SERIAL NUMBER LOCATION, NOMENCLATURE (OPERATING INSTRUCTION. ELECTRICAL CONTROLS, Inaturents and Inclstor Lights iin Swe Neactight Control Switch Horn Button Tur Signal Control Switch 2 MECHANICAL CONTROLS ‘Steering Lock. Front Brake Lever. Handle Clamp Lever ear Change Pedal High Low Speed Range Seloior Lever CGhok Lover and High Altitude Selector Koad. FUEL AND OL ! Fuel Valve Fel Tan mC O NT ENT Smee | oll Recommendation. PRERIDING INSPECTION. STARTING THE ENGINE ‘Starting 2 Cold Engine Starting in Extreme Cold weather Starting 4 Warm Engine SREAC-IN PROCEDURE RIDING THE MOTORCYCLE PARKING MAINTENANCE MAINTENANCE SCHEBULE MAINTENANCE OPERATIONS Engine Olt Replenishment Engine Ol Change oir Spark Plug Contst Breaker Point Gap Ignition Timing Valve Tappet Cisranice A Cleaner : ‘Throttle Cable Throttle Grp Flay SeeReReeeeERRBERYCcarburetoe Fuel Strains Cuteh Brive Chain Drive Chain Lbicstion ‘ire Inflation Pressure Front suspension Front Fark Of Bstery Front Wiel Removal Rear Wheel Removal Headlight Beam Stoplight Suited Headlight Bulb Replacement TalStoplght Bulb Replacement Turn Signallight Bulb Replacement TooU KIT... SPECIFICATIONS. WIRING DIAGRAM eins saaanceeeen ‘The frame seal number © is stamped on the left of the stering head pine, and the engine serial number @ i located on the crankcase directly Shove the step bar attaching point ‘These serial numbers are required when registering the motorcycle. Further, the frame serial number must be indicated when processing the warranty {aim and for ordering spare pats Engine sei BambeeNOMENCLATURE~ Speedometer ont bake lever ete rip © Headlight control switch © Rear brake pedal ick starter pedal (© Rear brake lever @ Horn button (below) Handle lamp lever © Main switch @ Gear change pedal @ Tailstop ight iidal” @) Rear brake pedal Fuel nkOPERATING INSTRUCTIONS ~ ELECTRICAL CONTROLS Instruments and Indicator Lights ‘The speedometer is mounted on the headlight caso and the Indicator ights are incorporated within the speedometer, The funcions are shown ia the fable on the next page sped range Indestars Speedometer Odometer Neutral indicator | light (green) High beam indi- ator light (ed) ear speed range indeators Turn signal ind ator light (amber) Function Indicates driving speed Indcates total accumulated distance travelled Light wil be on when the twansmision isin neutral Light wil be on when height is on igh beam ‘refer to page 13) Indicates proper speed for each shit | igh will ash ovhen the turn signal light (option! is operating‘Main Swit ‘The main switch & located on the let side ofthe steering head pipe Functions. of the respective switch Postiont are shown inthe chat below. © "ORE aon ON pontine dt Trerrontn[ SSCs «dey Rena sore” Allelecical ccs ate open; engine does | Key can, be oe tart removed. Recalled ening can be son» stted; headlight and talstop ight ean cannot ON" ert neual innit Bon when | be vcmowed Headlight Conteol Switch ‘The headlight control switch @ Is mounted on the eight handle grip switch housing. The switch can be operated by the thumb without faking, the hand off the handle ‘The red dot postion @ i for day time riding, The headlight and ta will not be on. The “L” @ and the "H" @ postion are for riding with both tights be_on; In which ease, "L" @ is for low beam or dim, used ‘when approaching or following ater vehicles, The "H” @ postion is for Tigh beam and in this postion the high bear indicator light In the spoed- meter will be on. ‘The. headlight. wil only come on wien the main switch i im the on Potton. (refer to page 12, 5 Low tam on gn bam pn S ieedtate ctl onto an 3Horn Button “The horn button (Di located on the let handle grip swith housing. While the horn button is depressed, the horn wl operate. Turn Signal Control Switeh| When the turn signal Hght is being used, 1 is operated by the turn signal control siteh (Tun signal lights are optional part sng vay MECHANICAL CONTROLS ‘The front brake lever @ is located at the right handle grip switch housing. ‘elie oe Tek ert oo ae Be cea ns 1m Sern lek (9 Fret brake everHandle Clamp Lever The handle ofthe HONDA CT9O ie designed so that it can be pivoted at handle bar stom to provide compacinss for tse in transporting