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Honda Super Cub Etc.

Frame & Forks

Introduction

This section is all about how to strip, servioce and rebuild the frame and forks of the Honda Super Cub and

other bikes using the same frames, plus all the anciliary components not covered in the Engine, Electrics, or

Maintenance Sections. This page is still under construction

All the models using the Super Cub frame are covered here, although models such as the CT50 will have far

fewer components. The only area or real difference between models is the forks - some use leading link and

others use telescopic types. Note that although the frames may appear to be the same, there are any number of

detail differences that, although the stripping and rebuilding methods are the same, many components are not

interchangeable. Frames fall into 4 main groups:

A - Pre 1968 (C100/C102/C105)

B - 1968 to 1983 Small (C50/C70/CT50/CT90)

C - 1968 to 1983 Large (C90)

D - 1982 to present (C50/C70/C90)

Note that the CT series used telescopic forks even though the C50/C70 used leading link forks with basically the

same frame. Note also the CT70 is not part of the same family, it used an ST type of frame.

Remember to disconnect the battery if you intend disconnecting any electrical items, and to reconnect it again

later.

Contents

Section Component

1 Engine

2 Front Wheel & Brake Assembly

3 Front Fork Assembly - Leading Link types

4 Front Fork Assembly - Telescopic types

5 Rear Wheel & Brake Assembly

6 Rear Suspension

7 Seat, Rear Mudguard, & Air-Cleaner

1.0 Engine

How many parts you remove while dropping the engine out of the frame depends on the reason for taking the

engine out. If it is to work on the frame, many components can remain attached to the engine, the fewer

components you remove then the less chance there is of loosing something. There is always the time factor to be

considered as well.

1.1 Lean the bike against a wall, but make sure it will not fall as you work on it.

1.2 Remove the left hand side cover, held on by three screws. Disconnect the wiring loom. Disconect the

carburettor overflow pipe, a plastic pipe usually attached forward of the generator.

1.3 Remove the chain from the engine either by splitting the chain at its split link, or by removing the 2 bolts

holding the engine sprocket on. Once the engine sprocket bolts are removed you will have to rotate the sprocket

retention plate until it comes off the splines. Remove the sprocket (screw the retention plate to the sprocket to

keep everything together).

1.4 Remove the screw holding on the carburettor access panel (the black plastic panel on top of the frame above

the engine.

1.5 Remove the 2 bolts fixing the inlet manifold to the engine cylinder head. (Only remove the carburettor if

you intend to work on it or the frame, see the carburettor section). Stuff some clean kitchen towel or cloth into

the intake port of the engine to stop things falling into it.

1.6 Remove the bolts holding on the plastic legshield, if fitted. Also remove the 2 straps, one each side of the

engine, rhat form part of the legshield mount.

1.7 Move to the right hand side of the bike and remove the muffler/exhaust system. There are 2 nuts at the

engine end and one bolt on the frame. Remove the spark plug lead.

1.8 Remove the upper and rear engine hanger bolts, these are the large bolts that hold the engine in, one is at the

top of the transmission housing and the other is near where the engine sprocket is mounted. Slacken Remove the

nuts and washers from both first, then you will have to try and lift the engine slightly to pull out the upper bolt

(you may need to tap it lightly with a soft mallet to start it. Gently lower the front od the engine down to the

ground. By supporting the engine on the footpeg you should be able to remove the rear engine mounting bolt.

You may have to wriggle the engine to pull it out from the frame.

1.9 (If stripping the engine) Remove the footpeg bar, held on by 4 bolts underneath the transmission, and the

gear pedal. Note that you might have to use an old screwdriver to open out the clamp a bit to pull the gear pedal

off its splines.

Give the engine a clean off as it will probably have accumulated a quantity of road dirt. Don't let anything enter

where the air intake manifold was bolted.

Summary of content (6 pages)

PAGE 1
Honda Super Cub Etc. Frame & Forks Introduction This section is all about how to strip, servioce and rebuild the frame and forks of the Honda Super Cub and other bikes using the same frames, plus all the anciliary components not covered in the Engine, Electrics, or Maintenance Sections. This page is still under construction All the models using the Super Cub frame are covered here, although models such as the CT50 will have far fewer components.
PAGE 2
For stripping the engine, see the 'Horizontal OHC 49-86cc Engine' page. Refitting the engine is basically a reversal of the removal. 1.10 Fit the footpeg bar. 1.11 Lift the back of the engine into the frame and slide the rear mounting bolt through. 1.12 Lift the front of the engine and slide the upper engine mount bolt through. 1.13 Fit the nuts on the rear and upper mounting bolts and tighten. 1.14 Fit the muffler, making sure that a gasket ring is fitted. 1.
PAGE 3
2.16 Grease the bearings. Fit one, then the distance collar and then the second bearing. Fit the oil seals. 2.17 Fit the four 8 mm bolts and the hub into the wheel, tighten all eight wheel bolts evenly. 2.18 Fit the brake cam and then the external operating arm. Fit the springs to the shoes, and then fit the shoes to the brake unit. 2.19 Make sure that the speedometer gear is installed on the brake panel.
PAGE 4
CF front fork assembly 4.1 Disconnect the speedometer cable and the front brake cable. 4.2 Remove the headlight assembly and disconnect the turn signal/horn switch leads and dimmer switch leads. 4.3 Either disconnect the throttle cable from the carburetor or remove the throttle unit from the handlebar or just be prepared to hang the handlebar from the bike if it is only the forks you are interested in. 4.4 Remove the upper handlebar holders, remove the choke cable stay and remove the handlebars. 4.
PAGE 5
.8 Remove the 50mm snap ring and remove the sprocket. Checking the tyre and brakes is that same as for the front wheel. Check the sprocket for tooth wear. Check the 4 rubber wheel dampers for condition. 5.9 Reassemble the brake and wheel the same way as the front wheel. 5.10 Fit the 4 rubber wheel dampers in the hub, fit the sprocket and the 50 mm snap ring. 5.11 Fit the wheel back into to swinging arm, making sure tha t you include the side collar on the brake side of the wheel. 5.
PAGE 6
.14 Put the bike back on the ground. 6.15 Fit the swinging arm spindle washer and nut. 6.16 While sitting on the seat, tighten the swinging arm pivot nut, all 4 of the shock absorber mounting nuts, and the brake torque link bolts. 6.17 Adjust the rear brake. 6.18 Make sure everything is secure and give the bike a gentle road test. 6.19. Check to make sure everything is still secure and re-adjust the brake if required. 7.