HONDA COMMON SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
HONDA COMMON SERVICE MANUAL – PDF DOWNLOAD
IMPORTANT SAFETY NOTICE
WARNING
Indicatas a strong possibility of ,evere personal Injury or death if in8’ructions “”‘ not followed.
CAUTION:
Indicates a possibility of equipment damage ;f !nstructions are not followed.
NOTE;
Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included It is important to note that this manual contains some warnings and cautions against some specil1c service methods which could cause PE!ISONAL INJURY to service personnel or could damage a vehicle or ,ender It unsafe Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be d@e or of the possibly hazardous consaque~ces of each conce;vable way, nor could Honda ;nvestigate all such ways, Anyone us;ng service procedures or tools, whether or not recommended by Honda, mus, s&tlsfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected
HOW TO USE THIS MANUAL
- This manual explains the theory of operation of the various systems common to HONDA motorcycles and motor scooters arid A TVs.
- It also provides basic 1nformat1on on troubleshooting, inspection and repair of components and systems found on these machines. Refer to the Model Specific Service Manual for the model you are servicing for adjustments, maintenance and repair information for components on that model.
- Section 1 provides general information on the whole motorcycle as well as Warnings and Cautions to remember when performing maintenance and repairs. Sections 2 through 1 5 cover all aspects of the engine ar1d drive train. Sections 16 through 20 include all of the component groups that make up the chassis.
- Section 21 through 25 apply to the various electrical and systems found on Honda motorcycles. An extensive alphabetized Index provides rapid access to information on specific components or systems. jAi1 information, illustrations, .directions .
- specifications included in this publication are on the latest product information available at the time of for printing. Honda Motor Co., LTD. reserves the right to make change, at any time without notice and without any obligation whatever. No part of this publication L may without written
TABLE OF CONTENTS:
HONDA COMMON SERVICE MANUAL – PDF DOWNLOAD
Front Cover...................................... 1 Common Service Manual............................ 2 Picture...................................... 3 Safety Notice................................ 4 Contents..................................... 5 Symbols...................................... 6 Abbreviations................................ 7 1 General Information............................ 8 1-1 General Safety........................... 8 1-2.......................................... 9 1-3 Service Rules............................ 10 1-4...................................... 11 1-5...................................... 12 1-6 Fastners................................. 13 1-7...................................... 14 1-8...................................... 15 1-9...................................... 16 1-10..................................... 17 1-11..................................... 18 1-12..................................... 19 1-13..................................... 20 1-14 Ball Bearing Replacement................ 21 1-15..................................... 22 1-16..................................... 23 1-17 Tool Compatability Chart................ 24 2 Maintenance.................................... 25 2-2 Fuel Line................................ 26 2-3 Throttle................................. 27 2-4 Oil Pump and Line........................ 28 2-5 Carburetor Choke......................... 29 2-6 Air Cleaner.............................. 30 2-7 Crankcase Breather....................... 31 2-8 Spark Plug............................... 32 2-9 Valve Clearance.......................... 33 2-10..................................... 34 2-11 Engine Oil.............................. 35 2-12..................................... 36 2-13..................................... 37 2-14..................................... 38 2-15 Decarbonizing........................... 39 2-16 Carburetor Synchronization.............. 40 2-17 Radiator Coolant........................ 41 2-18 Cooling System.......................... 42 2-19 Secondary Air Supply.................... 43 2-20 Transmission Oil........................ 44 2-21 Drive Chain............................. 45 2-22..................................... 46 2-23..................................... 47 2-24..................................... 48 2-25 Final Drive Oil......................... 49 2-26 Battery................................. 50 2-27 Brake Fluid............................. 51 2-28 Brake Shoe Wear......................... 52 2-29 Brake System............................ 53 2-30 Brake Light Switch...................... 54 2-31 Headlight Aim........................... 55 2-32 Clutch System........................... 56 2-33 Side Stand.............................. 57 2-34 Suspension.............................. 58 2-35 Spark Arrester.......................... 59 2-36 Wheels/Tires............................ 60 2-37..................................... 61 2-38 Steering Head Bearings.................. 62 2-39 Wheel Alignment......................... 63 3 Engine Testing................................. 64 3-1 Trouble Shooting......................... 64 3-2 Compression Testing...................... 65 3-3 Leak-Down Testing........................ 