the motor: cycle Follow the procedure below for preparing the handle. ‘Rake and pull the handle clamp fever @ al the way t0 the fea to une hoa the Rendle and then pivot the handle Bar counterclockwise 50 20 that ie parlgl fo the (ane centering, Reset the chimp lever to lock the handle bs. 2. To prepare the motorycle for riding reset the handle bar to the normal Postion by aligning tha td marke on the center oF the handle Br. oa) (Mane camp ever) Index nace Gear Change Pedal ‘The gear change pedal @ located near the let foot rest i ofthe propressve shit postive stop type, which means one fll stroke of the gear Caange pecs hi Sore 'earpoiion. ‘The shitingscwence’ sanged {shown in the figure ‘Shiting from the neutral postion into 1s (lw) gears pertormed by depres: ‘ing the, forward end of the gear change pedal with the toe, Sting, to rd Sand th top) gear pataned by progressively depresing the {orvard end of the pede shitng down tote lower pours perigened by progressively depresing the rear end’ ofthe pesel © Gar chang pial ‘Biing wensWigh-Low Speed Range Selector Lever ‘The above speed range selector lever) i located at the left crankcase cover on the bottom side of the postiorque cover. The lever selection Stand SH are stamped on the positorgue cove. When additonal power i required for climbing steep grade or riding with a heavy load, siting the selector lever tothe “L” range will provide the necessary power (0 Wlebtow seed range slo ever Choke Lever and High Altitude Selector Knob ‘The choke lever © and a high altude selector knob @ ts located on the Tet side ofthe carburetor. Rating the ‘choke lever will close the choke valve (refer to page 25~27 {or itt use), To eblain maximum petfoemance for riding in high altitude es Righ attude selector knob is provided to give the proper fuel mix- lure for the alttude condition, Pall this knob out when traveling at Ltitade above 6000 fect, low 600 fet, push the Knob in ID Cink leverFUEL AND OIL, Fuel Valve The fuel valve @ is located at the let side of the carburetor. When the fuel valve sin the "S poston, fuel can nat flow from the fuel tank to the carburetor. The fuel valve should be set in this postion when the motoreycle is parked. Turing the fuel valve to the “ON” positon lows fuel to flow to the carburetor trom the main fuel supply. Turning the ful valve to the "RES" poston allows fuel to flow from the reserve. supply When the main fuel supply is exhausted, the fuel valve should be turned to the “RES” poston thereby allow ing you to proceed to the nearest Screw out the drain valve @ to empty the fuel contained in the carburetor when carrying the motoryce, Fuel Tank The il tk i octed under the eat The fel tak acy 6 US gal Goliten including 17 US pt Oliten in the reserve supDy Premium grade ful with an octane rating of 85 oF above must be used Benak mis ofl with he fue 12 Pa fo ep(it Recommendation It is very important to use only premivm qualty lls intended for service IMS, DO, DMG (API service classification) or is equivalent. SAE 10W-20 Than all weather oll and should be used over the normal range of outside temperature. Oil should be changed at the prescribed Intervals according to the MAINTENANCE SCHEDULE” on page 3 SE] SE] SE NOTE: Nondetergentandlow aval | caques_feuresTne] ORES iy. are 5 ot recom tnended. The use of proper engine tre Siesod_ oll change intervals are || #9 our ‘best assrance of continued elle Telabilty and. performance from " our HONDA engine. Also, the re- |[ #2 ee mental aaatives || gay "ind will only ne olfle costs a PRE-RIDING INSPECTION Prior to starting your motorcycle, it Is advised that you perform 2 general eet ron at's mater of abl to. make sure that the motoreycl isn reese riding condition. This nection wil only quite 2 few minutes Boe tve you mich time and expense in the Long run aoe ee Sbuing items and it adjustment or servicing i necessary, eefer fo the appropriate section Inthe manual +L Engine ol fvel—adé engine oil ft below the lower level mark on the dipstick (page 32) 7 re eee a mtotine when isnot enough for travel, (page 20 2B ue ev) rear brakes--edjuat free ply Inthe front brake lever and brake pedal ft incorrect. (page 51,32) Pret ir pressre.inflat