the 100 day promise a guide to changing from the

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Canon NP-A2SV Service Handbook. Canon NP-A2SV Service Manual. When stopper block is pressed in, the tensioner shaft should be pushed into the body. Do not turn the Install the cam chain over the cam sprocket and crankshaf t while insert the camshaft into the crankcase. Take care not to damage the cylinder wall and piston. Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal. Do not strike the Remove the following: cylinder too hard cylinder and do not damage the mating surf ace with a screwdriver.Never use a wire brush; it will scratch the groove. INSPECTION CYLINDER Inspect the cylinder bore for scratch or wear. Measure the cylinder I.D. at three levels in an X and Y axis. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-ring groove clearance. SERVICE LIMIT: 0.06 mm (0.002 in) CYLINDER STUD BOLT REPLACEMENT Remove the stud bolts from the cylinder. Install new stud bolts in their proper positions and tighten them. Apply molybdenum oil solution to the piston pin outer surface. Apply engine oil to the piston pin hole and connecting rod inner surface. Be caref ul not to Install the cylinder over the piston while damage the piston compressing the piston rings with your fingers.Make sure that the cylinder touches the crankcase evenly. To service the reverse stopper shaft and gearshift spindle, the engine must be removed from the frame. Be caref ul not to Unstake the clutch lock nut.Set the special tool into the grooves in the drive plate and hold it, and loosen the lock nut. TOOLS: Clutch holder 07GMB-HA7010B. Check the drive plate boss and clutch drum inner contact surfaces for abnormal wear or damage. CLUTCH DRUM AND LINING Check the weight contact surface for scratches or abnormal wear. Remove the following: outer plate clutch spring inner plate Measure the height of the clutch spring. SERVICE LIMIT: 2.73 mm (0.107 in) WEIGHT SPRING. Install the front crankcase cover (page 9-18). CHANGE CLUTCH REMOVAL Remove the centrifugal clutch assembly (page 9-4). Remove the following: washer and lifter lever lifter bearing and bearing holder Loosen in a. Check the cam plate, ball retainer and adjusting plate for abnormal wear or damage. CLUTCH SPRING Replace the clutch Measure the clutch spring free length.Check the plate warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 21.93 mm (0.863 in) Measure the crankshaft O.D. at the primary drive gear. SERVICE LIMIT: 26.93 mm (1.060 in) ASSEMBLY Apply engine oil to the primary drive gear inner surface. Install the following: bearing holder and lifter bearing lifter lever by aligning wide groove (indicated by punch mark) with wide tooth of spindle washer. Check the return spring and reset spring for fatigue or damage.REMOVAL GEARSHIFT SPINDLE Remove the following: retaining bolt gearshift spindle spindle arm REVERSE STOPPER ARM Pull the stopper arm shaft out of the crankcase while holding the arm to release it from the shift drum. Set the spring end onto the arm groove. Install the shaft of the stopper arm into the hole in the crankcase securely while pressing the spring against the crankcase bottom and set the arm to the shift drum. Coat new O-rings with engine oil and install them onto the joint pipe. Install the spring onto the ball retainer and install them onto the lifter cam.Install the twelve bolts with the engine side cover stay and tighten them in a crisscross pattern in several steps. Install the oil level dipstick. To service the alternator stator, flywheel and starter clutch, the engine must be removed from the frame (these items can be serviced by removing the swingarm if no additional engine work is needed). Remove the wire clip from the recoil starter housing. Remove the three mounting bolts and the recoil starter assembly. DISASSEMBLY Remove the following: bolt ratchet cover ratchet guide and spring seat spring ratchet and pin Check each part for wear or damage. Check the starter rope for wear or damage. Check the starter spring for damage or break. W ear eye Remove the spring and replace it if it is broken.Route the rope end through the starter grip and stopper, then tie it in a square knot. Press the knot in the stopper and install the stopper into the starter grip securely. Remove the recoil starter (page 10-3). Hold the recoil starter driven pulley using a screw- driver and loosen the bolt. Remove the bolt, O-ring and the driven pulley. T he cover ( stator) Remove the seven bolts, clamp and the alternator is magnetically. T he cover ( stator) Install the alternator cover.Remove the driven gear while turning it clockwise. Hold the flywheel with the special tool and remove the