Honda CH80 Manuals

Manuals and User Guides for Honda CH80. We have 1 Honda CH80 manual available for free PDF download: Service Manual

Honda CH80 Service Manual (186 pages)

Brand: Honda | Category: Scooter | Size: 41.45 MB

How to Use this Manual
1
Contents
1
General Information
2
Service Rules
2
Model Identification
3
Specification
4
Torque Values
6
Engine
6
Frame
6
Standard Torque Values
7
Tools
8
Special
8
Common
8
Cable & Harness Routing
9
Emission Control System
14
Lubrication
16
Service Information
17
Engine Oil
18
Oil Level
18
Oil Change
18
Engine Oil Filter Screen Cleaning
19
Oil Pump Removal
19
Oil Pump Disassembly
20
Oil Pump Inspection
21
Oil Pump Assembly
22
Oil Pump Installation
22
Transmission Oil
23
Oil Level Check
23
Lubrication Points
24
Control Cables
24
Maintenance
25
Maintenance Schedule
26
Fuel Lines
28
Fuel Filter
28
Throttle Operation
28
Air Cleaner
29
Crankcase Breather
29
Spark Plug
30
Valve Clearance
30
Carburetor Idle Speed
31
Evaporative Emission Control System
31
Ignition Timing
31
Belt Case/Air Cleaner
32
Brake Shoe
32
Brake System
33
Brake Light Switch
33
Headlight Aim
34
Clutch Shoe Inspection
34
Suspension
34
Nuts, Bolts, Fasteners
35
Wheel/Tires
35
Recommended Tire and Pressure
35
Steering Head Bearings
35
Fuel System
36
Carburetor Removal
39
Starting Enrichment Thermal Valve
39
Inspection
39
Removal
40
Starting Enrichment Thermal Valve Inspection
40
Installation
40
Vacuum Chamber
41
Disassembly
41
Vacuum Piston Inspection
42
Assembly
42
Float Chamber
43
Float/Float Valve Inspection
45
Float Chamber Assembly
45
Float Level Inspection
45
Carburetor Installation
46
Air Screw
46
Adjustment
46
High Altitude Adjustment
47
Automatic Fuel Valve
48
Fuel Tank
48
Fuel Unit Removal
48
Fuel Unit Installation
48
Air Cleaner Housing
51
Crankcase Breather Separator Removal
52
Evaporative Emission Control System (California Model Only)
53
Evap Canister Removal
53
Evap Canister Installation
53
Engine Removal/Installation
54
Engine Removal
56
Engine Installation
58
Cylinder Head/Valves
59
Camshaft
62
Rocket Arm/Rocket Arm Shaft
64
Camshaft Holder Assembly
65
Cylinder Hear Removal
67
Cylinder Hear Disassembly
68
Valve Spring Free Length
68
Valve/Valve Guide
69
Valve Guide Replacement
70
Valve Seat Inspection and Refacing
70
Valve Seat Grinding
71
Cylinder Head Assembly
73
Cylinder Head Installation
74
Cylinder Compression
74
Cylinder/Piston
75
Cylinder Removal
77
Piston Removal
78
Piston/Piston Ring Inspection
78
Piston Ring Installation
80
Piston Installation
81
Cylinder Installation
81
Drive Pulley/Clutch/Driven Pulley
83
Drive Belt
86
Drive Pulley
87
Movable Drive Face Disassembly
88
Movable Drive Face Inspection
89
Movable Drive Face Assembly
90
Drive Pulley Installation
90
Clutch/Driven Pulley
91
Clutch Outer Inspection
91
Driven Pulley Disassembly
92
Driven Face Spring Inspection
93
Clutch Shoe Replacement
93
Driven Face Disassembly
94
Driven Face/Movable Driven Face Inspection
94
Driven Face Bearing Replacement
95
Driven Pulley Assembly
96
Starter Gear Removal
97
Starter Installation
99
Final Reduction
101
Final Reduction Disassembly
103
Gear Case Cover Bearing Replacement
105
Left Crankcase Bearing Replacement
106
Final Reduction Assembly
107
Alternator
109
Alternator Removal
111
Alternator Installation
112
Crankcase/Crankshaft
114
Crankcase Separation
116
Cam Chain Tensioner Inspection
117
Crankshaft
118
Bearing Inspection
119
Crankcase Assembly
119
Frame Covers
121
Left/Right Side Cover Removal
123
Front Turn Signal Base Removal
123
Trunk/Leg Shield Removal
124
Frame Cover Installation
125
Steering/Front Wheel/Brake/Suspension
126
Headlight
129
Removal/Installation
129
Disassembly/Assembly
129
Turn Signal Light Replacement
130
Instruments
130
Bulb Replacement
130
Instrument Assembly/Installation
132
Handlebar
133
Front Wheel
136
Front Brake
140
Pivot Arm Removal
144
Shock Absorber Removal
145
Front Shock Absorber Installation
146
Fork
146
Front Fork Removal
147
Front Fender Removal
147
Ball Race Replacement
148
Fork Installation
148
Rear Wheel/Brake/Suspension
150
Rear Wheel Removal
152
Rear Wheel Inspection
152
Rear Wheel Installation
152
Rear Brake Drum Inspection
153
Lining Inspection
154
Rear Suspension
155
Spring Inspection
156
Electrical Equipment
158
Battery
161
Charging
161
Charging System
162
Charging Circuit
162
Leak Test
162
Charging Voltage Inspection
162
Regulator/Rectifier
163
Alternator Inspection
163
Voltage Inspection
163
Ignition System Circuit
164
Ignition Coil Inspection
164
Ignition Control Module
165
Exciter Coil Inspection
165
Ignition Pulse Generator Inspection
165
Starting System
166
Starting Circuit
166
Starting Relay Inspection
166
Starter Motor
166
Ignition Switches
168
Front/Rear Brake Light Switch
169
Fuel Unit Inspection
169
Fuel Gauge Inspection
169
Horn
169
Resistor
170
Taillight/Rear Turn Signal Light
170
Wiring Diagrams '85
171
Wiring Diagrams '86
172
Wiring Diagrams after '86
173
Troubleshooting
175
Engine Does Not Start or Is Hard to Start
175
Engine Lacks Power
176
Poor Performance at Low and Idle Speeds
177
Poor Performance at High Speed
177
Engine Noise
178
Clutch, Drive and Driven Pulleys
178
Handling
179
Poor Suspension Performance
179
Poor Brake Performance
179
Fuel Gauge
180
Pointer Does Not Register Correctly (Ignition Switch On)
180
Pointer Fluctuates or Swings (Ignition Switch On)
180
Starter Motor will Not Turn
181
Starter Motor Turns Slowly
181
Starter Motor Won't Stop Turning
181
Under Charge/Over Charge Battery
182
No Spark at Plug
183
Index
184

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