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And by having access to our ebooks online or by storing it on your computer, you have convenient answers with 1980 Honda Cr125 Repair Manualsuzuki Df90a Outboard Service Manual. To get started finding 1980 Honda Cr125 Repair Manualsuzuki Df90a Outboard Service Manual, you are right to find our website which has a comprehensive collection of manuals listed. Our library is the biggest of these that have literally hundreds of thousands of different products represented. I get my most wanted eBook Many thanks If there is a survey it only takes 5 minutes, try any survey which works for you. Is this your domain?Disclaimer: Sedo maintains no relationship with third party advertisers. Reference to any specific service or trade mark is not controlled by Sedo nor does it constitute or imply its association, endorsement or recommendation. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting, Steering, Seats, Clutch, Suspension, Locks, Brakes, Lubrication, Electrical, Frame, Fuel System, Exhaust, Battery, Wiring Diagram etc. Something went wrong. Get what you love for less.User Agreement, Privacy, Cookies and AdChoice Norton Secured - powered by Verisign.
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If handle turning is uneven and bending, stuck, or the handle can be operated in vertical direction, then adjust the handle top bearing by adjusting the steering nut. Check Caution Park the scooter on flat ground with its main stand. Remove the oil level check bolt, and check if the oil level is placed on the hole of check bolt. Driver Belt Remove left crankcase cover. Check if the belt is crack or worn out. Replace the belt if necessary. Idle speed check and adjustment have to be done after engine is being warn up. Move the headlight for adjustment its light beam. Tighten the headlight mounting bolt after adjusted. Caution Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting for safety distance. If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should be conducted air-bleeding operation. Remove the luggage box and seat. Loosen the mounting nut of the oil pump control cable, and remove the control cable. Remove the luggage box and seat. Battery Remove the oil input tube from oil pump, and then drain oil to a clean container. Oil tube Remove the oil level switch wire of the oil Blot. Crankcase Crankshaft Related bolts tightening torque for removal of engine: Engine hanger bolt 5.0kgf-m Engine bracket bolt 6.0kgf-m Rear shock absorber upper mounting bolts 4.0kgf-m Rear shock absorber lower mounting bolts 2.7kgf-m. Remove the spark plug cap from the spark plug section. Remove the fuel output and the vacuum tubes Oil control cable Oil tube from fuel pump. Remove the oil control cable from oil pump. Brake cable Remove air cleaner mounting bolts. (2 bolts) Mounting bolt Support the engine and then remove shock Shock absorber lower absorber lower mounting bolt.Engine mounting bolt Engine installation Install in the reverse order of removal procedures. Torque value: Engine hanger bolt: 5.0kgf-m Rear shock absorber upper mounting bolts:.
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It should clean the engine to prevent dirt from entering into cylinder and crankcase before removal. Remove all washes from the interfaces of cylinder head, cylinder and crankcase. Remove spark plug cap. Remove fan cover. Remove engine shield. Engine shield Remove two connection nuts of the exhaust pipe. Tightening bolt x 2 Remove exhaust muffle mounting bolt, and then remove the exhaust pipe. Service limit: 0.10 mm Tightening bolts Cylinder Head Installation Replace the cylinder head gasket with new one, and place the cylinder head onto cylinder. Caution Do not have pry out operation between cylinder and crankcase. Or let radiation fan be knocked seriously. Piston Removal Place a clean rag onto crankshaft to cover the piston. Service limit: 0.10 mm In “X” and “Y” direction, measure the cylinder for worn out as the three levels shown in the figure. With the max. Service limit: 0.40 mm Caution With the piston, push each piston ring into cylinder correctly. Connecting Rod Inspection Install bearing and piston pin onto connecting rod small end, and then check its clearance. Please refer to Chapter 15 for the relative alternator inspection. Torque value: Flywheel 3.8kgf-m Tool General tool Rotor puller Universal holder Coil resistance value for the A.C. Remove two bolts and then take out cooling fan cover. Bolt Remove four bolts, and then take out the cooling fan. Cooling fan Hold flywheel with universal holder. Universal holder Support the flywheel and the remove the 10 mm nut on the flywheel. Remove the pulse generator and alternator four (4) bolts, and then take out the alternator assembly. Caution Care to be taken for not damaging the alternator coil. Remove air cleaner. Remove kick start arm. Remove left crankcase cover. Kick start arm Return spring Disassembly of Kick Starter Remove snap clip and thrust washer from left crankcase cover. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary.
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Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle. Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage Universal holder reduction gear system. Torque value: 3.8kgf-m Universal holder Movable Drive Face. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable face. Movable drive face Weight roller Inspection The weight roller is to press movable driven face. Measure the outer diameter of drive face boss, and replace it if it exceed service limit. Service limit: 19.98 mm Measure the inner diameter of drive face, and replace it if it exceed service limit. Crankshaft Drive Face Installation Drive belt Press down Press drive belt into pulley groove, and then pull the belt on to crank shaft. Install drive face, washer and nut. Caution Do not press the compressor too much. Replace it if exceeds service limit. Service limit: 2.0 mm Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 92.7 mm Free length Driven pulley. Caution Some of models are equipped with one mounting plate instead of 3 snap clips. Check if spring is damage or insufficient Snap clip elasticity. Snap clip Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Caution Clip If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. Apply with specified grease to lubricate the inside of sliding pulley. O-ring Specified grease Sliding pulley Install sliding pulley onto driven pulley. Remove rear wheel. Remove gearbox cover mounting bolts from the clutch side and then remove the cover from the rear wheel side. Install gearbox cover. Install driven pulley, drive belt, and left crankcase side cover.
