Honda AX-1 Manuals

Manuals and User Guides for Honda AX-1. We have 1 Honda AX-1 manual available for free PDF download: Shop Manual

Honda AX-1 Shop Manual (270 pages)

Brand: Honda | Category: Motorcycle | Size: 33.4 MB

Important Safety Notice
1
Contents
2
General Information
3
General Safety
3
Service Rules
3
Model Identification
4
Frame/Engine Serial Number
4
Carburetor Identification Number
4
Color Label
4
Specifications
5
Torque Values
7
Tools
9
Cable & Harness Routing
11
Lubrication
15
Lubrication Service Information
17
Lubrication Specifications
17
Lubrication Torque Value
17
Lubrication Troubleshooting
17
Engine Oil Level Check
18
Engine Oil & Filter Change
18
Engine Oil Strainer Cleaning
19
Oil Pump Removal
19
Oil Pump Inspection
20
Oil Pump Assembly
21
Oil Pump Installation
21
Lubrication Points
23
Control Cable Lubrication
23
Maintenance Service Information
24
Maintenance Schedule
26
Fuel Line
27
Fuel Strainer Screen
27
Throttle Operation
27
Carburetor Choke
28
Air Cleaner
28
Crankcase Breather
29
Recommended Spark Plugs
29
Valve Clearance Inspection
29
Shim Selection Chart
31
Carburetor Idle Speed
32
Radiator Coolant
32
Cooling System
33
Cylinder Compression
33
Drive Chain Slack Inspection
34
Drive Chain Adjustment
34
Drive Chain Slider
35
Brake Fluid
35
Brake Shoe/Pad Wear
36
Brake System
36
Brake Shoe Inspection
36
Brake Pedal Height/Free Play
36
Brake Light Switch
37
Headlight Aim Adjustment
37
Clutch System
37
Clutch Lever Free Play
37
Side Stand
38
Front/Rear Suspension
39
Nuts, Bolts, Fasteners
39
Wheels/Tires
40
Tire Pressure
40
Steering Head Bearings
41
Fuel System
42
Fuel System Specifications
44
Fuel System Service Information
44
Fuel System Troubleshooting
45
Fuel System Torque Value
45
Fuel System Tools
45
Fuel Tank Removal
46
Fuel Tank Installation
46
Air Cleaner Case Removal/Installation
47
Carburetor Removal
48
Carburetor Disassembly
49
Carburetor Assembly
52
Carburetor Installation
57
Pilot Screw Adjustment
57
Accelerator Pump
58
Cooling System Service Information
61
Cooling System Specifications
61
Cooling System Torque Values
61
Cooling System Troubleshooting
62
Cooling System Tools
62
System Testing
63
Coolant
63
Radiator Cap/System Inspection
63
Coolant Replacement
64
Thermostat Removal
64
Thermostat Inspection
64
Thermostat Installation
65
Radiator/Cooling Fan Removal
65
Radiator/Fan Inspection
66
Water Pump Mechanical Seal Inspection
67
Water Pump Mechanical Seal Replacement
67
Reserve Tank
69
Engine Removal/Installation
70
Clutch
82
Clutch Service Information
84
Clutch Specifications
84
Clutch Troubleshooting
85
Clutch Torque Values
85
Clutch Tools
85
Right Crankcase Cover Removal
86
Clutch Lifter Removal/Inspection
86
Clutch Removal
87
Clutch Inspection
88
Clutch Installation
89
Primary Drive Gear
91
Clutch Lifter Assembly
91
Crankshaft Oil Seal
91
Primary Drive Gear Removal
91
Primary Drive Gear Installation
92
Gearshift Linkage Removal/Installation
92
Right Crankcase Cover Installation
93
Alternator/Starter Clutch
114
Alternator/Starter Clutch Service Information
116
Alternator/Starter Clutch Torque Values
116
Alternator/Starter Clutch Tools
116
Left Crankcase Cover Removal
117
Flywheel Removal
118
Starter Clutch Removal
119
Alternator Replacement
119
Starter Clutch Inspection/Disassembly
119
Starter Clutch/Flywheel Installation
121
Left Crankcase Cover Installation
122
Cylinder Head/Valve
124
Cylinder Head/Valve Service Information
126
Cylinder Head/Valve Specifications
126
Cylinder Head/Valve Troubleshooting
127
Cylinder Head/Valve Torque Values
127
Cylinder Head/Valve Tools
127
Cylinder Head Cover Removal
128
Camshaft/Cam Chain Tensioner Removal
128
Cylinder Head Removal
131
Cylinder Head Disassembly
132
Valve Guide Replacement
135
Valve Seat Inspection/Refacing
136
Valve Seat Cutters
136
Valve Seat Refacing
137
Cylinder Head Assembly
138
Cylinder Head Installation
140
Camshaft/Cam Chain Tensioner Installation
141
Cylinder Head Cover Installation
144
Cylinder/Piston
145
Cylinder/Piston Service Information
147
Cylinder/Piston Troubleshooting
147
Cylinder/Piston Specifications
147
Cylinder/Piston Torque Value
147
Cylinder Removal/Inspection
148
Piston Removal/Inspection
149
Piston/Piston Ring Inspection
149
Piston Ring Installation
151
Piston/Cylinder Installation
152
Crankshaft/Transmission
153
Crankshaft/Transmission Service Information
155
Crankshaft/Transmission Specifications
155
Crankshaft/Transmission Torque Values
156
Crankshaft/Transmission Tools
156
