HONDA Z50R Z50A Motorcycle Service & Repair Manual (1970 to 1981) - !

- - ···'--n - - --- --- -- HONDA Z50A

This Manual Z50AK5 covers all Information on the models Z50A. Z50K2 . Z50AK3 . Z50AK4 and Z50AK5 Al tho end of the manual are hSled main modifications and servICing of the models mentioned above baSing upon the model ZSOAK2 for qUick reference Following lire t ho Inlllal numbers of each model at the time of change M odel Serial number ZSOA (baSIC model) Z50A- l 0000 I - Z50A- USA tYpe only _ - ZSOA USA I ype Z50AK2 USA type ZSOAK3 USA type Z50AK4 USA type Z50AK5 USA type 120087 l50A-l 20088 - l50A 270235 l50A 270236 - Z50A -l 00000 1 - Z50A - 3000001 - l50A- 500000 1 - Z50A General expol! Z50A-t 56932 - Z50A - type 298503 Z50AK2 General expon type l50' 298504 - HONDA MOTOR CO .. LTD . Service Publ ica t ions Office MAIN FEATURES OF Z50A SPECIFICATION TABLE SPECIAL TOOL SET .. ENGINE •• .... .. ..... 1 Engine Assembly Diagram 2 Engine Removal J Engine Inslallallon 4 lubrication 1011 Pump) 5 Cvllnder and Cvllnder Head . 6 PISlon and Piston Ring ... 7 ClUTCh 8 Crankshaft 9 TransmiSSion . 10 Gear Shift Mechanism .. .. 11 Kick Starter 1 2 Carbuletor . TROU8LE SHOOTlNG TABLE .. FRAME Front Suspension 2 Rear Brake .. FRAME (K3 , K4, K5) 1 Front Suspen s ion 2 FUnClIon 01 Rear Suspension J Cam ChalO Adjustment 4 Dftve Chain Malntenence ... 5 Fronl Whee l and Front Brake 6 Rear Whoel and Rear Brake 7 Steeling System 8 Front Shock Absorbers 9 Real Suspension 10 Frame BodV Seal. Tank and Air Cleaner . . 11 Electrical System TECHNICAL SERVICE DATA .. . TORQUE SPEC1FICATlONS .. . . 3 6 6 7 7 8 9 15 1 7 1 A 20 21 23 24 27 31 31 34 34 35 35 39 42 4& 47 48 50 52 64 66 WIRING DIAGRAM .. . .. .... ........... 57

MAIN FEATURES OF Z50A • The overhead cam design enables a qUIet operation and a constant tugh output over a broad speed range starting at slow speed With very hHle eftOf! · Incorooratlon of the 011 damper type cam chain tenslonar automallcally maintainS the proper tenSion and min i miZeS the chain nOise funher . challl adjustmont 15 unnecessary • Riding IS simplified by the use of the automatic clutch which IS Interconnected with the gear change pedal • Melal screen and centrifugal filter assures only clean 011 to lubricaTe the crilical moving pans • Foldable handle bar makes storing In narrow space poSSible · Frame IS welded pipe backbone deSign haVing a double channel welded 10 a single main pipe 10 reduce weight · To prellent spillage of fuel dUring transponal10n Iuel shul off votlo'es or provldeCJ In the filler cap and lhe carouretor GENERAL EXPORT TYPE

2 • t TYPE (F r om F. No . 120001) ) I • U.S.A. TYPE (From F. No . 270236) ) • • TYPE (From F. No. 5 000001 - t ---- ----____ r-- --

