H Series Service Manual

Table of Contents     For reference only...no links in the TOC

Unit Conversions ....................... Chart 1 Chart 2

AC generator ......................... 22 23 101 103 120

Adjustment

Air screw ................................... 10 52
     Brake
                    Front ..................... 67 68 78
                    Rear............................. 67

Brake lamp switch
                    Front......................... 68 78
                    Rear............................. 67

Carburetor................................. 9 10 52

Chain ....................................... 63 94

Clutch.......................................... 12

Float........................................... 52

Fuel level...................................... 52

Idle....................................... 9 10 11

Ignition timing

H1 CDI.................................... 107
          Contact breaker ignition.................. 109
          Magneto CDI............................... 118

Jet needle................................... 48 49

Oil pump..................................... 11 12

Pilot screw..................................... 49

Point gap.................................. 107 109

Shock absorber............................... 91 92

Signal generator........................... 109 118

Starter lever................................... 11

Steering..................................... 90 91

Throttle

Cable ................................... 9 10
          Grip.................................... 11 83
          Stop screw ................................ 10

Air cleaner....................................... 13 14

Air pressure, tire .................................. 57

Alignment, wheel .............................. 55 61 94

Arm, swing..................................... 54 55 56

Axle

Runout.......................................... 60
     Torque ......................................... 61

Baffle tube...................................... 99 100

Balance, wheel.................................... 57 61

Bead protector....................................... 57

Bearings

Clutch.......................................... 30
     Connecting rod small end........................ 20
     Main............................................ 38
     Steering stem................................... 89

Big end, connecting rod ....................... 37 38 43

Boring............................................ 17 18

Brake lamp switch .......................... 67 68 74 78

Brake lining thickness............................... 65

Brakes

Disc........... 69 70 71 72 73 74 75 76 77 78 79 80
     Expansion.................. 61 62 63 64 65 66 67 68

Bushing clearance, swing arm......................... 55

Carburetors ............... 9 10 11 46 47 48 49 50 51 52

CDI

HI ............................ 108 109 110 111 112
     Magneto CDI................ 113 115 116 117 118 119

Chain, drive ............................... 23 61 94 95

Check valves .................................. 45 46 71

Cleaner, air...................................... 13 14

Clearance

Clutch housing/plate ........................... 30
     Connecting rod, big end ..................... 37 38
     Cylinder/piston.............................. 17 20
     Main bearings................................... 38
     Selector fork .................................. 41
     Swing arm bushing/sleeve........................ 55
     Transmission gears.............................. 41

Clutch................................ 12 27 28 29 30 31

Compression, cylinder ............................ 17 18

Connecting rods............................. 20 37 38 43

Conversion tables............................... 129 130

Crankcase ..................................... 34 35 36

Crankshaft..................................... 36 37 38

Cutaway, throttle valve .......................... 48 52

Cylinder.................................... 15 16 17 18

Cylinder head .............................. 15 16 17 18

Cylinder port

Measurements.................................... 15
     Timing ......................................... 15

Damper, steering ................................. 85 93

Diameter

Brake drum ..................................... 65
     Bushing, swing arm.............................. 55
     Cylinder........................................ 17
     Needle jet ..................................... 49
     Piston.......................................... 17
     Sleeve, swing arm .............................. 55
     Sprocket
               Engine................................ 23
               Rear.................................. 66

Disc brake.......... 69 70 71 72 73 74 75 76 77 78 79 80

Distributor................................ 24 25 26 108

Drive chain................................. 23 61 94 95

Drum, brake..................... 61 62 63 64 65 66 67 68

Drum, shift ............................. 32 33 34 39 40

Engine

Adjustments ............................ 9 10 11 12
     Components....................................... 5
     Left side ................................ 22 23 24
     Minor disassembly.............................. 5 6
     Mounting......................................... 9
     Removal.................................... 6 7 8 9
     Right side............................. 24 25 26 27
     Sprocket.................................. 22 23 24

Exhaust pipes ................................... 99 100

Expander ring ................................. 20 21 22

Float level ................................ 47 48 51 52

Float mechanism............................. 47 48 51 52

Foot rests........................................... 98

Fork, front.................. 83 84 85 86 87 88 89 90 91

Frame................................................ 53

Friction plates ......................... 27 28 29 30 31

Fuel tank...................................... 95 96 97

Fuel tap.................................... 95 96 97 98

Gap, spark plug ................................ 107 118

Gasoline tank.................................. 95 96 97

Gasoline tap ............................... 95 96 97 98

Gear, primary .................................... 31 32

Gear shift mechanism .................... 32 33 34 39 41

Generator

AC............................... 22 23 101 103 120
     Signal ......... 23 108 109 110 115 116 117 118 120

Handlebars .................................... 81 82 83

Head, cylinder ............................. 15 16 17 18

Honing............................................ 17 18

Hubs.............................61 62 63 64 65 66 67 69

Idle adjustment................................. 9 10 11

Ignition

HI CDI......................... 108 109 110 111 112
     Contact breaker........................ 105 106 107
     Magneto CDI ................113 115 116 117 118 119