tires IF 1 to0 low: (page 54) see eieaahat chain tenion when Its t00 sloppy. (page 47 Trotle operation repair i Ie not smooth. (page 43) sete At and headight-repair when they do not light propery. (pase 3982. sere 23STARTING THE ENGINE Staring a Cold Engine Pall the high aitude selector knob out when traveling at altude above St feet Selow 00 feet, push the knob In 1. Turn the fuel valve to the “ON” postion 2 Insert the key into the main switeh and turn to the on postion, At this time, abvewve the green neutral inaestor light on the elt side of the speedometer. The ight will be lighted when the transmission i i the seul positon 4 Rake the choke lever tothe fll closed poston 4 Twist the thottle grip inward sighty and step on the Kick starter pedal With a rapid kick stoke perform the kick stating until the engine tart I'the engine fas to stare after severe! repeated attempts, turn of the main switch and ower the choke lver tothe full open poston, twist the Theat’ geip inward. fly and. crank the engine using the tick starter pedal. this is then followed by turning the main switch to the on Poaition and folowing the starting procedure outlined in steps 1 through WPhowever, at thn time use of the choke Is nok necesty 5. After the engine stats, operate. at approximately 30D%pm until the engine will properly respond to the throtie when the choke is open Starting in Extreme Cold Weather Prime the engine before stating by cranking several times with the kick tarter pedal, The main switeh should be tured of. The choke. should be fly closed and the throtle opened. Followed by the procedure for Starting 4 cold engine. Starting a Warm Engine ‘When the engin is to be restarted while itis sill warm, proceed a8 for (old engine sarting procedure, however, the use of the choke ts not necessary,BREAKIN PROCEDURE, “The motorcycle should not be exposed to severe or abusive riding conditions. This precaution wil be rewarded with extadong trouble free life of the rmotoreyle. is recommended that fr the fit 600 miles (1000), the motoreyle not be operted in excess of 0% of the maximum speed in the respective sean RIDING THE MOTORCYCLE 1. After the engine has been warmed up, the motorcycle fs ready for siding 2. While the engine is ili, depress the forward end ofthe gear change pedal to shit nto low (It gear 1. Increase the engine speed by twisting the throttle grip inward. ‘When the motoreycle attains & speed of approximately TO mph, close the Trot and shift to 2ad gear By depressing the forward end ofthe gear ‘change pedal 5 This tequcnee is repeated to progressively shift to 3rd and sth (top) eat The shiting pattern ingested on page 1. The maximum allow ble speed for the respective geas are shown in the following table moh (isin sw [ae | a _| ho low peed range | | a] ee 6 When decelerating the motorcycle, coordination of the throttle and the front and rear brakes Is most important. {y'The smooth gradval application of both the ffont and rear brakes Together with the required thrttle” coordination wil, under most Conditions, assure postive speed reduction and stability. As the Imotoreyle speeds are reduced, I i common” practice to shit the TTansmision propretsvey into the gear appropriate forthe mtoryee This assures manimam control through better braking effectiveness tnd acceleration when necessary For maximum deceleration and stopping, simultaneously cose the throttle, disengage the clutch and appiy bot the front and rear brakes, ts the motoreycle comes to 2 stop disengage the clutch. This mae reaver requires smooth coordination of the controls and to maintain Skil should be practiced frequenty 2 27Independent aplication of either the front or rear brakes is posable, but if only one brake is applied strongly enough to lock the respective wheel, braking effectiveness is greatly reduced and control of the Imotoreyle is if PARKING ‘When parking the motorcycle, postion the main switch to the off postion land remove the key. The steering should abo be locked. "Turn the fuel valve to the "5" postion. snnemenener MAINTENANCE MAINTENANCE SCHEDULE ‘The mileage intervals shown Inthe MAINTENANCE SCHEDULE ae intended tse guide for esablihing regular maintenance and