Activa Scv110

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HONDA ACTIVA
SHOP MANUAL
© Honda Motor CO.,Ltd 2009
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A Few Words About Safety
Service information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the
vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommended
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety
and the reliability of the vehicle. Any error or oversight while servicing a Improper service or repairs can create an unsafe con-
vehicle can result in faulty operation, damage to the vehicle, or injury to dition that can cause your customer or others to be
others. seriously hurt or killed.
For Your Safety Follow the procedures and precautions in this manual
Because this manual is intended for the professional service technician, and other service materials carefully.
we do not provide warnings about many basic shop safety practices
(e.g,. Hot parts – wear gloves). If you have not received shop safety train-
ing or do not feel confident about your knowledge of safe servicing prac-
tice, we recommended that you do not attempt to perform the procedures
described in this manual. Failure to properly follow instructions and precautions
can cause you to be seriously hurt or killed.
Some of the most important general service safety precautions are given
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precautions in this manual
arise in performing service and repair procedures. Only you can decide carefully.
whether or not you should perform a given task.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using
safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make
sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes sparks and flames away from the battery and all fuel-related parts.

FRAME/BODY PANELS/EXHAUST SYSTEM
HOW TO USE THIS MANUAL CONTENTS

This service manual describes the service procedures for the
SCV110. GENERAL INFORMATION 1
Follow the Maintenance Schedule (Section 3) recommendations FRAME/BODY PANELS/EXHAUST
to ensure that the vehicle is in peak operating condition. SYSTEM 2
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break-in
period.
MAINTENANCE 3
Sections 1 and 3 apply to the whole scooter. Section 2 illustrates
procedures for removal/installation of components that may be
LUBRICATION SYSTEM 4
required to perform service described in the following sections.
Section 4 through 18 describe parts of the scooter, grouped FUEL SYSTEM 5
ENGINE AND DRIVE TRAIN

according to location.
Find the section you want on this page, then turn to the table of ENGINE REMOVAL/INSTALLATION 6
contents on the first page of the section.
Most sections start with an assembly or system illustration, service CYLINDER HEAD/VALVES 7
information and troubleshooting for the section. The subsequent
pages give detailed procedures. CYLINDER/PISTON 8
If you don’t know the source of the trouble, go to section 20
KICKSTARTER/DRIVE AND
Troubleshooting.
DRIVEN PULLEYS/CLUTCH 9
Your safety, and the safety of others, is very important. To
help you make informed decisions we have provided safety FINAL REDUCTION 10
messages and other information throughout this manual. Of
course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle. You must use
ALTERNATOR 11
your own good judgement.
You will find important safety information in a variety of forms
including:
CRANKCASE/CRANKSHAFT 12
• Safety Labels – on the vehicle
CHASSIS
FRONT WHEEL/BRAKE/
• Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER, WARNING, or
SUSPENSION/STEERING 13
CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if
REAR WHEEL/BRAKE/SUSPENSION 14
you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
BATTERY/CHARGING SYSTEM 15
You CAN be HURT if you don’t follow instruc-
ELECTRICAL
tions.
• Instructions– how to service this vehicle correctly and safely.
IGNITION SYSTEM 16
As you read this manual, you will find information that is preceded
ELECTRIC STARTER 17
by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment. LIGHTS/METERS/SWITCHES 18
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS
AND SPECIFICATIONS INCLUDED IN THIS PUBLICA- WIRING DIAGRAM 19
TION ARE BASED ON THE LATEST PRODUCT
INFORMATION AVAILABLE AT THE TIME OF AP-
PROVAL FOR PRINTING. HONDA MOTOR CO., LTD.
TROUBLESHOOTING 20
RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATEVER. NO PART OF THIS
INDEX 21
PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN
FOR PERSONS WHO HAVE ACQUIRED BASIC
KNOWLEDGE OF MAINTENANCE ON HONDA MO-
TORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: January, 2009

© Honda Motor Co., Ltd. 2-3

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these
symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equiva-
lent).
Example: Molykote® BR-2 plus manufactured by Dow corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equiva-
lent).
Example: Molykote® G-n paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid.
2-4

1. GENERAL INFORMATION
SERVICE RULES 1-1 LUBRICATION & SEAL POINTS 1-11
MODEL IDENTIFICATION 1-2 CABLE & HARNESS ROUTING 1-13
SPECIFICATIONS 1-3 EMISSION CONTROL SYSTEMS 1-18
1
TORQUE VALUES 1-8 TUFFUP TUBE 1-20
TOOLS 1-10
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s
design specifications may cause damage to the scooter.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing this scooter. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates while reassembling.
5. When tightening bolts or nuts, begin with the larger diameter of inner bolts first. Then tighten to the specified torque diagonally
in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all cables,electrical wires and wiring harness as shown in pages 1-13 to 1-17, Cable and Harness Routing.
1-1

GENERAL INFORMATION
MODEL IDENTIFICATION
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side
frame body. of the crankcase.
CARBURETOR IDENTIFICATION NUMBER
COLOR LABEL
The carburetor identification number is stamped on the left The color label is pasted in the luggage box under the seat.
side of the carburetor body. When ordering color-coded parts, always specify the desig-
nated color code.
1-2

GENERAL INFORMATION
SPECIFICATIONS
GENERAL
ITEM SPECIFICATIONS
DIMENSIONS Overall length 1761 mm (69.3 in)
Overall width 710 mm (28.0 in)
Overall height 1147 mm (45.2 in)
Wheelbase 1238 mm (48.7 in)
Seat height 765 mm (30.1 in)
Ground clearance 153 mm ( 6.0 in)
Dry weight 107 kg (236 lbs)
Curb weight 111 kg (245 lbs)
Maximum weight capacity 170 kg (375 lbs)
FRAME Frame type Under born type (steel)
Front suspension Bottom link, Leading arm
Front axle travel 80 mm (3.15 in)
Rear suspension Final drive unit/swingarm
Rear axle travel 70 mm (2.76 in)
Front tyre size 90/100 - 10 53J
Rear tyre size 90/100 - 10 53J
Front tyre brand NYLOGRIP FE (MRF)
Rear tyre brand NYLOGRIP FE (MRF)
Front brake Mechanical leading trailing
Rear brake Mechanical leading trailing
Caster angle 27° 30'
Trail length 92 mm (3.6 in)
Fuel tank capacity 5.3 liters (1.4 gal)
Type Gasoline, air-cooled 4-stroke
ENGINE Cylinder arrangement Single cylinder inclined 80° from vertical
Bore and stroke 50.0 x 55.5 mm (1.97 x 2.19 in)
Displacement 108.9 cm3 (6.65 cu-in)
Compression ratio 9.5 : 1
Valve train Chain driven, SOHC
Intake valve opens 10° BTDC (at 1 mm lift)
closes 35° ABDC (at 1 mm lift)
Exhaust valve opens 25° BBDC (at 1 mm lift)
closes 0° ATDC (at 1 mm lift)
Lubrication system Forced feed and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous Paper filter
Engine dry weight 25.1 kg (55.4 lbs)
Engine curb weight 25.9 kg (57.2 lbs)
Carburetor type Piston valve

CARBURETOR
Throttle bore 15 mm (0.59 in)
Clutch system Dry, automatic centrifugal clutch
DRIVE TRAIN Final reduction 9.423 (50T/20T x 49T/13T)
Gear ratio 2.50 – 0.85
Ignition system AC-CDI
ELECTRICAL Starting system Electric starter motor/kickstarter
Charging system Single phase alternator
Regulator/rectifier SCR switching regulator, AC regulator built-in type/
single phase, half-wave rectification
1-3

GENERAL INFORMATION
LUBRICATION
ITEM STANDARD SERVICE LIMIT
Engine oil capacity At draining 0.7 liters (0.7 US qt, 0.6 lmp qt) —
At disassembly 0.8 liters (0.8 US qt, 0.7 lmp qt) —
Recommended engine oil Honda 4-stroke oil or equivalent motor oil
API service classification: SJ —
Viscosity: SAE 20W-40
Oil pump Rotor tip clearance 0.15 (0.006) 0.20 (0.008)
Outer rotor-to-body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Pump side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
FUEL SYSTEM
ITEM SPECIFICATIONS
Identification number PB16 x 1

Venturi diameter 16 mm (0.63 in)
Main jet #90
Slow jet #35 x #35
Float level 11.7 ± 0.5 mm (0.46 ± 0.02 in)
Jet needle clip position 3rd groove from top
Air screw initial opening 1 7/8 turns out
Air screw final opening 4 turns out
Idle speed 1,700 ± 100 min–1 (rpm)
PAIR control valve specified vacuum 420 mmHg (16.54 in Hg)
Unit: mm (in)
CYLINDER HEAD/VALVES
2
Cylinder compression 843 kPa (8.6 kgf/cm , 122 psi) at
—
520 min–1 (rpm)
Valve clearance IN/EX 0.16 ± 0.02 mm (0.006 ± 0.001 in) —
Camshaft Cam lobe height IN 32.066-32.226 (1.2625-1.2688) 32.041 (1.2615)
EX 31.816-31.976 (1.2526-1.2589 ) 31.791 (1.2516)
Cylinder head warpage — 0.05 (0.002)
Rocker arm I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Valve, Stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1945) 4.90 (0.193)
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve spring Free length 29.78 (1.17) 26.8 (1.06)
Valve seat width 0.7 – 0.8 (0.02-0.03) —
1-4

GENERAL INFORMATION
Unit: mm (in)
CYLINDER/PISTON
Cylinder I.D. 50.005 – 50.015 (1.9686 – 1.9690) 50.10 (1.972)
Out of round — 0.05 (0.002)
Taper — 0.05 (0.002)
Warpage — 0.05 (0.002)
Piston, Piston O.D. 49.980 – 49.995 (1.9677 – 1.9683) 49.91 (1.966)
piston ring, Piston pin hole I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
piston pin
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Cylinder-to-piston clearance 0.010 – 0.035 (0.0004 – 0.0013) 0.10 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Connecting rod-to-piston pin clearance 1.010 – 1.034 (0.0397 – 0.0407) 1.05 (0.041)
Piston ring-to-ring groove Top/second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
clearance
Piston ring end gap Top/second 0.10 – 0.25 (0.004 – 0.010) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) —
Unit: mm (in)
KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH
Drive belt width 18.5 (0.73) 17.5 (0.69)
Movable drive face Busing I.D. 22.035 – 22.085 (0.8675 – 0.8695) 22.60 (0.889)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.705 – 0.712) 17.40 (0.670)
Clutch Outer I.D. 125.0 – 125.2 (4.921 – 4.929) 125.5 (4.941)
Lining thickness 4.0 (0.16) 2.0 (0.08)
Driven pulley Face spring free length 108.5 (4.27) 92.2 (3.63)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
FINAL REDUCTION
ITEM SPECIFICATIONS
Final reduction oil capacity At disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
At draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
Recommended final reduction oil Honda 4-stroke oil or equivalent motor oil
API service classification: SJ
Unit: mm (in)
CRANKCASE/CRANKSHAFT
Connecting rod big end side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod big end radial clearance 0 – 0.012 (0 – 0.0005) 0.04 (0.002)
Crankshaft runout — 0.1 (0.04)
1-5

GENERAL INFORMATION
Unit: mm (in)
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
Cold tyre pressure Driver only 150 kPa (1.50 kgf/cm2, 22 psi) —
Driver and passenger 150 kPa (1.50 kgf/cm2, 22 psi) —
Rim size 10 x 2.15 in
Front axle runout — 0.20 (0.008)
Front wheel rim runout Radial — 2.0 (0.08)
Axial — 2.0 (0.08)
Front brake drum I.D. 130 (5.12) 131 (5.16)
Unit: mm (in)
REAR WHEEL/BRAKE/SUSPENSION
Cold tyre pressure Driver only 200 kPa (2.00 kgf/cm2, 29 psi) —
Driver and passenger 250 kPa (2.50 kgf/cm2, 36 psi) —
Rim size 10 x 2.15 in
Rear wheel rim runout Radial — 2.0 (0.08)
Axial — 2.0 (0.08)
Rear brake drum I.D. 130 (5.11) 131 (5.16)
1-6

GENERAL INFORMATION
BATTERY/CHARGING SYSTEM
ITEM SPECIFICATIONS
Battery Capacity 12 V – 5 Ah
Specific gravity Fully charged Above 1.270 – 1.290 at 20°C/68°F
Needs charging Below 1.260 at 20°C/68°F
Current leakage 1.0 mA max.
Charging rate Normal 0.5 A/5 – 10 h
Quick 5 A/0.5 h
Regulator/rectifier Regulated voltage Charging 14.0 – 15.0 V/5,000 min–1 (rpm)
Lighting 12.6 – 13.6 V/5,000 min–1 (rpm)
Alternator coil resistance at 20°C (68°F) Charging coil 0.2 – 1.0 Ω
Lighting coil 0.1 – 0.8 Ω
IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug NGK CPR7EA-9
Standard CPR7EA-9
Ignition primary peak voltage 100 V minimum
Exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 15° BTDC at idle speed
Maximum timing (Advance) 36° BTDC at 3,000 rpm
Unit: mm (in)
ELECTRIC STARTER
Starter motor brush length 9.0 (0.35) 3.5 (0.14)
LIGHTS/METERS/SWITCHES
ITEM SPECIFICATIONS
Bulb Headlight High beam 12 V – 35 W
Low beam 12 V – 35 W
Tail/brake 12 V – 5/21 W
Front turn signal light 12 V – 21 W x 2
Rear turn signal light 12 V – 21 W x 2
Meter light 12 V – 1.7 W x 2
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Fuse Main fuse 10 A
1-7

GENERAL INFORMATION
TORQUE VALUES
STANDARD
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt and nut 12 (1.2, 9)
10 mm bolt and nut 34 (3.5 , 25) 8 mm flange bolt and nut 26 (2.7, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
• Torque specifications listed below are for important fasteners.

• Others should be tightened to standard torque values listed above.
NOTES: 1. Apply oil to the threads and seating surface.

2. Lock nut: replace with a new one.
3. U-nut.
4. Apply locking agent to the threads.
ENGINE
THREAD DIA. TORQUE
ITEM Q’TY REMARKS
(mm) N·m (kgf·m, lbf·ft)
MAINTENANCE:
Spark plug 1 10 16 (1.6, 12)
Valve adjusting screw lock nut 2 5 10 (1.0, 7) NOTE 1
Engine oil drain bolt 1 12 24 (2.4, 18)
Engine oil strainer screen cap 1 30 20 (2.0, 14)
Final reduction oil check bolt 1 8 13 (1.3, 9)
Final reduction oil drain bolt 1 8 13 (1.3, 9)
LUBRICATION SYSTEM:
Oil pump mounting bolt 2 6 10 (1.0, 7)
Oil pump plate attaching screw 1 4 3 (0.3, 2.2)
FUEL SYSTEM:
Carburetor mounting nut 2 6 12(1.2, 9)
CYLINDER HEAD/VALVE:
Cylinder head cover bolt 2 6 12 (1.2, 9)
Cylinder head bolt 2 6 12 (1.2, 9)
Cam chain tensioner lifter plug 1 6 4 (0.4, 2.9)
Cam sprocket bolt 2 5 9 (0.9, 6.5) NOTE 1
Cylinder head nut 4 7 18 (1.8, 13) NOTE 1
Breather separator plate screw 3 4 3 (0.3, 2.2)
Intake shroud attaching screw 3 5 0.8 (0.08, 0.6)
Exhaust shroud attaching bolt 1 6 7 (0.7, 5.1)
KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH:
Left crankcase cover plate screw 5 4 3 (0.3, 2.2)
Kickstarter pedal bolt 1 8 29 (3.0,22)
Drive pulley face nut 1 14 93 (9.3, 69) NOTE 1
Clutch outer nut 1 12 49 (5.0, 36)
Clutch/driven pulley nut 1 28 54 (5.5, 40)
ALTERNATOR:
Fan cover bolt 3 5 0.8 (0.08, 0.6)
Flywheel nut 1 10 39 (4.0, 29)
Ignition pulse generator mounting bolt 2 5 6 (0.6, 4.3)
CRANKCASE/CRANKSHAFT:
Cam chain tensioner pivot bolt 1 6 10 (1.0, 7)
Left crankcase bolt 8 6 13 (1.3, 9)
OTHERS:
Center stand spring pin bolt 1 8 22 (2.2, 16)
Rear brake anchor pin nut 1 8 20 (2.0, 14)
1-8

GENERAL INFORMATION
FRAME
THREAD DIA. TORQUE
ITEM QTY. REMARKS
(mm) N·m (kgf·m, lbf·ft)
FRAME/BODY PANELS/EXHAUST SYSTEM:
Muffler protector bolt 2 6 14 (1.4, 10)
Exhaust pipe protector 2 6 14 (1.4, 10)
Exhaust pipe/muffler mounting bolt 2 10 49 (5.0, 36)
ENGINE REMOVAL/INSTALLATION:
Air supply hose band screw 1 4 3 (0.3, 22)
Engine mounting nut (Engine side) 1 10 49 (5.0, 36) NOTE 3
Engine mounting bracket nut (Frame side) 1 10 69 (7.0, 51) NOTE 3
FRONT WHEEL/BRAKE/SUSPENSION/STEERING:
Handlebar post pinch nut 1 10 49 (5.0, 36) NOTE 3
Front axle nut 1 12 59 (6.0, 43) NOTE 3
Front brake arm nut 1 6 10 (1.0, 7)
Front wheel hub nut 4 10 49 (5.0, 36) NOTE 1, 3
Front cushion upper bolt 2 8 32 (3.3, 24) NOTE 1, 2
Front cushion pivot arm mounting nut 2 8 26 (2.6, 19) NOTE 3
Front cushion pivot arm cover screw 2 5 4 (0.4, 2.9)
Front cushion pivot arm grease nipple nut 2 MT 6 4 (0.4, 2.9)
Steering stem lock nut 1 BC 1 68 (7.0, 51) see page 13-20
REAR WHEEL/BRAKE/SUSPENSION:
Rear axle nut 1 16 118 (12.0, 87) NOTE 1, 3
Rear brake arm bolt 1 6 10 (1.0, 7) NOTE 2
Rear wheel hub nut 1 10 49 (5.0, 36) NOTE 1, 3
Shock absorber upper mounting bolt 1 10 39 (4.0, 29)
Shock absorber lower mounting bolt 1 8 22 (2.2, 16)
OTHERS:
Auto cock nut 1 16 18 (1.8, 13)
1-9

GENERAL INFORMATION
TOOLS
DESCRIPTION TOOL NUMBER REFERENCE SECTION
Float level gauge 070MJ – 001-I110 5

Clutch center holder 070MB – KPL-I200 9
Universal holder 070MB – KPL-I100 9, 11
Fly wheel puller 070MC – KPL-I200 11
Bearing remover weight 070MC – KPL-I300 9, 10
Attachment, 32 x 35 mm 070GD – 002-I140 10, 13
Attachment, 37 x 40 mm 070GD – 002-I150 10
Attachment, 30 mm I.D. 070GD – 003-I120 13
Pilot, 12 mm 070GD – 004-I130 10, 13
Pilot, 17 mm 070GD – 004-I150 10
Pilot, 20 mm 070GD – 004-I160 10
Bearing remover shaft 070GD – 005-I100 13
Bearing remover head, 12 mm 070MD – 005-I130 13
Remover shaft 070GC – 001-I120 13
Adjusting remover head 070GC – 001-I110 13
Driver 070GD – 001-I100 9, 10, 13
Valve spring compressor 070GE – 001-I100 7
Seat cutter, 27.5 mm (45° EX) 070MF – 003-I180 7
Seat cutter, 22 mm (45° IN) 070MH – 003-I150 7
Flat cutter, 28 mm (32° EX) 070MH – 002-I120 7
Flat cutter, 24 mm (32° IN) 070MH – 002-I180 7
Interior cutter, 26 mm (60° IN/EX) 070MF – 004-I150 7
Cutter holder 070MH – 005-I150 7
Valve adjusting wrench 070MA – 001-I110 3
Lock nut wrench 070MA – KPL-I200 13
Lock nut wrench, 45.5 mm 070MA – KPL-I100 13
Bearing remover head, 12 mm 070MC – KPL-I400 10
Bearing remover shaft, 12 mm 070MC – KPL-I410 10
Bearing remover shaft, 15 mm 070MC – KPL-I510 10
Valve guide driver 070ND – 006-I150 7
Attachment, 44X49.5 mm 070MD – KPL-I210 13
Bearing driver 070MD – KPL-I100 9
Crankcase assembly collar 070MF – KWP-110 10
Assembly collar attachment 070MF – KWP-120 10
Crankcase assembly shaft 070MF – KWP-130 10
Valve guide reamer 070MH – 001-I160 7
Socket wrench, 39 x 41 mm 070MA – KPL-I300 9
Peak voltage adaptor 070GJ – 002-I110 16
Clutch spring compressor 070ME – KWP-110 9
Bearing remover (Driven face) 070MC – KWP-410 9
Bearing installer (Driven face) 070NC – KWP-410 9
Case/driven gear puller 070MC – KPL-I100 10
Slider base piston 070SRT – KSP-008 7
Snap ring plier 07914 – SA50-001 9
1-10

GENERAL INFORMATION
LUBRICATION & SEAL POINTS

ENGINE
LOCATION MATERIAL REMARKS
Camshaft cam lobes molybdenum oil solution

(Mixture of the engine oil
and molybdenum grease
in a ratio of 1 : 1)
Oil pump rotor Engine oil
Oil pump driven gear teeth
Stem seal fitting surface
Cylinder stud bolt threads
Camshaft holder nut threads and seating surface
Camshaft bearing rotating area
Cam sprocket teeth
Cam sprocket bolt threads and seating surface
Cam chain
Rocker arm slipper and sliding surface
Valve adjusting screw lock nut whole surface
Rocker arm shaft sliding surface
Valve stem sliding surface
Cylinder wall
Piston outer surface and piston pin hole
Piston pin outer surface
Piston ring whole surface
Drive pulley face nut threads and seating surface
Connecting rod big end
Connecting rod small end
Crankshaft bearing rotating area
Timing sprocket teeth of crankshaft
Oil pump drive sprocket teeth of crankshaft
Each bearing rotating area
Each O-ring
Each oil seal lip and circumference
Bearing hole in oil pump cover Multi-purpose grease
Oil pump driven gear shaft journal
Kickstarter driven gear shaft journal Apply 0.2 – 0.3 g
Kickstarter driven gear friction spring sliding area
Kickstarter spindle journal Apply 0.1 – 0.3 g
Starter pinion shaft journal Apply 0.1 – 0.3 g
Driven face boss inner surface Apply 5.0 – 5.5 g
Driven face ball bearing cavities
Driven face needle bearing rollers
1-11

GENERAL INFORMATION
FRAME
LOCATION MATERIAL REMARKS
Steering head bearing steel ball and race Multi-purpose grease
Front wheel dust seal lip
Speedometer gear teeth and sliding surface Do not contaminate the brake
Front brake cam pivot and shoe contacting area (Drum) lining surfaces.
Front brake panel anchor pin shoe contacting area (Drum)
Front brake cam dust seal sliding surface (Drum)
Front brake panel dust seal lip (Drum)
Speedometer pinion teeth and sliding surface
Speedometer pinion dust seal lip
Rear brake cam pivot and shoe contacting area
Rear brake panel anchor pin shoe contacting area
Rear brake dust seal lip
Front wheel hub nut thread and seating surface (Drum)
Rear wheel hub nut thread and seating surface
Center stand pivot
Front cushion upper bolt
Brake master cylinder push rod contacting area
Brake caliper pin boot inner surface
Brake caliper pin sliding surface
Each dust seal lips
Each O-ring
Front brake lever pivot Silicone grease

Rear brake lever pivot
Inside of front brake cable boot (Drum)
Inside of rear brake cable boot
Inside of throttle cable boot
Inside of speedometer cable
Seat catch wire and brackt connecting area
Front wheel hub stad bolt (Drum) Locking agent
Rear wheel hub stad bolt
Fork socket bolt thread
Rear axle nut threads and seating surface Engine oil
Handlebar post threads
Air cleaner connecting tube seating surface Cemedine #540 or
Handleber grip inside surface equivalent
Speedometer cable Cable lubricant
Throttle cable
Front brake cable (Drum)
Rear brake cable
1-12

GENERAL INFORMATION
CABLE & HARNESS ROUTING
SPEEDOMETER CABLE
FRONT BRAKE CABLE
REAR BRAKE CABLE
CAPACITOR DISCHARGE IGNITION

(CDI)
THROTTLE CABLE
STARTER RELAY
TURN SIGNAL RELAY
BATTERY
BATTERY BREATHER TUBE
HORN
1-13

GENERAL INFORMATION
FRONT BRAKE CABLE
REAR BRAKE CABLE
MAIN FUSE (10 A)
THROTTLE CABLE
CHOKE CABLE
SPEEDOMETER MAIN WIRE HARNESS

CABLE
1-14
GENERAL INFORMATION
SPEEDOMETER CABLE
FRONT BRAKE CABLE
THROTTLE CABLE
REAR BRAKE CABLE

STARTER RELAY
REGULATOR/
RECTIFIER
CHOKE CABLE UNIT
MAIN WIRE HARNESS
1-15
GENERAL INFORMATION
THROTTLE CABLE VACUUM TUBE
MAIN WIRE HARNESS
FUEL LINE
REAR BRAKE CABLE
CHOKE CABLE OVER FLOW TUBE
VACUUM TUBE
FUEL LEVEL
SENSOR WIRE
THROTTLE CABLE
CHOKE CABLE
FUEL LINE
MAIN WIRE HARNESS
SPARK PLUG WIRE
1-16
GENERAL INFORMATION
FUEL LINE
THROTTLE CABLE
VACUUM TUBE
MAIN WIRE HARNESS
CHOKE CABLE
REAR BRAKE CABLE
REAR RIGHT
TURN SIGNAL WIRE
BRAKE/
TAIL LIGHT WIRE
REAR LEFT TURN SIGNAL WIRE
1-17
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very important
because under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent the discharge of crankcase emissions into the atmosphere. Blow-
by gas is returned to the combustion chamber through the air cleaner and carburetor. Residual oil is collected in the breather pipe.
FRESH AIR
AIR CLEANER HOUSING
BLOW-BY GAS
CARBURETOR
BREATHER PIPE
1-18
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM)

The exhaust emission control system consists of a pulse secondary air injection system which introduces filtered air into the exhaust
gases at the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and
carbon monoxide into relatively harmiess carbon dioxide and water vapor.
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. PAIR check valve prevents reverse air flow
through the system. The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine
deceleration, thereby preventing after burn in the exhaust system.
No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is
recommended.
PULSE SECONDARY AIR INJECTION

(PAIR) CHECK VALVE
PULSE SECONDARY
AIR INJECTION (PAIR)
CARBURETOR CONTROL VALVE
FRESH AIR
VACUUM AIR
EXHAUST PORT
1-19
GENERAL INFORMATION
TUFFUP TUBE
TUFFUP tube is composed of double tubes which make a liquid room at tread side of the tyre to prevent puncture. The construction
is such that when a foreign body, a needle, nail etc. makes a pinhole, keep the air leak to minimum.
When the needle makes a pinhole, the liquid will be pushed between the needle and the tube. A fibre that is filled with a liquid will be
inserted between the needle at that time, and moreover, it is able to maintain an airtightness by a powder and extra liquid that includes
the liquid block up to the chink of fiber that already blocked up the pinhole.
(The material of liquid: antifreeze mixture, fiber, etc.)
If the needle comes off while riding, the liquid will be pushed to the pinhole then it will be blocked up in the same way as when it was
pricked with the needle. The liquid room that is included with the liquid is whenever influenced by the air pressure of the tube then if
the liquid room had a pinhole wherever, the liquid certainly will be pushed then block up the pinhole.
Detail of A:
DOUBLE TUBE
TUBE
LIQUID
LIQUID
AIR
PRESSURE
GROUND
Be blocked up by fiber and etc.

