- SHOP MANUAL $90 CLIOL C90 i CL90 CD90 CT90FOREWORD This stop monal is a reference end a ide book for the proper servicing of the Honda 90 series motoreyle, The Infomation contained horin i based on the 590 with equal opelicabilly to the CL.90, CLPOLL, tener POe> poers po e> CONTENTS, Inspection. . Serre Pocenenbhy <5 ssyreaeceevensary=tevacewssvsversvecrsventetcwieerie GEAR SHIFT MECHANISM. saeeiNl Constuction. 2 z CRANKSHAFT... Constuction. Dicassomoly Inspection ‘ Reassembly TRANSMISSION, Constwuction Disassembly... lespecticn. Recssembly CRANKCASE Construction... Deassombly Inspection. Recssonbly KICK STARTER AND GEAR INTELOCK MECHANISM, POSL-TORGUE MECHANISM (CT 90)... Constretion Discsserbiy « CARBURETOR . Construction . Function of Each Comechent Adjust sees Adjustment for High Speed. . Adjament for inermeciate Speed, Achusment for Slow Speed... e+e et ‘Acting the Fost Level. "4 STEERING HANDLE 78 ‘Conetnction ee 75 DlassenHY racine -veneeeger ree aren 76 78 179 Inspection Isteerng handle! Rooscombly. oas PRESEN PFoDNP Pe PKPUFNOPrF OQ DNP Pao POPP. ONO Fee TDN PPD CONTENTS STEERING STEM, ‘Construction . . Disassembly ..... Inspection Reassembly . FRONT FORK. ‘Construction . . Diuseribiyesncinnscheton ser te tee ase Inspection....... Reassembly....... FUEL TANK .. Construction Disassembly inepectlon Bocce 5 ananw Mn RRMA a Wha cosas Resse bl Gee Ie seo ndecnnecrinen FRAME BODY... ‘Construction Disassembly Inspection... .. Reassembly Construction... +++ Disassembly Inspection. Roassombly. : BRAKES SYSTEM enscn ergs Steen Jao acs tune eeatuanimemmeraty srs 94 Construction Disassombly MUFFLER, . Construction Disossembly inbpoctonivesterrivieder veweresner wees ROGESOMBIY, cece veces se nccenstetedeeewerenereneeeseeeeeernereeeene 7 AIR CLEANER, . « Construction Disossembly Inspection. Reassombly. REAR FORK AND CUSHION DAMPER, .0..scvsseessereveessstnussnieenes 100 Construction . . Disossombly ...+ 04+contents - 100 2. Reasenbly st etal 4.11 REAR FOR CUSHON DaMER, 101 AL COMIREHON..sseessesesenseeeretee Soe iw 8 Diosrertly aan . ote toa Ctpection, . coe 108 4.12. FRONT Wet 104 A. Comtrction ee Gerri stunt etaneyeenisn 10% 3 Diowently 105 Cregeen 106 De Romsomby. eee z 107 413 REAR WHE ccc cease Pee A Consttioa. eo esesseee S18. Be DOSER, ose ssecsersecsecesee cies 108 C_hepecton : i 0 D. Reowerbly. Pecsares caesetl 5. PERIODIC ADJUSTMENT... Eeaiheaerane 4 ns 5. 1. MAINTENANCE INSPECTION Sioa lis A. Engine Adistro ns. 3 Lubvicalng <2 © Dive Chain Acisnent os 1a3 2. Brcko Adistnent . = 124 Mer Coming . a . 128 Be Soke WOO. nck es nannssssn sone sever ere cl G. fetta Fepecton. ievectavawnu tier 126 H. Diva Orin Senco, ssesceeee 5? “7 1. Opercting nvwetion foe Svie Testor, Type ST AD4 . 128 J. Secuity spoction of Pas. cess esevveveess ets 5, 2 PROD INFECTION AND SERVICING . +135 1A. Coty Ipocton ia iss 2. Pores lpecion se eres ste ASE 65, TROUBLE SHOOTING 2138 6. 1 MAIN ENGINE TROUBLE. 2138 6 2 CARBURETOR TROLALE, ee ar) 3 ENGNE NOE. Mr 6. 4 STEERING SYSTEM. 142 4&5 QWUICH system. ey 6. 6 GEAR CHANGE SYSTEM... 143 6.7 SUSRINSION. ss sses 4 er1. FEATURES 1.1 ENGINE ‘The engines used on the HONDA 90 series ore besicaly identical with the mojor diferonce in that the 590, CL90, CL9OL ard CD90 ore equppod with a mans opercted clutch ord tho C90 ord CT90 faving on cutometic cluch A. Chein driven ov ‘The camthaft is driven by © constant tension chain, cisuing quiet operation ord precio valve timing. Further, it enables greater power output due to avalcbilty of higher opercting RPM. OHY and somi-spherical combustion chamber Tre overhsod woe design provides greater cir intake Volumetric efficiney. Tre temi-schercal contustion chonber assures 0 smooth fame propagotion which is further enhanced by tho incorporation of © special squish area. _ Dovble oil filter Tre oil system incorperctes 0 fine mesh screen fltar ord cerisfupal fiir 19 sypply the engine with a highly cleon il. This minimizes the wear fo the engine components, reducing maintenance ond ‘oxtoncing the life of the engine. D. Clutch Right ection ctch lever is employed on the $90, CL90, CL90L ard CD90, with curorctic clutch Fstolled on the €:90 ond C790. E. Transmission All speeds ore constant meshed to provide smacth geor chonges. The $90, CL90, CL90L end. C790 have four forward speeds whereas the C9D has three speeds. Further, tha CT'90 is equipped with @ positorque mechanism for selecting the low speed |, reduction range. fod camshaft 10 the cylinder ore a consequent Figher 1.2, FRAME AL Rigid lightweight frome Tre frame of the $90, CL90, CL90 and CD90 ore mode of pressed steel seet of monocoq.e design. Frane of the C90 end CT90 is @ combination of pressed steel sheet with a large dianeter see! pipe supporting the steering hea. Thase designs give rigid lightweight frame of high strength, B. Rear suspension Swing crm suspension is provided with a two stogo cushion ll dampor to provide comfortable riding under various losding ond road conditions. C. Front suspension Telescoping type front cushions ore employed on the $90, CL90, CL9OL and CT 90 models from frame serial No. OOOUOIAL. Bottom lick tyres are sed on the C90, CD90 ond CT 90 models (from frome soriel No. 100001). D. Broke Trolling leading type ro fede brckes cre wed on both the front ord recr wheels, The right handle lever operates the front broke ond the sight foot pedal operotes the rear broke, The CT 90 is ‘equipped in oxkdtion with a left hond lever to operate the rear broke.2. SPECIFICATIONS AND PERFORMANCES 2.1 SPECRicATIONS = es] im | exso, eusoe | Miercbicoware | [naute Von 50 Dinetione ‘Overall length 1,890 mm 1,830 mm aan es an | Ove with 50 nn 1000 Ba ee Over ict 920 nn 1,050 rm Beet lige — 1195 ne 1,200 tipco'n Le iit d| ee nel ene in Weiot Wik npy asia 22019 5603 ka 23 - Betig cts fos Fone sein Max 139 60k (22,960 fr at 21.75 mile/h! (47.6 ft @ 31 mile/hl Foal consumption 75 mil ot AO kh 80 kn/l et 40 bh T176mileWV. S. gel. @ 24. BSmile/bl | (188 mile/US. go, @ 25 mi Climbing obiiny: 18° 20 | a -2.) SPECIFICATIONS a @ | Tr 90 00 | a ee (from F, No, 000001) | Honde 90 Hondo 99 Honda 90 | Honda 90 o sien ae ee eee em 072i 210% wore 736i 640 am 640 am 6500 680 nm (25.22 (522) (25.61) (26810 955 0m 995 0m 980 am 1,040 am (97.63 0 39.201 (38.61 a (41.010 1.1820m 1,190.8m 1,188 mn 1215 om (45:39 (46.89! (46.81 7310 130m 130/mm 137 mm 175 nm 6120) 6.12) (40ia (69 85.040 B1.si9 9ka @ (187.00 tot (179.30 les {200 te Mor. 475m ot 35th |Max 68m ot 354m | Max. 5.5m ot 30km/h | Mot, 5.5m ct 30 km/h (2a 4th @ 21.75 rien) | (22.69) (21.75 mle) | CBI (19 meh BH 8 ley BOkm/l at 35km/h BDkm/2 ot 30 ken/h TS kenfl ot 40 km/h 75kmjl ot 40km/h TBS. go (188 mie/US. 901 C74 mie/US. ok (76g. oa @2A7mioh | @ 16.64 milo) a) 25 milo/h) @ 25 mile/hl 1° High range 18° High ronge 18° | Low range 25° Low ronge 25° 1 i‘ 2. SPECICATION AND PEFORMANCES eee ] $90 L990, CLSOL Min, turing ox 1,950 mm 1,890 mm 76830 1) aan) Nowe and Model Hondo $908 Honda C1908 Type fool used Gorstine Same o& lot Type ergo | Ate cooled 4. stoke cyclo Sano ce loft No.of cylinder and onangoment, Srgle cylinder, ted forward 75° | Sane os loft Valve crrongement Overhead valve Samo of left Totel piston displacement | 69.8.0 89.60 (5.47 cain (5.47 eu. iv Boro Stoke 50% 45 om 5045.6 nm (137x177 0.97 x1.80'n) Conpresson iio 82 82 Comprescn presire 12kgjont 12kglent (170876 bjt 11702676 bist Max, output 8.0 PS/9500 rpm CL 90 + 8.0 PS/9500 rpm CLOOL: 4.9 PS/8000 rpm Max. torque 0.45 ig.0/8000 rom CLO + 0.85 keen/8000 rm (4.701. t/8000 rpm) (4.7. 1/8000 raed CL9OL: 1.97 ke-y/3500 rem (14.261. 1/3500 rpm ees) eee eee ST voor eal aE Marufocturer | Tokyo Roki ‘Same os left (tebe 8) rst (EUs x) Fee eee ie Pe ae eared ar eae beter | ames foot (BUS) | one (Bus 2crv OW i cee {from F. No. 000001) 1,630 mm 1,910 00 1900.00 1900 mm 64.22 in (75.2519 (74.86 in) 174,86 i) Honda CD 90 E Honda G90 Hondo CT 90E | Honda C908 Some ot lof Sono as left Same oe loft Some as left Soro of loft Some os left Same o& loft Some os left Some os loft Sane o3 loft Same ce loft Some as felt Somo os loft Some os left Some oft Sone ot left 89.6 cc | 7.6.00 89.6 co Same os left (547 ox i) (5.47 ev. id (5.7 oxi 50% 45.6 mem 50% 45.6 mm 50% 45,6 mm Same os lett (1.97 1.89 in) (0.87 1.80 in 0,971.80 in 82 82 a2 Some os left 12kalen® 12 ka) 12iglem® Some os left (170.676 ton (170.876 lof’ (1701876 tie 7.5 PS/9000 rem 7.5 ?5/9500 1pm 7.0 P5/8500 cpm Some os lot 0.72 4g-m/6000 rem | 0.67 kgen/4000 rer 0.6? ka-m/5000 rm | Some ot loft (S216. 1/6000 rpm | (4.848. 1/6000 rpal | (4.791. 1/6000 rpm 350 g/PS-h/7000 rem 505%280%345mm | 550% 280%945 mn (17.90 311.00 13.59 il) (91,7 3011.2%13.6 ed Sane os lel 2A lg (52.8 bs) 241g (52.8 ks) 25ko (55k Some os felt Some 3 left Same loft j Sone os let Same os felt Some os loft Some os lft Sane os left Piston valve type, 1 each | PY 1SHAL, 1 exch Peton vohe typo, 1 each | Same as left Kehin Sei Kein Sok Keltin Sot Some os left Soma at lo | some os tof Sane os left | Samo as fit | Some os tot Same os lof 150.5. pt) | N1SUS. A3TULS. pe 1,6U.S. oo 701 (38mm) | 85! (aot ee) [654 (aime) | 6° Siena) Presse type Presue type Frossre type Sone as left Trochcid type Trochoid type Trochsid pump Sane os left Some os loft Samo as left Some os loft Sane os left 1.9 U.S. pl 1.9 U.S. pl 1.90U. 8, Pr) 1.9 U.S. bt a9 (etme ee) | °%F (Nein pe) | 29% (rtm tu) [094 (etn i)2. SPECIFICATIONS AND PERORMANCES Medel Typ0 ion System leetion Method. Type Ipttion Coil Manufacturer Type Spark Plug Manufacturer Electrical System Battery No. and type Volt ond AH ‘Manufoctror ‘Type generator Monufactret Princry reduction method Reduction ratio ‘Clutch type ‘Type transmission Gear change method Gor ratio, lt gecr Gozr ratio, 2nd gecr Gorr ratio, Sid gear Goxr ratio, 4th gear Sub troremision Secondary reduction method Reduetion rerio Steering System Steering fondle wining racius Steering honda width Coster Teal Tie, froot Tie, Broke System Type broke, front $90 Battery ignition R68 29700-101-0 ‘Kokusan Denki Nihon Dereo DeHW NGK Spek Plug Co. Lid MA36A oF 836-6, 1 each 66 Yuosa Denki 37000-026-0 EG-21 Nippon Denso | Koluson Derk Cox 372 Wet multisle disc type Constont meshed gears Left foot opercted return type 254 1.83 1.09 0.88 | Chin 321 se 620 me (24.426 In) 6s | 75mm 12.985 in) 250-18 (4 PR) 250-18 (4 PR Internal expanding shoe cL 90, CL9OL K 205, NGK Spork | Nippon Dewso Plug Co.,Ltd, | Some os left 66 Some ot left 37000-026-0 | EG-26 Nippon Denso Kokuson Danki Same os left 372 Some cs left Some cs left Some os left 254 1.61 19 0.96 Some a: left 321 ea 770 men (30.3 i) je 73 mm (2.87 in) 250-18 (4 P2) | 275-18 (4 FR) Sore as left2.1 SPEORCATONS QO aa 7 oe on cree (tom F: Nor 0200014) | | ‘Same os left Some. os left Some os left Some os left @ s178 s79 Eee a ef Kokuson Denki Kokusan Denki Some os left sus Noxzors| O-8HW oars eee NGK Spark Nippon | NOK Spa Fluo Co.-L. | GK Spark Hug Co., id. Sono as lft a Ys Cont "Bono B 108-6, leach B37-6A, Lech 837-6 A, | each Same as left 6-6 &6 6-55 ‘Seme os left Same os left ‘Some os loft ‘Some os left Same cs left | s7e00-088-0 aoe | es On inn | Sone okt soe os let sone ste ry 372 372 372 3.722 ‘Same os left ‘Automatic wet multiple | Some os left ‘Some os loft @ Sarma Seow Seno amt cores fone cs kit See ot ome dae Be 2308 2.598 7981 Sore vet 1.565 wt) 008" san ce ot 19 1.000 10 e202" Stn bk 096 aisee 1.769% | Sano ott 1000 267% | Sone os lat foe ene sam a heath Sivw-c ih 3.00 2.887 2.000 shaw ath @ | as as as Sore os 1oft 40mm 25226 | 630 am (2482210) 635° 6" 63. Same as left 75mm (2.985in) 75 mm (2.955in1 751m (2955) Visa i 260-17 (4 280-17 ltt) 250-17 275-17 478 280-17 220-17 PR 27617 276-17 48 eae Sot sew 3 eh Senn ot om° 2. SECITICATIONS AND PERFORMANCES Model Tye | 590 190, cL90L Type beck, r0or Ineo expandina shoes Some 5 ltt Motnod of apelcstion, front Right hand lover opaccted Samo os left Mattod of opslcatin, rear | Rglt foot pedal oporcted Samo os let Suspension System Suspension method, fren! | Telescope type “Telescorie type Sispersion wethod, rear | Swing cnn type Same as left Donpening system, fent | Hycroie Same os lft Danpening sytem, rear | Hyetoulie Same as lft rome Tyee Bectbone type Same os let Lighting System Beodigh type 46-0109 Monufoctuer Sterley Fcc, Kilo Sehsisho Stanley Flere Heodight cotiag 6V—25/25W 6V—25/25 W Teitohtrateg 6v—2w ov-sw Tollanp conbination with License fight Sane os left Sep bit rong év-8w ov-17W Tum sige type Magnetic. beating element Some os left Tum sign rating é6v-8w ev—1ew Instrument Hom type Fleere Fat type Some os lot Meruioctuer Mistba Deskt Speedometer Typo Wledereter Wlodoneter Merufochrer Nippon Sei Feflox ceector type £2 20 Walon 830 Whim Morufactier Sonley Flere Sane os let2.1 gromcanions . on cw ain uaa ‘Some os loft | somo os tft Soo os left Some left Same os lot Sone os let Some 0: lft Sone ot left Same os lot | Sore o2 let Baht Foo! peda end oft | Same os left | ted lover cpsrced | Botom link type Sane os let fottom rk typo | Telescopic Type Some ot lt | Same Sone 0 lt | Sane es lf | Sone os lot | Sore os lit Some os let | Some os let | some os ttt Sane os let Same as lot Sone os left | Some os lot Sane os let Some at lot Sone of lef | ASS-11 ASS Sane of left Stonley Hectic Some os lo Sane af lef 6v—25/25 6v—2525W 6v—25/25 W Some os let sv-3W ov-5w Sone os lef Sao 0s lot | Sa Same os lot Sane of left | 6v—10w |“ 6y—tow 6v—18w ey-11W Sawa he | Sen es tte 6v—10W 6v-8w 6N-18W option) Sore os lot | Some os lett Same os let Some os let Mitba Sei or Nippon | Sane os left Denso Mogeticaly diven | Sam os lft Sve os le | Niton Set or Nipon | Sane os ll 30 Wisillonp 8820 Witallone Some 03 lft Sane os lef10 2. SPECIFICATIONS AND PERFORMANCES 2.2. PERFORMANCES MODEL $90Shatt output Torque km) 5 2.2 FEREORMANGES 5.90 PERFORMANCE CURVES 0B AO 10 Driving speed ikm/¥r) $90 ENGINE PERFORMANCE ter 7 ae Engine speed R. P.M) Driving force (Ke)2.2 FERFORMANCES CL90 PERFORMANCE CURVES Engine speed RPM. 00 Diving speed (Kim /+4) C90 ENGINE PERFORMANCE CL9OL ENGINE PERFORMANCE rey r3) | i i E [ : : a Py fresh £ is | Ieee i is i ; — roe 8 3 re st (nA)pst Saft output | ae a 2.2 RGFORMANCES (CD 90 PERFORMANCE CURVES loxio? Engine speed RPM won ime ay ca Driving speed. (Km Hr) CD90 ENGINE PERFORMANCE a8 ios. es 8 8.8 Fuel consumption (57/PS-4:) 3644 3 tox10* Engine speed (P.P.M) is 100 viving force (Ke)2, SECIRCATIONS AND PeReORMANCES ‘MODEL C90 >‘att outout ms ps7. bo. 300 Ey 2.2 BRORMANCES (C90 PERFORMANCE CURVES 1oxt0* 100 so 2 2 Driving speed (Kin Hr) C90 ENGINE PERFORMANCE & consumption (G/PeHn)2. SECIFICATIONS AND FESFORMANES MODEL CT 90 Prier to CT90 F, No, 122550 Posi-torgue (F. No. 122551 and subsequent)Posi-torque (F No. CT 90 ENGINE PERFORMANCE —Sx10* Ergne speed (RAM) 22 PERFORMANCES, 00001 ond subsequent) ‘CT 90 PERFORMANCE CURVES Dvir speed Indicate when3. ENGINE Tools Necessary for Disassembly and Reassemély - : | oC fw \--— @ cliche 3 o ® © 0 @ & « B oO ow oe @ ne Hh : we a“TOOLS NECESSARY FOR DISASSEMBLY AND REASSEMBLY. a 2 @ a TOOL No. DESCRIPTIONS @ 07022-20001 Drie sprocket holder @ 07024-01101 Chueh cuter roller ® 07086-03001 horde box wrench, 16 mm @ 07046-21601 Valve guide ceiver ® 07047-04001 Valve quide ronover ® 07046-02801 Valve guide cevor ® 07008-90101 Valvo guido roarncr ® 07031-20001 Valve lift @ 07081-00101 Topper axpsting wranch ® 07087-00101 Tappat lock mit cocker wrench @ 07024-03401 Church cuter holder ® 07007-02801 Valve seat culter holder ®B 07003-02801 Inlet valve fot sufoce seat cuter | 07004-07801 Exhaust valve fat surface seat cutter B 07001-02801 Valve seat cutter, 90 degree ® 07005-02801 Inet valve interior seat cxtter 07006-02801 Exhaust valve interior seat cur ® 07032-03301 Piston ring comprossor ® 07057-03301 il seal guide @ 07038-03301 Civich disassombling & assomling too! @ 07011-20001 Dyramo rotor puller @ 07033-03301 Piston boro @ 07061-0280) Timing inspection cover3. ENGINE a Gp 5 Cyl © Paton on con fee de © Com coin tensioner @ Drive sprocker @3.1 ENGINE DESCRIPTION All ofthe models incorporate the ©. H.C. design ven from the loft sido of tho engine by a ligit- ‘weight endless chain, This provides the engine with high speed ond high power output due to the elimination cf the recierceating movements ard mechanical losses, ond reduction in weight. Further the chain is clways melrtained in a conetant torsion by the cil pressure and soring operated cutomatic tensioner to esse quiet cperction ond procice valve timing at all speeds ‘Tre luericotion system ulllzes @ trockold type oll Pump driven through the cam chain guide sprocket 10 provide lubricction under pressure to oll of the primary moving parts of the engine and in corr tion, @ sereen and a centrifuga iter ore iocexpovated tho system to assure that only highly purified cil fs cleuated within tho engine to minimize the ps ‘weer end attoting to the extended engine Wie, Fig. 3.1) 3.2 POWER TRANSMISSION SYSTEM The evergy prosuced by the combustion of the fuel nixtire in the cylinder 1s applied to the top of the Piston, this 1s transmitted to conecting rod —> hich drive ploto — clich outer —> friction disc > chich center —> primary drive goor —> primary driven geor—> ronsmision main. shalt 3.1. ENGINE ofscuPTON a > main shaft gear—> counter sheft geor counter shalt —> drive sprocket —> drive. chain — diiven sprocket —> to the rear wheel, pro qrosively in succession, (Fig. 3.2) 3.9. ENGINE REMOVAL $90, CL90, CL90L, CD90 1. Ronove the step bor 2. Ronove to muff. 3. Fomovo the loft ereckease reor ver en un took the drive chan fom tho sprocket (Fig. 3.3) NOTE Tie c ples of ww fo both ends of the chain 10 provert the enis fem being drawn nto the chain ca:o. This will feclitate the work ding ergine instalation, ($ 90, CD 90) Fig. 3.3. Fewoving te dive an © ce taa 2. ENGINE 4. Discomect the clutch cable ©) from the clutch lever @. (Fig, 3.4) 5. Discomrect the air inlet pipe at the cylinder head end olso remave the high tension cord Feom the spark lg 6. Remove the battsry cover ond di bottery lead from the battery. romnect he Fig. 3.4 Dissomecteg © Gives cote 7 Unhook the brake podal spring. Fomove the nuts mounting tho ongina (3 for $90, CL.90, CL9OL, 2 for CD 90) ond the roar encine unser bolt. Pull cut the two 10mm hex bolt, and the engine can be separated from the frome, (Fig. 3.5) € 90, cr 90 Remo front cover (C90), remove milord (C190). Remove the min pipe cover (CT 90 rode from trrme No. 000001) 2 Remove the stop bar. 3. Remeve the leit crankcase rear cover and 1° nove the chain ont clip to dscereact the civo NOTE: Tia @ piece of wie to both ends of tho chain 10 proven the ends ‘tom being cravn ino the Fie 3:6. money et pea chon coe, This wil focitote the vesk rg © Inlet pipe @ Flonge mouning bat ‘engine instcllation (C90). > 4. Renove the mf: 5. Disconnect the or inlet pipe ot the oyinor head. (Fig. 3.6) -* 6, Disconnect the electiical leods at the con rector a 7. Fonove tho high tension cord fom the spot pg 8. Uno the broke pedal eping. 