Injectolube................................. 43 44 45 46

Jet

Main................................... 48 50 51 52
     Needle................................. 49 50 51 52
     Pilot.................................. 49 50 51 52

Jet needle .............................. 48 49 50 51 52

Kick stand........................................... 98

Kick starter ............................ 24 25 26 42 43

Length, spring

Brake shoe ..................................... 65
     Clutch.......................................... 30
     Front fork...................................... 89
     Master cylinder................................. 79

Level, float chamber fuel .................. 47 48 51 52

Lining thickness, brake.............................. 65

Lubrication ................................ 43 44 45 46

Needle Jet .............................. 48 49 50 51 52

Main jet.................................... 48 50 51 52

Mufflers......................................... 99 100

Oil, front fork ..................................... 89

Oil pump........................ 11 12 24 26 43 44 45 46

Oil tank.......................................... 95 97

Overheating................................... 15 80 124

Oversize pistons .................................... 18

Performance curves ................................. 3 4

Pin, piston ................................... 18 19 20

Pinion gears ........................................ 24

Piston......................................... 18 19 20

Piston pin..................................... 18 19 20

Piston rings ............................ 18 19 20 21 22

Pivot shaft

Nut torque...................................... 56
     Runout ......................................... 55

Plates, clutch .......................... 27 28 29 30 31

Play, connecting rod small end ...................... 20

Plug torque

Spark plug...................................... 18
     Oil drain plug.................................. 27

Plug, spark................................ 1 18 107 118

Port, cylinder

Measurements ................................... 15
     Timing.......................................... 15

Pressure, tire air .................................. 57

Primary gear ..................................... 31 32

Pump, oil....................... 11 12 24 26 43 44 45 46

Rectifier .................. 101 102 103 104 113 114 120

Regulator....................... 103 104 105 113 114 120

Rim, tire ........................................ 57 60

Rings, piston ........................... 18 19 20 21 22

Runout

Axle............................................ 60
     Crankshaft ..................................... 38
     Disc............................................ 80
     Pivot shaft .................................... 55
     Rim............................................. 60

Schematic diagrams ......... 131 132 133 134 135 136 137

Seat................................................. 99

Seizure, piston ..................................... 19

Selector fork clearance ............................. 41

Semiconductors.................................. 102 103

Shift mechanism ......................... 12 32 34 39 41

Shock absorbers

Front .................. 83 84 85 86 87 88 89 90 91
     Rear ..................................... 91 92 93

Signal generator .... 23 108 109 110 115 116 117 118 120

Small end, connecting rod ........................... 20

Spark plugs................................ 1 18 107 118

Specifications...................................... 1 2

Spoke size........................................... 57

Spring length

Brake shoe ..................................... 65
     Clutch.......................................... 30
     Front fork ..................................... 89
     Master cylinder ................................ 79

Sprocket

Engine.................................... 22 23 24
     Rear...................................... 62 65 66

Stands............................................... 98

Starter, kick ........................ 24 25 26 41 42 43

Steering damper .................................. 85 93

Steering stem................ 83 84 85 86 87 88 89 90 91

Swing arm...................................... 54 55 56

Switch, brake lamp ......................... 67 68 74 78

Tanks.......................................... 95 96 97

Thickness

Brake lining ................................... 65
     Friction plates................................. 30
     Disc ........................................... 80

Throttle valve ...................................... 50

Thyristor..................................... 94 96 103

Timing

Distributor..................................... 26
     Ignition
            HI CDI ................................. 107
            Contact breaker......................... 109
            Magneto CDI............................. 118
     Port (valve).................................... 15

Tires....................................... 56 57 59 60

Torque

Axle............................................ 61
     Cylinder head .................................. 17
     Crankcase ...................................... 36
     Disc brake parts................................ 72
     Swing arm shaft nut............................. 56
     Spark plug...................................... 18
     Transmission oil drain plug .................... 27

Torque table ....................................... 128

Transmission................................... 39 40 41

Tube, baffle .................................... 99 100

Tube (bead) protector ............................... 57

Tube, tire........................................ 59 60

Valves, check ................................. 45 46 71

Valve timing ........................................ 15

Ventilator........................................ 64 66

Voltage regulator .............. 103 104 105 113 114 120

Warp

Connecting rod ................................. 37
     Rim............................................. 60
     Swing arm....................................... 55
     Disc ........................................... 80

Weights, wheel balance .............................. 61

Wheel balance..................................... 57 61

Wheels................................ 56 57 58 59 60 61

Wiring diagrams ............ 131 132 133 134 135 136 137

Supplement

Electrical system (Hl-E)

CDI unit test.............................. 151 152
     Distributor test .......................... 150 151
     Dynamo test................................ 149 150
     Ignition circuit........................... 146 147
     Regulator test................................. 152

Engine: Detailed Maintenance

Ignition timing adjustment (Hl-E).......... 137 138
     Lubrication system (H2-B) ......... 138 139 140 141

Frame (H1-E, H2-B)

Front fork tubes .......... 141 142 143 144 145 146

Wiring diagram ................. 153 154 155 156 157 158