How to repair
The TUFFUP tube can be repaired same as a usual tube. Follow below
cautions. REPAIR POINT
• Do not inflate a TUFFUP tube larger than the tyre size as you do in a
conventional tube, or air will flow into the liquid room and lower its
performance.
• When finding a hole, inflate a TUFFUP tube to the same size as the inside
of the tyre and look for the hole from where liquid is leaking out.
• When fixing the TUFFUP tube, hold the area where a patch is attached
higher than other parts of the tube so that the liquid does not flow over the
area. Then wipe off the liquid thoroughly and attach the patch firmly or it
may cause air leak.
• TUFFUP tube cannot always prevent tyre puncture.

• Always use a proper size TUFFUP tube for the tyre.
• Because of its construction, foreign object(s) may be stuck into the tube even if the tyre seems to be inflated to the proper pressure.
If any foreign objects are found during maintenance, remove them and repair as soon as possible.
• Sometimes air leak does not stop after a nail etc. is removed from the tyre. In that case, tapping the tread of the tyre several times
can stop the air leak. Even if the air leak stops after tapping, it may starts leaking again. Repair it as soon as possible.
• Even if the air leak stops after tapping, it may starts leaking again. Repair it as soon as possible.
• When a tyre rim is wet or a tyre seems under-inflated, check for any abnormalities on the tyre and repair if necessary.
• When the liquid contacts with your skin or eye(s), rinse with plenty of water immediately.
• Like a conventional tube, damage over 3 mm cannot be repaired. In that case the whole tube must be replaced.
• Always use a new TUFFUP tube that is proper for tyre size when replacing.
• Always inflate to the specified pressure.
TUFFUP tube cannot prevent puncture in the following cases:

— A burst
— Damage on other area than tread (non-liquid room area)
— A hole caused by a rusty nail etc.
— When the CAUTION statements are not properly observed. (See above)
1-20
BODY PANEL LOCATIONS
FRONT HANDLEBAR COVER REAR HANDLEBAR

COVER SEAT
INNER COVER
BODY COVER
REAR FENDER
FRONT COVER
FLOOR PANEL
UNDER COVER
2-2
2-0
2. FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS 2-0 INNER COVER 2-6
SERVICE INFORMATION 2-1 UNDER COVER 2-6
TROUBLESHOOTING 2-1 REAR FENDER 2-7
FRONT CENTER COVER 2-2 HANDLEBAR COVER 2-7 2
FRONT COVER 2-2 MUFFLER 2-8
SEAT 2-2 MUFFLER PROTECTOR 2-8
BODY COVER LIFT UP 2-3 SARI STEP 2-9
BODY COVER 2-4 SIDE STAND 2-10
FLOOR MAT/FLOOR PANEL 2-5
SERVICE INFORMATION
GENERAL
Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• This section covers removal and installation of the body panels and exhaust system.
• Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install the exhaust pipe fasteners. Always tighten the exhaust pipe fasteners first,
then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Muffler mounting bolt 49 N·m (5.0 kgf·m, 36 lbf·ft)
Muffler protector mounting bolt 14 N·m (1.4 kgf·m, 10 lbf·ft)
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-1

FRONT CENTER COVER SCREWS

FRONT CENTER COVER
REMOVAL/INSTALLATION
Remove the screws (4 nos.) and release the front center
cover bosses (4 nos.) from mounting grommet.
Installation is in the reverse order of removal.
Grommets provided with locks, remove front center

SCREWS
cover carefully. Grommets may come along with the
BOSSES
cover while removing.
FRONT COVER
INNER COVER
Remove the front center cover (page 2-2). FRONT COVER
Remove the bolts (4 nos.) from the front cover.
Remove the screws (8 nos.) from the inner cover side

and (2 nos.) from lower side. BOLTS
Remove the front cover.
SCREWS
SEAT IGNITION KEY
Open the seat by using the ignition key.
2-2

Remove the nuts (2 nos.).
Remove the seat.
Installation is in the reverse order of removal. NUTS

SEAT
For removing the hinge seat, remove hinge pin.
HINGE SEAT
HINGE PIN
HELMET HOOKS
LUGGAGE BOX ASSEMBLY SCREWS A SCREWS A

Open the seat (page 2-2). BOLTS
Open luggage box cum petrol tank cover screws A
(4 nos.). SCREWS
Remove bolts (3 nos.). B
Remove luggage hook screws B (2 nos.)
Remove the screw C (1 no.) located slightly above the
luggage box hook.
Remove the luggage box assembly.
SCREW C
Always use bit T spanner with screw bit 2 H for removing

luggage hook screws.
REAR GRIP
Open the seat (page 2-2).
Remove the luggage box assembly (page 2-3).
Remove mounting bolts A (2 nos.).
Remove mounting bolts B (4 nos.).

Remove the rear grip.
BOLTS B
BOLTS A
BODY COVER LIFT UP BOLTS
Remove the Bolts (3 nos.) from the luggage box.

(page 2-3)
2-3

Lift up the body cover and stand the rod securely.

BODY COVER
Do not move the scooter when body cover is lifted up.
ROD
BODY COVER SEAT CATCH CABLE
Remove the Bolts (3 nos.) from the luggage box.
(page 2-3)
Detach the seat catch cable from the seat catch bracket.
SEAT CATCH BRACKET
Disconnect the rear turn signal light connectors and rear

brake/tail light connector.
Release wire from wireband. BODY COVER
Remove the body cover.

BOLTS
NOTE:
For easy installation, check the position of the bracket of
the body cover and boss of the frame.
BRAKE/
Never close the seat when seat latch cable is detached
TAIL LIGHT
from seat latch bracket.
CONNECTOR
BODY COVER DISASSEMBLY/ LUGGAGE BOX

ASSEMBLY REAR GRIP
Remove the seat (page 2-2).

SCREWS
Remove the rear grip (page 2-3).
Remove the luggage box (page 2-3).
Remove the screws (2 nos.), body cover hanger.
BODY COVER
HANGER
2-4

Remove the following

REAR CENTER COVER
—Front center cover screw (A) (6 nos.).
TAIL/BRAKE LIGHT
—Rear center cover screw (B) (4 nos.).
—Under cover screw (C) (4 nos.).
—Tail/brake light screws (D) (4 nos.).
—Stay front body cover bolts (A) (2 nos.).
—Rear grip support bolts (B) (4 nos.).
UNDER
COVER
REAR GRIP
SUPPORT
STAY FRONT
BODY COVER
FRONT CENTER COVER
FLOOR MAT/FLOOR PANEL FLOOR MAT
FLOOR PANEL
Liftup the body cover (page 2-4).
Remove the floor mat.
Remove the side screws (2 nos.). BOLTS A
Remove the bolts A (3 nos.) and Remove floor panel left
side cover.
Remove the bolts B (5 nos.). BOLTS B
Remove the floor panel.
SCREWS
Be careful not to damage the boss of the floor mat.
2-5

INNER COVER
INNER COVER
Remove the floor panel (page 2-5).
Remove the screws (8 nos.) from the inner side and
(2 nos.) from lower side. (page 2-2).
Disconnect the choke cable.
Remove the bolt (1 no.) and inner cover.
Installation is in the reverse order of removal. BOLT
CHOKE CABLE
UNDER COVER

Remove the inner cover (page 2-6).
Disconnect the battery breather tube.
Remove the bolts (4 nos.) and under cover.
UNDER COVER
BOLTS
2-6

REAR FENDER
BOLTS
REMOVAL/INSTALLATION OVER FLOW TUBE
Remove the body cover (page 2-4).
Disconnect the pulse secondary air injection (PAIR) air

cleaner tube.
Release fuel pipe and vacuum pipe from rear fender slot.
Release the over flow tube from the inside of the rear
fender.
Remove the bolts (3 nos.) and rear fender.
REAR FENDER SUB AIR CLEANER TUBE
FUEL PIPE
VACUUM PIPE
HANDLEBAR COVER
REMOVAL/INSTALLATION REARVIEW MIRRORS
Remove the followings:

— Rearview mirrors SCREWS
— Front side screw/washer (1 no.)
— Rear side screws (4 nos.)
Disconnect the head light/front turn signal light

connector.
Remove front handlebar cover assy.
FRONT
HANDLE BAR
SCREW/WASHER COVER ASSY
HEAD LIGHT / FRONT TURN

SIGNAL LIGHT CONNECTOR
2-7

Disconnect the following:

— Speedometer connector and wire REAR HANDLEBAR COVER
— Right and left handlebar switch connectors SPEEDOMETER
— Speedometer cable AND WIRE
Remove the inner side screws (2 nos.), rear side screw/ RIGHT
washer (1 no.) and rear handlebar cover. HANDLEBAR
SWITCH
Installation is in the reverse order of removal. CONNECTORS
SCREW/
SCREWS
WASHER
SPEEDOMETER CABLE
LEFT HANDLEBAR
SWITCH CONNECTORS
MUFFLER GASKET
Remove the exhaust pipe joint nuts (2 nos.) and muffler

mounting bolts (2 nos.).
NUTS
Remove the muffler and exhaust pipe gasket.
BOLTS
MUFFLER PROTECTOR PIPE PROTECTOR

Remove the bolts (3 nos.) and pipe protector.
Remove the bolts (2 nos.) and muffler protector.
MUFFLER PROTECTOR BOLTS
2-8

INSTALLATION GASKET
Install the muffler protector and tighten the bolts to

specified torque.
NUTS
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)
Set the new gasket to the exhaust pipe.

Install the muffler and loosly tighten the exhaust pipe
joint nuts (2 nos.).
Tighten the exhaust pipe joint nuts securely.
Install and tighten the muffler mounting bolts (2 nos.)
securely.
BOLTS
SARI STEP
LUGGAGE
BOX
Remove the rear fender (page 2-7).
BOLTS
Align the sari step with matching holes in the frame.
HOLES TO ALIGN
2-9

Insert the bolts (2 nos.) and tighten the nuts (2 nos.).
BOLTS
SIDE STAND
Lift up the body cover. (page 2-3).
Remove the floor mat from the floor panel.
FLOOR PANEL
FLOOR PANEL
Remove the floor under cover (page 2-6).
FLOOR UNDER COVER

BOLT
Align the hole of side stand bracket with matching holes

in the frame.
ALIGN
2-10

Insert the bracket bolts (2 nos.) and tighten the nuts

(2 nos.).
BOLTS
Align the hole of side stand with matching hole in the

bracket.
ALIGN
Insert the bolt (1 no.) side stand pivot and tighten it.
(One side of the hole of side stand is threaded in which NUT
the bolt is tightened.) BOLT
Tighten the nut with the side stand bolt.
Fit the side stand spring with the frame and side stand by
using screw driver.
Install the floor panel and floor mat in the reverse order of
removal.
SCREW
DRIVER SPRING
SIDE STAND
2-11

3. MAINTENANCE
SERVICE INFORMATION 3-1 DRIVE BELT 3-12
MAINTENANCE SCHEDULE 3-3 FINAL DRIVE OIL 3-12
FUEL LINE 3-4 BATTERY 3-12
THROTTLE OPERATION 3-4 BRAKE SHOES WEAR 3-13
CARBURETOR CHOKE 3-5 BRAKE SYSTEM 3-13
AIR CLEANER 3-5 BRAKE LIGHT SWITCH 3-15
3
CRANKCASE BREATHER 3-6 HEADLIGHT AIM 3-15
SPARK PLUG 3-6 CLUTCH SHOES WEAR 3-15
VALVE CLEARANCE 3-7 SUSPENSION 3-16
ENGINE OIL 3-8 NUTS, BOLTS, FASTENERS 3-17
ENGINE OIL STRAINER SCREEN 3-10 WHEELS/TIRES 3-17
ENGINE IDLE SPEED 3-10 STEERING HEAD BEARINGS 3-17
SECONDAR AIR SUPPLY SYSTEM
(AIR CLEANER) 3-11
SERVICE INFORMATION
GENERAL
• Support the scooter on a level surface before starting any work.
• Gasoline is extremely flammable and is explosive under certain conditions.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored
can cause a fire or explosion.
• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
— If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.

3-1
MAINTENANCE
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle grip free play 2 – 6 mm (1/12 – 1/4 in)
Standard CPR7EA-9
Spark plug gap 0.8 – 0.9 mm (0.031 – 0.035)
Valve clearance Intake 0.16 ± 0.02 mm (0.006 ± 0.001 in)
Exhaust 0.16 ± 0.02 mm (0.006 ± 0.001 in)
Engine oil capacity At draining 0.7 liter (0.7 US qt, 0.6 Imp qt)
At disassembly 0.8 liter (0.8 US qt, 0.7 Imp qt)
Engine idle speed 1,700 ± 100 min–1 (rpm)
Drive belt width 18.5 mm (0.73 in)
Final reduction oil capacity At draining 0.10 liter (0.11 US qt, 0.09 Imp qt)
At disassembly 0.12 liter (0.13 US qt, 0.11 Imp qt)
Front brake lever free play 10 – 20 mm (3/8 – 3/4 in)
Rear brake lever free play 10 – 20 mm (3/8 – 3/4 in)
Cold tire pressure Driver only Front 150 kPa (1.50 kgf/cm2, 22 psi)
Rear 200 kPa (2.00 kgf/cm2, 29 psi)
Driver and Front 150 kPa (1.50 kgf/cm2, 22 psi)
passenger Rear 250 kPa (2.50 kgf/cm2, 36 psi)
Tire size Front 90/100 - 10 53J
Rear 90/100 - 10 53J
Tire brand Front NYLOGRIP FE (MRF)
Rear NYLOGRIP FE (MRF)
TORQUE VALUES
Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft)
Valve adjusting screw lock nut 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply oil to the threads and seating surface.
Engine oil drain bolt 24 N·m (2.4 kgf·m, 18 lbf·ft)
Engine oil strainer screen cap 20 N·m (2.0 kgf·m, 14 lbf·ft)
Final reduction oil check bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
TOOLS
Valve adjusting wrench 070MA – 001I110
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean. R: Replace. A: Adjust. L: Lubricate.
Frequency whichever odometer reading [note (1)]
COMES SERVICE 1 st 2nd 3rd 4th PAID SERVICE

(Subsequent days/kms applicable from last service)
FIRST DAYS 30 120 210 300 90 180 REMARK

ITEM NOTE KMS 750 3000 6000 9000 3000 6000
* FUEL LINE I
* THROTTLE OPERATION I I I I
* CARBURETOR CHOKE I I I I
AIR CLEANER (NOTE 2)
Do not open the air cleaner element until
15000 kms. unless there is any driveability problem. Replace every 15000 kms
CRANKCASE BREATHER (NOTE 3) C C C C

SPARK PLUG I I I R I Replace every 9000 kms
* VALVE CLEARANCE I I
ENGINE OIL (NOTE 2) R I R I Top up every 3000 kms. Replace every 6000 kms.
* ENGINE OIL STRAINER SCREEN C C C

SECONDARY AIR FILTER (NOTE 2) C C C C C Replace every 12000 kms
* DRIVE BELT I Inspect every 9000 kms

Replace every 24000 kms
* FINAL DRIVE OIL (NOTE 4) Inspect every 12000 kms

Replace every 24000 kms
* ENGINE IDLE SPEED I I I I I

DRIVE BELT CASE C C C C
BATTERY I I I I
BRAKE SHOES I I
* BRAKE LOCK OPERATION I I I I I
BRAKE LIGHT SWITCH I I I I I
STARTER SWITCH I I I I I
* HEADLIGHT/INDICATOR SWITCH I I I I I
**CLUTCH SHOES WEAR I I I I
* HEADLIGHT ADJUSTMENT I I
* SUSPENSION I I
* NUTS, BOLTS, FASTENERS I I I I I
**WHEELS/TYRES I I I I I
**STEERING MOVEMENT I I I I I
WASHING AND CLEANING C C C C C
TEST DRIVE I I I I I
CLUTCH/BRAKE/THROTTLE I I I I
FREE PLAY
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and
is mechanically qualified.
** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skills.

3-3
MAINTENANCE
FUEL LINE
FUEL LINE
Lift up the body cover (page 2-3).
Check the fuel line for deterioration, damage or leakage.

Replace the fuel line if necessary.
THROTTLE OPERATION
Check for any deterioration or damage to the throttle cable.
Check the throttle grip for smooth operation. Check that
the throttle opens and automatically closes in all
steering positions.
If the throttle grip does not return properly, change the

throttle cable.
Reusing a damaged or abnormally bent or kinked

throttle cable can prevent proper throttle slide
operation and may lead to a loss of throttle control
while riding.
With the engine idling, turn the handlebar all the way to
2 – 6 mm (1/12 – 1/4 in)
the right and left to ensure that the idle speed does not
change. If idle speed increases, check the throttle grip
free play and the throttle cable connection.
Measure the throttle grip free play at the grip flange.
THROTTLE GRIP FREE PLAY: 2 – 6 mm (1/12 – 1/4 in)
Adjustments are made with the upper adjuster.

Slide the boot off the upper adjuster.
Loosen the lock nut and turn the adjuster as required.
After adjustment, tighten the lock nut and install the boot
over the adjuster properly.
Recheck the throttle operation.
Replace any damage parts, if necessary.
ADJUSTING NUT LOCK NUT
3-4
MAINTENANCE
CARBURETOR CHOKE CHOKE KNOB

Check for smooth choke knob operation.
Check the choke cable for frayed, kinked or other damage.
AIR CLEANER AIR CLEANER SCREW B

AIR CLEANER
ELEMENT COVER
Remove the screws A (6 nos.) and the air cleaner cover.
NOTE:
If the scooter is used in wet or dusty areas, more frequent
inspections are required.
SCREWS A
Remove the screw B (1 no.) and air cleaner element

assembly from the air cleaner housing. Replace the air
cleaner element as per maintenance schedule.
Do not clean with solvent to remove dust and also do not

use forced air on it. The special oil will be lost and filter
becomes dry. As the base filter paper is coarse, it cannot
block fine dust when it becomes dry.
Replace the air cleaner if it is excessively dirty, torn or

damage.
Do not place filter horizontally on any surface as dust can
stick to the filter due to oil present. If necessary place
vertically. Install immediately after inspection.

3-5
MAINTENANCE
CRANKCASE BREATHER
NOTE:
Service more frequently when ridden in rain, at full throttle,
or after the scooter is overturned. Service if the deposits
level can be seen in the drain tube.
Remove the clamp from the crankcase breather drain

tube and drain the deposits into a suitable container, then
install the clamp securely.
CLAMP
DRAIN TUBE
SPARK PLUG SPARK PLUG

Remove the spark plug cap and clean around the spark
plug base.
NOTE:
Clean around the spark plug base with compressed air
before removing the plug, and be sure that no debris is
allowed to enter the combustion chamber.
Remove the spark plug.
Check the insulator for cracks or damage, and the
electrodes for wear, fouling or discoloration.
If the electrode is corroded with carbon deposits, clean
the electrode using the wire brush or spark plug cleaner. CENTER ELECTRODE INSULATOR
Replace the plug if necessary.
RECOMMENDED SPARK PLUG:
NGK
Standard CPR7EA-9
SIDE ELECTRODE
Measure the spark plug gap between the center and side
electrodes with a wire gauge.
SPARK PLUG GAP: 0.8 – 0.9 mm (0.031 – 0.035 in)
If necessary, adjust the gap by carefully bending the side
electrode. PLUG GAP
Thread the spark plug in by hand to prevent cross-
threading then tighten it.
Install the spark plug cap.
Lift down the body cover (page 2-3).
3-6
MAINTENANCE
VALVE CLEARANCE CHOKE CABLE
NOTE: CLAMP
Inspect and adjust the valve clearance when the engine
is cold (below 35°C/95°F).
Liftup the body cover (page 2-3).
Disconnect the crankcase breather tube from the

cylinder head cover.
Release throttle cable and Choke Cable from the head
cover clamp. CRANKCASE
THROTTLE CABLE BREATHER TUBE
Remove the bolts (2 nos.) and cylinder head cover.

Remove the fan (page 11-2). CYLINDER HEAD COVER
BOLTS
Turn the crankshaft clockwise and align the “T” mark on

INDEX MARK
the flywheel with the index mark on the right crankcase.
Make sure that the piston is at TDC (Top Dead Center) on

the compression stroke.
Rocker arms should be slightly loose. If the rocker arms

are tight, turn the crankshaft clockwise 360° (one full turn)
and align the “T” mark with the index mark.
"T" MARK
Check the valve clearance by inserting a feeler gauge

between the valve adjusting screw and valve stem.
VALVE CLEARANCE:
IN/EX: 0.16 ± 0.02 mm (0.006 ± 0.001 in)
FEELER GAUGE
INDEX MARK

3-7
MAINTENANCE
If the valve clearance is incorrect, loosen the valve

adjusting screw lock nut and adjust the valve clearance ADJUSTING SCREW/
by turning the adjusting screw until there is a slight drag LOCK NUT
on the feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TOOLS:
Valve adjusting wrench 070MA – 001I110
Recheck the valve clearance.
VALVE ADJUSTING WRENCH
Check that the cylinder head cover gasket is in good

CYLINDER HEAD COVER
condition and replace it with a new one if necessary.
Install the cylinder head cover and two bolts.
Connect the crankcase breather tube to the cylinder head

cover.
Install the removed parts in the reverse order of removal.
GASKET
ENGINE OIL OIL FILLER

CAP/DIPSTICK
ENGINE OIL LEVEL CHECK
Place the scooter on its center stand on level ground.
Start the engine, let it idle for 2 – 3 minutes.
Stop the engine and wait for 2 – 3 minutes.
Remove the oil filler cap/dipstick, wipe it and insert it
without screwing it in.
Remove the oil filler cap/dipstick and check the oil level.
The oil level should be between the upper and lower
level marks on the dipstick.
If the oil level is below or near the lower level mark, add
the recommended engine oil to the upper level mark.
RECOMMENDED ENGINE OIL:

Honda 4-stroke oil or equivalent motor oil UPPER
API service classification: SJ LEVEL MARK
LOWER
LEVEL MARK
3-8
MAINTENANCE
NOTE: OIL VISCOSITIES

Other viscosities shown in the chart may be used when
the average temperature in your riding area is within the
indicated range.
Reinstall and tighten the oil filler cap/dipstick securely.
ENGINE OIL CHANGE

NOTE: OIL FILLER
CAP/DIPSTICK
Drain the engine oil while the engine is warm. This
ensures complete and rapid draining.
Place the scooter on its side stand.
Remove the oil filler cap/dipstick.
Place oil drain pan under the engine to collect the oil,
then remove the oil drain bolt.
O-RING
After draining the oil completely check that the sealing
washer on the drain bolt is in good condition and replace
if necessary.
Install and tighten the drain bolt.

OIL FILLER
NOTE:
CAP/DIPSTICK
If the maintenance for the engine oil strainer screen is
scheduled, perform it before filling the crankcase with
engine oil (page 3-10).
Fill the crankcase with the recommended engine oil
(page 3-8).
ENGINE OIL CAPACITY:

OIL DRAIN BOLT
0.7 liter (0.7 US qt, 0.6 lmp qt) at oil change
0.8 liter (0.8 US qt, 0.7 lmp qt) at disassembly
Install the oil filler cap/dipstick.
Check the oil level.
Make sure that there are no oil leaks.

3-9
MAINTENANCE
ENGINE OIL STRAINER SCREEN

Drain the engine oil.
Remove the oil strainer screen cap, spring and oil strainer
screen.
Clean the oil strainer screen thoroughly.
Check the screen for damage and the O-ring for damage
or deterioration.
Replace the oil strainer screen if necessary.
Install the oil strainer screen, spring and cap. OIL STRAINER SCREEN CAP
Tighten the oil strainer screen cap.
CAP STRAINER SCREEN

Fill the crankcase with the recommended engine oil

(page 3-8).
O-RING SPRING
ENGINE IDLE SPEED

NOTE:
• Inspect and adjust the idle speed after all other
engine adjustments are within specifications.
• The engine must be warm for accurate inspection and
adjustment.
Warm up the engine to normal operating temperature.

Stop the engine and place the scooter on its center stand
on level ground.
Lift up the body cover (page 2-3). THROTTLE STOP SCREW
Connect a tachometer.
Start the engine, check the idle speed and adjust by THROTTLE STOP SCREW
turning the throttle stop screw if necessary.
IDLE SPEED: 1,700 ± 100 min-1 (rpm)
3-10
MAINTENANCE
SECONDARY AIR SUPPLY SYSTEM

NOTE:
The secondary air supply system introduces filtered air
into exhaust gases in the exhaust port. The secondary air
PAIR CONTROL VALVE
is drawn into the exhaust port whenever there is negative
pressure pulse in the exhaust system. This charged PAIR CHECK VALVE
secondary air promotes burning of the unburned exhaust
gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively
harmless water and carbon dioxide respectively.
Remove the following:

— Fuel tank (page 5-11)
Check the air injection hoses between the pulse

secondary air injection (PAIR) control valve and cylinder
head cover for deterioration, damage or loose
connections. Make sure that the hoses are not cracked.
NOTE:
If the hoses show any signs of heat damage, inspect the
PAIR check valve in the PAIR control valve for damage.
Check the air suction hose between the air filter,

air chamber and PAIR control valve for deterioration,
damage or loose connections. Make sure that the hoses
are not kinked, pinched or cracked.
SECONDARY AIR SUPPLY SYSTEM HOUSING COVER

(AIR CLEANER)
Remove the screw and housing cover from the
secondary air cleaner.
Remove and clean the secondary air cleaner element as
per maintenance schedule.
SCREW
Wash the element in non-flammable or high flash point

solvent, and let it dry thoroughly. SECONDARY AIR CLEANER
ELEMENT
Never use gasoline or low flash point solvent for
cleaning the element. A fire or explosion could result.
Soak the element in engine oil (SAW 20W40) equivalent
and squeeze out any excess oil.
Do not rinse the filter element with both hands.

