Honda COMMON SERVICE MANUAL – PDF DOWNLOAD

Description

Honda COMMON SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

Honda COMMON SERVICE MANUAL – PDF DOWNLOAD

IMPORTANT SAFETY NOTICE

WARNING

Indicates a strong possibility of ,personal Injury or death if in8’ructions “”‘ not followed.

CAUTION

Indicates a possibility of equipment damage ;instruction are not followed.

NOTE;

Gives helpful information

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included It is important to note that this manual contains some warnings and cautions against some specil1c service methods which could cause PE!ISONAL INJURY to service personnel or could damage a vehicle or ,ender It unsafe Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be or of the possibly hazardous ~of each concevable way, nor could Honda ;all such ways, Anyone service procedures or tools, whether or not recommended by Honda ,himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.

HOW TO USE THIS MANUAL

• This manual explains the theory of operation of the various systems common to HONDA motorcycles and motor scooters arid A TVs. It also provides basic 1nformat1on on troubleshooting, inspection and repair of components and systems found on these machines.
• Refer to the Model Specific Service Manual for the model you are servicing for adjustments, maintenance and repair information for components on that model. Section 1 provides general information on the whole motorcycle as well as Warnings and Cautions to remember when performing maintenance and repairs
• Sections 2 through 1 5 cover all aspects of the engine ar1d drive train. Sections 16 through 20 include all of the component groups that make up the chassis. Section 21 through 25 apply to the various electrical componerns and systems found on Honda motorcycles
• . An extensive alphabetized Index provides rapid access to information on specific components or systems. jAi1 information, illustrations, .directions . •~ specifications included in this publication are baced  on the latest product information available at the time of for printing. Honda Motor Co., LTD. reserves the right to make change, at any time without notice and without including any obligation whatever. No part of this publication L may without written manual

TABLE OF CONTENTS:

Honda COMMON SERVICE MANUAL – PDF DOWNLOAD

Front Cover......................................  1
Common Service Manual............................  2
	Picture......................................  3
	Safety Notice................................  4
	Contents.....................................  5
	Symbols......................................  6
	Abbreviations................................  7
1 General Information............................  8
	1-1 General Safety...........................  8
	1-2..........................................  9
	1-3 Service Rules............................ 10
		1-4...................................... 11
		1-5...................................... 12
	1-6 Fastners................................. 13
		1-7...................................... 14
		1-8...................................... 15
		1-9...................................... 16
		1-10..................................... 17
		1-11..................................... 18
		1-12..................................... 19
		1-13..................................... 20
	1-14 Ball Bearing Replacement................ 21
		1-15..................................... 22
		1-16..................................... 23
	1-17 Tool Compatability Chart................ 24
2 Maintenance.................................... 25
	2-2 Fuel Line................................ 26
	2-3 Throttle................................. 27
	2-4 Oil Pump and Line........................ 28
	2-5 Carburetor Choke......................... 29
	2-6 Air Cleaner.............................. 30
	2-7 Crankcase Breather....................... 31
	2-8 Spark Plug............................... 32
	2-9 Valve Clearance.......................... 33
		2-10..................................... 34
	2-11 Engine Oil.............................. 35
		2-12..................................... 36
		2-13..................................... 37
		2-14..................................... 38
	2-15 Decarbonizing........................... 39
	2-16 Carburetor Synchronization.............. 40
	2-17 Radiator Coolant........................ 41
	2-18 Cooling System.......................... 42
	2-19 Secondary Air Supply.................... 43
	2-20 Transmission Oil........................ 44
	2-21 Drive Chain............................. 45
		2-22..................................... 46
		2-23..................................... 47
		2-24..................................... 48
	2-25 Final Drive Oil......................... 49
	2-26 Battery................................. 50
	2-27 Brake Fluid............................. 51
	2-28 Brake Shoe Wear......................... 52
	2-29 Brake System............................ 53
	2-30 Brake Light Switch...................... 54
	2-31 Headlight Aim........................... 55
	2-32 Clutch System........................... 56
	2-33 Side Stand.............................. 57
	2-34 Suspension.............................. 58
	2-35 Spark Arrester.......................... 59
	2-36 Wheels/Tires............................ 60
		2-37..................................... 61
	2-38 Steering Head Bearings.................. 62
	2-39 Wheel Alignment......................... 63
3 Engine Testing................................. 64
	3-1 Trouble Shooting......................... 64
	3-2 Compression Testing...................... 65
	3-3 Leak-Down Testing........................ 66
		3-4...................................... 67
4 Lubrication.................................... 68
	4-1 Service Data............................. 68
	4-2 Troubleshooting.......................... 69
	4-3 System Descriptions...................... 70
	4-4 Wet/Dry Sump............................. 71
	4-5 Two Stroke Systems....................... 72
	4-6 Premix................................... 73
	4-7 Oil Pump Descriptions.................... 74
	4-8 Plunger Type............................. 75
	4-9 Oil Pressure Check....................... 76
	4-10 Pressure Relief Valve................... 77
	4-11 Oil Pump/Line Bleeding.................. 78
	4-12 Oil Cooler Inspection................... 79
5 Cooling System................................. 80
	5-1 Service Information...................... 80
	5-2 System Descriptions...................... 81
	5-3 Radiator................................. 82
	5-4 Radiator Cap............................. 83
	5-5 Thermostat............................... 84
	5-6 Coolant.................................. 85
	5-7 System Testing........................... 86
		5-8...................................... 87
		5-9...................................... 88
6 Exhaust System................................. 89
	6-1 Service Information...................... 89
	6-2 System Description....................... 90
		6-3...................................... 91
7 Emission Control Systems....................... 92
	7-1 Service Information...................... 92
	7-2 System Descriptions...................... 93
		7-3...................................... 94
	7-4 Noise Emission Control System............ 95
	7-5 System Inspections....................... 96
	7-6 AVCV..................................... 97
		7-7...................................... 98
	7-8 Secondary Air Supply System.............. 99
	7-9 Emission Control Information Labels......100
8 Fuel System....................................101
	8-1 Service Information......................101
	8-2 Troubleshooting..........................102
	8-3 System Description.......................103
		8-4......................................104
		8-5......................................105
		8-6......................................106
	8-7 Accelerator Pump.........................107
	8-8 Fuel Line................................108
	8-9 Carburetor Disassembly...................109
		8-10.....................................110
		8-11.....................................111
		8-12.....................................112
		8-13.....................................113
		8-14.....................................114
		8-15.....................................115
		8-16.....................................116
		8-17.....................................117
	8-18 Pilot Screw Adjustment..................118
		8-19.....................................119
		8-20.....................................120
		8-21.....................................121
		8-22.....................................122
	8-23 Limit Cap Installation..................123
	8-24 Accelerator Pump Adjustment.............124
9 Cylinder Head..................................125
	9-1 Service Information......................125
	9-2 System Description.......................126
	9-3 Valve Train..............................127
	9-4 Valve Lifter Mechanism...................128
	9-5 Camshaft.................................129
	9-6 Rocker Arm...............................130