lubrication periods for your HONDA. Sustained severe or high speed operation under adverse Conditions may necessate more frequent servicing, To determine specific fecommendations for conditions under which you use your moteroyce, ‘onslt your authorized HONDA dealer. Especially when your HONDA C10 has been turned over or involved in Zeolion, have Your HONDA dealer carefully inspect the major components, ‘pam, suspension and steering pars, for misalignment or damage to Insure further safe operation,sere Maint = sere aid Fi ond ea ree si, Pit Par ir sates Se apne oe =o erie =a EE Sree Stine a Sap iee tt mel pepe be “apie Lau} Ht Fs oes otto =a 8 -check oF adjust — oyoToto sponta wecessary ae = ‘ivy Cain and Srocket—adiot 2° Un peop eek o[olo } ibrieate or replace o}o}ojo ae = i 1MAINTENANCE OPERATIONS Engine Oil Replenishment . cr cgi fv! spring inspection page 2) and replenish engine Sasha the lee lower than the Tower level marks Cec the fv Sith theo lle cap ptt wthost Sewing in Entine Oil Change “he engine othe cit facoraflecing the pestrmance andthe sic Iteet the engine. Tortora teeommendd on pe 32s be toed andthe a Siva rnin Pere the ol atthe proper level Should be changed at the MAINTE- NANCE SCHEDULE a5 shown on page 20. Perform the engine oll Change in the following manner Drain the lf while the engine still ‘warm 36 ths will assure complete nd rapid draining. Remove the ail iler cap © from 32 the right crankcase cover. Place 2 chp pan under the engine to catch the oll, and then remove the dain plug © with the mm spanner. Alter the oil tops dralaing trom the crankcase, operate the kick starter Several times Yo sean any all which maybe left fm the engine \When the oi has been completely drained, reinstall the dra plug making sure thatthe packing ored on this plug i good condition. 5. Fil he crankcase through the oll filer epening with approximately 19 US pt @3liten of recommended glade oll (fer to page 22). Make sure thatthe ol eve between the upper ® and lower marks Ifthe level i ow, addi. NOTE: When operating the motor ‘eyele in unusual dusty condition, Wis recommended that the changes be performed at more frequent intervals than that spe fied in the MAINTENANCE SCHE- © Dain be“The oil fter is of the centrifugal and screen type, Prindple operation of the centrifugal fiter Isto seperate al the impurities fand metal tps in the oll by centrifugal force and permitting only the highly pried il to come in contact withthe moving part ofthe engine. 1 Drain the engine olin accordance with Engine Ol Change on page 32~ a 2 Remove the footrest and kick starter pedal from the engine. 3. Remove the right cankease cover by unscrewing the screws = 4, Separate the right erankease cover fake from the right crankcase. Pol out the seeen fiter © from the righ crankease and wash it tnth lean solvent of gasoline Seren ter Remove the culch outer cover @ from the clutch outer «by uncom tng the two screws. Remove all metal chipe and tt from the center of the clutch outer, sing 2 clean rag Resstembly of the component pats performed inthe reverse order of the procedure above, further, replace the damaged of defective crank- cise’ gasket with new Roms.Spark Plog. INGK D-OHS i used on thi model. : Servicing ofthe sparkplug ia follows pet Pls wrench which is provided in the tool ue aaa? ca Teal hr et Neb Sk et wah (grounded) electrode «. Sa as Er es Hes bear 5 eran sk gas borning Do not use improper heat range park plugs tor Z (0 Sorkin emp) Negative eave BY Contact Breaker Point Gap 4 2 TRomove the point and. dynamo covers Spee the conta! breaker points @ arith tiger or small screw driver ee and examine for pitung. I pitted or burned, the pont should be foplsced and the condenser checked. A gay digcooration normal and CBS removed yh pon He iling soul be done crtly and Geb ‘e'rinimom.” Clean the poit contacts after fing with a ean pice of unrated paper sich ssa busines ardor chemical point cleaner Rotate the dynam Foor in the_countercockwise erection (se arow) fe find the potnt where each breaker point gap Is at maximum and heck using 9 clearance gauge ‘ihe standard gap 8 0020616 in aa~o4mm When’ adusiment is nocesary, loosen the contact breaker plate IGekng screws © and) move the Gn breaker plate to achieve CGrret gap. When propel gep- ods reighien the locking few 6 Contact beater pnts ets Eres Bite oking sereneDo not perform this operation unl point gaps have been adjusted ". Rotate the dynamo rotor in the. counterclockwise direction and align the “F mark © to the index mark dh At thie time, the contact breaker points @ should jut stat to open 2. To adjus, loosen the two base plate locking screws @ and move the contact breaker baseplate @. Moving the plate in the clockwise diet tion wil advance the timing @ 1p Contact lers plate tnder'mark —Buorpeteneing news” Buse alate 3 Alter performing the ignition timing adjustment, recheck the contact breaker point gap @ to asure that It had not been changed The state ignition timing i relatively accurate and will give satsfctory engine performance, however, the use ef the sabe timing method will Sssure the most precise timing. ‘When using the stabo timing ight to check the timing, ile the engine at 10-9. Perform the adjustment in the same manner as described adove,Valve Tappet Clearance Excessive valve tappet clearance will cause tappet ote, and litle or no Gearance wil cause valve damage and loss of power Therefore, the valve lappet clearance should be mantsined proper The valve tappet clearance mutt be checked when the engine i col 1"Remove the dynamo cover and tappet adurting ole caps 2 Rotate the dynamo rotor counterlackwise-untl the: mark @ on the Gynamo rotor ines up wth the ting index mark © onthe sat. ST mark Alling wry ok rt 13 Gitar eee In this postion, the piston may either be on the compresion or the exhaust stroke ‘he adjustment must be made when the piston is on top of the com- pression stoke when both the inlet and exhaust valves ate closed. This Eonation can be determined by shifting the tappes with fingers though the tappet adjusting holes. i the tapes are fee, itis an indision that the valves are closed and that the piston is on the compression stroke. the tappes are tight and the valves are open, rotate the dymamo fotoe 360° and reign the *T” matk to the timing Index mark, Check the clearance of both valves by inating the W002i. (405mm) clearance f1uge provided in the tool Kit between the adjuting screw and the Wit is necessary to make an adjustment, loosen the adjusting screw lock rut @ and turn the adjusting screw (so that the valve clearance. will Ofer a slight resstance when the clearance gauge @ is inierted. After completing the adjustment, tighten the adjusting screw lock nut while holding the adjusting screw to prevent from turning, Finally recheck the clearance again to make sure that the adjustment has not been disturbedAir Cleaner ‘When the air eleaner is logged with dust, affects the engine performance tnd therelore, it should bo cleaned periodical T'kemove the wing nut © and si cleaner tube setting screw ©, and remove the air cleaner tobe 4 i 2 Unscres he fing late setting bolt @ and semove the fixing pate ©. 4 Puivout the alr cleaner clement ponge) from the ae cleaner cas 4 Soa the a, eaer ‘loner inetgoe of crag oat By hand and then Asan teeing ser 1B Ae dame eemone Throttle Cable Chock for smooth rotation of the thotle gti {fom the full pen to the full close postions Check when at ful left and flight steering postions. Inspect the condition of theote cable from the that. grip down to the Carburetor. Ifthe cable is kinked, challed or impeopery route, it should bbe replaced andjor rerouted. Recheck cables for tension or ses at both {Ul Tet and ful eight stering postions ‘Throttle Grip Play Stand thle wi play pproxiatly WF ofthe gp routon When iti found to be excesve, remove the main pipe cover, and ad just atthe tote cable adster 2 by sliding back the rubber sleeve @> ‘on the carburetor end of the cable (2 Torte cable jerCarburetor A carburetor which i out of adjustment will adversely affect the perfor mance of the engine, thereforo, Its Important that the carburetor always bbe maintained. in perfect adjustment. “Carburetor adjustment should only bbe made wen the engine Is operating temperature, 1. Set the idling speed to. 1.200rpm with the throtle stop screw “Turning the screw clockwise direction wil increase engine speed 22, Manipulate the air screw @ to obtain the maximum and stable engine speed. The standard air screw Sertng is between 1, to T open {com full dose positon, 4, Readjit the throtle slop screw ifitis necentary to rest the sing speed NOTE: Malfunction of the engi high speed can be ca System therefore, determing the hose the tube etore fempting 40 correct the cont By adjusting screws. 