Rozdział 4 - Układ paliwowy i wydechowy,

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Chapter 4
Fuel and exhaust systems
Contents
Air filter replacement ............................see Chapter 1
Air filter housing - removal and installation .................... 12
Carburettor overhaul - general information .................... 5
Carburettor synchronisation ......................see Chapter 1
Carburettors - disassembly, cleaning and inspection ............ 7
Carburettors - reassembly, float height and fuel level check ...... 9
Carburettors - removal and installation ....................... 6
Carburettors - separation and joining ........................ 8
Choke cable - removal and installation ....................... 11
Exhaust system - removal and installation .................... 13
Fuel pump - check, removal and installation ......... .see Chapter 9
Fuel system check ..............................see Chapter 1
Fuel tank - cleaning and repair ............................. 3
Fuel tank and tap - removal and installation ................... 2
General information and precautions ........................ 1
Idle fuel/air mixture adjustment - general information ............ 4
Idle speed check ...............................see Chapter 1
Throttle and choke cable check ................... .see Chapter 1
Throttle cable - removal and installation ...................... 10
Degrees of difficulty
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult, |k,
suitable for competent S^
DIY mechanic
IjS
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Specifications
Fuel
Grade ................................................. Unleaded, minimum 91 RON (Research Octane Number)
Fuel tank capacity .......................................... 19 litres
Fuel tank reserve capacity ...................................
2.5
litres
Carburettors
Type
600 cc engine ........................................... 34.0 mm CV
650 cc engine ........................................... 36.5 mm CV
Carburettor adjustments
Pilot screw setting (turns out)
600 cc engine
J
and K models ........................................ 13/4
M models ............................................ 17/8
650 cc engine
P models ............................................. 21/2
S and T models ........................................ 21/4
Float height
600 cc engine ........................................... 7.0 mm
650 cc engine ........................................... 9.2 mm
Idle speed ................................................ see Chapter 1
Synchronisation vacuum range ............................... see Chapter 1
4*2 Fuel and exhaust systems
Jet sizes
Pilot jet
600 cc engine ........................................... 38
650 cc engine ........................................... 42
Main jet
600 cc engine
J and K models
Front cylinder ....................................... 135
Rear cylinder ........................................ 130
M models (both cylinders) ................................ 128
650 cc engine
P models
Front cylinder ....................................... 132
Rear cylinder ........................................ 128
S and T models (both cylinders) ........................... 125
Torque settings
Fuel tank mounting bolts
Front ................................................. 12Nm
Rear ................................................. 22 Nm
Exhaust system
Downpipe nuts .......................................... 27 Nm
Clamp bolts ............................................. 27 Nm
Silencer bolts ........................................... 27 Nm
eneral information aril
precautions
Always perform service procedures in a
well-ventilated area to prevent a build-up of
fumes.
Never work in a building containing a gas
appliance with a pilot light, or any other form
of naked flame. Ensure that there are no
naked light bulbs or any sources of flame or
sparks nearby.
Do not smoke (or allow anyone else to
smoke) while in the vicinity of petrol or of
components containing it. Remember the
possible presence of vapour from these
sources and move well clear before smoking.
Check all electrical equipment belonging to
the house, garage or workshop where work is
being undertaken (see the Safety First! section
of this manual). Remember that certain
electrical appliances such as drills, cutters etc
create sparks in the normal course of
operation and must not be used near petrol or
any component containing it. Again,
remember the possible presence of fumes
before using electrical equipment.
Always mop up any spilt fuel and safely
dispose of the rag used.
Any stored fuel that is drained off during
servicing work must be kept in sealed
containers that are suitable for holding petrol,
and clearly marked as such; the containers
themselves should be kept in a safe place.
Note that this last point applies equally to the
fuel tank if it is removed from the machine;
also remember to keep its cap closed at all
times.
Note that the fuel system consists of the
fuel tank and tap, with its cap and related
hoses.
Read the Safety first! section of this manual
carefully before starting work.