9. Ronove the 2 engine mounting nts and thon pal ou! the rr engine order bolt ond ear engine hanger boi Fig, 8.7 ge cay (0) 10, The engine con be removed. (Pig. 3.7)3.4 ENGINE INSTAILATION a oe 3.4 ENGINE INSTALLATION Genaraly, the engine Installenion is performed in the reverse order of removal 1. Set the engine on @ black and sido funder the frome. ooocuones Tove the orhe wire kanes 1p ino to SSSEOCTSSS battery box where the engine ard frame, ond @-@ tenporarly inset a sciendiver o a 103 of == Lo, -eprceisto diameter to spond the engine 2. inert th encne mounting bolts rom the left Fi 3.8. Seting deston of chan cip Sid, lo roploce the serwsriver ond stall oc roe es ee ® Drive chain torque the nuts. Hock the broke arm retun @ Cohn jon spring on the lower mounting bolt. ees ere pe 3. Comect all electrical laods 40 the wire harness, © Chain ji to 4. Comect the batieyy leads 10 the battery fesmirals, push the wire bundle op into the top of the bottery box where it will not interfere With battery installation. install battery ond hack to make swe that the wires ore nat being eS ~ pinched. ‘mm / 5, Route tho battery vont tube though the floor a of the bottory comporinont ond moto swe that the tue Is not pinchod or kinked, preventing proper venting 4. Recomect the clutch oable to the dutch lover 7. Install the inet pipe on the corburstor and bolt 40 the cylinder tec. Install the high tension Coble hold down clip under the ight inlet pipe mounting bolt. Mae sire that the O ring is Frstolled betwoan the cylinder heed on ink! Pipe. 8. Intoll the mufer. 9. Loop the drive chain over the drive sprocket ‘ond comect the chain. Tho open end of the chain jolet clip myst be Ietollad focing In the ‘opposite direction of the chain movement, (Fig. 3.8) 10. Ista the choin cose, the rear crarkeare cover ond the footest bar. 11, Adjust the chain with the chain axiuster ruts fon both sides of the rear wheel so that there sa slock of 1~Zem (0.4~0.8 in) when chockod with finger on the bottom loop ct mide point between the sprockets. (Fig. 3.9) 3.9 Adilbe the chin2. Viren Fig. 3.10 Cylinder heod Figs 8.11 Sauk oa Fig. 212 Revove the ster esenbly @ Siler cxsently Fig, 9.13. Renovng the ror © toer @ fete euler ENGINE 3.5. CYLINDER HEAD AL Construction, ‘The cylinder heal is mode of lightweight cost alurinm clloy for good haat cisipotion ond in- corporates the camshaft, con sprocket, valves, valve rocker arms, spark advancer ond breaker assomly ‘Tho ovethoad conshalt ie diiven by the cam chain through tho cam sprocket, Combustion chamber is of som spherical dosign for better cocling ond Increased combustion offcioncy. (Fig. 3.10) (Squish Ares) This is on ares provided between the piston ond cylinder head to futher comeress pert of the fuel ce mixture ot the end of tho compression ecko to create o turbulence of the rein fuel mixture, The switing fuel misture is directed toword tho spark play whore it Js ignited, The fame propaga: tion 18 cealercted, allowing the leanee than nome fuel aie ratio or the slower buming fuel minke to bum smoothly, futher, decrecsing the tendency for rocking. (Fig. 3.11) 8. Disossembly (Cylinder Head Block) Remove the point cover ord then the left cronkeseo cover. CAUTION: Oil may flow our when removing the left crankcase cover. 2. Remove the stator cssenbly ©, (Fige 3.12) 3. Remove the rotor @ using a dynamo rotor pallor @) {Tool No. 07011-20001), (Fig. 3. 13) CAUTION: When removing the rotor. caution not fo apply excossive force so a3 to bend the cronksha8.5 CYUNDER HEAD 4, Remove tho rocker arm side cover. 5. Remove the contact brecker osvenbly D ond disconnect the lead wie @. (Fig. 3.14) move the spark advarcer by removieg the hex bolt and renove the 3%5.2 dowel pi 7. Remove the point base D by king off the three menting screws. (Fig. 3.15) 8. Rotote the cranksratt so that wooduff toy © ib aligned with the 325.2 dowel pla hole in the camshalt and then tomove tho camshaft by inscewieg the 10 tals. (Fig. 3.16) ‘caUTION Pecform the with the cylinder stud bolt ny salt dic ly cred ese Yighiened 9. Remove the cylinder head cover red the cylinder head. IF the head is light, top around the patting sxface of the cylinder head lightly with o soft tose hares 0. Discssonble the valves csing o vaive lifter Teo! Ne. 07031-20011. (Fig. 3.17) Fla. 2.15 Reng te pot bore @ Feit boxe ‘Wostndl ley Dowel vin tte Fig. 3.17 Dsmonbing th voles © Valve Whee 22» 3.18. Chestng evinder bead worrrae © cyindae tant 2.9 mann epee ore @ Sons pope Fig. 9.20 Cheeling te valve guide censor © Oyindie gaze ENGINE C. Inspection ond Repoir The cylinder head () is exposed to. the high Pressure ond temperature resulting from the combus- tion of the fusl mixture: futher, when the eyliner hood is unevenly torqued, it may develop cracks oF warpage and will be the case of defective sacting botwoon the food ond the cylinder ord realt in 965 eck, oir sucking, with consequent crop in com pression, The worpoge of tho cylinder hood does not develop suddenly ond it may be overlooked, there fore, coution should bo exercised during reatsonbly sipce the uneven torquing of the cylinder hood is 0 very common fault To inspect for woxpage of the cylinder head copply a thin cont of bling or red lead @ on o surface plate ond work the moting surface of the clinder head on the suface plate: the warpoge can bo determined by the transfer of the thing on 10 the cylinder hood. (Fig. 3.18) To comuct tie warpoga, lop the eylinder head fon the sufoce plore with a £200 sancpaper, finally finih by wsing @ £400 sondpacer ond than inspect ‘ogsin with the bing. (Fig. 3, 19) Te Inspect the combustion chorber, extoust pots for crocks 2. Cylinder head combustion chamber, jet ond | Sndad vole Velie ctrrenca| Sie vlve = 001~0030e | o08m jo00o%~c.00r2 4 | 120028) 0030.05 | Olam ooorz~o.002beu | .008zh) ‘Chock the valve guide dianster ot the top, ‘center ond bottom in both tho X ord Y axes, ling © precision cylinder gauge D. Check the volvo stom with @ micrometer. (Fig. 3. 20)3.5 CYUNDER HEAD 4, Inspect valve guide Valve ide, lot Senseo serdard vie | See Ta0ss—in.066 Cunide Din | iiseuawo.3se6in) leefernce FH | pgcharco.anz6ia | — felace Ini 2 owen 8525 a2isy—0.r6l mn | om 5825 IF the valve guide inside diameter is. beyond servicenble linits. may be repaired by using a reaner @) (Tool No, 07008-00101) and replacing the valve with ono of on oversize, (Fig. 3.21) 5. When replacement of the valve guide becomes necessary, remove and replace with on oversize uide, use the valve guide remover (Tool Ne. (07047-04001) nd the valve guide diver (Too! No, 07046-21601) for replacement eporaticn. ‘After instaling the valve guide, uso rearrer to ‘obtain the proper valve clearance, (Fig. 3. 22) 6. Volve Seat “The condition of the valve sect plays ‘prominent roll in determining the performance of the engine, further, it serves as @ means for ssipating the hea! from the valves ‘A valve seat in good condition should have «2 full sxface contact with the valve face. Standard volvo D—0.7~1.2 rem (0.028~0,048 in Sorvicocbo lint —in excess of 2 mn 10.08 I) “The volvo soot contact con bo checked. by ‘eppiying «thin coating ‘bing or ted Toor evenly on the entie surface of the valve foco cd roteo the wave while Fotdng It fly agaist the valve seo! A goed valve seating crdiin will show © uniform end centinoss width of ‘Buing on the valve sect Rawotting of the valve, seas performed by The 90” culer is ted for fing te valve contest crea, end the locaton ond width of the soot conrct aren is ‘ecconplithed with the 60° and the 30” cutters Final. the valve opping operation i parfermed by lapping the gud vaN face 10 the volvo feet ising © literal avout of loppng corpowrd atthe volve face end work the valve back ard ‘oh ising @ seton cup lapping tec. Wash off tho compeund coreletly before making the test oF before csserbly. (Fig. 3.24) 2 sel of irae cutters O. 1-21) Valve guide veorme —@) yedor two rea Yee ate ae 8 Gitte! a, Figs 29 valve wot ovis area 1D Yolve so conch wid Fig. 2.24 Renoling te yoNe sat Vave aot eer2» 3. ENGINE Fig. 3.25 eka aod i © tera @ Siem sonster © Hone cine ig 3.27 Mecsrieg velve @ Dis gane @V beet 7. Inspection of valve sealing Assemble the valve into tho cylinder heod os shown in Fig. 3.25 20 that the valves are well seated ord fil he cylinder bead conustion cham- berwith ol, ject blast of oir 2ko/em? (28.4 psi in from the ilot ord orhast ports and if ony bubbles should appear, itis an indication that the valve seats cre rot completely cooled. (Fig, 3. 25) (el_Exoust valve (Fig. 3.26, 27) 060 ® love if under lerath @ | ipS9a~26nn in esa astm p |, sasesans | tela alee Sone gzistwaztes | Sue 73009 | eed elocn if uncer Micnaet @ O30 Geconicty 002TH | Bepice if toon | as woo (bl Inlet volve (Fig. 9.26, 27) Wen | Sandard woke | Servceale th won |g Z2eirs | Rosaceae asiomassein | “tos tassdin Stem da ®| qaitpoihssin | $198 aa hd veo 0508 | Replace if ver cls @| lWaze~oos2w | C3 wor Cencenery| 00218 | Rapice 4 over atvelvetaca| —@a0r2iy | Ou3 W.0012') Valve Mechanism oth the inlet and exhaust valves ore incorporoted in tho coméustion chamker. The inlet valve is de- signed larger than the exzoustvalvo 10 afford groater volumetric effeioncy. The exh! vive i constantly exposed to extremely high temperature; teeters, It Is made oF special high heat resisting matoral to Withstand the high tengerorue at wall atthe weer, The com chain revolves ot @ very high speed within the cam chain chanber which Is located on the left side of the cylinder. making i necessary Yo uso a hoot resstent as well os a wear resistant ruber on the com chain giiso sprocket and com Chain tensioner roller to proven! chan noise, Further, in contrast 10 tho conventional push rod type of mechanism, this system has loss recierocateg mov. Ing pars to coxse hing noses, mekina the operationsuch sebolter ord cunt I Is very atl for igh spane to erble the increase In power ou. (Fs 3.28) 1. Valve Spring Dual valve springs ee uted for oe ‘ard 10 prover? valve oct speed, They cre onorges siege wl rege omed or bave (al Oster vole spina (Fig, 8.29) 3.5 Cuno HAD S Ow oreFla, 3.30 conten @ 721.982 @973in) Tg 3 con Gorn tae cree 2 Comat ln a four woke ele eng, she eonctott mates ere evel for avery to vvcltors Cf the canal. The power to civ‘ cam Shalt ic touch the cam chan ckven by. tho sere! Te Libiatng oi prose fd no the gh Side cf tha conanf} ac ford cut of the totes tho com to Meat the com aefacs, the rocter arms ord tha sinpos. The cans | made of speci cost sel wilh the com and hs bang crea bal precionly ground oft oor teatrert. fis peated ot both es by Ire bearhgs in tho cinder bao. com pelt ‘5 Intoed on tho lft ond of the conchae wih ‘1m bas nd Ib ehiven ot cre tll cab speed by 1 “iehg splociat prse‘ted 10 the crorlsoft ond, though the ht welnhe endless lar. Fie. 3.30, 31] ‘he saad lope cleaancss reared cold cre .05%rm (0.00210) fer both tho inet ond exh The it the clemence momued when the rocker ‘1m is apc the he! of the com aba order to ahioin ths concn, the crank! mist bo refed so thatthe "7" fei mak cx tba drs rofer is aligned wit th Hn mak onthe str eruite, 79 oct 2m ray on th iting spe of tho can, Te oning ord cloing oF the vive te deter rived by tho sistem cioko ard is tm tothe coorkseft retain, Dang the inet cyte, the rlot valve ie opened ond closed. Dug the evant ‘ce, fhe sore opens end closing sence tales ce with the exaust valve Tho oper ange Letween th opening ances isthe same: os the pis tovel, However, shoo it Ie he same orth crtishatt rotation, js epee in toms of angio: roves ‘When point" nth Fig. 3. $2 pases bovord the rocker crm, tbo vetical nevernen of te vale eteoes. ort 0 erin pln where th com lobe ne: 10 © pool, tha mavenen! ofthe valve sows oun and. cones to a ballot point "b'* on the tapoel clarence i ested when the rector fon is ofthe expesed sition of the het oF the ‘con between ports "e" end "al a25 cn HAD 2 1. Vole tink Fig. 9.93) orm | tet wd | gs 8.64. ecg sarls it foo eaten Goto becom baer Mosinaien | predict eh diameter rd wlio —> 83.495~59. 285 (2103~ 21089 Savicebla fait —> Repos if ander 5300 207 ge 3.35 Honey cnet od dena @ Consett @ Mena4 Rocke con (Fig. 3.34) 26 Sek om Sipper fe 5. Recker com soft (Pi. 9.37) | 7 ie DL Re iy 1. Apply ergre silo te solve stews before ‘uorely ito to ender hows 2. Asontle reler am a vecler orm shll fo the cylnde hood ord Isto racer crm ee caver. 3, laste tho cylinder bead. (Fi. 3,38) NOTE: Beech coe 10 mate au thet the cher fea gusle', liter sh poste! a com choin guile: © retles pomely 12 prover ol leas * tyinen hes ean maser @ Cometan 4 Ina the eye hod cover on ghen tho ‘ats agora end wiley Ye 1S0~200kg-em (45~18.1bo+f). rere trqieg wal cose ol leak. (Fig. 2.39) 3.99 Toxin mame of ine4 cvinves s mo 5. Position tre craishott 0 thet the woodutt ey © te en tho cylinder artrino ond inthe ivi of the cylnlr tea Align he °O* ink © on me can sproctst to the redox mak cn the cyinde: hood he serclet rowntrg tol Foe wl ow 9h he er cota @ cand then eornoct the cam chain GD), (Fig. 3. 