3-11
MAINTENANCE
DRIVE BELT
Remove the drive belt (page 9-9). COG
Check the drive belt for cracks, separation or abnormal

or excessive wear.
Measure the drive belt width.
SERVICE LIMIT: 17.5 mm (0.69 in)
Install the drive belt (page 9-18).
FINAL DRIVE OIL OIL CHECK BOLT

Remove the oil level check bolt.
Remove the oil drain bolt, slowly turn the rear wheel and
drain the oil.
NOTE:
Replace the final drive oil as per maintenance schedule.
After the oil is completely drained, install the oil drain bolt
with a new sealing washer and tighten it.
Fill the transmission case with recommended oil through OIL DRAIN BOLT
the check bolt hole up to the bottom edge of the check
bolt hole.
RECOMMENDED OIL:
Honda 4-stroke oil or equivalent motor oil
OIL CAPACITY:
Install the oil level check bolt with a new sealing washer
and tighten it.
BATTERY
Place the scooter on its center stand on level ground.
Remove the front center cover (page 2-2).
Remove the battery from battery case (page 15-6).
Check the electrolyte level of the battery.
When the electrolyte level nears the lower level line,
remove the filler caps from the battery and add distilled
water to the upper level line.
3-12
MAINTENANCE
After filling, install each filler cap firmly.

Charge the battery (Page 15-7).
Check the specific gravity (Page 15-7).
Install the battery in the reverse order of removal.
NOTE:
Add only distilled water. Tap water will shorten the service
life of the battery.
Never apply grease on the battery terminals. Always use
petroleum jelly.
BRAKE SHOES WEAR REFERENCE MARK INDICATOR ARROW
FRONT BRAKE
Replace the front brake shoes if the indicator arrow on
the brake arm aligns with the reference mark “Δ” on the
brake panel when the front brake is fully applied.
Refer to page 13-8 for front brake shoe replacement and

brake drum inspection.
REAR BRAKE INDICATOR

Replace the rear brake shoes if the indicator of the brake
arm aligns with the reference mark on the transmission
case when the rear brake is fully applied.
Refer to page 14-4 for rear brake shoe replacement and

brake drum inspection.
REFERENCE MARK
BRAKE SYSTEM
10 – 20 mm
(3/8 – 3/4 in)
FRONT BRAKE
Measure the front brake lever free play at the tip of the
brake lever.
FREE PLAY: 10 – 20 mm (3/8 – 3/4 in)

3-13
MAINTENANCE
If adjustment is necessary, turn the front brake adjusting

nut. ADJUSTING NUT
Check the brake cable for kinks or other damage.

Check that the brake arm, spring and fasterners are in
good condition.
while installing Speedometer and brake cable make

sure that both are always routed via the given
hose-clamps
REAR BRAKE
10 – 20 mm
Measure the rear brake lever free play at the tip of the (3/8 – 3/4 in)
brake lever.
FREE PLAY: 10 – 20 mm (3/8 – 3/4 in)
If adjustment is necessary, turn the rear brake adjusting

nut.
ADJUSTING NUT
Check the brake cable for kinks or other damage.
Check that the brake arm, spring and fasterners are in
good condition.
BRAKE LOCK OPERATION

NOTE:
Check the brake lock operation after the rear brake lever
free play check and adjusted.
Squeeze the rear brake lever and set the lock lever.
Check that the rear wheel is locked completely.
BRAKE LOCK LEVER
3-14
MAINTENANCE
BRAKE LIGHT SWITCH

BRAKE LOCK LEVER
The brake light switch at the brake lever cannot be

adjusted. If the brake light switch actuation and brake
engagement are off, either replace the switch unit or the
malfunctioning parts of the system.
Check that the brake light comes on when the brake lever
is pressed and the front-rear brake engagement begins.
HEAD LIGHT AIM

NOTE:
Adjust headlight beam as specified by local laws and
regulations.
Support the scooter on its center stand.
Adjust the head light beam vertically by loosening the
headlight adjusting bolt.
After adjusting the headlight aim, tighten the headlight
adjusting bolt.
ADJUSTING BOLT
CLUTCH SHOES WEAR CLUTCH SHOES

Remove the clutch shoes (page 9-12).
Check the clutch shoe for wear or damage.
Refer to (page 9-14), for clutch shoe lining inspection.
SHOE LINING

3-15
MAINTENANCE
SUSPENSION
Loose, worn or damaged suspension parts impair

scooter stability and control. Repair or replace any
damaged components before riding. Riding a scooter
with faulty suspension increases your risk of an
accident and possible injury.
FRONT
Check the action of the front suspension by applying the
front brake and compressing the forks several times.
Check the entire assembly for signs of leaks, damage or
loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer section 13 for fork service.
REAR
Check the action of the rear shock absorber by
compressing it several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer section 14 for shock absorber service.
Raise the rear wheel off the ground by placing the scooter
on its center stand.
Check for worn engine mounting bushings by grabbing
the rear wheel and attempting to move the wheel side to
side.
Replace the bushings if any looseness is noted
(section 14).
3-16
MAINTENANCE
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to
correct torque values (page 1-8).
Check that all cotter pin, safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELS/TYRES
NOTE:
Tyre pressure should be checked when the tires are
COLD.
Check the tire pressure with the tire pressure gauge.
RECOMMENDED TIRE PRESSURE:

Driver only:
Front: 150 kPa (1.50 kgf/cm2, 22 psi)
Rear: 200 kPa (2.00 kgf/cm2, 29 psi)
Driver and passenger:
Front: 150 kPa (1.50 kgf/cm2, 22 psi)
Rear: 250 kPa (2.50 kgf/cm2, 36 psi)
Check the tires for cuts, embedded nails, or other

damage.
Check the front and rear wheels for trueness.
Check the wear indicator to check for insufficient tread
depth.
If the wear indicator is visible, the tire should be replaced.
WEAR INDICATOR
STEERING HEAD BEARINGS

Support the scooter on its center stand, and raise the
front wheel off the ground.
Check that the control cables do not interfere with the
handlebar rotation.
Check that the handlebar moves freely from side to side.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings
(section 13).

3-17
LUBRICATION SYSTEM
INTAKE ROCKER ARM
CRANKSHAFT
OIL STRAINER SCREEN
OIL PUMP
4-2
4-0
4. LUBRICATION SYSTEM
SERVICE INFORMATION 4-1 OIL PUMP 4-2
TROUBLESHOOTING 4-1
SERVICE INFORMATION
GENERAL
4
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
SPECIFICATIONS
Unit: mm (in)

Engine oil capacity At draining 0.7 liters (0.7 US qt, 0.6 lmp qt) —
At disassembly 0.8 liters (0.8 US qt, 0.7 lmp qt) —
API service classification: SJ —
Oil pump Rotor tip clearance 0.15 (0.006) 0.20 (0.008)
Outer rotor-to-body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Pump side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
TORQUE VALUES
Oil pump mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Oil pump plate attaching screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
TROUBLESHOOTING
Oil level too low
• External oil leaks
• Worn valve guide or seal
• Worn piston rings or incorrect piston ring installation
• Worn cylinder
• Oil not added frequently enough
Oil contamination
• Oil not changed often enough
• Worn piston rings

4-1
LUBRICATION SYSTEM
OIL PUMP
REMOVAL OIL PUMP COVER
Drain the engine oil (page 3-9).

Remove the alternator assembly (page 11-2).
Remove the oil pump cover bolts (2 nos.).
BOLTS
Screw the two 5 mm bolts into the threaded holes in the

oil pump cover and pull the cover out of the right 5 mm BOLTS
crankcase.
Remove the oil pump gear shaft and gear.
OIL PUMP GEAR
GEAR SHAFT
Remove the oil pump mounting bolts (2 nos.) and the oil
pump assembly.
OIL PUMP
BOLTS
4-2
LUBRICATION SYSTEM
DISASSEMBLY SCREW
Remove the dowel pins (2 nos.).
Remove the oil pump plate attaching screw (1 no.) and
DOWEL PINS
pump plate.
PUMP PLATE
INSPECTION
FEELER GAUGE
Check oil pump gear for any damage/worn-out teeth.
OIL PUPM GEAR
Insert the oil pump gear into the oil pump.
Measure the outer rotor-to-body clearance. ROTOR
BODY
Measure the rotor tip clearance.
Pull out the oil pump gear.
Measure the pump end clearance.
Remove the inner and outer rotors from the pump body.
Clean the all disassembled parts thoroughly.

4-3
LUBRICATION SYSTEM
ASSEMBLY
OUTER ROTOR
DOWEL PINS
INNER ROTOR
OIL PUMP GEAR
PUMP PLATE
PUMP BODY
GEAR SHAFT
PUMP COVER
Install the outer and inner rotors into the pump body.
Install the two dowel pins. SCREW
Install the pump plate by aligning the holes in the pump
plate with the two dowel pins.
DOWEL PINS
Install and tighten the pump plate attaching screw.
TORQUE: 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Check that the oil pump rotates smoothly with the oil pump
gear.
PUMP PLATE
INSTALLATION
Install the oil pump assembly onto the right crankcase and
tighten the mounting bolts (2 nos.).
BOLTS
4-4
LUBRICATION SYSTEM
Install the oil pump gear and gear shaft into the oil pump.
OIL PUMP GEAR
GEAR SHAFT
Apply grease to the oil pump gear shaft hole in the oil
pump cover.
O-RING
Coat a new O-ring with oil and install it onto the oil pump
cover.
Install the oil pump cover into the right crankcase.
OIL PUMP COVER
Install and tighten the oil pump cover bolts(2 nos.).

Install the alternator assembly (page 11-3).
Fill the crankcase with recommended engine oil

(page 3-8).
BOLTS

4-5
FUEL SYSTEM
12 N·m (1.2 kgf·m, 9 lbf·ft)
5-2
5-0
5. FUEL SYSTEM
SERVICE INFORMATION 5-1 THROTTLE SWITCH 5-9
TROUBLESHOOTING 5-2 AIR SCREW ADJUSTMENT 5-10
AIR CLEANER HOUSING 5-3 FUEL TANK 5-11
CARBURETOR REMOVAL 5-4 SECONDARY AIR SUPPLY SYSTEM 5-12
CARBURETOR INSTALLATION 5-8
SERVICE INFORMATION
GENERAL
5
• Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
• If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed
area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting
in loss of vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause
a fire or explosion.
• If the vehicle is to be stored for more than one month, drain the float bowl. Fuel left in the float bowl may cause clogged jets
resulting in hard starting or poor driveability.
• For the fuel level sensor removal/installation and inspection, refer to section 18.
• Before removing the carburetor, place an approved fuel container under the carburetor drain tube, loosen the drain screw and
drain the carburetor.
• When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any
foreign material from dropping into the engine.
SPECIFICATIONS
ITEM SPECIFICATIONS
Identification number PB16 x 1

Venturi diameter 16 mm (0.63 in)
Main jet #90
Slow jet #35 x #35
Float level 11.7 ± 0.5 mm (0.46 ± 0.02 in)
Jet needle clip position 3rd groove from top
Air screw initial opening 1 7/8 turns out
Air screw final opening 4 turns out
Idle speed 1,700 ± 100 min–1 (rpm)
PAIR control valve specified vacuum 420 mmHg (16.54 in Hg)

5-1
FUEL SYSTEM
TORQUE VALUES
Carburetor mounting bolts 12 N·m (1.2 kgf·m, 9 lbf·ft)
TOOL
Float level gauge 070MJ – 001-I110
TROUBLESHOOTING
Engine won’t start Backfiring or misfiring during acceleration
• No fuel in fuel tank • Fuel mixture too lean
• No fuel to carburetor • Ignition system faulty (section 16)
— Fuel stainer clogged • Lean mixture in slow circuit
— Fuel tube clogged • Faulty PAIR control valve
— Fuel valve vacuum tube clogged • Faulty PAIR check valve
— Float valve stuck • Clogged hose of the PAIR system
— Float level misadjusted
— Fuel tank cap breather hole clogged Lean mixture
• Too much fuel getting into the carburettor • Fuel jets clogged
— Air cleaner clogged • Float valve faulty
— Flooded carburetor • Float level too low
— Float valve wornout • Fuel tank cap breather hole clogged
— Deposition on float valve seat • Fuel strainer clogged
— Fuel tank cap breather hole block • Fuel tube restricted
— Intake air leak • Intake air leak
• Fuel cock stuck • Throttle valve faulty
• Bad fuel quality • Carburettor tunning
• Fuel jet clogged
• Fuel contaminated/deteriorated Rich mixture
• By-starter valve faulty • Float valve faulty
• Ignition system faulty (section 15) • Choke valve in close position
• Float level too high
Engine stalls, hard to start, rough idling • Air passage clogged
• Fuel mixture too lean/rich • Air jets clogged
• Fuel contaminated/deteriorated • Air cleaner contaminated
• Intake air leak • Choke valve faulty
• Idle speed misadjusted • Ignition timing improper
• Air screw misadjusted
• Float level misadjusted
• Carburetor clogged
• Compression too low
• Ignition system faulty (section 16)
• Flooded carburetor
• Improper carburetor tunning
• Bad quality of fuel
• Fuel tank cap breather hole block
• Air filter chocked
• Fuel line restricted
5-2
FUEL SYSTEM
AIR CLEANER HOUSING ENGINE BREATHER HOSE
For air cleaner housing cover removal and element

replacement (see page 3-5). SCREW
REMOVAL
Loosen the air cleaner connecting guide band screw.
Disconnect the engine breather hose from the cylinder
head cover.
Disconnect the transmission case breather tube from

the air cleaner housing. BREATHER TUBE
Remove the mounting bolt (2 nos.) and air cleaner

housing.
BOLTS
AIR CLEANER HOUSING
INSTALLATION
Install the air cleaner housing in the reverse order of
removal.
Route the tubes properly (page 1-16).
Lift down the body cover.

5-3
FUEL SYSTEM
CARBURETOR REMOVAL
CARBURETOR TOP
THROTTLE VALVE
Loosen the carburetor top.
Remove the carburetor top and throttle valve from the

carburetor. THROTTLE VALVE
Remove the throttle cable from the throttle valve while

THROTTLE VALVE SPRING
compressing the throttle valve spring.
THROTTLE CABLE
Remove the valve plate set and jet needle.
Check the throttle valve and jet needle for scratch, wear
or damage. THROTTLE VALVE JET NEEDLE
VALVE PLATE SET
5-4
FUEL SYSTEM
CARBURETOR BODY THROTTLE SWITCH

BOLTS CONNECTORS
SCREW
Gasoline is extremely flammable and explosive under

certain conditions. Work in a well ventilated area.
Smoking or allowing flames or sparks in the work area
or where gasoline is stored can cause a fire or
explosion.
Disconnect the fuel tube from the carburetor.

Remove the choke cable.
Disconnect the throttle switch connectors. CHOKE CABLE FUEL TUBE
Remove the drain tube.

Loosen the air cleaner connection guide band screw.
Remove the carburetor mounting bolts (2 nos.), insulator
and carburetor.
DISASSEMBLY
SCREWS
Remove the float chamber screws (2 nos.) and float
chamber.
FLOAT CHAMBER
Pull out the float pin and remove the float and float valve.
FLOAT PIN
Inspect the float valve and seat for wear or damage. FLOAT VALVE
Replace the float valve if it is damaged.

If the seat is damaged, replace the carburetor body.
FLOAT

5-5
FUEL SYSTEM

O-RING NEEDLE JET
— Main jet
— Needle jet NEEDLE
— Needle jet holder JET
— Slow jet WASHER HOLDER
— Air screw/Spring/Washer/O-ring
AIR
— Throttle stop screw/spring MAIN
SCREW
JET
NOTE:
Before removing the pilot screw, record the number of
turns until it seats lightly; then remove the air screw.
SPRING
THROTTLE SLOW
if the air screw is tighiened against the seat, air screw seat O-RING STOP SCREW JET
will get damaged.
Blow open each air and fuel passages in the carburetor

body with compressed air.
Check each part for wear or damage and replace them if

necessary.
ASSEMBLY AIR SCREW
THROTTLE FLOAT PIN

CABLE
FLOAT VALVE
THROTTLE STOP
RETAINER SCREW
FLOAT
DRAIN SCREW
JET NEEDLE
NEEDLE CLIP
NEEDLE JET HOLDER
THROTTLE
VALVE
SLOW JET NEEDLE JET
O-RING
MAIN JET
FLOAT CHAMBER
5-6
FUEL SYSTEM
Install the following:

O-RING NEEDLE JET
— Throttle stop screw/spring
— Slow jet NEEDLE
— Needle jet holder JET
— Needle jet WASHER HOLDER
— Main jet
AIR
SCREW MAIN
JET
Handle all jets with care. They can easily be scored or
scratched.
Install the air screw/spring/washer/o-ring and return it to SPRING

its original position as noted during removal. THROTTLE SLOW
Perform the air screw adjustment procedure if a new air O-RING STOP SCREW JET
screw is installed (page 5-10).
Install the float and float valve in the carburetor body, then
install the float pin through the body and float. FLOAT PIN
FLOAT VALVE
FLOAT
FLOAT LEVEL INSPECTION FLOAT LEVEL GAUGE
With the float valve seated and the float arm just touching
the valve, measure the float level with the special tool as
shown.
FLOAT LEVEL: 11.7 ± 0.5 mm (0.46 ± 0.02 in)
TOOL:
CARBURETOR FLOAT LEVEL GAUGE
070MJ – 001-I110
The float cannot be adjusted.

Replace the float assembly if it the float level is out of
specification.
Install a new O-ring into the float chamber groove.
O-RING

5-7
FUEL SYSTEM
Install the float chamber.

Install and tighten the screws (2 nos.) securely. SCREWS
FLOAT CHAMBER
CARBURETOR INSTALLATION BOLTS

THROTTLE SWITCH
CONNECTORS
CARBURETOR BODY SCREW
Install the carburetor body into the insulator and air

cleaner connecting tube.
Tighten the carburetor mounting bolts and air cleaner
connecting tube band screw.
Install the fuel tube and drain tube.
Install the choke cable.
Connect the throttle switch connectors.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) CHOKE CABLE FUEL TUBE
THROTTLE VALVE
Install the needle clip into the jet needle.
JET NEEDLE
STANDARD POSITION: 3rd groove from top
Install the jet needle into the throttle valve.

Install the valve plate set. THROTTLE VALVE
VALVE PLATE SET
5-8
FUEL SYSTEM
Install the throttle valve spring onto the throttle cable.

THROTTLE VALVE SPRING
Connect the throttle cable to the throttle valve while
compressing the throttle spring.
THROTTLE CABLE
Install the throttle valve into the carburetor body.

THROTTLE VALVE
Tighten the carburetor top securely.
After installation check that there is no fuel leaks. CARBURETOR TOP
Perform the following adjustment:

— Throttle grip free play (see page 3-4).
— Idle speed adjustment
IDLE SPEED: 1,700 ± 100 min–1 (rpm)
THROTTLE SWITCH
REMOVAL
Disconnect the throttle switch wire connectors
(page 16-7).
Remove the screws (2 nos.) and throttle switch.
SCREWS

5-9
FUEL SYSTEM
Remove the O-ring from the carburetor body.

THROTTLE SWITCH
O-RING
Throttle switch inspection (see page 16-7).
INSTALLATION
THROTTLE SWITCH
O-RING
Install a new O-ring to the carburetor body.
Install the throttle switch by aligning the hole of the
carburetor with the hole of the throttle switch.
ALIGN
Install and tighten the screws ( 2 nos.) securely.
SCREWS
AIR SCREW ADJUSTMENT

IDLE DROP PROCEDURE AIR SCREW
NOTE:
• The air screw is factory preset and no adjustment is
necessary unless the carburetor is overhauled or the
air screw is replaced.
• Use a tachometer with graduations of 50 min–1 (rpm)
or smaller that will accurately indicate a 50 min–1 (rpm)
change.
1. Turn the air screw until it seats lightly, then back it out THROTTLE STOP SCREW
to the specification given.
This is an initial setting prior to the final air screw
adjustment.
5-10
FUEL SYSTEM
Damage to the air screw seat will occur if the pilot screw is
tighten against the seat.
INITIAL OPENING: 1 7/8 turns out
2. Warm up the engine to operating temperature.

Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect the tachometer,
according to the manufacturer’s instructions
4. Start the engine and adjust the idle speed with the
throttle stop screw.
IDLE SPEED: 1,700 ± 100 min–1 (rpm)
5. Turn the air screw in or out slowly to obtain the highest

engine speed.
6. Lightly open the throttle 2 or 3 times, then adjust the
idle speed with the throttle stop screw.
7. Turn the air screw in until the engine speed drops by
50 min–1 (rpm).
FINAL OPENING: 4 turns out
8. Readjust the idle speed with the throttle stop screw.
FUEL TANK FUEL LEVEL

SENSOR WIRE
Gasoline is extremely flammable and is explosive

under certain condition. KEEP OUT OF REACH OF
CHILDREN.

Disconnect the fuel level sensor 2P connector. FUEL TUBE
Disconnect the fuel and vacuum tubes from the fuel valve.
Remove the wire bands.
Remove the bolts (4 nos.), seat lock bracket and fuel tank
from the frame
For fuel level sensor removal/installation and inspection, BOLTS

refer to section 18.
NOTE:
• After installation, check that there are no fuel leaks. SEAT LOCK
BRACKET FUEL TANK
• Route the cable, wire and tubes properly (page 1-16).

5-11
FUEL SYSTEM
SECONDARY AIR SUPPLY SYSTEM

SYSTEM INSPECTION
Start the engine, and warm it up to normal operating
temperature, then stop the engine.
SCREWS
Disconnect the air suction hose from the secondary air
cleaner housing.
COVER PAIR CONTROL
Check the air suction hose port is clean and free carbon
VALVE BODY
deposits.
Check the PAIR check valve if the port is carbon fouled
Disconnect the vaccum hose from the intake pipe,

and connect it to the vaccum pump.
Install the plug to the intake pipe.
Start the engine, and open the throttle slightly to be
certain that air is sucked in through the air suction hose .
If the air is not drawn in, check the air suction hose for
clogging.
With the engine running, gradually apply vaccum to the
PAIR control valve vaccum hose.
Check that the air suction hose stop drawing air, and that
the vaccum does not bleed.
SPECIFIED VACCUM: 66.7 kPa (500 mmHg)
If the air is drawn in or if the specified vaccum is not

maintained, install a new PAIR control valve.
Remove the plug from the intake pipe.
Disconnect the vaccum hose from the vaccum pump,
and connect it to the intake pipe.
PAIR CHECK VALVE REMOVAL/

INSTALLATION
Remove the screws (2 nos.) of PAIR check valve cover
and remove the cover from the PAIR control valve body.
SCREWS
COVER PAIR CONTROL

VALVE BODY
5-12
FUEL SYSTEM
Inspect the check valve for damage or fatigue. Replace if

necessary. COVER CHECK
Replace the PAIR check valve if the seat rubber is cracked, VALVE
Deteriorated or damaged, or if there is clearance between
the reed and seat.
Install the PAIR check valve and cover.
Install and tighten the screws (2 nos.) securely.
SEAT RUBBER
PAIR CONTROL VALVE REMOVAL/

INSTALLATION
Remove the PAIR check valve (page 5-11).
Disconnect the vacuum tube from the PAIR control valve.
PAIR CONTROL
VACUUM TUBE VALVE BODY
Disconnect the PAIR air cleaner hose.

Remove the bolts (2 nos.) and PAIR control valve body.
PAIR AIR
CLEANER HOSE
BOLTS
PAIR CONTROL
VALVE

5-13
ENGINE REMOVAL/INSTALLATION
49 N·m (5.0 kgf·m, 36 lbf·ft)
6-2
6-0
6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 6-1 ENGINE INSTALLATION 6-4
ENGINE REMOVAL 6-2
SERVICE INFORMATION
GENERAL
• The following components can be serviced with the engine installed in the frame:
— Oil pump (section 4)
— Carburetor (section 5)
— Drive and driven pulleys/clutch (section 9)
— Final reduction (section 10)
— Alternator (section 11) 6
• The following components require engine removal for servicing:
— Cylinder head/valves (section 7)
— Cylinder/piston (section 8)
— Crankcase/crankshaft (section 12)
ITEM SPECIFICATIONS
Engine dry weight 25.1 kg (55.4 lbs)
Engine oil capacity at draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
at disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt)
TORQUE VALUES
Air supply hose band screw 3 N·m (0.3 kgf·m, 22 lbf·ft)
Engine mounting nut 49 N·m (5.0 kgf·m, 36 lbf·ft)
Engine mounting bracket nut 69 N·m (7.0 kgf·m, 51lbf·ft)

6-1
ENGINE REMOVAL
VACUUM TUBE
Place the scooter on its center stand and support the frame
securely.
Drain the engine oil if the crankcase is to be serviced
(page 3-9).
Remove the body cover (Page 2-4).

— Throttle valve (page 5-4).
— Choke cable (page 5-5).
— Spark plug cap (page 3-6).
Disconnect the fuel tube from carburetor and vacuum

tube. 2P CONNECTOR
Disconnect the following:
— starter motor (2P) connector (page 17-3).
— alternator wire connectors (page 11-2).
— Ignition pulse generator wire connector (page 16-5).
Release the wires from the wire band and clamp.
WIRE BAND
Loosen the screw (1 no.) and disconnect the air supply

hose.
Disconnect the starter motor ground wire from frame.
Disconnect the air duct from the frame. GROUND WIRE AIR DUCT
SCREW
AIR SUPPLY HOSE
Remove the rear brake adjusting nut, disconnect the brake

cable from the brake arm and remove the brake arm joint.
Remove the brake cable from the crankcase and cable
clamp.
BRAKE CABLE ADJUSTING NUT
BRAKE ARM JOINT
6-2
Remove the engine mounting nut and pull out the

mounting bolt from the left side.
ENGINE MOUNTING NUT
Remove rear shock absorber upper mounting bolt

(page 14-6).
UPPER MOUNTING BOLT
Remove the engine from the frame.
Support the frame securely to prevent it from turning

over.
Check the engine mounting bracket for damage or

deterioration and replace if necessary.
If you want to remove the engine mounting bracket,

remove the engine mounting bracket nut and pull out the
mounting bolt from the left side. BOLT
Install the engine mounting bracket and mounting bolt.

Install and tighten the nut. NUT
TORQUE: 69 N·m (7.0 kgf·m, 51lbf·ft)
ENGINE MOUNTING BRACKET

6-3
ENGINE INSTALLATION
Route the wires, tubes and cables properly (page 1-16).
Install the engine into the frame.
Insert the engine mounting bolt from the left side.

Install and tighten the nut.

ENGINE MOUNTING NUT
Install rear shock absorber upper mount bolt

(page 14-6).
UPPER MOUNTING BOLT
Install the brake cable to the crank case and cable clamp.
Install the brake arm joint and connect the brake cable.
Install the rear brake adjusting nut.
Adjust the rear brake lever free play (page 3-14).
BRAKE CABLE ADJUSTING NUT
BRAKE ARM JOINT
Connect the air duct to the frame.

