Honda NHSO aeroBO 1983 Shop Manual Download Page 104

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CRANKCASE�RANKSHAFT

CRANKCASE ASSEMBLY

Install a new gasket and dowel pins on the crank·

case mating surface.

Assemble the crankcase halves; place the collar

(07965-GC70100) with the small O.D. against the

right crankshaft bearing. Thread the bolt from as

sembly tool ( 07965-1480200) onto the crankshaft.

Hold the bolt and turn the nut clockwise to draw

the crankcase halves together.

Install the right oil seal; place the collar (07965-

GC70100) so its stepped end is against the crank·

case and oil seal.

Thread the bolt from as.sembly tool (07965-

1480200) onto the crankshaft. Hold the bolt and

turn the nut clockwise to install the oil seal into

place.

1 0- 6

DOWEL PINS

ASSEMBLY TOOL COLLAR

07965-GC70100 (INC. IN 07965-GC70000)

ASSEMBLING TOOL

07965-1480200 (INC. IN 07965-GC70000)

ASSEMBLING TOOL COLLAR

07965-GC70100 (INC. IN 07965-GC70000)

1 1 0

ASSEMBLY TOOL

07965-1480200 (INC. IN 07965-GC70000)

Date of Issue: May, 1 983

Summary of Contents for NHSO aeroBO 1983

Page 1: ...D SHOP MANUAL NHSOaeroBO...

Page 2: ...is scooter read the w 2 2 w CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEAD CYLINDER PISTON ALTERNATOR DRIVE AND DRIVEN PULLEYS KICK STARTER...

Page 3: ...uery especially while charging ir 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalents Parts that do not meet HONDA s design specifications may damage the scooter 2 Use t...

Page 4: ...r is stamped on the back of the crankcase near the rear wheel 1 2 4 HONDA NHSO The vehicle identification number is on the frame pipe of the center of the front cover The carburetor identification num...

Page 5: ...er 1983 5 American Honda Motor Co Inc 1983 All Rights Reserved GENERAL INFORMATION SPECIFICATIONS 1 685 mm 66 3 in 665 mm 26 2 in 1 070 mm 42 1 in 1 1 70 mm 46 1 in 730 mm 28 7 in 256 mm 10 1 in 1 1 0...

Page 6: ...signals Front Rear Speedometer light Oil indicator light Turn signal indicator High beam indicator 1 4 6 HONDA NH80 SPECIFICATION Piston valve 16 mm 0 63 in venturi dia PB540 Refer to page 4 10 8 5 mm...

Page 7: ...Rear shock absorber 8 20 30 2 0 3 0 14 22 Lower Rear shock absorber 8 15 25 1 5 2 5 11 18 Apply a locking agent damper lock nut Rear brake arm 5 4 7 0 4 0 7 3 5 Kick starter pedal 6 8 10 0 8 1 0 6 7 F...

Page 8: ...om mended Refer to the alternative column COMMON DESCRIPTION NUMBER Float level gauge 07401 0010000 Universal holder 07725 0030000 Pin spanner 07702 0020000 Attachment 32 x 35 mm 07746 0010100 Attachm...

Page 9: ...r corner Clean the attaching surface thoroughly before applying tape Do not use wires or harnesses with a broken insula tor Repair by wrapping them with a protective tape or replace them Route wire ha...

Page 10: ...GENERAL INFORMATION 1 8 SPEEDOMETER CABLE MAIN HARNESS SPEEDOMETER 10 HONDA NHSO SPEEDOMETER CABLE REAR BRAKE CABLE JUNCTION BOX REAR BRAKE CABLE Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 11: ...OIL CONTROL CABLES STARTER RELAY OIL CONTROL CABLE TURN SIGNAL RELAY Date of Issue May 1983 HONDA MOTOR CO LTD FUEL GAUGE SENSOR RESISTOR REAR BRAKE CABLE 11 GENERAL INFORMATION THROTTLE CABLE OIL LEV...

Page 12: ...LUBRICATION OIL PUMP 2 0 HONDA NHSO OIL TANK CARBURETOR INTAKE PIPE 14 OIL STRAINER Dateof Issue May 1983 HONDA MOTOR CO LTO...

Page 13: ...he carburetor if the line is disconnected SPECIFICATIONS Engineoil recommendation Final reduction oil capacity Final reduction oil recommendation TORQUE VALUE Final reduction oil drain bolt TROUBLESHO...

Page 14: ...the following items Damaged or weak O rings Damage to crankcase mating surface Damage to pump body Control lever operation Worn or damaged pump gears Oil leaks CAUTION Do not disassemble the oil pump...

Page 15: ...e oil outlet line 01 LINLET LI NE 01 L PUMP CAUTION Bleed air from the oil lines whenever the oil J lines or pump have been removed or there is air in the oil lines Fill the oil tank with recommended...

Page 16: ...ould be adjusted after the throttle grip free play adjustment Remove the frame center cover Page 1 1 3 Loosen the oil pump control cable lock nut and open the throttle fully Check that the aligning ma...

Page 17: ...0 1 4 kg m 7 10 ft lb NOTE Check that the sealing washer is in good condi tion Fill the final reduction case up to the proper level with recommended oil OIL CAPACITY 90 cc 0 09 US qt SPECIFIED OIL HON...

Page 18: ...BLE LUBRICANT SPEEDOMETER CABLE STEERING HEAD BEARING I I I I I WHEEL BEARINGS 1 SPEEDOMETER DRIVE GEAR 2 6 FOOT PEG PIVOT CENTER STAND PIVOT 20 HONDA NHSO THROTTLE GRIP I I I I I FINAL R UCTION GEAR...

