f ¦•
SHOPMANUAI
FOREWORD
CONTENTS
This Manual Z50AK5 covers all information on the models Z50A. Z50K2. Z50AK3. Z50AK4 and Z50AK5 At the end of the manual are listed main modifications and servicing of the models mentioned above basing upon the model Z50AK2 for quick reference
Following are the initial numbers of each model at the time of change
Model Z50A (basic model)
U S.A type only Z80A USA lype
Z50AK2 U S.A. type Z50AK3 U S.A. type Z50AK4 U S.A. type Z50AK5 U S.A type Z50A General export
type Z50AK2 General export
type
Serial number Z50A-1 00001 ~Z50A-
120087 Z50A-120O88-Z5OA-
270235 Z50A-270236~ Z50A-1000001 -Z50A-3000001-Z50A-5000001-Z50A-156932~Z50A-
298503
Z50A-298504~
HONDA MOTOR CO.. LTD.
Service Publications Office
MAIN FEATURES OF Z50A................ 1
SPECIFICATION TABLE............... 3
SPECIAL TOOL SET ...................... 4
ENGINE .............................. 6
1 Engine Assembly Diagram .......... 8
2 Engine Removal .......... , . 7
3 Engine Installation................ 7
4 Lubrication (Oil Pump) .............. 8
5 Cylinder and Cylinder Head.......... 9
6 Piston and Piston Ring...... 15
7 Clutch........ ...... 17
8 Crankshaft ..... .18
9 Transmission.......... 20
10 Gear Shift Mechamr.m .. .21
11 Kick Sl8ner........................ 23
12 Carburetor.......................... 24
TROUBLE SHOOTING TABLE ............. 27
FRAME
1 Front Suspension .................. 3 1
2 Rear Brake ........................ 31
FRAME (K3. K4. K5)
1 Front Suspension ....... .... 34
2 Function of Rear Suspension ........ 34
3 Cam Cham Ad|ustment.............. 3 5
4 Drive Chain Maintenance.......... 3 5
5 Front Wheel and Front Brake..... 3 9
6 Rear Wheel and Rear Brake 4 2
7 Steering System................ 4 5
8 Front Shock Absorbers........... 4 7
9 Rear Suspension.................... 48
10 Frame Body. Seat. Tank and
Air Cleaner...................... 50
1 1 Electrical System.................... 52
TECHNICAL SERVICE DATA................ 54
TORQUE SPECIFICATIONS ................ 56
WIRING DIAGRAM........................ 57
.'
1
MAIN FEATURES OF Z50A
.
• The overhead cam design enables a quiet operation and a constant high output over a broad speed range starting at slow speed with very little effort
• Incorporation of the oil damper type cam chain tensioner automatically maintains the proper tension and minimizes the chain noise further, chain adjustment is unnecessary
• Riding is simplified by the use of the automatic clutch which is interconnected with the gear change pedal
• Metal screen and centrifugal filter assures only clean oil to luhncato the critical moving parts
• Foldable handle bar makes storing in narrow space possible
• Frame is welded pipe backbone design having a double channel welded to a smgle main pipe to reduce weight
• To prevent spillage of fuel during transportation fuel shut off valves are provided in the filler cap and the carburetor
GENERAL EXPORT TYPE
TYPE (From F. No. 120001)
U.S.A. TYPE (From F. No. 270236)
TYPE (From F. No. 5000001- )
3
SPECIFICATION TABLE
USA TYPE ZbOA K2 |Ftom No F 2702361 usa Type Z60A-K3. K4 k&
GENERAL EXPORT USA TYPE (From No F 10000011
TYPE |Fiom No F 1200011 IFtom No F 30000011 (Fiom No F 50000011
DIMENSION
Overall length I 2 70 mm (60 0 m| 1 280 mm (50 4 ml 1 300 mm
Ovarii! width 635 mm (25 0 in|| 590 mm i23 2 m| 580 mm (22 B ID] 610 mm
OvflUH imighl l 000 mm I39 4 mi| 880 mm |33 9 ml 865 mm (34 1 ml 86C
Wheel base 880 mm (34 7 in| 9 9?i mm
Win ground (JIIMnMIQI I 70 mm i 6 7 ml 1 50 mm
-ii weight 49kg (I08lbsi | 50kg (MOIbsi | 53 5 kg (1 I 8'bsi 58 kg 1123 lbs)
FRAME
Suspension (F) Telescopic loo Tumnpir Km
Suspension IRI Rigid liama Swing aim
Biakei Internal e>pan%ion il expanding 1 24 ¦in'
FubI lank rapai:ii» 2 5 in 10 7 U S gal 0 6 Imp gal i llOUSgil 0 Simp gel I
rratl 40 mm it 5 7 m| 4 2 mm 11 7 >n|
Caciai 67" 86*
liia t.tr mil III pressure (F ft 3 50-8 I0 kg/cm' (14 2 pail f » 3 SO H 1 PH 1 U kg/cm' 114 2p»l)
ENGINE
Cylinder layout S'l-gla till up 10" 'torn ho'irontal Smgle 60" inclined from vafiir.ai
Vilva atiengement OHV ovgrhaad camshalt dVtvejd ova' haad camahall
Bar* and stroke 39x41 4 mm (t 535x1 B3U m| J90«Ji 4 mm iw 636xl 030 m]
Lonipiaiiinn 'mo 8 8 1 88 1
itplsci 49cc (3 Oeu'i) 49 cc (3 Ocu mi
On capacity 0 8 lit. (1 7U S pt t 4 Imp pi | 0 8 S pi 14 imp pi 1
Pressure luUncalion & wet sump Forced ami wai sump
On lillan Centntugai and ;ceen mesh Centntugal ana screen mesh
Raduclion ratios
Primary 3 :.' 22
- ilj'i 2 615 2 y 1 ----
Can mini
in 3 162 3 is:
1 824 1 824
1 190 1 190
Sinning method • ¦ lUftai Kick starte'
PERFORMANCE
M«> tOi ; 0 31 «g m/4,200rpm i2 2 II ID/ 4 200 mrni 0 28 kg m/4 000 -p-n |2 02 H lb/4000 rpm|
Ma> output 1 95 ps/5 000 rpm ----
Mm turning circle 2 6m 18 r 2 6m |B 8 111
ELECTRICAL
i -non Flywheel magneto viiriHi -nagnaia
Span NGK C 8 M 01 ND U20FS NGK C6M ot ND U20F5
Haad light 6V-15W BV-IS/ISW 6V-I6/15W
rau/itcti ngiii 6V-83W 6V-17/5 3W 6V-5 3 watt
. I
4
SPECIAL TOOL SET
1 CD jL J£ ® ®
® ** © ® ® 6
f No Tool No Description
07900-0450000 Z50M/Z50A Special tool set
1 07980-0360100 Inlet valve seat cutter. 90°
-' 07980-0360200 Exhaust valve seat cutter. 90°
3 07980-0360300 Inlet valve seat top cutter
4 07980-0360400 Exhaust valve seat top cutter
