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Ownersmanual c200 1968 en 08062014 0047

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48 views27 pages

Ownersmanual c200 1968 en 08062014 0047

Uploaded by

yuyu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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EXONIDA ~~ Foreword ( We take this opportunity. of welcoming you to the HONDA fraternity, also for choosing this machine from the many others available to you. To assist you in keeping this excellent machine “in peak condition" we have set out for your guidance, the correct handling procedure and adjustments that are required from time to time. We advise you to read this booklet carefully so that you will be familiar with your €200. ( (The specifications in this booklet are subject to revision without q prior notice.) { HONDA MOTOR CO., LTD. #5-5, YAESU, CHUO-KU, TOKYO, JAPAN GN _—— Table of Contents DISTINCTIVE FEATURES OF HONDA 90 4 PRINCIPAL DATA ......cccceseceeeeeseeerseene TECHNICAL INFORMATION FOR OPERATION SIBHING! sgelerulecerpvesitensaceneucnenenean 16 Gear Changing Operating on Grades Stopping and Parking Procedure Operation of Principal Parts... INSPECTION AND ADJUSTMENT ..... 18 Daily Inspection Periodic Inspection........sececseee Ignition Timing Adjustment Valve Clearance Adjustment ........ Clutch Adjustment ......sccccccceseseeeee Front Brake Adjustment Rear Brake Adjustment .. Drive Chain Adjustment. Carburettor Adjustment Changing Engine Oil Dusting of Air Cleaner Cleaning of Oil Filter .. Cleaning of Fuel Strainer......... Decarbonizing of Spark Plug Checking of Battery Solution Decarbonizing of Muffler .... Inspection of Tightened Parts ... Adjustment of Throttle Wire. Removing Front Wheel Removing Rear Wheel PORTABLE TOOL KIT WIRING DIAGRAM FOR HONDA 90. PRECAUTIONS IN HANDLING REGARDING FUEL AND OIL GENUINE HONDA PARTS NNICASE® OF TROWERE svcic cases deca svaticotvesase dovtele, Oniteed HONDA HEAD OFFICE AND OVERSEAS SUBSIDIARIES ... Distinctive Features of Honda 90 Newest style @ Perfect electrical equipment HE Weight is only 85.5kg se | Completely enclosed drive chain Wet type multi-plate hand clutch Utilization of 4-cycle engine Suitable transmission for high power output and high efficiency C4) HONDA 7 Principal Data MM ENGINE Cooling system and cycle......... O.H.V., Air-cooled & 4 cycle Number of cylinders and arrangement. .One, rising angle of 10° from horizontal BOG: 26 StORG! eee. sa ssiisians ouereres ---49X% 46 mm (1.92X 1.76 in) Total exhaust volume... +86.7 ce (§.31 cu in) Compression ratio ..... <8:0'2 1) Mas OUtpUh) oc. nemsinaeie -6.5 PS/8,000 r.p.m. MGR FORGUE! see's) cosnacviawiaave senses 0.65 m-kg/6,000 r.p.m. (4.74 ft-lb/6,000 r.p.m.) Ignition method sicuisens sane ses Battery ignition WSRITON: SMING,:: § eseneia, enetarezal@ sitensne a eabs 25-35° before upper dead center SPOnKPIUGSiwiacrsceasucrinn: sme aed NGK's D-6HW, Nippon Denso's X20F BONSiys Sdn tab oisis flues ects 6V, 6AH (B108~6) GOS UPEHOES ti cite re, wale spares aa he Keihin Seiki's PW18HA LUBFICGHION SYSPOM) 65.6 ei ciidies vie ee a0 Forced lubrication QU PUR sore eres o15, 6 whois ann eee, ye Gear type C5) (6) ROSE ES PAE coc acepiscotie’a-eaupeivesiazni-oua Teme: oil o5ne/e 0s Wet multi-plate type Transmission .-Constant mesh gear type Gear operation 4-speed return type operated by left ’ foot Gear ratio - Tst ‘speed (LOW) sescssavecens 2,540 total reduction ratio (25.20) 2nd speed (Second) 1,610 ” (16.00) 3rd speed (Third) .. 1,190 ib (11.80) 4th speed (Top) - -0,960 * 1 9.51) : Primary tive sis: s: sees) epee Gears Gear ratio for the above.........+ 3.72 | Finaldtive | .0.° ceitnaestke 2 oes Chain i Reduclion rutio for the above ...... 