Page 19: ...BOLTS FASTENERS WHEELS STEERING HEAD BEARINGS 3 8 3 8 3 8 3 9 3 10 3 10 3 10 3 11 3 11 3 11 3 12 Standard For cold climate below 5 C 41 F For extended high speed riding NGK I ND BPR6HS I W20FPR Spark...

Page 20: ...CH SHOE WEAR z 0 WHEELS z STEERING HEAD BEARINGS FI ST 600 mi EVERY 1 000 km I NOTE l NOTE 1 I I 2 YEARS R MONTH I I I I I I I I I 2 500 mi 5 000 mi 7 500 mi Refer to 4 000 km 8 000 km 12 000 km page...

Page 21: ...dule page 3 2 Remove the frame center cover and battery box Sec tion 11 Disconnect thefuel lines from the fuel filter Replace the fuel filter with a new one Gasoline is flammable and is exp osil e und...

Page 22: ...e the throttle grip free play at the throttle grip flange FREE PLAY 2 6 mm 1 8 1 4 in Adjustments can be made by loosening the lock nut and turning the throttle grip free play adjuster Replace the thr...

Page 23: ...e leftframecover Remove the carburetorchoke cleaner chamber and re move the element Wash the element in non flammable or high flash point solvent squeeze out the excess and allow it to dry Never use g...

Page 24: ...y hand to prevent crossthreading Tighten the spark plug another 1 2 turn with a spark plug wrench to compress the plug washer Then connect the spark plug cap ENGINE OIL LINE Remove the frame center co...

Page 25: ...for leaks MUFFLER DECARBONIZATION Remove the muffler Page 13 2 Remove the carbon fromthe muffler Reinstall the muffler Page 13 3 CARBURETOR IDLE SPEED NOT E Inspect and adjust idle speed after all ot...

Page 26: ...When the fluid level nears the lower level mark refill with distilled water to the upper level Check the specific gravity of the battery electro lyte in each cell Page 15 3 Recharge the battery if nec...

Page 27: ...er FREE PLAY 1 0 20 mm 3 8 3 4 in If adjustment is necessary turn the front brake ad justing nut REAR BRAKE Measure the rear brake lever free play at the tip ofthe brake lever FREE PLAY 10 20 mm 3 8 3...

Page 28: ...per time NOTE The brake light switches cannot be adjusted HEADLIGHT AIM Adjust the headlight beam vertically by turning the vertical adjusting screw Turn the adjusting screw clockwise to direct the be...

Page 29: ...Check the shock absorber for damage Tighten all rear suspension nuts and bolts NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values Section 1 at the...

Page 30: ...Rear 0 8 mm 0 03 in STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar rotation Raise the front wheel off the ground and check that the handlebar rotates freely...

Page 31: ...FUEL SYSTEM FUEL TANK FUEL TUBE 4 0 FUEL STRAINER VACUUM TUBE 34 Date of Issue May 1983 HONDA MOTOR CO LTO 1...

Page 32: ...assembly Bleed air from the oil outlet line whenever it is disconnected TOOLS Special Hand vacuum pump Common FIoat level gauge SPECIFICATIONS Venturi dia 1 Identification number Float level Air screw...

Page 33: ...uretor top Disconnect the throttle cable from thethrottle valve Remove the throttle valve spring carburetor top and sealing cap 4 2 HONDA NHSO CARBURETOR TOP THROTTLE VALVE TH ROTTLE CABLE 36 SEALING...

Page 34: ...k the jet needle and throttle valve for wear or damage CARBURETOR REMOVAL Remove the right and left frame covers Loosen the drain screw to drain fuel from the carbu retor Remove theair cleaner element...

Page 35: ...carburetor attaching bolts NOTE Remove the frame center cover for easy re moval of the attaching bolts if necessary Disconnect the control box and bystarter tubes from the carburetor 4 4 CARBURETOR T...

Page 36: ...Remove the carburetor float and float valve by re moving the pin F LOAT FLOAT VALVE INSPECTION Check the valveseat for wear ordamage Check the float for deformation or fuel inside the float Date of Is...

Page 37: ...nt damage to the seat Remove the main jet needle jet holder and slow jet Blow open all jets and body opening with compressed air JETS FLOAT VALVE FLOAT ASSEMBLY Install the slow jet needle jet holder...

Page 38: ...e float tip Check operation of the float and install the float chamber CARBURETOR INSTALLATION CAUTION Do not allowforeign particles to enter the car buretor Connect the control box and bystarter tube...

Page 39: ...rtop Install the air cleaner element Install the right and left frame covers Perform the following adjustments and operation Throttle cable free play adjustment Page 3 4 Oil pump adjustment Page 2 4 I...

Page 40: ...nnect the throttle cable to the throttle valve Slide the throttle valve into the carburetor body NOTE Align the groove in the valve with the throttle stop screw on the carburetor body Tighten the carb...

Page 41: ...osi tion as noted during removal Perform air screw adjustment if a new screw is in stalled Install a new limiter cap Page 4 1 1 ADJUSTMENT NOTE The air screw is factory pre set and no adjust ment is n...

Page 42: ...6 500 ftl install a 82 main jet and readjust idle speed Remove the carburetor from the engine and remove the float chamber Replace the standard main jet with the high altitude 82 main jet Assemble an...

Page 43: ...clearance between the seat and reed Replace the valve if necessary CAUTION lDo not disassemble or bend the reed stopper To do so can cause loss ofpower and engine damage I f the stopper reed or valve...

