1982 Honda NU50M Urban Express NU50 Shop Manual (P/N 61GC100)

• 1982 model coverage is for the Honda Urban Express NU50, equipped with a kickstarter, and NU50M, equipped with both kick and electric starting. The model-identification page gives a beginning frame reference of *AB132CS000010**. The core repair manual is model-year 1982; the included Service Tool News applies required tooling to 1982–1983 NU50/M machines. No 1984 repair supplement is included.
• Engine and fuel-system chapters cover oil-tank and oil-pump service, oil-line bleeding, PA13E carburetor and automatic-choke work, reed-valve inspection, compression testing, cylinder-head and piston decarbonizing, top-end inspection, and engine removal and installation.
• V-Matic drivetrain repair includes the drive pulley, weight rollers, V-belt, kick-start mechanism, centrifugal clutch, driven pulley, final-reduction gears, bearings and seals, plus crankcase separation and crankshaft inspection and assembly.
• Front and rear chassis procedures address handlebars, steering stem and ball races, wheel bearings and spokes, drum brakes, brake cams and wear indicators, the grease-lubricated front fork, rear wheel, and rear shock absorber disassembly and assembly.
• Electrical diagnosis separates NU50 and NU50M charging arrangements and covers the alternator, CDI ignition, battery, switches, horn, oil-level sensor, and the NU50M starter relay and starter motor, with resistance tables, continuity charts, and fault-isolation checks.
• Honda special-tool coverage identifies the driven-pulley locknut wrench, clutch spring compressor, flywheel puller, crankcase puller and assembly tool, bearing removers, steering-race tools, and rear-shock compressor. The added tool bulletin supplies approved substitutions and a crankcase-tool modification template.
• 175 PDF pages total — 166 pages for the official Honda shop manual, P/N 61GC100, issued November 1981; 3 pages of October 1982 Service Tool News; a 2-page September 1982 battery-tray product update; and a 4-page January 1983 air-cleaner-bracket recall bulletin.

Repair Scope and System Detail

The manual is organized into 16 technical sections rather than a maintenance-only checklist. Top-end service can be performed with the engine in the frame, while oil-pump and crankshaft repair require engine removal. The procedures are tied to inspection limits, cylinder classification marks, tightening data, lubrication requirements, and final checks. Oil-system coverage includes the strainer, pump inspection and installation, control-cable adjustment, and separate bleeding of the inlet and outlet lines.

Fuel-system work runs through throttle-valve removal, float and float-valve inspection, jet service, float-level checking, carburetor installation, fuel valve and tank service, reed-valve inspection, and the bystarter chamber with its bimetal-controlled automatic choke. The section-level troubleshooting isolates no-start, rich or lean running, rough idle, fuel restriction, and control-box faults.

The transmission chapters treat the drive face and boss, rollers, belt, kick-start spindle and driven gear, clutch shoes and outer, driven faces, guide hardware, torque spring, shafts, gears, bearings, and oil seals as separate repair groups. Factory limits are supplied for belt, pulley, clutch, and kick-start wear. Final-reduction and crankcase sections continue through component inspection, bearing and seal installation, crankshaft runout checks, and crankcase assembly.

Chassis work includes the speedometer and headlight assemblies, ignition switch and indicator lamps, handlebar controls, front wheel and brake, fork inspection, steering-stem and ball-race service, rear wheel and brake, and rear-shock disassembly. Key tool references include locknut wrench 07916-1870001, clutch spring compressor 07960-1870000, flywheel puller 07933-1550002, crankcase puller 07935-1870000, and case assembly tool 07965-1480001. The tool bulletin also documents modified tool 07933-1470000 as a crankcase-puller substitute.

Diagrams, Test Data, and Troubleshooting

Named technical illustrations include the lubrication-system flow diagram, cable and wire-harness routing views, automatic-choke control-box schematic, V-Matic drive and driven-pulley section views, oil-level-indicator construction and operating circuits, and separate NU50 and NU50M wiring diagrams with switch-continuity charts. The wiring sheets carry Honda diagram codes 0030Z-GC1-6700 and 0030Z-GC1-7000. Exploded assembly views support the engine, transmission, steering, brake, and suspension procedures.

Section 15 supplies indexed diagnostic charts for loss of engine power, poor idle and high-speed performance, steering faults, NU50M starter problems, and oil-level-indicator failures. The reference tables cover component torques, lubricant and capacity data, wear limits, dimensional clearances, carburetor settings, charging-output tests, electrical resistance values, switch continuity, brake and wheel limits, and suspension inspection data.

Included Honda Updates

The battery-tray-spacer bulletin identifies affected 1982 NU50 frames as JH2AB130CS000001 through CS019004, JH2AB131CS000001 through CS019004, JH2AB130CK000001 through CK04388, and JH2AB131CK000001 through CK001301, including Iowa models. It addresses a tray condition that can damage the oil line routed behind it.

The January 1983 recall bulletin covers certain 1982 NU50 and NU50M machines. It documents old- and new-style air-cleaner brackets, the stiffener and mounting kit, muffler-spacer changes, related fasteners, rear-brake-cable location, and the X mark on the upper-left engine mount used to identify a completed update. A cracked bracket can eventually allow the rear fender to contact the rear tire.

Oil-injection setup is a genuine repair trap: trapped air after pump or line work can interrupt lubrication, and the pump-control alignment must not fall on the closed side of its index mark. During top-end assembly, the piston’s EX mark, the non-interchangeable top and second rings, and the ring-gap locating pins must be observed or ring, piston, and cylinder damage can result. A replacement cylinder must also match the original A/B classification.

The manual carries specific shop cautions for gasoline, battery electrolyte and charging gas, spring-loaded assemblies, hot exhaust parts, rotating components, and brake dust. This description is a contents overview, not a substitute for the factory repair procedures, measurements, or safety instructions.