Honda TG50M Gyro S User Manual

Outlines warnings and cautions for safe operation and maintenance of the scooter.

Explains how to navigate and find information within the shop manual.

Covers essential safety warnings and precautions for operating and servicing the scooter.

Details the recommended rules and procedures for servicing the vehicle.

Identifies key serial numbers and model details of the scooter.

Provides detailed specifications for dimensions, frame, engine, and carburetor components.

Lists specifications for drive train, electrical system, and lighting components.

Details critical torque values for engine and chassis fasteners.

Lists standard torque values for common fasteners like bolts and nuts.

Lists specific and common tools required for maintenance and repair.

Illustrates proper routing for cables and harnesses to prevent damage.

Explains regulations and prohibited acts related to the noise emission system in the USA.

Provides general information, specifications, torque values, and troubleshooting for lubrication.

Details the procedures for removing, inspecting, and installing the oil pump.

Explains how to bleed the oil pump and lines after service.

Describes the process for removing and cleaning the oil strainer.

Outlines the steps for removing and installing the oil tank.

Specifies transmission oil capacity and torque values for the level check bolt.

Identifies critical points on the scooter requiring lubrication.

Covers service information, specifications, and torque values for maintenance tasks.

Provides a detailed maintenance schedule based on mileage and time intervals.

Details the removal, cleaning, and installation of the air cleaner element.

Explains how to adjust the carburetor's idle speed for optimal performance.

Covers throttle operation checks and free play adjustments.

Describes the procedure for cleaning the fuel filter screen.

Details the inspection and maintenance of the fuel line system.

Covers wheel inspection and tire pressure specifications.

Outlines checks for front and rear brake lever free play and adjustment.

Details the adjustment procedures for rear brake lever free play and parking lock lever.

Explains how to adjust steering head bearings for smooth operation.

Covers inspection of front and rear suspension components.

Provides information on spark plug selection, gap, and installation.

Covers the operation and adjustment of headlights and horn.

Details ignition timing checks and cylinder compression testing.

Covers proper tightening of nuts, bolts, and fasteners.

Overview of fuel system service, specifications, torque, tools, and troubleshooting.

Steps for cleaning the fuel filter and servicing the fuel tank.

Covers removal and installation of the air cleaner case.

Details the process for disassembling the carburetor's throttle valve.

Outlines carburetor removal and inspection of the auto-starter system.

Step-by-step guide for disassembling the carburetor float chamber.

Covers float level checks and the installation of the auto-starter.

Details the reassembly of the carburetor and throttle valve components.

Covers removal, inspection, and installation of the reed valve.

Explains the procedure for adjusting the carburetor's air screw.

Provides service information, specifications, and torque values for engine removal/installation.

Details the initial steps for removing the engine from the scooter.

Continues the process of disconnecting components for engine removal.

Covers disconnecting the fuel line and mounting nuts for final engine removal.

Outlines the engine installation sequence and post-installation adjustments.

Overview of service information, specifications, torque, and troubleshooting for these components.

Lists common issues and probable causes for cylinder head, cylinder, and piston problems.

Step-by-step instructions for removing the cylinder head.

Guides on cleaning carbon deposits from the combustion chamber.

Details the process for removing the cylinder and piston assembly.

Continues the procedure for removing the cylinder and piston, including ring removal.

Covers inspection of cylinder wear, piston O.D., and piston ring end gap.

Details the installation of the connecting rod and piston/cylinder assembly.

Continues the piston/cylinder installation, including ring alignment and lubrication.

Step-by-step instructions for installing the cylinder head and related components.

Provides service information, torque values, and lists required tools for alternator service.

Details the removal of the left crankcase and related components.

Covers the disassembly of the left crankcase cover.

Outlines the process for removing the alternator from the engine.

Details the steps for installing the alternator assembly onto the engine.

Guides on assembling the left crankcase cover with new bearings.

Details the installation of the left crankcase cover onto the engine.

Overview of service info, specs, torque, tools, and troubleshooting for the clutch/transmission.

Provides troubleshooting steps for common clutch and transmission issues.

Steps for removing the right crankcase cover and related components.

Details the disassembly of the right crankcase cover and clutch components.

Covers inspection of gears, gearshafts, and the second clutch assembly.

Details inspection of the low clutch outer for wear or damage.

Outlines the removal of the low clutch and drive plate.

Covers the removal of the parking arm and related components.

Details the removal of the oil pump drive and driven gears.

Outlines the removal of the starter pinion.

Covers inspection and installation of the starter pinion.