!. 07980-0360500 Inlet valve seat interior cutter
ii 07980-0360600 Exhaust valve seal interior cutter
7 07981-0360000 Valve seat cutter holder
a 07933-0010000 Flywheel puller
9 07925-0010000 Flywheel holder
10 07908-0010000 Tappet adjusting socket wrench
11 07984-0980000 Valve guide reamer
12 07916-0010000 Lock nut wrench. 1 4 mm
1 3 07960-0110000 Clutch disassembly & assembling tool
Ref No Tool No Description
14 07922-0400000 Drive Sprocket holder
07923-0350000 Clutch outer holder
15 07942-3290100 Valve guide remover
16 07942-3290200 Valve guide driver
18 07957-3290000 Compression valve lifter
19 07945-8150000 Bearing driver
20 07902-0010000 Pm spanner. 36 mm
21 07945-0450000 Front wheel oil sea1 driver
22 07947-0450000 Rear wheel bearing driver
23 07949-2860000 Bearing & oil seal driver handle
24 07915-0300000 Stem nut socket wrench
25 07902-2500000 Main switch pin spanner
— 07797-0510100 Valve seat cutter case
27 07797-2920300 Float level gauge
— 07401-0010000 Tool case
6
ENGINE
1. ENGINE ASSEMBLY DIAGRAM
F.g 1
7 2. ENGINE REMOVAL
1. Loosen the muffler flange and mounting bolts, and remove the muffler
2 Disconnect the throttle cable from the carburetor
3 Detach the high tension cord by pulling the plug cap off the spark plug 4. Disconnect the electrical wiring (Fig. 2)
<£ Electric "cads coupler Fig. 2
5 Set the fuel cock to the OFF position and disconnect the fuel tube from the caibummi
6 Unscrew the left crankcase cover mounting screws and remove the cover
7 Unfasten the drive chain joint clip and disconnect the chain.
8 Remove the two engine hanger bolts and dismount the engine from the frame (Fig 3)
i pump body gasket ® Oil pump dwoll pi
<3> Oil pump body <$ 0 mm hex bolt
(Si Oil pump outer rotor f> Oil pump Inner rotor
M (2> | 1 1L ®
J%ji*> Vr.l W
(J) Rocker KID
<5* Ctankshatl Fig 10
<2) Camshall cj: Valve 8 mm scaling washer
9
Valve lace contact area $ Cylinder head body Fig 17
® Valve guide
2. Inspecting the valve seat
The standard width of the valve contact surface is 0040-0051 (10-1.3 mm). When the contact surface becomes wider than 0.080 (2.0 mm). the valve seat should be repaired with a seat cutter (included in the special tools). Valve seat is cut to the proper dimension using the valve seat top and interior cutters The 90° seat cutter is used to repair the valve seat contact surface
II 2} i— P m
1 ! "vf -'
t t
£i Valvo seat cutlei 90* 2< Valve seal culler holder FiB 18A
fj> Valve sear ion cutter rji Valve seat cutler holder Fig. 188
(J Valve seat interior cutter rji Valve seat cutter holder Fig 18C
Whenever the valve seat has been repaired or the valve replaced, the valve must be lapped to the seat
To lap the valve, apply a small amount of lapping compound to the valve contact surface and rotate the valve back and forth against the seat using a suction cup tool. lifting the valve off the seat occasionally After the valve lapping is completed. wash off the lapping compound thoroughly from both the seat and face of the valve. Finally, check the seating of the valve with Prussian blue or red lead to assure that a good seat has been obtained
Note:
1 Read carefully the instruction provided with the valve seat grinder 07782-0020000. A set)
(Tool No
Apply a small amount of oil to the valve stem when inserting the vaive into the guide.
After the valve has been assembled into the cylinder head, check the sealing of the valve by pouring a small quantity of engine oil into the combustion chamber until the valve heads are covered and then apply compressed air at 28.4 psi (2 kg/cm:) alternately into the inlet and exhaust ports and check for any bubbles arising from around the valve seats If there are no bubbles, the valves are sealing properly
13
Measuring the wear of the valve stem and valve guide.
Place a dial gauge against the valve stem and move the valve sideways, and lore and aft The amount of wear in any direction will be indicated on the gauge (Fig. 19)
Standard Value i Serviceable Limit
Item
Inlst
Exi\aust
0 0004-0 0012
(0 01-0 03 mm) 0 0012-0 062 (0 03-0 05 mm)
Replace il over 0 0032 (0 08 mm) Replace il over 0 004 (0.10 mm)
4 Measuring the valve dimension
The valve stem diameter is measured with a micrometer (Fig. 20)
hem Standard Value Serviceable Limit
Inlet 0 2148-0.2187 (5 465-5 465mm) Replace if under 0 2126 (5.40mm)
Exhaust o 2070-u :i09 <5 435-5 445mm) Replace it under 0 2048 (6 38mm)
5. Replacing the valve guide
If the valve guide is worn excessively and requires replacement, follows the procedure below
a Remove the valve guide from the cylinder head using the valve guide remover (Tool No 07942-3290100)
b Install the new valve guide using the valve guide driver (Tool No 07 942-32 90200). and carefully drive the guide into the head The replacement valve guide should be one that is of an oversize
c After the new valve guide has been installed, it must be reamed to the proper finish size using a guide reamer (Tool No. 07984-0980000) Excercise care when using the reamer and apply small amount of oil occasionally to lubricate when the reamer starts to operated hard, pull out the reamer and remove the metal chip before continuing to ream The standard valve guide diameter is 0.2156-0.2159 (5.475-5.485mm). Measurement can be made with a cylinder gauge (Fig. 22).