Page 44: ...ine after the remaining fuel 5 10 cc has been drained out of the fuel valve and fuel line thoroughly Should fuel fail to stop flowing out of the fuel line check the vacuum tube for blockage 2 Disconne...

Page 45: ...ENGINE REMOVAL INSTALLATION 5 0 27 33 N m 2 7 3 3 kg m 20 24ft lb 48 HONDA NHSO 30 40 N m 3 0 4 0 kg m 22 29 ft lb Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 46: ...vicing Oil pump Starter motor Crankshaft SPECI F CATIONS Engine weight 18 kg 40 lbs TORQUE VALUES Engine mounting bolt Rear shock absorber upper mounting bolt Rear shock absorber lower mounting bolt D...

Page 47: ...1 Remove the battery cover and disconnect the bat tery ground cable from the battery negative termi nal Remove the spark plug capfrom the spark plug Remove the alternator and starter coupler and con n...

Page 48: ...m tube and fuel line Disconnect the rear brake cable Remove the rear shock absorber Date of Issue May 1983 HONDA MOTOR CO LTD ENGINE REMOVAL INSTALLATION CARBURETOR TOP VACUUM TUBE FUEL LINE CABLE CLA...

Page 49: ...to the specified torque values TORQUE Engine mounting bolt 27 33 N m 2 7 3 3 kg m 20 24 ft lb Rear shock absorber upper mounting bolt 30 40 N m 3 0 4 0 kg m 22 29 ft lb Rear shock absorber lower moun...

Page 50: ...CYLINDER HEAD CYLINDER PISTON 6 0 54 8 12 N m HONDA NHSO 0 8 1 2 kg m 6 9 ft lb Date of Issue May 1 983 HONDA MOTOR CO LTD...

Page 51: ...D 11 994 12 000 mm 0 4722 0 4724 in Piston to piston pin clearance 0 002 0 012 mm 0 0001 0 0005 in Piston ring end gap top second 0 15 0 35 mm 0 006 0 014 in r Connecting rod small end J D 17 005 17...

Page 52: ...st muffler Page 1 3 2 Remove the cooling fan cover Remove the spark plug cap and spark plug Remove the rear shock absorber Remove the air cleaner case rear fender Remove engine shroud A 6 2 FAN COVER...

Page 53: ...der head NOTE Loosen the bolts in a criss cross pattern in 2 3 steps to prevent distorted head CYLINDER HEAD I NSPECTION Check the cylinder head for warpage with a straight edge and a feeler gauge in...

Page 54: ...being careful not to let the piston get damaged CAUTION Do not pry between the cylinder and crank case or strike thefins Place a shop towel into the crankcase around the piston Remove one piston pin c...

Page 55: ...r damage Clean carbon deposits from the cylinder exhaust port area and piston as shown CAUTION Do not scratch or score the cylinder and pis ton Inspect the cylinder bore for wear at three levels in X...

Page 56: ...ase Measure the piston O D at a point 4 mm from the bottomof the skirt SERVICE LIMIT 47 900 mm 1 8858 in Calculate the piston to cylinder clearance SERVICE LIMIT 0 100 mm 0 0039 in Measure the piston...

Page 57: ...in the second ring groove Align the ring ends with the locating pins in the ring grooves and install the top and second rings in their respective ring grooves NOTE The top ring is a keystone ring and...

Page 58: ...e in theirgrooves 011er the locatingpins to prevent ring breakage andpiston and cylinder damage Place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crank ca...

Page 59: ...cylinder gasket on the crankcase Lubricate the cylinder and piston with 2 stroke oil and install the cylinder over the piston while com pressing the piston rings CAUTION Avoid damaging the sliding sw...

Page 60: ...g m 6 9ft lb Install engine shroud B Clean the cylinder head mating face of the control box and install the control box Install engine shroud A Install all removed parts in the reverse order of re mov...

Page 61: ...ALTERNATOR 7 0 66 HONDA NH80 Date of Issue May 1983 HONDA MOTOR CO LTO...

Page 62: ...with the engine installed Do not remove the pulse generator from the stator base See Section 15 for alternator inspection TORQUE VALUE 7 ALTERNATOR 7 1 7 2 7 4 Flywheel 35 40 N m 3 5 4 0 kg m 25 29 f...

Page 63: ...1er Remove the four bolts attaching the cooling fan and remove the cooling fan Remove the right floor board Attach the universal holderto the flywheel Hold the flywheel and remove the flywheel 10 mm f...

Page 64: ...alternator wire connectors Remove the two bolts attaching the stator and re move the stator NOTE Do not remove the pulse generator from the stator base Avoid damaging the stator coils Date of Issue M...

Page 65: ...ase Install the stator Install the woodruff key in the keyway in the crank shaft Connect the alternator wire connectors NOTE Route the alternator wires properly and se cure with the wire clamp 7 4 70...

Page 66: ...re are no foreign particles inside the flywheel Torque the flywheel 10 mm flange nut TORQUE 35 40 N m 3 5 4 0 kg m 25 29ft lb Install all removed parts in the reverse order of re moval Start the engin...

Page 67: ...DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH 35 40 N m 3 5 4 0 kg m 25 29 ft lb 8 0 72 HONDA NH80 Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 68: ...starts but scooter won t move 1 Worn drive belt 2 Damaged ramp plate 3 Worn ordamaged clutch lining Dateof Issue May 1983 HONDA MOTOR CO LTD STANDARD 24 000 24 021 mm 0 9449 0 9457 in 23 970 23 990 m...