1 Aree Strainer ‘The fuel strainer is incorporated in the carburetor body. Accumulation ‘of dit inthe srsiner will restrict the flow of the fuel and. cause the ca. buretor to mallunction, therfore, the fuel strainer should be serviced periodically 4L Remove the main pipe cover. 2 Turn the fuel valve to."S” postion and remove the strainer cap, remove the © ring seal @ and the screen filter ©. Wash in solvent o gasoline and reassemble. Turn fuel valve to “ON” position and check for leas,cuteh 1L Clutch must be adjusted with the engine shut of Loosen the adjuster Tock nat 12 Tum the clutch adjuster > dockwise about one tum; do not turn exces- sively ext, slowly turn the adjuster counterclockwise and stop when the screw fa to turn heavy 4 From this point, back off the adjuster in the clockwise direction 12 to 418 ton, and ghten the lock nut Chock to make sure thatthe clutch eperates properly after adjustment "The engine should. start easly With the hick starter without the teh sipping 2) When changing. gear, the clutch Slipping. shoule be smooth and Tight, "especially ‘hen shifting ‘down in gear to the newt gear a © Cash ster 1 ode net Drive chain ‘The condition of the’ dhve chain will have considerable ffect on the transmision af power from the engine tothe rear wheel. I not propery maintained, the deve chain can cause. premature wear and_ damage tO transmision and rear whe bearings and sprockets av well a5 9 ae A propery adjusted and lubricated ive chain assures safe, smooth and trouble free operation ofthe vital dive system 41 Place the motoreycle on its main stand 2 Move the chain up and down at the midpoint between the sprockets {and check the total movement, ‘The standard slack should be 04 ~Uain. (10~20mm), 4. To adjust the chain sack, frst loosen the rear axle nut (> and sleeve nut @ (eter to page 48:4. Looten the adjusting nut «> on both the right and left chain adjusters and turn the aglusing nt. Turn the adjusting nut clockwise to decrease chain sack, Align the index mark on both chain adjusters © to the same poston ‘onthe both side scales @ ofthe rear fork 5. Make sure that the rear axle nut, sleeve nut and lock nuts are properly tightened 6, Readjust the rear brake as necessary to correct for the repositioning of the eear wheel assembly. (refer to Page 32) 7. Remove the main sind and check the chaln slack while siting on the machine. Rll ether forward or Backward for enough tobe cetain there ino tight spots ‘When the dive chain adjustment have been performed, recheck for contect dive chaln sick, 8 fee tas Ie f¢ Chain Lubrication Remove the dive chain by removing the etining clip with pliers Do not bend or twist the lp. When possible Installs new haste nk Clean the chain thoroughly in a suitable solvent." Rinse In cloan lent and alow to dy. Inspect the chain for wear {oi sloppines) stifness and binding at the joints and broken or separated walers If any of ‘these condtions exist the chain should be replaced. ‘Alo inspect sprocket teth for wear. Never install a new chain on bay ‘wor sprockets or install 2 badly worn chain on new sprockets Yous HONDA dealer can help you determine the condition of there hem Immerse the chain in 2 pan or vestl containing 4 mature of SAE TOW- 30 engine oil and petroleum jellyratio of TUSqu (1 ite) ll «9 Dor {20051 petroleum ely and heat to "GO to 250 for approxima 10 minutes,Remove the pan from the source of heat and carefully agitate immersed chain with a crew driver, When cool, remove the chain allowing i 0 hangover the: pan and. drain of excess lubricant. Use 2 cloth or 28 to wipe off remaining excess lubricant. 