starter clutch bolts. TOOL: Flywheel holder 07725-0040000 or. Measure the starter driven gear boss O.D. SERVICE LIMIT: 45.65 mm (1.797 in) STARTER CLUTCH INSTALLATION Lubricate the sprag clutch with engine oil and install it into the starter clutch outer with the flange side facing the flywheel side. Install the washer and needle bearing onto the crankshaft. Clean any oil from the tapered portions of the crankshaft and flywheel. Install the woodruff key into the crankshaft key groove. Install the flywheel on the crankshaft, aligning the key way with the woodruff key. Shift the transmission into neutral to align the groove in the shift drum with the lug on the crankcase.To service these parts, the engine must be removed from the frame (section 6). Remove the following: washer and sub-gearshift spindle output shaft and washer shift fork shaft shift drum shift forks shaft and reverse idle gear mainshaft and countershaft as an assembly For crankcase bearing replacement, see page 11-12. Disassemble the mainshaft and countershaft. Check the gear dogs and teeth for abnormal wear or damage. Measure the gear I.D. SERVICE LIMITS: 23.04 mm (0.907 in) 18.05 mm (0.711 in) C1, C2, C3, CR: 25.05 mm (0.986 in) Reverse idle: 13.04 mm (0.513 in) SHIFT DRUM Check the shift drum guide grooves for abnormal wear or damage. Check the shift drum journals for scoring, scratches or evidence of insufficient lubrication. SHIFT FORK Check the shift fork guide pins for abnormal wear or damage. Check the spindle arm for wear or damage. ASSEMBLY Clean all parts in solvent and dry them thoroughly. Apply engine oil to the gear teeth, sliding surface, shifter grooves and bushings. Assemble the mainshaft and countershaft. Apply engine oil to the mainshaft and countershaft journals. Engage the mainshaft and countershaft gears. If removed, install the crankshaft and balancer (page 11-11). Be sure to install Install the mainshaft and countershaft assemblies the thrust washers. Install the sub-gearshift spindle and the washer. Assemble the crankcase halves (page 11-16). Remove the transmission (page 11-4). Be caref ul not to Remove the crankshaft and balancer from the rear damage the crankcase using a hydraulic press. SERVICE LIMIT: 0.8 mm (0.03 in) Measure the radial clearance at the connecting rod big end. SERVICE LIMIT: 0.05 mm (0.002 in) BALANCER Check the balancer gear for wear or damage. Align BALANCER Be caref ul not to Assemble the special tools onto the crankshaft. Drive the crankshaft, output shaft, shift drum, mainshaft and countershaft bearings out of the front crankcase. Apply engine oil to new bearings. Drive the bearings in with the marking side facing out using the special tools. TOOLS: Bearing remover set, 07936-KC10000 15 mm not available in U.S.A. Bearing remover, 07936-KC10500 15 mm remover head 07936-KC10200 remover shaft 07936-KC10100 not available in U.S.A. Remover weight 07936-371020A or 07936-3710200 Drive the countershaft and balancer bearings out of the rear crankcase. Blow through the oil passages in the crankcases with compressed air. Wash the strainer screen thoroughly in high flash point solvent until all accumulated dirt has been removed. Install the output shaft driven gear and the drive DRIVE GEAR gear with the spline side facing out. Install the following: camshaft (section 7) flywheel and starter clutch (section 10) Do not twist or bend the brake hose and pipe when servicing. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. Refer to section 14 for brake system information. Remove the following: fuel tank breather tube cover cap two screws handlebar cover Except U.S.A. Apply Honda Bond A or Honda Hand Grip Cement (U.S.A. only) to the inside surface of the handlebar grip and to the clean surface of the handlebar. Align the right edge of the bracket with the outside punch mark on the handlebar, and tighten the upper screw first, then the lower screw.Loosen the cable adjuster. Bend down the lock washer tab and remove the pivot nut, lock washer, throttle arm and return spring, then the throttle lever with the plastic washer. Do not interchange the left and right tires. Install the wheel nuts with the tapered side facing inward and tighten them.If the rest of the bead cannot be pushed down into the center of the rim by hand, loosen the press head bolt and the lever nut. Apply cement to the rubber plug. Push the inserting needle with plug into the injury until the plug is slightly above the tire. Be caref ul not to Twist the needle and remove it from the tire;. TOOL: Ball joint remover, 28 mm 07MAC-SL00200 Apply grease to the ball joint remover at the point Apply grease here PRESSURE BOLT shown. This will ease installation of the tool and prevent damage to the pressure bolt threads. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub or knuckle. Inspect the knuckle for damage or cracks. Install the distance collar. Support the center Drive in a new outer bearing squarely with the boss of the hub to marking side facing up until it is fully seated. Apply grease to a new inner dust seal lips and install it until it is fully seated being careful not to damage the lips. Make sure that the waterproof seal on the brake drum is packed with the multi-purpose grease (NLGI 3) (page 14-9). Press the ball joint out of the upper arm.Press the ball joint out of the knuckle.Inspect the ball joint boots for tears or other damage by moving the ball joint studs. They should move freely and smoothly. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the frame. BEARING REPLACEMENT Remove the upper and lower dust seals. Remove the snap ring. Apply grease to the shaft bushing inner surface. Install the steering shaft into the shaft bearing. Hold them in that position and tighten the ball joint lock nuts.Check the pivot collar for wear or damage. Check the bushings for wear or damage. Check the damper unit for leakage or other damage. Replace the shock absorber assembly if necessary. INSTALLATION Apply molybdenum disulfide paste to the lower bushing of the shock absorber. Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the. Support the vehicle with a support block to raise the rear wheels off the ground. Remove the nuts and wheel. INSTALLATION Install the wheel with the arrow mark facing in the normal rotating direction. Install a new upper mounting nuts and tighten the nut and bolt.Loosen the joint boot band screw. Loosen the right pivot lock nut and remove it. TOOL: Lock nut wrench 07908-4690003 Remove the right and left pivot bolts and release the joint boot off the swingarm, then remove the swingarm. Drive in a new bearing squarely until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 37 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 Pack 3 g (0.1 oz) of grease into each bearing cavity and grease holder. Install the final drive and rear axle (page 16-16). 13-9. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front brake Recommended brake fluid Honda DOT 4 brake fluid Drum I.D. 160.0 (6.30) 161.0 (6.34) Shoe lining thickness 4.0 (0.16) 1.0 (0.04) Brake panel warpage 0.4 (0.02) Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. Use only DOT 4 brake fluid from a sealed container. Do not release the brake lever until the bleed valve has been closed. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. INSPECTION Check the piston cups for wear, deterioration or damage. Check the spring for damage. Check the master cylinder and piston for scoring, scratches or damage. Apply silicone grease to the brake lever contacting surface of the piston. Apply silicone grease to the brake lever pivot. Install the brake lever and pivot bolt, and tighten it.BRAKE PANEL Clean any grease from the brake panel thoroughly. HUB NUT Check the brake panel at the waterproof seal lip contact area for abnormal scratches or wear.BRAKE DRUM Press the drum Place the waterproof seal on a clean surface plate, onto the seal and press the brake drum into the waterproof seal, SURFACE Apply water evenly, so the lips making sure that the clearances between the drum PLATE will not be. Install the wheel hub onto the drive shaft, if it was removed. Apply grease to the hub nut threads and seating surface. Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole. Loosen the pipe joint nuts and remove the brake pipe. Remove the nuts, washers and bolts and the wheel cylinder A and B. CYLINDER Check the cylinder bore and piston for scoring, scratches of damage. Check the adjuster for wear or damage. BOOT Check the lock spring for fatigue or damage. LOCK SPRING ADJUSTER Measure the wheel cylinder I.D. Do not allow the Install the piston into the wheel cylinder.Apply silicone grease to the boot grooves in the piston and cylinder body. Install the piston boot onto the cylinder and piston grooves securely. Tighten the oil bolt. DISASSEMBLY Always replace the Remove the following: brake shoes in cotter pins pairs. Apply grease to the brake cam spindle and install it. Install the cable springs onto the cables and the joint pins into the brake arm. Connect the brake cables to the brake arm with the adjusting nuts. TOOL: Oil seal driver 07965-MC70100 Install the drum cover and tighten the six bolts. Apply molybdenum disulfide grease to the seal lips of a new hub dust seal and install it with the flat side facing in until it is fully seated. Disconnect the pedal brake cable from the brake arm (page 14-15). Remove the