Page 69: ...he 1 0 mm flange nut and drive face Remove the drive belt Remove the gasket and dowel pins CAUTION j onotbendthe driveb _ e _ lt _ _ _ _ _ _ _ J DRIVE BELT I NSPECTION Check the drive belt for cracks...

Page 70: ...ly Remove the drive face boss Remove the three bolts attaching the movable drive face cover and remove the cover Remove the ramp plate Date of Issue May 1983 HONDA MOTOR CO LTD DRIVE AND DRIVEN PULLEY...

Page 71: ...OVABLE D R IVE FACE INSPECTION Check each roller for wear or damage Measure each roller O D SERVICE LIMIT 17 40 mm 0 685 in Measure movable drive face bushing I D SERVICE LIMIT 24 070 mm 0 9476 in 8 4...

Page 72: ...it Check the face seal for wear or damage MOVABLE DRIVE FACE ASSEMBLY Use 10 15g of grease and apply evenly to the in side of the drive face Then install the weight rollers NOTE Specified grease Lithi...

Page 73: ...lb NOTE Make sure that the 0 ring is in position Install the drive face boss in the movable drive face MOVABLE DRIVE FACE INSTALLATION Clean the hole in the movable drive face drive face boss and cran...

Page 74: ...e face and tighten the 10 mmflange nut TORQUE 35 40 N m 3 5 4 0 kg m 25 29 ft lb NOTE Do not get oil or grease on the drive belt or pulleys Install the left case coverand kick starterpedal Install the...

Page 75: ...DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH KICK STARTER 8 8 80 HONDA NHSO Date of Issue May 1983 HONDA MOTOR CO LTO...

Page 76: ...washer from the kick starter spindle Remove the kick starter spring from the kick return stopper Remove the kick starter spindle GASKET DOWEL PINS PLAIN WASHER KICK STARTER SPRING KICK STARTER SPINDLE...

Page 77: ...NH80 KICK STARTER IDLE SHAFT KICK STARTER D ISASSEMBLY KICK STARTER SPINDLE Disassemble the kick starter spindle SPECIAL PIN Disassemblethe kick starter idle shaft DOWEL PIN I FRICTION SPRING 8 1 0 82...

Page 78: ...or damage Inspect the kick starter spindle bushings and idle gearshaft bearings for wear or damage Inspect the idle gear and shaft for wear or damage Date of Issue May 1983 HONDA MOTOR CO lTO DRIVE AN...

Page 79: ...NHSO STARTER IDLE GEAR SPRING IDLE GEAR SHAFT RETURN SPRING KICK STARTER SPINDLE KICK STARTER I NSTALLATION CUTOUT Apply grease to the spring groove and spline ofthe idle gear Install the kick starte...

Page 80: ...dle return spring on the spring stopper as shown Install the drive belt and movable drive face assem bly Page 8 6 Install the left case cover and kick starter pedal Page 8 7 Install the frame center c...

Page 81: ...DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH CLUTCH DRIVEN PULLEY 8 1 4 86 HONDA NHSO 35 40 N m 3 5 4 0 kg m 25 29 ft lb Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 82: ...driven pulley in the clutch spring com pressor tool Turn the compressor handle to compress the spring Be sure the drive bolt is centered on the pulley Place the compressor in a vise and remove the 28...

Page 83: ...DRIVEN PULLEYS KICK STARTER CLUTCH HONDA NHSO SPRING CLUTCH SPRING CLUTCH WEIGHT Remove the seal collar 8 1 6 88 DRIVE PLATE CLUTCH OUTER 28 mm SPECIAL NUT SEAL COLLAR Date of Issue May 1983 HONDA MOT...

Page 84: ...the guide roller pin andguide roller DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH GUIDE ROLLER GUIDE ROLLER PIN DRIVEN FACE MOVABLE DRIVEN FACE GUIDE RDL r Date of Issue May 1983 HONDA MOTOR CO LTO G...

Page 85: ...0501 00 and Bearing Remover Head 15 mm 07746 0050400 Remove the snap ring and removetheouter bearing with Bearing Remover Shaft 07746 0050100 and Bearing Remover Head 12 mm 07746 0050300 AP R INGS I J...

Page 86: ...1 0 SERVICE LIMIT 112 5 mm 4 43 in Inspect the clutch shoes forwear ordamage Measure the thickness of each shoe SERVICE LIMIT 2 0 mm 0 08 in Measure the driven face springfree length SERVICE LIMIT 59...

Page 87: ...060 mm 1 3409 in Check the guide groove for wear Check the oil seal for wear damage or other faults DRIVEN FACE ASSEMBLY Using Bearing Driver 07945 GCSOOOO install the outer bearing in the movable dr...

Page 88: ...0040300 install the inner bearing in the movable driven face with the sealed end facingout Install the snap ring Install the movable driven face guide roller and roller pin Install the seal collar Da...

Page 89: ...4 0 kg m 25 29 ft lb CLUTCH DRIVEN PULLEY INSTALLATION Install the driven pulley on the drive shaft Install the clutch outer and torque the nut while holding the clutch outer with the universal holde...

Page 90: ...FINAL REDUCTION 9 0 96 HONDA NHSO Date of Issue May 1983 HONDA MOTOR CO LTO...

Page 91: ...1660001 not available in U S A or107936 1660100 07936 KC10000 not available in U S A L07936 3710200 Common Attachment 32 x 35 mm Attachment 37 x 40 mm Pilot 12 mm Pilot 15 mm Pilot 17 mm Driver TROUBL...