G> Small Fig 19
dial gauge $ Va
(D Micrometer F.g 20
(J- valve
the cylinder head (Fig. 27)
2. Make sure that the respective gaskets. dowel pins and rings have not been overlooked
Piston diameter Fig. 30
i ftucknoss gauge rji Piston ring t3> Cylinder Fig 31
d> Piston PtBIOn ring* ij) Thickness gauge Fig. 32
Fig. 33
C. Inspection
1 Measuring the piston
Measure the piston diameter at the piston skirt at right angle to the piston pin axis using a micrometer (Fig. 30)
Sianaau Value Serviceable Limit
1 5346-1 5354 (38 98-39 00 mm) Replace if under 1 73 (38.88 mm)
0—-¥tSv ^--®
/''^Q ^T ' --"^"l
T_-^ Lisa' ^5)
2 Measuring the piston ring end gap
Insert the piston ring into the cylinder skirt and measure the ring end gap witn a thickness gauge (Fig. 31)
Standard Value
Serviceable Limit
0 004-0 012 (0 1-0 3 mm)
Replace il over 0 02 (0 5 mm)
Note:
For preventing damage to ihe piston nng the piston is an available ana convenient tool to insert Ihe nng into ine cylinder 3 Measuring the piston ring side clearance Measure the clearance between the piston ring and piston land with a thickness gauge (Fig 32)
'ii I Standard Value Serviceable Limn
1op and 0 0006-0.0018 i Replace if over
second nngs(0 015—0 045mm)i 0 0039 (0 1 mm)
Oil -ing
0 0004-0 001B Replace if over 1(0 010-0 045 mm) 0 0039 (0 1 mm)
4 Piston and piston ring are available m four standard oversizes of 0 01 (0 25 mm) up to 0 04 (1 Omm)
D Reassembly
Perform the reassembly in the reverse order of disassembly as described on page 9 — 10 and 13-14.
Note :
When assembling the piston to the connecting rod. make sure that the arrow marked on the piston head is pointing downward. (Fig. 33)
17
7 CLUTCH
A. Description
The clutch is a wet multiple disc, automatically engaging, centrifugal type The gear change operation can be performed smoothlv since the gear change mechanism is interconnected with the clutch pedal and when the clutch pedal is depressed, the ball retainer will be activated and causes me clutch to disengage
As the engine speed increases the rollers are forced outward by the centrifugal force causing the clutch plate and friction disc to engage, permitting the power from the crankshaft to be transmitted to the transmission (Fig. 341
Clutch center (J) 14 mm lock washer
I Hmm lock nut <$ Ball retainer complete
05 Clutch lifter plate $ Right crorikcnso covor
Lock nut wrench Clutch outer holder Fig. 35
18
0 Clutch adjuster fj) Lock mil Fig 36
fl) Veirnui caliper ij Friction disc Fig 37
(I) Vermel caliper ® CI.. Fig 38
Fig. 39 Oil How
Inspection
1 Clutch adjustment
a Clutch must be adjusted with the engine shut off Loosen the adjuster lock nut
b. Turn the adjuster clockwise about one turn. do not turn excessively
c Next, slowly turn the adjuster counterclockwise and stop when the adjuster to turn heavy.
d From this point, hack off the
adjuster m the clockwise direction
'fc to l/i turn, and lighten the lock nul (Fig. 36)
Check to make sure that the clutch operates properly after adjustment
• The engine should start easily with the kick starter without the clutch slipping
• When changing gear, the clutch slipping should be smooth and light, esoecially when shifting down in gear to the neutral position
2 Measuring the friction disc
Measure the thickness of the friction disc using a vernier caliper (Fig 37)
Standard value Serviceable Limit
n too it cn—_\ Replace II under 0 138 (3 50 mm) 0 122 (3 10 mm)
3. Inspecting the clutch spring
Measure the free length of the spring using a vernier caliper (Fig 38)
Standard Value Serviceable Limit
0 772 (19 6 mm) Replace if undei 0 72 (18 2 mm)
D Reassembly
Perform the reassembly m the reverse order of disassembly as described in page 16
8. CRANKSHAFT
A Description
The connecting rod is assembled on the crank pin. The bearing at the large end is lubricated by the pressurize oil which flows through the crankshaft (Fig 39)
1
19
B. Disassembly
1 Remove the cylinder head and cylinder in accordance with the procedure described
on page 9—10. 2. Remove the clutch assembly in accordance with the procedure described on page 16
3 Remove the primary driven gear and the kick starter spring
4 Remove the oil pump.
5 Remove the gear shift stopper and plate
6 Loosen the left crankcase cover screws and then remove the cover, flywheel itatOi and the cam chain
7 Pull off the rubber plug and remove the gear shift drum stopper bolt.
8 Remove the final drive sprocket 9. Remove the right crankcase
10. Lift out the crankshaft assembly from the case.
C Inspection
1 Measuring the crankshaft balance
Support the crankshaft on V-blocks at the bearings Rotate the crankshaft and measure the amount of runout at both ends of the crankshaft using a dial gauge (Fig. 40)
0 Crankshaft <2> Dial gauge Fig. 40
Hem Standard -aiue Sarvicc-auie Limit
Left end. at 1 .2
(30 mm) from the
weight 0 0006 Repair if over
Right end at 1.0 (25 mml from ih« (0 015 mm) 0.002 (0 05mm)
weight
Measuring the connecting rod side play Measure the amount of connecting rod side play using a thickness gauge (Fig. 4-1)
Standard Value
Serviceable Limit
0 004-0 014
(0 t-0 35 mm)
Replace if over 0 0315 (0.80 mm)
Measuring the radial clearance of the connecting rod large end bearing Measure the amount of clearance at the connecting rod large end by using a dial gauge (Fig 42)
fl) Crankshaft 4 Connecting rod (J) Thickness gauge Fig 41
Standard Value Serviceable Limit
0.0005 man (0 012 mm m.i i Replace if over 0 002 (0 05 mm)
D. Reassembly
Perform the reassembly in the reverse order of disassembly
Connecting rod Fig 42
20
9. TRANSMISSION
This motorcycle use a constant mesh three speed transmission.
(D Transmission mainsiuiii $ Transmission counttnstiaM Fig. 43-A Neutral position
Fig 43 B Low gea' (Ct snitied)
Fig 43 C 2nd goai (M, smiled)
Fig 43 0 Top gear 17 mm circlip $ Mainshalt top gear
rj) 17 mm circlip <1> Transmission countershaft
(J) Countershalt low gear 0 17 mm spline washer
jj 17 mm circlip ® Couniarshalt second geai
Q Countershaft top gear & Gear collar
Q 13 5 mm thrust washer
Fig. 45
10. GEAR SHIFT MECHANISM
A. Description
The gear SDindle arm which is connected to the gear shift spindle rotates the gear slnli drum and this causes the gear shift fork to move lefl and right in the drum groove. The gear shift fork is controled by the groove in the drum and this in turn causes the gears to slide and change gears.
B Disassembly
1 Refer to the section on disassembly of the crankshaft assembly on page 18.
By removing the right crankcase. the gear shift drum and the fork assembly can be removed together with the transmission gear as a complete unit
22
Gear shilt lork ends Fig. 46
i'l» Gear shift lork <3) Cylinder gauge Fig. 47
d» Gear shilt drum Micrometer Rg. 48
(D Guide pin clip Fig. 49
C. Inspection
1. Measuring thickness ot the gear shilt fork ends
The thickness of the snift fork end is measured with a micrometer (Fig. 46).