Tighten the air duct band screw.
SCREW
Connect the air duct from the frame.
AIR DUCT
6-4
Tighten the screw and connect the air supply hose.

Connect the starter motor ground wire from frame.
GROUND WIRE
AIR SUPPLY HOSE
Connect the following.

— Starter motor 2P connector (page 17-3). 2P CONNECTOR
— Alternator wire connector (page 11-2).
— Ignition pluse generator (page 16-5).
Connect the wire to the wire band and clamp.
WIRE BAND
Connect the vacuum tubes and fuel tube in carburetor.

Connect the air supply hose and tighten the screw.
VACUUM TUBE
FUEL TUBE
— Throttle valve (page 5-8).
— Choke cable (page 5-5).
— Spark plug cap (page 3-6).
Adjust the throttle lever free play.

6-5
12 N·m (1.2 kgf·m, 9 lbf·ft)
4 N·m (0.4 kgf·m, 2.9 lbf·ft)
18 N·m (1.8 kgf·m, 13 lbf·ft)
7 N·m (0.7 kgf·m, 5.1 lbf·ft)
0.8 N·m (0.08 kgf·m, 6 lbf·ft)
7-2
7-0
7. CYLINDER HEAD/VALVES
SERVICE INFORMATION 7-1 VALVE GUIDE REPLACEMENT 7-9
TROUBLESHOOTING 7-2 VALVE SEAT INSPECTION/REFACING 7-10
CYLINDER COMPRESSION 7-3 CYLINDER HEAD ASSEMBLY 7-15
INTAKE/EXHAUST SHROUDS 7-4 CYLINDER HEAD INSTALLATION 7-16
CYLINDER HEAD REMOVAL 7-5 CAMSHAFT REMOVAL 7-19
CYLINDER HEAD DISASSEMBLY 7-7 CAMSHAFT INSTALLATION 7-20
CYLINDER HEAD INSPECTION 7-8
SERVICE INFORMATION
GENERAL
7
• The engine must be removed from the frame to service the rocker arms, camshaft, cylinder head and valves.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft and rocker arm lubricating oil is fed through the oil passages in the cylinder head. Clean the oil passage before
assembling the cylinder head.
SPECIFICATIONS
Unit: mm (in)

Cylinder compression 843 kPa (8.6 kgf/cm2, 122 psi) at
—
520 min–1 (rpm)
Valve clearance IN/EX 0.16 ± 0.02 mm (0.006 ± 0.001 in) —
Camshaft Cam lobe height IN 32.066-32.226 (1.2625-1.2688) 32.041 (1.2615)
EX 31.816-31.976 (1.2526-1.2589 ) 31.791 (1.2516)
Cylinder head warpage — 0.05 (0.002)
Rocker arm I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Shaft O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Valve, Stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1945) 4.90 (0.193)
valve guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve spring Free length 29.78 (1.17) 26.8 (1.06)
Valve seat width 0.7 – 0.8 (0.02-0.03) —
TORQUE VALUES
Cylinder head cover bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Cam chain tensioner lifter plug 4 N·m (0.4 kgf·m, 2.9 lbf·ft)
Cam sprocket bolt 9 N·m (0.9 kgf·m, 6.5 lbf·ft) Apply oil to the threads and seating surface.
Cylinder head nut 18 N·m (1.8 kgf·m, 13 lbf·ft) Apply oil to the threads and seating surface.
Breather sparator plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Intake shroud attaching screw 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
Exhaust shroud attaching bolt 7 N·m (0.7 kgf·m, 5.1 lbf·ft)

7-1
TOOLS
Valve spring compressor 070GE – 001-I100
Valve guide reamer 070MH – 001-I160
Valve guide driver 070ND – 006-I150
Seat cutter, 22 mm (45° IN) 070MH – 003-I150
Seat cutter, 27.5 mm (45° EX) 070MF – 003-I180
Flat cutter, 24 mm (32° IN) 070MH – 002-I180
Flat cutter, 28 mm (32° EX) 070MH – 002-I120
Interior cutter, 26 mm (60° EX) 070MF – 004-I150
Cutter holder 070MH – 005-I150
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end
noises with a sounding rod or stethoscope.
Compression too low, hard starting or poor performance Excessive noise

at low speed. • Incorrect valve clearance
• Valves • Sticking valve or broken valve spring
— Incorrect valve clearance • Worn or damaged camshaft
— Burned or bent valve • Worn or damaged rocker arm and/or shaft
— Incorrect valve timing • Worn or damaged cam sprocket teeth
— Broken valve spring • Loose or wom cam chain
— Uneven valve seating • Worn or damaged cam chain tensioner
• Cylinder head • Loose spark plug
— Leaking or damaged cylinder head gasket • Faulty connecting rod or crankshaft (section 12)
— Warped or cracked cylinder head • Worn,damaged or pitted ball bearing.
— Loose spark plug
• Faulty cylinder or piston (section 8) Rough idle
• Low cylinder compression
Compression too high
• Excessive carbon built-up on piston or combustion
chamber
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Faulty cylinder or piston (section 8)
7-2
CYLINDER COMPRESSION
If the engine must be running to do some work, make

sure the area is well-ventilated. Never run the engine
in an enclosed area.

Stop the engine,
Liftup the body cover.
Disconnect the spark plug cap and remove the spark COMPRESSION GAUGE
plug.
Install the compression gauge attachment in a spark plug

hole.
Connect the compression gauge to the attachment.

Open the throttle all the way and crank the engine with the
starter motor or apply kick 5-6 times and check the gauge
reading.
Crank the engine until the gauge reading stops rising.

The maximum reading is usually reached within 4 – 7
seconds.
STANDARD: 843 kPa (8.6 kgf/cm2, 122 psi) at

520 min–1 (rpm)
If compression is high, it indicates that carbon deposits

have accumulated on the combustion chamber and/or
the piston crown.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of clean

engine oil into the cylinder through the spark plug hole
and recheck the compression.
If the compression increases from the previous value,

check the cylinder, piston and piston rings.
• Worn piston ring
• Worn cylinder and piston
If compression is the same as the previous valve, check

the valves for leakage, cylinder head bolt looseness.

7-3
INTAKE/EXHAUST SHROUDS
REMOVAL
BOLTS NUTS
Remove the bolts (3 nos.), gasket and air supply hose.
— Carburator (page 5-4).
— Cooling fan cover (page 11-2).
— Muffler assembly (page 2-8).
Remove the nuts (2 nos.) and insulator.
AIR SUPPLY HOSE INSULATOR
Remove the screws (3 nos.), bolt (1 no.), intake shroud

and exhaust shroud.
SCREWS INTAKE SHROUD
BOLT
EXHAUST SHROUD
INSTALLATION
Install the intake shroud and exhaust shroud.
Install and tighten the screws (3 nos.) to the specified SCREWS
torque. INTAKE SHROUD
BOLT
TORQUE: 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
Install and tighten the bolt (1 no.) to the specified torque.
EXHAUST SHROUD
Install the insulator and tighten the nuts.
Install the new gasket, air supply hose and tighten the
bolts (3 nos.) securely.
BOLTS NUTS
— Cooling fan cover (page 11-2).
— Carburator (page 5-4).
AIR SUPPLY HOSE INSULATOR
7-4
CYLINDER HEAD REMOVAL

CRANKCASE BREATHER PIPE
— Engine (page 6-2)
— Intake/Exhaust shrouds and seal (page 7-4)
— Cooling fan and cover (page 11-2) CYLINDER HEAD COVER
— Spark plug (page 3-6)
— Muffler assembly (page 2-8)
Disconnect crankcase breather pipe from cylinder head

cover. BOLTS
Remove the bolts (2 nos.) and cylinder head cover.
Rotate the crankshaft clockwise and align the “T” mark

on the flywheel with the index mark on the right
crankcase.
Make sure that the piston is at TDC (Top Dead Center) on
the compression stroke.
The rocker arms should be loose.
INDEX MARK
If the rocker arms are tight, rotate the crankshaft one turn
and realign the “T” mark with the index mark.
"T" MARK
Remove the cam chain tensioner lifter plug and O-ring.

LIFTER PLUG/O-RING
Install the stopper tool to the cam chain tensioner lifter.
Make a tensioner shaft stopper tool out of a thin piece of 16.5 mm

steel (0.8 mm thick) using the diagram.
Turn the cam chain tensioner shaft clockwise with the

stopper tool to retract the cam chain tensioner lifter, then 9.5 mm
insert the stopper fully to hold the cam chain tensioner in
the fully retracted position.
8.5 3.5
mm mm

7-5
Remove the cam sprocket bolts (2 nos.) while holding

the crankshaft. Remove the cam sprocket from the CAM CHAIN
camshaft and the cam chain from the sprocket.
Suspend the cam chain with a piece of wire to prevent it
from falling into the crankcase.
BOLTS
CAM SPROCKET
Remove the tensioner shaft stopper tool, bolts (2 nos.),

BOLTS
tensioner lifter and gasket.
CAM CHAIN TENSIONER LIFTER
Remove the nuts (4 nos.).

Remove the bolts (2 nos.) and cylinder head.
BOLTS
NUTS
Remove the cylinder head gasket and dowel pins.

GASKET
Remove the cam chain guide from the cylinder.
Check the cam chain guide for excessive wear or
damage.
DOWEL PINS
CAM CHAIN GUIDE
7-6
CYLINDER HEAD DISASSEMBLY ROCKER ARM
Screw a 6 mm screw into the threaded hole in the rocker

arm shaft and pull the shaft out of the camshaft holder.
Remove the rocker arm.
Remove the other rocker arm shaft and rocker arm.
Remove the insulator carburator.
6 mm SCREW
INSPECTION
Inspect the rocker arms and shafts for wear, damage or
clogged oil hole.
Measure the rocker arm I.D.
Measure the rocker arm shaft O.D.
Compress the valve springs using the valve spring

compressor, and remove the valve cotters.
TOOLS:
To prevent loss of tension, do not compress the valve

springs more than necessary to remove the cotters.
VALVE SPRING COMPRESSOR
Remove the valve spring compressor, then remove the

retainer, spring and valve.
Remove the stem seals and spring seat. Do not reuse STEM SEAL
VALVE
the old stem seals.
SPRING
COTTERS
Mark all parts during disassembly so they can be placed
back in their original locations.
SPRING SEAT
RETAINER

7-7
CYLINDER HEAD INSPECTION

Remove the carbon deposits from the combustion
chamber and clean off the head gasket surfaces.
Check the spark plug hole and valve areas of the
combustion chamber for cracks.
COMBUSTION CHAMBER
Check the cylinder head for warpage with a straight edge

and feeler gauge.
Measure the free length of the valve springs.
SERVICE LIMITS: 26.8 mm (1.06 in)
Insert the valve into the guide and check that the valve
moves smoothly.
Check each valve for bending, burning, scratches or

abnormal stem wear.
Measure and record the valve stem O.D.
7-8
Ream the valve guide to remove any carbon buildup be-

VALVE GUIDE REAMER
fore measuring the guide.
Insert the reamer from the combustion chamber side of
the head and always rotate the reamer clockwise.
TOOL:
Valve guide reamer 070MH – 001I160
Measure and record each valve guide I.D.
Calculate the valve stem-to-guide clearance.
SERVICE LIMITS: Intake: 0.08 mm (0.003 in)

Exhaust: 0.10 mm (0.004 in)
If the stem-to-guide clearance exceeds the service

limits, determine if a new guide with standard
dimensions would bring the clearance within tolerance.
If so, replace any guides as necessary and ream to fit.
If the stem-to-guide clearance exceeds the service limits
with new guides, also replace the valve.
Inspect and reface the valve seats whenever the valve

guide are replaced (page 7-12).
VALVE GUIDE
VALVE GUIDE REPLACEMENT VALVE GUIDE DRIVER
Chill new valve guides in the freezer section of a

refrigerator for about an hour.
Heat the cylinder head to 130 – 140°C (275 – 290°F) with
a hot plate or oven.
Using a torch to heat the cylinder head may cause

warpage.
Wear heavy gloves to avoid burns when handling the

heated cylinder head.
VALVE GUIDE DRIVER

Support the cylinder head and drive the valve guides out
of the cylinder head from the combustion chamber side.
TOOL:
Valve guide driver 070ND – 006I150
Install the new clip to the new valve guide. Drive in the
valve guide from the camshaft side of the cylinder head
while the cylinder head is still heated.
TOOL:
Valve guide driver 070ND – 006I150

7-9
NOTE:
VALVE GUIDE CYLINDER HEAD
Install the valve guide while measuring the valve guide
height from the cylinder head.
SPECIFIED HEIGHT:
IN/EX: 9.7 – 9.9 mm (0.382 – 0.389 in)
Let the cylinder head cool to room temperature.
VALVE GUIDE CLIP
Ream the new valve guides.

Insert the reamer from the combustion chamber side of VALVE GUIDE REAMER
the head and always rotate the reamer clockwise.
TOOL:
Valve guide reamer 070MH – 001I160
• Take care not to tilt or lean the reamer in the guide

while reaming.
• Use cutting oil on the reamer during this operation.
Clean the cylinder head thoroughly to remove any metal
particles after reaming and reface the valve seat (page
7-14).
VALVE SEAT INSPECTION/REFACING

INSPECTION
Clean all intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of Prussian Blue to each valve face.

Tap the valve against the valve seat several times using a
hand-lapping tool, without rotating the valve, to make a
clear pattern.
Remove the valve and inspect the valve seat face.
The valve cannot be ground. If the valve face is burned or

badly worn or if it contacts the seat unevenly, replace the
valve.
Inspect the valve seat face for:

• Uneven seat width:
— Bent or collapsed valve stem:
Replace the valve and reface the valve seat
• Damaged face:
— Replace the valve and reface the valve seat
DAMAGED FACE UNEVEN SEAT
WIDTH
7-10
• Contact area (too high or too low area):

— reface the valve seat
TOO LOW TOO HIGH
Inspect the width of valve seat.

The valve seat contact should be within the specified
width and even all around the circumference.
STANDARD: 1.0 mm (0.04 in)

If the valve seat width is not within specification, reface

the valve seat (page 8-11).
CONTACT AREA
VALVE SEAT REFACING
• Follow the refacer manufacturer’s operating

instructions. 45°
• Be careful not to grind the seat more than necessary.
60°
32°
If the contact area is too high on the valve, the seat must
CONTACT TOO HIGH
be lowered using a 32° flat cutter.
OLD SEAT WIDTH
If the contact area is too low on the valve, the seat must
be raised using a 60° inner cutter. Refinish the seat to
specifications, using a 45° finish cutter.
32°
CONTACT TOO LOW
OLD SEAT WIDTH
60°

7-11
Using a 45° cutter, remove any roughness or irregulari-

ties from the seat. ROUGHNESS
TOOLS:
Valve seat cutter, 22 mm (45° IN) 070MH – 003I150
Valve seat cutter, 27.5 mm (45° EX) 070MF – 003I180
Valve seat cutter holder 070MH – 005I150
Using a 32° cutter, remove 1/4 of the existing valve seat

material.
TOOLS: OLD SEAT WIDTH

Valve seat cutter, 24 mm (32° IN) 07780 – 0012900
Valve seat cutter, 28 mm (32° EX) 070MH – 002I120
32°
Using a 60° cutter, remove 1/4 of the existing valve seat

material.
OLD SEAT WIDTH
TOOLS:
Valve seat cutter, 30 mm (60° IN/EX) 07780 – 0014000
60°
Using a 45° cutter, cut the seat to the proper width.

Make sure that all pitting and irregularities are removed.
0.9 – 1.1 mm
(0.035 – 0.043 in)
45°
7-12
After cutting the seat, apply lapping compound to the valve

face, and lap the valve using light pressure.
• Excessive lapping pressure may deform or damage

the seat.
• Change the angle of lapping tool frequently to prevent
uneven seat wear.
• Lapping compound can cause damage if it enters
between the valve stem and guide.
After lapping, wash any residual compound off the

cylinder head and valve and recheck the seat contact.
BREATHER SEPARATOR CLEANING BREATHER

SCREWS SEPARATOR PLATE
Bend up the lock tabs of the breather separator plate.
Remove the two screws and breather separator plate.
Clean the separator plate and inside of the cylinder head

cover thoroughly.
Install the breather separator plate and tighten the screw
(3 nos.) to specified torque.
Bend the lock tabs of the plate against the screw heads.

7-13
ASSEMBLY CYLINDER HEAD VALVE COTTERS
SPRING RETAINER
VALVE SPRING
STEM SEAL
SPRING SEAT
VALVE GUIDE
VALVE GUIDE CLIP
INTAKE VALVE
EXHAUST VALVE
Blow through the oil passage in the cylinder head with

compressed air.
Install the spring seats and new stem seals.
STEM SEAL
Lubricate the valve stems with clean engine oil and VALVE
insert the valves into the cylinder head. OUTER SPRING
COTTERS
To avoid damage to the stem seal, turn the valve slowly

when inserting. SPRING SEAT
RETAINER
Install the valve springs with the tightly wound coils

facing the cylinder head. OUTER
Install the spring retainer.
COMBUSTION CHAMBER SIDE
7-14
CYLINDER HEAD ASSEMBLY

Compress the valve springs and install the valve cotters.
TOOL:
To prevent loss of tension, do not compress the valve

springs more than necessary to install the cotters.
VALVE SPRING COMPRESSOR
Support the cylinder head so that the valve heads will not
contact anything that causes damage.
Seat the cotters firmly using two hammers as shown.
Hold one hammer on the valve stem and gently tap in COTTERS
with the other hammer.
Install the insulator carburettor.
INSULATOR CARBURETTOR
Install the rocker arms and shafts into the holder.

ROCKER ARM
Install the rocker arm shaft with the threaded side

facing out.
6 mm SCREW

7-15
CYLINDER HEAD INSTALLATION GASKET

Install the cam chain guide so that its bosses are placed
in the grooves in the cylinder.
Install the dowel pins and a new gasket.
DOWEL PINS
Install the cylinder head.

Suspend the cam chain to keep it from falling into the
cylinder. BOLTS
Install the bolts (2 nos.) and loosely tighten them.

NUTS
Install the washers and cylinder head nuts (4 nos.), then
tighten the nuts in a crisscross pattern in 2 or 3 steps.
Install the sealing rubber.
Install the stopper tool to the cam chain tensioner lifter.

BOLTS
Turn the cam chain tensioner lifter shaft clockwise with
the stopper tool to retract the cam chain tensioner lifter,
then insert the stopper fully to hold the cam chain
tensioner lifter.
Install the cam chain tensioner lifter and tighten the bolts
securely.
CAM CHAIN TENSIONER LIFTER
Turn the crankshaft clockwise slowly and align the “T”

mark on the flywheel with the index mark of the right
crankcase.
INDEX MARK
"T" MARK
7-16
Align the timing mark (index line) on the cam sprocket

with the top surface of the cylinder head. CAM CHAIN
Install the cam chain onto the cam sprocket, then install
the cam sprocket onto the camshaft.
Make sure that the timing mark (index line) aligns with
the top surface and the “T” mark aligns with the index
mark.
Cover the cam chain opening with a shop towel to
prevent from the cam sprocket bolts falling into the
crankcase.
CAM SPROCKET
Align the bolt holes in the camshaft and cam sprocket,

and install the cam sprocket bolts.
Tighten the cam sprocket bolts while holding the

crankshaft.
BOLTS
Install a new gasket into the groove in the cylinder head

cover.
Install the cylinder head cover on the cylinder head.
CYLINDER
HEAD
COVER
GASKET
Install new rubber washer to the cylinder head cover bolts.

RUBBER WASHER

7-17
Install and tighten the cylinder head cover bolts.

BOLTS
Remove the stopper tool from the tensioner lifter.

STOPPER
TOOL
Install the plug with a new O-ring and tighten it.

LIFTER PLUG
Install the cam chain tensioner hole cap.
O-RING

— Spark plug (page 3-6) CYLINDER HEAD COVER
— Intake/exhaust shroud (page 7-4)
— Cooling fan and cover (page 11-4) INTAKE SHROUD
EXHAUST SHROUD
7-18
CAM SHAFT REMOVAL CYLINDER HEAD COVER

— Intake/Exhaust shrouds and seal (page 7-4) INTAKE SHROUD
— Cooling fan and cover (page 11-2)
— Spark plug (page 3-6)
— Cam sprocket (page 7-6).
EXHAUST SHROUD
Remove the camshaft retainer bolt (1no.)
BOLT
Remove the camshaft.

NOTE:
Do not hammer the cam shaft out as it can damage the
camshaft as well as the spring used for decompression
mechanism.
CAMSHAFT
For camshaft removal no need to open cylinder head
nut/ bolts.

7-19
INSPECTION
Check each cam lobe for wear, scratches or scoring.
Measure the cam lobe height.
SERVICE LIMITS: Intake: 32.041 mm (1.2615 in)

Exhaust: 31.791 mm (1.2516 in)
Turn the outer race of each camshaft bearing with your

finger.
The bearing should turn smoothly and quietly.
Check that the inner race of each bearing fits tightly on
the camshaft.
Replace the camshaft assembly if the bearing does not
turn smoothly, quietly, or if it fits loosely on the camshaft.

CAMSHAFT RUNOUT
Support both ends of the camshaft and check the

camshaft runout with a dial indicator.
Actual runout is 1/2 the total indicator reading.
CAMSHAFT INSTALLATION
Clean each parts of the assembly in solvent and
lubricate them with clean engine oil.
Install the camshaft into the cylinder head by aligning the
cam lobes with the cutouts in the holder.
Install the retainer bolt (1 no.).
BOLTS

— Cam sprocket (page 7-17). CYLINDER HEAD COVER
— Cooling fan and cover (page 11-4)
— Intake/Exhaust shrouds and seal (page 7-4) INTAKE SHROUD
EXHAUST SHROUD
7-20
CYLINDER/PISTON
8-2
8-0
8. CYLINDER/PISTON
SERVICE INFORMATION 8-1 PISTON REMOVAL 8-3
TROUBLESHOOTING 8-1 PISTON INSTALLATION 8-5
CYLINDER REMOVAL 8-2 CYLINDER INSTALLATION 8-6
SERVICE INFORMATION
GENERAL
• To service the cylinder and piston, the engine must be removed from the frame.
• Take care not to damage the cylinder wall and piston.
• Be careful not to damage the mating surfaces when removing the cylinder.
SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 50.005 – 50.015 (1.9686 – 1.9690) 50.10 (1.972) 8
Out of round — 0.05 (0.002)
Taper — 0.05 (0.002)
Warpage — 0.05 (0.002)
Piston, Piston O.D. 49.980 – 49.995 (1.9677 – 1.9683) 49.91 (1.966)
piston ring, Piston pin hole I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
piston pin
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Cylinder-to-piston clearance 0.010 – 0.035 (0.0004 – 0.0013) 0.10 (0.004)
Connecting rod small end I.D. 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Connecting rod-to-piston pin clearance 1.010 – 1.034 (0.0397 – 0.0407) 1.05 (0.041)
Piston ring-to-ring Top/second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
groove clearance
Piston ring end gap Top/second 0.10 – 0.25 (0.004 – 0.010) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) —
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Worn, stuck or broken piston ring
• Worn or damaged cylinder or piston
Excessive smoke
• Worn cylinder, piston or piston rings
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings

8-1
CYLINDER/PISTON
CYLINDER REMOVAL CYLINDER

— Cylinder head (page 7-5).
— Cam chain guide.
— Cam chain tensioner (page 7-5).
Check the cam chain guide and cam chain tensioner for
excessive wear or damage, replace them if necessary.
Be careful not to damage the sliding surface of the

piston and cylinder.
Lift the cylinder, and remove it, be careful not to

damage the piston with the stud bolts.
GASKET
Remove the dowel pins and gasket.
Clean any gasket material off the mating surface of the

cylinder, be careful not to damage the mating surface.
DOWEL PINS
INSPECTION
Inspect the cylinder bore for scratch or wear.
Measure the cylinder I.D. at three levels in an X and Y
axis.
Take the maximum reading to determine the cylinder wear.
Calculate the cylinder-to-piston clearance.

Refer to page 8-4 for measurement of the piston O.D.
Calculate the cylinder taper and out-of-round at three

levels in an X and Y axis. Take the maximum reading to
determine the taper and out-of-round.
Y
SERVICE LIMITS: Taper: 0.05 mm (0.002 in)
Out-of-round: 0.05 mm (0.002 in) TOP X
The cylinder must be rebored and an oversize piston

fitted if the service limit is exceeded. MIDDLE
The cylinder must be rebored so that the clearance
between oversize piston and rebored cylinder should
be maintained between 0.010-0.040 mm BOTTOM
(0.0004-0016).
8-2
CYLINDER/PISTON
Check the top of the cylinder for warpage with a straight

edge and feeler gauge.
PISTON REMOVAL PISTON PIN
Place a clean shop towel over the crankcase to prevent

the clip from falling into the crankcase.
Remove the piston pin clips with the pliers.

Push the piston pin out of the piston and connecting rod,
and remove the piston.
PISTON PIN CLIP
Spread each piston ring and remove it by lifting up at a

PISTON RING
point opposite the gap.
Clean carbon deposits from the piston.
• Do not damage the piston ring by spreading the ends

too far.
• Be careful not to damage the piston when the
piston rings are being removed.
• Clean carbon deposits from the ring grooves with a
old piston ring. Never use a wire brush; it will scratch
the groove.
INSPECTION
Inspect the piston rings and replace them if they are
damaged.
Inspect the piston rings for movement by rotating the rings.
The rings should be able to move in their grooves without
catching.
Push the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the ring-to-ring
groove clearance.
SERVICE LIMITS: Top: 0.08 mm (0.003 in)

Second: 0.08 mm (0.003 in)

8-3
CYLINDER/PISTON
Insert each piston ring into the bottom of the cylinder

squarely using the piston.
Measure the ring end gap.
PISTON RING
SERVICE LIMITS: Top: 0.45 mm (0.018 in)
Second: 0.45 mm (0.018 in)
Measure the piston O.D. 90° to the piston pin hole and at
point 10 mm (0.4 in) from bottom of the piston skirt.
Compare this measurement against the maximum

cylinder I.D. measurement and calculate the cylinder-to-
piston clearance (page 8-2).
Measure piston pin hole I.D. in an X and Y axis. Take the

maximum reading to determine the I.D.
X
Y
Measure the piston pin O.D. at three points.
Calculate the piston-to-piston pin clearance.
Measure the connecting rod small end I.D.
Calculate the connecting rod-to-piston pin clearance.
8-4
CYLINDER/PISTON
PISTON INSTALLATION PISTON RING

Carefully install the piston rings into the piston ring
grooves with the markings facing up.
• Do not damage the piston ring by spreading the ends

too far.
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.
• After installing the rings they should rotate freely,
without sticking.
Be careful not to damage the piston and rings during

installation.
Stagger the piston ring end gaps 120° degrees apart

from each other.
Stagger the side rail end gaps as shown.
MARK
MARK
120°
TOP RING
120° 120°
SECOND RING
}
SIDE
SPACER OIL RING
SIDE
TOP
SECOND
Clean any gasket material from the cylinder mating

surface of the crankcase. MATING SURFACE
When cleaning the cylinder mating surface, place a shop

towel over the cylinder opening to prevent dust or dirt
enter the engine.
Apply engine oil solution to the connecting rod small end

inner surface.