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Bolts Install the crankcase puller onto the right crankcase with two (2) bolts, 6mm, as the Crankcase puller diagram shown. Disassemble the right crankcase. Right crankcase Crankshaft Removal Crankcase puller As the diagram show with 3 special bolts to install the crankcase puller onto the left crankcase. Service limit: 0.60 mm Measure the radial clearance of connecting rod big end at X-Y directions as diagram show. Service limit: 0.04 mm Place the crankshaft on a V-block, measure run-out points A and B of the crankshaft with dial gauge. Then, check for damage or other foreign materials attached. Install new bearing into right crankcase. Caution All rotation and sliding surfaces have to be applied with clean engine oil. Screw the right crankshaft puller onto crankshaft. Turn the puller in C.W. Idle speed adjustment.FUEL SYSTEM Carburetor Throttle Valve upper part Removal Remove the body cover. Remove the carburetor upper part, throttle valve spring and sealed cap. Remove the throttle valve cable from the throttle valve. Remove needle clamp and fuel needle. Oil hose Inspection Throttle valve spring. FUEL SYSTEM Carburetor Remove Remove the body cover. Disconnect the auto by-starter connector. Auto by-starter Loosen draining screw and then drain out fuel Carburetor Fuel hose upper part inside the carburetor. Loosen carburetor upper part and remove Bolt carburetor upper part. FUEL SYSTEM Remove carburetor, and allow it to cool off for 30 minutes. Connect fuel rich circuit with a hose and pump compressed air to the hose. Air should flow into fuel rich circuit. Replace the auto by-starter if the circuit clogged. Connect battery to starter’s connectors and wait for several minutes. Remove the float pin and then remove float and float valve. Check the valve seat for worn out or damage. Check float for bend and if fuel inside the float. Before removing both the throttle valve stopper Float cap and air screws, record their original turns for.
FUEL SYSTEM Float Level Inspection Measure float fuel level to have the upper end of float just contact with the float. Float fuel level: 8.8 mm Carefully bend the float arm for adjustment. Check the float operation and the install it. Carburetor Carburetor Installation Fuel hose. FUEL SYSTEM Inspection Reed valve Check the reed valve for damage and its reed Reed stopper strength. Check the reed valve seat for crack, damage and the clearance between the seat and the valve. Replace reed valve if necessary. Caution Do not bend the reed valve stopper. Loosen connection hose clamp. Remove 2 bolts and then remove the air cleaner outer case. Install in the reverse order of removal procedures. FUEL SYSTEM Notes: 10-10. BRAKE SYSTEM Front Drum Brake System 0.55kgf-m 2.5kgf-m 6.0kgf-m 11-2. BRAKE SYSTEM Rear Drum Brake System 2.5kgf-m 11.0kgf-m 0.55kgf-m 11-3. BRAKE SYSTEM Maintenance Information Precautions in Operation Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. BRAKE SYSTEM Hydraulic Disc Brake Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Lower level Cap plate Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir Diaphragm becomes horizontal, then remove the brake fluid Upper level. Caution Do not release the brake lever before the drain valve is closed. BRAKE SYSTEM Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel. BRAKE SYSTEM Master Cylinder Inspection Cylinder gauge Check the master cylinder for damage or scratch. Replace it if necessary.
Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. BRAKE SYSTEM Install the rubber pad into the groove correctly. Master cylinder Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. Brake lamp switch Connect brake hoses with 2 new washers. BRAKE SYSTEM Drum Brake To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts. BRAKE SYSTEM Installation Bolt Apply with a thin coat of grease to the brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam and the anchor pin. Screws Slide the side cover backward so that their hooks are out of slots. Take out the side cover end part and then remove the cover. BODY COVER Luggage Box Removal: Lift up seat cushion. Remove luggage box mounting screws (1 screw). Remove luggage box bolts (4 bolts) Remove oil tank cap and oil guide rubber. Hold the luggage box in both front and rear sides by two hands, and then lift up Bolts the box to remove it. BODY COVER Body Cover Bolts Removal: Remove 3 bolts from rear carrier, and then remove rear carrier. Remove the luggage box. Remove 4 screws from the two side cover, and then remove the side cover. Screws Remove 4 screws from the both sides. BODY COVER Remove 1 screw from the front side. Screw Remove the body cover. Installation: Install in reverse order of removal procedures. 12-7. BODY COVER Front Cover Removal: Remove 2 screws from the inner cover and front cover. Screws Remove 1 screw from the front cover. Screws Push the front guard up and then remove Installation Install in reverse order of removal procedures.
