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Manuals
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Honda Manuals
Motorcycle
S90
Shop manual
Honda S90 Shop Manual
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Table Of Contents
180
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Foreword
Contents
Features
Specifications
Product View S90
S90 Performance Curves
S90 Engine Performance
Product View CL 90
CL90 Performance Curves
CL90 (L) Engine Performance
Product View CD90
CD90 Performance Curves
CD90 Engine Performance
Product View C90
C90 Performance Curves
C90 Engine Performance
Product View CT90
Posi-Torque (F.no. 000001A and Subsequent)
CT90 Performance Curves
CT90 Engine Performance
Engine
Tools Necessary for Disassembly and Reassembly
Engine Assembly Diagram S90, CL90, CL90L
Engine Description
Power Transmission System/Diagram
Engine Removal
Removing the Drive Chain
Disconnecting the Clutch Cable
Engine Assembly
Removing the Inlet Pipe
Engine Installation
Setting Direction of Chain Clip
Adjusting the Chain
Cylinder Head Construction
Disassembly (Cylinder Head Block)
Squish Area
Removing the Starter Assembly/The Rotor
Removing the Contract Breaker Assembly
Removing the Point Brake/Camshaft
Disassembling the Valves
Cylinder Head Inspection and Repair
Checking/Repairing Cylinder Head Warpage
Checking the Valve Guide Diameter
Inspect Valve Guide
Valve Seat Contact Area
Reworking the Valve Seat
Valve Mechanism
Inspection of Valve Seating
Exhaust/Inlet Valve
Measuring Valve
Outer/Inner Valve Spring
Camshaft
Camshaft Construction
Cam Contour
Valve Timing
Cam Sprocket Root Diameter
Measuring Camshaft Height
Cylinder Head Reassembly
Rocker Arm/Arm Shaft
Assembling the Cylinder Head
Torquing Sequence of Cylinder Head
Cylinder Construction
Connecting the Cam Chain
Assembling the Camshaft
Installing the Point Base
Piston
Cylinder Offset
Cylinder Disassembly
Piston Ring
Removing the Cylinder
Cylinder Inspection
Removing the Piston Pin/Ring
Measuring the Cylinder Bore
Measuring Piston Skirt Diameter
Measuring the Piston Ring Side Clearance with a Thickness Gauge
Piston Ring Groove Dimensions Ring and Gap
Piston Ring and Gap
Cylinder Reassembly
Checking Piston Ring Contact
Assembling the Piston
Cam Chain Tensioner Construction/Detail Diagram
Cam Chain Tensioner Disassembly/Inspection/Reassembly
Removing the Cam Chain Tensioner
Removing the Tensioner Push Rod
Component Parts of the Cam Chain Tensioner
Construction and Operation of Clutch
Clutch Mechanism S90, CL90, CL90L, CD90
Clutch Mechanism C90, CT90
Clutch Disassembly
Component Parts of Clutch S90, CL90, CL90L, CD90
Removing the Clutch Outer Cover
Clutch Inspection
Removing the Clutch Assembly
Inspecting the Clutch Spring
Clutch Reassembly
Friction Disc and Clutch Plater
Clutch Outer and Drive Plate or Clutch Plate
Clutch Center Guide
Flow of Lubricating Oil
Oil Pump Construction/Disassembly
Gear/Trochold Oil Pump
Oil Pump Inspection/Reassembly
Gear/Trochoid Type
Gear Shift Mechanism Construction
Gear Shift Mechanism Disassembly/Inspection/Reassembly
Removing the Primary Driven Gear/The Gear Shift Spindle
Assembling Shift Drum Stopper
Crankshaft Construction/Disassembly/Inspection
Removing the Crankshaft
Measuring Crankshaft Alignment
Crankshaft Reassembly
Measuring Axial Clearance
Connecting Red
Reassembling the Crankcase
Transmission Construction
Raduction and Torque Ratios
Number of Gear Teeth, Indicate CD90
Low Gear
Second/Third/Top Gear
Neutral
Transmission Disassembly
Removing the Kick Starter Spindle
Removing the Gears
Removing the Gear Shift Fork
Transmission Inspection
Main/Counter Shaft to Gear Clearance
Shift Drum Groove
Transmission Reassembly
R Mark on the RH Gear Shift Lock
Checking the Gear Shift Cam
Crankcase Construction
Crankcase Disassembly/Inspection/Reassembly
Measuring the Crankcase Flatness with a Thickness Gauge
Kick Starter Mechanism
Kick Starter and Gear Interlock Mechanism
Posi-Torque Mechanism Construction
Power Transmission in the Posi-Torque Mechanism
Earlier Series Rear Sprocket (Prior to CT 90 F)
Low Speed Range
Posi-Torque Mechanism Disassembly
Carburetor Construction
High Speed Range
Cross-Sectional View of Carburetor
Main Jet
Choke
Air/Needle Jet
Carburetor Adjustment
Throttle Valve
Slow Jar
Air Screw