40) & Sco te cama @ 1 tn end bed though the speockr Iho toad cove ‘uth he pi Pole taverd The valve ord the psn are nthe top canter postin of he composi stoke, (Fg, Fig 2.40. Carr he om lon a a Bviane ey BD" nok) Can nde 7 Asoka te post bore @ on the camshaft ‘tenon ting on al seo) do too (loo) Na 530)). (Fa. 3.42) Donage 19 tha ol ol roy ea IF tool rot eed, eatirg oll bok, 8 otal the 3% 5.2 guide pln ond ane he 0. Aanble th A.C. geerator on heist 1. Pein texpet coerce cxhwtmnt ond nk CG tan thnk. Flas 841 eg ie a Geanemtt” GC sxecter 2 ala te pein covey and the elt cashes 3.6 CruNDER A. Consetion The eyihdor is mate el spacial cs ton. The insie ever wal ¢ expoens To heh tanperate ad prose ‘ogether th the woaing eatin of No rei acating piston operating ct High speedo - o Frosice a grt waning fect. Added to this a 8.42 eho teenie tok be fhe att it cod the Foreign object cre the netale dist ctenitng te ofl wil Ronen he 0 of wor Heroes, edomte ctomien should 2 given 10 te Gearing of tho of Tier aul the omer. (Fg. 2.42) @ The poten receives the combution cneay ond lonsils th High wecprocaing mation ar enk ‘fal where Wi coneited to the rotabona tion ae fo the Hoh spd lion between the ston (22 oyfedet, the nicton of the moti ond tho telaance of the movies arts kst be ein with @ ‘gest coe, Fi 2.43 oye3 ENGINE ia, 846 Peo Bote ‘THe pion a clorinm easing med. fem ‘lect rarer. (Fig. 3.44) This mac ght avd stale fr Hoh speed In ossiien to tavng good hoot oxductng propery to disipate the heat roxy, Furheor, the cor lfcion of boo caponion is ene, ts mining ‘na warpage a elovated larperoheo ond porting sal psn to cyledar cearoncs design The fxpe of the piton ison eligteal tcper. The heed Gf the pit, corpored fo te ait. omposed to Higher terparohra od sia tha expan i grea, Ih tpered emaler foward the top, The taper ing of th piston aso tds to lesen te pte Slop whe the stoma eighty marped witha the orgie boing loaied. The piston enploys 0 thee slop ‘ope The ion ph Eos ee wee clr, Hea, rel ing in gostor expaon of Hoh lerporonee. For ‘hs reasor the cloner oF tho pin sit fri sale inthe decion of he plzen piso hao the ich operating temperate, the pln wil end Ivo a tne chcor ope, Tha skit is corey povided wih Noity Ye cee tha no cferetion il real even fron exerded conus aig. “Tha pion pi & Ofset Irn (O4ie) from the Piston cererte nthe dtecton ofthe Inet side £9 that when the cion approaches the top-dosd- tier of the compression stk, he sido loa fron the cyt woves fom the vg seo tha lei Wik'2"O" feet, tho pont will mave to ain ‘sith tonchat-cnder of the conprasion stots (Pg. 3.45) ‘As shown in Foe 9.45, the poitt of wxainen contusion poise ocr aller the tocoad eer, ‘terfere, the pupore of te of! = to nove ho pont oward tho pot of weaker presse wich is fore top-eadcener, 8 by 10 dog, etapa: tte powerul presure rovenent ord mcks i) posible 4p eimino tha pster sp. ‘The pistn seg pina itl inetion of ass ‘rg pcper contusion ord tronaiton of fhe 10 allan fre, “he lop ord sicond reg sve oto zal forthe ‘onustion chorter, the ol cone! tng Leaps the ‘rene oll from the eyindor wel to carkol te feyinder wal WsictinFatter, thoy tro tho high fercorehio of the sition 19 the eyledor wall where it Is aspated cut trough the cylinder cooing fi.For this recto, 0 spec ally of cost en ie iad to provide crongth, voor restaree, ate Slee, and gore! heat conditng pcpntinn cr unter Ite ger paltieng yaatnen or ‘cx ein, Tha top tha expsctlly te pred om the over sufoco with hard chime ard fished by wet To peeve’ hier, te shkrae of the enge 6 rrada roower ar iter. neta is ads exer to facieoie te prose aga the c/keer wot Further a top and second ergt or ade at o Sait tar where It contacts the eyinde- wll 0 "har the tina tegdred for wearin ie laters (Fig. 3.46, 3.47), A. Disetrombly 2. Remove te rection 3-8-8 2. Renae tie can choir @ fom the inky sproctet ond raneve the cylinder D tageter withthe chon, (Fig. 3.48) as cyuNoER had seg oto Patt 8 Gr ses tw it 2 cm aona. 3.47 Seep te pt 2 Sra pa ee ro Grae ng Paice Pon tng waving So 0 Fig 182 eonrrg pt in ones Oras D Marae 3. The cam chan aide rolor ean be removed from the cyl by rewovaa to cam chan ito rater ph 4, emexe tho piston pin elp ond sh os the psn pi to clesonbie he isto fm te comsctrg tod. (Fig. 3.49) CAUTION: ‘When reraing te piston in cp. core sou be erercisd e tha th lp 6005 net 5. omove she pon vhge dD) feo He by wits a ring removing tool pci! toc. if no tool Is ove, the eg ay ob ber. roves by tend, by sposding the tng ot te opening wih both Fand,thy rno shad rat be ‘ws. (Fig. 3.50) Inspection 1, hace the cyte bore, top, ele! with © preebion eyindor gouge (D. Tako ta reoararent a ti top, nia od bottom both the X ond Y cams, (Fig. 251) Sprit asta | RES Tin Bas Sane | ME meee = 2, The cecscce balwsen he pstan cd ender ull greatly ake: he ergs pclrmonce Bos caus ofthe giston bias clipe, the-cecronca Is conrad vary closely, The closurees rot the save, towmor, ety cao i groter then O.lnm 0.0049, the eller shad be reecred ard fied th an eves pst voce pitare a9 alate i 0.25, 0.89, 0.75 ond 1.00 rm (0.01, 0.02. 0.03 rd 0.08 3 Wan removing caon devo from ite pston op ard ing coves, coe shoot be exersed seh tg coe a1) erate cx carogse 0 ro the skit fhe piton perpendiator oe paton pe tow. (Fig 432),5. Monaro tho piston tng do cence wih 2 res game. (Fig, 252) = [ten | Serine vote | Seeman tm Ma) as te pe ie done one Sree ae ater 4. Pon tng ove. (Pg. 2.54) Tas it a Boia Sachem oJ T 2. on ong Meesne the sig ent cap by iaitng the piston sing @ loo the eyBide a0 the the rg 2 @ gt onde to te cylinder onc. (Fg 3.55) ea ern Notes 1, Omelze pst irgs a ovatitle a far sizes; 0.28, 089, 0.75 ond 1.007 1001, 0.02, 003° ond 0.04 in).© 8. ENGINE 2. When king pian ing end gop esse rent, ner the ing coe ito te ender to rover scoihes geusee 16 th eye Di Reastorly 1. etl the pls sirgs en the pido in the {ere rereor ei woe removes. Tha berom ol papepeniars Shuts: 149.56 ce met ‘en non stn a Ela «check om sea be ne ce fl feay slr or ‘in the groove, This can be cone by rolling the: fe ice fre! coca. nl pin goo dM 20) The ig tn So aed eo down the wil cnse ot papa. Te opt of he D (rr |S etched at tho ord with the bitist oF the rede’ ne. Ra 3.57) ie othe cn thy oo wi ite inition oper psy in eae. 2. Anes pe to ant ad he cies tr 24/ caKYe pecrs be rensied $9 Iter the nitan pa. Alnave as 267 Pang Inuell new piston pin cs D Now CAUTION: Tha. clon st be sont 30 tht the "nN stomped on the pasion head ie toword tho top tho fe engi isin ho rome. tt (Fig, 3.58) 3. Rsanbie tho con eho oud cam oi guide ral to the syle A ntl thee ‘CAUTION, Te tng gop of the trae piston rings shel fe stogotes 120° opor se of the piston ring conpresor fool (Tool Ns. O7032~03901) for Fataing the cyl Fig, 248 Avenblag te pan wil prevrt danas to the een ing of BUN" mat Tr ll pty he wok Check to mote sw thet te ear cronser 5. Inetal the syindor head br cccondoce with pergh 3:50,2.7 cm Cat Toone 3.7 CAM CHAIN TENSIONER AL Constrction The cabal is chiven of of th fon the crab tra the com chin wich loceled on he lft sco ord teased win the com ton charbor. (Fg. 9.59) te 39 GeENoINE 8. Diroasembly avowe the A.C. genorotr in accadance wih Frocedue described iy secon 56, 2 Rovave to cancalt in acz ccedte desibad i section 3.58, 4. ferove the am chon fromthe tng sprocket cre then the com eben pide epoch in towne by reno ftachig er ein tomer stig cote G) to te leaker. (a 3.69) 4: Rnove the com Ing the tree Sm eco G'can cle oe @ Em com ah soon 5 Uncen the 18m saatng clap © fom the cre of the lonikrer gutrad ord remmve the sgrrg @ ond od @. (ig. 2.61) Mee set ou B Soro @ tovere po sot 1 Grech ark cea ere Sy ero LL Oo ® Oe Eas @ Tomer cen ner Di Recssemly 1B Tentonr prod Deen oe | Assonble the coreond pts in tho verse @ em msg tee frocedie ot deaconby davcbed in section Oem ware he aea8 c.UTcH Consevction| The freon ef the cltch Yo tempor a ngage te rernirg ofthe cola motion between the engine and the trnanison cag nor charge ‘oe then ftor the gaar change, pawit a areoth ower tereon. The cordon of the cuch wi hove o voryhe fact on the ofciensy of the power tension, Tha hich en al of the mods cre of the com vetional wet type muti duc. The C50 ord C190 medals reopporots.cn ovonatc Forte to perce rte chreh ergage and dsergage fection ‘whereas, the clker meds are provided monol froin Construction and Operation of Cutch The chic is between the ong body erd the (gem ehfttromnison, comers or icomects omer Wararicéon wen ques, sich ce Fv gar iting. o stata the eran ete. ‘Acoordrgly, ech ports os te days of erga: nent coarecy, the silty #0 slaronge completely, smoctines: and lipage wien engnaed oF aie ‘engaged, oe, bozon9 ingot ($90, C190, CL90L, cD90) “he cvch of te nox $90, C190, C190, CD50 faa wet mitipoe hype. Acstown in Fig. 2.63 A cd Fig. 9.04, when th gl crrkeose cover I removed, he deh cuter portion Eexrored Ini, the ctch she, hive pit, ech pte, od elteh {etl det ave cxemiied The felon dsc has Jeeth at ins ier creveirece, the eovton feng tte spin ost ithe external cheunforence of the iva gear, and coup ro © withthe dive ‘oer in tho Gkecton of rotation Tho crive. goor ‘Seared onthe const through te dich carer ‘gide ond car o'ate feel on the aarkhals on the cthor ford, thee ere gone: clin he inteor of the dive plot 1 ft he spine cat ot tho tp of ‘conkthalt tte chive pst ic fcterad 10 tho croh- salt by o 16am ck mt, firing 2. seals ut Sree, 09 the exter of the v0 plo end ehh Plot. festh engage the stoves at inthe nvror 1 the cle touting, thm cular lich, the ive Plate, ord the ett ploe rae together with ho atlital, Thao, when the ckch is eronoed, ae cuuten ig: 263A CEA mcr S90, 17H ELIOL OVOa ENGINE @ Ge eee 8 one one ou nei the dive pale, eich Flan ds, ead the ehch plota oe ald ky the elves seg forming « shale Uri by mutual fection end renting in the ror rion ef the rotation oF the crankshaft di ee The dive gh fe ergased wih the dtiven gear ‘nd the power i comeyed to the trnsnisen. hen the mane lover i pea te cite dae engage lover i rtd by the citch tle. The cach er om, cttxcied to. the clich ver, cz tho ctch Min eye rtetiont moron tho cllch Hier peses the elich exterior tovgh th lich euler cover, racer tha foros of the uich spire Jo zo, ond foci she ave plat, hick plote, ond Fetion dsc. Thelen, the ‘olin ofthe eve ple one cut ple le not omit 1 he Fiction dic: to dive goor stops end power toneninkn ie rol perooned. la don, the lich dompor sing is isoled sdo- ways lo prever nose cxised by illag inthe Giecion of rotor of the dive clota ond the ulch oxarce, provrtng domace 10 the toot. [90, Cr90) (Fig. 3.638) ‘ho etch ued en the C90 ord CT90 bo wol type muiele dic, avoneteally opened by contigo! fore, + Chich contr @ ond dive gear @) A seas apr ie incrported to ongace the uch dng stat al ali to nnn th chick ‘ergnged when wig the ergke composer for bali. + Chred woigt © ond rlooe oping @ Wher the clic revcluen atbins = specified spon, tte cenrlogol force covet the cuch ‘reiits fo rove radially ctword. io begin com sing he Sich eleme srng ‘As The chich speed evetes, groter force | oped 19 tte reece spina, ovardhg tho force of the rleoso sping cre paring the uch ploto te ergape wtih. tha ton alae, es, pening the power frm the engine 1 be trxemited 10 the reruns ond 10 the rear shoo The chtch rleno serigs contol fhe rina speed oF Wier the exgie expt Net the roar ‘hoa = Chtch eth machen ‘The deve pote @ fied othe cron the tev compononr cf the click osanbly. Chechao cuurew “s Gopense. | es ieee @ tine eps ee © bem lv By stagpina on the anor chores pods, the latch cor pote ® ack, cain the pres ture lo be oroed apse the ektch oitr ond beeing He chk. Siree the chonge pacsl 6 drocty comecred fo the cutch cam pte, tte clteh ésersages efor the gna change Bs wecied. aching go ering 10 be pafoines enoothy bom op ond dove willow fieuty B. Discasembly 1. Renove the clich cove Figs 1.85 neigh ey er oor 2 Renovo the rich creas cover. © Cater cover 8. Remove the chich over cover. (Fla. 9.65) awa owYa 84 fem he ey (Gee ove) lem ek tT se @ Urn le nt @ Cue cu ble 2) @ cua eooly Fig, 348 pei he ech wig sang tee Ste 4 Unloze the 16 wm lock otar ene urcrw tho léme feck nut OD, the clutch caerdly an bo renoned ce 0 writ. (Fig. 266) ote eich ower Helier Toot No. C7924 1103) 10 hald te ch orc rem ft Wh tte Yé nm bx wraneh ‘or0e6-03001 5. The Woik of ciaworbtng tho cick oxembly D can be sinplifed by the ws of cecal tool © Wee} No. 97038. S200, (Fig 3.67) NOTE: When ing the spectd tol, void he cve ito, danpar sng rer, cherie tha cre Fate corrot be compressed GInepecion| 1. Gch spire (Fig. 3-68) NOTE: Use call suing fazer {Tool Ne. 97184— 99901) for testing the vlve sxieg tosion,2. Fiction dic on chic plot (Fig 3:69) 3._Qutch outer ard ave alata or etch pete, Guich eoror guce (Fis. 3.70) Penny dive oor Fe 24co~24tcen| Spice 1 om 2. Reantanbly 1. lwo tho uch oie, axnbo the cteh sping diva pte, hcier doc ond doch plots, fad then cirgrest the dive ple hn azsordorce With te posed in section 68-4 and inet the 20 reg» ll ech damper ug. 2. Anorble the diva gear, ech coner ie together wh the eich aionly on the canke shal, ‘ormie th lock rt to 80~480 bg. ow (54~04 bs.) NOTE: ‘The lock waber (D raxt be locked by ben dg the 13 fier tour the nit; if ho eke of the rut dows rot alcn wih tha tab her the ne furer 0 part locig, db loon (Fig. 3.72) 3. Auenble the dutch otter cove 4. Invall ho righ arkzose cover ‘5. layal th chtch cover legthar ith the chich Wer end oll ida pects he cach oe us poe @) di enge 27 tn lt ak wate© Contnt © tauren fe 573 Fis ot tres ot @ tein wala © cn © oun comic © Codena9 OM rum AL Construction The Hondo $0ce movccycle orgie ercloys o ex type oll pure for the exer modes ond rodheld type for he later mecee t2 furnish of ede press io ll ong pes 0 prevent ee ‘rite wea: Tha ei hin has boon drawn tp from the surp i poued through the sicher cond ts vaded in two ceo, ‘Ghe weutes he Gil & sant thous the eer stelt © erd 10 the Yersision where the congas en: pont of the rein stlt @) ond te carter shelt D ore keicaed The otter vie: te oll fe ped teach the potsngas Inthe right cakesse ore he eartcnte cover whos its tor broncos 12 tha ene. of tho rove libreo'es the clonihet ad compare pork ord the cher lz rte 19 the nalow inthe corch whete the moving eats win the epider ood sch ot he roca rm, costa (Sond Lebreoes tho cam chon ® cr ie vay back 10 fhe srip, The movin pars weh cs goa, beats ‘ie of ot leben bf presse cis Mca by all epath a spr. (Fig 3.73) 1 Dizstenbiy 1. Renova the eich osanbly os 6 wrt in accor ance with tocien 3.8 2 Tho ol punp cn bo fonaved by ancrewing ‘he thes Geer screws (ond spcia tex col 3. ia. 3.74) NOTE: Al enisns ubsoaeet fo the frome npnbor town below a exuped wih a dng poco ght cece cover, F. No. 5 90-478103 c170-120015 €201-166081 (cD 90, pe @ bam Con ea 1D Spode fia 3748 Tota ol oo (© Som ont teu 1 Somer hex bat* 3. ENGINE e0% Fig. 275A Caer a pnp © Gt enp com {@ Oi pnp cover get Gi par tay © Ot pnp coe 5 EE a, 3.728 Toned ol amp D'Ot pay sone @ Ot paw cos ge © Ol pom so5p © Om rater 1 eae bd caxane © In scar 3. Tho reocval of the two Siam screws wil ie ‘ssanble the of np. (Fig. 3.78) lepection 1. Tha norma! copay of to ol pomp is 1200c0 (73.22euin/rne (@) 4000%pe: if th expacty fale blew 1006.ce 61,02. Il ee ie & a oe of devotes oie esiane, therfore, the Fane Seu be repored 0: epaced. (Trochid np 1400ce 185.43 cv nin @) 8000 om) 2, Clases oF commonent site aS nnn | Se | orc asi) | Trecid Type Gee 0 bina) yanon—o.nbon | Oa OU A foe cootirbooss | Ba anor 1D. Reattembly 1. Auonble te ol pimp ord itl on to the gt ake, 2. Inval tho chich asenbiy ed the veh eran emo cover In oceorance wih procaine cat ‘nad fy secin 3. 80.3.10. GEAR SHIET MECHANISM ‘AL Construction “he goa shit fort ie moved Iraw'y by the eer shh cm Wan hn the goar shit sine, aes te ahi om 1 row sift ine costvsa or crater costa rection, depondeg won whaler te Fewad or eacce’ tore samsia sess 70 ssi tea so DSi so spon pone tex of the padol i deprecad, The sift fons a0 ited ever ta ft cam an aude in Us linear movenert by fhe com gioova en te sufoce of the i dum into wich tho fork guido pine ‘99 insted. Retaion of the dan alls the forks to the righ ox lt wich in nr prone the gor shitig. gow sa rat sping eke tho peor curse pec to Ms noenel pstion oie oach peor charge sicke. (Fig. 3.78) 1. Disoreombly 1. Renove the cle) osnbly in oxcordonse ith sacion 8136, 2. Ranowe the prnery diver oper @ by sore veg the 20/nm exci. (Fig. 8.77) 2. Ranove the ehft com stosper, Pl out the goor shit seinde wih the ond of the ahft am ergageg the shit dm bes the descton of ows (Figs 3,78) Inspection Inspect tho gearshift ern, gear ait om ‘ord sar shit forks for tit x bond 2. inspect the gear sth chan ore gil pin for Sicoiti0 eon 3. Geek the spring for reskoge ond groper tore on, Di. Reostonly 1 Atsonble the ga Sa splaie the reverse cer of the soa.eeco decribed ia he uasem- Uy scion B ctove. Allor ostently, mole 8 thatthe cpartien ie sxapar and es xine that tte at seem sein pln Ts not ben 2 all tha if drum stepper @). ond ston ‘aonb the den gear (Fig. 3.79) 3, etal the chich wit cd the Hg erkenie ‘exer i exoadince wit secon 3.8.3.11 CRANKSHAFT ‘AL Cootirtion The corkhnlt fe crshncind of Sigh ster catbon veal ar tageor with the cerns re, reciprocating tion of the glfon to the tory sion ore. iv ein, preforms, the furction of the Ayal by abserbieg tho fucka tig fora. he ri end loft crckit eanporerte ro pots fied to the sickel cme raiyndrue cork pin wh the eonnactng ros ceertle. “ho tiring spreclat wich deve tho ear etal fa drink fited 10 the lol) crank Cronishats csarbiy ie appnted et 140 poms by heavy duty eal baring Tho ght conleasa tcoperares 6 conor al ppaioge tesugh which cl wid erator posse 12 the conpin to IUbicole the age ee of the com acing vod (Pig. 8.80) 8. Diearrambly 1. Renovo the chtch asanbly fy» occardane ‘th 88 and the goo enft nd oceordonce th 10, 2. Renae he lft crnkccte Forave tho cyfede: reod in accords wit ‘5B ani sh cyltdor cxcovdance with 6B, 4, Ramave the 6:16 hex bolt ord smorat the kf ook ‘The ceriahat ent frais wil be ook petaly expore. 