Page 92: ...on case Page 2 4 Remove the rear wheel Page 13 2 Remove the transmission case cover bolts and re move the transmission cover Remove the final gear and countershaft Remove the drive shaft from the tran...

Page 93: ...ION INSPECTION Inspect the drive shaft and gear forwearor damage Inspect the countershaft and gear for wear or dam age Inspect the final gearfor wear or damage Date of Issue May 1983 HONDA MOTOR CO LT...

Page 94: ...available in U S A Inspect the left crankcase bearings oil seal and countershaft bore for wear or damage Use the bearing remover if drive shaft bearing re placement is necessary 9 4 COUNTERSHAFT BORE...

Page 95: ...m 07749 0010000 07746 0010100 07746 0040300 Install a new oil seal in the transmission cover Drive thefinal shaft bearing into the left case Date of Issue May 1983 HONDA MOTOR CO LTD DRIVER 07749 0010...

Page 96: ...drive shaft bearing into the left case Slide the drive shaft through the bearing from the inside 9 6 ATTACHMENT 32 x 35 mm 07746 0010100 DRIVE SHAFT 102 HONDA NH80 OIL SEAL DRIVER 07749 0010000 PILOT...

Page 97: ...utch assembly Page 8 22 Install the drive pulley drive belt and left case cover Page 8 7 Install the frame center cover Section 11 Install the rear wheel Page 13 3 Pour the specified amount of oil thr...

Page 98: ...CRANKCASE CRANKSHAFT 1 0 0 104 HONDA NH80 Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 99: ...and crankshaft force the crankshaft into the case bore with the special tool rested against the crankshaft bearing inner race To do this it is necessary to remove the old bearing from the crankshaft...

Page 100: ...Separate the right crankcase half CRANKSHAFT REMOVAL Attach the special tool on the left crankcase as shown with the three special short bolts Remove the crankshaft CAUTION Do not drive the crankshaft...

Page 101: ...connecting rod big end side clearance with a feeler gauge SERVICE LIMIT 0 5 mm 0 02 in Measure the connecting rod big end radial clearance at two points in the X and Y directions SERVICE LIMIT 0 04 mm...

Page 102: ...placed if it is noisy or has excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in solvent and blow dry with compressed air Check for cracks or other faults NOTE Apply clean engine oil to all...

Page 103: ...0 onto the crankshaft Hold the bolt and turn the nut clockwise to fully install the crankshaft lubricate the crankshaft main and journal bearings with Honda 2 stroke oil or equivalent Date of Issue Ma...

Page 104: ...ves together Install the right oil seal place the collar 07965 GC70100 so its stepped end is against the crank caseand oil seal Thread the bolt from as sembly tool 07965 1480200 onto the crankshaft Ho...

Page 105: ...rotates freely after tightening the bolts Install the following Final reduction Page 9 5 Alternator Page 7 4 Piston cylinder and cylinder head Page 6 7 Drive and driven pulleys Page 8 6 8 22 Oil pump...

Page 106: ...FRAME COVERS 1 1 0 1 1 2 HONDA NH80 Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 107: ...HONDA NHSO FRAME COVER REMOVAL FRAME COVER INSTALLATION Date of Issue May 1983 HONDA MOTOR CO LTD 113 1 1 FRAME COVERS 11 2 11 4 1 1 1 Ill...

Page 108: ...floor mats Open the glovebox lid and remove the glovebox by unscrewing the nut two bolts and ten screws Remove the two bolts attaching the floor plate and remove the floor plate 1 1 2 114 HONDA NHSO...

Page 109: ...our bolts and cap nut and removethe framecenter cover RIGHT AND LEFT FLOOR BOARD REMOVAL Remove the glovebox and floor plate Page 1 1 2 Remove the frame center cover Remove the right and left floor bo...

Page 110: ...of Issue May 1983 HONDA MOTOR CO LTD Radial I Axial 1 2 STEERING FRONT WHEEL BRAKE SUSPENSION 12 1 12 2 12 3 12 6 12 9 12 13 12 16 12 20 STANDARD SERVICE LIMIT 225 8 mm 8 89 in 110 0 mm 4 33 in 4 0 m...

Page 111: ...to oneside ordoes nottrack straight 1 Uneven front shocks 2 Bentfront fork 3 Bentfront axle Front wheel wobbling 1 Bent rim 2 Axle nut tightened improperly 3 Bent spoke plate 4 Faulty or unevenly worn...

Page 112: ...ght covers by re moving the screws Disconnect the front turn signal wires Remove the two bolts attaching the handlebar front cover and remove the front cover with the right and leftfront turn signals...

Page 113: ...light Remove the windshield by removing the three screws and two nuts Disconnect the meter wires and the speedometer cable Remove the rear view mirrors and meter cluster assembly 1 2 4 122 HONDA NHSO...

Page 114: ...ETER D ISASSEMBLY Remove the four screws and remove the meter as sembly Remove the meter cover Remove the indicator panel by releasing the locking pawls Date of Issue May 1983 HONDA MOTOR CO LTD STEER...

Page 115: ...e reverse order of disassembly and removal HANDLEBAR R EMOVAL Remove the meter assembly Page 12 3 Remove the left handlebar switch by removing the two screws Remove the right handlebar switch by remov...

Page 116: ...ligning the tabs of the han dlebar bracket with the grooves in the steering stem Date of Issue May 1983 HONDA MOTOR CO LTO 125 STEERING FRONT WHEEL BRAKE SUSPENSION EXTENSION 07716 0020500 OR COMMERCI...

Page 117: ...sing Tighten the forward screw first then tighten the rear screw After tightening the screws check that the throttle grip rotates freely in Ill steering positions Install all the removed parts Perform...