Standard Value I"'- 1 '.•" ..... '
0 191-0 I9& (4 86 — 4 94 mm) Replace il unaei 0 181 (4 6 mm)
Measuring lhe inside diameter of the gear shift fork
The inside diameter of the gear shift fork is measured with a cylinder gauge or an ms'de micrometer (Fig. 471
Standard Value
I 3385-1 3395
i j4 0-34 025 mm)
Serviceable Limit
Replace it over 1 346 (34 2 mm)
Measuring me outside diameter of trie gear shift drum
The diameter is measured with a micro-meier (Fig. 48).
¦ • ¦.- : i ¦ • • . - '••-...,!'• n ii
1 3366-1 3377 Replace it under (33 95-33 98 mm) t 335 (33 9 0
in the reverse Exercise care on the
D. Reassembly
Pertcm the reassemoiy order of disassembly following points
Make sure that the guide pin and guide pin clip are properly installed on the gear shift drum for both the right and left shift forks (Fig. 19).
i
23
Kick siarier pinion iji 17 mm circlio ® Kick spnng leiainei
16 mm circlip D 20 mm set ring $ 20 mm washer if Kick sta'ter ratchet spnng
0 17 mm thrust washer 1Q1 Kick staner spindle
Fig 51
24
B. Disassembly
1. Reler to the section on disassembly of the crankshaft on page 18
By removing the right and left crankcases. the kick starter spindle assembly can be removed
C. Inspection
Check to make sure that the kick starter pinion is operating smoothly
D Reassembly 1. Perform the reassembly in the reverse order of the disassembly
12. CARBURETOR
A. Description
The carburetor mixes the fuel and air taken into the engine in a correct proportion to produce a mixture and which is further atomizes so that it is easily combustible. The construction of the carburetor is shown in Fig 52
(D Float valve seat 3> Float vnlve Q Float arm pin & Float (Si Needle clip plate Slow jot * Float clamper wasne' Hi Needle jet ® Needle |et holder 4} Main jet Fig 62
25
Item Specification
Setting mark M J (Mam Jet) A J (Air Jet) Z50M II * 50 |100
A B (Air Bleed) AB1 AB2 AB3 AB4 AB5 05x2 05X2 0 5x2
N.J (Needle Jet) J N (Jet Needle) C A (Cut away) A S (Air Screw) P J (Pilot Jet) VS (Valve Seat) B.P (By-pass) Mam Bora Fuel Level 2 1 mm (0 083 in ) X 3R 2°. 2 Steps. 2 05 mm (0 0907 m.) #2 (Cut awayl. Width 1 mm (0 0394 in.) Depth 0 2 m m (0 0079 in ) \%±% *38 0 6 mm (0 024 in ) 0 9 mm (0 035 in | P = 5 3 mm (0 209 in ) 9 mm (0.354 m ) 18 mm (0.709 in i
B Removal
1 Turn the fuel cock to the OFF position ana disconnect the fuel tube from the carburetor
2. Remove the cap ana disconnect throttle cable from the throttle '/olve
3 Unscrew the two carburetor mounting bo'ts to remove the carburetor
4 Loosen the air cleaner tube connecting clamp and separate the air cleaner assembly from the carburetor
5 Remove air cleaner cover and lift out the air cleaner element
C. Inspection
1 Washing the components
After the carburetor has been disassembled, wash the parts m solvent (or gaso' and dry with compressed air
2 Inspecting the float Shake the float to see if there are any gasoline contained inside or for any deformation of the float If the float contain the gasoline or is deformed. replace it with a new float
3 Carburetor adjustment a Adiustmg the idle
The idling is adjusted in the following manner with the throttle stop screw and the air screw (1) Sets the engine to the proper
idling speed (,1200 rpmj with the ffi Throt„e gtop icr8w 9 Air 8C,aw
throttle stop screw Fig. 53
26
(2) Next turn the air screw slowly back and forth to obtain the point of the highest rpm
13) If the engine rpm has increased as result of section (2) above, reset the engine speed back to the proper rpm with the throttle stop screw
(4) Once again manuplate the air screw to see if the rpm will be increased.
(5) If the speed should increase again, perform section (3) (4) above again
However the adjustment of the air screw should be within 1%±>jj of a turn b Acijustnig the slow speed
The luel mixture adjustment between idle to % throttle opening is made by the air screw and the cut away on the throttle valve
(1) Air screw
Turning in the clockwise direction will produce a rich mixture
(2) Throttle valve cut away
In the vicinity 'g throttle opening, there may be cases where the fuel mixture cannot be adiusted by the air screw only In such case, if the fuel mixture is too rich, the throttle valve must be replaced with one having a cutaway of a large number size and then readjust the air screw
c Adjusting intermediate speed
At the throttle opening range between i-jj-% the fuel mixture adjustment is made primary by the position of the jet needle steps and replacement of the cut away of the throttle valve However changing the cutaway of the throttle valve will also affect the thiuttle opening between the % 'o 5& therefore, the adjustment of the intermediate speed by replacing the throttle valve cut away only is very difficult. Ii is recommended that the adjustment for the intermediate speed be made by the jet needle, and stay within the range of acceptable acceleration performance since this would provide greater fuel economy
d Adjusting the high speed
While driving at high speed, if the speed increases when the choke is closed slightly, ii is an indication that the carburetor is set too lean Progressively replace the main jet with one of a large size and readjust the carburetor
Note : Main jet sizes are numbered in the following manner Abqve ft 100 105. 110. 115 Below 5 100 98. 95. 92, 90
if the speed drops when the choke is closed slightly, it indicates that the main jet is nither of the proper size or that it is too large, in which case, perform the lollowing check to make the determination
o Proper jet size
Progressively replace the main jet with one of a smaller size until there is a drop in speed and the speed increases when the choke is closed slightly, the installed jet is too small and should be replaced with one of a size larger, this is the proper jet size.
.
27
TROUBLE SHOOTING CHART
(CARBURETOR)
Troubles Probable Cause Remedy Procedure
Engine will not start Fuel cock in the closed position Position cock to the open position
Insufficient fuel Pour fuel or position cock to RES position
Excessive use of choke has resulted in carbu retor flooding Clean spark plug Perform starting with the choke lever opened and the throttle at Full OJWI
Clogged or frozen fuel line Clean • Clogged air vent icing condition .tin clogged in valve • Clean water which has accumulated in the float chamber (exercise care il water is frozen) • Condition outside of the carburetor will be clogged tank vont. strainer clogged with dirt 01 ice clogging ol the fuel lines
Flooding Repair Relei to section on Hooding
Pool idling performance Readjust air screw Ad|ust Turn the air screw in all thu way lightly and then back off to the stand ard setting of 1-3/8 open Stan IN engine and turn the ait scow back and forth approximately 1/8 turn to locate the point where the engine speed is the nignest Finally set the idle speed with the throttle stop screw
Throttle stop sc-ew Adjust Turning screw in will result in jfl creased engine spued Turning screw out will result in decreased engine spaed When turning screw out will nol effect decrease in engine speed, ad lust with the cable ad|iistoi
Clogged slow |«t or loosened jet Clean or 'etighten the |Bt When slow |et is clogged disassemble the carburetor remove Iho screw and clean out with c> i ait
Carburetor flooding Repair Refer to section on Hooding
Poor intermediate speed performance Clogged slow |et or loosened jet Clean or retighten the |8t Refer to sectim- above
Not dhie to operate at cruising soeed Clogged air vent pipe Clean Remove the ait vent pipe and clean
Float level Adjust float level If needle valve is worm, replace with a new part
Improper setting ol the let needle Adjust it necessary Normally set the needle to the third step however there may be a difference ol one step loi w summer
-
28
Troubles Probable Causa Remedy Procedure
Poor high speed performance Choke iQtt in closed position Open choke full Set the choke lever to open
Fuai lever cock Set to open 0' RES Position the lever to one of the position
1 ujed an vent Clean Remove and clean.