following: spring brake cable cotter pin washer brake pedal dust seals INSTALLATION Apply grease to the lips of the new dust seals and install them with the flat side facing to the pedal. Perform the gear contact pattern and backlash inspection whenever you replace the bearings, gears or gear case. Remove the cotter pin and loosen the hub nut. Remove the cotter pins and loosen the ball joint nuts. Release the ball joints, using the special tool according to the instructions on page 12-12. Check the drive shaft joints for excessive play or noise by moving the joints in a circular direction. If the outboard joint seems to be worn or damaged, the drive shaft must be replaced. Note the installation direction of the boot bands. Forward direction Pack the outboard joint with 30 50 g of molybde- num disulfide grease. See page 15-6 f or Install new boot band A onto the outboard boot and band installation the band B onto the inboard boot. Pull the propeller shaft joint forward, then separate it from the engine (output shaft joint). Separate the other drive shaft from the differential as you remove it. They must be checked after disassembly; replace them if necessary. Replace the pinion shim with a thinner one if the contact pattern is too low, toward the flank. The pattern will shift about 0.5 1.0 mm (0.02 0.04 in) when the thickness of the shim is changed. Remove the following: differential cap cone spring shim left face cam six cam followers A and six cam followers B right face cam DIFFERENTIAL COMPONENTS If the dif f erential. Replace the cam Check the shim, face cams and followers for f ollowers as a set damage. ( 12 pieces). Remove the oil seal, O-ring and stopper ring. Be caref ul that Unstake the pinion bearing lock nut with a drill or metal particles do. Remove the pinion shim. Install the shim and bearing onto the pinion gear.TOOLS: Driver 07749-0010000 Attachment, 52 55 mm 07746-0010400 Pilot, 28 mm 07746-0041100 Apply grease to new dust seal lips and install them into the case and cover. TOOL: Attachment, 20 mm I.D. Remove the needle bearing and tool assembly from the freezer and drive the bearing into the gear case using the special tools. Only strike the driver once. If you strike it more than once, the ring may slip out of the groove. TOOL: Driver, 40 mm I.D. 07746-0030100 Keep the driver centered with the bearing outer race during installation. Install a new lock nut and tighten it. TOOL: Lock nut wrench, 34 44 mm. Apply molybdenum disulfide grease to the pinion gear shaft spline and install the pinion joint until the stopper ring seats in the groove. Make sure that the stopper ring is seated properly by pulling on the pinion joint lightly. Tighten the six bolts in a crisscross pattern in several steps.If the the cover evenly touches the case. Then, while ring gear shim is rotating the pinion gear, tighten the bolts to the too thick, the. Install the drive shaft into the differential (page 15- Set the mounting bracket over the front mounting boss of the differential and onto the frame, then install the two mounting bolts and tighten them. SERVICE LIMIT: 3.0 mm (0.12 in) AXLE BEARING Remove the dust seals from the axle housing and brake panel. Drive the axle bearings out of the brake panel. Support the Drive the outer bearing (brake drum side) squarely bearing housing with the sealed side facing down until it is fully section of the seated, then the inner bearing with the sealed side brake panel when. INSPECTION DRIVE SHAFT Check the splines of the drive shaft for wear or damage. If the splines are damaged, check the pinion and universal joint splines also.If the backlash is too small, replace the ring gear right side shim with a thicker one. Backlash changed by about 0.06 mm (0.002 in) when thickness of the shim is changed by 0.12 mm (0.005 in). The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the case or cover. Then, while rotating the pinion gear, the bolts. If the tighten the bolts to the specified torque in a ring gear shim is crisscross pattern in several steps. Be caref ul that Unstake the pinion bearing lock nut with a drill or metal particles do grinder.Drive the bearing with the marking side facing up. TOOLS: Driver, 40 mm I.D. Install each oil seal with the flat side facing out until it is flush with the case or cover. TOOL: Driver 07749-0010000 Attachment, 52 55 mm 07746-0010400 PINION NEEDLE BEARING Remove the stopper ring by rotating it until the end of the stopper ring appears in the access hole. If the the cover evenly touches the case. Then, while ring gear shim is rotating the pinion gear, tighten the bolts to the too thick, the. Install the axle into the final gear case from right side until it is fully seated.