5, The crrishlt ouerbly @D eon be: remove! from tho loft crake, © (Fig. 3.8} Inspection 1. Sipert the crakshalt @ on V backs at bth Geance ond nese the onoutt of snow IF. 8.82) ams. | ee an cnsawr Fig. 2.81 ecwia te oma @ cenit8 ENGINE 2. The came iy te booting fe meonied by ) Fang the caekalt en centre and moving the bealng hte adel orl ye (ip. 3.83) | Sori Fo] Wier the clescrce in the axl rection A Mein wl cen Co 1010s when ercho i raving and prodcn vedersichl cis at wells cag, uneven wea 10 he cylinder, psn end tho ting oer It wll ao sexton the fe of the cc IT thw clcrnce Ie Y00 sal, will enzo @ ocraces In the sewer Supt and shorten the Hie of te crite, ®. Comsctng rod swol end bore, (Hg. 3.84] Incomes excesve, the crcl wi move fom — Sted whe 1402-1408 (08517-0852 Senile Init—tapace ver 14.08 55 9 @ D. tocneny 1. Aarti te cal bly to th 2 parte to ooh cena D 46 he lt orkeate, 2) (Fin. 3.05) Caution Co forget ro nt the two dene pre (Fig 9.89) 2 la een sh le tin dance with section 3.60. ord the cylindor head @ rd cover in exorsonca with section 2.50, 5. Aszamsle tho goar sift mince in accondan with secion 3.108. —Assertle the chich ant Ino the cankce ond incl the rg erokemeo cover f eszordance wit section 380.2.12, TUASMISSION 3.12 TRANSMISSION AL Constevtion The ronson receives the rary power from Whe creriaalt ae! trush seis of eo changes red speed-ord then wrurts 8 10 he ive chain sect to ave the rear wheel it to te The tonstison on the SPO, Cis 0, €D80 oe C790 tes four gods. C90 bas hn spoods, Al he goo arecontand moved, wing smcoth gear dongs. The later series Hunision fon the CTS0 ie agénoad ty @ abrasion tnbich bat @ low seed range saleclabiy, 280 saclien 3.18. “he primary roducien rao lor 90ees 3.722 (Fie, 3.88), 1. Opesaen cr ($90, 50, cL90L, CD50 Lew! (Fig, 3.88) Tha power from tho corks ts vomited Yhough tho leh tte spine fas cre gor cn the Srision cin shal. ‘The power from the werenissen en a i treed fon the ain set ive gear to te frely stain canter sc low cea owover, hs courer tf score gear) whch ie altos fo th ca the low ge @ by the ait for ond is loc by mean of o deg, fomeg on integral unt wit the couieatalt to Hane the diving fxeo to ‘he cve eaoctat mcurad on the lait ord of he countor dt a : ® ® Ti 364 tain oa ye ee 8 Sen or oom zu ow 2 ap fe @ low eer { aunalencovveat © Center low poor conte ced geter mminee eat 1 Mara Wed ser @ Metal! 9d gear @ ‘hornine costes @ tm Seconds (Fig. 2.89) The rein shaft tit gocr D which te ctre sdo moved oy the alt fork 10 lock wh the second ocr © Fitas 19 sho rein ens by, ers > the cater shit Jee foe ota nowneg tha man sho acer poor wt Conor shit socond gear G? hence 10: dive tha sprdat Thirds (Fig. 3.90) The power fon the tenaniton ein soft @ is troweitad to the coaer sat hrs otar @ by roving wih the nin shal thad geo’. Tha courter sholt smcerd gear © when is spine sido fit te ved by tho shit fork fo lock wih the. rotating thd ger @ by mecrs of a. deg, ths ait) to rate ard in an chives tha cele Tops (Fc. 3.91) The nai shit thd goa @D is moved by the thir fork to lock wih the fea reatag ep oa" D by moans of @ og, tat peming te tore sissen of pone’ Fo the mein salt 46 the cantar elt by masing the main stot ep oo th the Heed aun a o chive the sproche,2.12 THNENISSON Nevirals (Fig. 3.92) “The geo aie vot beled The nin shaft low ge © is meshed wth the eoireer shalt low gue ©) oe tho main shat ied goa & mhod yh cater sft ths geor @), tewever, the counter thoit goa resto loaly ond thclere ro power fa delved to the tive spc! 2, Operation IC 901 Lows (Fg. 3.93) “he poner fron tte crticalt te ronnted ttrcsh the etch fo the spine fed ven gaar D ‘on he torsnsion mon eft @. The pom from tre torsion main shit it oreited fer the cin stot diver ome tothe Fealy counter salt low sar @, However, the counerehaiteecend ocr (sich is ena to the cuntr ott ond 1s maved eg the law goo bythe sift ok ord Is locked by mors of 3 deg, forming on Integr vt wth the counter stot © fo tram the diving foica 0 tho dive spocler @ noured cn ‘he lel ‘ond of the counter eft Seconds (Fig. 9.94) “The wah shat op obs GD s mova by the Silt fork 10 lect with the ‘tee stating tocand goa by meons of ¢ doa, tus peti te tonzision ef cower trom tha min silt @ to the counter thal @ by wasting the mein sho sscord geor wwPh the counter soll secant gear ® 10 dive tie sproste. Tops ig. 9.95) The counter shat second gear @ is movad by the shét fork to engace tke top goa by moans ‘of dog. Tha pone Is tarsited fom the mein thoi top gear @ ond fo the cower dal top gece © ond to he sve merce.s a. enemne 8. Dinossenbly Rorore te cyledr hood azsordonee with ‘ection 2.58, 2, Remove cyl In oscocorce wth ction 268 3. Renovate chtch avently fh ancordonce wih sechan 3.68, 4. Rerove the gear sift Fork in accoronc. with sacton 3.108 5. Sopacte ta ih ond llt cerkcase in ecco @ Yarettos aa ot rents wil be ezesod @ Treen cetera 6. Full ut te Lick stoner sca, © Ger si em (fig. 5.94) 7, Reneve the asin halt D. comer shat @ rd the goat shit dary ©) fom the ls cate a: indivehal onorbles. (ia. 9.971 cork TB romin nan lt 8 coo mh om |, Remove tho gearshift guide pin clp Dor pall atthe gor sil lok dein: the peor ft foe ©) con be dearer fom the gear ‘hit dun. Fig. 3.98) ND Ger Werte ie @ cor at ora2 Tuoussens G.Inspection 1. Main lt 10 main ef peor clerance (Fe. 3.99) sod vg] ARM, [ttn voor | dueitie, | erica 2 Counter shalt 0 comer stat gear clearance (ig. 3.100) oniba.szee | toca i co wwexee=been | Stn ise tow one | sae—a08z—n eee 3. Teanenision gear bok ‘Stonore velva 0.084~0.170 ‘0.0034~0.0068 4 Serccble let Repsce if cear 0. rw (0.008 in A. Shalt 10 booing coaence Mor tefl le | (unooe~botas | OiSne th Goa ‘Comte aati yo| ROA DRRa | Banlace Foor SSPEREL | eocer—ncets hea 5, Saft fk 20 sit da coornce Standard vole 0.025~0.075 me ‘o.0010~0,0030 1 Sersceabe lint 0.18 mm [0.0060 in, rploce 6 Bord st fosk ‘Stordard vole 0.05 me (0.0020 in) Sejviceabe lint: 0.2 nm (0.008, ropoce 2. Sift dom gexve (Fa. 3.101) ‘Sherdod vale: 6.1~6.2 nm (2401~0.2441 nh Servicecie in « Replace if over 6.4m (0254 in o Te 2 Wak ac ge cearoee 1) Met alt fp peor Dosen peob, Recerenbly atl the aser sift fos @ on the nor Silt cm Invert the goor ent quae pike ard fic Fb pace by sates the erty tos cot re 3 ee eee © Geo it an 6 @ 4 2 which cre fea rotating mst be tolled sth tho tat washes, Aller tho ceionbly, chock fer proper pmraten. Ietall rarer man cal, centr 2a gee: shih crue cxenbly on the leit crkease. (Fig. 8.103) 4. ital the Wek eter epncla Assent te UH orc BH creases fn exconde creo wih estlon 3.110. stl the ceo rd te civen gsc Oe the hac ceonbly the RH crerhcate cover in accordance vit soaion 28. Irtll eylner accordonce with section 8.50 ad te eyleder hoot In occoince wih tion 860, Ital tho goor #9 sino in the rovre order of section 9128 8 10. Fig, 3164, Gusig te ger st am CAUTION: When cxenbying, check fo wea "a" perce "kn or cho clack the sth eatin sing ria for bore. (le. 3.104) Fetal the shit dium stopper ond the diven esr etal the oll pure. tll te cick sion: Ly in axcorince with section 3.6. the lek warher, lock ut ord lock tho mit by ban ira the vesber 3b Ital he chtch cuter cover ard tho tht29 cues 3.13 CRANKCASE ‘AL Conatrction The cronkeae & on bres! pot ol the Kees mision rede in the gt ond left haves from stun otcy do cotta. (Fig. 9. 105) The eylider Ie mous of te forward erd cr held place by th cylinder hood te bobs reioned into the cralear. ‘A bicker conpornant and rember sage 20 Incrpocte it the upper ection of bath crank cme Folves to dispate tho ronaze tulhep inthe ‘A can chia lorserer 5 ‘copaied io te leit eronkcave Fafa the forward loner secon of tho righ cronkerse is incited an of seaner nd which togeler with he coma! iter pifas he ican oll wrich ts presane fed to te view conprents of the err, IGREATHERS ‘Tha loror of the crerkcae it continually under vexying prunes, bult wp by the recreating sister, In ean, tho ctenlcose 1 fled wih the (3205 from tha Blowby ef th ptien ard th gust, i coir Tie. 3166 Gone @Leckoe Deowkwe Ol. ceca come o}Fa: 3107 Meaney ie eaene fovae wih @ Wek 1D ever age proces by he hect of the erorkeate, For she eaten, the decsrerenson of the cl looks of the ie pating oes heres The bvostor ¢ sense ond incorpocted otha e210 ts exbast the aot to to euse ond clas 4 moincin © consent presse thn the crake cata: (Fig: 3.106) 8. Dieortenbly 1. Ronove cyleser bea, ter to sector 9.58 2. Remove cyan, tot to section 3.68 3, Remove lich casenily. os © nit, refer to fection 9.88, 4 Remove ger ft spiro, solar to section 2.108, Soporte the ht crake fom the I rafor to secon 3.118. 6. Remove tte oh shalt ond comer sh eer fo ection 2128, The gear shih fok onently and the hick store con be resoved. The cleft can be decceniy, 7. The tight crrkcove wil hove the ol shber nd the lat cankens wll have tba com eon fericne and ignition cll mtod. Tho ol itr screen con be ranoves fom te sgh ccrkoae. removed 06 0 wit C._tespection 1 Chock for damages apacily coud the Hinad sing axles soca even = sal cafact wil ase ol looks, Tre meting sufaces shuld be lat fo witin 0.05 mm 0.002 01 Moasve with ticks gauge. (Fg. 3.107) ©. Reostenbly 1, Assanéle a he vevarie dar of section 3.1383.14 KICK STARTER AND GEAR INTERLOCK MECHANISHA bn the aston, whee the kik ster inion @ ‘ongnged fo te low geor @®, he bel or tang 1c light nd cory, and he we of tho harman ‘0 recices the posilty of ‘rable ‘As shown ia Fig. 3.108, when tha Hi ster spiro D ie rotated bye hick, the hick strtr vt set forge G), is roctad simtorasy The shal of te hick sor rte Hage eee down fom the Lick strier rachel ido (0 ord is pressed 10 the toot oF the Hick stare pin by ‘he shat ening ®, Power ie trounited to he conechatt low goor @ fon te lick ster pion. @ ‘Wen the kik sorter sin retuns fier thing © shown in Fig. 3.109 the fick ssater root fonge i pros’ tock by the Hidalater sp, The seit ides on the lik ster socket guide fd the ick sorer sion is red, Fig. 3.110 stone tho gpor intelock ‘tem the . Shewtiaes 8 fay ek tate scr) Coutts @ Nn satHollow sed sect cranial, tom whi pasts of chats 3.15 POSETORGUE MECHANISM [CT 90) AL Convection ‘The CT9D medals frm frane No. 122551 ard 200001A) ro equeped wih © pos-torae select betwem the High ond low speed range, fas of epaceg the space! os Fhe eater seis. to provide enter diving power in tho fal ave oF reckced speed “Tha icorparction of the. posttorqie regs: cry the cporation of the tigtlow speed range ‘elector 10 charge tha diidng seed. © fect tne favng over the sollor terse whch romied te rertanting of te lage soclet ax ehnging the lenght of tha chan. Fig. 3.112, 3.112) FOVIER TRANSMISSION I THE POSLTORGUE MECHANISM * Low speed venga (Fig. 3.113) Jn the low speod range, tho elector shdos to splined positorme Figh oper @ to mech with the divon gacr of tha pos-torqae cantar shalt 3) The gower From th cane sit Df toe riled to he posilorave cantor shlt 3) on tien fo the fee rooting spoctet ve goor unt @ where the speod redicton tees slece. The ‘chin D is cen by the sprciat which roses et peed leet thn tho coutor ent216 CaRsuRETOR High weed rrge (Fig. 9.114) Ire high spmed ronge, the eaectr elder the ‘pled pos teres igh goa) to lock with the Few rotting rclel dive gor it @, The power fom th cower shalt Dic ered fron the postr igh or dct fo the roe rleng Sprocket ive gpor iit ©) 19 dhe the sce the coma spose ot the cou: aha, % Disersenbly 1. moe the four, 6m teens and te of ‘he pel serie corer 2, Remove the posiiorqe low gear ord tte ‘couver gear atonbly together wih the cower thot ‘To duowestlo te posi.trque hgh gx omave the 20 me cic ons the slinos was, 4. The lot crodease cover mat be renaved fond the chain urooled fiom the sirocat 10 ecezanble tho dive sprocket. 3.18 CARBURETOR A. Conervction Tho et taken ie from the ei cloarer ono tte ‘let sido U) of te eabsetor a: a mn clr. Naw oce under the Hwotle Wave (6 ond then aoe the cerauetor touch passage (Bl to bo token info te engine. This flow of of cates a megane prone eos the neecle jot (A) ont coueee the sl inthe Neat clerk 12) 9 tm cow op shragh ke rcin ft (10), te naadle et Hoter ¢) whee 1 is med wih the ob that Yolen in f air ict ‘51 ond ene tag he bled eles Loe and the ne lo ft Fotor 13), end ie thon chotged between the aoaile fl ler jel mele 71 localed drwy below the tole vate (6 Tho cischrgpe el = med withthe min or Flow cot ooze 9 tan Ita Pe engine thoi core. te ‘ck flen fh tron exbeci he fst isi ot eral ‘lr II passes by she opering 121 of the a scow 11, onore tho 20% jot (13) by the way of te eed hole, ond tion is mised with the fal ce charged fiom he Hole located txder the ttle Yale 0 produce ric lee! isha, Ts cichage foo! mise Ie mies oh the main lat oF few ‘and folen nto the engine, Tho fuel miko ede“ 3 ENGINE meee of the sow syste is ode by repustng theais carsusrroe ital 10 ste trots opening ond engine spond. Howover, fe thr pupozo, 1 & necomory to kop fu level cortant in tho cobieoton, THs is por formed by the foot chamber Te fel fon the fufonk poses throw the zane (14), Botween eve seat 18) ar! the vane (16%, ard han ertrs ‘he oat chanbar (Zl, Tha dest 171 baconae voyant oe fuel enti, sits the Foot yoke (16) ings a! te Poo! am and whic seats the float ole ito te valve sect to top the Bow of the fal. When fil in the ot charbe:'s conned ro tha ful love hep, the Naat 17), lower org With the fol level Cecrance botween te Valve (el and the vale sect (18, allot foe! fener tno foot chanbar. 8/ repeatiag thy tho level Ie ovoyseeinkined const, sping fed nto ta tation of tha vave (16) whch contects the foot om i, ond proverts the valve tenia tg. ‘Whee tho Vebilo ie on a grade er when dit «lodged between the valve cr set, goalie wil ‘ver Now ond enters the eyleser. Theofo, fox rotating th foal from ing above a consi lve cn ern fe is istalod, (Fig, 3.116) (3) Cre Whee an engiva Is cold ox the tenporctne ts lou ding earing, 0 rh fel mb is torpocoly reauled. Ths canbe hd by to uo ofthe choke. ‘When the chats lover ie led wp, the ctabe 20) is fully closed. The opening (Za is rormly closed by th sole! vce 2, ower, cg sxtto ‘hon the thotle ic opored aproxinaraly 1/4 ond Iho Kick starter oparted: the noma cresixe cmcte! nthe cylidar wil caso the reef vale (21 to open by tho preger anos ited tection 24) ord port or to pas Hoi the cabreor ths fw of ar crane the fol ct of the readin ie! ll Yo provide a a fuk mira dot for tot Ing. Alor he ergo sis. the ie! rogarve ome increaeas, ans cts tho raat va (2) a open couespondagly wider to ese © alabie rwocuxo. Th, the pang of re ralaf valve (21 ctorges occardag t2 the cperiea of tho tte ‘ole (), scion 25). (Fg. 3.117) 8, Functions of Each Component U1 Main Jot Its min opone iso cin a proper fl mine rate by comraing th fw of fue whan te thea Ea 15 filly opored (operating ot the maximum sped However, te hel rao fenced donn to aoind fon ha those pening (Fg. 3.118) Air Jo To: provrt the ned gos tram taconing rich of high speed, or Jean ot low speed, i fosd to tho needle jot holdar The firton of te oF fet is 10 conkols tha cna of cAI © coretnt Hote pang. the lager the a i, th sraller the dferenen in Fil Now ttwser igh cant low sete, cr a conseqpert roceton in fl ow. (Fig 9.119) (3) Neda J) Tho wood fet conte the fel wich had been tratnad by she nai je tetvacn the inemadate 26 ‘ul tote, The contol fs paroined by vary ing tho clase between the need [et crd jo nacclo doicibed in the folonirg sei. Hole in vel the ceeds jot f mec with tgh degree oF pre sion 10 cee ocewat foe! cart (Fig. 3.120) 4) J need Tho jet need, io conenstn with the cove rrentons na la jt, conte the fel mia rt at itertodare rote cpsing Incinty betvaan 1/4 to V/2l. Tho lrg toparad jst needle i fed fy the cower hole of th hota val wih he taped ‘ond inserted into the ned ot. Th vet mone iat of the trcte yoke consszendagy moves the tapered fet noodle within Fe noodle ie, vay rg the clecrance between the nascla cre the jo. fd fn thew, th proper Fy mise ie caine in reloroxce 10 to postion of the that valve. Tiare ce fe clp giaove podane on the head becomes cher 's moved fiom the feat grove lg toverd the Ahh goove, (Fig, 3.120) 19. Troll vote The thetla voNe rogulter the enburt of ek token ito the ein, this ewertilly conte the igre spas os wll or the power output in ad tien, tho trolls vaNe performs otter Inger contra fictions Te shit of th tote vali a ot on glo fn the int sido; the za of this etoway le do. aatod by th ctavay ruber wich ie deseibed in wecoodey section F.2. By charging te vahe with 0 diferert size eaway, the nego presse In th veity of he needle jet changed, offet Ing th fel Now er eentaquentiy charging tho fs oterife robo, This chang is elstve in tho sow speed ronge between idling and 1/4 tote pene bho er las m0 eect arora 1/2 those open, (Pig. 3.122) 161. Sow jet “he siom jot metas He fom ol th fel ct ing ‘and ithe slow speed ronge, a cases the fel 10 be elonizad by wisrg * mith tha ar then in from tho a bleed hen. (Fig. 3.123) 1 At cen “he or sow roe the ancunt of lr rtring "Ye slow sposd system The cir which pases by the ct screw mses with th ful fn te low jt ‘ond cicharged the proper meine, eroccing 46 eray 10 cast vancizaion, Fig. 3.124) CAdustent| In ower for the eaureler to prodieo the nox ‘nom paomerce cf the gine’ copay It mast bo adistos 10 that © proper fuel miko evo tele over the complete apoed songs from idling To the rmcewm spac, and futos, b2 bie 19 rs. Jaw ths condition, The coetor has been de signed cra nonloctwed to soy thn crors by the precicon noniocwe cf the conperens ow specally fn the tse of apetcr guy wear skin! mesial. The jot nucle, nad a, Hoe to voNe ord the ficat valve bei etesprela fo weer, bos keen made of nota ponesina good wecvng chyerterstes, pracy rmefoct#ed or sarfoco veaed 19 ge oxended sosactoy sence without change to porforaree. Tho