8-5
CYLINDER/PISTON
Apply engine oil to the piston pin outer surface.

“IN” MARK
Install the piston with the “IN” mark toward the intake side PISTON PIN
and insert the piston pin through the piston and
connecting rod.
Install new piston pin clips into the grooves of the piston
PISTON PIN
pin hole.
Place a shop towel over the crankcase opening to

prevent piston pin clips from falling into the crankcase.
• Make sure that the piston pin clips are seated

securely.
• Do not align the piston pin clip end gap with the
piston cutout. PISTON PIN CLIP
CYLINDER INSTALLATION
Install the dowel pins and a new gasket. GASKET
Apply engine oil to the cylinder wall, piston and piston

ring outer surfaces.
DOWEL PINS
Route the cam chain through the cylinder and install the
cylinder over the piston while compressing the piston
rings with your fingers.

— Cam chain guide.
— Cylinder head (page 7-16).
— Cam chain tensioner (page 7-17).
Be careful not to damage the piston rings and cylinder

wall.
8-6
KICKSTARTER/DRIVE AND PULLEYS/CLUTCH
93 N·m (9.3 kgf·m, 69 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)
9-0
9. KICKSTARTER/DRIVE AND DRIVEN PULLEYS/CLUTCH
SERVICE INFORMATION 9-1 CLUTCH/DRIVEN PULLEY
REMOVAL 9-11
TROUBLESHOOTING 9-2
CLUTCH/DRIVEN PULLEY
KICKSTARTER 9-3
INSTALLATION 9-16
STARTER PINION 9-8
DRIVE PULLEY INSTALLATION 9-18
DRIVE PULLEY REMOVAL 9-9
SERVICE INFORMATION
GENERAL
Never operate the starter motor with the left crankcase cover removed.
• Avoid getting grease and oil on the V-belt and pulley drive faces in order to prevent belt slippage.
• Do not apply grease to the movable drive face and weight rollers.
SPECIFICATIONS 9
Unit: mm (in)

Drive belt width 18.5 (0.73) 17.5 (0.69)
Movable drive face Bushing I.D. 22.035 – 22.085 (0.8675 – 0.8695) 20.60 (0.811)
Boss O.D. 22.010 – 22.025 (0.8665 – 0.8671) 21.98 (0.865)
Weight roller O.D. 17.92 – 18.08 (0.705 – 0.712) 17.40 (0.670)
Clutch Outer I.D. 125.0 – 125.2 (4.921 – 4.929) 125.5 (4.941)
Lining thickness 4.0 (0.16) 2.0 (0.08)
Driven pulley Face spring free length 108.5 (4.27) 92.2 (3.63)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
TORQUE VALUES
Left crankcase cover plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Kickstarter pedal bolt 29 N·m (3.0 kgf·m,22 lbf·ft)
Drive pulley face nut 93 N·m (9.3 kgf·m, 69 lbf·ft) Apply oil to the threads and seating surface.
Clutch outer nut 49 N·m (5.0 kgf·m, 36 lbf·ft)
Clutch/driven pulley nut 54 N·m (5.5 kgf·m, 40 lbf·ft)

9-1
TOOLS
Clutch center holder 070MB – KPL-I200
Universal holder 070MB – KPL-I100
Socket wrench, 39 x 41 mm 070MA – KPL-I300
Bearing driver 070MD – KPL-I100
Bearing remover (Driven face) 070MC – KWP-410
Bearing installer (Driven face) 070NC – KWP-410
Clutch spring compressor 070ME – KWP-110
TROUBLESHOOTING
Engine starts but scooter won’t move
• Worn drive belt
• Damaged ramp plate
• Worn or damaged clutch shoe
• Broken driven face spring
Engine stalls or scooter creeps

• Broken clutch shoe spring
Poor performance at high speed or lack of power

• Worn drive belt
• Weak driven face spring
• Worn weight rollers
• Contaminated pulley faces
9-2
KICKSTARTER PILLION STEP COVER
LEFT CRANKCASE COVER REMOVAL SCREWS
Remove the left floor side cover (page 2-5).

Open the screws (2 nos.) and remove pillion step cover.
Remove the rear brake cable from the cable holder.

BOLTS
Loosen the air duct band screw and disconnect the air
duct from the left crankcase cover. LEFT CRANKCASE COVER
Remove the left crankcase cover bolts (8 nos.).

Remove the left crankcase cover.
CABLE HOLDER
Remove the dowel pins (2 nos.).

DOWEL PINS
DISASSEMBLY SCREWS
Raise the lock tabs of the left crankcase cover plate.

Remove the screws (5 nos.) and left crankcase cover
plate.
COVER PLATE

9-3
Remove the kickstarter driven gear while turning the

KICKSTARTER DRIVEN GEAR
kickstarter pedal.
Remove the thrust washer.
FRICTION SPRING
THRUST WASHER
Before removing the kickstarter pedal, mark the pedal

and spindle for proper installation position. BOLT KICKSTARTER PEDAL
Remove the bolt (1 no.) and the kickstarter pedal.
MARK
Carefully unhook the return spring from the pin on the

crankcase cover. RETURN SPRING
Remove the snap ring and washer. SPINDLE UNHOOK

Remove the kickstarter spindle and return spring.
SNAP RING/WASHER
Remove the spindle bushing and collar.

COLLAR BUSHING
9-4
INSPECTION
SPINDLE
Inspect the following:
COLLAR
— spindle for wear or damage
— gear teeth for wear or damage
— return spring for weakness or damage
— bushing for wear or damage
RETURN SPRING
BUSHING
— driven gear for wear or damage

— friction spring for weakness or damage DRIVEN GEAR FRICTION SPRING
— starter ratchet teeth of the drive pulley face for wear or
damage
STARTER RATCHET
— crankcase cover bearings for wear or damage.

COLLAR BUSHING

9-5
ASSEMBLY
KICKSTARTER PEDAL
RETURN SPRING
BUSHING
COLLAR
SPINDLE
COVER PLATE
SNAP RING
DRIVEN GEAR FRICTION SPRING
Install the bushing and collar into the left crankcase cover.
Apply grease (0.1 – 0.3 g) to the kickstarter spindle COLLAR BUSHING
journal.
Install the spindle and return spring into the crankcase

cover and hook the short end of the spring to the spindle LONG HOOK
RETURN SPRING
groove. (Do not hook the long end of the spring.)
HOOK
Install the washer and snap ring to secure the spindle.
Make sure that the snap ring is seated into the spindle
groove securely, then hook the long end of the return
spring to the pin on the crankcase cover.
SHORT HOOK
SNAP RING/WASHER
9-6
Install the kickstarter pedal in its original position as

marked during removal and tighten the bolt (1 no.). BOLT KICKSTARTER PEDAL
TORQUE: 29 N·m (3.0 kgf·m,22 lbf·ft)
MARK
Install the thrust washer onto the crankcase cover.
THRUST WASHER
Apply grease (0.2 – 0.3 g) to the driven gear shaft and

friction spring sliding area. DRIVEN GEAR
Turn the kickstarter pedal and hold it.
Install the driven gear while aligning the friction spring
hook with the groove in the crankcase cover, and return
the pedal to engage the driven gear and spindle gear.
FRICTION SPRING
Install the left crankcase cover plate and tighten the

screws (5 nos.). SCREWS
Bend the lock tabs of the cover plate against the screw
heads.
COVER PLATE

9-7
LEFT CRANKCASE COVER

INSTALLATION DOWEL PIN
Install the dowel pins (2 nos.) and apply liquid gasket.
GASKET
Install the left crankcase cover and cable holder, and BOLTS
tighten the bolts (8 nos.) in a crisscross pattern in 2 or 3
steps. LEFT CRANKCASE COVER
Install the rear brake cable in to the cable holder.
Connect the air duct to the left crankcase cover and tighten
the band screw (1 no.) securely.
After installation, check that the kickstarter pedal

operates properly.
Install the left floor side cover (page 2-5).

Install the pillion step cover.
CABLE HOLDER
STARTER PINION STARTER PINION

HOLDER
REMOVAL
Remove the left crankcase cover (page 9-3).
Remove the starter pinion holder.
Remove the starter pinion.

STARTER PINION
9-8
INSPECTION
Check that the starter pinion operates smoothly.
Check the pinion gear teeth and shaft for wear or damage.
Check the starter driven gear teeth of the drive pulley face
for wear of damage.
INSTALLATION
Apply grease (0.1 – 0.3 g) to the starter pinion shaft
journal.
Install the starter pinion into the left crankcase.
STARTER PINION
Install the starter pinion holder by aligning its bosses

with the grooves in the left crankcase. STARTER PINION
HOLDER
Install the left crankcase cover (page 9-8).
BOSSES AND GROOVES
DRIVE PULLEY REMOVAL DRIVE PULLEY FACE NUT
Remove the left crankcase cover (page 9-3).
Hold the drive pulley face with the special tool, and remove
the drive pulley face nut.
TOOL:
CLUTCH CENTER HOLDER

9-9
Remove the washer and drive pulley face fin and drive
face. DRIVE PULLEY FACE
WASHER
Remove the washer and drive belt from the crankshaft.

DRIVE BELT
WASHER
Remove the movable drive face assembly while holding

the back of the face (ramp plate).
MOVABLE DRIVE FACE

— drive face boss SLIDE PIECES
— ramp plate
— slide pieces DRIVE FACE
— weight rollers BOSS
RAMP
WEIGHT PLATE
ROLLERS
9-10
INSPECTION
WEIGHT ROLLER
Check each roller for wear or damage.

Measure the weight roller O.D.
DRIVE FACE BOSS
Check the drive face boss for wear or damage.

Measure the boss O.D.
Measure the drive face bushing I.D.
CLUTCH/DRIVEN PULLEY REMOVAL CLUTCH OUTER NUT

UNIVERSAL HOLDER
Remove the drive pulley (page 9-9).
Hold the clutch outer with the special tool and remove the
clutch outer nut.
TOOL:
Remove the clutch outer.

9-11
Remove the clutch/driven pulley assembly and drive belt.

CLUTCH/DRIVEN
PULLEY ASSEMBLY
DRIVE BELT
Set the clutch spring compressor onto the clutch/driven

pulley, aligning the bosses with the holes in the clutch. CLUTCH/DRIVEN
PULLEY
TOOL:
Hold the clutch spring compressor in a vice.
CLUTCH SPRING
COMPRESSOR
Remove the clutch/driven pulley nut using the socket

wrench. CLUTCH/DRIVEN
PULLEY NUT
TOOL:
Loosen the spring compressor and remove the following:

— driven pulley
— driven face spring
— spring seat
— clutch
For clutch outer and clutch shoe lining inspection, refer to

SOCKET WRENCH
(page 9-14).
Remove the E-clips (3 nos.) and plate.

SPRINGS E-CLIPS
PLATE
DAMPER RUBBERS
CLUTCH SHOES
9-12
Remove the clutch shoe springs and clutch shoes from PLATE
the clutch drive plate. DRIVE PLATE
Remove the damper rubbers (3 nos.).
Remove the seal collar.

MOVABLE
DRIVEN FACE
Pull out the guide roller pins (3 nos.).
Remove the moveable driven face from the driven face.
SEAL COLLAR PINS
Remove the oil seals and O-rings.

OIL SEALS O-RINGS
DRIVEN FACE BEARING

NEEDLE BEARING
REPLACEMENT
Remove the needle bearing using the special tools.
TOOLS:
Bearing remover (Driven face) 070MC – KWP-410

9-13
Remove the snap ring and drive the ball bearing out of
the driven face.
SNAP RING/BALL BEARING
Pack new ball bearing cavities with grease.
Drive the ball bearing into the driven face with the sealed
side facing down.
TOOL:
Bearing Driver 070MD – KPL-I100
Install the snap ring properly into the driven face groove.
Pack the inside of the driven face with 5.0 – 5.5 g of

grease. NEEDLE BEARING
NEEDLE BEARING
Apply grease to a new needle bearing.
Press the needle bearing into the driven face with the
markings facing up.
TOOLS:
Bearing installer (Driven face) 070NC–KWP–410
INSPECTION
DRIVE BELT COG
Check the drive belt for cracks, separation or abnormal

or excessive wear.
Measure the drive belt width.
CLUTCH OUTER
Check the clutch outer for wear or damage.

Measure the clutch outer I.D.
9-14
CLUTCH SHOE LINING
Check the clutch shoe for wear or damage.

Measure the thickness of each shoe.
DRIVEN FACE SPRING
Measure the driven face spring free length.
DRIVEN FACE
Check the driven face for wear or damage.

Measure the driven face O.D.
MOVABLE DRIVEN FACE
Check the movable driven face for wear, scratches or

damage.
Measure the movable driven face I.D.

9-15
CLUTCH/DRIVEN PULLEY
INSTALLATION
Clean any oil and grease from the pulley faces and clutch
outer. Replace the contaminated clutch shoes.
DRIVEN FACE PIN
NEEDLE BEARING
MOVABLE DRIVEN FACE
OIL SEAL
O-RINGS
SNAP RING
SEAL COLLAR
BALL BEARING
DRIVEN FACE SPRING
E-CLIP
SPRING SEAT
PLATE
DRIVE PLATE DAMPER RUBBER CLUTCH SHOE
Clean the pulley faces.

Apply grease to new oil seal lips and install them into the OIL SEALS O-RINGS
movable driven face.
Coat new O-rings with grease and install them onto the
movable driven face.
Apply grease to the inside surface the movable driven
face.
Install the movable driven face onto the driven face. PINS
Apply grease to the guide pins and install them into the
holes in the driven face.
Fill the movable drivenface in side with grease (5.0 – 5.5
g).
9-16
Install the seal collar.
SEAL COLLAR
Install the damper rubbers onto the clutch drive plate.

Install the clutch shoe springs onto the shoes. DAMPER RUBBER CLUTCH SHOE
Install the clutch shoes and springs onto the drive plate.
Install the plate and secure them with E-clips.
E-CLIP
DRIVE PLATE PLATE
Assemble the following:

— driven pulley
— driven face spring
SOCKET WRENCH
— spring seat
— clutch
Set the clutch spring compressor over the clutch/driven

pulley, aligning the bosses with the holes in the clutch.
TOOL:
CLUTCH
SPRING
Hold the spring compressor in a vice. COMPRESSOR
Install the clutch/driven pulley nut and tighten it with the
socket wrench.
TOOL:
Remove the spring compressor from the clutch/driven

pulley assembly.

9-17
Install the drive belt and clutch/driven pulley assembly.

CLUTCH/DRIVEN
PULLEY ASSEMBLY
DRIVE BELT
Install the clutch outer and nut.
Hold the clutch outer with the special tool and tighten the CLUTCH OUTER NUT
clutch outer nut. UNIVERSAL HOLDER
TOOL:
Install the drive pulley (page 9-18).
DRIVE PULLEY INSTALLATION SLIDE PIECES
• Clean any oil and grease from the pulley faces.

Replace the contaminated drive belt.
• Do not apply grease to the movable drive face and
weight rollers.
Install the weight rollers into the movable drive face.

Install the slide pieces onto the ramp plate.
Install the ramp plate over the moveable drive face. RAMP PLATE
WEIGHT ROLLERS
Install the drive face boss into the movable drive face.
DRIVE FACE BOSS
9-18
Install the movable drive face assembly onto the

MOVABLE DRIVE FACE ASSEMBLY
crankshaft while holding the ramp plate.
Install the drive belt onto the drive face boss.
Install the drive pulley face and washer.

DRIVE PULLEY FACE
WASHER
Apply oil to the drive pulley face nut threads and seating
surface and install it. DRIVE PULLEY FACE NUT
Hold the drive pulley face with the special tool and tighten
the drive pulley face nut.
TOOL:
Install the left crankcase cover (page 9-8).
CLUTCH CENTER HOLDER

9-19
FINAL REDUCTION
10-0
10-2
10. FINAL REDUCTION
SERVICE INFORMATION 10-1 FINAL REDUCTION INSPECTION 10-4
TROUBLESHOOTING 10-2 BEARING REPLACEMENT 10-5
FINAL REDUCTION DISASSEMBLY 10-3 DRIVESHAFT INSTALLATION 10-7
DRIVESHAFT REMOVAL 10-3 FINAL REDUCTION ASSEMBLY 10-7
SERVICE INFORMATION
GENERAL
• The final reduction servicing can be performed with the engine installed in the frame.
• When installing the driveshaft, be sure to use the special tool; position the special tool against the bearing inner race and pull the
driveshaft into the bearing.
SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Final reduction oil capacity At disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
At draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
10
TORQUE VALUES
Final reduction oil level check bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)

10-1
FINAL REDUCTION
TOOLS
Case/driven gear puller 070MC – KPL-I1001
Bearing remover set, 12 mm
— Bearing remover head, 12 mm 070MC – KPL-I400
— Bearing remover shaft, 12 mm 070MC – KPL-I410
— Bearing remover weight 070MC – KPL-I300
Crankcase assembly collar 070MF – KWP-110
Assembly collar attachment 070MF – KWP-120
Crankcase assembly shaft 070MF – KWP-130
Attachment, 32 x 35 mm 070GD – 002-I140
Pilot, 12 mm 070GD – 004-I130
Pilot, 17 mm 070GD – 004-I150
Pilot, 20 mm 070GD – 004-I160
Driver 070GD – 001-I100
TROUBLESHOOTING
Engine starts but scooter won’t move
• Damaged transmission
• Seized transmission
• Faulty drive and driven pulleys/clutch
Abnormal noise
• Worn, seized or chipped gears
• Worn or damaged transmission bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase
10-2
FINAL REDUCTION
FINAL REDUCTION DISASSEMBLY TRANSMISSION CASE
Drain the final reduction oil (page 3-9).

— rear wheel (page 14-2)
— rear brake adjusting nut and brake arm joint
(page 14-3)
— Left crankcase cover (page 9-3)
— Clutch/driven pulley (page 9-11)
Disconnect the final reduction breather tube from the air

cleaner housing. BOLTS
Remove the bolts (7 nos.) and the transmission case.
Remove the dowel pins (2 nos.) and gasket.

GASKET
DOWEL PINS
Remove the final shaft.

Remove the counter gear shaft and counter gear. FINAL SHAFT
COUNTER GEAR SHAFT/

COUNTERGEAR
DRIVESHAFT REMOVAL DRIVESHAFT
Install the case/driven gear puller onto the left crankcase.

Remove the driveshaft from the crankcase.
TOOL:
Case/driven gear puller 070MC – KPL- I1001
CASE/DRIVEN GEAR PULLER

10-3
FINAL REDUCTION
Remove the driveshaft oil seal.

OIL SEAL
FINAL REDUCTION INSPECTION

Check the left crankcase and transmission cover
bearings for wear or damage.
Check the final shaft for excessive wear, damage or signs

of seizure.
Check the counter gear shaft and counter gear for

excessive wear, damage or signs of seizure.
10-4
FINAL REDUCTION
BEARING REPLACEMENT BEARING REMOVER
LEFT CRANKCASE
Remove the final shaft bearing, counter gear shaft
bearing and drive shaft bearing using the special tools.
BEARING REMOVER
SHAFT
Be careful not to damage the left crankcase and
transmission case mating surfaces.
BEARING REMOVER
WEIGHT
TOOLS:
Counter gear shaft bearing:
Bearing remover head, 12 mm 070MC – KPL-I400
Bearing remover shaft, 12 mm 070MC – KPL-I410
Final shaft bearing:

Drive shaft bearing:

Apply engine oil to new bearing rotating areas.

PILOT
Drive new bearings into the left crankcase.
ATTACHMENT
TOOLS:
Driver 070GD – 001-I100
Pilot ,12 mm 070GD – 004-I130

Driver 070GD – 001-I100
DRIVER
Pilot, 15 mm 070GD – 004-I140
Driveshaft bearing:
Driver 070GD – 001-I100
Pilot, 17 mm 070GD – 004-I150

10-5
FINAL REDUCTION
TRANSMISSION CASE
OIL SEAL
Remove the final shaft oil seal from the transmission
case.
Remove the final shaft bearing from the transmission

case.
FINAL SHAFT BEARING
Remove the driveshaft bearing and counter gear shaft

BEARING REMOVER
bearing using the special tools.
BEARING
TOOLS: REMOVR
Bearing remover head, 12 mm 070MC – KPL-I400 SHAFT
BEARING REMOVER
WEIGHT
Apply engine oil to new bearing rotating areas.

DRIVER
Drive new bearings into the transmission case.
TOOLS:
Driveshaft bearing:
Driver 070GD – 001-I100
Pilot, 12 mm 070GD – 004-I130

Driver 070GD – 001-I100
Pilot, 12 mm 070GD – 004-I130
PILOT ATTACHMENT
Driver 070GD – 001-I100
Pilot, 20 mm 070GD – 004-I160 OIL SEAL
Coat the circumference and lip of a new final shaft oil

seal with engine oil.
Install a new final shaft oil seal.
10-6
FINAL REDUCTION
DRIVESHAFT INSTALLATION ASSEMBLY

COLLAR
Install the driveshaft into the transmission cover. ATTACHMENT
Position the assembly collar against the driveshaft
bearing inner race.
Thread the assembly shaft onto the driveshaft.
Hold the shaft and draw the driveshaft into the bearing
inner race by turning the nut.
TOOLS: CRANKCASE
Crankcase assembly collar 070MF – KWP-110 ASSEMBLY
Assembly collar attachment 070MF – KWP-120 COLLAR
Crankcase assembly shaft 070MF – KWP-130 CRANKCASE ASSEMBLY SHAFT
Coat the circumference and lip of a new oil seal with

engine oil.
Install the oil seal into the left crankcase until the depth OIL SEAL
from the crankcase end surface is 0 – 0.5 mm (0 – 0.02
in), using the special tools.
TOOLS:
Crankcase assembly collar 070MF – KWP-110
Assembly collar attachment 070MF – KWP-120
Crankcase assembly shaft 070MF – KWP-130
FINAL REDUCTION ASSEMBLY FINAL SHAFT
Install the counter gear shaft and counter gear into the
transmission case.
Install the final shaft.
COUNTER GEAR SHAFT/

COUNTERGEAR
Install a new gasket and the dowel pins.

GASKET
Install the transmission case onto the left crankcase.
DOWEL PINS

10-7
FINAL REDUCTION
Tighten the bolts (7 nos.).

TRANSMISSION CASE
Connect the final reduction breather tube.

— clutch/driven pulley (9-16)
— left crankcase cover (9-7)
— rear wheel (page 14-4)
— rear brake adjusting nut and brake arm joint
(page 14-4)
Fill the transmission case with the recommended oil

(page 3-8).
BOLTS
RECOMMENDED OIL:
Honda 4-stroke oil or equivalent motor oil
Viscosity: SAE 20W40
OIL CAPACITY:
Install the oil level check bolt with a new sealing washer
and tighten it.
10-8
ALTERNATOR
39 N·m (4.0 kgf·m, 29 lbf·ft)
6 N·m (0.6 kgf·m, 43 lbf·ft)
0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
11-2
11-0
11. ALTERNATOR
SERVICE INFORMATION 11-1 ALTERNATOR INSTALLATION 11-3
ALTERNATOR REMOVAL 11-2
SERVICE INFORMATION
GENERAL
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition
switch is ON and current is present.
• This section covers service of the alternator stator, flywheel and the cooling fan. These parts can be removed with the engine
installed in the frame.
• Refer to section 15 for alternator stator inspection.
TORQUE VALUES
Fan cover bolt 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
Flywheel nut 39 N·m (4.0 kgf·m, 29 lbf·ft)
Ignition pulse generator mounting bolt 6 N·m (0.6 kgf·m, 4.3 lbf·ft)
TOOLS
Flywheel puller 070MC – KPL-I200
11

11-1
ALTERNATOR
ALTERNATOR REMOVAL LIGHTING COIL LINE

CONNECTOR
Liftup the body cover (Page 2-4).
WIRE BAND
Disconnect the alternator wire connectors.
PULSER COIL
CONNECTOR
EXCITER COIL
LINE CONNECTOR
Remove the two screws (2 nos.), bolts (2 nos.) and the

cooling fan cover. SCREWS
BOLT FAN COVER
Remove the bolts (3 nos.) and cooling fan.

COOLING FAN
BOLTS
Hold the flywheel with the universal holder and remove

the flywheel nut (1 no.). FLYWHEEL NUT
TOOL:
UNIVERSAL HOLDER
11-2
ALTERNATOR
Remove the flywheel with the flywheel puller.

FLYWHEEL
TOOL:
Flywheel puller 070MC – KPL-I200
Remove the woodruff key from the crankshaft.
FLYWHEEL PULLER
Remove the bolt A (1 no.), wire clamp and grommet from

the crankcase.
Remove the bolts B (2 nos.) holder and ignition pulse GROMMET BOLT A /
STARTER WIRE
generator.
CLAMP
BOLTS C
Remove the bolts C (2 nos.) and alternator stator.
BOLTS B /HOLDER
IGNITION PULSE GENERATOR
ALTERNATOR INSTALLATION
Install the stator and tighten the bolts C (2 nos.). GROMMET BOLT A /
Install the wire clamp and tighten the bolt A (1 no.). STARTER WIRE
Install the grommet into the right crankcase. CLAMP
BOLTS C
Install the ignition pulse generator and holder, and tighten
the mounting bolts B (2 nos.).
TORQUE: 6 N·m (0.6 kgf·m, 4.3 lbf·ft) BOLTS B /HOLDER
IGNITION PULSE GENERATOR
Install the woodruff key into the crankshaft groove.
WOODRUFF KEY

11-3
ALTERNATOR
Clean any oil or grease from the tapered portion of the

FLYWHEEL NUT
crankshaft and the tapered hole in the flywheel.
Install the flywheel on the crankshaft by aligning its groove

with the woodruff key.
Install the flywheel nut (1 no.).

Hold the flywheel with the universal holder and tighten
the nut.
TOOL:
UNIVERSAL HOLDER
Install the cooling fan and tighten the bolts (3 nos.).

COOLING FAN
NOTE:
Bolts other than actual can damaged the stator coil
windings.
BOLTS
Install the fan cover and tighten the screws (2 nos.).

SCREWS
Install the fan cover bolts (2 nos.) and tighten them.
TORQUE: 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
BOLTS FAN COVER
Connect the alternator (wire) connectors.

