ion and maintenance inspection, for easy reference. Any revisions to this manual
will be notified by the Service Bulletin. July 20, 1967. Service Department.
SHOP MANUAL HONDA
-. MODEL
P50
• I
I
FOREWORD
The P-50 is a gasoline engine powered bicycle, affording all the simplicities of the bicycle with the powered features of a mopet, yet so easy to handle that anyone who Is able to ride a bicycle can ride the P-50 without any previous
-
experience. It is designed to fulfill the need for a safe, economical and easy handling family transportation. This manual has been prepared as a servicing guide for the P-50, and all personnel who will be servicing the P-50 should read this manual carefully to become familiar with all of its sections. The manual is written in tow parts, construction and maintenance inspection, for easy reference. Any revisions to this manual will be notified by the Service Bulletin.
July 20, 1967
Service Department Honda Motor Company Ltd.
I
II 1. 2.
CONTENTS
II
FEATURES SPECIFICATION & PERFORMANCE SPECIFICATION FOR P - 50
. .. . . . . . . .. . .. . . .. . . . . . . . . . . . . . . . .. . . .. . .. . . . . . . . . . 2
DRIVING PERFORMANCE CURVES .. . . .. . .. . . .. .. . . .. .. .. .. . .. . . .. . .. . . . . . . 4 ENGINE PERFORMANCE CURVES .... ..................... . ................... 4 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 (For General export type) . .. .. .. .. . .. . . .. . . . . . . . .. . . . . . . . . .. . .. . .. .. . . . . .. . .. . . . . . 6 ( For U. S. A. export type)
. . . . . .. . .. . .. . .. . . . . . .. . .. . . .. .. .. .. . .. .. . . . . .. . .. .. . ..
7
(For France and Belgium export type) .. .. . .. . .. . . . . . .. . . .. . .. .. . .. . .. . .. .. .. .. 8 (For Holland export type) . . . . . . . . . . . . .. . . .. . . . . .. . . . . .. . . . . . . . . . . . . . . . .. . . . . .. . . ..
8
(For England export type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 (For Germany export type)
.. . . .. .. . .. . . .. . .. . . . . . . . . . .. . .. . .. . .. . .. . . .. . .. . . . . . . 9
DIMENSIONAL DRAWING ....... . ............. . .......... . ... .. .. ... . ... ....... 10
GENERAL DESCRIPTION 3.
ENGINE Operation of Four-cycle Engine
.. .. ...... .... ..... ...... . ....... . .. . ........ 12
Intake (Intake of the fuel-air mixture)
.. ..... . .. . .... .... .... ...... .... 12
Air Cleaner . .. .. . .. .. .. ..................... . .. . ..... ... .. . . .. . .. .... ..... .. . . . . .. . ...... 12 Fuel Tank ... .. .... . . .. . .. ... . . . .. . ... . ....... . .. . .... . .. . ... . .. .. . .. . . ..... . .. .. . ......... 13 Fuel Cock ............ . . . . . ... . .. . ......... . .. . ... ...... . ... . . . . ....... .. . .. .. . ............ 13 Carbu retor
. . ........ .. ...... .. . .. . ...... . .. . . .................. .. .... . . .. .. . . .... . .... .. 13
P-50 Carburetor Construction ......................................................... 16 Operation of P-50 Carburetor Component Parts ................................. 18
Compression (Compress the fuel air mixture in the cylinder) ... 19 Piston ........... ....... .. . . ... . ... . .. .. . .. . . . .. . .. ...... .. .. . ..... .. . . ....... ...... .... . ... . 19 Piston Offset
......... . ..... ... . .. . ........ . ....... . .. . ............ ....... . ... . . .. . ... . 20
Piston Shape . ..... . .. . .. . . .. .. . ... . . ...... . .. . . . . .. . . .. ... . ... . ... . .. . .. . .. . . .. . . .. . ...... 20 Piston Rings ...... . .. . .. . ..... ... . . .. . ... . .. . . ......... . . .... . . . . .. .. .. . ... . .. .. .. . ....... 20 Cylinder ...... .. . .............. . ...... . ... . ... . ...... . .. .. .......... .......... .. . .... .... ... 21
Combustion (Ignition of the compressed air-fuel mixture by the spark plug to cause combustion) ................. ................. ..... 2 1 Ignition System ............... .. .. .. ...................................................... 21 Flywheel AC Generator ... ....... ....... . ............. .. .. . .. ... ........ . ... ....... . .. 22 Ignition Coil ............................... . . ......... . . . .. . ......... . ....... .. ........ . .. 22
1
I
FEAT~~
Engine 1.
CHAIN DRIVEN 0. H. C., 4·CYCLE ENGINE is used to provide quiet efficient power.