• , 3 SPECIFICATION TABLE .J " I USA p,- ,~vA': .. 1(4 III> GEN(RAl£l(PO AT USA TYPE USA TYPE lJ-romNo F 1000001, l50'" 1(2 TYPE !F.am NO f 120001 1111'1Om No F 7702311\ !~Iom No F 30000011 ____________ r-____________ -L ______________ '-r ____________ -t ________ ""'"~.m~No .. _"_'S"O"O"O,O,O",'l DIMENSION I Ov ••• 11 I, .. ;". I 110 mm teo O,nl I' 180 mm (60 " ,m! 0 ..... '1 "",dill 1135mm 125 0'"11 590m'" 12311111 580mm (22 8,"1 0" •• ,11 ""11"\ 1 000 mm 139 • In! 8110 mm 133 9 "Ii IllS "'m 134 1 .nl Wt\ft l b," 880 ,.,," 134 1 tnl M,n 9'OUnJJ (1"" 1>0;' C.. ,b _'11'11 "'MAM[ SlIsptllJlU1I 1Ft .suJj)<oIn,l('Jn IAI 8r.ln F"~I ,. "_ (,'U '''''V h •• 1 C.<I., 1". 1.,..1>11 'd g',n., •• I" & At [NGINf: Cyl.fICM, "\'0'" Y.I~I .1I'I\9.m'I'\I 80" .. na 11' ...... Como,,,,,on '.100 OIIIlI.c, ..... "'1 all C'PICII\I l"1I.oe;.1I0,, 0,1 "h.,. R.II",IIOII "IIC1a Pllm •• '1 'iIKQtlo.l.,. G", '.,_ ,,, 2..d ]., 51""11\1 1'IIe11>Od P[RF ORM"'NCE Nih IOhWot M I< QUlaul M," lUI"'"" ~jtet. (LECTl'ltC",L Ign'hon Sp,H plug Ilud ,gilt r ", '&Wfo I'ont 170m", t 157'1'1 "!I_IIP0811l" I 50~g/l101hl 5l5~1I1118Ibl' T,I~c IQ" RIIiI'd h.m • Int,,",1 "1l11l11On 25 10 1 ,01U511' 081mllllill .. 0 "'''' II 57 '1'1 ". lSO-8 I 04licm ' l'oI lpt'l s""V" nl! UOII 10· ltom "Do'lon .. ) OH.... 0.., .... 0 elm.n"., 391'<"1 ""' ... II 5]5.' 11]0-111 .. , "9ee II Oeu'lIl 081', 111US 01 , .. Imo PI PI"'"", luDnelllorl 6 WI' .",mll C''''''''''9.1 .1\0 .e,un ",un 3722 1 182 I 824 1 190 (,e ' "'''"' 2 91 , 031'11"'1"·200,,,", 12 2 II ,0,4 ZOOroml I 95 ~f5 000 ,om 115m 18 1'1'11 fl~ ...... " 1 ""gl\lIO NGII: C 8 H or ND U20FS 15V-15W 1 15V-IS,ISW 8V-8.3W I W-l1iS JW I ]00 mm 810",,,, 860",", 8C)'i "'''' 150 r1'm 58 1 0111l ' bll f,I'~IlI>C ",.j Sw'"g I,m InlilOUtl ,.p,"lI'"g 121 c... ' 3B.,\ (I OUS gl' 081rng 1iI.11 12""n """1 .S· ~ R 1 SO. 2PR I Q'!1{Cm' ,tl 2'""1 S""u" 80 'fIC-J.~ 110ft' "",,.ell Ch"" " ••• ,,- ·h.' I'ttld c.,m,hlll 390XII<II ... ", ~ &J5'-1810,nl .. , 19 te I) ac", In, o 8'" f1 . U S P' 1" ''''JI 1111 !'n'e," 'I'" w" I"'mo C ... ".I"'III' ,"a -K'I'" _tn ] n.Z 1 18] 1824 , 190 11;. _. 'l.fI., 078 _II ....... 000 111m 12 02 /Ilb / .OOO .pml Z 8 m ,ft 8111 fl't'W,,"' '"1Q"'tO !\oCf Clltt lJI NO U20rS 8V I !Ill SW 6V·!t'l .... "1