adsense seaictely rade ond par foxmenee checled ty both the remotes or foctory parcel 10 osu6 tar the ating of tho orev! pals ae precio, Thosiere, whon raking ‘ry adustnens, peers eye repair: weploe- rg wom port, ge paniclr cremion 10 the fk. ‘owing points @ Maks ase thar ta erghe i offsted in cxcornce with the mecFeators ® Check to 200 tot there ce wo of laks 2 the cabeler mouring Fong. @ When the centring congoren: kecore wom, replace wih neu pat Fie 212 Siow ee Baa SNeenoine D. Adjustment for High Spee Ts eel th Kel se bea 12 aul tak eee veces moh a 2.128) elias fat Asan ee © fod aie ae 1) AVA cl, ¥ fe ech seed zoe er bal Bele WANG) aw a taster of len alten Peay ters iauemiunu pares Cares ee Oe ‘re rartered in cage of 5) Oa oo el ed pb eh iis dee ese ee ea ee erg ae mel Vin Hoos dl oe ores bak ci ens te cae i Fe ate oe eee £ (eae wae au eae edeetuined four) the pet youn fo ee SRY Gack ach Sn Ge et fhe pepr theo re sab eae es eee merece ence thee ts apes cal fat og tela te vit fe exon bd coe Jae af al ooo os @ ate me E Acjutmant for Inermaciote Spesd Tio fel rik cuieme tn rains poet rigs boron 1/8 fo 1/2 tate open i red by long tt med pray dp ord epochs to thot whew ha of fn x0 czoroy. Honor, changin he Wet vr wil os fe! th epraigcrcion blow te sod rage of 1/8 atl oe. hele, : 1s wey feo et for inerneit Sport CES i Dioplent iba edie ache ly, oiee \eeSnrted tt fa cate fr he Hemede Sed a te by ba eekly i ithaca eels social Sheers ther the wold Gro 0 fel comroon ots teh ker Fn. 2.126) 1) ber moe 10. ek tcl eed fon te alos ox ot warmed speed ton Iden of {bo (E falire ob cared byCatto the et meade to a lower pation Ib) Ft spot GSinler 10 engine ising cng ‘ecalotin oF af lnemedloto speed ial. ‘ales tha! the fuel ste fs too lan and Ie corectes by odjstag th Jat needle 10 13 hoher poston. (2 Thotla vahe litanay! “ho thotte vase i rimbsced 2 thot sho larger the tosped rinter ize, leaner the fel rue wll be. Whar cheng the Hct vale it mit} be eansdered that dow seead wil 86 freced os sell or ‘te intomecte eed F._Adiusiment for Slow Speed The cxfwinant of th Tush ide betwoon 1/8 throtilacpenirg nd lrg Is ace by the i screw cond the eutswoy of trate waive. (He, 3.127) (Die scien Tha fel mixure odin ct lg spoos Is mods by tte ar teew, Turing tke scrow th clock ceeton will prodice a rich rise ture; @ Jean motira can be hed oy ‘ring the sare inthe cowler cockeize dicstion Hom the ie screw 1b nat ery 10 oaks tro iding since atention shui alsa bo civon tothe transon prod fom iding te thotte opens, In othr words, the Teal mike provide th smooth cporten af the polt wher thetio i ‘pened slghily bxyond the Ee spond G. Adjusting the Fuel Level Sree it Gift 10 mesure the acc ig of tho fel lowel, the mossrenent of te heht of ‘he feat vdve Is mode which, will coxeypord to she sight ofthe Feat reoswing method (el Tap tha foot tiglly from leit 0 right wih tho finger nd locate tho postion where the tip ef the Toa! vohe last basly comes in —_ a aS “A 7n 3. ENGINE contact with a 2 clearnce of 0.1 nn (2.008 erie Eetwoen the oat am. (Wn te poston, te dstonce Letween the box of tha foot ce the cursor body @) shoul! mane 21,0 mw (0.827 i, dust i requed, carefully betd the Noor arm by tho proper ena caution, 1 spr rcorprtod in tho bain of the fe vole, teafors IF the oat om kerio’ et the valve, tha speg wil recede into the vahe crd te incestion wil tet be cbled. Corefl cbasation rest be made to occurly cetet te ln of contact between the foat orm ord the foot wave (C90 Model From Frame No, 000001) ‘An aliud telecor nod & inceroiatad in tho coructer of the CTO mal etevieg with tom erick No, (CT90-000001 Alensire ser] No, CTIOE-OOOOOTA, This moles oraiatle opin corbuelor pxforrarce fer roma or hgh olin metorycle creator Pul the knob out fer rida ot olive of 6,000 feet above sea level. This will rovide odor sppy cf a 10 the pesca jet fom the main cir pply passage. AY the some tne, aitiond 1s oso salad 10 ow jot from the slow ayer sir oteoge, 10 loan out whe fl mae, Putieg In the knob wil cove off the cir suply fo both the slow ord win sysens. @ Thos cable oti © Heine @ Meter 1B hore ore GD Arsoww Bo @ Prot sele (3 tere St fo an 1 Nees cp late Gre D fs te ome 1 Top water 8 hte exo tame 1G Cot soe ( Neel @ Gal wha O Ores & Spc ip Ot Btcanner ser HH ne | oy me ot | wha Sere weneer—acol |g oA TRO RTH Cr sew sev OMLIES ZOLRINBAYD4, FRAME Toole Necessory for Dinassenbly and Reossenbly ® © ® ® ® © TOOL Ne. DESCRIPTION D 07045-15301 Reem gin sole! wrench © 07035-03301 Resor ester deowensing & ostenblng too! © 07083-99001 Stem nit eoelat wierch @ 07048-09001 eairg ver @ 07072-0010) Fin Seamer, 34mm @ 07071-25001 Min switch gin sperver © 07782-99925 Swap rng pla lk) © 07054-02801 Fert Fe el eal vor @ 07790-02001 Tost cose401) STEBRING HANDLE AL Convection The seorng handiss of ail he model 90 motor @ cycles wit the excepicn of C50 ore wae formes sel pp. They cle howled to the fant fok ky being coma between the gpa ac lowe ha pipe elder ard bolted Yo the fore top tndge plate The sear onde of to C70 mace of rested @ shoo! teel yt a cortivone veel pee ge wel ddd for reinforcer ee | cr tn 1-8 | phone 4.15 C190 eeatg bore08% Mencia” Fin, 44. Dahman snc lone ‘Basia led 4 FRAME 8. Discssonbly 1899, cL 90, a. 904) 1. Hold te front take orm ©) back ned screw the ediateg mt. (Fg. 4.21 2. Dicomect he cutch cable D lower end from the chich lover ®, (Fig 4.9) CAUTION. fend eylrde: food fn when ranoviag. the bi. Tho tsk con bo sini by losseing the ehusog Sew ot ho honda lever ond ord 9 tho eb 5. Dacerract the thotle cable at the ‘hte waive D by wscrewig the exbirtor cop, pallro atthe hone vake ard than wrteotis the theta cstlo ®. (Fig, 4.4) 1 hn, te signa ond emer switch lacd D by loosing the scrowe oo Front of the heodicht cote, and dicommting te comactors witin he headish cove, (Fg. 4.8)5. onove the fow fox belie wating the hale pe beiween the upper rd lower Foliers ord ranove ho soaring hala D togethor ith te cent cables. (Fig, 4.) 6. The foi top bridge @) is roneved togoter ‘with the tn sgn gh by renving the fon fore bole @ ord to ston Fs. 4.7) Use stan rut socket wrench (Tost No, (07083-03001! to loosen the str rat Tin 4.7. fonoorg thy be pe Sep sce tm 7. In exe 0 rou te cteh ond bck enbee from the Rondo lover, leozon the ele existing hols ©. din the bck rat D 10 the prow ford sepacre fron the halo lover. Ronowe the cable end fom the lov. (Fl. 4.8) 5, Remoue the two Sram teens 10 epee the Yight hale ai bracket, ten signal awich cesertly, rol gip pga crd then dszonract the tratle cable © fom the rote cable Hinge @. (Fg. 4.9) a 9. Renee tho hox sem nit to atotonble to @ horde sip lower heder, lerde achion upp! ‘nd lower riters ond terdle aston sect from ng the harcle pee lower holder from the top bridge, loczen the 10m ex mt before removing he onde. This wil proven tho elder ond nut from fuming end fcittes Ly eens grote ati removel 1D Troe ecb” “arte cate Hoe(€90, cr90) 1. Remove the fot cover, (C90) 2. Uneoiple the speodineter cable and ds correct te fron! brota cable 2. (Fig. 4.10) Tho left bane lover cf the CT 9D & the broke lover forthe veer broke Fame tho cable ord om the hans Inve Lecering he citer mt cf ha var whl al Sopify the to. 3. Decorract tho throtle cable ot the thot velve by fist wsziening be extarstor cap ©, polleg cut te thotte ave ord thon unho- ‘okey the tect eat. D (Fg. 4.11) 4. Femowe the hoadlgt# mooring screw ond pl Off the heodish wil, iscrrec! ‘he hor, ton of tte Sigal ond the dinner switche ccomoctors within he hoasiht cote Fig. 4.12) 5. Unciew the two top bikge sxtiog bots @ fram wihin the frongrt cae and remove te ‘wo Sam hore sting mits ©. (C90) [Fg 4.13) on it of the handle ogetna with tre cer ons less, 6. Remove the far nm ho« bats to sxparcte the ferelo po ueper toldar, Thon, pall cot fe steoine kendo (D logeler with the cables cd chic los (Fg. 4. 14 (CO 90 & C90) [C180 Model fram Frame No, 0000014) 1. Rerove the fon txcke axis! at ond front ake cable fron the fron! am tio! bre cable nay be tzennocod fro to trate lever 2. Remove the fear broke cable for the rear rake lover 3. Remove the corbastor cop and duoitenbls the rote valve footer with the thot cca from the correo. aoe Hecate C790, 4. Remove tte hecdiht ond diconmect the roe © cian be spective lets 5. Use the fou handle mounting balls and resove the horde bor G_Inapection (socring hendle) 1 repect the hatte, uch, fcr broke ond Tear Brke ICT 90) cables for esr end done 2s, alo check for snoctires of operation. 2° Gheck the Inne levers for sroath cpmation 3. epect he hone pe for deformation ond 4, Check oll the switches for proper operction a. 413 Ronin te eg oy ou iret te electrical lors for danagen. ‘B etn nt a” Sm fox batD._ Reottembly 1. Ase Chin sper and tower nbe, un soral Laie rd fondle cision sotto the Sop begs ate @ 2. Aaserkie te tote on font txcke exces, rote arin and switch extaabiy tothe steag bande, Notes ‘Apply grease on both the side and ose ff he pipe where che tote gip fe Yo be om intelas, Tht & 49 Mbiceto the movement of the thotie. gp @ end fs component pas (Fig. 415) b. Check the proper oxerton of ol abl 5. Asetio mo lor top ordge alate on tte front fk ced isl te rot fork bol od 4. ean th ibs ed lca sin it fpe lest ep cies es sc ees byw bape ree tie fe ict ier Rede pean irk ete ig bot notes @ Tibor the two fwd tt at fre es bec deomee of 02 f OS rm {©008~0010 ia clecice tele fe ine Solera ces eae fiend Die eet arte ts eae eee te Comte eeu fete pas felerent se heaps ole a taeda 4. Torgus he hols 0 B0~110Kgiem (5.8~ Boh. a 5 Comact ol the eletice lead 10 the leas of th sao colar witin tre oadgh! exe 6 stall rd coraect the thote cable to the trata vave ert setow on the cxrstar sap. ‘Aalst the cate for eoperomcart of py. 7. Comect the chtch cutie to the chich om @ ‘and odjst the ploy offer Faclefon to 10~ 20 re (040~0.80 of fro travel tho ond ofthe chichleve, (5 90,90, CL 901, CD 90) NOTE: Tho acrmert of the cUich lever fre travel cat bo mode ct both clch ccble upper coder (Fig. 418A) ex at he chsch bla Or odinstor (D (Fig. 4.168) vende tron we Fi 4168) Cachet pei Fin, 148 D Che cals ofter @ ve ws8. Comes: tha frat beste cabo ord male the ismont with the cia cm. Adis 20 tot te mi Dot the broke 5 10mm to 201m (040~0.20in) of tee roxel ot the bale lores (Fa. 4.17) 4.2. STEERING STEM A. Conetretion The steaihy sian i the pivot pot for the from wheel end i nppertad in the Fare heed Bie by two sets of core cnt orl sa bal 1s mode of hgh erengih hoot necied etal to Witheand tke sock imcored by scugh toads end so tho high frequency vbration whi te to fee tho etal 2 fake bee i taton bison rrB. Disessenbly (590, cL99, cL 0b) Diosonble the lore @ in secordonas wth 4. din ond te tan idge (Fie. 4.19) 412 neg fo topo pte fat tp te pare 2. Ducssentla the ‘ret action Dn excorserco Fig. 4.20), Tho how csembly © veoved from the fork > 6X12 hes a botom bg ky revoving the fw (the hem may bo renoved cltor beloe o ‘fier te renova of the stetng stn) 648 tea to cnn 9 hood top tread ® ath No 07072~ rer () tcl 1 26mm hock 00101 cr ple seeing som cut th Eten, (Fig. 4.21) CAUTION: Co, rot top cut tho $6 sel bate ing @ Snug med trees(99, €90, cr 90) 1. for destortly, rfer to te ispectve fron! fork removal for COP, C90 and CT9O in 438, caurion When rereviag te tent fh, exon Wot hop sel tals ictled fy the storing head (Fig. 4.22) (C790 Mote! Fron Frome No, 000001) Ge we ee ces va iecion 108 0, 2 Unter cert fat ll rt Peete hss ee 2 Unc he fro i cde Ee ot tome nie le od ct 12m i — ‘oot ons) 4. Remove the front fender & es fam oie os ace pee im meee ace ts fe ae etl Mnals l faoth GA 6. Loosen the Fron euion moving Eel on the front foc bottom bridge od chop the hort fork cxenbly Loosen the seer head top thead using the S64 hook sponrar and remove the star~ ing stam cut the botton Not Exarete eae nat 10 hop he saa bls when renorieg the seeing stow Inspection 1. Irapect the 26 sla! balls for crock and woot 2. nspect sooing st for bed re ws. 3. evect the soot Bellon and top core raat and ball rocee for ciicot, wor ert sraks, 1D. Reassenbly 1. Weth sto cone aff ll races ced the stool bos, ond pack with raconetonded now for grace. NOTE: The op let after oll 21 of the sleel ball cre 0.080 (Fig. 4.23) 2, Perform the wecizenbly in the vote exceeds OF desonbly. Exercise easion on the Following poles Ul Do not dap ‘to 20) balding the inerion of He Heong stom: (2% Steeing sion soul bo fohined so thal ony © abt presixe teu tr the wel novia to ether edo under own woigh nila rag th whl ff the grosnd, however, F sill not be leote to the extent shat excamive clewnes 1 even tho vacs! sido, cna foro ond oft dlscton ‘when checked with the wheel vlsed off the grou Lod sould be between 1 to 2mm (0.040~ @4.3, tone Fou a 4.3 FRONT FORK A. Conatrction The fiction oF the front cistion is to provide ood sewing chrocerstes and tgeter wih the ‘er cuthen ord confortable ring. The front fork. in pater, mat geevent tha vibaton of he font wheel created by the reugh rood can ton fom beng tonmited to the ride, It mat te made study fo withsond the high les pos sk (Fig. 4.24) oD ie Ti 4104 fi aalln meio Capen 90) © finn ck se 1B Pie est (fet ee pr clin 9 ret ce hart coin oa ber (@ fret ton fet ber A (9 tot Sr” @ tas conor ea camps 1 beet aoe St oa 1B fer ave rer ctr @ fest cate Pe ae @ fet deme st te Tip 248 Fo amen (69H, GPO CEPOL, CLO fom F No, GORDA Rae rate ieee ioe (9 FSP ern vice ow etn Sma nS nie ( tr fo ata (0 fr foe poe se (fra foe bot ee (fr fs fon fo pon nes {© ttn eg oreBL. Disensombly (550, cL 90, cL 904) 1. Daassaniie the steering hone i occorkrce wh 418 2. fareve the weodonster exile exp fom te broke pel remove the two 832? be bls @ fren bot sider of tho oadight and remove the Feadight body. (Fig. 4.25) Figs 425 tomo hadi @ 9362 en ta ‘3. Rarowe the lt ord atom Fork coves (Fig. 4.26) 4 Place on osequete ord below the engine 2 rate the Flow whee. Remove the fort het colo me @ ard pt othe fert axle. Thor, tho font wheel wil hon away. (Fe. 4.27) Gotan al hoe aban 5. fenone the fron! Faery renening 2 ox bate @ frow each sie, (Fig. 4,28)& Renove sta Iwo fen! exshion sting bols ct thant fork boom bridge ond remax, the front sation: @, (Fig, 4.29) CAUTION: Ssfora roroeng the fet cutie, rk the Ant fk pe Oren tok 7. Drain hao ote. ine by semen dian pag beers cinstenby ofthe ower 7 fede 8. Duauonble the fork axertly by renova CO - the lover cover sta prio, over ovr @ bot, cal spieg and epehg gud 9. Uso 5 sr0p tng ples 10 wenave the 37 ea Tew ct Spe theo pon ot nh NS ‘top trg om the for boom sine 5 @ ® Fig. 432 Cenpntt prof et fo (c090 & c190) Dre eee 1. arave the handle rd th fot tp EG as aes i eccrine wit scion 41.3 ‘Bm ony ee 2. Fecove to heedign com @ by renoveg ic a ‘he two 625 fox bits itn the Feo a season oso onl the 6340 cross scion. (Fg. 4.31) 0}8, Floce o auteble stord iret the ebyna ond remove th fon broke tere te @ fran the free bic evel © (Fig. 4.22) "Sho tte oul 4. amove tte font lo nl an the Ben box ‘apenson om ard ull @ len tho oppose sid tho tert whaol wll top out. (Fig, 4.33) ee er oe ren tem LE) Pe 3 acl aaine ae ne he oa eres os Wo the Font forces! 4. Using © sé em hook spanner ‘oot Now 1707200101) renee tho bang bee! tp tread, (FG: 4,95) ah es memes gsc “ a163 Mr fom o 7. Thm tert fock con be removed togeher with Re foe eshions by seg oat the oto, (Fie. 4.38) 8 To dostemblo the fret exsion, looten the nm sf locking rat ond ronove th ent am, ‘rat bot. Aud enave the front euthicn wpose ls by rancingtho 18 jam nt, the Bn hx bel fing the rbourd toppers Then, the front ucion Fig. 4.97) oo bo roroved together with the lt xapersion aims from fhe front fo. 2. Remove tho front cushion under bol by remem FA 36. Benoni ft fo veg the Bram hex ns. thea the font hier © enti ‘can be ditertles fon the eecension orm. (Fis. 4.38) CAUTION & Wher sepzcticg the fat spenion am from tho frat cation, ee shew be tehen Yo prover to font cuhon lower dst sect 0p, cst sal and dete col from dope 1 Reove the pot st seo by unlacing the sHcking end remove: the cist sa ee pio! call. 10. The front cuicn dsossently con be perfor Ped by renovng to fron ewhion lock nit rl then removig the fon) anton sng, ‘cAUTION, ‘he front doer Kottom med sho wot bo lacspbed os | roqsres spac tools adhe ‘component parts not sod indy, (C190 Model From Frame No. 0060014) 1. Remove the ar fore ately frm he frome in occordance with secon 4.2.8 (CT90, 2 Disasenble te Loot, spring ide, front cattion spi ond ote from the fron) fork xen 3. Remove tte 37rn cicip ard separate the frort fork pipe fom the front fork bottan cow, as Fe 28 i 1. Remove tho searing hart cxcononce Oreo wih A 2 Poca 0 aie oe eg Yo rte to rt hae Ierore te ent bls tors bt by smog idm Ecins mt. fonev be elo cpl Cut fo tort es ae he epost tartan he Fert vd il Son os, 2. Ung 0 86m tok gamer Fonts Set lod op the cd dew te ent Yok cof the reed Sr. 4 Tenor 1 brn ck pe OIE na, ct ton te fort coon ket wer cd lt ber apie mares Ned by forvig te feet om pct bt ow 0X42 ex bo te ot xen cnt te foe‘enpenion arn con be renoved together fom tho rent fo The frent om rebound stopper con tart bo removed. 