Clogged main jet Clean Remove the main iet and clean out witn compressed an before assembly
Dirty air cleaner Clean or replace
Overflow Clogged Hoai vaivo ilUSt Clean Remove the float charnoei cover II there are accumulated dust, remove dust by blowing air or remove the valve seat and clean it
Damaged 01 worn valve and valve seat Replace as assembly Replace he valve assembly
Punctured float Replace Remove Hie float and shake to check if ts corresponding parts. See page 18
An cleaner ana tube • Chec* and clean Wrien me an cleaner element ana an inlet tube are clogged clean the elemeni by an and lemove Ihe dint inside inlet tube
Ignition liming lanoet clearance and engine s knocking Adjust and correct Align the "F" mark on the flywheel to the index mark on the case The contact Dreake' point should iust begin to open tins time Correct the proper tappet clearance oy using a thicuness gauge
Compression pressure Inspect retighten and replace Measure compression pressure by gauge If gauge snow less (trait 8 Okg¦cm' Replace the piston ring and omen. Retighten trio cylinder and cylinder head bolts
iparl plug Clean or replace ClBan soark plug electrode using a stiff wire and adjust the electrode gap 10 024-0 028 in or 0 6-0 7 mm) or replace the propei heat range plug
r
29
Troubles Probable Cause Remedy Procedure
Lubrication Pour or change oil Shortage of ail amount ur infenoi oil cause engine searing and stick Suoplv oroDOt grade oil or change if necessary
Fuel 1 Check Premium quality gasoline is being used.
High oil consumption 3) Wear of engine's pari Replace Worn piston, piston nng and cylinder should be replaced
$ Clearance between waive and valve guide Replace Replace both valve and valve guide in case there are large clearance between them
iji Piaion ring insial lation DisassomDling and Inspect Each piston ring must bo installed P'opeily on the piston and piston ring gaos must be staggered at 120* It
Q Amount ol oil Check When the oil was ft fill! 1 II II oil to bring to the piope' oil law
i$ Leakage Check Replace the gaict* If. ll U d rengnten the screws
(CLUTCH MULFUNCTION)
Troubles Probable Cause Remedy Procedure
Cluioh slippage Wear clutcn plate and clutch friction disk and soring damage Cnec* and repair Spring compressive force arm iroe length are beyond the serviciablo limn thuv should be replaced Ro-place the pa'is m case the c1 and plates are distorted or excessively worn
Clutch slick OH and defe Inspect and adjust installation Readiust the clutch oi replace the clutch disks and plates if necessary
Chattering noise Clutch spring Check and ad|ust Adjust the same height of clutch spring and replace >f the springs are disf
Gear shift operation
Not able to ll !l'.! :¦ i Gea' shift fork shift arm. spring Inspect and 'epiace CD Broken wear and laTi "i« of ihese parts should be replaced 9 Repair the gear shaft arm or drum 1 ioy do not operate smoothly
Gear change pedal does not return to the normal position Gea' shift return soring and gear shift arm spring Inspeci of the front fork cushion into the steering handle holder before tightening the bolts
2. REAR BRAKE (USA- Type
A. Description
The rear brake is operated by the right foot pedal or the left hand lever
B. Disassembly
1 Remove the brake rod adjusting nut and separate the brake rod ® from the brake lever (Fig. 55)
(D Brake rod adjusting nut ft Brake rod ® Fig. 65
J
31
(Ji 6 mm lack nut (J> Circular lock "ul
<3> Brake cable «d)iisiiog bolt $ Brake rod ®
Fig 56
(J) Pin <2i Brafcs padal pin nul
lh« pedal spring gi Stop lamp switch spring Fig 57
Fig. 58
2. Loosen the circular lock nut and remove the brake cable from the brake rod ® (Fig. 56).
3. Remove 6 mm lock nut and a pin. Then remove the brake rod ® and <8> (Fig. 56. 57).
4 Remove Ihe brake pedal pin nul. unhook the brake pedal spring and slop lamp switch spring from the brake pedal end remove the brake pedal iFig. 67).
5 Perform the rear wheel removal
C. Inspection
1 Check me brake rods for oeni and damage Straighten the bent rod and replace the rod if damaged
2 Check the spring and brake pedal for deformation or damage. If damaged. replace them with new one.
3 Check the brake cable for break. Replace the broken cable with new one
D. Reassembly
Perform the reassembly in the reverse order of disassembly
E. Adjustment
1 Make the adjustment of left hand lever play independently by turning the brake cable adjusting bolt Turn clockwise to increase the play The nominal free play is 0 8-1 2 [20-30 mrnj
33
Make the adjustment of pedal up travel with the brake rod adjusting nut Turn clockwise lor less free travel, counterclockwise for greater tree travel. The nominal troa play is 0 4-0 8 (10-20 mm)
Thg light should come on when the brake pedal is depressed 0 <* ilOmm). Turning the adjuster nut clockwise will delay the swicn engagement (Fig. 60i.
jsting nul ® Circular luc' rilll 'Si Brana cabia dd|uming run Fig. 69
Fig 60 0 Adjuster nut
34
FRAME (K3, K4, K5)
1 FRONT SUSPENSION
On the models Z50AK3. Z50AK4 and Z50AK5. the overall length and stroke were changed
09 3
^f'
r\<
55mm (2 16m.)