66 3-4...................................... 67 4 Lubrication.................................... 68 4-1 Service Data............................. 68 4-2 Troubleshooting.......................... 69 4-3 System Descriptions...................... 70 4-4 Wet/Dry Sump............................. 71 4-5 Two Stroke Systems....................... 72 4-6 Premix................................... 73 4-7 Oil Pump Descriptions.................... 74 4-8 Plunger Type............................. 75 4-9 Oil Pressure Check....................... 76 4-10 Pressure Relief Valve................... 77 4-11 Oil Pump/Line Bleeding.................. 78 4-12 Oil Cooler Inspection................... 79 5 Cooling System................................. 80 5-1 Service Information...................... 80 5-2 System Descriptions...................... 81 5-3 Radiator................................. 82 5-4 Radiator Cap............................. 83 5-5 Thermostat............................... 84 5-6 Coolant.................................. 85 5-7 System Testing........................... 86 5-8...................................... 87 5-9...................................... 88 6 Exhaust System................................. 89 6-1 Service Information...................... 89 6-2 System Description....................... 90 6-3...................................... 91 7 Emission Control Systems....................... 92 7-1 Service Information...................... 92 7-2 System Descriptions...................... 93 7-3...................................... 94 7-4 Noise Emission Control System............ 95 7-5 System Inspections....................... 96 7-6 AVCV..................................... 97 7-7...................................... 98 7-8 Secondary Air Supply System.............. 99 7-9 Emission Control Information Labels......100 8 Fuel System....................................101 8-1 Service Information......................101 8-2 Troubleshooting..........................102 8-3 System Description.......................103 8-4......................................104 8-5......................................105 8-6......................................106 8-7 Accelerator Pump.........................107 8-8 Fuel Line................................108 8-9 Carburetor Disassembly...................109 8-10.....................................110 8-11.....................................111 8-12.....................................112 8-13.....................................113 8-14.....................................114 8-15.....................................115 8-16.....................................116 8-17.....................................117 8-18 Pilot Screw Adjustment..................118 8-19.....................................119 8-20.....................................120 8-21.....................................121 8-22.....................................122 8-23 Limit Cap Installation..................123 8-24 Accelerator Pump Adjustment.............124 9 Cylinder Head..................................125 9-1 Service Information......................125 9-2 System Description.......................126 9-3 Valve Train..............................127 9-4 Valve Lifter Mechanism...................128 9-5 Camshaft.................................129 9-6 Rocker Arm...............................130 9-7 Cylinder Head Inspection.................131 9-8 Cylinder Head Disassembly................132 9-9 Valve Guides.............................133 9-10.....................................134 9-11 Valve Seats.............................135 9-12.....................................136 9-13.....................................137 9-14 Cylinder Head Assembly..................138 9-15 Initial Camshaft Lubrication............139 10 Cylinder/Piston...............................140 10-1 Service Information.....................140 10-2 System Description......................141 10-3 Piston..................................142 10-4 2-Stroke................................143 10-5 Cylinder................................144 10-6 Piston/Piston Ring......................145 10-7.....................................146 10-8 Piston Pin Inspection...................147 10-9 Piston Installation.....................148 10-10 Cylinder Installation..................149 11 Clutch........................................150 11-1 Service Information.....................150 11-2 System Descriptions.....................151 11-3 Judder Spring Purpose...................152 11-4 One Way Clutch System...................153 11-5 Power Flow Diagram......................154 11-6.....................................155 11-7 Wet Multiplate Centrifugal Clutch.......156 11-8 Gear Shift Lifter.......................157 11-9 Separated Shift Clutch..................158 11-10 Clutch Inspection......................159 11-11 Clutch Removal.........................160 11-12....................................161 11-13....................................162 11-14....................................163 11-15....................................164 11-16....................................165 11-17....................................166 11-18....................................167 11-19 Clutch Reassembly......................168 11-20....................................169 11-21....................................170 11-22....................................171 11-23....................................172 11-24....................................173 11-25....................................174 