2.
POWER TRANSMISSION IS PERFORMED by a specially engineered three st age speed n'!duction and a reliable centri fugal clutch that automatically disengages at idling speed and engages when throttle is opened ; eliminating any need for a manual clutch or gear shift.
3.
ENGINE STARTING AND STOPPING is by opening or closing the decompression lever which relieve the compression from the cylinder.
4.
THE ENGINE AND THE COMPLETE POWER TRANSM ISSION UNIT are contained within the rear wheel hub together with the rear brakes.
5.
SHIFTING THE CYCLING LEVER located on the engine disengages the engine to permit pedal operation of the P·50.
6.
CHOKE BUTTON IS CONVENIENTLY LOCATED on the steering head, accessible while riding.
Frame 1.
A STEP THROUGH FRAME WITH A LOW CENTER·OF·GRAVITY makes it easy t o mount or dismount and provides for greater stability.
Frame main structure is a monocoque,
welded pressed steel sheet for high strength and ridgidity. 2.
EXPANDING BRAKE SHOES in the front and clamping band brakes in t he rear operated independently by the handle levers assure good braking .
3.
AUTOMATIC ARM CHAIN TENSIONER constantly maintains the pedal drive cllain in proper t ension, eliminating any need for ad justment.
4.
THE EASY STEERING BICYCLE TYPE HANDLEBAR is vertically ad justable.
5.
A CONVENIENT BASKET IS MOUNTED ON THE FRONT FORK for carrying shopping or u Llit:!r ligill luetu.
r
2. SPECIFICATION & PERFORMANCE
1
SPECIFICATION FOR P-50 Specif ications
De scription
Name of motorcycle Model type Type of vehicle
Honda
p.so Motorcycle
Dimen sions 1,730 mm ( 68.2 in) ( For Holland)
Over all ler1 g th
1,'570 mm ( 65.7 in)
Over all width
620 mm (24.4 in)
Overall height
1,020 mm (40.2 in) 1,070 mm ( 42.4 in)
1,050 mm ( 41.4 in) ( For Holland) 1,090 mrn ( 42.9in) ( For Holland)
110 mm ( 4.3 in)
130 rnm ( 5.1 in) (For Holland)
Wheelbase Min. ground clearance
Weight 46 kg (101.3 lbs) (For Holland) 13 kg ( 28.6 lbs) ( For Holland)
Weight, empty Empty weight distribution, front Empty weight distribution, rear
45 kg ( 99.1 lbs)
Full load weight distribut ion, front
29 kg ( 63.8 lbs)
33 kg ( 72.7 lbs) (For Holland) 37 kg ( 81.5 lbs) (For Holland)
Full load weight distribution rear
71 kg (156.41bs)
84 kg ( 185 lbs)
14 kg ( 30.81bs) 31 kg ( 68.3 1bs)
(For Holland)
Perform once Max. speed Climbing ability : grade
40 km/ h ( 25 mile / h)
37 km/ h ( 23 mile / h)
5 °10'
Engine Type fuel used
Gasoline
Type engine No. of cylinder and arrangement
Air cooled 4 stroke cycle Single cylinder, tilted up 10° from horizontal
Valve arrangement Total piston displacement
49.3 cc ( 3.0 cu. in)
o;;c
and valve
Bore x Stroke Compression ratio
42 X 35.6 mm ( 1.65 X 1.4 in)
Compression pr essure
12 kg / cm2 (17llbs/ in2)
Max. output Max. torque Min. fue l consumption at max. load
0.25 kg·m ( 1.81 ft . lbs)/2,800 rpm 270 gr / Ps·h / 2,900 rpm 350 g r / Ps·h/ 4,000 rpm (For Holland type )
8 .7 :1 1.38 PS / 5,000 rpm
cx 278 w x 310 h ( 15.6 x ll.OX 12.2 in)
Dimension (mm)
396
Totar weight Installation and method
12 kg ( 25.4 lbs)
Start ing method Carburetor No. and type
Pedal starter Single, dawndraft
Air filter t ype
Dry (urethene foam)
14 kg (30.9 1bs) (For Holland type)
Mounted on rear wheel with torque link
Fuel tank capacity
2.51it. (0.7 US gal .. 0.6 lmp. gal.)
Lubrication method Lubrication system capacity
Splash 0. 7 lit. ( 1.5 US pint, 1.2 Imp. pint)
3 Description
Specifications
Ignition system Ignition method
Fl ywhee l magneto
Ignition coil
High voltage A.C.
