVI TER 78 79 78 79 t 1 VRIM SliGRAE 8VZZER RELAV 78 79 JVRCT OR I I TV RW S GNAL 1978 ev6 979 GL 3000 s ere not equ pped w th the l ezevve ght ng stem descvIDed oA peges 7 23 thl Ollgh 7 23 ...

Page 305: ...ft tI C FBSIStQI BSSBA L IV A I tvVG d GOBS BII IGCBtB 3 Uf dBI tI 8 SB VfCBCGA PBf tfTiBA t IBf t SldP CGVPi BS S GVVf RESERVE RESERVE LIGHTII IG SWITCHII IG UI IIT I 75 77 8 WIR E CONNECTOR i i j 3 Ni in C OK 8 EC FOR POSE BOX DIODES I 75 77I TBStS Qf tF 8 RBSBFVB I lghtfAg DVSFBfT lACIUijB ff fpilt BAd QUtpUt VGItBgBS BAd CGAtf A f ft i tPStS 01 ti iB f SISt0F Bf i d t VG dfQdBS MALE PLUG PEMAI...

Page 306: ...e dcf oss lf 18 L G 8I an 3 Ci leads A IUst bp I 0 to I 3 volts i I P svvftch fr 0 Uf ft Is dpfectfve the t il light burneci out the voltage across the fl 3 7 at d 6 lear 5 must be 6 lo 8 volts Qr I p SVvi i Cl IAq Ijf 1 15 IPf BCttVB lf t 8 TAI L IAdfcatof ldtttp ref Bins Gff vvhen tt 8 slop svvftch is af irate j the voltage acf riss hP LG BAcl 3 Iea js f If st bp 0 to 1 3 v lt s fstol light svvi...

Page 307: ... burned out continuity must exist across the 8 8k and G 7 terfnin fls Of the resistor or the resfStor IS jpfeCtfVB Reserve Lighting Diodes lderitify the high beam and low beam Iiodes as sl iowA l3iode Continuity Test y lien the high beam dOes Aot light c heck corfrfnufty between tile I 6 8 k and P pins 0f tlie hfgl beaA I dl0cle I Vhen t ie low beam does not light check I of coAIIAU fty b etween t...

Page 308: ...CPSS tG the fUses aAd replace bUrned o lt fUsps as necessary spare fUses ale IGcated IA the fUse box cGver MOTE Wiving lf elec tl fcal pi obletns pet sist after CQ r npGAPA ts Of SWlfcheS leave been f GUfld good Gf havp been I pplaced test the wiviltg to the switch Gr cGf ApGAPA tfof cont AU lty Replace wlv Qr CQAAectot as fecessdf y I f the ohmmeter indicates very high rPsfstaAGP thrGUgh tl le co...

Page 309: ...IJf ll I STOP I A V Q v S W B IG I GAD Bk Y RESERVE L GHTNMG UNIT GH BNI l Qjq lQL I Qi Bg Q7 QS DIMMER Wl T H LO Ill I G T Q W k Q F f f BFBk Q 2 QS B I LIGHT L IG HT FM I f I Ahff D f CA I 40W 50W f j HIG H BEAM i INDICATOR 6 J WIFfE HARNESS LING QROI IND WIRE f Alfk ESS I fG REII IND O f f 0 0 0 S H O P M A N I I A I I 8 8 An nl II zn H n ld a Mfofn l C n I In P f lnl I t n S A i 78 ...

Page 310: ... Fuel Temperature Volt IVleter Accessory Terminal Righ l it ancglIher Sw rrch T urn Signal Buzzet Relay Lett Handlebar Swf tcn Thermostatic Fan Switch Tenaperature Sensor Og PressureeSwitch Left l ianrlle ha Switch ...

Page 311: ...co I v Ct 0 C 3 ICI CD CD C M I CD C ID I z 0 CD Ct C c a c Z C cc Z lf a I cct CO CO CD Z z g rf f f CC Z cc z C Z C C C C Z t Z I COg V C3 D V CD at Z Iz Vt 3 I D ID Z Z CD 3 CO K U 0 0 Z K 3 C cc ra c Ct ID O C cc a a a a a CD Cl Z Z CC CD Z Z ID 0 C t Z Ct ID ra Ct C cc V a CD a X cc g m C CD Z a CD 5 c CC CD a vC 3 Ct ID Z C at C ID I ...

Page 312: ... Z M w 0 Cl 1 4I 4 X X SZ 0 W a I X e Z C 0 4 CL C IC a 8 M Cl a W 55 mliliI 4 4I IC IO X 0 1 4I a 4I Mt Q Z C 4l Z 8 Z o a 0 CO 0 Z NOX ZO 0 0 CC a a C X 0 0 4 0 0 Z 4 J 2 0 Z X I g 5 0 o 0 85 Z 4 I IX 0 W a al a B Z Z X 0 0 Z z a X 5 Z Z 4I M 8 M08 g 4I a e It Z 0 X 0 I Z g O X G L 1000 SHOP MA N U A L c 1 9 7 8 A m e r ican Ho nda Mo tor Co Inc P rinted in U S A 7 7 8 17 28 ...

Page 313: ...0 L I 000 SHQP IVAMUA L P tf tl t8 f I fl UP 0 A 7 8 tc I 976 Attest ICtttt HOt tCftt ttffO fOt CG ftt C 3 8 ...