------as gt^v/N/v
3EE
(ft From cushion spring
lj> Spring upper holder
if) Fronl cushion stopper rubber
* Snnng pin
Fig
¦J Fork pipe guide
i Fork pipe guide cap
I Oil seal
a from tork bool
1
2 FUNCTION OF REAR SUSPENSION
On the model Z50AK3 the rear suspension was newly employed in connection with the change m shape of the fram This rear suspension uses single tube, friction type dampers. Each cylinder is filled with some amount of grease tor lubrication
• Operation
The head of the damper rod acts as a piston and it slides along the internal woll of the cylinder to cause the friction to be produced
• Smce friction is produced in both directions iwhen the shock absorber contracts and extends), this rear damper is of a double acting type
• The rebound stop spring is provided to absorb a shock load when the shock ahsorber is fully extended
d) Roar cushion rebound spring <2> Rem CUSh'On rod guide (Ji Hod ®> Grease $ Piston <|> Rebound stoppe1 spring teal Fig 2
35
3 CAM CHAIN ADJUSTMENT
Too tight or too loose a cam chain will adversely affect the engine Ad|ust the cham tension while the engine is idling
1 To adiust, loosen the lock nut ® and back off the tensioner adjusting bolt (2) approximately 1/2 turn
2 If the chain is still noisy after ad|ustmg, loosen the 14 mm sealing bolt located at the left lower side of the crankcase and tighten the tensioner bolt ($) gradually umii the chain becomes quiet Upon completing the ad|ustment, tighten the tensioner adjusting bolt, lock nut and 1 4 mm sealing bolt securely
Tensioner bolt Fig 3
fj Tensioner arj|usnng oou lock nut <$ Tensions! adjusting boll
| -msioner boll ill 14 mm scaling holt Fig 4
4 DRIVE CHAIN MAINTENANCE
Adjustment of the drive chain tension will have a considerable effect on the transmission ol power from the engine to the rear wheel and on the service life of the chain Theieforo. the chain tension should always be ad|usted correctly Every time the chain tension is adjusted, the chain must be lubricated
36
(D Drive chain Fig. 6
| Rui axlo rim Index mark <8> Cham ad|ustoi loci (3i Side scale Fig 6
(}) Rear axle shall CSi Cham adjusier
$ Index mark Cham adjuster lock nui
ij) Side scale
Fig. 7
4 S
Push the chain up and down at the midpoint between the sprockets to check the chain tension The maximum slack of the cham should be 3/4 inch
To ad|ust. loosen the rear axle nut
Then turn the chain adjuster lock nut in either direction Turning the lock nut clockwise will decrease the cham slack or turning it counterclockwise will increase the chain slock When the adjustment is completed the index marks on the right and left chain adjusters should be aligned with the reference marks on the both sides of the rear fork
Finally, lighten the axle nut securely
If the drive chain is excessively dirty, clean it in the following manner
a Carefully remove the master link retaining clip 0 with pliers Do not bend or twist the clip Remove the master link Remove the drive chain from the Mini-Trail
(J) Retaining clip 3> Pliers Fig 8
'
37
Clean the cham m solvent and dry it (Fig 9)
Check the chain lor wear or damage Replace any chain that has damaged rollers loose fitting links or otherwise appears unserviceable
Check the sprocket teeth for wear or
damage ana replace if necessary
(Fig. 10)
Never use a new drive cham wuh
badly worn sprocket Both the chain
and sprockets must be in good con
dltion
Lubncaie the cham Commercially availade drive chain lubricants may be purchased at most motorcycle shops and should be used in pre ference to motor oil or other lubricants
Saturate each chain link |0int so that the lubncani will penetrate the space between the adjacent surfaces of the link plates and rollers
Cham Fig 9
Damaged Sprocket Teeth
Worn Sprocket Teeth
Normal Sprocket Teeth
(J) Drive sprocket Fig 10
Drive chain llibl Fig 11
e Install the chain on the sprockets and lorn the ends with the master link For ease of assembly, hold the chain ends against the adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end will (ace m the direction of forward wheel iota
lion
The master link is the most critical part affecting the security of tne dnve chain Master imks are reusabi-they remain in excellent condition, hut it is recommended that a new master link be installed whenever the drive chain is reassembled
f Adiust the chain tension (See page 36)
Note :
If the drive chain is excessively loose when the rear axle ¦$ moved to the rearwaid limit of adjustment, it is worn out ana must be replaced
«
5. FRONT WHEEL AND FRONT BRAKE
39
•I Pioni wheel a»le
•Si from wheel side collar
<3> Lell wheel nm
<$ Wheel me
(Ji Rigm wheel inn
$ Oil seal 21 k3Bx56
iJJ Internal 32 mm en din
i$ Radial 6201 ball bearing
iji Front wheel hub
r^ Front axle distance collar
© Radial 8201R ball bearing
® Brake $hoe
r£ Rear oi3k« cam
# Rear brake panel
($ Front brake arm
Fig 14
Disassembly
1 Place a proper wood block under the engine to raise the from wheel off the ground,
2 Remove the front brake adjusting nut ® and disconnect the front brake cable from the brake arm
3 Remove the front axle nut ® and pull out the front axle ® (Fig 1 5).
4 Remove the front wheel
(\) Front bioko ad|iisting mil
tjl From axle Mil
From axle Fig 16
40
n brake panel Fig 21
Final driven
sprocket <£i loll wheel nlfl 1 Wheel tube (Ji Wtieel nre | Right wtieel rim if: Oil seal 18328 9 6201 radial ball
bearing ifti Rear ante
distance collar @ Rear wheel hub rfj 6201H radial ball
bearing @> Brake shoe iff Rear orake cam $ Ri- ¦¦. ianel
® Rear brake << Fig 25
A Disassembly
1 Loosen the axle nut and ad|uster nut
2 Disconnect the rear brake rod (Fig 26).
,1 Bnka '"d <2> Brake panel A Brake arm Fig 26
3 Remove the drive chain joint
4 Remove the axle nut and pull out the axle shaft (fig 27). Take out the wheel
5 Remove the brake panel from the wheel hub
6 Remove the brake cam. cam spring and brake shoes.
7 Remove the three 8 mm nuts and remove the final driven sprocket (Fig. 28).
8 Pull out the oil seal, bearing and distance collar
9 Remove the 6 mm bolts and 8 mm bolts and remove the wheel rims, wheel hub and tire
B. Inspection
1 Check the rear axle for bend
2 Check the wheel bearing for looseness
3 Check the wheel rims for runout
A Check the wheel hub for wear (Fig. 29).
5 Measure the brake lining thickness (Fig. 30).
6 Check the brake panel for damage
7 Check the oil seal for damage
8 Check to see if metal pieces or stones are bitten in the tire tread pattern or wall
9 Check for air leakage from the tire valve
(D Axle shall Fig. 27
Vernier cilium
Fig. 30
44
([> Wheel hub ® Grease Fig. 31
ili Groove in brake panel Fig. 32
C. Assembly
1 . To assemble, reverse the disassembly
procedures.