LIGHTING COIL LINE
Lift down the body cover. CONNECTOR
WIRE BAND
PULSER COIL
CONNECTOR
LIGHTING
EXCITER COIL
COIL LINE
CONNECTOR
LINE CONNECTOR
11-4
10 N·m (1.0 kgf·m, 7 lbf·ft)
12-2
12-0
12. CRANKCASE/CRANKSHAFT
SERVICE INFORMATION 12-1 CRANKSHAFT INSPECTION 12-4
TROUBLESHOOTING 12-1 CRANKSHAFT/CRANKCASE
ASSEMBLY 12-5
DISASSEMBLY 12-2
SERVICE INFORMATION
GENERAL
• This section covers the crankcase separation to service the crankshaft.
• The engine must be removed from the frame to separate the crankcase.
• The following parts must be removed before separating the crankcase:
— air cleaner housing, carburetor (section 5)
— alternator (section 11)
— drive pulley, clutch/driven pulley (section 9)
— cylinder head (section 7)
— cylinder, piston (section 8)
• In addition to the parts listed above, remove the following parts when the left crankcase half must be replaced:
— final reduction (section 10)
— rear brake (section 14)
• Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
• The crankcase oil seals must be replaced with new ones when assembling the crankcase halves.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT 12
Connecting rod big end side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod big end radial clearance 0 – 0.012 (0 – 0.0005) 0.04 (0.002)
Crankshaft runout — 0.1 (0.04)
TORQUE VALUES
Cam chain tensioner pivot bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Left crankcase bolt 13 N·m (1.3 kgf·m, 9 lbf·ft)
TROUBLESHOOTING
Abnormal engine noise
• Worn or damaged connecting rod bearing
• Worn or damaged crankshaft bearings

12-1
DISASSEMBLY
Remove the parts required for crankcase separation
(page 12-1).
Remove the center stand return spring.
RETURN SPRING
Remove the cotter pin, washer, center stand pivot bolt

COTTER PIN/WASHER
and center stand.
PIVOT BOLT
CENTER STAND
Remove bolts (2 nos.) and oil seal stopper plate from the
left crankcase. CAM CHAIN
TENSIONER
Remove the cam chain tensioner pivot bolt and cam chain
tensioner.
BOLTS
PIVOT BOLT
Remove the crankcase bolts (8 nos.).

Place the crankcase with the left crankcase down and BOLTS
remove the right crankcase from the left crankcase.
Separate the right crankcase while tapping it at several

locations with a soft hammer.
Be careful not to damage the crankcase mating surface.
12-2
Remove dowel pins.

Clean off crankcase mating surface.
DOWEL PINS
Remove the crankshaft from the left crankcase.

Remove the cam chain. CRANKSHAFT
CAM CHAIN
Remove the oil seal from the left crankcase.

OIL SEAL
Remove the oil seal from the right crankcase.
OIL SEAL

12-3
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance with
a feeler gauge.
Measure the connecting rod big end radial clearance.
Set the crankshaft on V-blocks and read the runout using

dial indicators. Actual runout is 1/2 of total indicator read- 35 mm 65 mm
ing. (1.38 in) (2.56 in)
BEARING INSPECTION
Turn the bearings with your finger. The bearings should
turn smoothly and quietly. Also check that the inner race
fits tightly on the crankshaft.
Replace the crankshaft assembly if the races do not turn
smoothly, quietly, or if they fit loosely on the crankshaft.
12-4
CRANKSHAFT/CRANKCASE
ASSEMBLY OIL SEAL
Clean the insides of the crankcases.

Check the crankcases for cracks or other faults.
Coat the lip and circumference of a new oil seal with
engine oil.
Install the oil seal into the right crankcase so that the
depth from the inside of the case is 0 – 1 mm (0 – 0.04 in).
Coat the lip and circumference of a new oil seal with

engine oil. OIL SEAL
Install the oil seal into the left crankcase so that the depth
from the outside of the case is 0 – 0.5 mm (0 – 0.02 in).
Be careful not to damage the crankcase mating

surfaces.
Install the cam chain into the left crankcase.

CRANKAHAFT
Install the crankshaft into the left crankcase through the
cam chain, being careful not to damage the oil seal lip.
CAM CHAIN
Note the connecting rod location when installing the

crankshaft.
Install the dowel pins and a liquid gasket.
DOWEL PINS

12-5
Place the right crankcase over the crankshaft and on the

left crankcase, being careful not to damage the oil seal BOLTS
lip.
Install the crankcase bolts (8 nos.) and tighten them in a

crisscross pattern in 2 or 3 steps and specified torque.
Check that the crankshaft turns smoothly.
Install the chain guide.

Install the cam chain tensioner and tighten the pivot bolt. CAM CHAIN
TENSIONER
Install the oil seal stopper plate and tighten bolts (2 nos.).
BOLTS
PIVOT BOLT
Install the center stand onto the crankcase, insert the

pivot bolt and secure it with the washer and a new
COTTER PIN/WASHER
cotter pin.
PIVOT BOLT
CENTER STAND
Hook the center stand return spring to the stand and spring
pin.

— cylinder/piston (section 8)
— cylinder head (section 7)
— drive pulley, clutch/driven pulley (section 9)
— alternator (section 11 )
— carburetor, air cleaner housing (section 5)
— engine in the frame
RETURN SPRING
12-6
49 N·m (5.0 kgf·m, 36 lbf·ft)
68 N·m (6.9 kgf·m, 50 lbf·ft)
4 N·m (0.4 kgf·m, 2.9 lbf·ft)
59 N·m (6.0 kgf·m, 43 lbf·ft)
13-2
13-0
13. FRONT WHEEL/BRAKE/SUSPENSION/STEERING
SERVICE INFORMATION 13-1 HANDLEBAR 13-12
TROUBLESHOOTING 13-2 STEERING STEM/FRONT FENDER 13-15
FRONT WHEEL 13-3 FRONT CUSHION 13-20
FRONT BRAKE 13-8
SERVICE INFORMATION
GENERAL
• Riding on damaged rims impairs safe operation of the scooter.
• When servicing the front wheel, fork or steering stem, support the scooter.
• A contaminated brake disc or pad (drum or shoe) reduces stopping power. Discard contaminated pads (shoes), and
clean a contaminated disc (drum) with a high quality brake degreasing agent.
• Raise the front wheel off the ground by supporting the frame securely when servicing the front wheel and suspension.
• After the front wheel installation, check the brake operation by applying the brake lever.
• Refer to the brake system information (section 13)
• This scooter is equipped with the TUFFUP tube.
• Refer to the TUFFUP tube repair (section 14)
• Refer to section 18 for light, meter and switch inspection.
SPECIFICATIONS Unit: mm (in)

2
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm , 22 psi) —
2
Driver and passenger 150 kPa (1.50 kgf/cm , 22 psi) —
Front axle runout
Radial
—
—
0.20 (0.008)
2.0 (0.08)
13
Front wheel rim runout
Axial — 2.0 (0.08)
Front brake drum I.D. 130 (5.12) 131 (5.16)
TORQUE VALUES
Handlebar post pinch nut 49 N·m (5.0 kgf·m, 36 lbf·ft) U-nut
Front axle nut 59 N·m (6.0 kgf·m, 43 lbf·ft) U-nut
Front brake arm nut 10 N·m (1.0 kgf·m, 7 lbf·ft)
Front wheel hub nut 49 N·m (4.9 kgf·m, 36.14 lbf·ft) Apply oil to the threads and seating surface.
U-nut
Front cushion upper bolt 32 N·m (3.3 kgf·m, 24 lbf·ft) Apply oil to the threads and seating surface.
Lock bolt replace with a new one.
Front cushion pivot arm mounting nut 26 N·m (2.6 kgf·m, 19.17 lbf·ft) U-nut
Front cushion pivot arm cover screw 4 N·m (0.4 kgf·m, 2.9 lbf·ft)
Front cushion pivot arm grease nipple nut 4 N·m (0.4 kgf·m, 2.9 lbf·ft)
Steering stem lock nut 68 N·m (7.0 kgf·m, 51 lbf·ft)

13-1
TOOLS
Bearing remover head, 12 mm 070MD – 005-I130

Bearing remover shaft 070GD – 005-I100
Driver 070GD – 001-I100
Pilot, 12 mm 070GD – 004-I130
Lock nut wrench 45.5 mm 070MA – KPL-I100
Adjusting remover head 070GC – 001-I110
Remover shaft 070GC – 001-I120
Remover weight 070MC – KPL-I300
Attachment 42 x 47 mm 070GD – 002-I160
Attachment 070MD – KPL-I210
Attachment, 30 mm I.D. 070GD – 003-I120
Lock nut wrench 070MA – KPL-I200
TROUBLESHOOTING
Hard steering
• Steering top cone race too tight
• Worn or damaged steering bearings
• Worn or damaged steering bearing races
• Bent steering stem
• Insufficient tire pressure
Steers to one side or does not track straight

• Damaged or loose steering bearings
• Bent fork
• Bent front axle
• Bent frame
• Worn or damaged front wheel bearings
Front wheel wobbling

• Bent rim
• Worn or damaged front wheel bearings
• Faulty front tire
• Unbalanced front tire and wheel
Front wheel turns hard

• Faulty front wheel bearings
• Bent front axle
• Front brake drag
Hard suspension
• High tire pressure
Soft suspension
• Weak fork spring
• Low tire pressure
Front suspension noise

• Loose front suspension fasteners
13-2
FRONT WHEEL BRAKE ARM JOINT
REMOVAL SCREW
Support the scooter on its center stand.
Remove the screw (1 no.) and front fork cover.

Remove the front brake adjusting nut, brake cable, brake
arm joint.
ADJUSTING NUT FRONT FORK COVER
Push the tab and disconnect the speedometer cable.

AXLE
Loosen the front axle nut.
Support the frame securely and raise the front wheel off
the ground.
Remove the axle nut, axle and front wheel. TAB
SPEEDOMETER CABLE
DISASSEMBLY
Remove the brake panel from the left wheel hub.
BRAKE PANEL
Remove the collar from the right side of wheel hub.

COLLAR

13-3
Remove the dust seal from the right side of wheel.

DUST SEAL
Insert the bearing remover head into the bearing.

From the opposite side install the bearing remover shaft
and drive the bearing out of the wheel.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing remover head, 12 mm 070GD – 005-I130
Bearing remover shaft 070GD – 005-I100
Replace the wheel bearings in pairs.
REMOVER SHAFT REMOVER HEAD
Remove the nuts (4 nos.) and wheel hub.

NUTS
WHEEL HUB
INSPECTION
FRONT AXLE
Set the front axle in V-blocks and measure the runout

using a dial indicator.
AXLE BOLT
13-4
WHEEL RIM
Check the rim runout by placing the wheel in a truing

stand.
Spin the wheel slowly and read the runout using a dial
indicator.
SERVICE LIMITS: Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)
WHEEL BEARING
Turn the inner race of each bearing with your finger. The
bearings should turn smoothly and quietly. Also check
that the bearing outer race fits tightly in the hub.
Remove and discard the bearings if the races do not turn

smoothly, quietly, or if they fit loosely in the hub.
WHEEL BEARING
Check the rotating direction mark on the tire.

ROTATING DIRECTION MARK

13-5
ASSEMBLY
WHEEL HUB
BEARING
COLLAR
BEARING
49 N·m (4.9 kgf·m, 36.14 lbf·ft)
DISTANCE COLLAR
DUST SEAL
Install the front wheel hub and tighten the nuts to

specified torque. NUTS
Pack all bearing cavities with grease.
WHEEL HUB
Never reinstall an old bearing, once a bearing has
been removed, the bearing must be replaced with a
new one.
DRIVER
Drive in a new left bearing squarely with the sealed side
facing up until it is fully seated.
Install the distance collar.
Drive in a new right bearing squarely with the sealed side
facing up until it is fully seated.
Do not allow the bearings to tilt while driving them in.
TOOLS:
Driver 070GD – 001-I100
Attachment, 32 x 35 mm 070GD – 002-I140 ATTACHMENT
PILOT
Pilot, 12 mm 070GD – 004-I130
13-6
Apply grease to a new dust seal lip and install it. COLLAR
Install the collar from right side of wheel hub.
DUST SEAL
Install the brake panel from left side of wheel.
BRAKE PANEL
INSTALLATION
Install the brake panel assembly.

BOSS/GROOVE
Install the front wheel between the fork legs by aligning
the brake panel groove with the boss of the left fork leg.
Apply thin coat of grease to the front axle and insert it from
the left side.
Install the axle nut and tighten it.

AXLE BOLT
Connect the speedometer cable by aligning its tab with
the groove of the speedometer gear box.
TAB
SPEEDOMETER CABLE

13-7
Install the brake arm joint into the brake arm.

BRAKE ARM JOINT
Install the brake cable through the brake panel and to the
brake arm.
SCREW
Install the brake adjusting nut.
Adjust the front brake lever free play (page 3-13).
Install the front fork cover and tighten the screw (1 no.) to
specified torque.
ADJUSTING NUT FRONT FORK COVER
FRONT BRAKE AXLE BOLT

Remove the front wheel (page 13-3).
Remove the brake panel.
BRAKE ARM
BRAKE CABLE
• A contaminated brake drum or shoe reduces
stopping power. Discard contaminated shoes and
clean a contaminated drum with a high quality brake
degreasing agent.
• Inhaled asbestos fibers have been found to cause
respiratory disease and cancer. Never use an air
hose or dry brush to clean brake assemblies. Use ADJUSTING NUT BRAKE ARM JOINT
a vacuum cleaner or alternate method to minimize
the hazard caused by air borne asbestos fibers.
INSPECTION
BRAKE DRUM
Measure the brake drum I.D.
SERVICE LIMIT: 131 mm (5.16 in)
BRAKE PANEL DISASSEMBLY

Remove the speedometer drive gear from the brake panel.
Check for any wear and damage.
SPEEDOMETER DRIVE GEAR
13-8
Remove the brake shoes and springs. BRAKE SHOES
• Replace the brake shoes as a set.

• Mark the brake shoes to ensure that they are
reinstalled on their original position.
SPRING
Remove the brake arm nut and bolt (1 no.).

BRAKE ARM NUT
Unhook the return spring from the brake arm.
RETURN SPRING
BOLT
Remove the indicator, return spring and brake cam.

INDICATOR
BRAKE CAM
RETURN SPRING
Remove the felt seal and dust seal.

FELT SEAL
DUST SEAL

13-9
ASSEMBLY
SPRING
DUST SEAL
BRAKE PANEL
FELT SEAL
BRAKE SHOE 10 N·m (1.0 kgf·m, 7 lbf·ft)

SPEEDOMETER
DRIVE GEAR
RETURN
SPRING
INDICATOR
BRAKE CAM
Apply grease to the felt seal and install it into the brake
panel. FELT SEAL
Apply grease to a new dust seal lip and install it into the
brake panel.
DUST SEAL
Apply grease to the brake cam sliding surface and install

it into the brake panel.
BRAKE CAM
13-10
Install the return spring, inserting its end into the hole in
the brake panel. INDICATOR
Install the wear indicator plate on the brake cam, aligning

its wide tooth with the cam’s wide groove.
ALIGN
RETURN SPRING
Install the brake arm onto the brake cam, aligning the
BRAKE ARM NUT ALIGN
punch marks on the arm and cam.
Install the brake arm bolt and nut, and tighten the nut.
RETURN SPRING
BOLT
Apply grease to the brake cam and the anchor pin. BRAKE SHOES
• Contaminated brake linings reduce stopping power.

Keep grease off the brake linings.
• Wipe any excess grease off the brake cam and anchor
pin.
Install the brake shoes and springs.
SPRINGS
Apply grease to the speedometer drive gear and install it,
Install the brake panel.

Install the front wheel (page 13-3).
SPEEDOMETER DRIVE GEAR

13-11
HANDLEBAR
BOLT
REMOVAL
Remove the handlebar cover (page 2-7).
Remove the bolt (1 no.) and front brake lever
bracket/throttle housing of upper side.
FRONT BRAKE LEVER BRACKET/

THROTTLE HOUSING
Disconnect the throttle cable and remove front brake

FRONT BRAKE LEVER
lever bracket/throttle housing of lower side. THROTTLE CABLE
BRACKET/THROTTLE
HOUSING
GRIP
Remove the bolt (1 no.) and rear brake lever bracket. BOLT REAR BRAKE LEVER BRACKET
Remove the handlebar post pinch nut (1 no.) and bolt

BOLT
(1 no.) .
Remove the handlebar.
NUT
13-12
INSTALLATION
HANDELBAR
Install the handlebar and align with the hole in the
steering stem.
STEERING STEM
Align the bolt hole in the handlebar post with the hole in
BOLT
the steering stem and insert the handlebar post pinch
bolt (1 no.) and collar from left side and also insert a
collar from right side.
Install and tighten the handlebar post pinch nut.
NUT
If the handlebar grips were removed, apply Honda Bond

A or its equivalent to the inside surface of the grips and to HANDLEBAR GRIP THROTTLE GRIP
the clean surface of the left handlebar and throttle pipe.
Wait 3 – 5 minutes and install the grip.
Rotate the grips for even application of the adhesive.
Allow the adhesive to dry for an hour before using.
Apply grease to the throttle grip inner surface.
Install the throttle grip onto the handlebar.
THROTTLE GRIP

13-13
Install the front brake lever bracket/throttle housing of lower

THROTTLE CABLE
side and align the locating pin with the hole in the
handlebar.
ALIGN
Install the front brake lever bracket/throttle housing of

upper side and tighten the bolt (1 no.). BOLT
FRONT BRAKE LEVER BRACKET/

THROTTLE HOUSING
Install the rear brake lever bracket and align the locating
pin with the hole in the handlebar. REAR BRAKE
LEVER BRACKET
ALIGN
Install and tighten the bolt (1 no.) securely. BOLT
Route the wires and cables properly (page 1-13).
13-14
STEERING STEM/FRONT FENDER

REMOVAL
— Front wheel (page 13-3)
— Handlebar (page 13-12)
Remove the steering stem lock nut.
TOOL:
STEM LOCK NUT
LOCK NUT WRENCH
Remove the top cone race.
TOOL:
Support the steering stem.
LOCK NUT WRENCH
Remove the upper steel balls (26) from the steering head.
Be careful not to loose the steel balls.
STEEL BALL
Remove the lower steel balls (19) from the steering stem.
Be careful not to lose the steel balls.
STEEL BALLS

13-15
Remove the bolt (1 no.) from the front fender.
BOLT
Remove the bolts (2 nos.) from the front fender inner

side.
BOLTS
BEARING RACE REPLACEMENT

BOTTOM CONE RACE
BOTTOM CONE RACE
Remove the bottom cone race and dust seal from the
steering stem.
DUST
SEAL
Install the a new dust seal onto the steering stem.

Press a new bottom cone race onto the stem using the
special tool.
TOOL:
Inner driver, 30 mm 070GD – 003-I120
BOTTOM CONE RACE DUST SEAL
INNER DRIVER
13-16
BALL RACE
REMOVER WEIGHT
Drive the top ball race out of the steering head using the
special tool. ADJUSTING
REMOVER HEAD
TOOLS:
Remover weight 070MC – KPL-I300
REMOVER
SHAFT
TOP BALL RACE
Drive the bottom ball race out of the steering head using
the special tool. ADJUSTING BOTTOM BALL
REMOVER HEAD
TOOLS:
Remover weight 070MC – KPL-I300 REMOVER REMOVER SHAFT
WEIGHT
Drive new top ball races into the steering head using the
special tools. DRIVER
TOOLS: TOP BALL

Driver 070GD – 001-I100 RACE
ATTACHMENT
Drive new bottom ball races into the steering head using
the special tools. BOTTOM BALL RACE
TOOLS:
Driver 070GD – 001-I100
ATTACHMENT
DRIVER

13-17
ASSEMBLY
STEM LOCK NUT
TOP CONE RACE
STEEL BALL
TOP BALL RACE
BOTTOM BALL RACE
STEEL BALL
BOTTOM CONE RACE
DUST SEAL
Install the front fender and tighten the bolts (2 nos.)

securely.
BOLTS
Install and tighten the bolt (1 no.) securely.
BOLT
13-18
Apply grease to the bottom steel balls (19) and install it

onto the steering stem.
Be careful not to loose the steel balls.
STEEL BALLS
Apply grease to the upper steel balls (26), and install it

onto the steering stem.
STEEL BALL
Tighten the steering top cone race fully by hand.

TOP CONE RACE
Tighten the steering top cone race using the special tool.
When using the lock nut wrench, use a deflecting beam

type torque wrench 10 inches long. The lock nut wrench
increases the torque wrench’s leverage, so the torque
wrench reading will be less than the torque actually
applied to the lock nut. The specification below gives both
actual and indicated.
TOOL:
LOCK NUT WRENCH
TORQUE: Actual: 11 N·m (1.1 kgf·m, 8 lbf·ft)
Indicated: 9 N·m (0.9 kgf·m, 6.5 lbf·ft)
Turn the steering stem lock-to-lock several times to seat

the bearings and races.
TOP CONE RACE
Loosen the top cone race.
Tighten the top cone race fully by hand, then loosen it 45°
(1/8 turn).

13-19
Install the steering stem lock nut to the steering stem.
STEM LOCK NUT
Tighten the steering stem lock nut to the specified torque.
TOOL:
Make sure that the steering stem moves smoothly

without play or binding.

— Handlebar (page 13-12)
— Front wheel (page 13-3)
NOTE: LOCK NUT WRENCH
Check for both sideways and axial play in the steering.
FRONT CUSHION
PIVOT ARM
— Steering stem (page 13-15)
— Front fender (page 13-15)
Remove the pivot arm mounting bolt/nut.
BOLT/NUT
Remove the bolt (1 no.) and front cushion.

BOLT
CUSHION
13-20
INSPECTION
SHOCK ABSORBER
Visually inspect the shock absorber for oil leaks or other
faults.
INSPECTION
PIVOT ARM
Check the pivot arm for wear or damage.
If you fill up the pivot with grease, loosen the grease nut
and do it.
GREASE NUT
INSTALLATION
32 N·m (3.3 kgf·m, 24 lbf·ft)
FRONT CUSHION
26 N·m (2.6 kgf·m, 19.17 lbf·ft)
PIVOT ARM

13-21
Install the front cushion and tighten the bolt (1 no.) to

specified torque. BOLT
CUSHION
Install the pivot arm and tighten the nut (1 no.) to

specified torque.
PIVOT ARM

— Steering stem (page 13-18)
— Front fender (page 13-18)
BOLT/NUT
13-22
39 N·m (4.0 kgf·m, 29 lbf·ft)
22 N·m (2.2 kgf·m, 16 lbf·ft)
118 N·m (12.0 kgf·m, 87 lbf·ft)
14-2
14-0
14. REAR WHEEL/BRAKE/SUSPENSION
SERVICE INFORMATION 14-1 REAR BRAKE 14-4
TROUBLESHOOTING 14-2 SHOCK ABSORBER 14-7
REAR WHEEL 14-3
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• Riding on damaged rims impairs safe operation of the scooter.

• When servicing the rear wheel and suspension, support the motorcycle using a center stand or hoist.
• A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes, and clean a con
taminated drum with a high quality brake degreasing agent.
• After the rear wheel installation, check the brake operation by applying the brake lever.
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
• Refer to the brake system information (page 14-3).
• This scooter is equipped with the TUFFUP tube (rear tyre only).
• The TUFFUP tube is able to repair same as a usual tube. Follow bellow caution:
– Do not inflate a TUFFUP tube larger than the tire size as you do in a conventional tube, or air will flow into the
liquid room and lower its performance
– When finding a hole inflate a TUFFUP tube to the same size as the inside of the tire and look for a hole where
liquid leaks out
– When fixing the TUFFUP tube, hold the area where a patch is attached higher than other parts of the tube so
that the liquid does not flow over the area. Then wipe off the liquid thoroughly and attach a patch firmly or it may
cause air leak
REPAIR POINT
14
• TUFFUP tube cannot always prevent tire puncture.

• Always use proper size TUFFUP tube for the tire.
• Because of its construction, foreign object(s) may be stuck into the tube even if the tire seems to be inflated to the
proper pressure. If any foreign objects are found during maintenance, remove them, and repair as soon as
possible.
• Sometimes air leak does not stop after a nail etc. is removed from the tire. In that case, tapping the tread of the
tire several times can stop the air leak. Even if the air leak stops after tapping, it may starts leaking again. Repair
it as soon as possible.
• When a tire rim is wet or a tire seems under-inflated, check for any abnormalities on the tire and repair if
necessary.
• When the liquid contacts with your skin or eye(s), rinse with plenty of water immediately.
• Like a conventional tube, damage over 3.0 mm (0.12 in) cannot be repaired. In that case the whole tube must be
replaced.
• Always use a new TUFFUP tube that is proper for tire size when replacing.
• Always inflate to the specified pressure.

14-1
• TUFFUP tube cannot prevent puncture in the following case:

– A burst
– Damage on other area than tread (non-liquid room area)
– A hole caused by rusty nail etc.
A contaminated brake drum or lining reduces stopping power. Discard contaminated linings and clean a contaminated drum
with a high quality brake degreasing agent.
• Always check the brake operation before riding the scooter.

• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
SPECIFICATIONS
Unit: mm (in)

2
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm , 29 psi) —
2
Driver and passenger 250 kPa (2.50 kgf/cm , 36 psi) —
Rear wheel rim runout Radial — 2.0 (0.08)
Axial — 2.0 (0.08)
Rear brake drum I.D. 130 (5.11) 131 (5.16)
TORQUE VALUES
Rear axle nut 118 N·m (12.0 kgf·m, 87 lbf·ft) Apply oil to the threads and seating surface.
Rear brake arm bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOK bolt: replace with a new one.
Rear wheel hub nut 49 N·m (5.0 kgf·m, 36 lbf·ft) Apply oil to the threads and seating surface.
Shock absorber upper mounting bolt 39 N·m (3.9 kgf·m, 28.76 lbf·ft)
Shock absorber lower mounting bolt 22 N·m (2.2 kgf·m, 16 lbf·ft)
TROUBLESHOOTING Poor brake performance

• Improper brake adjustment
• Contaminated brake shoe lining
Rear wheel wobbling • Worn brake shoes
• Bent rim • Worn brake cam
• Worn or damaged final shaft bearing • Contaminated brake drum
• Worn or damaged engine mounting bushings • Worn brake drum
• Faulty tire
• Axle nut or engine mounting nut not tightened properly Soft suspension
• Insufficient tire pressure • Weak rear shock absorber spring
• Unbalanced tire and wheel • Faulty rear shock absorber damper
Hard suspension
• Bent rear shock absorber damper rod
• High tire pressure
14-2
REAR WHEEL
REMOVAL
Place the scooter on its center stand.
Remove the muffler (page 2-8).
Remove the axle nut, washer and the rear wheel.
AXLE NUT/WASHER
Check the rotating direction mark on the tire.

ROTATING DIRECTION MARK
Remove the nuts (4 nos.) and wheel hub.

NUTS
WHEEL HUB
INSPECTION
Check the wheel rim runout using a dial indicator.
SERVICE LIMITS: Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

14-3
WHEEL BEARING
Turn the inner race of each bearing with your finger. The
bearings should turn smoothly and quietly. Also check
that the bearing outer race fits tightly in the hub.
Remove and discard the bearings if the races do not turn
smoothly, quietly, or if they fit loosely in the hub.
WHEEL BEARING
INSTALLATION NUTS
Install the wheel hub on the wheel and tighten the nuts
(4 nos.) to the specified torque.
WHEEL HUB
Install the rear wheel and washer.