4 SPECIAL TOOL SET ® ® ® \ 1 = , Ref No Tool No Description 07900 0450000 Z50M / Z50A Special tool sel 07980-036010 0 Inlel valve seal cutler, 90· 2 07980-0360200 Elthaust valve seat cutter. 90· 3 07980-0360300 Inlet valve seal lOp cutler ) 4 07980 -0360 400 Exhaust valve seat top cutlsr 5 07980 -0360500 Inlel valve seal Inienor cuner 6 07980-0360600 e.haust valve seal I'lienor cunar 7 07981-0360000 Valve seal cutler holder • 8 07933-0010000 Flvwheel puller 9 079250010000 Flywheel holder 10 07908 -0010 000 TaDpel adjusting socket wrench 1 1 07984 -09 80000 Valve gUide reamer 1 2 07916 -00 10000 lock nUl wrench. 1 4 mm 1 3 07960 -01 10000 Clutch d is assembly & assembling 1001 -

5 • , . -- -- - -~- ~ .. Ref No Tool No Description 14 07922-0400000 Dnve sprocket holder 07923-0360000 Clutch outer holder 1 5 07942-3290100 Valve gUide remOver 16 07942-3290200 Valve gU i de driver 18 07957-3290000 Compress i on va lve hfter 19 07945-8150000 Bearing driver 20 07902-0010000 Pin spanner . 36 mm 21 07945-0450000 Front wheel a ll seat driver 22 07947-0450000 Rear wheel bearing dr iver 23 07949 - 2860000 Bearing & 011 seal driver handle 24 07915 - 0300000 Stem nUl socket wrench 25 07902 -2 500000 MaIO sWllch pin spanner 07797 - 0510100 Valve seRt culter case 27 07797 - 2920300 Float 18 ... el gauge 07401 - 0010000 Toot case

6 ENGINE 1. ENGINE ASSEMBLY DIAGRAM --- Fig 1 • ) - - ,

• • 2. ENGINE REMOVAL 1 loosen the muffler flange and mounting bolts : and remove the muffler 2 Disconnect the throttle cable from the carburetor 3 Detach the high tension cord by pulling the plug cap off the spark plug 4. Disconnect the electrrcal wlnng (F ig. 2) Eleelnc l«Iad S coupler Fig . 2 7 5 Set the fuel cock 10 the OFF poSition and disconnect the fuel l ube from rha carburetor 6 Unscrew the leh crankcase cover mounting screws and remove the cover 7 Unfasten the orlve chain JOlnl clIp and disconnect the chetn . a Remove the two engine hanger bolts and dismount the engme from the Irame (FlO 31 3. ENGINE INSTALLATION (J) EnQIf'18 nange, bolts Fig . 3 Perform the engine Installallon In the reverse order of the engln8 remoyal deSCribed above Noto : When installing the drille chain JOint clip. make sure that the opon ond 01 lhe cliP IS m the opposite direction to tt,e normal chain rolation (Fi g .4 I

B Dll ection 01 R otall<W1 - ~--~ J -2, ( - - - m O .4- 0.8in) FIg . 4 ChaIn jomt chp InliaHauon Fi g. 5 Englntl 011 10ull'lS <D 011 punlp Issol"lbly Fig . 6 ) 4 . LUBRICATION lOlL PUMP) A. Desc ription The engine oil which has been picked up by the trochoid p ump 16 diverted InlO TwO routes (Fig . 51 . Route one all IS. sent through the nght cran kcase - uQht crankcase cover - centrl 'ugal filter - connecting rod large end rollers Route two 0.1 IS sent through Ihe cylinder sTud boh - rock.er arm Side cover ca mshaft profiles and oeanngs - valve mechanism B. Disassembly 1 Unscrew the light crankcase covel moun· ung screws and remove the COveT 2 Remove the clutch DUler cover 3 Unscrew and remalle the 14 mm clutch lock nUl and washer, and then 'emove the clutch assembly 4, Loosen the three 6 mm 011 pump moun· tlng bolts and remove the 011 pump assemblv 5. loosen the three ClOSS scre ..... s attaching the all pump cover, the oil pump can then be disassembled IFig . 6) , •

HONDA Z50R Z50A Motorcycle Service & Repair Manual (1970 to 1981) - !

You're Reading a Preview

Recently Viewed