©B250-350_ : @ .250°350 3. y :FOREWORD ‘This Manuel is a guide to the inspection end servicing of the Honda motoreycle, Honda 250/350, ‘Model CB250/350, CL250/360 and SL360. ‘The CLS50 is used es a bose for this manual, therefore, the photographs end drewings are of this model. However, since all models are practically identical, the information contained will apply equally to the other models. This manval, the Minor Change (MMC) Table on page 19 shows the principal modifications of other models towards CL250 Model (basic model). Great changes in construction and mi tenance are given in the text of the manuel and minor changes in those items re omitved, ‘Any information which are peculiar to aay of the models will be identified to the applicable model by the use of the codes listed below: Applicable to Code ALL CB/CL260, 350 models Honde 250/350 ALL CB259, CB950_ models (CB250/300 ALL CL250, CL350_models (€1250/360 ALL CB250, C1250. models CB/CL250 ALL CBS60, CL350_ models CB/CL350 ALL SL350 models ST.350 Service and maintenance procedures are outlined in detail to enable the shop personnel 10 locate the problems rapidly and meke repairs with mach saving in time. ‘This manual hes been prepared by major groups, assemblies and sections for easy use. Further, all work procedures are descriptive and accompanied by many photographs and drawing for clasity. Following are the initial serial numbers of esch model at the time of change Mel Frame No | Faline ca Toon ~s2sa06 | sooo aoe CmsoKe dooms — | eLoKe Son001 9X69 Caos {eon 020057 L ssa Coen somo. C10 soy001 soe | sone sooo =e cx Cranks snot 31813 CK crake ‘anoot~ Cosoxs oomo.an” | eLeaKs Sonoot CaNoKL ‘eo ~ — (CB350G- ‘S000001~ ‘SL350 1000001~ SLsox oon! 2190, sus Som HONDA MOTOR CO., LTD, SERVICE DIVISION f° 1 CONTENTS 1, TECHNICAL DATA A 2, SPECIAL TOOL... ae % 3. MINOR MODEL CHANGE TABLE OFF PRINCIPAL MODIFICATIONS ..... 19 A. ENGINE. ccstcennnon 4-1 Main Features 462 Power Transmission System 4-3 Dismounting the Engine 4-4 Remounting the Engine 2 455. Valve Mechanism Description Disassembly Inspection... Reassembiy Pistons and Cylinders... arent a et ae Description Disaosembly, Inepection VOP> Ss VORP Reassembly, ‘Cam Chain Tensioner hi ee ‘Description Disassembly ... Inspection ... Reassembly Lubrication System .. “4 Description B668 Disassembly Inspection popr., pone Reassembly. Claten Description Disassembly... Inspection . popp Reassembly 4:10 Crankshaft and Connecting Rod, 31 A. Description Sees 31 B. Dinassembly .. a 51 C__ Inspection Hite, 51 1D. YReassembly 4-11 Transmission‘A. Description B. Disassembiy ... C._Inspeetion .... D. Reassembly ... 412 Gear Shift Mechanism A. Description Disassembly Inspection .. Reassembly B. < D, 4-13 Bick Starter A, Description B. Disassembly CC. Inspection D. Reassembiy (Crankeases Description Disassembly Inspection Reassembly ages: op hee Carburetor Deseription Disasserably Taspection FRAME ...., Handlebar. Description Disassembly Inspection . ‘Reassembly pomp Fork Top Bridge . Description Disassembly Tnspection Reassembly ppp Front Cushion Description Disassembly Tnspeetion pomp Reasserably Pom. Steering Stem Description Disassembly, Inspection Reassembly + ep eses seese a a eee « 8 6 3 6 6pomp pop poop “8 A BR ic omp 61a A B Poel Tank Description Disnssembly Inspection Reassembly Frame Body Description Disassembly . Taspection Reassembly Seat y 2 “ Description Disassembly Inspection .. Reassermbly Stand and Brake Pedal .. Description ow ee oS m baa ® Put Pies nd Maen = Decroien “ts Dim e ee Boer ee aes ae a de Occ 2 Decne Dewey tape oe : ear Foo an Ret Fender ait Pee aeiea ee = ome iat z aaa Hee CEs Tay la B nest Oso e Patcpin B. Caiee pe oan ee = Decca Date ba sme re i Dissent oom tnpecin pereel | ise = a Pron Wheel oo es Taal ; sv Inspection. D. Reassembly FRONT WHEDL (with m dia broke system) A, Disassembly B. Inspection ©. Assembly e ‘A. Disewembly of calipers end manter cylinder a B. Inspection of calipers and master cylinder 93 CC. Assembly of ealipers and masier cylinder .. 