Apply oil to the axle nut threads and seating surface, and
WASHER
install it.
Tighten the axle nut.
Install the muffler (page 2-8).
NUT
REAR BRAKE
Remove the rear wheel (page 14-3).
INSPECTION
Measure the rear brake drum I.D.
SERVICE LIMIT: 131 mm (5.16 in)
14-4
DISASSEMBLY
• Replace the brake shoes as a set.

• Mark the brake shoes to ensure that they are reinstalled
on their original position.
Remove the brake shoes and springs.
SPRINGS
BRAKE SHOES
Remove the adjusting nut, brake cable and brake arm

joint from the brake arm.
ARM
Remove the brake arm return spring. RETURN
CAM
Remove the brake arm bolt, brake arm, brake cam and SPRING
BOLT
dust seal from the brake panel (transmission case).
BRAKE
ADJUSTING
CABLE ARM PIN NUT
ASSEMBLY
DUST SEAL
BOLT ANCHOR PIN

BRAKE ARM
ADJUSTING NUT BRAKE SHOE
BRAKE ARM
BRAKE CABLE
RETURN SPRING
BRAKE CAM SHOE SPRING

14-5
Apply grease to a new dust seal lip and install it into the
brake panel (transmission case).
Apply grease to the brake cam sliding surface and install
it into the brake panel.
BRAKE CAM
Install the brake arm onto the brake cam, aligning the
punch marks on the arm and cam. BRAKE CAM PUNCH MARKS
BRAKE
ARM
Install and tighten the brake arm bolt (1 no.) .

RETURN
Install the return spring. SPRING
BOLT
Install the brake arm joint, brake cable and brake adjust-
ing nut (page 3-14). ADJUSTING
NUT
BRAKE
CABLE ARM PIN
Apply grease to the brake cam and anchor pin.
When the brake shoes are reused, install them on

their original position.
Install the shoe springs onto the brake shoes.

Install the brake shoes and springs onto the brake cam
and anchor pin.
Install the rear wheel (page 14-3).
SPRINGS
Adjust the rear brake (page 3-13). BRAKE SHOES
14-6
SHOCK ABSORBER UPPER MOUNTING

BOLT
REMOVAL
Place the scooter on its center stand.
Remove the body covers (page 2-4).
Remove the upper and lower mounting bolts (2 nos.) ,
and the shock absorber.
LOWER MOUNTING
BOLT
INSPECTION SHOCK ABSORBER

Visually inspect the shock absorber for oil leaks or other
faults.
INSTALLATION UPPER MOUNTING

BOLT
Install the shock absorber and tighten the upper and lower
mounting bolts (2 nos.) .
TORQUE: Upper: 39 N·m (3.9 kgf·m, 28.76 lbf·ft)

Lower: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Install the body covers (page 2-4).
LOWER MOUNTING
BOLT

14-7
MEMO
14-8
SYSTEM DIAGRAM
LIGHTING SWITCH
DIMMER SWITCH
REGULATOR/
RECTIFIER
BATTERY
EARTHING CABLE
ALTERNATOR
15-2
15-0
SEC00-15.pmd 2 2/17/2010, 1:40 PM

15. BATTERY/CHARGING SYSTEM
SYSTEM DIAGRAM 15-0 CHARGING SYSTEM INSPECTION 15-8
SERVICE INFORMATION 15-1 ALTERNATOR INSPECTION 15-10
TROUBLESHOOTING 15-3 REGULATOR/RECTIFIER 15-10
BATTERY 15-6
SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician.
• Electrolyte is poisonous.
— If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a
physician.
• KEEP OUT OF REACH OF CHILDREN.
• Always turn "off" the ignition switch before disconnecting any electrical component.
• If the breather tube is blocked, the battery's internal pressure will not be relieved the breather may come off, or the battery may
crack as a result.
switch is "ON" and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal.
• Tap water will shorten the service life of the battery. 15
• Immediately wash off any spilled electrolyte.
• Avoid filling the battery above the UPPER LEVEL line to prevent an electrolyte overflow which could corrode the engine or
nearby parts.
• The battery can be damaged if over charged or undercharged, or if left to discharge for long period. These same conditions
contribute to shorting the “life span” of the battery. Even under normal use, the performance of the battery deteriorates after
2–3 years.
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out.
For this reason, the charging system is often suspected to be the problem. Battery overcharge often results in problems in the
battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and battery voltage does
not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes
down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the
battery is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the
scooter.

15-1
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge
the battery. Also, the battery life is lengthened when it is initial-charged.
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 15-3).
For battery charging, do not exceed the charging current and time specified on the battery. Use of excessive current or charging time
may damage the battery.
BATTERY TESTING
Refer to instructions in the Operation Manual for the recommended battery tester for details about battery testing.
The recommended battery tester puts a “load” on the battery so that the actual battery condition can be measured.
Recommended battery tester BM-210-AH or BM-210 BATTERY MATE or equivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V, 5 Ah
Specific gravity Fully charged Above 1.270 – 1.290 at 20°C/68°F
Needs charging Below 1.260 at 20°C/68°F
Current leakage 1.0 mA max.
Charging rate Normal 0.5 A/5 – 10 h
Quick 5 A/0.5 h
Regulator/rectifier Regulated voltage Charging 14.0 – 15.0 V/5,000 min–1 (rpm)
Lighting 12.6 – 13.6 V/5,000 min–1 (rpm)
Alternator coil resistance at 20°C (68°F) Charging coil 0.2 – 1.0 Ω
Lighting coil 0.1 – 0.8 Ω
15-2
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Remove the battery (page 15-6). Incorrect • Faulty battery

Check the battery condition using the recom-
mended battery tester.
RECOMMENDED BATTERY TESTER:

BM-210-AH or BM-210
BATTERY MATE or equivalent
Correct
2. Install the battery (page 15-6). Incorrect Disconnect the regulator/rectifier 4P connector and
Check the battery current leakage recheck the battery current leakage.
(Leak test page 15-9).
STANDARD: 1.0 mA max Correct Incorrect
• Faulty regulator/rec-
tifier
Correct
• Shorted wire harness
• Faulty ignition switch
3. Check the alternator charging coil (page 15-10). Incorrect • Faulty charging coil
STANDARD:
0.2 – 1.0 Ω (20°C/68°F)
Correct
4. Remove the battery (page 15-6). Correct • Charging system is normal

Measure and record the battery voltage using
digital multimeter (15-8).
Install the battery (page 15-6).

Start the engine.
Measure the charging voltage (page 15-8).
Compare the measurement to result of the fol-
lowing calculation.
STANDARD:
MEASURED BATTERY VOLTAGE <
MEASURED CHARGING VOLTAGE <
15.5 V at 5.000 min– 1 (rpm)
Incorrect
(To page 15-4)

15-3
(From page 15-3)
Check the regulator/rectifier connector voltage and Incorrect • Open circuit in related wire
resistance (page 15-10). • Loose or poor contacts of related terminal
• Shorted wire harness
Correct
• Faulty regulator/rectifier
15-4
LIGHTING CIRCUIT FAULTY
Before starting the troubleshooting, check for burnt bulb of the headlight, tail light, and meter illumination light, and make sure the bulb
wattage is specified.
Measure the regulated voltage of the lighting sys- Too low or Check the alternator lighting coil resistance (page
tem (page 15-9). no voltage 15-10).
Correct Incorrect
• Open or short circuit

in the alternator
Check the continuity between the regulator/rectifier

and alternator connector Yellow terminals.
Continuity No continuity
Too high
• Open circuit in wire
harness
Check the alternator lighting coil resistance be-

tween the Yellow line of the alternator wire connec-
tor and ground.
Correct Incorrect
• Open circuit in wire

harness
Check the continuity between Green wire terminal Incorrect • Open circuit
of the regulator/rectifier and the body ground (page in wire har-
15-10). ness
Correct
• Faulty regulator/rectifier
• Poorly connected connector

15-5
BATTERY
REMOVAL
— Front center cover (page 2-2) COVER
— Ignition control module connector (page 16-6) COVER STAY
POSITIVE
Remove the bolt cover stay and cover.
CABLE
Remove the battery breather tube from the battery.
Disconnect the negative cable connector first and then

the positive cable connector, and then remove the battery.
INSTALLATION
Install the battery in the reverse order of removal with the
proper wiring as shown.
After installing the battery, coat the terminals with

petrolium jelly.
NEGATIVE CABLE
Reinstall the removed parts.
BOLT
Connect the positive terminal first and then the negative
cable. BREATHER TUBE
INSPECTION
Check for cracked or broken case or plates.
Check the plates for sulfation.
Replace the battery if damaged or sulfated.
Check each cell’s electrolyte level.

If low, add distilled water to bring the level to the upper
level mark.
In order to obtain an accurate test reading when check-

ing the charging system, the battery must be fully charged
and in good condition. Perform the following inspections
and tests before attempting to troubleshooting charging
system problems.
15-6
SPECIFIC GRAVITY
The battery electrolyte contains sulfuric acid. Avoid

contact with skin, eyes or clothing.
The specific gravity must be checked with a hydrometer.

Test each cell by drawing electrolyte into the hydrometer.
SPECIFIC GRAVITY:
Fully charged: 1.270 – 1.290 at 20°C/68°F
Needs charging: Below 1.260 at 20°C/68°F
• If the difference in specific gravity between cells ex-

ceeds 0.01, recharge the battery. If the difference in
specific gravity is excessive, replace the battery.
• There is a change in specific gravity of approximately
0.007 per 10°C change in temperature. Be sure to con-
sider this when taking measurements.
• Reading of the hydrometer’s fluid level should be taken
horizontally.
VOLTAGE INSPECTION
Remove the center cover (page 2-2).
Remove the battery cover.
Measure the battery voltage using a commercially avail-
able digital multimeter.
VOLTAGE (20O C/68OF):
Fully charged: 12.7-12.9 V
Under charged: Below 12.3 V
If the battery voltage is below 12.3 V, charge the battery.
NEGATIVE TERMINAL POSITIVE TERMINAL
BATTERY CHARGING
Remove the battery (page 15-6).
Remove the cell caps.
Fill the cells with distilled water to the upper level line, if
necessary.
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the charger negative (–) cable to the battery
negative (–) terminal.

15-7
Normal Quick
Charging 0.5 A 5A
current
Charging time 5 – 10 hours 0.5 hour
• The battery gives off explosive gases; keep sparks,

flames, and cigarettes away. Provide adequate ven-
tilation when charging.
• Turn power ON/OFF at the charger, not at the battery
terminal.
• Quick-charging should only be done in an emergency;

slow charging is preferred.
• For battery charging, do not exceed the charging
current and time specified on the battery. Using exces-
sive current or extending the charging time may
damage the battery.
CHARGING SYSTEM INSPECTION

CHARGING VOLTAGE INSPECTION
If the engine must be running to do some work, make

sure the area is well-ventilated. Never run the engine
in an enclosed area. The exhaust contains poisonous
carbon monoxide gas that may cause loss of
consciousness and may lead to death.
Remove the center cover (page 2-2).

Remove battery cover (page 15-6).
Be sure the battery is in good condition before

performing this test.
15-8
CHARGING OUTPUT:
Stop the engine, and connect the multimeter as shown.
• To prevent short, make absolutely certain which are

the positive and negative terminals or cable.
• Do not disconnect the battery or any cable in the
charging system without first switching off the igni-
tion switch. Failure to follow this precaution can dam-
age the tester or electrical components.
NEGATIVE TERMINAL POSITIVE TERMINAL
Connect a techometer according to the tachometer

manufacture instruction.
Restart the engine.
With the headlight high beam, measure the voltage on
the multimeter when the engine runs at 5,000 min-1 (rpm)
STANDARD
Measured BV < Measured CV < 15.5V
• BV = Battery voltage (page ....)
• CV = Charging Voltage
LIGHTING OUTPUT:
Open the front handle bar cover (page 2-7).

(Do not remove headlight assy.)
Connect the voltmeter positive (+) probe to the headlight
Blue terminal, and negative (–) probe to the Green wire
terminal.
Start the engine and light switch is “ON” and the dimmer
switch is “Hi” position, and read the voltage.
REGULATED VOLTAGE:
12.6 – 13.6 V at 5,000 min– 1 (rpm) HEADLIGHT 3P
CONNECTOR
• Measure the voltage with the headlight wire
connectors connected.
CURRENT LEAKAGE INSPECTION

Remove front center cover & battery cover.
Turn the ignition switch off and disconnect the battery
negative cable from the battery.
Connect the ammeter (+) probe to the ground cable and
the ammeter (–) probe to the battery (–) terminal.
With the ignition switch off, check for current leakage.
NEGATIVE CABLE

15-9
• When measuring current using a tester, set it to a high

range, and then bring the range down to an appropri-
ate level. Current flow higher than the range selected
may blow out the fuse in the tester.
• While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.
SPECIFIED CURRENT LEAKAGE: 1.0 mA max.

If current leakage exceeds the specified value, a shorted
circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
ALTERNATOR INSPECTION
It is not necessary to remove the stator coil to make this
test.
Disconnect the alternator 2P connector (page 11-2).
Check the resistance between following terminals.
STANDARD:
Charging coil (White – Green (Ground)):
White-Green 0.2 – 1.0 Ω (at 20°C/68°F)
Lighting coil (Yellow – Green (Ground)):
Yellow-Green 0.1 – 0.8 Ω (at 20°C/68°F)
Replace the alternator stator if readings are far beyond
the standard.
Refer to section 11 for stator removal.
Connect the alternator 2P connector..
Lift down the body cover.
REGULATOR/RECTIFIER
SYSTEM INSPECTION
Remove the regulator/rectifier 4P connector, and check it

for loose contact or corroded terminals.
If the regulated voltage reading (page 15-8) is out of the

specification, measure the voltage between connector
terminals (wire harness side) as follows:
REGULATOR/RECTIFIER 4P CONNECTOR
15-10
Item Terminal Specification

Battery Red (+) and Battery voltage
charging line ground (–) should register
Charging coil White and 0.2 – 1.0 Ω
line ground (at 20°C/68°F)
Lighting coil Yellow and 0.1 – 0.8 Ω
line ground (at 20°C/68°F)
Ground line Green and Continuity
ground should exist
If all components of the charging system are normal and

there are no loose connections at the regulator/rectifier
connectors, replace the regulator/rectifier unit.
REGULATOR/RECTIFIER UNIT
BOLT
Remove the regulator/rectifier unit mounting bolt (1 no.).
Disconnect the connector and remove the regulator/
rectifier unit.
Install the regulator/rectifier unit in the reverse order of

removal.
REGULATOR/RECTIFIER 4P CONNECTOR

15-11
IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION CONTROL IGNITION COIL

IGNITION SWITCH
MODULE (ICM)
EARTHING CABLE
SPARK PLUG
IGNITION PULSE
GENERATOR
16-2
16-0
16. IGNITION SYSTEM
SYSTEM DIAGRAM 16-0 IGNITION TIMING 16-6
SERVICE INFORMATION 16-1 IGNITION COIL 16-6
TROUBLESHOOTING 16-2 IGNITION CONTROL MODULE (ICM) 16-6
IGNITION SYSTEM INSPECTION 16-3 THROTTLE SWITCH 16-7
SERVICE INFORMATION
GENERAL
switch is ON and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting on page 16-2.
• The CDI ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the ignition
timing.
• The ignition control module (ICM) may be damaged if dropped. Also, if the connector is disconnected when current is flowing,
the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing.
• A faulty ignition system is often related to poor connections. Check those connections before proceeding.
• Make sure the battery is adequately charged. A weak battery may be unable to turn the starter motor quickly enough, or
adequate ignition current may not be supplied.
• Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
• For ignition switch inspection, see section 18.
• For ignition pulse generator (alternator starter) removal/installation, see section 10.
SPECIFICATIONS
ITEM SPECIFICATIONS
Standard CPR7EA-9
Ignition primary peak voltage 100 V minimum
Exciter coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 15° BTDC at idle speed
TOOLS 16
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 070GJ – 002I110 with
Commercially available digital multitester (impedance 10 MΩ/DCV minimum)

16-1
IGNITION SYSTEM
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
— Faulty spark plug
— Loose spark plug cap or spark plug wire connections
— Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
• If there is no spark at cylinder, temporarily exchange the ignition coil with the other good one and perform the spark test. If there is
spark, the exchanged ignition coil is faulty.
No spark at spark plug
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)

Ignition coil Low peak voltage 1. Incorrect peak voltage adaptor connections. (System is normal if measured
primary voltage voltage is over the specifications with reverse connections.)
2. The multimeter impedance is too low; below 10 MΩ/DCV.
3. Cranking speed is too low.
4. The sampling timing of the tester and measured pulse were not synchro-
nized. (System is normal if measured voltage is over the standard voltage
at least once.)
5. Poorly connected connectors or an open circuit in ignition system.
6. Faulty exciter coil (Measure the peak voltage).
7. Faulty ignition control module (ICM) (in case when above No. 1 thru. 6 are
normal.)
No peak voltage 1. Incorrect peak voltage adaptor connections.
2. Faulty ignition switch or engine stop switch.
3. Loose or poorly connected ICM connectors.
4. Open circuit or poor connection in ground wire of the ICM.
5. Faulty peak voltage adaptor.
6. Faulty exciter coil (Measure the peak voltage).
7. Faulty ignition pulse generator (Measure the peak voltage).
8. Faulty ICM (in cases when above No. 1 – 7 are normal).
Peak voltage is normal, but no 1. Faulty spark plug or leaking ignition coil secondary current ampere.
spark jumps at plug 2. Faulty ignition coil.
Exciter coil Low peak voltage 1. Multimeter impedance is too low; below 10 MΩ/DCV.
2. Cranking speed is too low.
• Operating force of the kickstarter is weak.
3. The sampling timing of the tester and measured pulse were not
synchronized (System is normal if measured voltage is over the
specifications at least once).
4. Faulty exciter coil (in cases when above No. 1 – 3 are normal).
No peak voltage 1. Faulty peak voltage adaptor
2. Faulty exciter coil
Ignition pulse Low peak voltage 1. The multimeter impedance is too low; below 10 MΩ/DCV.
generator 2. Cranking speed is too slow.
• Operating force of the kickstarter is weak.
3. The sampling timing of the tester and measured pulse were not synchro-
nized (System is normal if measured voltage is over the standard voltage
at least once.)
4. Faulty ignition pulse generator (in case when above No. 1 thru. 3 are
normal.)
No peak voltage 1. Faulty peak voltage adaptor.
2. Faulty ignition pulse generator.
16-2
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER
• If not spark jumps at the plug, check all connections

for loose or poor contact before measuring each peak
voltage.
• Use a commercially available digital multimeter (im-
pedance 10 MΩ/DCV minimum).
• The display value differs depending upon the internal
impedance of the multimeter.
• If the Imrie diagnostic tester (model 625) is used, fol-
low the manufacturer’s instructions.
PEAK VOLTAGE ADAPTOR
Connect the peak voltage adaptor to the digital multim-
eter.
TOOL:
Peak voltage adaptor 070GJ – 002I110
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
IGNITION PRIMARY PEAK VOLTAGE
• Check all system connections before this inspection.

Poor connected connectors can cause incorrect read-
ings.
• Check that the cylinder compression is normal and
check that the spark plug is installed correctly in the
cylinder head.

Disconnect the spark plug cap from the spark plug.
Connect a good known spark plug to the spark plug cap
and ground the spark plug to the cylinder head as done
in a spark test.
With the connector connected, connect the peak voltage

adaptor probes to the ignition coil primary terminal and
ground.
CONNECTION: GOOD KNOWN SPARK PLUG

Black/yellow wire terminal (–) — body ground (+)
Turn the ignition switch ON.

Crank the engine with the kickstarter and read the igni-
tion coil primary voltage.
PEAK VOLTAGE: 100 V minimum
Avoid touching the spark plug and tester probes to

prevent electric shock. IGNITION COIL
If the peak voltage is lower than the standard value,

follow the checks described in the troubleshooting on
(page 16-2).

16-3
IGNITION SYSTEM
EXCITER COIL PEAK VOLTAGE

Remove the front center cover (page 2-2). ICM 9P CONNECTOR
Disconnect the ignition control module (ICM) 10P
connectors (page 16-6).
Connect the Imrie tester or peak voltage adaptor (+) probe
to the exciter coil (Black/Red) wire terminal of the 10P
connector, and the (–) probe to the body ground.
TOOL:
Peak voltage adapter 070GJ – 002I110 with
Commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
CONNECTION:
Black/Red terminal (+) — Body ground (–)
Crank the engine with the kickstarter and read exciter coil
peak voltage.
PEAK VOLTAGE: 100 V minimum
To avoid possible electrical shock during voltage mea-

surements, do not touch test probe metal parts.
If the peak voltage measured at the ICM connector is

abnormal, disconnect the exciter coil line connector (Black/
Red) and connect the adaptor probes to the exciter coil
terminal and body ground.
EXCITER COIL
In the same manner as at the ICM connector, measure LINE CONNECTOR
the peak voltage and compare it to the voltage measured
at the ICM connector.
• If the peak voltage measured at the ICM is abnormal

and the one measured at the exciter coil is normal.
The wire harness has an open circuit or loose con-
nections.
• If both peak voltages measure are abnormal, check
each item in the troubleshooting chart. If all items are
normal, the exciter coil is faulty.
16-4
IGNITION SYSTEM
IGNITION PULSE GENERATOR PEAK

VOLTAGE ICM 10P CONNECTOR
Check that the cylinder compression is normal and the

spark plug is installed correctly in the cylinder head.
Disconnect the ignition control module (ICM) connector

(page 16-6).
Connect the peak voltage adaptor probes to the ignition
pulse generator wire and ground wire terminals of the
wire harness side connector.
CONNECTION:
Blue/Yellow wire terminal (+) — green wire
terminal (–)
Turn the ignition switch ON.

Crank the engine with the kickstarter and read the peak
voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ICM connector is

abnormal, disconnect the ignition pulse generator IGNITION PULSE GENERATOR
connector and connect the adaptor probles to the ignition CONNECTOR
pulse generator side connector.
In the same manner as the ICM connector, measure the
peak voltage and compare it to the voltage measured at
the ICM connector.
• If the peak voltage measured at the ICM connector is

abnormal and the one measured at the ignition pulse
generator connector is normal, the blue/yellow wire
has an open or short circuit, or loose connections.
• If both peak voltages are abnormal, follow the checks
described in the troubleshooting on (page 16-2).

16-5
IGNITION SYSTEM
IGNITION TIMING
SCREWS
When the engine must be running to do some work,

make sure the area is well ventilated. Never run the
engine in a closed area. The exhaust contains
poisonous carbon monoxide gas that may cause loss
of consciousness and lead to death. Run the engine
in an open area or with an exhaust evacuation system
in an enclosed area.
BOLT FAN COVER
The ignition timing is factory preset and only needs to be

checked when an electrical system component is
replaced.
INDEX MARK
Warm up the engine to the normal operating
temperature.
Remove the fan cover.
Connect the timing light and a tachometer.
Read the manufacturer’s instructions for the timing light

and tachometer.
The ignition timing is correct if the “F” mark on the
flywheel aligns with the index mark of the right crankcase "F" MARK
at idle.
Install the fan cover.
IGNITION COIL IGNITION COIL
Disconnect the ignition coil primary wire connectors.
Remove the spark plug cap and the spark plug

(page 3-6).
Remove the bolts and ignition coil from the frame. BOLTS PRIMARY WIRE
CONNECTOR
Install the ignition coil in the reverse order of removal.
IGNITION CONTROL MODULE (ICM) 10P CONNECTOR
Remove the ignition control module (ICM) from the
battery stay, disconnect the connectors and remove the
ICM.
Install the ICM in the reverse order of removal.
Check continuity between green wire and body ground. IGNITION CONTROL
MODULE (ICM)
16-6
IGNITION SYSTEM
THROTTLE SWITCH BOLTS

THROTTLE SWITCH
CONNECTORS
SYSTEM INSPECTION SCREW

Disconnect the Yellow/Blue and Blue/Green wire
connectors of the throttle switch.
CHOKE CABLE FUEL TUBE
Check for continuity between the Yellow/Blue and Blue/

Green wire connectors with the throttle position while
operating the throttle grip.
Fully open: no continuity

Fully closed: continuity
If there is abnormal continuity, replace the throttle switch.

16-7
ELECTRIC STARTER
SYSTEM DIAGRAM
FRONT BRAKE
LIGHT SWITCH
REAR BRAKE
LIGHT SWITCH
STARTER
SWITCH
FUSE 10 A
EARTHING CABLE
STARTER RELAY SWITCH
STARTER
17-2
17-0
17. ELECTRIC STARTER
SYSTEM DIAGRAM 17-0 STARTER MOTOR 17-3
SERVICE INFORMATION 17-1 STARTER RELAY 17-6
TROUBLESHOOTING 17-2
SERVICE INFORMATION
GENERAL
Always turn the ignition switch OFF bofore servicing the starter motor. The motor could suddenly start, causing serious injury.
• The starter motor can be serviced with the engine installed in the frame.
• When checking the starter system, always follow the steps in the troubleshooting flow chart (page 17-2).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• See section 18 for starter switch and ignition switch inspections.
• See section 9 for starter pinion inspection.
• The following color codes are used throughout this section.
Bu = Blue G = Green Lg = Light green R = Red
BI = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light blue P = Pink Y = Yellow
SPECIFICATIONS Unit: mm (in)

Starter motor brush length 9.0 (0.35) 3.5 (0.14)
17

17-1
ELECTRIC STARTER
TROUBLESHOOTING
Starter motor will not turn
• Check for a blown main fuse (10 A)
• Check that the battery is fully charged and in good condition.
With the ignition switch ON and the brake lever Clicks Connect the starter motor terminal directly to the
squeezed (or pedal depressed), push the starter battery positive terminal. (Because a large amount
switch and check for a “Click” sound from the starter of current flows, do not use a thin wire.)
relay switch.
Starter motor turns Starter motor
does not turn
No clicks
• Faulty starter motor
• Loose or disconnected starter motor wire

• Faulty starter relay switch
Cleck the starter relay voltage (page 17-7). Abnormal • Faulty starter switch
• Faulty ignition switch
• Loose or poor connector contact
Normal • Open circuit in wire harness
Check the starter relay switch operation (page 17- Abnormal • Faulty starter relay switch
7).
Normal
Check the starter relay coil ground line and related Abnormal • Loose or poor connector contact
circuits (page 17-7). • Open circuit in wire harness
• Faulty brake light switch
Normal
• Loose or poor ignition control module (ICM)

connector contact
• Faulty ICM
17-2
ELECTRIC STARTER
STARTER MOTOR DUST COVER/SCREW
REMOVAL
Always turn the ignition switch OFF before servicing

BOLTS
the starter motor. The motor could suddenly start,
causing serious injury.

