2002-2006 Honda CHF50 Metropolitan Service Manual

Description

2002-2006 Honda CHF50 Metropolitan Service Manual

This is the full workshop service manual for the Honda CHF50 Metropolitan scooter, covering the 2002 through 2006 model years. It is the same class of document a Honda service department uses to service the Metropolitan — organized by system, with removal and installation steps, inspection limits, torque values, exploded assembly illustrations, wiring diagrams and troubleshooting charts across roughly 319 pages.

File Details

• Manual type: Service / Workshop Manual
• Brand: Honda
• Model: CHF50 Metropolitan
• Model years covered: 2002, 2003, 2004, 2005, 2006
• Language: English
• File format: PDF
• Page count: Approx. 319 pages
• Publisher: Honda Motor Co., Ltd. Service Publication Office
• Coverage note: Includes separate specifications and procedures for ’02 – ’05 models and After ’05 models where they differ

IMAGES PREVIEW

Chapters Covered

• 1. General Information — service rules, model identification, serial numbers, labels, general specifications, standard torque values, lubrication and seal points, cable and harness routing, emission control systems
• 2. Frame / Body Panels / Exhaust System — body panel removal chart, trim clips, front cover, front fender, seat, luggage box, body cover, side cover, step floor, leg shield, lower cover, rear fender, front meter cover, muffler
• 3. Maintenance — maintenance schedule, fuel line, throttle operation, air cleaner, crankcase breather, spark plug, valve clearance, engine oil, oil strainer screen, engine idle speed, radiator coolant, cooling system, secondary air supply system, brake shoes wear, brake system, brake lock, headlight aim, suspension, nuts and bolts, wheels and tires, steering head bearings
• 4. Lubrication System — lubrication system diagram, oil pump
• 5. Fuel System — component location, air cleaner housing, carburetor removal, disassembly, assembly and installation, pilot screw adjustment, high altitude adjustment, starting enrichment (SE) valve, secondary air supply system, PCV control solenoid valve / PCV reed valve, fuel tank
• 6. Cooling System — system flow pattern, coolant system testing, coolant replacement, water pump, thermostat, radiator, radiator reserve tank
• 7. Engine Removal / Installation — component location, engine removal and installation
• 8. Cylinder Head / Valves — cylinder compression test, cylinder head cover removal, camshaft and rocker arm removal, cylinder head removal, disassembly, valve guide replacement, valve seat inspection and refacing, assembly, installation
• 9. Kickstarter / Drive Pulley / Driven Pulley / Clutch — belt case cover, kickstarter, drive pulley, clutch and driven pulley
• 10. Final Reduction — final reduction oil, disassembly, bearing replacement, assembly
• 11. Alternator / Starter — removal and installation
• 12. Crankshaft / Piston / Cylinder — crankcase separation, crankshaft and piston removal, inspection, installation, crankcase assembly
• 13. Front Wheel / Brake / Suspension / Steering — front wheel, front brake, fork, handlebar, equalizer, steering stem
• 14. Rear Wheel / Brake / Suspension — rear wheel, rear brake, rear shock absorber
• 15. Battery / Charging System — system diagram, battery, charging system inspection, alternator charging coil, engine control module (ECM), main relay
• 16. Ignition System — system diagram, ignition system inspection, ignition coil, ignition timing, throttle position sensor
• 17. Electric Starter — system diagram, starter relay, engine control module (ECM)
• 18. Lights / Meters / Switches — headlight, turn signal light, brake/tail light, license light, turn signal indicator, speedometer, fuel gauge / fuel level sensor, coolant temperature indicator / ECT sensor, fuel pump, ignition switch, handlebar switches, brake light switch, horn
• 19. Wiring Diagrams — standard (’02 – ’05), P-type (’02 – ’05), After ’05 model
• 20. Technical Features — magnetic-coupling water pump, brushless alternator/starter
• 21. Troubleshooting — engine does not start, engine lacks power, poor performance at low/idle/high speed, poor handling
• 22. Index

The 2002-2006 Honda CHF50 Metropolitan service manual is arranged so a technician can find a system on the contents page, open the section, and work from a system illustration, service information and troubleshooting block before reaching the detailed procedures. Sections 1 and 3 apply to the whole scooter; Section 2 illustrates how to remove and install the body panels and components needed to reach the service area; Sections 4 through 18 break the machine into systems grouped by location. Every torque figure, service limit, clearance and fluid capacity is printed in metric and imperial units, and the maintenance schedule ties directly to the CARB emission standard the Metropolitan was built to meet.

What This Manual Enables You To Do

With the Honda Metropolitan CHF50 service manual open on your bench, you can perform the full range of work this scooter requires:

• Set valve clearance (IN 0.10 ± 0.03 mm, EX 0.19 ± 0.03 mm) and replace shims from 1.200 mm to 2.900 mm in 0.025 mm increments
• Adjust carburetor pilot screw, float level (13 mm) and idle speed (2,000 ± 100 rpm)
• Service the starting enrichment (SE) valve, PAIR control valve and PCV reed valve / PCV control solenoid valve
• Change coolant, bleed the system, test the radiator cap and inspect the thermostat (begin to open 74 – 78 °C)
• Remove and install the water pump, radiator and reserve tank
• Rebuild the drive pulley, weight rollers, ramp plate, clutch and driven pulley
• Disassemble the final reduction, replace bearings and refill with Hypoid gear oil #90
• Remove and install the alternator/starter, flywheel and ignition pulse generator
• Separate the crankcase to service the crankshaft, piston, cylinder and connecting rod
• Service the front and rear drum brakes, brake cams, shoes and equalizer
• Rebuild the front fork and replace steering head bearings
• Diagnose electrical faults using the ECM 26P and 6P connector pinouts, main relay checks, charging voltage tests and the full wiring diagrams
• Troubleshoot no-start, poor idle, lack of power, overheating and poor handling conditions

Correct procedures and the right specifications matter on a machine this compact. A mis-set pilot screw or an incorrectly seated cam chain tensioner can turn a routine service into a top-end rebuild. The CHF50 Metropolitan repair manual supplies the exact sequences, service limits and torque values so the job is done once, correctly, and to the standard the scooter left the factory with.

Instant PDF Delivery

This 2002-2006 Honda Metropolitan service manual is delivered as an instant PDF download — no shipping, no waiting, no physical book to lose. Open it on a laptop in the garage, a tablet on the lift, or print just the pages for the system you are working on. Keep it on any device you own and use it for every service, repair and diagnostic job on your CHF50 for the life of the scooter.