4 D. Adjustment of disic brake % 514 Rear Wheel 6 A. Description 6 B. Disassembly . 7 C. Inspection 98 D. Reassembiy 9 6. ELECTRICAL PARTS 10, 6-1 Ignition System. 101 1. Tanition Coil 101 A. Description so B. Removal 101 C. Inspection 101 D. Reassembly 102 2. Spark Advancer 102 A. Description 102 B. Removal... 102 ©. Inspection . 102 D, Reassembly 102 3. Breaker Point 103 ‘ A, Deseription 103 B. Disassembly 103 ©. Inspection .. 103 D. Reassembly 105 4, Capacitor 105, AL Description os... 105 B. Removal. 105 : Inspection 105 5. Spark Plug 106 A. Deseription a : saan 6 B. Removal 107 ©. Inspection ... i 107 D. Installation 107 6. Noise Suppressor 108 A, Description 108 B. Removal 108 C. Inspection 108 D. Reinstalation 108OP ees oomee S PPR, BOPP GY POBPe OOD P yp oop ey pamper s Pe Generating System AC. Generator Description Disessembly Inspection ..... Reassembly est Current Limiter (Regulator) .. Description Disastembly Inspection i no Reassembly “ee ee once 10 Rectifying System Fda a in tis no Deseription sanenremnernenenten Mec TD Disestombly tee “ eee etee san Taspection .. 0 Reassembly i Battery ML Description seo m Removal, _— . fret egertane TUE Tnspection mz Starting System at Starting Motor... taste cose Description ae 3 5 Disassembly hee a Inspection 16 Reassembly ur Starting Clutch u7 Description ut Disassembly uy Inspection - er uz Reassembly ns Solenoid Switch, 8 Deseription cee eed rs snp rg ewe OB Remove. na Inspection... cog Reassembly Penta escag stesso EAB Safety Equipment. no Homa ‘ atl Description iggnaneasicciannaet ie Removel _ u9 Inspection 5 se ug, Reassembly sons sinnonnin Paesen Speedometer end Tachometer st ge Description naDragopre oe Poppe up ePpa or PORP» DOB PS UPB EE Pre DOPPas Removal. 19 Reassembly . 119 Headlight ... 120 Description xo Removal, 120 Inspection 120 Reassembly wt ‘Tail/Stop Light 12 Description 321 Removal. 121 Inspection sade Reassembly ees ay ‘Turn Signal Light . ra Description sat Removal 1 Inspection 1 Reassembly = ae : os 1D Flasher Relay pate hae ioe Deseription ne rites ME Removal. 12 Inspection .. i amie ster 12 Reassembly 1 Swltehes oon 3 ia ry Ignition $ Description Removal Taspeetion Reasserably Stoplight Switch Description Remove. Inspection - 13 Reassombly ener i a Starter Switch Bution and Lighting Switch 1 Deseription cnn eusin = : 1a Removal... : sera in 134 Inspection Reasoombly ‘Tura Signal Control Switch and Hera Control Switch, Description Disessembly... Inspection Reassorably Neutial Switch ae nthe BS Description e Removal a0) 15Tnepection Reassembly Wiring Harness Description Removal. Taspection Reassembly 7. ENGINE (SL356) POmMrPea oO T+ Dismounting the Engine 7-2 Remounting the Engine T+3. Primary Kick Starter _ A. Disassembly B. Inspection G. Reassembly 4 A B A. Deseription 8.2 Fork Top Bridge A. Description Front Cushion Description Disestembly Taspection Reassembly pope Steering Stem Description B. Disassembly C._ Inspection 1D, Reassembly 8-5 Fuel Tank A. Description > 8.6 Frame A, Desesiption B. Disessembly C. Inspection D. Reassembly T Seat A, Desssiption 8-3 Mufler A. Deseription - 134 134 138 135 136 136 136 17 13 1a 138 8 1388-9 Air Cloner... 