Owners of machines used in the US,
particularly California, should note that their
machines must comply at all times with
Federal or State legislation governing the
permissible levels of noise and of pollutants
such as unburnt hydrocarbons, carbon
monoxide etc. that can be emitted by those
machines. All vehicles offered for sale must
comply with legislation in force at the date of
manufacture and must not subsequently be
altered in any way which will affect their
emission of noise or of pollutants.
In practice, this means that adjustments
may not be made to any part of the fuel,
ignition or exhaust systems by anyone who is
not authorised or mechanically qualified to do
so, or who does not have the tools,
equipment and data necessary to properly
carry out the task. Also if any part of these
systems is to be replaced it must be replaced
with only genuine Honda components or by
components which are approved under the
relevant legislation. The machine must never
be used with any part of these systems
removed, modified or damaged.
General information
The fuel system consists of the fuel tank,
the fuel tap and filter, the fuel pump, the
carburettors, fuel hoses and control cables.
The fuel tap is of the gravity type with an
integral filter inside the fuel tank.
The carburettors used on all models are
Keihin CV types. On all models there is a
carburettor for each cylinder. For cold
starting, a choke lever mounted on the left-
hand handlebar and connected by a cable,
controls an enrichment circuit in the
carburettor.
Air is drawn into the carburettors via an air
filter which is housed under the fuel tank.
The exhaust system is a two-into-one
design.
Many of the fuel system service procedures
are considered routine maintenance items
and for that reason are included in Chapter 1.
Precautions
Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don't smoke or
allow open flames or bare light bulbs near
the work area, and don't work in a garage
where a natural gas-type appliance is
present. If you spill any fuel on your skin,
rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses and
have a fire extinguisher suitable for a class
B type fire (flammable liquids) on hand.
removal and installation
Ixi
Warning: Refer to the
precautions given in Section 1
before starting work.
Fuel tank
Removal
1 Make sure the fuel tap is turned to the OFF
position and the fuel cap is secure.
2 Remove the seat and the left-hand side
panel (see Chapter 8), then disconnect the
battery, negative (-ve) terminal first.
2 Fuel tank and tap -
^
Fuel and exhaust systems 4*3
2.3 Release the clamp and detach
the fuel hose from the tap
2.4a Unscrew the tank
rear mounting bolt...
2.4b . .. then the front mounting bolt...
2.5 ... and remove the tank
2.7 Do not forget the rubber mounts
on each side of the tank
2.8a Install the front mounting bolt.
2.8b ... then the rear mounting bolt
2.9 Connect the fuel hose to the tap
2.14 The tap is secured to the tank
by a nut (arrow)
3 Release the fuel hose clamp and detach the
hose from the tap, noting its routing
(see
illustration).
4 Unscrew the fuel tank rear mounting bolt
first, then the front mounting bolt, and remove
the bolts with their collars, noting how they fit
(see illustrations).
5 Remove the tank by carefully drawing it back
and away from the bike
(see illustration).
Take
care not to lose the mounting rubbers from the
front and rear of the tank, and from between the
sides of the tank and the frame, noting how they
fit. On all except J models, note the routing of
the overflow drain hose into the drain tray.
6 Check the tank mounting rubbers for damage
or deterioration and replace them if necessary.
Installation
7 If removed, install the tank mounting rubbers
(see illustration).
Carefully lower the fuel tank
into position, making sure the rubbers remain
in place and that the overflow drain hose is
correctly routed. Check that the tank is
properly seated and is not pinching any control
cables or wires.
8 Install the front mounting bolt and its collar
first, and tighten it to the torque setting
specified at the beginning of the Chapter
(see
illustration).
Next install the rear mounting
bolt and its collar, and tighten it to the
specified torque setting
(see illustration).
9 Reconnect the fuel hose to the tap, making
sure it is correctly fitted and routed, and
secure it with its clamp
(see illustration).
10
Connect the battery, fitting the negative (-
ve) terminal last, then install the seat and the
left-hand side panel (see Chapter 8).
11 Turn the fuel tap to the ON or RES position
and check that there is no sign of fuel leakage.
Start the engine and check again that there is
no sign of fuel leakage, then shut if off.