Page 314: ...842 986 Ib r 0 787 tnI 6r r A r se Gits 00 I 0 140 kg cn3 I8 0 i22 fn ibI i 2nff 4 sff r if iei G I il fQr gPl ereTor rn Gr 8 To 9 kg n id i ri it fh i 8 ii Pt v 8 i I evel st c UI 3 b cI Pc ed f egul rly ef d rilled wi ik disrified vvdrer whef Aecessery yf beni chfsfi gft f he t d i iPry Uicf ch ergf I Ig 5 Qul j QI3ly be d on f f r eni 8 Tiet gen cy slow cher gf f fg PiefrtQV I e bekrery irGimth...

Page 315: ... SWITCH f VOLTAGE REGULATOR j RECTIIFIIER MAIN F USIE L AC GEPJERATOR IGMIITION SWIITCH 3QA Wiioip F R W R I R f P 6 8ATTE R V L y STARTE R REl AV G L i 000 Std OP MANU L i9 76 merino frond Mntar Ca inc printed in LJ S r 78 ...

Page 316: ...fVB Ignf IGf SWftch Lo f v PGwer Key Turned OA i 4fi 8 k bet t ef y Qi vv bettery PlecirGiytP level b I gA ii iGf SVVftCi I lett C f 8 0 r I 8 8gIA gsystP T I f eliLfI8 2 L GGSB conffe ctfGrf t ovv Povver Engine Running A 8 ak bet tery 8 Lovv L ettery Biectf DiytP Ievei b Of P Qf fTiOre rjeed CeliS 2 Ci ef ging syst Af feflure interrA ttent PDwer I L DG58 bettBry connectlGA 2 L r ose ci ergl l g s...

Page 317: ...ed IB f ilii st then the pr3sitiveceble Recr3nnect the negetfve ceble Iest Refnove the battery frcfrn the rrfotorcycle for cherging whenever pressfl3le If bettef y n3fJst be chef ged on the rrfr3tof cycle disconnect the Laettery cebles STARTER RELAy POSITIVE CARLE I f P i H OLD D N S IV EGATI VE SPARE MAIW FUSE HOLDER 6 L 1000 SHOP MANUAL Prfntes in U S A 8 i f976 A mef feign Honda Motor Co fna IM...

Page 318: ... coat tI 8 I Bf O finals with petf Oleum f elly ICAUT OM Q CHARGING SYSTE AMlVIETE R Charging Output Test CGnnect a 0 20 V vrt ltmete and a 0 t aftlp anlfrfeter Ic check tl le output Gl the chal ging system with the 8 n gff t8rIJnnIng BOA the BngfAP fof rive rnlfnutes bPfol 8 takfng I Badlngs II lake this test witl i 8 fully charged battery i dimmer svvitch Gn IHIGH faA f Aotof oft ansi BAgfAB spe...

Page 319: ...y yelIow IPad ls f lot cofitfAUQUs w th the othef s ov ff any Iced has contiflUlty t gl QUA 3 VO1T OHMME TE B BECTlllFIEB Cheek cofltinfl fty thf ough the fectf tIBr ivfth a volt hfnmetef Of Contff Ulty testen Pi UG Contfintlfty iT Ust BXlSt betWBBA tWO gveef leads Cofftif Ufty ITIfjst BXlst hetWeefi tWO I 8 3 wf lte IP acIs i i 1 O 8 f l f l l i i i ii I i i i f i i l l f P t l i i i I t 0 l B H ...

Page 320: ...s ctttt t isft sw I t3 GstseA 2000 Oitf sts iftstlti i slit w i tt Gt tset t 2000 sltA ts UTttOI t ti 4 l t P A 000 OhM s if ttt ti Bl ACK YELLOW i i C 0 I I I l 80 i 8 V 0 l t 0 I 8T 8I 8 C 0SSi I I8 I BT48t P CQI IOPC t 80 8tTIITIP I8I I 9 5 8iQtpsi b8ssw880 iIOP I PgUIBI QI 8t 1 gt OUI ICI I Is t 4 I 8gt t Itt I OI P8r 10 ITIBI tC8 Wft h T PI 80igtOP I Uf IBIIT J 1 B8 I 8tjt tl8iIOI ITIUST dtV8...

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Page 323: ...Worn or corroded rollers wfll Often ceUse the starter to spin wfthout rotating t he engllA8 or eBlll t af lolLKII scl eechfng Aofs8 as th8 engine Is befng rGtated l3 RQLLERS IMSIDE RernQve thle hGldfng tab an 1 sl fcle tffe drlvef I sferQcket cha in and s tartef spf Qcket frQIA snaft P emQve the bearfrfg holder bQi ts and sf fde the genef a tQr df fve assembly free Qf the case ...

Page 324: ... BAG stoppei plMe fov weak Replace lf isece sai y RU88ER STOPPER PLATE auaaaa j r I PR ESSURF y V COITER GEAR A CiIRCLIP SPRIMG OAMPER PLATES R ETA I MER ra I I 00 0 S H I M A N 0 i 0 0 1 1176 s Nrnai can Ho ndaMo Ior Co Inr Printed in ll 5 A 7 7R 3Q 12 ...

Page 325: ...th ReesseAIiole the drive essembly gear dempei pletes dempeI rUbbei s I3eef IAg BAd beet i Ag covef Piece thB essemblV IA 8 pI ess BAd iAsteil the demper spIiAg dempeI spi IAg I BteIABI BAd cottei s 88 cei teIA thet the cotteI s GI 8 fUll g sBetcd IA theII gI ooves MOTE L o Aot compt Bss tfIB spBAg moI 8 tl BA necessety to iIIstell the cotteI s ...

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