11-26 Clutch Lifter Reassembly...............175 11-27 Hydraulic Clutch System Service........176 11-28 Air Bleeding...........................177 11-29....................................178 11-30....................................179 11-31 Clutch Slave Cylinder..................180 11-32....................................181 12 V-Matic Belt Drive System.....................182 12-1 Service Information.....................182 12-2 System Description......................183 12-3 Drive Pully Operation...................184 12-4 Driven Pulley/Centrifugal Dry Clutch....185 12-5 Drive Belt..............................186 12-6 Drive Pulley............................187 12-7 Disassembly.............................188 12-8 Assembly................................189 12-9 Drive Pulley Face Installation..........190 12-10 Clutch/Driven Pulley...................191 12-11 Inspection.............................192 12-12 Clutch Shoe Replacement................193 12-13 Driven Face Bearing Replacement........194 12-14 Clutch/Driven Pulley Assembly..........195 12-15....................................196 13 Transmission..................................197 13-1 Service Information.....................197 13-2 System Description......................198 13-3 Planetary Gear Type.....................199 13-4 Shift Start.............................200 13-5 Constant Mesh Transmission..............201 13-6 Transmission Disassembly................202 13-7.....................................203 13-8.....................................204 14 Crankcase/Crankshaft..........................205 14-1 Service Information.....................205 14-2 System Descriptions.....................206 14-3 Crankshaft Inspection...................207 14-4.....................................208 14-5 Main Bearing Selection..................209 14-6.....................................210 14-7 Main Bearing Selection..................211 14-8 Connecting Rod Bearings.................212 14-9.....................................213 14-10 Connecting Rod.........................214 14-11....................................215 15 Final Drive/Output Shaft......................216 15-1 Service Information.....................216 15-2 Output Shaft............................217 15-3.....................................218 15-4.....................................219 15-5 Final Drive Removal.....................220 15-6.....................................221 15-7.....................................222 15-8.....................................223 15-9 Universal Joint Inspection..............224 16 Wheels/Tires..................................225 16-1 Service Information.....................225 16-2 Wheel Removal/Installation..............226 16-3.....................................227 16-4.....................................228 16-5 Rear Wheel..............................229 16-6.....................................230 16-7.....................................231 16-8 Wheel Bearing Replacement...............232 16-9 Basic Tire Information..................233 16-10....................................234 16-11 Tire Removal...........................235 16-12....................................236 16-13....................................237 16-14 Tire Installation......................238 16-15....................................239 16-16....................................240 16-17 Wheel Balancing........................241 16-18....................................242 16-19....................................243 16-20....................................244 16-21....................................245 16-22....................................246 17 Brakes........................................247 17-1 Troubleshooting.........................247 17-2 Brake System Descriptions...............248 17-3 Hydraulic Brakes........................249 17-4.....................................250 17-5.....................................251 17-6.....................................252 17-7.....................................253 17-8 Hydraulic Disc Brakes...................254 17-9.....................................255 17-10 Brake Pad Replacement..............256 17-11....................................257 17-12 Brake Caliper..........................258 17-13....................................259 17-14 Brake Disc Inspection..................260 17-15 Master Piston Inspection...............261 17-16 Mechanical Drum Brakes.................262 17-17....................................263 17-18....................................264 17-19....................................265 18 Front Suspension..............................266 18-1 Service Information.....................266 18-2 System Descriptions.....................267 18-3 Oil Damper Principles...................268 18-4 Telescopic Fork.........................269 18-5 Fork Removal............................270 18-6.....................................271 18-7.....................................272 18-8.....................................273 18-9.....................................274 18-10....................................275 18-11 Handlebars.............................276 18-12....................................277 18-13....................................278 18-14....................................279 18-15 Steering Stem..........................280 18-16....................................281 18-17 Race Replacement.......................282 18-18....................................283 