Type spark p lug
C·6HB
Power transmission system Primary reduction method
Sprocke t and cha in
Reduction ratio
2 .74 : 1
Clulcil type
Centr ifugal automatic
Secondary reduction method
Sprocket and chain ( Gear for Holland type)
Reduct ion rat io
6.25 : 1 ( 6.95: 1 fo r Holland type )
Steering system Steeri ng handle tu rning ra dius
75°
Steer ing handle width
5 70 mm ( 22.4 in)
Caster
66°
Trail
40 mm (1. 58 in) , ( 50 mm ( 1. 97 in) for Holland type ]
Tire, fron t
2.00.17 ( 2PR) (2 3 -2.00 for Holland)
T ir e, rear
2.25·17 (2PR) (2 3 ·2 .25 for Holland )
Brake system Type brake, fron t
Expand ing brake shoe
Type brake, rear
Externa l clamp ing shoe
Met11od of application, f ront
Right handle lever
Method of application, rear
Lett handle lever
Suspension system Suspension me t hod, front
Spring
Lighting system Headlight r ating
6V·l5W ( For U.S.A. type) 6V-10W ( For General expor t , England type) 6V-6W ( For Fr ance, Belgium, Holland type) 6V-1 5W ( For Germany t ype)
Tailli ght rat ing
6V -5.3W ( For U.S.A. type) 6V-3W ( For Gener al export . England type ) 6V-1.8W ( For Fr ance, Belg ium. Holland type) 6Y·l.8W ( For Ger many)
Stoplight rating
6V-17W (For U.S.A. type) 6V -8W ( For Genera l export , Engl and type) bV-5W
( ~ or ~ranee.
Belgium type)
4 DRIVING PERFORMANCE CURVES
8
3
X
10
15
7
,..... :E I:L
6
.,
5
4»
4
~
Q)
Q.
,.....
-.. 0)
..:.::
10
Q)
u 0
1.&.. 0)
UJ
c >
..
3
Q)
c
5
en
c
2
c
I.LI
1 0
10
20
30
40
50
Running Speed (km/hr) ENGINE PERFORMANCE CURVES
1.5
0.4
Q)
:I
0.3
IT"
oE
~·01
0.2
,.... cri
.::~
ns
.:
0.1
1.0
~
0
--
0.:
~
:I
ca.
:I
0
600 c 0 ·.;: 500 ca.,....
ns
.c
0
E~
400
0.5
300 200 2
3
4
5
6
7
X
:I tJj
'
tJj
c ca. o ....... 0 .. 01
4)~
:I
LL.
10'
Engine Speed (R.P.M.)
(General, England, Belgium, France and U.S.A. export type)
5 DRIVING PERFORMANCE
7
6 5 4
3 2
10
0
20
30
50
40
Driving Speed (Km/Hr)
ENGINE PERFORMANCE CURVES
1.5
0.4 0.3 u)
-
0.2
a.: c:
.2
1.0
0.1
•
·e•
-. -.. E
01
~
41
:I
CT 0
t-
-... .. ..c:
.
ell
c
--CG
Cll
t-
700
:I
D.
600
:I
0
D. .._
01
c 0 ·.;;
D.
0.5
500 E :I c 400 "' 0
0
300
Qi :I
1.1..
2
3
6 4 5 Engine Speed (R.P.M. )
( For Netherlands export type)
7
3
X
10
:-------------]
:
1
R. FRONT TURN SIGNAL LIGHT -~~~'!!_____ -----,
: l·· i , ,;=J
. I
I I I
o
r------ r-- -- - - -----~
I
.'1'
l']::i§ml' l r
FLASHE~RELAY
~
I
o
TURN SIGNAL SWITCH
i I
•
UQ···---~~~~~~NIUM RECTIFIER
r · -1···-G\''18
0 :
:II I ~ ,t
0y I
·,~6V lOW
I
fI
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:
:
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::::
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6V8W
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,
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L----t-----------~·---G'
fiR 8
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c ~---c--------+--.
81
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•---- -------------- -~- C'I BK
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IUil'· - _ .,.. (GY B~
_
:
:
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G')
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;;
:
......... 'II 0
R. REAR !URN
-- ~- .. J
SIGNAL liGHT GVF:W
I
·1,·--------------t~t:;~~~~~~~~~~~~~~-~~~~~~=~~~:~~~~:=~~;:~::t~~=~~~~---~~~~~~~;~~~~~=
G')
s:
_ .... --' II I
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--r--- -'
-1-----I
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TU8[)--- ---- ------- ----
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sl
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·l:tt• ...,...,R- - ----1--,
I
: 1
1-
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It~ ~
tusr ---- 1
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HEAD liGIIT
~~~~-~ ~f-.:\....--1 L FRONT TURN SIGNAL UGH I I
:I
!