Slide the dust cover off the starter motor terminal.
STARTER MOTOR
Remove the screw (1 no.) and disconnect the starter motor
wire from the starter motor.
Remove the mounting bolts (2 nos.), ground wire and the
starter motor from the crankcase.
Remove the starter motor gasket.
DISASSEMBLY
Remove the bolts (3 nos.) and motor case.
MOTOR CASE BOLTS

— armature GASKET
FRONT BRACKET
— front bracket
— springs
— gasket
ARMATURE
INSPECTION
Measure the brush length.

17-3
ELECTRIC STARTER
Inspect the commutator bars of armature for

ARMATURE COIL
discoloration.
Bars discolored in pairs indicate shorted coils.
Do not use emery or sand paper on the commutator.
COMMUTATOR BAR
Check for continuity between pairs of commutator bars.
There should be continuity.
Check for continuity between each commutator bar and

the armature shaft.
There should be no continuity.
17-4
ELECTRIC STARTER
ASSEMBLY
BOLT
SPRINGS
ARMATURE
BRACKET
MOTOR CASE
GASKET
O-RING
Install the springs into the brush holders.

SPRINGS
Push and hold the brushes into the brush holders, and
insert the armature into the front bracket.
Be careful not to damage the brush and armature.

17-5
ELECTRIC STARTER
Install the gasket onto the front bracket.

GASKET
Install the armature into the motor case while holding the
armature tightly to keep the magnet from pulling the
armature against the case.
The coil may be damaged if the magnet pulls the

armature against the case. MOTOR CASE
ARMATURE
Install and tighten the bots (3 nos.).
MOTOR CASE BOLTS
INSTALLATION DUST COVER/SCREW
Install a new gasket onto the starter motor.

Install the starter motor into the crankcase.
Install the ground wire and mounting bolts (2 nos.), and
tighten the bolts securely.
Connect the starter motor wire to the terminal, tighten the
screw (1 no.) and install the dust cover over the terminal. BOLTS
GASKET
STARTER RELAY
INSPECTION
Remove the front cover (page 2-2).
Remove the battery cover (page 15-6)
Remove the starter relay.
STARTER
RELAY
17-6
ELECTRIC STARTER
STARTER RELAY VOLTAGE
Measure the voltage between the yellow/red wire terminal

(+) and ground (–).
If battery voltage appears when the starter switch is
pushed with the ignition switch ON, the power source
circuit is normal. R/W R
Connect the starter relay switch connector.
Y/R W/G
GROUND LINE AND RELATED CIRCUITS
Disconnect the ignition control module (ICM) connector

(page 16-6).
Measure the following between the wire terminals of the
wire harness side connectors with the ignition switch
ON.
ITEM TERMINALS SPECIFICATIONS

Starter relay White/green (+) Battery voltage
switch ground and green (–) with the starter
line switch pushed
Starter switch Yellow/red (+) Battery voltage
line and green (–) with the starter
switch pushed
Brake light Green/yellow Battery voltage NO WIRE
switch line (+) and green with the brake
(–) applied
Y/R Bl/R G Bu/Y

Bl/Y W/G Bl/W Bl
NO WIRE

17-7
SYSTEM LOCATION
TURN SIGNAL
DIMMER LIGHT SWITCH LIGHTING SWITCH
SWITCH
FRONT BRAKE
LIGHT SWITCH
STARTER SWITCH
IGNITION SWITCH
HORN
SWITCH
EARTHING
CABLE
TURN SIGNAL
RELAY
18-2
18-0
18. LIGHTS/METERS/SWITCHES
SYSTEM LOCATION 18-0 IGNITION SWITCH 18-7
SERVICE INFORMATION 18-1 HANDLEBAR SWITCHES 18-8
HEADLIGHT 18-2 BRAKE LIGHT SWITCH 18-9
TURN SIGNAL LIGHT 18-3 FUEL METER/FUEL UNIT 18-9
TAIL/BRAKE LIGHT 18-4 TURN SIGNAL RELAY 18-11
COMBINATION METER 18-5 HORN 18-11
SERVICE INFORMATION
GENERAL
• A halogen headlight bulb become very hot while the headlight is "ON", and remain hot for a while after it is turned
"OFF".
Be sure to let it cool down before servicing.
• Note the following when replacing the halogen headlight bulb.
- Wear clean gloves by replacing the blub. Do not put finger prints on the headlight bulb, as they may create hot spots
on the bulb and cause is to fail.
- If you touch the blub with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
- Be sure to install the dust cover after replacing the bulb.
• Keep all flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye
protection.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the scooter.
• All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnect-
ing.
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be
made without removing the part from the scooter. Simply disconnect the connectors and connect a continuity tester to the
terminals or connections.
• The following color codes are used throughout this section.
Bu = Blue G = Green Lg = Light green R = Red
BI = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light blue P = Pink Y = Yellow
SPECIFICATIONS
18
ITEM SPECIFICATIONS
Bulb Headlight High beam 12 V – 35 W

Low beam 12 V – 35 W
Tail/brake 12 V – 5/21 W
Front turn signal light 12 V – 21 W x 2
Rear turn signal light 12 V – 21 W x 2
Meter light 12 V – 1.7 W x 2
High beam indicator 12 V – 1.7 W
Turn signal indicator 12 V – 3 W x 2
Fuse Main fuse 10 A

18-1
HEADLIGHT
BULB REPLACEMENT
Remove the front handlebar cover (page 2-7).
Remove the headlight bulb dust cover.
Remove the headlight blub while pressing down the
locking pin.
Install a new bulb in the reverse order of removal.
Install the dust cover with its "TOP" mark facing up.
BULB
RETAINER
DUST COVER
ADJUSTING BOLT/
Remove the handlebar front cover (page 2-7).
WASHER
Remove the headlight adjusting bolt (1 no.) and washer.
Unhook the clips (2 nos.) and remove the headlight

assembly.
Install the handlebar front cover (page 2-7).
CLIPS
HEAD LIGHT
ASSEMBLY
18-2
TURN SIGNAL LIGHT

FRONT TURN SIGNAL LIGHT
BULB REPLACEMENT
Remove front turn signal bulb holder by turning

counterclockwise.
Remove bulb by pressing in and turning counter clock
wise and replace it with a new one.
BULB
FRONT TURN SIGNAL UNIT REPLACEMENT

TURN SIGNAL
Remove the handlebar front cover (page 2-7). LIGHT ASSEMBLY
Remove the screws (3 nos.) and front turn signal light

assembly.
SCREWS

18-3
REAR TURN SIGNAL LIGHT

BULB REPLACEMENT
Insert hand from bodycover rear side, above rear fender BULB
area and remove rear turn signal bulb holder by turning
counterclockwise.
Remove rear turn signal bulb by pressing in and turning
counter clock wise and replace it with a new one.
TAIL/BRAKE LIGHT
BULB
BULB REPLACEMENT
Insert hand from bodycover rear side, above rear fender

area and remove tail/brake bulb holder by turning
counterclockwise.
Remove tail/brake bulb by pressing in and turning counter
clock wise and replace it with a new one.
18-4
COMBINATION METER
BULB
BULB REPLACEMENT
Remove the handlebar rear cover (page 2-7).
Pull the indicator and meter bulb socket out of the

combination meter.
Remove the bulb by pressing in and turning counter clock
wise and replace it with a new one.
REMOVAL REAR HANDLEBAR COVER

Remove the rear handlebar cover.
Remove the screws (2 nos.) and combination meter.
SCREWS
SPEEDOMETER
DISASSEMBLY
TABS METER
Unhook the retaining tabs (4 nos.) and remove the front MOUNTING
panel from the rear panel. SCREW
Remove the meter harness mounting screw (1 no.) ,

then remove the indicator light bulbs from the rear panel.
Remove the wire terminal screws (3 nos.) .
Remove the combination meter mounting screw (2 nos.)

and separate the rear panel from the combination meter METER HARNESS
assembly. MOUNTING SCREW
WIRE TERMINAL SCREW

18-5
ASSEMBLY
SPEEDOMETER
FRONT PANEL
METER
HARNESS
REAR PANEL
Assemble the combination meter in the reverse order of

removal.
• Connect the terminals and install the sockets are

according to the color codes indicated on the lower
case.
• Route the meter harness as shown in the illustration.
INSTALLATION
Install the combination meter in the reverse order of
removal.
Route the combination meter wire and cable properly

(page 1-13).
18-6
IGNITION SWITCH
INSPECTION
Remove the inner cover (page 2-6). IGNITION SWITCH
3P CONNECTOR
Disconnect the ignition switch 3P and 1P connector.
Check for continuity between the wire terminals of the

ignition switch connector in each switch position.
Continuity should exist between the color coded wires as
IGNITION SWITCH
follows:
1P CONNECTOR
R Bl/W G Bl
LOCK IGNITION KEY
OFF
ON
IGNITION SWITCH
REMOVAL/INSTALLATION IGNITION SWITCH
Remove the inner cover (page 2-6).

Remove the front cover (page 2-2).
Disconnect the ignition switch 3P and 1P connector

(page 18-7).
Open the bolt (1 no.) and remove the ignition switch cover
.
Remove the screws (2 nos.) and ignition switch. SCREWS

BOLT
Install the ignition switch in the reverse order of removal.
Always use bit T spaner for removing mounting screws.

Apply a locking agent to the mounting screw threads.

18-7
HANDLEBAR SWITCHES RIGHT SIDE:
Disconnect the handlebar switch connectors.
Check the continuity between the wire terminals of the

handlebar switch connector.
Continuity should exist between the color coded wire ter-
minals as follows:
RIGHT HANDLEBAR SWITCHES

STARTER SWITCH
Colour
Position Y/R G/Y
FREE
PUSH
LIGHTING SWITCH
Colour
Position Y Br
OFF
ON
LEFT HANDLEBAR SWITCHES LEFT SIDE:

TURN SIGNAL SWITCH
Colour
Position O Lb Gr
L
N
R
DIMMER SWITCH
Colour
Position W Br Bu
LO
N
HI
HORN SWITCH
Colour
Position Lg Bl
FREE
PUSH
18-8
BRAKE LIGHT SWITCH

Disconnect the brake light switch connector and check

for continuity between the switch terminals.
There should be continuity with the brake lever applied,

and there should be no continuity with the brake lever is
released.
FUEL METER/FUEL UNIT FUEL UNIT 2P

CONNECTOR
INSPECTION
Disconnect the fuel unit 2P connector.
Short the Yellow/White and Green wire terminals of the
fuel level sensor 2P connector with the suitable jumper
wire.
Turn the ignition switch ON and check the fuel meter
needle. The needle should move to “F”.
If the needle does not move, check the following.
Remove the combination meter (page 18-5).

Connect the combination meter 6P connector and black
wire connector.
Check for open circuit in yellow/white between the meter
and fuel level sensor.
If yellow/white wire is OK, measure the voltage between

the black wire (+) and green wire (–) with the ignition
switch ON.
There should be battery voltage.
If there is no voltage, check for open circuit in black wire
and/or green wire. COMBINATION
If the needle moves, check the fuel level sensor. METER
Install the removal parts in the reverse order of removal. Y/W G Bl
FUEL UNIT REMOVAL
Connect the fuel unit 2P connector. FUEL UNIT
Remove the fuel unit cover.
• Be careful not to damage the unit cable.

• Be careful not to bend the float arm of the unit.
UNIT HOLDER
Turn the fuel unit holder plate counterclockwise with a

pair of needle nose pliers and remove the fuel unit and
unit holder plate.

18-9
Turn the ignition switch “ON”.

Move the fuel unit float up and down and make sure that FUEL UNIT
the fuel meter needle moves smoothly.
FLOAT UP: Needle in “FULL”

FLOAT DOWN: Needle in “EMPTY”
If the system inspection is OK but fuel meter needle does

not move properly, replace the fuel level sensor.
FUEL UNIT INSTALLATION

FUEL UNIT
Check that the base packing is in good condition,
replace if necessary.
Install the fuel unit holder plate onto the unit.

Install the fuel unit and its holder plate to the fuel tank.
UNIT HOLDER
Then, turn the unit holder plate to the clockwise and lock
it.
Install and lock the holder plate in such a manner that

after locking, the arrow mark of holder plate should match
with arrow mark on fuel tank assembly.
UNIT HOLDER
18-10
TURN SIGNAL RELAY 2P CONNECTOR TURN SIGNAL RELAY
INSPECTION
Check the following:
— Battery condition
— Burned out bulb or non-specified wattage
— Burned fuse
— Ignition switch and turn signal switch function
— Loose connectors
JUMPER WIRE
If above items all normal. check the following:
Disconnect the connector from the relay.
1. Short the black and gray terminals of the turn signal

relay connector with a jumper wire. Check the turn sig-
nal light by turning the switch “ON.”
Lights comes on Lights does not come on
• Broken wire harness

• Falty turn signal relay.
• Poor connection of the connector.
HORN
Disconnect the wire connectors from the horn.
Connect the battery voltage to the horn terminals.
The horn is normal if it sounds when the battery voltage

is connected across the horn terminals.
HORN

18-11
19. WIRING DIAGRAM
19
19-1

MEMO
19-2

20. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW AND
HARD TO START 20-1 IDLE SPEEDS 20-3
ENGINE LACKS POWER 20-2 POOR PERFORMANCE AT HIGH
SPEED 20-4
POOR HANDLING 20-4
ENGINE DOES NOT START OR IS HARD TO START

Possible cause
1. Check the fuel flow to carburetor Not reaching • No fuel in fuel tank
carburetor • Clogged fuel tube/bent fuel tube
• Clogged fuel stainer
Reaching carburetor • Vaccum tube bent or disconnected
2. Remove and inspect spark plug Wet plug • Throttle valve excessively open
• Rich fuel mixture (section 5)
Dry plug
3. Perform spark test Weak or no spark • Ignition system problem (section 16)
Good spark
4. Test cylinder compression Low compression • Valve clearance too small

• Improper valve and seat contact
• Worn cylinder, piston and piston rings
Normal compression • Valve stuck open
• Improper valve timing
• Leaking cylinder head gasket
• Loose spark plug
5. Start by following normal procedure Engine fires but • Air leaking past intake pipe
soon stops • Misadjusted idle speed
• Improper ignition timing
• Improper valve clearance
• Clogged carburetor
• Fuel contaminated
• Clogged air filter
• Fuel tank cap breather hole block
20

20-1
TROUBLESHOOTING
ENGINE LACKS POWER

Possible cause
1. Raise rear wheel off ground and Engine speed does not • Clogged air cleaner
accelerate lightly increase sufficiently • Restricted fuel flow
• Clogged fuel tank cap breather hole
• Clogged muffler
Engine speed increase
2. Check ignition timing Incorrect • Faulty ignition control module (ICM)

• Faulty ignition pulse generator
Correct
3. Test cylinder compression Low compression • Valve clearance too small

• Improper valve and seat contact
• Worn cylinder, piston and piston rings
• Valve stuck open
Normal compression • Improper valve timing
• Leaking cylinder head gasket
• Loose spark plug
4. Check carburetor for clogging Clogged • Carburetor not serviced frequently enough
Normal
5. Remove and inspect spark plug Fouled or discolored • Plug not serviced frequently enough
• Use of plug with improper heat range
Not fouled or discolored
6. Check if engine overheats Overheating • Lean fuel mixture (section 5)

• Wrong type of fuel
• Excessive carbon build-up in combustion
Not overheating chamber
• Ignition timing too advance (Faulty ICM or
ignition pulse generator)
• Drive and driven pulleys/clutch slipping
(section 10)
• Any extra modification
7. Try rapid acceleration or run Engine knocks • Excessive carbon build-up in combustion
at high speed chamber
• Wrong type of fuel
• Lean fuel mixture (section 5)
• Ignition timing too advance (Faulty ICM or
ignition pulse generator)
• Throttle position switch faulty
20-2
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

Possible cause
1. Check carburetor air screw Incorrect • See section 5

adjustment
Correct
2. Check if air is leaking past intake Leaking • Loose carburetor and/or intake pipe
pipe • Damaged carburetor insulator
• Deteriorated intake pipe O-ring
Not leaking
3. Perform spark test Weak or intermittent • Ignition system problem (section 16)
spark
Good spark
4. Check choke valve Abnormal • Faulty choke valve
Normal
5. Check ignition timing Incorrect • Faulty ignition pulse generator

• Faulty ignition control module (ICM)

20-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

Possible cause
1. Check fuel flow from fuel tank Fuel flow restricted • Clogged fuel stainer
• Clogged fuel tube/vaccum tube
Fuel flows enough
2. Check carburetor for clogging Clogged • Carburetor not serviced frequently enough
Normal
3. Check valve timing Incorrect • Cam sprocket not installed properly
Correct
4. Check ignition timing Incorrect • Faulty ignition pulse generator

• Faulty ignition control module (ICM)
Correct
5. Check choke valve Abnormal • Choke valve open or broken
Normal
6. Check valve spring Weak • Faulty valve spring
POOR HANDLING
Possible cause
1. If steering is hard • Steering stem adjusting nut too tight

• Damaged steering head bearings
2. If either wheel is wobbling • Excessive wheel bearing play

• Bent rim
• Improper installed wheel hub
• Swingarm pivot bushing excessively worn
• Bent frame
3. If the scooter pulling to one side • Faulty shock absorber

• Front and rear wheel not aligned
• Bent fork
• Bent swingarm
• Bent axle
20-4
21. INDEX
AIR CLEANER ........................................................... 3-5 IGNITION CONTROL MODULE(ICM) ........................ 16-6
AIR CLEANER HOUSING .......................................... 5-3 IGNITION SYSTEM INSPECTION .............................. 16-3
AIR SCREW ADJUSTMENT ....................................... 5-10 IGNITION TIMING ....................................................... 16-5
ALTERNATOR REMOVAL ........................................... 11-2 INNER COVER .......................................................... 2-6
ALTERNATOR INSTALLATION ................................... 11-3 KICKSTARTER .......................................................... 9-3
BATTERY .................................................................. 3-12 LUBRICATION & SEAL POINTS ................................ 1-11
BODY PANEL LOCATIONS ........................................ 2-0 MAINTENANCE SCHEDULE ..................................... 3-3
BODY COVER ............................................................ 2-4 MODEL IDENTIFICATION .......................................... 1-2
BRAKE LIGHT SWITCH ............................................. 3-15 MUFFLER .................................................................. 2-8
BRAKE SHOES WEAR .............................................. 3-13 NUTS, BOLTS, FASTENERS ..................................... 3-17
CABLE & HARNESS ROUTING ................................ 1-13 OIL PUMP .................................................................. 4-2
CAMSHAFT INSTALLATION ....................................... 7-20 PISTON INSTALLATION ............................................. 8-5
CAMSHAFT REMOVAL ............................................... 7-19 PISTON REMOVAL .................................................... 8-3
CARBURETOR DISASSEMBLY/INSPECTION .......... 5-5 SARI STEP ................................................................. 2-9
CARBURETOR INSTALLATION ................................. 5-8 SIDE STAND .............................................................. 2-10
CARBURETOR REMOVAL ........................................ 5-4 SECONDARY AIR SUPPLY SYSTEM ......................... 3-11
CHARGING SYSTEM INSPECTION .......................... 15-8 REAR BRAKE ............................................................ 14-4
CLUTCH/DRIVEN PULLEY INSTALLATION .............. 9-16 REAR FENDER ......................................................... 2-7
CLUTCH SHOES WEAR ........................................... 3-15 REAR WHEEL ........................................................... 14-3
DRIVESHAFT INSTALLATION .................................... 10-7 REGULATOR/RECTIFIER ......................................... 15-10
COMBINATION METER .............................................. 18-5 SERVICE INFORMATION
CRANKCASE BREATHER ......................................... 3-6 BATTERY/CHARGING SYSTEM ..................... 15-1
CRANKCASE/CRANKSHAFT DISASSEMBLY ........... 12-2 CRANKCASE/CRANKSHAFT ......................... 12-1
CRANKSHAFT INSPECTION .................................... 12-4 CYLINDER HEAD/VALVE ................................ 7-1
CRANKSHAFT/CRANKCASE ASSEMBLY ................. 12-5 CYLINDER/PISTON ....................................... 8-1
CYLINDER COMPRESSION ..................................... 7-3 ELECTRIC STARTER ..................................... 17-1
CYLINDER HEAD ASSEMBLY ................................... 7-15 ENGINE REMOVAL/INSTALLATION ............... 6-1
CYLINDER HEAD INSTALLATION ............................. 8-6 FINAL REDUCTION ....................................... 10-1
CYLINDER HEAD COVER REMOVAL ....................... 8-2 FRAME/BODY PANELS/
CYLINDER HEAD DISASSEMBLY ............................. 7-8 EXHAUST SYSTEM ................................... 2-1
CYLINDER HEAD INSTALLATION ............................. 7-16 FRONT WHEEL/BRAKE/SUSPENSION/
CYLINDER HEAD REMOVAL ..................................... 7-5 STEERING ................................................ 13-1
CYLINDER INSTALLATION ........................................ 8-6 FUEL SYSTEM ................................................ 5-1
CYLINDER REMOVAL ............................................... 8-2 IGNITION SYSTEM ......................................... 16-1
DRIVE PULLEY REMOVAL ........................................ 9-9 KICKSTARTER/DRIVE AND
DRIVE PULLEY INSTALLATION ................................ 9-16 DRIVEN PULLEYS/CLUTCH .................... 9-1
EMISSION CONTROL SYSTEMS .............................. 1-18 LIGHTS/METERS/SWITCHES ........................ 20-2
ENGINE IDLE SPEED ............................................... 3-10 LUBRICATION SYSTEM ................................. 4-1
ENGINE INSTALLATION ............................................ 6-4 MAINTENANCE .............................................. 3-2
ENGINE OIL ............................................................... 3-8 REAR WHEEL/BRAKE/SUSPENSION ........... 14-1
ENGINE OIL STRAINER SCREEN ............................ 3-10 SERVICE RULES ...................................................... 1-1
ENGINE REMOVAL .................................................... 6-2 SHOCK ABSORBER .................................................. 14-7
FINAL DRIVE OIL ....................................................... 3-12 SPARK PLUG ............................................................. 3-6
FINAL REDUCTION ASSEMBLY ................................ 10-7 SPECIFICATIONS ...................................................... 1-3
FINAL REDUCTION DISASSEMBLY ......................... 10-3 STARTER MOTOR ..................................................... 17-3
FLOOR MAT/FLOOR PANEL ...................................... 2-5 STARTER PINION ...................................................... 9-8
FRONT CENTER COVER ......................................... 2-2 STARTER RELAY SWITCH ........................................ 17-6
FRONT COVER ......................................................... 2-2 STEERING HEAD BEARINGS ................................... 3-17
FRONT CUSHION ..................................................... 13-20 STEERING STEM/FRONT FENDER ......................... 13-15
FRONT WHEEL ......................................................... 13-3 SUSPENSION ........................................................... 3-16
SYSTEM LOCATION .................................................. 18-0
FUEL METER/ FUEL UNIT ........................................ 18-9
FUEL LINE ................................................................. 3-4 TAIL/BRAKE LIGHT .................................................... 18-4 21
FUEL TANK ................................................................ 5-11 TURN SIGNAL LIGHT ................................................ 18-3
HEADLIGHT ............................................................... 18-2 THROTTLE OPERATION ........................................... 3-4
HANDLEBAR ............................................................. 13-12 TOOLS .................................................................. 1-10
HANDLEBAR COVER ................................................ 2-7 TORQUE VALUES ..................................................... 1-8
HANDLEBAR SWITCHES ......................................... 18-8 TROUBLESHOOTING
HEADLIGHT AIM ........................................................ 3-15 BATTERY/CHARGING SYSTEM ..................... 15-1
HORN .................................................................. 18-11 CRANKCASE/CRANKSHAFT ......................... 12-1
IGNITION COIL .......................................................... 16-6 CYLINDER HEAD/VALVE ................................ 7-1

21-1
INDEX
CYLINDER/PISTON ....................................... 8-1

ELECTRIC STARTER ..................................... 17-1
ENGINE DOES NOT START
OR IS HARD TO START ............................ 20-1
ENGINE LACKS POWER ............................... 20-2
FINAL REDUCTION ....................................... 10-1
FRAME/BODY PANELS/EXHAUST
SYSTEM .................................................... 2-1
FRONT WHEEL/BRAKE/SUSPENSION/
STEERING ................................................ 13-1
FUEL SYSTEM ................................................ 5-1
IGNITION SYSTEM ......................................... 16-1
KICKSTARTER/DRIVE AND
DRIVEN PULLEYS/CLUTCH .................... 9-1
LUBRICATION SYSTEM ........................... 4-1
POOR PERFORMANCE AT HIGH SPEED ..... 20-4
POOR PERFORMANCE AT LOW AND
IDOL SPEEDS .......................................... 20-3
POOR HANDLING .......................................... 20-4
REAR WHEEL/BRAKE/SUSPENSION ........... 14-1
TUFFUP TUBE ............................................... 1-20
TURN SIGNAL RELAY ............................................... 18-11
UNDER COVER ........................................................ 2-6
VALVE CLEARANCE .................................................. 3-7
VALVE GUIDE REPLACEMENT ................................. 7-9
VALVE SEAT INSPECTION/REFACING ...................... 7-10
WHEELS/TIRES ........................................................ 3-17
WIRING DIAGRAM ..................................................... 19-1
21-2
Published by Honda Motorcycle & Scooter India (Pvt.) Ltd.
© Honda Motor Co.,Ltd. 2009 BOP200902900
62KPLN2 Printed in India

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What safety precautions should be taken when servicing a vehicle?

What safety precautions should be taken when servicing a vehicle?

What are some general service safety precautions mentioned?

What are some general service safety precautions mentioned?

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© Honda Motor CO.,Ltd 2009

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For Your Customer’s Safety

Important Safety Precautions

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HOW TO USE THIS MANUAL CONTENTS

ENGINE AND DRIVE TRAIN

Date of Issue: January, 2009

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Replace the part(s) with new one(s) before assembly.

Use recommended engine oil, unless otherwise specified.

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use Fork or Suspension Fluid.

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FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

CARBURETOR IDENTIFICATION NUMBER

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Carburetor type Piston valve

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Identification number PB16 x 1

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• Torque specifications listed below are for important fasteners.

NOTES: 1. Apply oil to the threads and seating surface.

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Float level gauge 070MJ – 001-I110 5

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LUBRICATION & SEAL POINTS

Camshaft cam lobes molybdenum oil solution

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Front brake lever pivot Silicone grease

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CABLE & HARNESS ROUTING

FRONT BRAKE CABLE

REAR BRAKE CABLE

CAPACITOR DISCHARGE IGNITION

TURN SIGNAL RELAY

BATTERY BREATHER TUBE

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FRONT BRAKE CABLE

REAR BRAKE CABLE

MAIN FUSE (10 A)

SPEEDOMETER MAIN WIRE HARNESS

BATTERY BREATHER TUBE

REAR BRAKE CABLE

MAIN WIRE HARNESS

THROTTLE CABLE VACUUM TUBE

MAIN WIRE HARNESS