18-19....................................284 18-20....................................285 18-21....................................286 18-22 Steering Head Preload..................287 18-23....................................288 19 Rear Suspension...............................289 19-1 Service Information.....................289 19-2 System Descriptions.....................290 19-3.....................................291 19-4.....................................292 19-5 Rear Damper Springs.....................293 19-6.....................................294 19-7 Shock Absorber..........................295 19-8.....................................296 19-9.....................................297 19-10....................................298 19-11 Swingarm...............................299 19-12....................................300 20 Frame/Body Panel..............................301 20-1 Service Information.....................301 20-2 Description.............................302 20-3.....................................303 20-4 Inspection..............................304 21 Electrical Fundamentals.......................305 21-1 Service Information.....................305 21-2.....................................306 21-3.....................................307 21-4.....................................308 21-5.....................................309 21-6 Basic Electronic Knowledge..............310 21-7.....................................311 21-8.....................................312 21-9.....................................313 21-10....................................314 21-11....................................315 21-12....................................316 21-13....................................317 21-14 Basic Electrical Diagnostic Methods....318 21-15....................................319 21-16....................................320 21-17....................................321 21-18....................................322 22 Battery/Charging/Lighting System..............323 22-1 Service Information.....................323 22-2 Troubleshooting.........................324 22-3 Charging System.........................325 22-4 Battery Descriptions....................326 22-5.....................................327 22-6.....................................328 22-7 Motorcycles Without Batteries...........329 22-8 Battery Removal/installation............330 22-9 Battery Testing/Charging................331 22-10....................................332 22-11....................................333 22-12 Charging System Descriptions...........334 22-13....................................335 22-14....................................336 22-15....................................337 22-16....................................338 22-17....................................339 22-18....................................340 22-19 Charging System Inspection.............341 22-20....................................342 22-21....................................343 22-22....................................344 22-23....................................345 22-24....................................346 22-25....................................347 22-26 Alternator.............................348 22-27....................................349 22-28....................................350 22-29....................................351 23 Ignition Systems..............................352 23-1 Service Information.....................352 23-2.....................................353 23-3.....................................354 23-4 Systems Descriptions....................355 23-5.....................................356 23-6.....................................357 23-7.....................................358 23-8.....................................359 23-9 Spark Plug..............................360 23-10 Spark Test.............................361 23-11 Ignition Timing........................362 23-12 Ignition Coil..........................363 23-13....................................364 23-14....................................365 23-15....................................366 23-16 Transistorized Ignition System.........367 23-17....................................368 24 Electric Starter/Starter Clutch...............369 24-1 Service Information.....................369 24-2 Troubleshooting.........................370 24-3 Disassembly.............................371 24-4.....................................372 24-5.....................................373 24-7.....................................374 24-8 Clutch Switch Diode Inspection..........375 24-9 Starter Pinion Inspection...............376 25 Lights/Meters/Switches........................377 25-1 Service Information.....................377 25-2 Oil Pressure Warning Light..............378 25-3.....................................379 25-4 Fan Motor Switch........................380 25-5 Coolant Temperature Guage...............381 25-6.....................................382 25-7 Fuel Gauge..............................383 25-8 Low Fuel Indicator......................384 25-9 Fuel Pump...............................385 25-10....................................386 25-11 Headlight Bulb.........................387 25-12 Switches...............................388 25-13....................................389 25-14....................................390 25-15....................................391 25-16 Turn Signal Lights.....................392 25-17 Horn...................................393
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