5. 8) removig he Bram bolt and th frm co “Hien wer tot, the fen ation ord the fos! ‘ssnersion ain con be separ. CC. bspection| 1. Check tha frat chin spe T i T mans sr | feos 1697 lO. (SBSH TAS) oma ela ee Tian 6 Tian 6 7 I ‘a a [ieee aso lewis. Greer ae =e festa | a Sioa a? — aS ealaiaaecns- a = ; gos eae me wss0mso27s (2191 200, apn wene 9085 11218 eh Front fot bovon coon 91.00~31099 .22~1.22500 al Row Heer SID C.Z2Sie) eae eet eae ad Qo ee See4. spect dist seal, bahinge ond sha or wor and donage;roloce ot naceecy D. Resstenbly ecsoble the font of dhomanby (C90 Modal From Frome No, 0090014) ‘AMterrecsenbly of the font foik on C190, i wth 130~140 ce 180~8 beu.h) of good (gece SAE}OW-30 ol fram tho front foi bol A Fue TANK A Contrvction “he foal tank @ ie mounted on the fame and hed ofthe seat on the $90, 0.90, CLIO end DIO. On ite C90 ond CTO, t loceted below tha oat ondis he stuckie-on which fe eat is mounted. (Fig. 4.394, 8) 8. Dieosenbly (590, 99, cL901, cD s0) 1. Tan off to fal at the bation of be fer ard disconnect hs fal Ine. (Fig. 4. 40) se eateg nts D and rove (Fig. 4.41) 2 nD er mnt at Sen3 Widow to fel fork D from the roar, wong 1 alloy. (Fig, 4.42) 4. Ta remove the tak sie cover @, remove ‘he ‘mo sere onthe enblem cre hen unzrew the site cover boll, Side ‘cover forwars vo renova, (Fg. 4.4) @ falta Tote sre » Fool cock con be ranoved by fist un weg 9 fuel Brame cop, renevieg the Met sexe ond thon te or ng bmw (Fig. a) (c, cr 90} > 1. Tam of the fuel cock, aconract the ft no ore chan the fuk Fow sto tk 2. Unicow the tok nouning bets D lates ot eth sds of he tk ord If of the rk (Fie. 4.45) _ Inspection 1, Flush the nile of the tonk to vemove ony teal oF char frsign rato. 2. Moko sino tht tera cre no look in he tr Fig. 445 ey el Yak a Gra ton tg tat folD. Rectrembly Porm tte reosenbly i the reves orcey of dissent. NOTE: (590, CL99, CL¥OL, CD90) 1 Make sure that the fas cock gate! is In (020 condition befor Ivalltion clo that the fel seal packing is on the fist cock ranting sau 2. Use the proper so bot (6% 10nm hex boli to isl the side cover on the fork Long tol wil botiom on fe tank on est vn parce (Fi. 4,48) 4.5 FRAME GODY A. Consriction The frame ie bocitons of the wotereyce ordi feckout tis tha the motorcycle is desired. Fact ts tho vory impotent farce in det wii the ratrcyce shying The ost inporont fureton of tho fone i+ vida the recesary stent f the ete nota Ir sppors the ging, the ker, congo mo though the tet ord cation, must withstand the shocks pedice by traveling over ragh rook Furher, from the soit of steering, Heh dogroo of rig is roquired cx on re other hand Fbines is deed for veing pefomerce, (S90, CL 90, CL9OL) (Fig. 447) 3. Dinossenbly emove the east in accordance wit section 2 Dhawerble the frome body in. oocordancs witha section 4 3. Remove tte ma ignition euch ® from the lot cortor of the frame wing the rain sich book seen. (Too No. O7071~25001) (Fig 44) (© S510. hs toh rome tas $99, 500 4st torts nc on ch @ tice ech ho er tah tonDonte ted pe nD eam ma ' oom 4. Remove the seksiie recs, anton wite hromets and the sop switch asendly tron te frame bed 5. Renow the stot tals ond dive ut the to roce® fom id the eeoing hos pe @ wit 1 wooden or fiber alt @, (Fg. 4.47) Ce Inspection Inspec the creat ote he fore cn, bicHng cctnd the ood pipe ond other drapes 2. Inspect tha alo of to hod pice end for Sitcten 3. Inepect tho ep ord borem bil roces for ‘ling, wear ond dene, NOTE: “ho ft borween the bal racer and the hoot Pipe’ ~0.003~+0,0081--0,0001~-0.0001 When cng cut the ball tee, make se that they ore dhven out fury. 4, rept the frame for tuelss, donogas ond ‘ho conten of te si. , Reattembly 1. tall the esl ce by divag it io shige without tte, 2, Mix te stool alsin gieawe ond ky the 2 ball Into the Yop ord the boron bail races, S. Ital sho repective electreal expan! in ‘he reise cde? of lasenbiy 4.6 SEAT A. Conststion ‘The sects on all the miaiel ae provide with ‘ite pain for ated confor. Flr, el the sts re tarde with he excep tion of he CT 90 when ts sngie. ‘A tool bon ie meted on the ottem of the saat cht side for $90, CL99 ond CL9D., B. Disassembly (590, cL99, cL 90L) 1. Unscrew the Io feat omibe mis D Neen toe dar tho each. (Fig. 4,50)t @ by pales yp end bx (Fe 451) 2. Remore the sea! by plfag vo a [cr 90, C0) he seat Dard detach the 4.53) “ Inspection 1. Chee he. seat covering for teas, broken Do 1, Assontle the seat ft fool box @ for the $90, CL70 ens Lis attaded fo the Kellan, it ado o ect, Tifton the we eck mt te preven (Fis, 454),4 pRAME fr oie ore Qa bes om 1B tae be fo 4.7 BRAKE SYSTEM AL Constration Good bales ave the mest inpertrt tom vequres| for sole vidng They sted clnays. be in. ‘oie! inthe cet of cordon The fet brcke 5 cpaated by te ght hard inp harcla lever ond the ror brake by the lot fect posal Tho coor broke cn the CT. 90. con be opened iter by he rg foot pedal or the Ia hond Pay ts wen eee: pen! ‘steoring handle lever, (Fig, 4. 55) 3 txce bane 1. Dicxembly 1. Front hoot Lrcke [all model) (1) Tovenove the fort tke laer @, remove the hare lear pivot sere on rea font brake che by aliging te giaores Inte handle lever ard tte et © (Figs 4.56) aBy removing tho afusing ns ct the frent wie the front beoke cae @ can be ranoved fren the Fen bake om fa ic. 4.57) Frort broke ($90, cL, cL90t) enor the Font broke cable and the specdenater cable ® fron the few brake pre. Renove the de mut @® ond pull cut he ace @ then tha fret bho. pel con be romeved toga wih tha roc 4.57) {c090, 90, cr 90) Discorect the. epectomctor cxble and from trcke cable ©, remove the costa ut @ crd plc the pana stopp batt Thon lesen the two Bim nex Lot 8, ot tho saeponon orn. onl rencve the ale rut ond pul ou tho axe “he fon! whee wil hop os from the fro fort. (Fig. 4.58) “Tha Font tke shoot D shat bo removed fron tho poe © by spredina the shoss galt the tecko shoes sprig Frese and pleg of (Fig, 4.59) tron trae cole Fla, 428 tenor Set tre ct © sector eae” Crile ot eo seperti ig. 459 fenoing fet le am ‘@ trom tre howe Frew br poli lg, 0 tenonr oe pec nf © vse pe spre Store 0 a oI SD semere a oa @ fae ate re sr 6 2. oa beck pad (599, cL90, cL 90t) Remove the rr. (For C190 ond rooval of mur wil rot veqsied Remove the broke posal sping © cd stop ft site @ fro the bce posel (fig. 4.60) Renove tho Qe eater pin D from ste cr bre pivot pipe (Fig. 4.41) Renovo the text belo dicteg ut ond renare to taka rad fiom the roar brcle tanaie method i to renew the 1.5 15 coer lo of the rar beck pase er oor brke tod in. ‘The rear broke pedsl con be sonoved hing the rox broke piv pl Ino the hole by taping with « rod and hammer. (cD90 @ C50) rvo¥9 the mir Renovo the iicke podsl sky ond the 0p [ght pig from the bate pedal Ranove the rear bicke oditieg ret ord remove the broke red tom the ake ar Renee the 61m mit from he roa bebe nd tear broke po pipe ord rotors fe eter pla from the cppasie ec (The renova con be paiomad more oxy ath he live chin cose Laver ball © rove! By veneving he vou ako give pce, the rte pes can ba reread CAUTION: The rear bake pio! pipe is conmonly tod fer ho main tnd, taelor, belero remark the tear tke lect ball place a ssicbie vond ure the erg ear whoo| cso vafor to section sia “Tho roor wheel can be deotonbld the sme manar os wih $90, 90L a AG Rove er tle ra em er ote om e750), “@ won oat vt @ ble ow 1. froke pode dsonbly a a Remove the ticks pada phy ord the top cht ping from tho belo pedal. Rorovo the bake cdstg ut O a « rove the ror bolo rod fom the rear bake orm (Fig. 4,62)(5) Remove she reer bro eatle © from the rhe rod ©. (Pg. 4.63) al Ramer the nr fe tt fram theo broke pipe ox! conor the cppastie en By poling a tho roar oko pice, te take ped cin be, rroved fcostor with 2. oor whee eaten (01 For dlasanding the mcr, whee, rela #0 the cover pn of soetken 4.13. 4.8 MUFFLER AL Construction Tho mle ond cus ip have been mode fo on Inloal wat by welling 1 grealy inerove Fro aloncingefectverese of th mul, The ree 1s firhee wean’ by th inception of ee Pipe tha my out. 8. Discssenbly (et! model) onove te two forge mcg ms fom the ‘Sohaist pe Ange ot tha cyincer oss 2. Rowove tho nue atocheg the muller brackets fo tho taro of sever poi Tha lectin of the brockets wl vay betwoon the cilerent models 3. Ths cfr pipa canbe removed by uncer. ing the 6X8 hax bo, Rowovor, te fier pipe is not ronovatlo on the USA expat nas (Fig. 4.65) C_Inspecton |. epee the mule ond eat pine Fr ku ‘hough Seo. loge dens eh may eee per 9 the mur cl aco! ily wih 2 ween fod ord shake cut the loosened entban pitiles 1D, Recstembly Featien the mor wit in poco, mag xo fot he galer & Wstad, ort fat ntl the exe ipo fnce to the evil head tempor ray 2 Tihian the tracer bats cd the fally Faken the fags, Fig, 453 ning er St elle D tar bc ee © bis ee 1: AE mtg an pre ‘@ oer pee @ bxB hoc4.9 AIR CLEANER AL Construction The i cleanse cowais a poper Mier clone 1do to moxie o ite: fro srloce I 5 signs fo porte he corbueor ‘ihich is eorugtod 10 a0 withthe crater volume oF cl ord least orcent of det, atsing maxinue powcr cuput and ond cance frow the erg The at cleaner i sported on the fone or! ed fiom Tle, 46 Ar cote (350 enclosed 50 that 1) is adeaztly © Ay cao the rok, cist end other avers elena (Oh the $70, CLIO ond CL FOL, ta fitor ie tecaied ot te contr of the frame below the fel tank (Fig. 464), fr the CD 90, the iter is osatac ‘on the left ede fame center, For the C90. a C150 ly of te soerng 20, Aeris located nthe B, Dicnenbly ($90, 150, cL 901) ‘one each cn the sgt ee ef side end take of the cover @, Uncaw th et cleaner mening bolt @. (ig, 4.67) er Ye tens ee cere oe he Se St ve, te oe id che ener case 3. Remove ta or cleaner cornecitg ibe eam from ct the ceorer ord though the ar clearer comecing hbe gov. free the cir closer ‘lonon By pg Towa tho rear and whan lsergaged fron tha hee, sida the elonent out of te exe. (ig. 4 68) “OD arcomme sent @ hr de(0 90) Rene the oir cloner con cover (D) mounted cn the Heht side ot ha cator of ha rama. The ir cleaner clowow aay be removed by escrewing tho attacking screw @. (Fg. 4.69) (C90, 10) sere the cao mvt remove the cover @ rd pul ot tho closer erent. (Fig. 4.70) Inspection |. Replace ery clamor which is doiomas ce semoges 2 Clos te stonent Dy fet topping Inhy to foe te dint ond thes bow oF the cist Ly aiving ory ccnpested ot fon the inte Fg. 4.71) CAUTION [All lode chat mat be renoved completly cr lie the det wil be then ilo the eyeder ond D. Recssenly Poon fe reanenbly in tho roraxe onder of eesoebly. 2 Baasng a srr 1C0901 1D cr ena ever @ Ae coon exe 1 Atoang sr ge 4.70 enong 3 cate (C80, CTI @ cop at Ae sie bre2 @ mcr eatin ae Te 472 teria rer what @) ta viet Figs AZE fang 0% fo Gm 1 er fo on 4.10 REAR FORK AND CUSHION DAMPER A. Conerustion Th tear fakes © swinging cm type deen supported by & sprng exon dope" ot the roa 7d hingod othe fet fo te main fae enter ‘Wen the rear wtool i In notion, the fork puot Ths hirge pin fs close eraigh 10 the. chia tive sproctt Mot he moveneet ef the whe! ha vor litle eect on the chain tron B. Discssemby 1. Set the motorcycle op on the mein std ord eno te roar whoo afer Yo Eeeton 4.138% Faroe the dine ch ich ae 30 eid, 3. torove tte rocr phon donpor lower bal fond detach the danger fern the reo fo 4 Revove he rear fork pivot not and seporee the fore fom the Fax, ese on the mode C Inpecton |. Danoged or wem dive chon come gasket Sod be refoce, 2. Check the roar fork pivot nkter basting for anoge, excesive wecr ond ogra. fee Bean a | 3, Check he rer fork for alge, veplace it Wisted grootr en | nm (2.040 D. Reossembly Aorble fok in te revase order of dios sony 2. Indl tho wheel and dive chin, ond edt4.11048 Fm OLSON oawret a1 4.11 REAR FORK CUSHION DAMPER AL Construction The roar fork ction damper @ col tye wih double order ll lyse danpo The eck is received by the danger and the reaction it is ‘rote by the il caper Tho oll dowpar con. fore dee. of SAE #30 shah sina (paatin) al no spociod arcu impotence the shock sarng eect ithe Fereased or dinnhed ie porartion tothe arcunt of Aid. (Fg. 4.76) Fa 74a eto vow of rn anton (890, C190, CLO) B am ether ea Der cols ae ell De coos ered Qe es ed ree {Dex cates topper comer Qasr canae srs se (© tar chen Ic (@ tee clon pt bk ceter (@ ten ents ok (@ teu ten on oo (0 te ashen er ee Tas A760 fon aon (9, €T00 tan nee fear ever te (@ fea cao cl 1 tas: dope fd ote fe can tains op © tow nts boon cam BB ts chon reg Bes cnion grag tar extn oton lt conte @ tes eon rer De5 Dirotrambly 1. Remove the Bran apper ond lower

Tun sven commerical wider clon Tha teppet cloaarce odisinant for ell vaver xo Idol.51 MunTeNance Weerend ns @ NOTE, 1. The odie mat be male with o ecld phe. Chaaurce is neaed with 2 0.05 rm (0.002 #) tetaas gums 2. When locking tbe adisting som, hall the 7 Serow winks long ta ne 40 prevent te @ fume. (Fi. 3.4) 3. Ipocton 1 Ghost to md ao tht the topet cleranes is win stad flere, Too anil Joaencs wil case re yove 19 soy open, ing posi leckoge ond roing in WS. 4 tokng tm citeg mF oO stating or no stra ot of @ Fm meres 8 Gheck for proper vohe ting. ae © Chock for erate in tho com chia 4. Check fr ay sips ofthe tng sock kor paint servicing ond gop adjustont 4. Remove the dynamo cover and broker pote lrpect bo srlocs of the txecker points Ihay oe tam or pied, sees tho astoce vith on olltona or o port dieithg fe 30 tot the pots cro neking parol contoc ‘Alter th points have bce crewed, wosh in gotaine oF sieioromhene t ramove all race of ol en Aang ne me core Tun the ommrctor rotor crunlerclckaise Se to the port vine ‘te baler porte xe beds om ct maximm operina, The roma axe D = 03 to Cem @.012~0016'0. Faxjus- now ie roca, lcoeen tho two broser fom caljsing screws @ crd move te satiom ‘ry breskar pot by faring a scoudver Ino the aducing ot to cktcin tho prorer ‘cap ard than rtighen fe crows, (Fi. 5. $) Irsicent booker poi gas hie (o} The spak fend to Inger, tat i the etenption Of the pena Fest no! eonptad ab the poi torelor, the seseday ch vellogo baldap i rece (©) The comed aroton of tte pitt ie lenge, prodicna feo! ant reaitirg i damage. a 16) conpncton with ‘chore, the pots wil bo le In operrg cauirg« delay i tho tition firing, te will eure © doo in power expt. Excasvw brcker pont go fe) The eatin fect the pois eve closed ts t00 fort f0 ab for slfoiert cart ow In he a inary cicuit with a conaqent Jew veliagene 5 mai09 aDnTNANT 7 Lnistup in the socondare oF the hgh torsion - voltage cra. This eardton wil cau pace feghe sioting spat mishy ol high speed wr 9 consomert Ibe of rowan 1b) Eine overhoaty vei, lel The ignition tning i grony ccna 4. ‘aston sting oclurtmere 2, Wave te becr poet 2p ht been ‘dha, to ‘gion trirg wil be ofeled ced therfore mut cba ho rete 5:4 Aeon ton te b. Wh te rare ear removed, rie the ore, oso rior conterchvte wil to ‘70k on the ytd bes op wih tho dlgenrt ak ® nthe ser (Fa 5.6) ft poston the broke pa ‘ald jon conmnas 16 cpon. Th con bo ocd who hin fica gauge. ed itt 5 recarzy. late to bo poe teens ® and roe te tus pie D by itoring « soendive i te eating st to aio te porartng. (ig. 5.7) The ste ignton ag ty osaucte cod wil ve ately ege parlerae, however, te isa of the service evr il re a7 eee crane ro mot prio Fine. Wefer fo 42, Meta it ‘ert inter orm ‘Wher ing @ stato tring Foi © 10 tec tring, ide the erin ot 1.200 pum (Pg. 5.8) 161 Ferd out of ting, prom te cdltren te sone momar deabad chow. esis of raed gion tg 1. opin pwar au 2. Siste temo inl crash 4. fag overt ith a posshity. of pion ous of ohoread Igiien sing 1. Peden locke ord dp h power cu tr sovorn cost, dnage 2 on, correcing Oe ee 10d, craishott may cont, hersfore, paride Tenant trpecton shoul bo pefomed. 