:
! :
I I
AC. IIORN
W2~
.
R
"r :----·;_.._-_-~~ -------w---J
r--J ........ ........ ............. J
I
~
:
I
..-
1
"' __ ; L... ..,
I
o
0..
FUSE 7A _ _
! :- --~~l!l-·R·-l1Am~-r------:
t
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:::s
II)
(II
r-
-
_l:_= ~~= ::::J f Al" i~NITION -G -
\
- ·
L R- 0
SELENIUM -
l
RECTIFIER-
I
L_____________
·-
.I l ..
":"
I
(D
I
-----~w
L-
:
BK j
,.
)C
I
I _J
"'
0
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y -ll
GV lOW
\ '•
...
l~ I
_-.... -TAILLIGHT 6V SW
j ~ J.___v--r_-~_=-_:_,.,_ __ __ - - - - - --
- - - - \ - / - t- - - -BR-«.J-8R----__J
~K v G R
f coNDENSER
n o
~====::s--~-cmi,-
~K
A.CIGNITION COIL 9
IJ-
\
,'
.----f:::F= --~...- ~
HIGil !EliSIONCABLE
11 1 YGR
·id. ...~ ,
, ,
;_::J
G1-SPARK PLUG
:::::14
, .j
~-l
~ ~-
"·c:3'mWEEL A.C. GENERATOR
.·-- r ··· (CONTACT BREAKER MOUNTED)
(For Germany export type )
0)SPEEOOMETER LAMP 4'f 6V l.SW
G(!
LIGHTING SWITCH
BR
HEAD LIGHT 6V ISW IDIN 72601 From Tl
-h-eR
6~R
_,
s~l
~
BR
I
~r--- --
A.C. IGNifiON COIL
C::::~:;:~
I
BK
R
~J
1 SPARK PLUGtM
~
TAIL LIGHT6V SW {DIN 72601 From L) BR-L l--HR-----4~3----J:hl
~
J--~~
LIGHTING SWITCH SWITCHINGARRANGEMENT
OFF ON
' ::SI r FLYWHEEL A.C. GENERATOR l . _ _Y (CONTACT BREAKER MOUNTED)
l
10 DIMENSIONAL ORA WING
-
- - (U! ( '( £/06(-
11
GENERAL DESCRIPTION 3. ENGINE In the gasoline engine. the fuel and air is mix in the proper ratio and this mixture is taken into the cyli nder in a vapor condition where i t is compressed and ignited, the r esulting combustion forces the piston down. ward, and tl1e com bustion pressure is transformed to the rota r y motion of the crankshaft by means of the conne· c ling rod. T he opera t ion of the eng ine is quit e sim ilar to the pedaling o f a bicycle, with power produced by ped. aling considered as the combus tion pressure of an air. fuel mixture, the foot acting the role of the piston, the pedal the connecting rod. and the spr. ocket simulating the crankshaft
i l Spark p lug 2 Valve '3' Cyl inder ·~ Piston t!?) Connectingrod ~ Crankshaft The gasoline engine produces power at the crankshaft by the following four sequence of events, or strokes. Intake -+ @:; Compression -+ @ Power ---+ @ Exhaust The term "cycle" is applied to one complete sequence of these four strokes. When the entire cycle of events in the cylinder reQuires four strok es ( two crankshaft revolu tion), t he engine is referred to as a fou r -c ycle engine. An engine which accomplishes the en t ire cycl e of events in two strokes (one cranksha f t revolut ion), is referred to as a two - cycle engine. P-50 is equipped w ith a f our.cyc:e engine. (Fig. 3- 3-6) Fig. 3-1
(!) Pedal
:g
Sproc ket
Fig. 3 -2
Fig. 1·23
10- 15 mm (3 , 8 - 5 18 in)
t1) Adjusting nut 3 T o decrease
?'
T o increase
Security of Component Parts
57
Fig. 1-24
C y
Crank arm set pin :~; Front whee l axle nut ~ Crank pedal (.5\ Rear torque arm '6 ' Carburetor cover 7: Rear ax l e nut :a Exhaust pipe
1~1 Crank arm
Fig. 1 -2 5
'1 6 x 14 bolt
1
Muffl er band
"?'
Spoke
'3• Rear axle nut
~· 6 X 14 screw ( 2 ea)
§ Spo ke
58 3.
Air Cleaner Servicing
An air cleaner clogged wi th dus t restricts the free passage of inlet air and resul ts in power loss or drop in accelera lion, therefore. periodic servicing of the air c leaner should be performed. ( 1)
Remove lhe air c leaner cover.
(2)
Remove the air cleaner case cap. (Fig. 1 26)
(3)
Remove the air cleaner element t ogether w ith the element set plate.