2.67 i FRAME ‘ PRET Has oetieiih atts nica te AxG~ EeeS ds RAEN ap balsas: Backbone type SUSHBHSIOMs saarse is -~.cse- cht. age IaeR a Se Pivot type (front and rear) BREE Aieeiet hon etace brah fot era.ne tastate ieee Inside expanding type (front and rear Haridle length... cece vesase ewe aes 625 mm (24.60 in) SHSSNNG ANGIE: _Increosing speed. =) Decreasing speed. Fig. 5 Fig. 6 With the clutch lever pulled to the full, depress the heel port a of the change arm and the gear will be engaged smoothly. (Fig. 5) Selection of the lower gear from the higher can be attained by depressing the heel part b. Increase the engine revolution by turning the throttle grip counter clockwise while slowly releasing the clutch lever. A changing order is arranged as seen in Fig. 6, the gear system being of "'return”” forward 4-speed type 4. Get the knack of shifting the gears according to motorcycle speed. the preceding 1. and 2 are repeated) (For operation, a Gear Low —+ second | Second — third | Third — Top Over 12km/h | Over 20km/h Over 30 km/h Speed (Over 8 mph) (Over 13mph!_| (Over 19 mph) 5. The speed control when the motor cycle is running on Top is done with the throttle grip 6. To indicate neutral position the neutral lamp (red) located on the speedometer goes on (Fig 7) (NOTES) 1. Pressure on the change arm should be firm. 2. A too quick release of the clutch lever sometimes stalls the engine ; exercise care. NEUTRAL LAMP ci) MB OPERATING ON GRADES (12) @ When climbing up grade 1. This motorcycle will climb practically all upgrades at normal running speed ; however, when driving with two persons or carrying an extra load, climbing should be done in third, second or low speed. 2. While running at top speed and coming to an up grade, if the speed is to be reduced, perform the operation opposite to that of accelerating. 3. In this case, try to operate the clutch lever and throttle grip quickly. shifting gears with left foot without losing the momentum of the motorcycle. @ When driving down grade 1. When going down grade close the throttle, applying the front and rear brakes gradually. 2. When running down a steep grade, use the engine brake by shifting into third, second or low speed with the throttle grip. closed. Use the front and rear brakes HB STOPPING AND PARKING PROCEDURE 1. Make it a habit to use both front and rear brakes simultaneously (When using the front brake, use it with the steering handle in a straight forward position.) 2. When the motorcycle stops, shift back into neutral. (Verify with : the indicating lamp of Fig. 7) 3. When parking the motorcycle, observe the following : (1) Close the gasoline cock (2) Remove key from the com- bination switch (3) Place theft protection lock on the handle (Fig. 8) fig. 8 (13) HB OOPERATION OF PRINCIPAL PARTS @ Combination switch Fig. 9 Key Whether key ‘ Function can be removed position ie OP 0 Stop (all electrical circuits are open) Removable I Daytime driving and starting (Directional signals, | Unremovable horn and stop light can be used) a0 Night driving and starting Unremovable (All safety devices can be used) 04 @ Directional Signal Lights Directional Signal Light can function when the key is in I or II position. When the knob is turned to R, — the right lamp flashes When the knob is turned to L, — the left lamp flashes. (NOTE) The bulb is 6V, 8W; always use the specified bulb: if a bulb of different power rating is used, the operation ek ‘ becomes unstable. . VWkel: ? Fig. 10 Cs) @ Headlight @ Stoplight 1, The headlight goes on when the key is on “II” position. When the knob is turned to a, illumination is straight forward (6V, 25W) When the knob is turned to b, illumination is deflected downward (6V, 25W) Qo 1. The stoplight goes on when the key is on “I” or “IL” position. 2. Adjust so the stoplight will go on when the rear brake pedal is pressed a normal amount. (Fig. 11) When the knob is between a and b, the headlight does not go on. 2. Adjust the headlight so it will illuminate the ground area 50m (165 ft) in front. 3. Adjust the angle of illumination with the adjusting screw. (Fig. 12) When this screw is turned clockwise, the light beam is lengthened. When turned counter clockwise, the light beam is shortened. 3. Loosen the nut a and adjust with the nut b. (Fig. 13) Turned to the right, the stoplight will go on quicker. Turned to the left, the stoplight will go on slower. 