	9-7 Cylinder Head Inspection.................131
	9-8 Cylinder Head Disassembly................132
	9-9 Valve Guides.............................133
		9-10.....................................134
	9-11 Valve Seats.............................135
		9-12.....................................136
		9-13.....................................137
	9-14 Cylinder Head Assembly..................138
	9-15 Initial Camshaft Lubrication............139
10 Cylinder/Piston...............................140
	10-1 Service Information.....................140
	10-2 System Description......................141
	10-3 Piston..................................142
	10-4 2-Stroke................................143
	10-5 Cylinder................................144
	10-6 Piston/Piston Ring......................145
		10-7.....................................146
	10-8 Piston Pin Inspection...................147
	10-9 Piston Installation.....................148
	10-10 Cylinder Installation..................149
11 Clutch........................................150
	11-1 Service Information.....................150
	11-2 System Descriptions.....................151
	11-3 Judder Spring Purpose...................152
	11-4 One Way Clutch System...................153
	11-5 Power Flow Diagram......................154
		11-6.....................................155
	11-7 Wet Multiplate Centrifugal Clutch.......156
	11-8 Gear Shift Lifter.......................157
	11-9 Separated Shift Clutch..................158
	11-10 Clutch Inspection......................159
	11-11 Clutch Removal.........................160
		11-12....................................161
		11-13....................................162
		11-14....................................163
		11-15....................................164
		11-16....................................165
		11-17....................................166
		11-18....................................167
	11-19 Clutch Reassembly......................168
		11-20....................................169
		11-21....................................170
		11-22....................................171
		11-23....................................172
		11-24....................................173
		11-25....................................174
	11-26 Clutch Lifter Reassembly...............175
	11-27 Hydraulic Clutch System Service........176
	11-28 Air Bleeding...........................177
		11-29....................................178
		11-30....................................179
	11-31 Clutch Slave Cylinder..................180
		11-32....................................181
12 V-Matic Belt Drive System.....................182
	12-1 Service Information.....................182
	12-2 System Description......................183
	12-3 Drive Pully Operation...................184
	12-4 Driven Pulley/Centrifugal Dry Clutch....185
	12-5 Drive Belt..............................186
	12-6 Drive Pulley............................187
	12-7 Disassembly.............................188
	12-8 Assembly................................189
	12-9 Drive Pulley Face Installation..........190
	12-10 Clutch/Driven Pulley...................191
	12-11 Inspection.............................192
	12-12 Clutch Shoe Replacement................193
	12-13 Driven Face Bearing Replacement........194
	12-14 Clutch/Driven Pulley Assembly..........195
		12-15....................................196
13 Transmission..................................197
	13-1 Service Information.....................197
	13-2 System Description......................198
	13-3 Planetary Gear Type.....................199
	13-4 Shift Start.............................200
	13-5 Constant Mesh Transmission..............201
	13-6 Transmission Disassembly................202
		13-7.....................................203
		13-8.....................................204
14 Crankcase/Crankshaft..........................205
	14-1 Service Information.....................205
	14-2 System Descriptions.....................206
	14-3 Crankshaft Inspection...................207
		14-4.....................................208
	14-5 Main Bearing Selection..................209
		14-6.....................................210
	14-7 Main Bearing Selection..................211
	14-8 Connecting Rod Bearings.................212
		14-9.....................................213
	14-10 Connecting Rod.........................214
		14-11....................................215
15 Final Drive/Output Shaft......................216
	15-1 Service Information.....................216
	15-2 Output Shaft............................217
		15-3.....................................218
		15-4.....................................219
	15-5 Final Drive Removal.....................220
		15-6.....................................221
		15-7.....................................222
		15-8.....................................223
	15-9 Universal Joint Inspection..............224
16 Wheels/Tires..................................225
	16-1 Service Information.....................225
	16-2 Wheel Removal/Installation..............226
		16-3.....................................227
		16-4.....................................228
	16-5 Rear Wheel..............................229
		16-6.....................................230
		16-7.....................................231
	16-8 Wheel Bearing Replacement...............232
	16-9 Basic Tire Information..................233
		16-10....................................234
	16-11 Tire Removal...........................235
		16-12....................................236
		16-13....................................237
	16-14 Tire Installation......................238
		16-15....................................239
		16-16....................................240
	16-17 Wheel Balancing........................241
		16-18....................................242
		16-19....................................243
		16-20....................................244
		16-21....................................245
		16-22....................................246
17 Brakes........................................247
	17-1 Troubleshooting.........................247
	17-2 Brake System Descriptions...............248
	17-3 Hydraulic Brakes........................249
		17-4.....................................250
		17-5.....................................251
		17-6.....................................252
		17-7.....................................253
	17-8 Hydraulic Disc Brakes...................254
		17-9.....................................255
		17-10 Brake Pad Replacement..............256
		17-11....................................257
	17-12 Brake Caliper..........................258
		17-13....................................259
	17-14 Brake Disc Inspection..................260
	17-15 Master Piston Inspection...............261
	17-16 Mechanical Drum Brakes.................262
