HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the scooter is in peak operating condition and the emis. sion levels are within the standards set by the U. S. Environmental Protection Agency and the California Air Resources Board. Perform- ing the first scheduled maintenance is very im portant. It helps compensate for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole scooter, while sections 4 through 16 describe parts of the scooter, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section Most sections start with an assembly or system illustration, service information and troubleshooting for the section, The sub- sequent pages give detailed procedures If you don’t know the source of the trouble, go to section 17, TROUBLESHOOTING. ENGINE CHASSIS CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON FINAL REDUCTION ALTERNATOR CRANKCASE/CRANKSHAFT FRAME COVERS ‘STEERING/FRONT WHEEL/BRAKE/ SUSPENSION REAR WHEEL/BRAKE/SUSPENSION ELECTRICAL EQUIPMENT WIRING DIAGRAMS TROUBLESHOOTING INDEXGENERAL SAFETY WW SERVICE RULES 14 MODEL IDENTIFICATION 12 SPECIFICATIONS: 1-3 GENERAL SAFETY Tahaled asbestos fibers have been found t0 cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake or clusch assemblies. In the United States, use an OSHA-approved vacuum cleaner or alternate method ap- proved by OSHA-designed 10 minimize the hazard caused by airborn asbestos fibers. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carhon monoxide gus that can ‘cause loss of consciousness and may lead to death. GENERAL INFORMATION TORQUE VALUES 15 TOOLS 17 gl CABLE & HARNESS ROUTING 19 EMISSION CONTROL SYSTEM 1-13 The battery electrolyte contains sulfuric acid. Protect your eves, skin and clothing. In case of contact, flush thoroughly with water and cail a doctor if electrolyte gets in your exes. The battery generates hydrogen gas which can be highly ex) sive. Do not smoke or allow flames or sparks near the rv, especially while charging it, ‘CAUTION Used engine vil may cause skin cancer if repeatedly left i: tact with the skin for protonged periods. Although this isu likely unless you handle used oil on an daily basis, it i© ac able (0 thoroughly wash your hands with soap and water as isoline is extremely flammable and is explosive under certain soon as possible after handling used oll, conditions. Do not smoke or allow flames or sparks in your working area. SERVICE RULES 1, Use genuine Honda or Honda-recommended parts and tubricants or their equivalents. Parts that do not meet Honda's design specifications may damage the scooter. 2. Use the special tools designed for this product. 3, Use only metric tools when servicing this scooter. Metric bolts, nuts, and screws are not interchangeable with English fas teners. The use of incorrect tools and fasteners may damage the scooter. 4. Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling, 5. When tightening boits or nuts, begin with targer-diameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly 7. After reassembly, check all parts for proper installation and operation. 8, Route all electrical wires as shown on pages 1-8 thru. 1-12, Cable & Harness Routing, and away'from sharp edges and ‘areas when they might be pinched between moving parts. 1-1GENERAL INFORMATION MODEL IDENTIFICATION "85 SHOWN; AFTER ‘85 Similar The engine serial number is stamped on bottom of the left crankcase. ‘The frame serial number is stamped on the left side of the The VIN (Vehicle Identification Number) is attached to the frame body frame tube forward of the front cover 1) COLOR LABEL