Details the installation of the oil pump gears.

Covers the installation of the parking arm assembly.

Details the installation of the low clutch and drive plate.

Guides on assembling the right crankcase cover.

Overview of service information, specifications, tools, and troubleshooting for crankcase/crankshaft.

Provides detailed service information for the crankcase and crankshaft.

Details the process of separating the crankcase halves.

Outlines the steps for removing the crankshaft.

Covers inspection of crankshaft runout and connecting rod big end clearance.

Details the installation of the crankshaft and bearings.

Guides on assembling the crankcase and final checks before installation.

Overview of service information for frame covers.

Details removal and installation of front cover, head pipe covers, and floor board.

Covers removal and installation of the body center cover.

Details the removal and installation of the rear cover.

Outlines the removal and installation of the engine cover.

Overview of service information, troubleshooting, and components for these systems.

Lists specifications, torque values, and tools for steering, wheel, brake, and suspension.

Provides troubleshooting guidance for common issues in these systems.

Details the removal of handlebar switch wire bands and housings.

Covers the installation of handlebar components and throttle grip.

Details the removal and installation of the parking lock lever.

Explains how to replace various control cables.

Covers the replacement of the rear brake cable.

Details the replacement of secondary control cables.

Guides on adjusting the rear brake for proper function.

Covers removal and inspection of the front wheel, axle shaft, and wheel bearings.

Details the disassembly and assembly of the front wheel bearings and seals.

Covers inspection of the front brake drum and lining thickness.

Details the disassembly of the front brake system, including shoes and springs.

Guides on assembling the front brake components.

Covers removal and inspection of front suspension components like forks and springs.

Details the installation of front suspension components.

Covers removal of steering components like the speedometer cable and horn.

Details inspection and replacement of steering ball races.

Guides on installing steering components and related parts.

Overview of service information, troubleshooting, and components for rear wheel/brake.

Covers removal and inspection of the rear wheel and its components.

Lists specifications and torque values for rear wheel and brake systems.

Provides troubleshooting for common rear wheel and brake issues.

Continues inspection of the rear wheel, focusing on runout and drum I.D.

Details the replacement of the rear wheel hub and related parts.

Guides the disassembly of the rear brake system, including shoes and springs.

Details the assembly of the rear brake components.

Overview of service information, troubleshooting, and components for rear shock/swing joint.

Lists specifications, torque values, tools, and troubleshooting for rear suspension.

Provides troubleshooting guidance for rear shock absorber and swing joint unit issues.

Details the removal of the rear shock absorber.

Covers the disassembly of the rear shock absorber.

Guides on assembling the rear shock absorber.

Details the installation of the rear shock absorber.

Outlines the removal of the swing joint unit.

Covers inspection of swing joint unit bushings and stoppers.

Details the disassembly of the swing joint unit.

Continues the disassembly of the swing joint unit, focusing on rubber components.

Covers inspection of compression rubbers and swing lock parts.

Guides on assembling the swing joint unit, including bearings and seals.

Details the final assembly of the swing joint unit and case components.

Covers the installation of the swing joint unit and related components.

Overview of service information for electrical components.

Lists specifications for battery, alternator, and spark plugs.

Provides troubleshooting for charging, ignition, and starting system issues.

Details battery service, voltage checks, and charging procedures.

Explains charging system operation and performance testing for the alternator.

Covers inspection of resistors and the regulator/rectifier unit.

Details ignition system components and inspection of the ignition coil.

Covers inspection of exciter coil, pulse generator, and CDI unit.

Illustrates the wiring diagram for the starting system.

Details starter relay inspection and starter motor removal.

Covers inspection and installation of the starter motor.

Details removal and replacement of instruments and indicator bulbs.

Covers inspection of the ignition switch and oil level sensor.

Details the operation of various switches like handlebar, engine stop, dimmer, and turn signal.

Covers brake light switch checks and headlight bulb replacement.

Details replacement of tail/brake and turn signal light bulbs.

Covers checking the horn operation and its connection to the battery.

Provides the overall wiring diagram for the scooter's electrical system.

Addresses problems with engine starting, power loss, and performance.

Covers troubleshooting for engine power issues and performance at low/idle speeds.

Addresses poor performance at high speeds and fuel flow restrictions.

Troubleshoots clutch, transmission, handling, suspension, and brake performance.

Troubleshoots problems related to the swing lock and parking lever.

Addresses troubleshooting for the oil indicator and indicator lamps.

Provides troubleshooting steps for starter motor not turning or turning slowly.