Fuel tap
Removal
12
The tap should not be removed
unnecessarily otherwise there is a danger of
damaging the O-ring or the filter.
13
Remove the fuel tank as described above.
Connect a drain hose to the fuel tap stub and
insert its end in a container suitable and large
enough for storing the petrol. Turn the fuel tap
to the RES position, and allow the tank to fully
drain.
14
Unscrew the nut securing the tap to the
tank and withdraw the tap assembly
(see
illustration).
Check the condition of the O-
ring. If it is in good condition it can be re-used.
If it is in any way deteriorated or damaged it
must be replaced.
15
Clean the gauze filter to remove all traces
of dirt and fuel sediment. Check the gauze
4*4 Fuel and exhaust systems
6.5 Release the fuel hose clamp and
detach the hose from the union (arrow)
6.6 Slacken the clamps securing the
carburettors to the inlet adapters
6.7 Carburettor drain screw (arrow)
for holes. If any are found, a new filter should
be fitted.
16
Apart from the tap control knob, filter and
O-ring, internal components are not available
for the fuel tap. If the tap is leaking, unscrew
the screw securing the knob to the tap and
remove the control knob. Tighten the screws
securing the tap cover to the tap body. If
leakage persists, the tap should be replaced
with a new unit, however nothing is lost by
dismantling the tap for further inspection.
Remove the screws and disassemble the tap,
noting how the components fit.
Installation
17 Installation is the reverse of removal.
the machine doesn't exceed the emissions
regulations.
2 The pilot screws are set to their correct
position by the manufacturer and should not
be adjusted unless it is necessary to do so for
a carburettor overhaul. If the screws are
renewed, they should be set to the position
specified at the beginning of the Chapter.
3 If the engine runs extremely rough at idle or
continually stalls, and if a carburettor overhaul
does not cure the problem, take the
motorcycle to a Honda dealer equipped with
an exhaust gas analyser. They will be able to
properly adjust the idle fuel/air mixture to
achieve a smooth idle and restore low speed
performance.
loosened but not removed by the solvent.
Once the cleaning process is complete,
reassemble the carburettor using new gaskets
and O-rings.
6 Before disassembling the carburettors,
make sure you have a carburettor rebuild kit
(which will include all necessary O-rings and
other parts), some carburettor cleaner, a
supply of clean rags, some means of blowing
out the carburettor passages and a clean
place to work. It is recommended that only
one carburettor be overhauled at a time to
avoid mixing up parts.
Carburettors -
removal and installation
3 Fuel tank -
cleaning and repair
5 Carburettor overhaul -
general information
l
Warning: Refer to the
precautions given in Section 1
before starting work.
1 All repairs to the fuel tank should be carried
out by a professional who has experience in
this critical and potentially dangerous work.
Even after cleaning and flushing of the fuel
system, explosive fumes can remain and
ignite during repair of the tank.
2 If the fuel tank is removed from the bike, it
should not be placed in an area where sparks
or open flames could ignite the fumes coming
out of the tank. Be especially careful inside
garages where a natural gas-type appliance is
located, because the pilot light could cause
an explosion.
1 Poor engine performance, hesitation, hard
starting, stalling, flooding and backfiring are
all signs that major carburettor maintenance
may be required.
2 Keep in mind that many so-called
carburettor problems are really not
carburettor problems at all, but mechanical
problems within the engine or ignition system
malfunctions. Try to establish for certain that
the carburettors are in need of maintenance
before beginning a major overhaul.
3 Check the fuel filter, the fuel hoses, the
intake manifold joint clamps, the air filter, the
ignition system, the spark plugs and
carburettor synchronisation before assuming
that a carburettor overhaul is required.
4 Most carburettor problems are caused by
dirt particles, varnish and other deposits
which build up in and block the fuel and air
passages. Also, in time, gaskets and O-rings
shrink or deteriorate and cause fuel and air
leaks which lead to poor performance.
5 When overhauling the carburettors,
disassemble them completely and clean the
parts thoroughly with a carburettor cleaning
solvent and dry them with filtered,
unlubricated compressed air. Blow through
the fuel and air passages with compressed air
to force out any dirt that may have been
Removal
1 Remove the fuel tank (see Section 2).
2 Remove the air filter housing (refer to
Section 12).