2. Upen canglo‘n of the pont gop ond itn tiring esimert, chk for aroper cpoiain ofthe spk odvarcer wih tha service tester @ma 5. Spark pha edlustment A dity oF danaged soak plus, er ps electr= det which fe ereced wil ot predict a. good strong frat, thoetoe, the spark lige stuld bo Inpoctes pedal ond clergy end ociatnerts rroce. Spore plge wh tomy, wat lactodst, or floctodes covered wih deposits will peri the High tenon vabage ta bypais the gop wiht seoting 1 Clarina © The ue of sta spark pip clawrer i the recemnended meted cf cleaning he phet, however, © salfactory chong con be parfortod by urg 0 nasslo or si wire fo venave tho deponts ard then woth fh (asline flowed by dyke wih compresied ot (Fig. 5.9) b. Adust tte spa gap oftor cocina. Sot the gap 10 06~07 rm 10024~ (0.028 in) by tending the electrode on the und side, Fig, 5.10), 2 Sean Pig Wspecton (2. Check the soc intently produced between tho gap af ta ground and to carer ec Ble Spake nneees Good contin Fed 5p cs reesen Poor contin Caze die 19: 1. tow spay vollage DeFoatve ‘gntion co¥ Defective spa play No sparkrg ray clio be ds 1 com prosion CAUTION: 1. Dp fot rove tha depcehs by bung 2. When ‘telling the spat piss, coon the ssoting ees fee of oll oF faoign mater ‘rd intel fngor tight before toxging with © peg vronch 3. The spa puge can be tered oor ci ret, wit the play taster. With the high tarson voltage maniin conlent, vary the fox ehancor prose and kepect he cond. fon of the spk ra, Lo —-, D Fig, $9. sgt py deo @ get ra SD Sea pg cone te 05~07am (0024~a.0%) 4.10 Mecsas ome@) Fal eck lever @ fat Fig. 5.124 Glporg el shar 99, L90, CLO C090) O-o"me @ soe B fan arom on @terne B seven 6. Ful supply syster Restcen i she fook wpely syst vel) prevent ufc! Wel fow 9 the cobietor ond coe ine to sper dung eceleren or the engine ray ea ot Nigh spoad a Chak fer affine Dicemect te ful leas tube © fom the co: fu fuel the tank Iarator and chock the ool dow with exch hte ON cr the ® postion [Fa sa) lV te ‘ue! aw is inert, smove the fue cock, asenbi ond cla, When the Pow i ail inadequate, ronovo tho ‘uel tank from fhe frome: boy oe eon internal CAUTION: D The inert fst Now may ko eawed by the plgged vent hole inthe filer cop ot wal the reticton in tho fel re. © The fool cock is se/lced 10. B (tered from the ON poston ten the fl tok beconoe eno Fe. Peal stcinar cling The fowin kskrent corse in the fel pasos tog tha fel Heo fom tha ful trk end ‘nies the scner cue, The freon substances and ‘voter, if not amazed, wil eter the cylhder end cares sci foe 1. Charing Set te fel cock tert the S postion 1 Renovo th shchar cap ort ler sic. © Chen tte sche ap ond Mer scraan (a. 5.12) Nore (© 0, C180, The ful enone ie neorporared tho rear end ofthe corset 8. Oil Alter sermon clang The mine cil is Miered tragh © system of ovbie ters bafre tE sipped to the vorout rats of the engte. When iguiies have eco mle the fers provent ts proper freon Mio ol szey to the varios port ce starved ard evertaly seat ia seiure ord damage to fergie. te theaore innoron thot the fit: be cloanos pail.@ 1. Cheoneg 1 Fareve the ick etter pac 1, Ranexe the right cankcozo cove, pul out the all seen and wash In gone. (Fg 5.13] CAUTION: Install the ll er seeen with she nano fopered ge toward the side and the Pe on tte fier screen tonard the bean. 9. Air claoner erviing ‘An of clearer logged wih dust reste the free possane of il ci ard rea in powor lone Gop in acceleration, thvloe, 12 ase proper erfornarce, peisic clearing of tho ar ceoner should be performed. 1 Reoval. (Fig, 5.14) eles 10 page 98~99. 2 Ceoing © Top the clean elerart itty to loeen the dat cr thon biow chy cannes or te sider ee 0 rath tere ‘ho at. (Fig. 5.15) caution. 1. Ar ckonarslenent ie moss of caulon ace: fale ord deorid cr dvaged, tik port sss 10 erter ergne cylider crt case orca v0 cyleder wor 2. il or water wil ene he clones to become ‘dogged orl wil eesit In lawned angi ex: 2.1 MANTENANGE PECTIN M@ Av dmner Sento @ AY cece: core 2 5:16 fw par of eth tere & FRONC AON 10, Clutch adjustment The fiction of the chich 1 rout oF dr ongzce te osary power podiced oy fo he tonnission. the cir borg compoely dizegaoed, te mot eye wil dat moving with @ jl oF he engho wil salou On the citar ar, f tha ech ts sping. she seed of the noloryse wil og’ seboton Yo the engine sce 1. Lever lay a: 17st heh tle Q 1 re nen oe Thore sell be 1 to I.Benl04~06 10 of onan free ploy ithe hich lever belo tha cltch atte 10 deengane, (590, CLP0, CLPOL, D290! (Fi. 18) 2. Adusmert (590, CL99, @.s0L, co90) The dich love poy con be alisted of the lever by looting. the lack nt and crowing ‘ho aor belt in or cut. Cr sore model hove Te oso @ proien t pafor the elustnan OF the cojeter auping loeares most on to che cable The froper hich lever ew tard said te epproinately 1~1.Sen (04~0.6 when 1s eae ane roccaze! of the ord of the lve. (Fl 5.17, © Gach th er ofa 1) (C90 ond C190) The C90 ond C190 are equipped wth on evomsic chich ord, thesior, door no! have © clich lee The cltey ome csutirg toon D (Fa, $.19) ocean the lack mé @ on teh un the cite crow D 10 tho it, ting @ rower, ia at baa ed oe en Whe erga dete cia sm rd ft the ek wl Tn ot prove fe pee teste don Wes are 2, By tba soba scr i te cach a ee ervcomert Ge domed ext flat sane wil be gies. trracten (850, CL90, cL 901, covey 1, st heer sit Ho fw ee, ‘Neg ud bs encod tics cay oF Sel fe pc ince 2 Mee eye deel cee exh clack ler aos ros5.1 MANITENANCE REPECTION m Qa (€ 90, CT 90} 1. When she tons i difted to low goat ‘while the engine iz ing, the engi shoud ro! sal or ph 2. As the tte i cpenad, to notoeyelo a sheuld sot 1 rove cody. 11, Cerbureter loaning end ediustnant A dey exbucior or cxburaor out of otis wert will coe foor erga peformance, A of fecrpe, © existe eat Yo 9 lan fil or ite Wl coue the engine fo ovebes wile © Hh fg, $20 twa tn caer ¢ vviewe will casa erga Yo nn suggich. An over thea sep acon ‘owing of fuel from tho cabicolor it © pombe B av fee hazeac, thle, prose ecrng od cat- wnt leuld bo pom 1. Cheoring ©. Disssanble the exurster ond woth the IDLING SPEED (RP) pats In gvolio. ee be Blow out the nozzles with ccrresind ie » cand olter chong ert reaxonbly, make the i, ocjatert, 2. lle ojurnert 1.400~1,600 Tho flo oduenow ic pofomes with both ha ei a thotle slp screw rd the dr sow by tho Felling proces (Fig. 5.20) Fie, S21, Mia seed ste tle ©. Set the theta sep sew Jo the spolfed lng spss. (Fig. 5.21) 1 Now, asi tho ie sea by ting slowly fon fo kts the Highs angina in both speed. Teg the srew in wil pradice sich fun nieve. Trenrg tho srw ot wil prodve © lan Foal ine & Rathco the engre speed whier har gore vp in fel fo tho spectfed HM by roguatng ( the tere stop screw At the tre Zep ser satire, recheck the cxbirelor aistrent by rerinlating tha © Mio the idling adnan! hos een com Pete, chack the estaetor by snoring the ‘roto oe ato check th thot rospoe The ce screw shoud beset 10 Ys tum of tho spucit eating. ale 10 page 73) NOTE: Al edstnen sell bo nats oer the engine hos alched oporting tempera,Fig §.22 feos son oar & RIOD sONETAENT SE ‘OuTStE SE roves _| renverarune | _ crours “cr #30 154 p60 200° #10030 24 Speed of pode Lebricting Te pupae of lbicotin & 40 proven) dec! taroce to euace covtoct of the movag pars by frovicng 0 fils cf il batweon the arlacas ond fherty, reek ficien ar peveriag waar. I ‘ko series #9 e20l he pate fon tte hoot ro cuca by feren Funer, ste hb penctes betwoon to Fislon ond cylinder to form sn ol fl ich a 5 0 sec to prover lose cf the cpr presare 1. Ferts not requiring periodic oil chonge oF lubrication ‘rs ow some pats Wech enly roles fet ion wheneier the pts xe cuawenbd fr pein er replaconort, Tims oe ‘Searing von sterl bal rd core rane 2. Froine oll chonge Chaos oat 1,500 1, 000 fe diving 1. Ol cenge ‘8. Remove the oll cao end cin the engine congleely of cil by unscrewing the dia lig @ et the boion of tha engee. (Fig. 5.2) NOTE: The cll shoul! be cin wile tha ange iI ser, 1 The srcpor cil level Is Tested by the ol eneen tte level males oo tho gage wien cheded widow sown, (Fig. 5.23) (08 exeaey Aller evetsing the on wih 09 11.9US pit, 1.58 pin of of, Foner, arg ol congo, rfl ozcacing 12 tte vel once. Ol Ber ont Coo The sre of ol for the ceason is shaven en the @ conkozee cower. Usa te oll eorespon: dng to MS. DG oF OM ip the APL. soniee clsioction (Fig. $.24) SAE 10W 1 SAE 20~20 ne SAE 30 SAE grip 10W-30 le on of i ond nay be wed over the normal ronge of cide tonporave,@ @ Nore: 1 Ol poys @ proment roe fh the le ord tte lle foe perlererce of cr engion tterfcre, t= vary inpcto tat she ol honors be cetforeed percically end rfin fiom wirg city cll over along. pviod “Tho mare froiont tho ol charge, the bar is for te eine be When safling cr esting oll i sould wot bo filed cocvo ho spociios lvel. Over firg. il cove. ell purging ond less of pow Use onty 1eznmendes ol 3. Greoring lubteation ‘Appi coat tote sroee ieple with grate on util fe gems i forced of ot the dow tances. [Fi 3-25) Use mtipupose NIGI No.2 gree Nore: (2 Cloon tho det fom th nipple bofow goa Fi tte grease gin nozzle seavely 10 the ripple when creasha. Exasizo coro rd é0 rot pot the reco 0 become containatd with det, dst or ined with ch Drive Chin Adustment Ao excenively slack sive cin wil cose chin 1 whi, wt cortoran conden wil produce resstonce, retling in loner power utp ft the rear wheel. Alvays mtn tho chain or ‘hs spect tenton, Tension Checking Focedre 2 Fevrave tie aspectn hale cap onthe cha nie on cect 10 so iF he tal vocal sek of te coin keetween 1~2cm (O4~ 08m, b. Forlorn cdwinsrt Ly osmiag the ado 1@ od sloow mut @ ord thor ods wih the aciita aut. © [Fig 5.27) Tur to the rit to decrose etan lack, “urn 10 tha let 10 Inraae chain sock, 2) ManT@UNce NBMETON ua Fig. 5.26 pect eee at teen D beomen ble ep Fie: 5.27 Adatag te ve chin 2 foe mt @ Sane ne B Minne © astra ntem (04 [~o8n) B. ® D 2. 1 oe eee pots is Biter oe the llolne to the sido do not maglect 12 perio tho pasos Fxpecton ed comoet ary CAUTION: “ho cxers shold te ofthe sone ofgrrent nas for both the ght nd lat eee afer tha cxjstnon! has boen corglated. Pevidicaly leon ond htrcate the chin. leek of oll wil eno the tein ts bird ard renting ie axcasive woor effec! to the spo Brake Adjustment secret 9 matter Row mina. Front broke athatnen! lever fee cloy (fig. 5.28) The foe ploy of tte eke lover, that he dorce Lehveen fhe natal atte cre ‘te port tore the Erbe oll stoud be 1~1.5an (0.4~D.6'e. Adjmimert node by the edhstor nt. (Fie. 5.29) Ten 10 the fight to dectem the free “Tur 10 the lft to icra tha fo oly. Font baka axjzient can oko be ace ot ho font beak lover on (Fig. 5.30) Tur tho oahatag batt nto the oe holder to inzease to leer aloy ond sow the exsrg tat of to. decreaee the phy. “itten she lose rat) ofte eebeonart Rex Leche ase Pedal tee ploy The free play of the eke pedal, hat isthe dterce between the roma cttiide ort ho paint whens the brko tare to tle held deuld bo 1.5~2en (0.6~0.8%, (ie. 5.31) Agininent & mace by ‘bo odustir ne. (fia. 5.22) Tort © the Agi 10 decroaro reds ple. Twn fo the left to fneense pede ply. When the tecking sole tana th flow ro condition le separa 191 Teo small © clesence Lebveen bre pore ond sto. 2) Lost of tein the Bote sina 8) Boke Ining damaged ce 16 overeatingB.1 MANTNANCE ReHECTON ns Muffler Claoning “he fincion of she ler I 19 ute tho rise ‘of ha owt gorse or Ht k entzed fiom the cenbuston chamber, In the preeos, the. carbon periées inthe gos accurdotes on the rafter arc fhe sii clpe, Exeas accurlaron cf tho ca ton wil reiki the flow of the exist eas creang tock presare which flees the ergine perlomree by lomring he power cup. 1. Cheng Rene the clfier pipe lckng Lot ond pull 0 the difieer nee © (Fg 5.33) (Gihser ppe nat renovcble en USA expat! Tap te pipe Ligh 0 remave the cxrbon fond then wh in solvent cr The clogging of thea cai diop ip the ongieo pom fon et the gait is recta rose fron loal Fe Spoke Toraung eing with loose spoke wil place cn wife loading on the rin a2 wall os on the renainng soles, terefere, the spoles shuld be ispeced leq and retorqued when they become lose Cf te Goad ond chock each any soko wih ore neticscbly 2 temed to he sae veluo 08 the ronaiing erolez. Use to spcle ple too er rot whoo + 4 ear wine: 8~2 L : i @ tong bat1G. Bettory Impection ‘ctxt lor long replenished paredcaly. Wien fhe eectalyte level dope 10 fe pola whe the ate 016 sxpoced i wil zd A hs aitry. Thee he baer shoul alos hha mcrtoind a the proper slcroiye ive 1, oorelye tev Rerove the tty box, connect the bony eabio fom the sot, unten the = totery cond ore the rene the boltry Oem (Fig. 5.35) 1. Voliage et coch batteries ate ot (Fig. 5.36) © Alvays moilan tte slctolyt level cbove the lower alecoyta lava ating on the batay. When roplrithrg, 83 detied Bia olor to sie the sects ve 0 the veer motting. (Fig. 5.37) 4 Replonsh by onoring to ory exp ot he top ord oil the. dled wore Al nee borery eas thodd bo Mad 10 the sore level 2. Daag! and diy Baery eat comecor hreoct tho comacters for elects ord danage. Cl tte diy comectors ot rphace ‘ionage! comacter: tafe rokrg connection orc arply 9 c2atng of etecxe or vaiaine on be carrectos to povert cttcson sees TE cesieis EEE tee octyl Aken ca gum eines ha Wace ree fae dy son ae Fis space ieviy of 1.280 ot clctaiyte tampa: votre of 20°C (60°, The specie geviy wil vary sonairha wit the teeta el the rate ©F 0.0007 specie eoy vexatn for each 1°C |8°P change i tener,@ SA MAIENANCE MeREETON Arse in tenperaure wil cose a decree = fn specie gavty and vies vo. (Fig. 5.38) CAUTION: ) De tet ed ony sire eek to the dsited loot wen replenishing When the chop in elects fovel is rapid ech tho dichage sate of te bate. (91 Greate coe no! fo inch the bay ould bo paid 10 He folowing. pains when "iro. (0) Alte serieg. Wear up the engin for 100 inks et low speed. When he engin Is old, the vicaty of tho oll is homy crd dot ret poceit aio.6:2 AINCDIC MSFECTON MW SAVIENO ‘gee Usiction to all rot 12) Do rat race the engine neds. {31 Rofran from abupt eccsleion cr being, Yoh comeing (4) Chock banery siscrelyte level wosty wih: ft fol, Under the fellorina caters, heels shad be male of a reve Feqert interes 1. Rideg in moms ron. 1b. Moro fraert iepacton if nacasony vibon idea ot Heh apec Periodic Inspection Povedie eepecion ad sxving Soll be pefome! in occornce withthe Folin tole ~ ‘300 | 1,000] 2.000] 3,090| 4,900) s,000| 4.0ne| 7.000 e.000| »,¢¢0_ 19,000 11,000 12.000 a | 103] Seta] £20] coup] Pet] fe sz race aca tsoua tocn 109 cmd [wlele|eleleielelels leis le ae Gam ga pg ho tal ore aang gig egeas Geet bay eaeele! : ee lols leleleler= Fern the pail hspaction on the scala wianges shown the chat to minian the molreyele In the poak of condien and ke ceswad of astensed treble fise serve.6. TROUBLE SHOOTING Is nos import tot the cae of ary teuble be Iocoed os soon os posible ard pestve comectve ction token so fat the servceobe fa of the engi wll bo evterded, |h tho Following toble re Isted the troubles, probable cntas andthe conectiva ocfions. 6.1 MAIN ENGINE TROUBLE Teas Frets cam I ‘Coaha an 1, Ceased fa a ‘Ca ord ect 22 Manel ot tle fn a cp — es | 5 ines et nealing ro or maknciow i wamae | elev wl slap 1 Gite la pn wah fecha isto ot | eon fat | Esco cleo fish sae | 1. Ot being pinged ino ita cantston | by che cam, roe ale ope ‘ove coer) ‘sto oseninly wow | he prs eed ‘adr, er fr Sd ‘ete pedicel our We sep ef | Was pn nd der Nese The emotes Ear he pon ond 2, fale comscing of, toe wd aor Adal t pepe denon 2. ies mech tl Taps ond eden toca Onteaia oa 1, Cote dest anion Drama ot am 2 Oho foes st po 2 Chay ay Fn lp, ce 2) lasses ee ea to ‘cei pa conn fon 4 nme tenon te ie Ca | 4 Aa pide, Usiare ee |” Mim pees {hove cs u 2. pion nag ot of etm @®T nee = eli wie ov |, Coon fa ek me 2 fed ees ne eee dose ity pe up Deny eaten doo erst i= loa tna oof fine tie oe eo incr tps (Ceoied toate Teas fl cimtin | Chain Conon tear pat 3p ot sua ay Sort fs seaman ot Defeat sok oly ede CCeoge or caw Iter yng a of ast Teor wate were ar wt | 1. Geog oF ier i aa echoes cease aces car nea 8 Upien Sing cof edie amare lf reed ‘Cov pasar pit Sort | Aan po crtin rote ean struts othCCondener test method ‘Alt toking the vesktonce vole with he mage tee a copeer wre fo shart aziit the tenirol, © grad hora srk shold be poskced of the invanes tho lad oe conto CCondanser meararement With the cortct breaker sokt oon, mecre the rcstoca berween he primary trnint ond the ciler sol, @ good eoncereer oud be meaied ff kest 540 rosstrce ct stordard temperate. “ho condone is delete f meses tolow ee awe. pate cAUTION: oom or intn cf tn contre or ty toenail exe inion to marion 4.2 CARBURETOR TROUBLE eal ovarfow 1. Contansated fat e 1, Remove foat chasber oe ie S ee saeco anette a it lodge in the vel od son by moaenke We v6 2 Domggud vale of vl sat 2, Replace tet the vaive and valve seat 3 tos fh Hea ais om ee (eateg weer) tare te fea f ot ator 902 Becwen, moves oo be and =, eat a Tank €.92.F01/C19D ard Der ot Pom eed rien So ond it fhe past whose feo porence ot inernes ee eee eee 2 Thole sop saw of of Bek te ae sp sey ae “en ta wop se no |4.9 maine NOISE paca Cove oto Fig 62 Acioneg he leg S50) Mig, 3. Asieha te ig KT 50) @ trav op tae @ Ar ew @ teote op ice) Ar er Tate Titi eee (Corea eo ‘fom poteerce ot are. | 1) Sem eration fo por ltg |b Che wow i Saeed Gas acl 2 to mei 9 cotati 2. Aol Ne Boom se Fer eee 3 Ineie Fat ve wit oe ot Hier iden ple need it dt | 1 Baro ein od toeen weal 4 foo Wh od afore ch od aa 5 Lane toads Fan dst 5 te olen len wat 2. Fn ck slo oon 6.3 ENGINE NOKE6.5. CLUTCH SYSTEM 1 Ooh aes 2 Gah il oe deroae 2 Were feet oF cam seit, Enka 1. Woe eh le ovo 8 oes 1 Cathe cones kek an ae ot wat Drie ates etch sew 42 Danas weiss ele 3 a tee 2. bat oon eto nbs 2 lene wake Wa 3 fe Dive ean ator of aman’ 1, fi ed srt bleed fet at Vien |. wae vere ee Roses ers 2. hermw edanet 1. Gretaly wan eth on dae 1 repre 1 aes 2 falas 1. hapa e ope 2 apse ropes 1. Bese er ice 2 Rosine vehce 1. ear 2, plo A 7 kage 2 tale 1. Ghee fo wom ad pins oF rgd 2. raion emt Hee ie 5. tape exace 6 ae 6 pepe ae 1, totce 2, tape 3 tor pares Sapa 1. tece par or lee 1. tear o eee 2, Avett pene spetnon @ >a ae aaa ei see ee 2 ee en ees irenmamaieral [1 ean wit vet engage | 1. Broken ton ahi dum eo EEeeaae ce Se xian te Ueicancos Rats ee peas res 3 ea ree ‘S Gear jes ont of eronpenen | 1, Wom fag on cater ut secon’ goir |1. sepa oreeoiny = oe ae * tome eee toe eee SE 2 Hard ampenion | totective frt onton dompor a 2 tate raion aor 3 Sagano soe i Gaon con otha F coon spr nie tale sera dar BRAKE SYSTEM. 