Air c leaner cover Air c l eaner cap
(4)
Tap the air c leaner element lightly to remov e the dust or wash in wa t er. (Fig. 1- 2 7 )
Fig. 1-27
2 (5)
Remove th \J clus t from the inside of air cleaner case. (Fig. 1 28)
- NOTE -
I.
Caution not to a llow oil to get on the air cleaner e lement.
After washing, reinstall the
air cleaner element after it
is completely
dried. 2.
After installing the air c l eaner case cover, check t o make sure that the cap is in c l ose
Fig. 1-28 (!\
fit with the air c leaner element.
Air cleaner case 3.
Check to make sure that there is no place for air to leek ln.
~· CD
· 0.:
Fig. 1·29
1 ~
Element set p l ate Air c leaner element
59 3.
1I
Other Inspections and Adjustments Adjustmen ts of Throttle Grip and Throttle Cable
••
When parallel
excessive play exists
in tha direction
to the shaft, turn up the grip rubber and
check the screw for looseness. (Fig. 1 30) ~~
When
excessive
play
exists
in
the
dir ection, adjust the throttle cab le.
rotat ing Make t he
adjustment with the adjusting bc.lt. After the adjustment, reinstall the cap securely. (Fig. 1 31 )
(l l Adjusting bolt 3) T o increase
2
2' T o decrease
4 Cap
Engine Decompression lever Adjustment The lever play should be 0.1.....,0.4 em (0.04.....,0.16
in). Fig. 1- 32)
Fig. 1·32 The adjustmsnt shall be made b y
lous~ning
Ci ) Engine lever (2) 0. 1 ~0.4 em (0.04~0.16 in)
ff - ,.----
t he nut
A and turning the nut B. (Fig. I 33)
Fig. 1-33
1 Nut B
P' ~
2 ) T o i ncrease 4) Nut A
3' To decrease
60 (3)
Handle and Saddle Height Adjustments Adjust the handle and th e saddle to the heights
most normally used. Handle Adjustment
CD ® ®
Loosen the 6 X 40 bolt. loosen the handle se t bol t and tap lightly. Ad just the handle to a suitable height between H and l marked on the stem and fix in place with the handle se t bolt and the 6 X 40 bolt. H - Upper limit
M - Middle L
Lower limit
(Fig. 1 34)
Saddle Adjustment
CO ®
Loosen the 8 X 4 2 bolt. Adju s t th e saddle to a suitable heig ht wi th the mark located within the frame, and fix the saddle in place with the 8 X 42 bolt. (Fig. 1- 35)
Fig. 1-34
'i" Handle se t bol t (J)
@ 6 X40 bol t Adjustin g position
Fig. 1-35 (!' Mark
(2) 8 X 42 bol t
61 (4)
Head light Adjustment
Bea m Adju stment
Th e head light case mount. with exczption of those for export to the U.S. A., is of ball and socke t type. Wi th l he nut loosened it can b: ad justable in any di· rections. (Fig. 1 36)
l ight case Focus Adju s tment
Th er e ar e two typ es of bulb.
e-
Type /\ bulb shall be installed by fi tting to the groove A in the socket a:1d t ype 8 bulb to the groove B.
This applies to standard model as we ll as export
models for Netherlands and the United kingdom.
(fig.l- 37)
Fig. 1-37
H eadlight bul b
62
2. ENGINE A.
SPECIAL TOOLS
Clutch outer holder
Top cone spanner
Flywheel holder Flywheel puller
Pedal remover
14 mm lock nut wrench
Stem nut spanner
63 B.
STANDARD TOOLS
10
x 14 mm
double open end wrench
Tire tool set Electrician screwdriver
21 mm T- handle socket wrench.
Common wood handle screwdriver
--=' Re d lead o r b l ui ng
Warped cylinder head may be repaired by sanding the cylinder head on the surface pla te using a :: 200 grade emery paper and t hen finishing with a :f 400 grade emery paper followed by checking as stated above. (Fig. 2 12 ) Combus tion Chamb e r
Item Height Volume
St andard valu e
Serviceabl e limit
5.5 mm ( 0.22 in) 5 CC
Use a carbon scraper or bru sh t o remov e the carbon
Fig. 2·12
(l) Cylinder head (~) ~
400 emery paper
from th e head and exerc ise care not to damage. 3. Inspect th e valve sea t by assembl y ing the v aives as shown in Fig 2- 13 and pour oil into t he combustion chamber to cover the valves. Apply a blast of compressed air into each ports: if bubbles are produced, it is an indication that tha valves are not properly sealing a,d repair is necessary. ( Fig. 2 13)
Fig . 2 · 13
l ) Cyl i nd e r head 2: Valve seat c utter
68 Ch
The valve c ontact
width will be indicated by tha t rans fer of t11e red lead or bluing. Standard Value :
0 . 7~ 1
mm ( 0 .028- 0.039in)
The valve seat is reworked by three types of cutter ; 30 ~. 45° and 60°. The 45° cutter is used for truing the sea l while the 30° and 60° cutter are used to cut the top and bottom of the valve •1 Dial gauge ~ Valve
Fig . 2- 14
seat to produce the proper seat width and also to position the seat. (Fig. 2 13) 4.