3 Detach the throttle cables from the
carburettors (see Section 10).
4 Detach the choke cables from the
carburettors (see Section 11).
5
Release the-clamp securing the main fuel
hose to the carburettors and detach the hose
(see illustration).
6 Slacken the clamps securing the
carburettors to the cylinder head inlet
adapters and ease the carburettors off the
adapters, noting how they fit
(see
illustration). Note:
Keep
the carburettors
upright to prevent fuel spillage from the float
chambers and the possibility of the piston
diaphragms being damaged.
7 Place a suitable container below the float
chambers, then slacken the drain screws and
drain all the fuel from the carburettors
(see
illustration).
Once all the fuel has been
drained, tighten the drain screws securely.
8 If necessary, release the clamps securing
the inlet adapters to the cylinder heads and
remove the adapters, noting how they fit
(see
illustration).
4 Idle fuel/air mixture
adjustment - general
information
1 Due to the increased emphasis on
controlling motorcycle exhaust emissions,
certain governmental regulations have been
formulated which directly affect the
carburation of this machine. In order to
comply with the regulations, the carburettors
on some models are sealed so they can't be
tampered with. The pilot screws on other
models are accessible, but the use of an
exhaust gas analyser is the only accurate way
to adjust the idle fuel/air mixture and be sure
Fuel and exhaust systems 4»5
6.8 Note the fitting of the inlet adapters as
they must be correctly installed (arrows)
Installation
9 Installation is the reverse of removal, noting
the following.
a) Check for cracks or splits in the cylinder
head inlet adapters. If they have been
removed from the cylinder head, make
sure they are installed with the slotted tab
.
on the adapter aligning with the raised lip
on the underside of the cylinder head
stub
(see illustration 6.8).
b) Make sure the air filter housing and the
cylinder head inlet adapters are fully
engaged with the carburettors and their
retaining clamps are securely tightened.
c) Make sure all hoses are correctly routed
and secured and not trapped or kinked.
d) Check the operation of the choke and
throttle cables and adjust them as
necessary (see Chapter 1).
e) Check idle speed and carburettor synchro-
nisation: adjust as necessary (Chapter 1).
H28932
7.1 Carburettor components
9 Pilot
screw
assembly
7
Carburettors -
disassembly,
| cleaning and inspection
Top cover
Spring
Jet needle retainer
Spring
Jet needle
Diaphragm/piston assembly
Air cut-off valve cover
Air cut-off valve assembly
70 P;7of/ef
11 Main jet
12 Needle jet
13 Float needle valve assembly
14 Float
15 Float chamber
Warning: Refer to the
precautions given in Section 1
before starting work.
Disassembly
1 Remove the carburettors from the machine
as described in the previous Section.
Note:
Do
not separate the carburettors unless
absolutely necessary; each carburettor can be
dismantled sufficiently for all normal cleaning
and adjustments while in place on the
mounting brackets. Dismantle the carburettors
separately to avoid interchanging parts
(see
illustration).
2 Unscrew and remove the four top cover
retaining screws
(see illustration).
Lift off the
cover and remove the spring from inside the
piston.
3 Carefully peel the diaphragm away from its
sealing groove in the carburettor and
withdraw the diaphragm and piston assembly.
Caution: Do not use a
sharp instrument to
displace the diaphragm as it is easily
damaged.
Note how the tab on the diaphragm
fits in the recess in the carburettor body.
4 If necessary, push down on the jet needle
retainer using a Phillips screwdriver and rotate
it until its tabs are released from the
protrusions inside the piston
(see
illustration).
Push the needle up from the
bottom of the piston and withdraw it from the
top. Take care not to lose the spring and other
components and note how they fit.
5 Unscrew the screws securing the float
chamber to the base of the carburettor and
7.2 The carburettor top cover
is secured by four screws (arrows)
7.4 The jet needle retainer locates under
three tabs in the piston (arrows)
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Rozdział 4 - Układ paliwowy i wydechowy,

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