4, Coretiy route drive chain onto the sprockets using the fear sprockets {6 poston the chain ends while insaling the master nk side plato and Fetaning cip. Note thatthe closed end of the retaining clip @) must face the direction of forward wheal rotation, 5. Adjust rear drive chain a8 decribed In steps 1~7 page 47~#8, Retaining ai Front Brake 11 Raise the front whee! off the ground by placing a support block under {hevcane pith front wheel by: hand and taste the amount the Iront bra iver must be moved before the brake starts take hold Be lege free ay @ shou be QB Lin ~My a he end of 2. Wadjurtment i necessary, turning the front brake adjusting aut @ in th Gockwie tirection will docrese the free play. NOTE: Make sure that the cut-out on the adjusting nut it seated on the brake arm pin after the fnal adjustment has been made © Frowt brake lever Free play ‘Front brake adjesting wat e|mie 4 The adjustment of the rear brake lever @ can be made independently ‘Rais the reir wheel off the ground by placing the main stand under by the adjuster st the lower end of the brake cable. the motorcycle, : oe “The nominal fee pay @) is epproximately Bin. mm) 2 Rotate the rear wheel by hand and note dstance the rear brake pedal 5 ithe adjustment fo necessary, looren the ciresar lock mut © and turn Up travel @ fore the brake holds the eable adjuster @ locke to increase the psy 3 Nomina fe travels Q3—42In. G~30 mm, i the adjustments necesary, make the adjustment by turning the cear adjusting nut, Turn clockwise for Tess tree tvel’counterloceviee Tor greater fro travelTire Inflation Pressure Correct tire inflation pressure wil provide maximum stability, riding comfort tnd te le Koop tres propery inflted, and check the inflation pressure before ring [ Tie inflation pressure Front 256psi, 1Bkglen? Rear 2Spsi, 20kg/em" Feont Suspension {Check the font fork assembly by locking the front brake and pumping the fork up and down vigorosy ig Inspect forthe smoot Cushion action and oll seepage around the cushion cies Creal inspect all front suspension fsteners for tighnes, this includes the atachment points of the fork tobe, brake components and handle br Front Fork Oil ‘To maintain good riding characteristics and increase fork service life, the Glin the front fork should be changed periodically 3 Unscrew the front fork drain plug at the bottom of fork cyiinder, ‘rain te ol by pumping the fork while plug is out. Replace the plug Securely ater dering. 2. Remove the top filler plug @ and fill the front fork cylinder with 46~ ‘tbonn, (130~tee) of premivm qualty ol of SAE WW-90 grade 3, Securely tighten the top filer plug after fillog. Stren fork Se Ps Top lee DeBattery 1 the motoreyele i operated with an insufficient (ow) batery electrolyte level sulfation and battery plate damage may occur. Inspecting and. mal taining the electrolyte level isa simple, quick operation, therefore should be" performed frequenty as indeated in the MAINTENANCE. SCHEDULE tee opage 3. ‘The 6V-55AH btery is mounted within the frame center Remove the right side cover and check the electrolyte level ‘The corect clecrolyte level Is between the upper & and lower level marks on the battery ate To correct the elecioyte level, remove the battery mounting band tnd remove the battery coll cps fromthe cells needing evel correction. For case of cell level ‘correction a mallsyringe or psc funnel should be wed. Carefully dd the proper amount of distiled P naters water to bring theelctroyte level) Upper rl mark (D lover irl mark ‘ofthe calls etween the lower and upper level masks. For maximum bat tery performance and ie, ony dtilled water should be added, however, In.an emergency stuation where electrolyte level found to be low and dlsited water iz not avaiable, inking water or alow mineral content ‘an be ured. Reina the cll caps NOTE: Battery removal may be necessary when battery electrolyte (SPECIFIC GRAVITY) reading is below 1200, indicating. the need of battery recharging, or when the battery is removed for storage. 