4. Standard bulb is 6V, 6 W. £4 @ Tail light HORN SUTTON é Fig 13 1. The tail light goes on when the key is on “II” position. 2. Standard bulb is 6V, 2W. 018) ee Inspection and Adjustment WM DAILY CHECK-OFF LIST FOR PERSONAL SAFETY Do the headlight and direction lights go on? Does the horn operate normally ? Do the tail light and stoplight go on? Does the clutch work all right 2 Is the engine oil level up to the specified level? (Capacity 0.94) Is there sufficient gasoline in the fuel tank ? Is the play of the front brake lever 20~30mm (0.8~1.2 in)? Is the play of the rear brake pedal limit 20~30 mm (0.8~1.2 in) ? Standard air pressure for the front tyre 1.7 kg/em® (24 Ib/in*) Standard air pressure for the rear tyre 2.1 kg/cm® (30 Ib/in*) Sv eNnanewoN > (NOTES) 1. Change the oil every 500km of repeated short distance and wintertime running. a. when daily run is over 50 km. 2. Check battery solution often ) b. when running in mountainous creas. c. when usual run is at high speed. C18) ,|_Carburettor adjustment MM PERIODIC INSPECTION Mai tenance items Ignition timing adjustment Valve clearance adjustment | Clutch adjustment Front brake adjustment Drive chain adjustment P @ Marked items are to be inspected periodically by the agent ; be sure to take the motorcycle to the agent issuing the service card or designated service station. © Marked items can be checked by yourself but prefer- ably at ao service station. 7 CeCe H | 4.000 (15,000) )}(1 1,000) 7,000 Greasing Changing engine oil | Cleaning air filter Cleaning oil filter | Decarbonizing Checking of battery solu Decarbonizing muffler Checking tightened parts IGNITION TIMING ADJUSTMENT (20) I. Remove the point cover; bring ‘‘F’ mark of the dynamo rotor to the pointer mark and make sure that this is the instant the point begins to Open. Maximum gap of the point is 0.3- 0.4 mm (0.01 2-0.016 in) Loosen screw a and adjust the clearance with a screwdriver. To adjust the ignition timing, loosen screw b and adjust the base plate If ignition timing pointer turn the base plate to the right. If it is advanced turn the base plate to the left. (NOTE) Dirty or damaged point contact surface causes irregular firing; check periodically and keep the contacts’ clean. FUE. eta ss a Fig. 14 WM EVALVE CLEARANCE ADJUSTMENT 1. 2; Remove the point cover and set the ‘'T’’ mark of the dynamo rotor to the pointer mark. (Fig. 15) Remove the cap for the cylinder head cover and check the clearance between the screw and valve. (Fig. 16) At this time, if the rocker arm (screw) is pressing the valve, turn one complete rotation and adjust Figs 15 so the valve is in closed state (upper dead point of compression). 3. Loosen the nut, by moving the screw, adjust the regular clearance ta 0 05mm (0.02 in) (0.04 ex). If tightened, the clearance narrows. If loosened, the clearance widens. (NOTES) 1. When tightening the nut, unless the screw is held unmovable, the clear- ance will change, so be careful. 2. Be sure to adjust when the engine is cold. Use a thickness gauge to measure the clearance. (aij HB CLUTCH ADJUSTMENT IB FRONT BRAKE ADJUSTMENT 1. Adjust the clutch lever so that its play from neutral position a to dis- 1. Adjust the brake lever so its play from its normal position a to braked engaged position b is 10~20mm (0.40~0.78 inl. (Fig. 17) position b is 20~30mm (0.78~1.18 in). (Fig. 18) 2. For adjusting, loosen nut ¢ and use adjuster d. b 2. Adjusting should be done with the adjusting nut. (Fig. 19) If the clutch disengages too quickly, turn to the right. When tightened, the play decreases; loosened, the slay" increowes: If the clutch disengages too slowly, turn to the left. Per Cha 8 vou lacie, (NOTE) The brake is a ‘life line ', so be sure to check it before using the motorcycle. => Does the engine start easily without slipping when kicked? => With the engine running and the clutch disengaged, does the motorcycle move when shifted into Low? Does the engine stop ? = Does it start smoothly when the engine revolution is in- creased and the clutch lever released gradually 2 Fig. 17 (22) | Fig. 18 Fig, 19 (233 MM EREAR BRAKE ADJUSTMENT 1. Adjust the brake pedal so that the distance between normal position a to its braked position b is 20~30 mm (0.78~1.18 in). (Fig. 20) 2. Adjusting should be done with the adjusting nut. (Fig. 21) Tightened, the pressing amount decreases Loosened, the pressing amount increases (NOTE) The brake is a ‘life line', so ‘e sure to check it before using the motorcycle. Fig. 20 (243 HM DRIVE CHAIN ADJUSTMENT 1. Remove the peep hole cap of the chain case. (Fig. 22) 2. Adjust the chain so that the maximum play is 10~20 mm (0.40~0.79 in), when the chain is moved up and down. 3. Loosen the axle nut and rear axle sleeve nut; adjust the tension of chain by moving the nut on chain adjuster. (Fig. 23) Os Ltt (8 Or * When tightened, the chain tension increases. When loosened, the chain tension decreases. (NOTE) Match the adjuster and the etched marks on the fork on the same positions both left and right. Wash off dirt with gasoline and lubricate periodically without fail. (25) I CARBURETTOR ADJUSTMENT (26) 1 Completely screw in the air screw (drive in lightly) and then return 134 rotations 2. Gradually loosen the throttle stop screw and reduce the revolutions to 1,200 r.p.m. Find a position where the revolution is increased by slowly turning (loosening and tightening alternately) the air screw. If the revolution increases, loosen the throttle stop screw and adjust to 1,200 r.p.m. by finding (with the air screw) a position where the revolutions increase. When the throttle grip is opened slowly, the revalutions from idling to stabilized revolutions (1,200 r.p.m.) should be smooth; if not, turn the air screw 1/4 turn back and forth and screw in the throttle stop screw to adjust the revolutions to 1,200 r.p.m. (NOTES) 1. Make these adjustments when the engine is warm. 2. Engine malfunction at the time of acceleration or running at a high speed is due mostly to the ignition and valve systems: however, to consider this type of malfunction only from the standpoint of the carburettor adjustment is dangerous. Have the motorcycle checked at a service station or at our agency. 3. Compounds of tetraethyl lead and other impurities sometimes accumulate on the bottom of the float chamber. Unless these are removed, fuel supply stoppage and other malfunctions may occur. Have the entire carburettor cleaned at a service station once every 6-8 months. (27) (283 GREASING Grease prevents the wearing of frictioning parts, prolongs the motorcycle life and promotes smooth operation of the motorcycle. Be sure to check the parls periodically and grease wherever needed. Fig. 26 The parts requiring grease are shown in Figs. 25~28. For the protection of your motorcycle, be sure to grease these points periodically, Fig.' 27 Fig. 28 HB CHANGING ENGINE OIL i. (30) After warm-up, remove the drain bolt on the bottom of the engine and drain the oil completely. (Fig. 29) After draining, replace the drain bolt and tighten it firmly. Pour in 0.9 ¢ (0.238 gal) of fresh oil through the oil hole. Insert the gauge rod attached to the cap to check the oil level: if it reaches the slot on the gauge rod (without the cap screwed in), a , ao the amor (NOTE) Fig. 29 Fig. 30 unt is 0.98 (0.24 gal). (Fig. 30) The engine oil affects the life of motorcycle and its operation, so never use soiled oil. Always check and change the oil whenever necessary HM DUSTING OF AIR CLEANER 1. Detach the air filter cover (right side of motorcyclel, remove the screw to remove the air filter. (Fig. 31) 2. Tap the filter lightly to remove dust and then clean the inside thoroughly with compressed air or a brush. (NOTE) Oil or water on the filter paper hinders the cir filtering action; keep the filter paper clean and dry WM CLEANING OF OIL FILTER 1. Detach the clutch wire from the clutch lever and remove the clutch cover. 