4.82 - 4.832mrn (0.1898-0.1902in)-
Va lve (Fig. 2 14) Standard va lue
Item
4.8- 4.81?m!Jl._ Q,l891\in)
r --ll< o18g-
Diameter
I
4.790~4.780
( 0 .189-0.188 in)
Overall 49.5 (1.945 in) leng th 0 . 4~0 . 6 Head thickness ( 0.016-0.024 in)
Ser viceab le limit 4. 7 4 ( 0.18 7 in) min. 48.6 (1.913 in) min. 0.2 ( 0 .008 in) min.
(Note) Va l ve marked " IN" must be used as in let valve, Fig. 2 -15
h owever, valve without any marking may be
Valve g uide dimensions
used for either Inlet or exha llst.
r-(o.7638111) [9.471I . 7~6.3 kgjT2 .45 mm ( 5.7~6.3 kg / 0.489 in)
Item
Fig. 2-17
I Serviceable
Standard value IN
EX
21.44 (0 .844 in) - 2-1.12 ( 0.834 in)
Serviceable limit 17:-8 (0.70 1 in) min. at base c ircle.
Replace cam sprocket if gear teeth are damaged or excessively worn.
69 8.
Cam sprocket root diameter. (Fig. 2 - 18)
'•7 .45
Standard value: 57.45 ~2.261 in)
(2.26in)
/-: ~
'
/'•
,-.
..:...:·
.
-+-
0
'\
.~-
30T Fig. Z-18 Cam sprocke t
D. I.
Reassembly
Reassemble th a va lve assembl y.
2. Assemble tile cy lind er hea d. exerc ise care not to damage the cam c hain and oil g uide. (Note) When installing the head, do not forget the head gasket and the tw o hollow dowel pins. (F ig. 2·19)
Fig. 2·19
•ll H o ll ow dowel pin •,6• Cylind e r h ead gasket
Fig. 2· 20
Torquin g sequence of cylinder head
Fig. 2 -21
(1) L eft cran k case index mark 2 ) Flywheel magnet J) " T " timing m a rk
3. Install the four 6 rnm nuts and a 6 rnm screw. TorQue the cylinder head nuts to 90~120 kg ·cm
(6.5-8.7 ft. lbs) (Note) T orque the nuts diago nally and with a uniform force . (Fig. 2-20)
4.
Align t he f lywh eel top.dead.center mark " T"
to
t he lef t crankcase index t imine mark . (Fi g. ? ·? 1)
70 5.
A lign the two holes in the cam sprocket so tha t t hey are para llel to th e gaskcling surfac e ( top.dead. cen ter) and install the cam chain. (Fi g. 2 22)
., Fig. 2 -22
11) Cam chain (2) Holes parallel to g asket surfa ce ~ Cam sprocket
6.
Align the holes in the oil guide and center pin and tap the center pin in wi th ligh t stroke. ( Fig. 2 23)
( N ote) a.
Insert the center pin so that the 0 ring on the center pin is below the cylinder head center pin h ole.
While installing, the exercise
care not to damage the 0 ring. b.
Check to make sure that the 10 mm washer is not missing.
Fig. 2 -23
1 1 Center pin ' 3l Oil guide
12 8.1 X 1.0 0 ring
7.
Alig n the camsha ft lock pin hole wi t h t he pin hole in the cy linder head by using a screwdriver for tuming and then drive in the 3 >. 12 dowel pin. ( Fig. 2 24)
( Note) a.
After assembly, rotate the flywheel several times to check for smooth ope rati on and a lso check the valve timin g.
b.
Curing the dowel pin installation, exercise care not to damage the gasket.
Fig. 2 -24
ci 1 3 x 12 on dowel pin
8.
Assemb le the c y linder head cover .
E.
Disassembly of Cylinder, Piston, Piston r ing
•2• Cam Shaft
Fig. 2-25
Cylinder
1.
Remove cyl inder head. r efer to sec tion 2. 2 . A.
2.
Remove cy linder ( Fi g. 2 25)
71 3.