		17-17....................................263
		17-18....................................264
		17-19....................................265
18 Front Suspension..............................266
	18-1 Service Information.....................266
	18-2 System Descriptions.....................267
	18-3 Oil Damper Principles...................268
	18-4 Telescopic Fork.........................269
	18-5 Fork Removal............................270
		18-6.....................................271
		18-7.....................................272
		18-8.....................................273
		18-9.....................................274
		18-10....................................275
	18-11 Handlebars.............................276
		18-12....................................277
		18-13....................................278
		18-14....................................279
	18-15 Steering Stem..........................280
		18-16....................................281
	18-17 Race Replacement.......................282
		18-18....................................283
		18-19....................................284
		18-20....................................285
		18-21....................................286
	18-22 Steering Head Preload..................287
		18-23....................................288
19 Rear Suspension...............................289
	19-1 Service Information.....................289
	19-2 System Descriptions.....................290
		19-3.....................................291
		19-4.....................................292
	19-5 Rear Damper Springs.....................293
		19-6.....................................294
	19-7 Shock Absorber..........................295
		19-8.....................................296
		19-9.....................................297
		19-10....................................298
	19-11 Swingarm...............................299
		19-12....................................300
20 Frame/Body Panel..............................301
	20-1 Service Information.....................301
	20-2 Description.............................302
		20-3.....................................303
	20-4 Inspection..............................304
21 Electrical Fundamentals.......................305
	21-1 Service Information.....................305
		21-2.....................................306
		21-3.....................................307
		21-4.....................................308
		21-5.....................................309
	21-6 Basic Electronic Knowledge..............310
		21-7.....................................311
		21-8.....................................312
		21-9.....................................313
		21-10....................................314
		21-11....................................315
		21-12....................................316
		21-13....................................317
	21-14 Basic Electrical Diagnostic Methods....318
		21-15....................................319
		21-16....................................320
		21-17....................................321
		21-18....................................322
22 Battery/Charging/Lighting System..............323
	22-1 Service Information.....................323
	22-2 Troubleshooting.........................324
	22-3 Charging System.........................325
	22-4 Battery Descriptions....................326
		22-5.....................................327
		22-6.....................................328
	22-7 Motorcycles Without Batteries...........329
	22-8 Battery Removal/installation............330
	22-9 Battery Testing/Charging................331
		22-10....................................332
		22-11....................................333
	22-12 Charging System Descriptions...........334
		22-13....................................335
		22-14....................................336
		22-15....................................337
		22-16....................................338
		22-17....................................339
		22-18....................................340
	22-19 Charging System Inspection.............341
		22-20....................................342
		22-21....................................343
		22-22....................................344
		22-23....................................345
		22-24....................................346
		22-25....................................347
	22-26 Alternator.............................348
		22-27....................................349
		22-28....................................350
		22-29....................................351
23 Ignition Systems..............................352
	23-1 Service Information.....................352
		23-2.....................................353
		23-3.....................................354
	23-4 Systems Descriptions....................355
		23-5.....................................356
		23-6.....................................357
		23-7.....................................358
		23-8.....................................359
	23-9 Spark Plug..............................360
	23-10 Spark Test.............................361
	23-11 Ignition Timing........................362
	23-12 Ignition Coil..........................363
		23-13....................................364
		23-14....................................365
		23-15....................................366
	23-16 Transistorized Ignition System.........367
		23-17....................................368
24 Electric Starter/Starter Clutch...............369
	24-1 Service Information.....................369
	24-2 Troubleshooting.........................370
	24-3 Disassembly.............................371
		24-4.....................................372
		24-5.....................................373
		24-7.....................................374
	24-8 Clutch Switch Diode Inspection..........375
	24-9 Starter Pinion Inspection...............376
25 Lights/Meters/Switches........................377
	25-1 Service Information.....................377
	25-2 Oil Pressure Warning Light..............378
		25-3.....................................379
	25-4 Fan Motor Switch........................380
	25-5 Coolant Temperature Guage...............381
		25-6.....................................382
	25-7 Fuel Gauge..............................383
	25-8 Low Fuel Indicator......................384
	25-9 Fuel Pump...............................385
		25-10....................................386
	25-11 Headlight Bulb.........................387
	25-12 Switches...............................388
		25-13....................................389
		25-14....................................390
		25-15....................................391
	25-16 Turn Signal Lights.....................392
	25-17 Horn...................................393

Customer Support: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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