2 Install the tire to the wheel rims in the same manner as in the from whoel
3 Fill the cavity in the ball bearing and inside the wheel hub with grease Put the distance collar in position and drive the ball bearing in
4 Install the wheel hub to the rims (Fig. 31).
5 Fit the lug of the rear fork into the groove in the rear brake panel (Fig. 32)
6 Insert the rear axle tighten the axle nut
D Rear brake adjustment
The rear brake pedal free play should be 0 4 to 0.8 inch (10 to 20 mm) as measured at the tip of the pedal ® (Fig. 33).
(D Rear brake pedal Fig. 33
3) Roar brake adiust nut Fig 34
Free play is the distance the brake pedal moves before the brake starts to engage
1 To adjust, turn the rear brake adjusting nut (D '" either direction (Fig. 34) Turning the adjusting nut clockwise will decrease the free play and turning it counterclockwise will increase the free play
J
45
7 STEERING SYSTEM
Right handle grip A
iji Handle holder knob
<3) Steeling handle holder
$ foil top bridge
dt Lighting switch
rj Lett steering nandie pipe
if Right steering handle pipe
ill Front Diane cable
6 Steering head top thread
® Steering top cons race
0*6 steel ban
@ Steering top ball race
4$ Steering bottom cone race
O Steering head dual seal
41 Steering head dust seal washer
<8 Front '
Fig 35
A Disassembly
1 Disconnect the brake cable from the right handlebar
2 Disconnect the throttle cable from the throttle grip pipe.
3 Remove the headlight and disconnect the wires inside the headlight casei Turn the handlebar holder knobs and remove the handlebar pipes Remove the front wheel (See Section 5-A.)
4
6 Remove the headlight case front fender, hom handle lock and turn signals
From lotk guide cap
Fig. 36
0 Sieol ball Fig 37
3) Sieenng stem Fig 38
7 Remove the Iront fork bolts and loosen Ihe fork guide caps (Fig. 36). Then pull out the Iront shock absorber assemblies
8 Remove the steering handle holder and remove the steering stem and Iront
9 Remove the steering head top thread and steering top cone race Then remove the steering top ball races, bottom cone race and steel balls
Caution:
Take care not to drop the steel balls
B Inspection
1 Check the control cables lor proper opera lion Also check for breakage or any-other damage Relubncate if necessary
2 Check the steel balls for wear or damage (Fig 37).
3 Check the contact surfaces ol the steering top and bottom cone races and steering top ball races for scores, scratches or wear
4 Check the steering stem for bend or twist (Fig. 38).
5 Check the threaded pans for breakage or deformation
6 Check the handlebar holder fni breakage
C Assembly
1 To assemble, reverse the disassembly procedures.
2 Before installing the cone races, ball races and steel balls, wash them clean and apply a coat of new grease to them (Fig 39).
3 Adjust the control cables
Q) Grease Fig. 39
47
8 FRONT SHOCK ABSORBERS
(J) From lork boh
1*1 Froni cushion spring
$) From rork pipe guide 9 Front lork boot
<2> Front cushion assy (9 Front cushion stopper rubber (gi Oil-seal
(f Spring upper holder (ft Soring lower holder q F0rk Pine guide cap
A. Disassembly F'9 40
1 Remove the front shock absorber assem blies (See Section 7-A.)
2 Pull out the spring pm and disassemble each shock absorber
B. Inspection
1 Measure the shock absorber spring free length
2 Check the spring stops for scores scratches or breakage
C Assembly
To assemble, reverse the disassembly procedures Tighten the bolts, nuts, etc to the specified torque (See page 56.)
Note :
The spring pm must be flush with the end faces of the piston
© Spring pin
Q Front cushion hail pipe
(D Stopper pin Fig 41
0 Fork top thread Fig 42
48
9 REAR SUSPENSION
Reai cushion upper metal igi Rear cushion spring guide
(3) Rear damper $ Roar cushion upper lock nut <8) Rear cushion spring
Fig 43
A Disassembly
1 Remove the rear wheel (See Section B-A.1 Remove the chain cover
2 3
4
Remove the rear shock absorber attaching cap nuts and remove the rear shock absorber assemblies from the frame and rear fork
Remove the brake pedal and brake rod
Remove the pivot bolt and nut and remove the 'ear fork
^oar lork
Rear brake rod £> Roar brake pedal
(5> Rear lork pivot rubber bush
(Ji Real lork pivot bolt
Fig 44
(D Chain case cover Fig. 45
49
b Using a special tool. loosen the locking nui remove ihe upper metal and disassemble each rear shock absorber (See Fig. 46.)
B Assembly
1 To assemble, reverse the disassembly procedures
Notes
1 Install the spring with the smaller pitch end upward
2 Apply a coat ol locking sealant lo the upper metal
2 Install the rear shock absorbers to the rear fork and frame and secure with the cap nuts (See Fig 47.) See the Tightening Torque Standard