Extract piston pin clip a,d remove pisto:1 pin (Fig. 2 26)
(Note) Caution not to drop clip into the case. 4.
F.
Remove p i s to:-~ ri:tg .
b Clip
Fig. 2·26
(1> Piston
Fig. 2 · 27
Measuring inner diameter
Fig. 2-28
·!': Micrometer \2' Piston
Fig. 2-29
Checking the c l earance
Inspection, Repa ir
1. Check cy linder d iameter I t ern
D.lam cte r
2.
Standar d value 42 .0~42.0 1
(1. 65 4~1.65 5 in)
Serv iceable limi t
4 2.1 (1.658 in) max.
-...!....----
Remove carbon deposi t from piston head and r ing g r oove, exercising car e not t o damage the piston.
(Note) Do not use emery paper.
3. Check piston diameter (Fig. 2 - 28) Item Standard v alue -D. - - -4co-8 ~42.o lameter ( 1.6 46~ 1. 654 in)
Serviceable limit
41.9 (1.650 in)min.
---"-----
4.
Pis t on r ing side c learanc e Check the clear ance w i th a new ring (Fig. 2-29)
5. Piston pin bore Item
Standard value 13.0 02~1 3.008
Diameter (0. 5119~0 .5121 in) 6.
Serviceable limit
13.05 (0.514 in) ma x.
Piston pin diameter Item
Standard va lue
Ser v iceable limit
12 .98 Diam eter (0.5116-0.5118 in) (0.510 in) min. 12.9 94~1 3 .000
72 7.
Pisto:·1 rinB end gap Fit the ring into the cylinder squarely and measure the end gap with a thickness gauge. (Fig. 2 - 30) Item End gap
8.
2nd ring Oil ring 9.
( 0.004~0.012
Star.dard
Top ring (1• Piston ring (2: Thickness gauge
0.1-0.3 in}
Serviceable limi l 0.6 (0.024 in)max.
Ring tension Item
Fig. 2·30
Standard value
valu~
0.35 0.65 kg ( 0.77-1.431bs 0.35-0.65kg ( 0.77-1.431bs) 0.58~0.9 3 kg ( 1.28~2.0~s )
Serviceab le limit 0.2 kg {0.441bs} min. 0 .2kg - (0.44 lbs) min. 0.45kg ( 0.99 lbs) min.
Ring width and thickness Standard value
1.90-2.10 . Thickness All nngs (0.0748-0.0827in) ~ u 95~uso op nng (0.04 70-0.0465in) . 1.195~1.180 Width nd nng 1( 0 0 470-0.046 5in) . . 2.480-2.495 0 ' 1 nng ( 0 .0976-0.0982in)
r
12
Fig. 2-31
' 1 Piston
Serviceable limit
1.14mm min. (0.0449 in) 1.14 mm min. (0.0449 in) 2.44 mm min. (0.0960 in)
2 Piston ring
G. 1.
Reassembly
Assemb le tt1e piston ring to the piston
(Note) a.
When a ssemblying new rings , roll the rings I n their respective p iston grooves to check the fit. (Fig. 2-31)
b.
The ring must have the maker's mark on the r ing toward the top. (Fig. 2 -32)
Fig. 2·32
1 Manufac turers mark
2.
Install the pis t on
( N ote) M ak e sure that the arrow on the piston head in pointing downward .
3.
Inst all the pin clips at both ends of the piston pin.
( N o te ) a.
The clip opening shoul d not be aligned to the
b.
Disto rted o r c l ips which have l ost its tension
c ut out. should be rep laced with a new part. Fig. 2-33
1 Arrow marking
73 4.
Before installing th e cylinder, make sure that the cylinder g asket and th e t wo hollow do·Ncl pi:ls are in place. (Fig . 2-34 \
5.
Space th e ring gaps eve.1ly apart for all rings.
6.
Trim th e c r ankcase g asket with a sharp kni fe if it ex t ends ebove th e cylinder mating surface.
Fig. 2-34
1 Cylinder ga sket Ho ll o w d owe l p i n
~
2. 3
Reduction, Cam chain tensioner, Oil guide, Crank shaft Troubl e
Engine will not star t
Cor rective A ct ion
Probabl e Cause
1.
Drive plates and fr iction plates arc not making
1. Replace or repair.
2.
Excessively worn friction pla t e disc
2.
refer t o section 3 - A Replace friction plate
3. 4.
Excessively worn ball rolling surface Weak c lutch spring
3.
Replace clu t ch outer,
5.
The clutch weight is no t pressing against the
uniform contact
friction plate due to excessive wear o f t he c lutch weight spr ing hook Eng ine speed with
1. Loss of c lutch spring t ension
clutc h disengaged is too fast or slow
3.