138 A. Deseription B, Disassembly. C. Inspection D. Resssembly 10. Rear Fork 109) A. Description 199 B. Disassembly .. C. Inspection... . 130 D. Reassembly 8:11 Rear Cushion fe sae 140, A. Description 40 B. Disassembly. 140 C. Iaspection 140 D. Reassembly M1 8:12 Front Wheel 1a au 1 ui aL ELECTRICAL sean hee 2 9-1 Ignition Coil 142 9.2 Horn 142 953. Speedometer occ : ua 9-4 Starter Lighting Emergency Switch uae AL Disassembly ua B._ Inspection pie uaz © Reassembly v2 WIRING DIAGRAM Fisica us ‘CB250KA Wiring Diagram (U.K. Type) ua CBIG0K4 Wiring Diagram (US.A. Type) . Ma CBI50K4 Wiring Diagram (General Type) 2 us CLa50K4 Wiring Diegeam (USA. Type 6 CL850KA Wiriag Diagram (General Type) ur SLA50K2 Wiriag Diagram (US.A. Type) 148, CBI60G Wit Diagram (US.A. Type) 149 ‘MAINTENANCE 151 10-1 Maintenance Sehedule........0 151 10-2 Tightening Torque Standard : 152 10.8 Trouble Shooting SpeInspection 1. Reascembly Wiring Harness Description Removal... Inspection D. Reascombly 7. ENGINE (SL35®) . 7+1 Dismounting the Engine 7+2 Remounting the Engine. 7.3 Primary Kick Starter A. Disassembly B. Inspection C. Reassembly .. PEP eve +4 Carburetor Specifications B, Carburetor Circuits & FRAME, 8+1 Handlebar Description . Fork Top Bridge Deseription Pa > Front Cushion Description Disassembiy . Inspection Reassembly pomp Steoring Stem Description e B._ Disassembly, ©. Inspection D. Reassembly 8-5 Fuel Tank Description 8-6 Frame ‘A, Deseription B. Disassembiy . C. Inspection D. Reassembly 7 Seat A, Deceription 8-8 Muller A. Description oe 18 28 126 Ls 138 i” wz 1 134 135, 138 136 136 136, 137 17 1? 18 138 138 188, 18 138 138— 1. TECHNICAL DATA CB250K4, K5 ‘oil ‘Motel CB250 (U.S.A. Type) (CBIS0K4 (U.K. Type) CB250K5 ek DIMENSIONS Over enh 2080 nn (8231) 201m (0031) aoe Oven wiih Timm (05a) Gam (59m) Timm ‘Overall height 1075 mm (423in) 7005 mm (O4in) Time Wheel bse mn GOI 77m in 713 eo dea Tien C590) Temi (Bn) ‘eee Cath el 10 (628) 1a kg GTB) aks Frag ant Fm | HARARE T2r9D «| Gao 6i/gt by we wedge | 7/0 PRAM Type Sensoube, ele Seni-dvbl, ele See secede Sa actoge wa | a a Tete Gk IMS pease aa eat EL ati rams ee 008 PR) 08 PR) BORA PRB pers Tae a8 PR a8 FR) [950-14 PR Bink pes Brake, froal, ining aren Taternal expamion, 822 m2 Tnteral expansion, 109 en", Bein Tnterpal expending, 163 ext Internal expansion, SLO cm#x2 gternal expansion, 15D em, Internal expanding, 150 emt cooled dstroke cocked 4 stroke Brake, rar, lining aren Eee Feel capacity iit. @2US gal, 26 imp. gal) | 12k. G2US gal, 25imp.qal) | 1.0te. Caster angle ee ar a0 ‘ral engin mm (35in) 85mm (336m) me = ENGINE Type OG. ewin cylinder, air- | O.H.G. twin cylinder, ai» | Air cooled 4stroke OH. enn: Cylindor arrangement Vertical, win parallel ‘Verieal, ewia parallel + Vertical win pavalle! 5 Bore de SixiOdom Gant) | xis wm TERIOR) | BOARS me Deon 2 OB2l on [ Bier aster Bes a oe Carburetor ‘Valve train Max torque Conseant velocity (ype, Keihin iain aves oven cm 211 bye 9500 rpm (155 1b 008m) Consant velocky ype, Kelhin hain driven overhead cay shake ‘214 hg 9,800 rpue (155 4b) 8300 pa) Consiane velociy wpe 20 ke-m/9,000 rom‘Model tem CB2s0 (USA. Type) (CROKE (UK. Troe) onesoKs Oi capacity 2Ie AUS ca, 18m 2th. @1US oun, 18 imp. usr) 2olie Tubrication system Forced and wee samp Forced and wet sump Forced and wet aump Towead gasoline with 9 iaace SL ae ae | eee fe ones ie ne feet ie eae ee es an eet i ae eee Paimary reduction ama ama vy 2nd | L686 1.636 a ‘L730 et | 