Adjustment for High/Intermediate Speed
Adjustment for Slow Speed
Measurement of Fuel in the Float Chamber
CT90 Model from Frame no 000001A
Carburetor Setting Table
Frame/Tools Necessary for Disassembly and Reassembly
Steering Handle Construction
Steering Handle Disassembly
Removing Brake Adjusting Nut
Disconnecting the Clutch Cable/Electrical Leads
Removing Throttle Cable from Carburetor
Removing Handle Pipe
Removing the Top Bridge Plate
Removing Brakw and Clutch Cables
Removing Throttle Cable
Steering Handle Inspection
Disconnect Spead and Brake Cable
Disconnect Electrical Leads (CT 90)
Removing Handle Setting Bolts
Steering Handle Reassembly
Removing Steering Handle (CD/CT90)
Assembling Throttle Grip
Clutch Cable Adjuster
Steering Stem Construction
Adjusting Front Brake
Steering Stem Section Diagram
Steering Stem Inspection/Reassembly
Steel Balls
Front Fork Construction
Front Cushion Sectional Diagram
Front Cushion
Front Fork Disassembly
Removing Headlight
Removing Front Fork Cover
Removing Front Wheel/Fender
Removing Front Fork Assembly
Component Parts of Front Fork
Removing Headlight Case
Disconnect Front Brake Torque Link
Removing Steering Head Top Thread
Front Cushion Assembly
Front Fork Inspection
Front Cushion Spring Table
Damping Capacity
Dimensions
Front Fork Reassembly
Fuel Tank Construction/Disassembly
Turn off the Fuel Cock
Removing Seat Setting Nuts
Fuel Tank Inspection
Removing Fuel Tank/Cock
Removing Tank Side Cover
Fuel Tank Reassembly
Frame Body Construction/Disassembly
Cross-Sectional View of Side Cover Installation
Removing Main Ignition Switch
Frame Body Inspection/Reassembly
Seat Construction/Disassembly
Removing Ball Races
Removing Seat Mounting Nut
Seat Inspection/Reassembly
Loose Upper Rear Cushion Cap Nuts
Removing Seat Hinge Pin
Tool Box
Brake System Construction/Disassembly
Rear Brake Operation
Removing Front Brake Lever
Removing Front Brake Cable/Shoes
Removing Brake Pedal and Stop Light Springs
Removing 3 MM Cottor Pin
Removing Rear Brake Rod from Rear Brake Arm
Muffler Construction/Disassembly/Inspection/Reassembly
Removing Rear Brake Cable
Removing Difuser Pipe
Air Cleaner Construction/Disassembly
Removing Air Cleaner Mounting Bolts
Air Cleaner Inspection/Reassembly
Removing/Cleaning Air Cleaner
Rear Fork and Cushion Damper Construction/Disassembly/Inspection/Reassembly
Rear Fork
Removing Rear Wheel/Fork
Removing Lower Bolt
Rear Fork Cushion Damper Construction
Sectional View of Rear Cushion
Rear Cushion
Rear Fork Cushion Damper Disassembly
Removing Rear Cushion
Disassembling Rear Cushion
Component Parts of Rear Cushion
Rear Fork Cushion Damper Inspection
Manual Operation of Rear Cushion
Front Wheel Construction
Component Parts of Front Wheel
Protective Covering
Front Wheel Disassembly
Removing Cables/Front Wheel
Separate Brake Panel
Front Wheel Inspection
Disassembling Brake Shoes
Removing Tire
Measuring Wheel Runout/Bend of Axle
Front Wheel Reassembly
Measuring Brake Lining
Seating Tube
Valve in Line
Rear Wheel Construction
Component Parts of Rear Wheel
Rear Wheel Disassembly
Disconnecting Drive Chain
Removing Rear Wheel/Sprocket
Rear Wheel Inspection
Component Parts of Final Driven Flange
Removing Final Driven Sprocket
Installing Rim Band
Rear Wheel Reassembly
Assembling Tire
Replacing Ball Bearing
Chain Clip Direction
Periodic Adjustment
Maintenance Inspection
Engine Adjustment
Measuring Cylinder Compression
Tappet Adjustment
Aligning to the T Timing Mark
Adjsuting Tappet Clearance
Breaker Point Servicing and Gap Adjustment
Locking the Adjusting Nut
Adjusting the Point Clearance
Ignition Timing Adjustment
Adjusting the Ignition Timing Advance
Spark Plug Adjustment/Clener
Measuring Spark Gap
Fuel Supply System
Fuel Strainer Clening
Oil Filter Screen Cleaning
Fuel Cock Lever
Air Cleaner Servicing
Removing Oil Filter Screen
Removing Air Cleaner
Cleaning Air Cleaner Element
Clutch Adjustment
Adjusting Clutch Cable
Carburetor Cleaning and Adjustment
Adjusting the Carburetor
Idling Speed Setting Table
Parts Not Requiring Periodic Oil Change or Lubrication
Engine Oil Change
Removing Drain Bolt
Oil Level Gauge
Drive Chain Adjustment
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This manual is also suitable for:
Cl90l
Cd90
C90
Ct90
Cl90
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