Page 118: ...left pivot arm bolts Remove the axle nut withdraw the axle shaft and remove the front wheel INSPECTION AXLE SHAFT Set the axle in V blocks and measure the runout The actual runout is 1 2 of the total...

Page 119: ...hey are noisy or have exces sive play WHEEL RIM Check the rim runout by placing the wheel in a truing stand Then spin the wheel by hand and read the runout using a dial gauge SERVICE LIMITS Radial 2 0...

Page 120: ...the right bearing NOTE Drive in the bearings squarely Install the bearings with the sealed ends facing out Cont ami nated brake linings reduce stop ping power Keep grease offthe linings and brake dru...

Page 121: ...ts TORQUE 20 24 N m 2 0 2 4 kg m 14 17 ft lb STOPPER HONDA NH80 AXLE SHAFT BRAKE PANEL GROOVE Tighten the axle nut tothe specified torque AXLE NUT TORQUE 50 70 N m 5 0 7 0 kg m 36 51 ft lb Connect the...

Page 122: ...ECTION Remove the front wheel Page 12 9 Remove the brake panel Measurethe brake drum 1 0 SERVICE LIMIT 1 1 1 0 mm 4 37 in Date of Issue May 1983 HONDA MOTOR CO LTD 131 STEERING FRONT WHEEL BRAKE SUSPE...

Page 123: ...health Do not use com pressed air to clean brakeparts Use a vacu um with a sealed dust collector Wear a protective f ace mask and wash your hands wizen fi ni shed BRAKE PANEL DISASSEMBLY Remove the br...

Page 124: ...e panel thoroughly Install the brake shoes Install the felt oil seal Install the wear indicator plate on the brake cam shaft NOTE Align the wide tooth on the plate with the widegroove on the camshaft...

Page 125: ...NG FRONT WHEE L BRAKE SUSPENSION FRONT SHOCK FRONT SHOCK REMOVAL Remove the front wheel Page 12 9 Remove the pivot arm boltand the pivot arm 1 2 1 6 134 HONDA NHSO Date of Issue May 1983 HONDA MOTOR C...

Page 126: ...per mount bolts FRONT SHOCK DISASSEMBLY Place thefront shock upper joint in a vise Compress the spring by hand and loosen the lock nut and joint Remove the joint and lock nut Remove the spring lower c...

Page 127: ...r joint in a vise Extend the damper rod fully Install the upper spring seat spring lower case and lower spring seat Apply a thread lock to the lock nut and screw the lock nut onto the damper shaft com...

Page 128: ...ing bolt TORQUE 30 36 N m 3 0 3 6 kg m 22 26ft lb Lubricate and loosely install the front fork pivot arms with the attaching bolts and nuts Install thefrontwheel Page 12 12 Dateof Issue May 1983 HONDA...

Page 129: ...K REMOVAL Remove thefollowing Meter assembly Page 1 2 3 Handlebar Page 12 6 Front wheel Page 12 9 Glovebox Section 11 Steering stem nut 1 2 20 LOCK NUT PIN SPANNER 07 02 0020000 07702 0010000 or M9361...

Page 130: ...steel balls in a parts tray so they are not lost FRONT FENDER REMOVAL Remove the two bolts attaching the front fender and remove the front fender Date of Issue May 1983 HONDA MOTOR CO LTD STEERING FRO...

Page 131: ...ewtop ball race until it bottoms NOTE Do not allowthe ball race to tilt during instal Iation BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race with a cold chisel be ing careful not to damage th...

Page 132: ...and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race Lubricate the top cone race with grease Screw in the race until snug against the top ball race then back it o...

Page 133: ...while holding the top cone race Install the following Front wheel Page 12 12 Handlebar Page 1 2 7 Meter assembly Page 12 6 Glovebox Section 1 1 1 2 24 142 HONDA NHSO HEAD TOP THREAD NUT PIN SPANNER 07...

Page 134: ...REAR WHEEL BRAKE SUSPENSION 30 40 N m 3 0 4 0 kg m 22 29 ft lb 20 30 N m 12 0 3 0 kg 1 3 0 144 HONDA NH80 80 100 N m 8 0 10 0 kg m 58 72 ft lb Date of Issue May 1983 HONDA MOTOR CO LTO...

Page 135: ...lder Common Rear shock absorber compressor TROUBLESHOOTING Rear wheel wobbling 1 Bent rim 2 Faulty tire 3 Axle not tightened properly Softsuspension 1 Weak shock absorber spring Brake squeaks 1 Worn b...

Page 136: ...e the exhaust muffler Remove the axle nut and the rear wheel REAR WHEEL RIM RUNOUT INSPECTION Check the rim for runout using a dial gauge as shown SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 0...

Page 137: ...ORQUE 22 28 N m 2 2 2 8 kg m 16 20 ft lb INSTALLATION Install the rear wheel and tighten the axle nut TORQUE 80 100 N m 8 0 10 0 kg m 58 72 ft lb Install the muffler TORQUE 8 mm bolts 40 50 N m 4 0 5...

Page 138: ...Measure the rear brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in Keep grease o f f the brake linings Wipe o f f excessgrease DISASSEMBLY Disconnect the brake cable from the brakearm Remove the br...

Page 139: ...oove on the cam with the wide tooth on the indicator plate Install the brake arm NOTE Align the scribed lines on the brake cam and brake arm Tighten the brake arm bolt to the specified torque TORQUE 4...