Remove 4 screws from the front inner box. Screw Remove 2 screws from the front upper part of the front spoiler and the front inner box. BODY COVER Front Inner Box Bolts Removal: Remove the front cover. Remove the front under spoiler. Remove 2 bolts from the floor panel. Remove 5 screws of the fuel filling cap. Screws Remove hook and 1 screw.Remove 4 plugs of the floor panel. 4 plugs and 4 Bolts Remove the floor panel. (4 bolts) Installation: Install in reverse order of removal procedures. BODY COVER Steering Handle Cover Screws Removal: Remove 1 screw under front light. Screw 3 Screws Remove 3 screws from the handle rear cover. Remove handle front cover. Remove 2 inner screws. Disconnect each switch connectors. Remove speedometer cable. BODY COVER Under Cover Removal: Remove the right and left side cover. Remove 2 bolts from the under cover. Remove under cover. 2 bolts 2 bolts Installation: Install in reverse order of removal procedures. 12-13. BODY COVER Note: 12-14. Remove throttle grip after mounting screw removed. Remove master cylinder (disc brake) after 2 bolts removed. Remove rear brake lever bracket after mounting bolt removed. Install the mounting seat. Tighten the upper part bolt, and then tighten lower bolt. Install all components in reverse order of removal procedures. Service limit: 0.20 mm Wheel axle Place the wheel on to a rotation seat, and turn Free play the wheel to check its bearing free play. Drive the left bearing and install the dist. collar. Bolts Install the right bearing. Caution Carefully install the bearing in correct and evenly. Stopper Caution Contaminated brake lining will reduce brake. Take out the hose from hose clamp. Bolts Remove the hose clamp mounting bolt and the clamp. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to Top cone race prevent from missing. Torque value: 1.5kgf-m Install in reverse order of removal procedures. Top cone race 13-10.
Bolts Remove rear wheel shaft nut and then remove the rear wheel. Shaft nut Inspection As the diagram shown, measure wheel rim. Tighten torque (bolt): 3.3kgf-m Tighten torque (nut): 1.2kgf-m Bolts Rear Shock Absorber Upper mounting bolt Removal Remove body cover. ELECTRICAL EQUIPMENT Maintenance Information Precautions in Operation When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing. ELECTRICAL EQUIPMENT Troubleshooting No voltage Intermittent power supply Battery discharged The connector of the charging system The cable disconnected becomes loose The fuse is blown Poor connection of the battery cable Improper operation of the main switch Poor connection or short-circuit of the discharging system Low voltage. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the scooter. Install the battery in reverse order of removal. Generator Current Leakage Inspection Ammeter Turn the main switch to OFF position, and Battery (-) terminal remove the negative cable terminal (-) from the battery. Ground circuit Connect an ammeter between the negative cable terminal and the battery negative terminal. ELECTRICAL EQUIPMENT Charging Voltage Inspection Caution Caution Before conducting the inspection, be sure To replace the old battery, use a new battery that the battery is fully charged. If with the same current and voltage.ELECTRICAL EQUIPMENT Headlight Voltage Inspection Front cover Connect a tachometer. Do not disconnect the headlight harness connector after engine started. Turn the headlight ON and to high beam position.ELECTRICAL EQUIPMENT Voltage regulator Voltage Regulator Inspection Check the each pins of connector on the voltage regulator.
Voltage regulator connector Inspection Probable cause Check voltage between battery terminal (red) and ground Blown fuse or poor main switch (green). ELECTRICAL EQUIPMENT Ignition Coil Inspection Remove body cover. Ignition coil Measure the primary coil resistance.Disconnect alternator connector.ELECTRICAL EQUIPMENT Starting System Starter relay Starter Relay Inspection Remove luggage box.Remove bolt and oil pump control cable. Disconnect starter motor harness connector. Starter motor Remove 2 bolts for separation starter motor and gasket. Remove 2 bolts for disassembly the starter motor. ELECTRICAL EQUIPMENT Oil Level Switch Troubleshooting Fuse Main switch If the oil level in oil tank is in specified level, but the oil level indicator still goes on. 1. Remove body cover. 2. Disconnect oil gauge wire, and turn the Indicator main switch to ON position. Disconnect fuel unit connector. Remove the fuel unit plastic cap. Turn the snap ring in CCW direction and then remove the fuel unit. Caution Do not bend the float arm. Remove main switch cover. Remove front inner box. Check continuity on each switch. The connected circles with a line are that they should be in continuity.ELECTRICAL EQUIPMENT Bulb Replacement Headlight Remove handle front cover. Remove bulb seat and replace the bulb. Install the all removed parts. Headlight Front winker light Remove front cover. Remove front winker light lens. Replace front winker light bulb. Install the all removed parts. ELECTRICAL DIAGRAM Notes: 16-2. Along with a speedometer, the front console has a fuel level gauge, and low oil (two-stroke oil) indicator. The front brake is a hydraulic disc, while the rear is a drum. The under-seat luggage compartment is suitable for helmet storage.You can help Wikipedia by expanding it. v t e By using this site, you agree to the Terms of Use and Privacy Policy. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Sym Excel 2 Service Manual.
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