3 Install the rear wheel (See Secnon 6 C.)
(1) Rear shock absorber uppai metal <2l Locking nut
® Rear shuck absorber ! Fig 46
<3) Cap nut (J Reai fork FiB 47
50
10 FRAME BODY. SEAT. FUEL TANK AND AIR CLEANER
Fig. 48 3> w"« •m'ness
<2> A C ignition coil assy
Hi Frame boav Hi Fuel tank
* i- ij) Fuel cock assv
CD Ait cleaner assy
fl) Setting 6 mm boll Fig. 49
A Disassembly
1 Remove the engine (See page 7.)
2 To remove the luel tank disconnect the fuel tube by pulling it and remove the 6 mm bolt
3 To remove the seat, remove the two 8 mm bolts
4 Remove the front wheel and front shock absorber assemblies (See Section 5-A.)
5 Remove the rear wheel and rear suspen sion (See Section 6-A.)
6 Remove the auxiliary equipment
7 Remove the electrical parts
® Seat rji 8 mm bolt Fig 50
51
Inspection
1 Check the welded parts for damage and the pipes for cracks, breakage or twist
2 Check the head pipe for deformation
3 Check for leakage from the fuel tank Also check the vent in the fuel filler cap for clogging, the cock valve and strainer cap gaskets for deterioration or damage and the fuel tube for deterioration or breakage (Fig. 51)
Note Flush the tank using new gasoline
4 Soak air filter element in 'clean gear oil (No 80~No 90) until saturated then squeeze out excess oil (Fig. 52)
Warnning :
Gasoline or low flash point solvents are highly flammable and must not be used to clean air filler elements
5 Check the painted surface of the con necting tube for peeling
6 Check the exhaust pipe gasket for breakage and replace it if necessary (Fig. 53)
Remove carbon, if aky. from the diffuser pipe using a wire brush and wash it clean
C. Assembly
1 To assemble, reverse the disassembly procedures
2 Route and connect the control cables and wires correctly (Fig. 54) Connect the wires, color to color referring to the wiring diagram at the end of this manual
3 Adjust the brakes, clutch and chain. Check the steering handlebars for proper operation,
(D Fual filler cap Fig 61
(D Air filter elemeni Fig. 52
® Diffuser pipe ® Wire brush Fig 53
(D High tension cable <2> Throttle cable <3> W Ignition coil iji Baileiy 8) Coil Inst switch d> Spark gnp check dial (J) Spoik flap findor Fig. 66
ijl 1 si olncirodo tji 2nd olacirode $> 3rd electiode & Spark Fig. 57
Tvoe Flywheel
Output 6V-15W
Battery capacity 6V 2AH
Speed under load 500-1 VOOOrpm
Battery polarity (ground) Negative
(T> Condenser Observing the spark lumping across a 3 point spark gap. turn the knob and measure Ihe jumping distance (Fig. 57)
D Red 9 Brown PtobM
54
TECHNICAL SERVICE DATA
Unit mm (in )
hem Assembly standard Service limit
Cylinder bore 39 00-39 01 (1 5354-1 5358) 39 05 (1 5374)
Piston OD 38.98-39 00 (1 5336-1 5354) 38 90 (1 5315)
Piston ring side clearance Top and 2nd rings Oil ring 0.015-0 045 (0 0006-0 0018) 0 01-0 045 (0 0004-0 0018) 0 10 (0 003 9) 0 10 (0 0039)
Piston ring gap Top and 2nd rings Oil ring 0 15-0 35 (0 0059-0.0138) 0 15-0 40 (0 0059-0 0157) 06 (0 0197) 0 5 (0 0197)
Valve to-guide clearance Intake side Exhaust side 0 01-0 03 (0 0004-0 001 2) 0 03-0 95 (0 0012-0 0020) 0 08 (0 0031) 0 1 (0 0039)
Oil pump body-to-outer rotor clearance 0 1-0 15 (0 0039-0 0059) 0 2 (0 0079)
Inner rotor-io-outer rotor clearance 0 02-0 07 (0 0008-0 0028) 0 12 (0 004 7)
Crankshaft |ournal runout Right side Left side 0 015 (0 0006) 0 015 (0.0006) 0 05 (0.0020) 0 05 (0 0020)
Connecting rod big end pley Axial direction Radial direction 0 1-0 35 (0 0039-0 0138) 0 010-0 012 (0 0004-0 0005) 0 8 (0 0315) 0 05 (0 0020)
55
Unit mm {in )
hem Assembly standard Service limn
Front wheel Front axle bend Ball bearing play Axial direction Radial direction 0 2 (0.0079) 0 05 (0.0020) 0 002-0 007 (0 0001-0 0003) 0 5 (0 0197) 0 1 (0 0039) 0 05 (0 0020)
Wheel nm face runout 0 2 (0.0079) 0 5 (0 019 7)
Wheel hub ID 109 9-110 1 (4 327~4 335) 112 (4 409)
Brake lining thickness 3.9-4 0 (0 1535-0 1575) 2 0 (0 0787)
¦ § Rear axle bend 0 2 (0 0079) 0 5 (0 0197)
Ball beating play Axial direction Radial direction 0 05 (0 0020) 0 002-0 007 (0 0001-0 0003) b 1 (0 003 9) 0 06 (0 0020)
Wheel rim face runout 0 2 (0 0079) 0 5 (0 0197)
Wheel hub 10 109 9-110 1 (4 327-4 335) 1 12 (4 409)
Brake lining thickness 3 9-4 0 (0 1535-0 1575) 2 0 (0 0787)
From shock absorber spring (ree length 196 8 (6 567)
(The above service data are subject to changa without notice or obligation )
56
TORQUE SPECIFICATIONS
(ENGINE)
Item Q ty Torque values
kg-m It-lbs
1 Cylmdei head cover a 0 9-1 2 6.5- 8 6
2 Cam sprocket 3 0 8-1 2 5 7- 8 6
3 Cylinder lighten 1 0 8-1 2 5 7-86
4 L crankcase cover 3 0 7~: 1 5 1-79
5 i ivwheel 1 3 0-3 8 21 7-27 4
a R crankcase cover 8 0 7-11 5 1-79
7 Clutch tighten 1 3 5-4 5 25 3-32 5
8 Shift drum stopper 1 0 9-1 4 6 5-10 2
9 Dram cock bolt 1 2 0-2 5 14.5-18 0
10 Drive sprocket 2 0 8-1 2 5 7-86
(FRAME)
item Q'ty Torque values
kg-m 1Mb*
1 Front u 1 3 0-4 0 21 7-28 9
2 Front cushion 2 2 0-2 5 14 5-18 1
3 Rear a 1 2 5-3 5 18 0-23 6
4 Rear cushion 2 2 5-3 5 18 0-23 6
5 Rear lark pivot 1 2 5-3 5 18 0-23 6
6 Engine haitger bolt 2 2 0-2 6 14 5-1B 1
7 Torque link tighten bolt 1 2 0-2 5 14 5-1 B.I
8 Steering stem 1 6 0-8 0 43 2-57 6
9 Driven spioket 1 1 8-2 3 13 0-16 6
St indard parts
Boll hex 6 mm 0 8-1.2 5 7-86
Boll hex 8 mm 2 0-2 4 14 5-17 3
w cross. 6 mm 0 8-1 2 5 7-66
WIRING DIAGRAM
GENERAL EXPORT TYPE
57
/
HIGH TEWmjaL—^. mim CQ.L
sparkplug' cp"
SPEEDOMETER LAMP 6V-15W
----h—B-t-----------
HEADUGHI 6V-15W
HORN BUTTON
Oi A.C.H0RN
i
=nf.
IGNITION SWITCH
U
hii
jfr WTUBE4
TAIL AND
STOPLIGHT
6V-8/3W
SIUPSWTCH
, c
U.S.A. TYPE (From F. No. 120001) -ffifa
High beam indicator ligW ft* * « IMS'
fc Bvn h/« *- «
i to ("/'
» M ft/I fa-.
* Hftatr 6.1 ..ta/1
»*•
58
U.S.A. TYPE (From F. No. 270236)
moil «*¦ inoKAioB iichi wnw
HIUllCHT HI
MMHlinn-
1 Fff"
l^, --------------' ut /nanwi wi»/1»
i+~ili
mm mm switch ina^uii
¦« NMMB
nrwHiiiicuaiMtai
win :»iicm tnuciw
K 1 c e, :l H(l c ¦ h, tmm
n 0 1 ojo kruilimxl
I ¦ ojo hmwM
0 IO " oto 0 o
a..
w «¦ «
M I. •
-•)
U.S.A. TYPE (From F. No. 5000001)
mmwrn
i^gS^)
mm? aim
wuumt:
b •
¦ o o
0I>
( 1
¦
m O- o
I. *-
o
IRM