Page 140: ...rake cable into the groove in the left crankcase and install the plate as shown REAR SHOCK ABSORBER 30 40 N m 3 0 4 0 kg m 22 29ft lb f t 1 5 25 N m REAR BRAKE CABLE HONDA NH80 PLATE 20 30 N m 0 kg m...

Page 141: ...r joint by com pressing it with the compressor WASHER It SPRING REAR DAMPER I STOPPER RUBBER LOCK NUT Date of Issue May 1983 HONDA MOTOR CO LTD REAR WHEEL BRAKE SUSPENSION ABSORBER ATTACHMENT A 07967...

Page 142: ...ear shock absorber Tighten the upper and lower mount bolts to the specified torques TORQUES Upper bolt 30 40 N m 3 0 4 0 kg m 22 29 ft lb Lower bolt 20 30 N m 2 0 3 0 kg m 14 22 ft lb Check the operat...

Page 143: ...FUEL TANK OI L TANK 1 4 0 154 HONDA NH80 Date of Issue May 1983 HONDA MOTOR CO LTD...

Page 144: ...certain conditions Work i n a well ventilatedarea Do not smoke or allowflames or sparksin the workarea TROUBLESHOOTING Enginefailsto start 1 No fuel in tank 2 Clogged fuel line 3 Clogged fuel strainer...

Page 145: ...Do not bend the floatarm Install the fuel gauge sensor with thearrow on the sensor aligned with the arrow on the fuel tank FUEL TANK REMOVAL Remove the frame center and rear covers Section 11 Disconn...

Page 146: ...lts and remove the fuel tank Remove and clean the fuel strainer Remove the fuel gauge sensor Page 14 2 Check the fuel gauge sensor s operation page 15 18 FUEL TANK I NSTALLATION The installation seque...

Page 147: ...l tank Disconnect the oil level indicator switch coupler Remove the oil tank Clean theoil strainer Page 3 6 To install reverse the foregoing removal procedure Bleed the oil line after installing the o...

Page 148: ...ble and can explode Ignition timing cannot be adjusted If the timing is incorrect inspect the COl unit and pulse generator and replace any faulty parts SPECIF CATIONS CHARGING SYSTEM ITEM Battery Capa...

Page 149: ...switch 6 Faulty starter relay 7 Poorly connected broken or shorted wire 8 Faulty starter motor 1 5 2 Intermittent power 1 Loose battery cable 2 Loose charging system connection HONDA NHSO 3 Loose conn...

Page 150: ...rcharged The battery must be charged if the specific gravity falls below 1 230 NOTE The specific gravity varies with the temper ature as shown Specific gravity changes by 0 007 for every 1 0 C Replace...

Page 151: ...prevent sparks near the battery cells Discontinue charging if the electrolyte temperature exceeds 45 C 111 F CAUTION Quick charging should only be done in an emergency slow chargingis preferred Charg...

Page 152: ...from the regulator rectifier coupler Open the fuse holder and disconnect the red wire from the holder Connect an ammeter and voltmeter as shown Start the engine and take meter readings The readings s...

Page 153: ...emoval installation Page 7 2 7 4 RESISTOR INSPECTION Remove the frame center cover Section 11 Measure the resistance between the resistor wire lead and any body ground RESISTANCE 6 7 Q NOTE A faulty o...

Page 154: ...oper tester or measurements in the improper range may give false readings Use Sanwa ElectricTester SP 10D 07308 0020000 Kowa Electric Tester TH 5H or Kowa Digital Multi Tester KS AHM 32 003 U S A only...

Page 155: ...ming is not correct check the CDI unit and alternator and replace any faulty parts Remove the fan cover and check the ignition timing with a timing light Timing is correct if the index mark aligns wit...

Page 156: ...INSPECTION NOTE It is not necessary to remove the stator to make this test Rem ve the frame center cover Section 11 Disconnect the stator coupler Measure the resistances between the terminals with an...

Page 157: ...Sanwa Electric Tester SP 100 07308 0020000 Kowa Electric Tester TH 5H or Kowa Digital Multi Tester KS AHM 32 003 U S A only In the table Needle swings then returns indicates that there is a charging...

Page 158: ...o the primary coil Check for continuity of the secondary terminals Replace the starter relay switch with a new one if there is no continuity STARTER RELAY REMOVAL Remove the frame center cover Section...

Page 159: ...TER MOTOR DISASSEMBLY Disconnect the starter wires NOTE The brush springs will pop out when re moving the brush holder plate Record the number and location of the commutator thrust washers BRUSH INSPE...

Page 160: ...n the segments There should be no continuity between the commutator and shaft STARTER MOTOR ASSEMBLY Install the brush springs and brushes in the holder plate Install the commutator and thrust washers...

Page 161: ...arter wires STARTER MOTOR INSTALLATION NOTE Before installing the starter test for operation by connecting the starter coupler to the wire harness Install the starter motor in the reverse order of re...

Page 162: ...COLOR RED BLACK BLACK CODE WHITE BAT 1 BAT2 IG ON OFF 0 LOCK TURN SIGNAL SWITCH COLOR GRAY LIGHT ORANGE CODE BLUE w R L R 0 o N L 0 HORN SWITCH COLOR LIGHT BLACK CODE BLUE HO BAT2 FREE PUSH 0 o HEADL...

Page 163: ...E FREE PUSH 0 9 L FRONT REAR STOPLIGHT SWITCH The switch is normal if there is continuity when the brake lever is applied The switches are not adjustable HORN The horn is normal if it sounds when a 1...

Page 164: ...FUEL GAUGE INSPECTION Connect the wire connectors and turn the ignition switch ON NOTE Before performing the following test operate the turn signals to determine that the battery circuit is normal Ch...