Excessively worn or burnt c lutch weight shoe Excessivel y worn clutch outer friction surface
4.
Excessivel y worn clutch weight hook
2.
friction pla te and/ or ball retainer 4.
Rep lace weight
1.
Replace, r efer to section 2.3 A
2.
Replace
3.
Replace
4.
Replace, refer t o section 2 .3 A
Clutch suddenly engages during idling and cause eng ine to stop
1.
Too high an idling speed
1.
Adjust to 1500 RPM
2.
Weak c lutch spring
2.
Replace
3.
Clutch def€ctive or cut of ad justment
3.
Replace or adjust
Cyc ling lever inoperative. w ill no t
1. 2.
Defective free pa wl Worn groove in secondary drivett sprocke t
1.
Replace
2.
engage with engine in
3.
Free pawl g uide disengag ed from free pawl
Replace secondary driven sprocket Repa ir
3.
ON position
Cycling lever in operati v e, will not disengage from engne in OFF position
1.
Excessively worn or defective cycling lever
2.
Free pawl spring bent over
Eng ine oil change s to
J.
Wat er mixed in oil
emulsion
2.
Slogged breather pipe
4.
Replace. refer to section 2.3 A
1. 2.
Replace Replace
Oil even t hough clean in appearance may be d ecomposed when used f or a long period, thins out and looses lubricating quality
74 A.
Disassembly of Redu ction Gear
l.
Remove engine. refer to sec tion 2. 1 A
2.
Remove r ear brake sho es ( Fig. 2 --35)
3.
Disconnect r ear brak e arm and r emove rea r brake cam.
4.
Remove right crankcase cover .
5.
Remove f inal driven sprocke t. ( Fig. 2 - 36)
..... Fig. 2·35
Fig. 2·36
· the hang er crank axle
lack of grease on the hanger pipe bushing
Apply grease
Torquing Table To rque va lue
It em kg · cm
ft · l bs
Engine Right crankcase Drain plug Clutch Right crankcase cover
8 mm cylinder bolt Cord clamp Dynamo stator Fly wheel Dynamo cover Cyli1,der head Cylinder head cover Spark plug T appet adjusting nut Tappet cap Stop switch brake arm
80 ~ 320 ~ 380 80 ~ 70 ~ 602018020""" 90 ~ 8011070 ~ 9080 ~
5.8 - 8.0 23.1-19.5 27.5- 32 5.8- 8.7 5.1 - 7.2 4.3- 6.5 1.5 ~ 2.9
50~
110 270 450 120 100 90 40 2 50 40 120 110 150 100 130 110 70
180 80 ~ 200 ~ 40""" 40 ~ 250 ~ 400 ~ 200400 ~
230 110 250 70 70 350 500 250 600
13.0-16.6 5.8- 8.0
13.0~18.1
1.5 - 2.9 4 .5 - 8.7 5 .8 - 8.0 8 .0 -10.8 5.1 - 7.2 6 .5 - 9.4 5.8- 8.0 3.6- 5.1
Frame Front cush ion pivot bolt Front cush ion bol ts Torque stopper bolt Torque arm nut Crank arm set pin Handle setting bolt Steering head stem nut Seat bol t Rear ax le nut
14.5~18.1
2 .9 - 5.1 2.9- 5.1 18.1-25.3 28.9-36.2 14.5-18.1 28.9-43.4
94 K.
l.
Reassembly Assemble the final driven shaft toget her with the 50 mm thrust washe r C to t he rear wheel hub.
2.
Apply g r ease on the final driven shaft ratchet g ro ove and assemble the ra tc het paw l.
3.
Assemble the free wheel spr ocke t A to the f inal driven sha ft.
( N ote) After assembl yi ng the fre e wheel spring A , check the spring tension. If the spring is weak Fig. 4 ·22
(f \
Ratchet pawl
or the o perati o n i s not smooth, the ratc het will produce noi se, and is some case, the p ower will not be transmitted to the rea r wheel , therefore, replace the spring. 4.
Appl y a coat ine of g rease on the inside of the free whee l sprocket,
hold the rack et pawl and
assemble on the f inal driven shaft. 5.
Coat th e free wheel spring 8 with g rease
and
assemble the pawl on the final driven shaft. 6.
Set the 50 mm thrust washer 8 and the 61 mm circlip on the sprocket.
7.
Set the 50 mm thrust washer A and the 50 mm circl ip on the final driven shaft.
(Note) If grease Is not applied, the sprocket will turn heavy, noisy and the operation will n ot be smooth .
\
\
(j)
HONDA NOTOB CO. L"''D.
-s
67~. ®B. 2
PRINTEQ, IN JAPAN