Crankshaft/Transmission Troubleshooting
157
Crankcase Separation
158
Transmission Removal
159
Transmission Disassembly
159
Transmission Inspection
160
Transmission Assembly
162
Crankshaft/Balancer Removal
163
Balancer Disassembly/Assembly
163
Crankshaft Inspection
164
Crankcase Bearings Replacement
165
Crankcase Assembly
167
Front Wheel/Suspension/Steering
170
Front Wheel/Suspension/Steering Service Information
172
Front Wheel/Suspension/Steering Specifications
172
Front Wheel/Suspension/Steering Torque Values
172
Front Wheel/Suspension/Steering Troubleshooting
173
Front Wheel/Suspension/Steering Tools
173
Handlebar Removal
174
Handlebar Installation
175
Front Wheel Removal
177
Front Wheel Inspection
177
Front Wheel Disassembly
178
Front Wheel Bearing Replacement
178
Front Wheel Assembly
179
Front Wheel Installation
181
Fork Removal
181
Fork Disassembly
182
Fork Inspection
184
Fork Assembly
185
Fork Installation
188
Steering Stem Removal
189
Steering Stem Bearing Replacement
190
Steering Stem Installation
192
Rear Wheel/Brake/Suspension
195
Rear Wheel/Brake/Suspension Service Information
197
Rear Wheel/Brake/Suspension Specifications
197
Rear Wheel/Brake/Suspension Torque Values
197
Rear Wheel/Brake/Suspension Troubleshooting
198
Rear Wheel/Brake/Suspension Tools
198
Rear Wheel Removal
199
Rear Wheel Inspection
199
Rear Wheel Bearing Replacement
200
Rear Brake Removal/Inspection
205
Rear Brake Disassembly
205
Rear Brake Assembly
206
Brake Pedal Removal/Installation
207
Shock Absorber
209
Shock Absorber Disassembly
210
Shock Absorber Inspection
210
Shock Absorber Disposal Procedure
211
Shock Absorber Assembly
211
Shock Absorber Installation
212
Shock Linkage Removal
213
Shock Linkage Bearing Replacement
213
Shock Linkage Installation
214
Swingarm Removal
215
Swingarm Inspection
216
Swingarm Pivot Bearing Replacement
216
Swingarm Installation
217
Hydraulic Brake Service Information
220
Hydraulic Brake Specifications
220
Hydraulic Brake Torque Values
220
Hydraulic Brake Tool
220
Hydraulic Brake Troubleshooting
221
Brake Fluid Replacement/Bleeding
222
Brake Fluid Draining
222
Brake Fluid Filling/Bleeding
222
Brake Pad Replacement
223
Disc Thickness
224
Disc Warpage
224
Master Cylinder Disassembly
225
Master Cylinder Inspection
226
Master Cylinder Assembly
226
Brake Caliper Disassembly
227
Brake Caliper Inspection
228
Brake Caliper Assembly
228
Fairing/Exhaust System
230
Exhaust Pipe/Muffler Removal/Installation
230
Seat & Fairings Removal/Installation
231
Rear Carrier Removal/Installation
232
Battery/Charging System Service Information
234
Battery Charging
234
Battery Charging/Testing Equipment
234
Battery/Charging System Specifications
235
Battery/Charging System Tools
235
Battery/Charging System Troubleshooting
236
Battery Removal
237
Urging System
238
Leakage Current Inspection
238
Regulated Voltage Inspection
238
Alternator Inspection
238
Ignition System
240
Ignition System Service Information
242
Ignition System Specification
242
Ignition System Tools
242
Ignition System Troubleshooting
243
Ignition Coil Removal
244
Ignition Coil Inspection
244
Ignition Coil Installation
244
CDI Unit Inspection
245
Pulse Generator Inspection
246
Ignition Timing
246
Electric Starter
247
Electric Starter Service Information
249
Electric Starter Specifications
249
Electric Starter Troubleshooting
250
Starter Motor Removal
251
Starter Motor Disassembly
251
Starter Motor Inspection
251
Starter Motor Assembly
252
Starter Motor Installation
254
Starter Relay Switch Inspection
254
Lights/Meters/Switches Service Information
255
Lights/Meters/Switches Torque Values
255
Lights/Meters/Switches Troubleshooting
256
Temperature Warning System
256
Headlight Bulb Replacement
257
Headlight Case Removal
257
Instrument Case Bulb Replacement
258
Instrument Case Meter Replacement
258
Turn Signal Light Bulb Replacement
259
Tail Light/License Light Bulb Replacement
259
Neutral Switch
259
Front Brake Light Switch
260
Rear Brake Light Switch
260
Clutch Switch
260
Handlebar Switch
260
Left Handlebar Switch
261
Horn
261
Ignition Switch Inspection
262
Ignition Switch Removal
262
Thermostatic Switch
263
Temperature Sensor
263
Wiring Diagram
265
Troubleshooting
266
Engine Does Not Start or Is Hard to Start
266
Engine Lacks Power
267
Poor Performance at Low and Idle Speeds
268
Poor Performance at High Speed
269

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Honda AX-1 Shop Manual (270 pages)

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