Page 165: ...loat raised fully measure the resist ance between the terminals IGreen Red to Black 1 I 340 Uapprox NOTE Operate the turn signals to see that the bat tery circuit is normal then perform the fol lowing...

Page 166: ...ve the turn signal lenses by removing the screws Replace the bulb with a new one Install the lens being careful not to overtighten the screws Date of Issue May 1983 HONDA MOTOR CO LTD 177 ELECTRICAL E...

Page 167: ...t i Lr I i l O I BA o TVRN SIGNAL DIMMER HORN WITCH SWITCH C ONTINUITY TURN SIGN AL SWITCH w A L A IO fO N L I l i COL OR G L8 0 Date of Issue November 1 983 IGNITION SWITCH 8AT 1 BAT2 IG E 0 o f 0 OF...

Page 168: ...zl r c BATTERY 12 V SA H 1 6 WIRING DIAGRAM v CJov wo C w r Bk Rc J l Bk R 8 V B Y W R W P M r G G 9 iTARTEA MOTOR BTJsrf L Bk Y I 0 v I I I I l I A REARTUR I t t 2V J I SPARK PLUG I C Ot UNIT I L LB...

Page 169: ...G l FRO S IGN A L CQO I o __ I w H L L 1 aAi J 1 6 2 WtTCH CONTINUITY TURN SiGNAL SWITCH w R L R 10 ro H L t COLOR Gr LB 0 TURN 1GNAL DIMMER HOR N WITCH IGN ITION SWlTCH BATI 8AT2 ON o ro OFF COLOR R...

Page 170: ...R TUR t 1 1V 3 SPARK PLUG COl UNIT N SIGNAL L LB l ____ G G Y _l I _ J I r i I G Y VIR I L f WIR FUSE lA R PS VITCtt c BATTERY 12V AH VIW G H a V W 0 OIL LEVEL SWITCH FUEL UNIT E L RE Bk BLACK Y YELLO...

Page 171: ...xture intothe com bustion chamber This swirl effect causes turbulence that will give the most efficient combustion This works with the special designs of the nozzle type exhaust port piston and combus...

Page 172: ...to momen tarily restrict the exit of the exhaustgases for a more complete combustion cycle The exhaust quickly exits the cylinder after passing the venturi of the exhaust port This is a way that emiss...

Page 173: ...nal increase in torque MOVABLE DRIVE FACE DRIVE FACE DRIVEN PULLEY DRIVE PULLEY When the engine is running at lovy speed the unit can increase or multiply torque so that moretorque is delivered than a...

Page 174: ...rollers against the drive face is attached to the bossof the drive face with a nut DRIVE BELT MOVABLE FACE ASSPEED INCREASES RAMP PLATE WEIGHT ROLLER As thespeed of the engine increases centrifugal fo...

Page 175: ...n the movable face to push it against the driven face Therefore when engine speed is increased the driven pulley turns and the clutch connects automatically The effective diameter of the drive pulley...

Page 176: ...IRES BUT SOON STOPS WET PLUG 187 18 1 18 2 18 3 18 3 18 4 18 5 18 6 18 7 Probable Cause 1 No fuel in fuel tank 2 Clogged fuel tube up to carbu retor vacuum tube up to inlet pipe 3 Clogged float valve...

Page 177: ...lty CDI unit 2 Faulty pulse generator TOO LOW 11Jo 1 Worn cylinder or piston rings 2 Blown cylinder head gasket 3 Flaws in cylinder or cylinder head 4 Faulty or deteriorated reed valve TOO HIGH 1 Carb...

Page 178: ...pipe gasket 3 Deteriorated insulator O ring WEAK OR 1 Faulty carbon or wet fouled INTERMITTENT SPARK spark plug 2 Faulty COl unit 3 Faulty pulse generator 4 Faulty ignition coil 5 Broken or shorted h...

Page 179: ...r t a 5 If there is abnormal noise or smell 1 Oily or greasy substances on drive belt pulley 2 Worn drive belt 3 Weak driven face spring 4 Worn or seized driven pulley bearing LOSS OF CONTROL Check t...

Page 180: ...nected terminal CORRECT 4 Remove oil level sensorand check operation Float up Lamp off Float down Lamp on CORRECT SIGNALS DIM REMAINED 1 Blown fuse ON OR NOT OPERATED 2 Weak ordead battery 3 Faulty ig...

Page 181: ...alancing coil INCORRECT 1 Disconnected terminal 2 Incorrectly connected terminals L 1 Shorted or broken balancing coil lead POINTER F LUCTUATES OR SWINGS VIOLENTLY IGNITION SWITCH ON Probable Cause 1...

Page 182: ...Loose connector or terminal NOT ROTATED 1 Worn brushes 2 Broken or shorted rotor windings 3 Broken starter motor sub wire 4 Loose terminal L i 1 Broken wire harness STARTER MOTOR ROTATES BUT SLUGGISHL...

Page 183: ...x 35 mm 0753491 07746 0010200 Attachment 37 x 40 mm 0959811 07746 0010300 Attachment 42 x 47 mm 0959871 07746 0040200 Pilot 1 2 mm 095988b 07746 0040300 Pilot 15 mm 095989 0 07746 0040400 Pilot 1 7 m...

Page 184: ...t removal adJustment 0753491 07746 0010200 Attachment 37 x 40 mm Top steering head race installation Use with Pilot 25 mm 07746 0040600 and 07749 0010000 0959811 07746 0010300 Attachment 42 x 47 mm Bo...

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