2. Remove the clutch outer cover. After taking out the filter plate, wash dirt and dust clear of the inside of the filter with petrol. (NOTE) Special care must be taken to see that dirt and dust do not get into the hole in the crankshaft while washing off dirt and dust. a eNO ei] et), CLUTCH ©) OUTER COs MM CLEANING OF FUEL STRAINER 1. Turn part a in the direction indicated by the arrow and detach the strainer cup. (Fig. 34) 2. Wash the dirt off the inside of the strainer cup; also wash the filter screen. (Fig. 35) HB DECARBONIZING OF SPARK PLUG (34) Ii If the plug electrode is smoky, wet or fouled with carbon, it "CLEARANCE GaucE & will not spark perfectly. Clean and adjust spark plugs periodi- cally. A spark plug cleaner is best for cleaning ; however, if not avail- Fig. 36 able, clean spark plugs with a needle or wire, wash them with gasoline and dry with clean, dry rags. Adjust the spark gap to 0.6~0.7 mm (0.24~0.28 in). (Fig. 36) Standard spark plugs used are NGK D6HW and Nippon Denso's X20F. (NOTES) 1. To attach a spark plug, screw it in by hand to the gasket, then tighten it further with a plug wrench. 2. Do not burn the electrode. WB OCHECKING OF BATTERY SOLUTION i. (NOTES) i 2. 3. The battery solution level must always be above the specified minimum level. When the level drops, pour distilled water until the level rises to the maximum level indicated. To pour distilled water, detoch the red covers at the upper side of the battery. Fill three tanks to identical levels as seen “DISTILLED WATER INLET from the side. A Ya B108-6 type, 6V-6AH is th 1 yan - | the standard battery. pee \ ic LU ee) hile Do not use diluted sulfuric acid. Do not obstruct the exhaust pipe. Semen When the solution decrease > is abnormally fast, check MP LG the charaing rate. WH ODECARBONIZING OF MUFFLER (36) 1. Remove the bolt and pull out the diffuser pipe. 2. Tap the diffuser pipe lightly to remove the carbon and wash it completely with cleansing oil or petrol. ‘DIFFUSER PIPE Fig. 39 I INSPECTION OF TIGHTENED PARTS Checking points are: @ Front and rear axle bolt. @ Upper and lower tightening bolts for the rear cushions @ Rear fork pivot bolt. © Attaching bolts for the handle bar. Front arm pivot bolt. Front cushion under bolt. Tightening bolts for the front brake torque arm ends. Gear box coupling nut for the speedometer cable. © © ©@® Spokes, front and rear ((Every 1,000 km (600 miles) travelling). Fig. 41 G7} REMOVING FRONT WHEEL HM ADJUSTMENT OF THROTTLE WIRE a 4 ieee 1. Place a stand underneath the engine to raise the front wheel off the ground, ire is adjusted with the adjusting bolt. The play of the throttle wire is a 2. Remove the adjusting nut and detach the brake wire. Tightened, the play increases 3. Remove 8 mm nut and separate the torque link and panel arm section. Loosened, the play decreases 4. Loosen two 8mm bolts, remove the axle nut, pull out the front axle and remove the wheel by rotating it in the forward direction. (Fig. 43) (NOTE) When the wheel is removed, be sure that the bearing inside the wheel hub is not dropped in dirt or injured in any way. Fig. 43 (39) (38) MB REMOVING REAR WHEEL C EION DA ~~ Portable Tools : ras 1. Draw out the latch clip, 8mm, remove nut and separate the torque link Spark plug wrench and panel arm section 23m m Box wrench Too! bag LSS 2. Remove the adjusting nut and detach the brake rod. Oe 3. Remove the axle nut, draw out the rear uxle and remove the wheel with the motorcycle body tilted. 17mm Box wrench Oni 10x14 Double end spanner A. ¢ i ; a) 3 qi 8mm Screw driver A — oy 6mm Screw driver B — e 6mm Screw driver C ea SR Smm Box wrench Grip Que =o Pliers 3mm Socket wrench Thickness gauge ee) Gy HONDA —— Wiring Diagram for Honda 90 Precautions in Handling | Mater top Maral ome eusy io | : 5 1. Perform daily and periodic inspection for protection of the motorcycle, to prolong its life and prevent trouble. a cow aed 512/08 ‘| tte a 2. Check important tightened parts daily for preventive maintenance. ne | 3. Before driving, run the engine at low speed for about two minutes; when ue the engine is cold, the oil does not circulate freely and the carburettor { | a 6 a id oes does not function smoothly. fg Sve ere A over : : ; , : | =

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