4 Battery installtion is performed in the revere order of removal. Pay paticuar attention tothe batery rabber mounts pads andthe ver! tobe outing. The vent tube Is not pinched or bent exeasvely, otherwise the battery may be damaged,Front Wheel Removal 4. alse the front wheel off the ground by placing a support under the engine 2. Remove the speedometer cable and front brake cable from the front brake pene. 3. Remove the front axle nut. 4 Pullout the front axle and the font wheel can be removed from the frame Reat Wheel Removal 1. Looe the rer ale nut, sleeve nut, drive chaln adjusting nut and dione eet the deve chain atthe joint eli. 2, Remove the rear brake adjusting aut and remove the rear brake rod from the brake arm. 3, Remove the rear Torque arm bolt a the rear brake panel ‘4 Pullout the rear ale and the rear wheel can be removed from the frame. NOTE: During reassembly, the drive chain joint should be installed in the way that the open end will face opposite to the divection of rotation. (Reler to page 50. Headlight Beam The headight must be properly adjusted forsale night diving. This mote cyte has provisions to sdjust the headlight Inthe vertical and sso horizontal Sections. “U"The verial adjustment Is made by the bolts which mount the head Tighe caze The headlight is normally adjusted Inthe vertical rection £0 thatthe center of the beam inspect the ground a the pont 16S feet {Gom) in front of the motoreyle i the riding atitude 2, The horizontal adjustment is made with the adjusting screw @ located ‘on the left side of the headlight when facing the matoreycle ‘Taming the serew in wll focus the beam toward the let side of the sider Menage mounting tate © Adie rer 59Stoplight Switch Headlight Bulb Replacement ‘The stoplight switch adjustment is made with the stoplight switch @® located LB ea te = ight rim from the headlight case by removing the two Seon Si sea oe soe i cane ee ee am aces win | * Regret at pi 0 and ure ok oe 9 2, Turn on the main switch (red dot postion. 4. Adjust ‘the stoplight switch #9 that the stoplight will come on when the brake pedal is depressed tothe point where the brake jst stats to luke hold. ifthe stoplight switch ate in switching on the stoplight crew in @ the switehadjsting tau and the stoplight comes fn too early, screw ut the Sdjsting nt i sa re 2 hajatine metTailstoplight Bull Replacement 1 Remove the screws ftaning the tallstopight fons 2 Prete the bulb @ Inward and twit to the lef, and the bulb can be removed. 4. Replace with a g00d bulb ‘4 When installing the talight fen, do not overtighten the screws, 25 ths may damage the lens Turn Signallight Bulb Replacement (optional pas) The bub replacement is made in the ame manner as forthe tailstopight bulb in the above paragraph, © Taleo bate “TOOL KIT: ‘The toolkit )i¢ mounted in the right side cover located at the frame Center. Minor adjustment and parts replacement can be performed with the tools contained in the Kit. "Adjustments or rapais which cannot be performed withthe tools in the Kit should be referred to your HONDA ‘ester. 12 Mbt ste everListed below arg the items included in the toolkit “D Woclamm open end spanner @ 852mm open end spanner © Sparc plug ereach: For spark log ( 2mm wrench: For rear ane sleeve nut {© mm wrench: For front and rear axle not © Wrench handle © Pls Tool bog { 9mm spanner: For valve tppet lock aut 4 Valve fappet adjust rene (W No. 3 cross polnt screw diver 1 No. 2 cross point serew driver (9 No. 2 stew driver & Screw diver arp: For screw diver & Clearance gauge? For lappet clearance adjustment items atached tothe motoreyle ina Separate package ‘D A.can of tovchp paint © Spare bauery fuse 0 —= or © om oo o— — o—=eeeeeneernennenee SPECIFICATIOOS Te DIMENSIONS [ ‘Overall length | 740m. 1800 mm ‘Overall with | asin C ce0mm) ‘Overall height | ax7in cco mm ‘whet base Moin. (120mm) weicnt ‘Corb weight er) CAPACITIES Engine oll A9Uspt. Coster Fuel tank “GUSgal. (ole) Fuel reserve tank A7USpL. (OBiter i) ENGINE {| Bore and stroke 171797 in. (50315 mm) __ Compression Displacement Horse power Contact breaker point Spark plug sap Valve clearance ‘CHASSIS AND SUSPENSION Caster Tel Tie size, font Tire siz, rear POWER TRANSMISSION Primary reduction Final reduction Gear ratio, 15 tna ard a SAB cuin. (9) 705/300 rpm ‘912~0016 in. 03~04 mm) (0624-0028 In. (06~07 mm) ‘602 in. (005 mm) or 255i0. 5 mm) 275-0 eR 275-7 PR) 300 an atPositorque gear ratio tow range 167 High vange +1000 FLECTRICAL 7 6v-55AH [AG generator Headlight ev-asiasw Talstopight ev-srew Meter light ev-isw Neutral indicator light evisw igh Beam indicator light 6V=13W Fre “samp