1. No range of adlament | 1, Wer tole tow 1 tesle 2. em toe ea sae 2 pea 3. Wem tat com 3. pte6 roWe siooTNG 6.9 DRIVE CHAIN 1, Dive sar sere ey 2. Ferenc g 2. Pad ial dr oroce | 2 tee ten Ty Beets ad epped fo ie ‘Gaerne soe cra 2, De 0 lo, osere hese rates 2. Saal wale te tie san 1. Ramana focign eee! rw cable oul 2 spect nt apar I erat i ecm | 2 et per htrcren 1. Gem reat owe fear ep7. WIRING DIAGRAM $90 GENERAL EXPORT TYPE Seas ae uourine oer sw reyaTe] Tors] [Rae] || comananen sen ae ie ler] e eran # oto) (SS) 7 oF St oa sagt yen sari i | a il fic sre ness outer $4 sevreu puor ts ye ne mans seo nce we Ns : Seer tat J oa i 4 TAL S10» ulcer “ a | Savi og Sie if i ‘EIA iy a aS Nv tue] \ wea se \ 0 wae 2 wie guess eomire Faoxt 190 8 ck rei we Hess cos ie a ‘womnce weLaT | 2 Lacie a over ope L scuren one =} saute eno Leu geen PI ta WenuTe ert. ye ucaT HEGN TH RED SPRAL TRACER ymsen We WATE SRNL TER WAYELLOW wT REO SAL. TCE Se YCHEEN ATH YELLOW SPL TRACER 06s srt$90 U.S.A. EXPORT TYPE _— as cusmso1 oe ae ma aie Joa Pa or en | i orca Whe ih pnerimr sen i ne 16000) eee ar ums, | j camo) EL } UGHT eva omen) We Net 1 Eas nm go a Se Ps aa won shaw ot stan SL / nee wamess nee LE ee, oF Bee \ = : : ce | au, - = t | acre ia ies . \tS ss Ea sera = a c= Oe = Anas ira it snes! Ser @. ® veagyion ewan pe a ce a x a ROI Lacan Sema, ora Seren PU a 2 vans wnnese ‘et cour tatty Buc ity im ace | rae vin = ¥-xcu.oH Lyne Gen WH REO SO}AL TRACE RALECD MTA WHTE SPRAL TRADER {Y/R-YELON Wi HED SAL TRACER G/cHten wt YELOW SPRL HACER ort WYYOVId ONRIM °/CL90 GENERAL EXPORT TYPE TURN SIGNAL INDICATOR LAMP 6V1.5W MAIN-IGNITION SWITCH () SELENUM RECTIFIER NEUTRAL INDICATOR ek Li LAMP VL. A ‘5 f07] UGHTING BEAM SWITCH Lal LH| ie FUSE eg ‘SPEEDOMETER 104 R REAR TURN SIGNAL Lae a OH Ys a LAMP. évEW 5 © L___@t-S=-@—§, ©] parreny oven Dales Net a. D-H P AiG Rs - 2 ot Seas ® TURN SIGNAL i @ . TAIL AND STOP LAMP 6YBW =e 5 \ y © UGHT 6va/10W x Aa a 3 Ly a) WIG x & s oT = es Gt ke, Ost; \ © ~ 53) Tho: [ist L REAR TURN o WIRE HARNESS 9, SIGNAL LAMP 6vEW HEAD cat — IGNITION COIL 625/250 HIGH uti | 2) tension [Se 3} 1 coRD HORN / i conpenser_ ep 0 @, WINER RELAY = UGHTING BEAM MAIN-IGNITICN. SWITCH @-=O-FT0 = a © a TN SWITCHING ARRANGEMENT SWITCHING ARRANGEMENT SPARK PLUG ER — Dh é iN fair |t |ov|se | L FRONT | NEUTRAL SWITCH] qep TURN SIGNAL 1H | A Tete tee lamp 6v@i/L_= i | | TORN SIGNAL HORN ~~] N o| oto) BUTTON SWITCH CONTACT BREAKER A.C GENERATOR t_|O-70r70 | or0 06 10CL 90, CL90L U.S.A, EXPORT TYPE wre awe STC Ny su potent enue FRONT TOR SleAl Liner Meo he oui Roa 4] sexu secre von sex sro wan sno aa ei ie / | [Hoe cal 1B sou. tor wwe e159 oF oe nat I ean onan ow BEAW Le evisw rH eve sme ‘NEUTRAL PLOT LAMP 64/156 r Tere oy A SPEEDOMETER LAMP 6/15 i _SEONEER UP : I 1 Lot ate wae_nemvess! | | 6. te f BI ube V7 [Let Ce i aaa HEAD LIGHT 6V 25/250 eS ee ue a it 25 WIRE HARNESS asa LFRONT TORN si, oer bunt umess FS ‘ ann Se Ah =} fone es IGNITION COL j | on reson ca io! ‘HORN ie 1% WINKER RELAY ‘i nee ONS cov Bennie Geom Gay \ is * ‘ swe Wests Br Brown . vevreaL wot Yolen Blot be Sea FUG ee Green Om Dee mia ee Sec LSA gen i ov footie fomne } fp 7 Lyi Light geen/Red i / ea | # YfacnYlu ted | a Brown) White iT A RUW Red/White } es Gee tor =e Z-_ CONTACT BREAKER HORN, BUTTON swircH ert Wyaovid SNA,CD 90 SELENUM RECTIER G@ojiaaxa) Sania ha Fy Te NOW LA ee ana = Sl ae FWINKER TURN SioNaL samc METER LAMP 6\1.5W tape LAMP 6780" a Saran suet ° ai si Soa Sire Jill Mite sal nt i ——— 3 =o ie i - : is = Yeliw| spiral on gren(Stop) = (Distance) a Brown (Tail) Tare me 8 al | ‘HEADUGHT 2 625/25 = ruse 198 _ 4 Tengen cox Le wen ecu | caer Tua St LP Light green eK a &p / 2) Unie ce oa | 120) |earfMory| weno | ov grate) | seceucw SeeaeUTOH (REO) _|carueacoy| HLCEROWN) | by (WHTE) | SE(YELLOW) wh SNITCH ‘OFF | Lefovt Tue su. LP ae * | : =o CONTACT BREAWER mm Trore nee ES Lcowensen [Ac GENensto3 06.49 oreTURN SIGNAL LAMP (RIGHT, FRONT 81) 5 ° TURN SIGNAL SWITCH power. r t NEUTRAL INDICATOR LAMP (1.5¥ METER LAMP U1. 5W, a C90 SELENIUM RECTIFIE 5 BATTERY ¢ FUSE (5A) FLASHER RELAY (16W) STOP LAMP SWITCH | g l TURN SIGNAL LAMP RIGHT, REAR, 8W) ow HEAD LIGHT @5W /25W)) TURN SIGNAL LAMP (LEFT FRONT BW) oo HEAD LAMP SWITCH HORN BUTTON roe CR I | | TAIL/STOP LIGHT dow aw) IGNITION | 3 col | OLS. GIeplolian - a i SS Bi TURN SIGNAL LAMP Rol aa S (LEFT, REAR, BW) len YF i , CAPACITOR COMBINATION SWITCH ‘Light green with red spiral tracer White with yellow spiral tracer Brown with red spiral tracer Green with yellow spiral tracer Red with white spiral tracer Blue with red spiral tracer Blue with yellow spiral tracer ost A Wvaovid ONIAIA,RLERONT TURN SIGNAL NEUTRAL i | PILOT LAMP. 6V/15W TURN SIGNAL SWITCH TURN SIGNAL PILOT cT90 FUSE 15A | ia | | STOP SWICTH | i = Bk, hte tee ~ set Gr Gr HEAD LIGHT 67/25W/25W WINKER RELAY 36W R REAR TURN SIGNAL LIGHT 6¥/18W TAIL/STOP LIGHT i 4 ee —h li cH ienon coi, °| _6v 21/3cp B/RIGRE ae | E Ht eee | oe BR WY. the | HORN LFRONT TURN SIGNAL LIGHTING DIMMER SWITCH ARRANGEMENT ‘White T LREAR TURN SIGNAL 06.19 ‘eis ( fal Jhisral | | , ___USHT 6/16W So i 1 N - “NEUTRAL SwTeH op eo DENSE Ne TS Jeat] wae al IGNITION SWITCH Ss eat cone isnTion swircH| “* |_| | ARRANGEMENT || |O-tO Not (—-—) INDICATE OPTIONAL PARTS Gray ‘Yellow Green Pink wa [6| ov] se] M8 Orange Light blue 1 * —— Brown eLight green ‘Red LG/R----Light green & Red on Black Blue & Red Blue RW Red & White IstR.FRONT TURN SIGNAL LIGHT 6V—1eW => TURN SIGNAL shiToH 1 = IGNITION giro | 1 SWITCHING ARRANOEVENT NEUTRAL PLOT LAMP wv-39" | \ Jato ' ern a \ grezgoueren wt th | owwairron Fe tape FAT PT | neu a ww [oto ce HigH BEAM Lob! eaont stop \. \ptortaver ft ' APT aL i sWITOH TURN SIONAL a PLOT LAMP 6v-3n t 1 SF Hf 1 SPEEDOMETER i ti -- i i CT 90 (FROM F. No. 000001) SELENUM_REGTIFIER Recher ea Ge HEADLIGHT ev-2bN 250 i i i ho I I I I HORN LigHTina swiTo#) LIGHTING DIMMER SH THING, rs | L om 4 ALREAR TURN SIGNAL. Light Bui pone A) iB os) {[ TAL/STOP Lohr i Ov-7/5 3M SUB HARNESS, IGNITION SWITCH ARRANGEMENT Ta] 6 [ov] 00m LREAR Tug SiONAL. Lion v= 16W Grmray roan soeearge BreeBrown RvwRed Blom Black Blug White Yalow P La Lit the LG might aren GY mGrean ond Yellow LG/Y=~-Light green and Red B/R Be and Rat UW wefed ane White WAY ite and Yellow tube zs “ Wyaovia ONIIM,8. SUPPLEMENT TO S90ZK1 1. CAM CHAIN TENSIONER ‘Te can chan ferdiorer was charged fram tho D hychoukc sefatisirg type to the rorely ok jimabe typ, | @® ry foc pans © Sim WF to cm eh i encnvely tay ih he encoe ‘leg. te ser of the con ch trope and reir Alara MO 1. To ara, ta the ing tal oer ot Tn fe. ofittg bo ac coda dec Yon hon the chin rade aching foe aed hon fn a committe @ teua of 0 wbhing toe, Set Pe cng toi fo o port whee te toh nate fe sole Tam @ paisa toJs 2, KICK STARTER The Hck state won chanand Yoo new ip ox shou in Fg. KI-3 Fate re 3. CARBURETOR Seng tone en bt as 4. FRONT SHOCK ABSORBER (FRONT FORK) Ol cxpaciy: 150-~140 cc 144~4,7 02s) (| spaciinwion ATF (Automate Teneninien fu © Ft Fok tot @ fot 1 eat sng 57 Wiahe (182%240m far goer Ol ne (Oe se cove ie Fw for ce ose (© fot sock sce sea 5 Fw ft boon com 1@ Sea ante pre ge Fo fot puts Ciiicecee me asc fot toton bie @ ton cow one B fson sep to@ & anaver 10 s#a20 5. REAR SHOCK ABSORBER (REAR CUSHION) Soring foo lrghh: 175.5 (6.881 etd lnc Load 157.1 any9. Sky 15.264 42.55 bad Hew wey 1D tow sone eae apr 6. WHEEL AXLE NUT ‘The Tent acs whl cle rte ware chenged te a costa nt tot thd by © ection eee ® Stoo sone ope oon Sion Goon &é u Take @ Wael ole t @ Colw prte 8. sumer 10 55020 2. MAINTENANCE SCHEDULE [Meni Mie in Eade Oi darge Zz Of Fle eean = Spat Plss—elean ond oda? or vepice Gan Guin axist Conte Seeder Forts chack oF ervice lorem Thaing—ceck & otha Yolve Taree! Closrrce—chect or oda! ‘Ne Chorer—claon and —repcce Trotile Operation check Caiosreter—cieck or Fuel Tork and Fuel Lines —chock Ghvch—ehoct or odist Drive Chale ones Sorackets—adjust and Wovieare or ‘eslace Fort and Hoar Bro ait Front and Hoar Brake Shoes check oF replace Front and Foor Scho Lika cick Wheel Kins er Sckes—stock Tres check 0° rope Front Fork Oll—ches foe leclage ond one Seti Hood Beahas check o odkat ‘Steerine Hondie Lock—check for operation Side Stone Spina check Battery Beckolte Level—check ord repenih receery Ue, Hor Spseoncte eck lr ein foseot Erery —Lipe pe 2a 3.000” 000 | 3000 | 4000 3008000. 10.000_| 5600 | 10.000 | Brey 1,000 pale 1.500 fm ° a 3 o|ofs Ons oniae [oO oOo} 6 S/o[els ofolo| 6 o 5 serene a0) [ap |ncne| eeaome ste "Soo. 7,300, 300. 000 [RGR OL Gree 7 Yo [ENTRRIGAL OL SOHERI—Girn 16 COL FLIER SCHEN—Ciem S @| SPARK RLUG—Con ond ch opp oF pce mo 3 CONTACT FONTS AND IGNITION TING Css, ck, |g a | crac eps mcasy |AYAIVE TAFET CLEARANCE Cho, on coat mcs. | @ o SCAM CHAIN TESSION- Ade e ° POLTURETHANE FOAM AR FLTER BEMENT Gaon ord oi | ToecuciT ot Gua] YEARIRETOR Coch, ond ada 1 mca. e arora THROTTLE CREATION ec cae, | Check, ord aut tee play. | © S| irl | FURL FER ScneeN Cn 3 FUE. LINES Gel |S @ SCUIGH Chace open ond aia if mcr. ° 3 DEVE CHAIN-Grck Usicat, ait if eee PAIK ABIESTOR ie onal BRAE SHOES —teret ad eds ¥ wor 6 BRAKE CONTROL LAGE Chest (ge en ie fey Cee ° WHEL @MS AND POKES—Chet iS Tefen pea ond ho wheel fee ° [FS —tegect oe deh or rere I FRONT FORE Ol—ron dl L_to FICNT AND HEAR SUSNSON—Cinck open 3 TEAR FORE BUSING Grae, ck fer een ose ° @ | “STERING HEAD SEARNIGS— Adj I ° CATTERY Check decroha lel da worry. | ot LUGHTING EGUPMENT —Check cd et raceway lao ‘AL NUTS, ECIS, AKO OTHE FASTRESS Cink = | aie a ery 2 an fea, @ es tec Ote nartnsie tore snl 10 perm nd may bo tniced by the Owe bina men |e aACUI ONTOL-MEROENOY ATONEMENT HY [Tee forTS [NI ee [aL REAR TURN SOUL LoAT es Stotol yaar es | ot ©) = 1 ‘SLICON RECTIFER Gam 71 or b= AOUOAT BEAN COMTIOL STEN ya ayy ae NEUTRAL INDICATOR LIGHT 6¥isW— Car Y BATTERY WAN SEL NOCATOR UGK ssw SPEEDOVETERLLMINSTRG LT 6 , é ‘HIGH BEAM INDICATOR LIGHT 7 4 ge specooe ale Tel iB | isk, i= ha a) hs Se z ‘ € iE f F 3 a al ew Er: +—Fr ie 6) / water aesvsw te i (1) 5 UL ST at io f ae e83/2W(3/2) ae ae | semen TBNTION COL & 5 i a ; FRONT TURN SIGNAL LISHT 6vIEW i‘ it Gr wo] HORN BUTTON eee IR | REAR STOP SWITCH he ‘SWITCH TO) I ran ase SH © | ab = span aus aon CAR TURN SL UT SN a ACT snc a AC GENERATOR Bee ae Se uit eli een Bet he i fet O-age Geman Pome = WV¥OVIC ONIYIM, 6 naan ~G30619 OL ININT: sot6. SPECIICATIONS item DIMENSION | Creal era we Great Hee wi Dry Wass FRAME Te Sosperion, Tvl Saspaion, Trove! Tro Sue. Type Tre 80, Type fke Brake Fel Copasty | fuel Reserve Cipcliy for Anse ral rath Fok Oil Copoaiy sone F ® F. 8 F. Type Cine Aieagonaa fore cr Soko Daplcerer Ceres Reo Nate Teh Oil Capaci Lubdesten Sten Ave Tost ears ‘Ais Sorsw Opening le Sons DRIVE TRARY ek ‘re Pay Resin Ger bse | ai W oN Find Racin Ge Sx Pa ELECTRICAL iin ‘Siteg Sten ‘Aeron Boitery Copaaiy Sat 0 ae im 74m (ism) (480-in) Caz in) 113881 98 Kooty. puto , to oF preeie 1.8 alan (26 pa 275-1748 Krotey patent tho or procare 22ka/o¥ (32 pe) ler ecconarg ence were! secoraing thos 33 ih 1.405. gd. 08 t ro N7US gh, 75am 19.0 mi Isa ex AAT Air coed ale orn Shale eyinr 75° heined from vera! S0.0% 48 60m (19701797 in) Boser S46 cui 22 (Crs ivan ove baad cone D7 hn 095.8 4), 08 ire gl Foc er wat simp INS EC: 005mm 10.002 ni Yt 1,300 rpm Wet moi—plets ayonatie ich ‘spans consent mach 3722 2538 vant 1190 S000 eve spoctat 15 T, criven qraet 46 T Let foot rmsd reir aysGrd COMPARISON OF CT9OKE 1. FuB cock retks nd their potions cn the jal cock was changed to © new tye. 2, HEADLIGHT AND ENGINE STOP swatch Tre cinrer sniich provowly offered an the Sivich hourrg at th right sdb of the hac, was rekco'ed to tte left swich honing The so nozessed crger tha casi of the‘3, TURN SIGNAL, HORN AND DIMMER SWITCH A new dimrar switch wos arktd 12 the tan Sigel ona hom nich nawing ot the lft eo of the hencleb. oe 4 THROTTLE GR The trotte gp wee changed t2 a raw win Irepection and odjystnent 1. Clack the fee play of tte trate ait deuld be 10-15 degrees of the ip ration 2 To ex, lcosen th lock rat ora tm the ‘per odster ether in or ou! as recesay. Retin of tha cchater na decton “A ecreoor tho ploy, ons retaing ne aocten 2 ineeoes th olay Tighten the lece rf tar asta 3. Chock the Proc cale Fer tisting or intr Freee with oxjoen! rts: oho for prover rading, whe turing the Fardabar 10 each laceeembly 1 toeean of hese easing: separate the hewin 2 Chaccrect” tha ttle cla ae from the theta at pps. 3. Wks the trate rp oom the Hrlbes 4 Assertle me vote gis the reverse ardor of deasenoly,5. SIDE STAND The ie tod was changed to new type wth 0 shock abserbing ner lock “his sore must oe irizected peroccally to de tering tha tie In good concn, Inspection 1. Cheek the onike side stad osenbly ‘ide slows tor, tacks orl ber bls for nerract Insokater, defamation or olhewse encesive 2 Check the sng for tras for damege cr thar cafes 8. Check he sid ser for proper cat pra ©. th te stand ale i he chi 1 deers tha god . Atoth ¢ spina. sccle jo tho tower on! of ‘to sind ond mera the force wih whch ‘he ond fr retered 10 85 criginl potion Tho dard conaition is corect ifthe meaire= net fos wihia 23g 44-56 bs sh stn rogues fercaaxcooing he cio It, tis mght b0 die to neglect hbrien- Hon ovmtichenad se strd pit bot, wom Sow be of brass! of otherse efcase fercon, Repl as neces. 4. Check the mber block far doterration ot ‘roar. When the ntber pod wear Ss ercathve £9 thal is woin down to he waar Ine, replace th a ub bode replecement 1. Romove the é rm bot; escorte the nbber Deck fom the bracket of to ade stot 2. alter melt sxe te colar & Fatale, put @ now ister block in lace nthe brocel wth te row rank os NOTE: Use rubber pad haeg he mak “IELOW 259 lke ONLY" 3 Soave the nbbor bled170 9. SUPPLEMENT TO CT ?0K2~K6 7. MAINTENANCE SCHEDULE & Some additions occured in the MAINTENANCE SCHEDULE, of which detalles are as shown immedictely below: [NITAL REGULAR SERVICE PERIOD MAINTENANCE SCHEDULE | SERVICE | Perform ot every indicated month or mileogs PERIOD | interval whichover occures frst. ‘This maintenance schedule is bosed upon averoge riding con | ee ee iy ay ditions, Machines subjected 10 severe use, or ridden in un 500 months | month _|_months —|__ months _ q Lsvolly dusty areas, require more frequent servicing niles 500 7,600 | 3,000 | miles miles milee | SIDE STAND—Check instoliotion, operation, deformation, daw: ‘age ond weer | items morked © should be serviced by on uthorized Honda desler, unless the owner hos proper tools and is mechanically proficient, Other maintenance items are simple to perform ond may be serviced by the owner, 8, WIRING DIAGRAM ) esis os SATE10. SUPPLEMENT TO CT90K8 (77) a Engine No. CT90E— 1800001 ond subsequent Frame No. CT90—1800001 and subsequent |. MAINTENANCE SCHEDULE @ = REGULAR SERVICE PERIOD puna Sivece | Pen ot oy dees Haat Ceaadetiet ast | Meese ae wie | S00 | s00 1,500 3,000) 6: in| 1,020 |i, 0002 00" s,c00 [10 Teo t seenmaicat O1 stra — SOIL UTR SCHeeN STAR NUS SCONTACT SA FONTS” SGNTION THING © VALE TAPE. CIEARANCE *Chon CHAN TENSCN POLTURETHANE FOAM AR FILTER ELEMENT “CARTER THROTTLE GHEATEN REL FLIER SEN RELINS sowicH —— one Hany SPAHR ABESIOR strat OS BRAKE CONTROL URRAGE wees ans @ THs = = 1 | c = aaa I cat “Tet [rae FONT FOR OL FICK AND HEAR SUSPENSION FEAR FOR ALSHING “STEERING FFAD BEARNIGS ‘DE STAND BATTERY LUGHTNG FGUPVENT UIs, BOLTS TIGHTEN fer rred * todo ove by ot coied HONDA cel, et tr une et pa fost er mechaARONT TURN SIGNAL UGHT Gzip! 28¥) SPEEDONETER NEUTRAL INDICATOR LIGHT svzee(2) TURN SIGNAL INDICATOR LIGHT 6YIc1W) METER LLUMNATING UGHT 0 HG BAM CATR ENSNE_STOP_sumTeH INTION sate 7% SulcoN aecrieR = TSE 15h REAR TURN SKGNAL LIGHT B¥atep(t6W). "9 prota TAL & STOP UGK 1/3265 3/2) (ZZ, 06 19) WY¥OVIG ONIMIAN | te em ja HEAOUGHT 6735/0" De HORN LLFRONT TURN SIGNAL. LIGHT 6r2cp(t8W) ¥ OF eapuciT omer T H ‘0202-102-7900 HAUGH DMMER-TURY SIGNAL HORN SAITOH Fen sarteu EHANGEVERT ENGINE STOP sw rts coNmensee A if L HAA oF F OF i 8 IRNTON COL is WIRECTEAY cure. [CONTACT SWITCH a [LREAR TURN SIGNAL LIGHT stop sam 5 tcp tBn) Gen Green Yeoelon Rew kad Bowes We Wite ProoFink Bre Bwn —Oerarge Fhe Bich —— GroGrey LGetigt Green LB-igh Ble g 2 3 Qe@ @ 3. SPECIFICATIONS DIVERSION Oat gh [vera west eal Copy | ee tre Cony [te ade Trot lng NGI aero | Bale Cassy Seah Pn | cers Capacty Sumevin To crsoxe £20) ra —isrome rae 7a 22.1 Nz20nn Bow. Frm 088! Msn gsr 96s 198.781) Foe lie 10290 OR ‘Surg ain, tors 77m 13 0h) | 275-17-atoctby, te oF pore 17ST Bo) 7 ae use 228iglow Sp Inert cepa oe In een ee S50. TSUS po 12h. 93 GBit (AUS cok OTBIen gal) 75m 89h) Si casted tikes OR, wags Ste ins 75" eted ran vied 0. G9sUs 9. OB pais al prgs ome 1950-48007 ISK Geis aren Soa