1260 | 1269 FE L975, re ee ee ee eee ee i is Final reduction if 2.376 Z | 2378 2378 Packs se = me Goce Staring svsem Motor and kick ‘Motor and kick ‘Starting motor and kick starter ‘Spark plug: NGK B-3ES, 'NGK B-8E3, ND NGK BEES, ND W-24ESCL330K4 ae ee C1350 (US.A. Type) CLasOK4 (U.S.A. Type) DIMENSIONS Overall length 2020 mm (795i) 2.005 mm (79.7 in) Overall width 0mm (27 in) Sm G27 Overall height 1000 mm (429m) 1200 mm 43318) ‘Wheel base 1820 mm (620in) [2220 mm 620% Ground clearance 180 mm ( &in) 160 mm (6.3 ia) Curb weight 357 kg 1845.418) 160 ke @72.618) ‘Weight distribution F/R | 91/125 kg (200.1/277.81b) 1/126 ky (2007/2778 1b) FRAME Type Semi double, cradle Semi-double, cradle ‘Suspension, trout Telescopic fork Telescopic fork — Brake, front, lining area Brake, rear, lining area 350-28 (4 PR) Internal expansion, 52.2em*x2 Internal expansion, S1Dem!x2. ‘Suspension, rear Swinging arm Swinging ams ae Tire size, front 3.00-19 (4 PR) | 00-19 (4 PR) Tire size, rear ‘350-18 (4 PR) Taternal expansion, 52.2 em®x2 Internal expansion, 51.0 em! x? Cylinder arrangement Bore and stroke Displacement eeLewaaie | 4%50.8 mm (2.52% 1.992 i 825 cc (19.8 cwin) Fuel cepacity 9it (24US. gel, 2.0 Imp. gal.) Slit AUS. gal, 201mp. gal) Caster angle oa" ve ‘Trail length 95 mm (3.74in) | 96mm (74a) ENGINE | Type OC. twin eylinder, aic-cooled Astroke | OH. twin cylinder, sircooled ‘stroke Vertical, twin parallel 64x50.6 mm (252X199 in) B25 ce (OBewin) Compression ratio Carburetor Valve tein } Max. torque a5 Constant velocity ype, Keihia Chain driven overhead camshaft 2.69 ka-m/8,000 rpm. (19.5 {1b /8,000 cpen) 95 ‘onstant velocity iype, Keihin Chain overhead camshaft 2.69 lcg-an/8 000 rpun (19.5 f-1b/8,000 rpm)nae = (CL350 (US.A. Type) CLBS0K4 (U.S.A. Type) Oil capacity Bie @1US. quart 18 imp. quart) Dit, @1US quart, 18Imp. quart) Labricstion system | Forced end wet sump Forced and wet sump Fuel required: ‘Octane mumber sbove 05 ‘Octane number above X Easine weight, | 2a cuS5Ib Soke (147 b) DRIVE TRAIN tet Wet, multplate type ‘Wes, multi plate type ‘Trenemission 5 speed forward, constant mesh 5 speed forward, constant mesh [_NGK BES Primary reductio. S714 37 Gear ratio Ist 2.388) 2.353, a za zd | (1.636 1.636 ad 1.289 1.268 Te ath 1006 1086 [ th 0900 | aso Aad Final reduction 2375 2375 ELECTRICAL Igeition Battery Beutery Starting system ‘Motor aad kick Motor and kick 5 Pattery capacity WV-12AH | agvazan a ‘Spark plug NGK BES ND W-2185CLS50K5 (US.A. Type) Tem Metric English Dimension | Overall length 2,025 mann 782in Overall width 810mm 3189 Overall height 3,100 mm 4330 “Wheel bese 41,820 mm 520ia at Seat height 20mm 3230 z Foot peg height 205 mm 120i0 Ground clearance 160mm ia Dry weight soz ke sb Frame Type Semi-double cradle suspension, tavel Telex ie Fork, travel 146mm (15% Swing arm, trevel 77.6 . suspension, travel 300-19 (PR) Blok perme a reonre LB aTen? OB tire size, presoure 450-18 (APR) Block patiorn, tire air pressure 20 kg/em* (28 ps F, RK F. tire sie, pressure R. F. "brake, lining ares Internal expanding sboe, lining swept area 109.en" (25.2 sa. ia) R. brake, lining acea Internal expanding shoe, lining swept area 150em! (23.30. in) Fucl capecity 85 it 2.2US. gal. 19 Imp. gl Fuel reserve cape ns 20 05 US. gal 0.4 tmp. gel Caster angle | Trail length 5 rom a7ie [Front fork oil capacity 125-130-ce (eo fill dry) 42-44om Front fork oil capacity | 105-110 (to fill ater draining) 36-87 ors Engine Tyee Cylinder arrangement Ai cooled, dstroke OC engine Vertical twia parallel | Valve train Bore and Stroke 61.0 50.6mm 2.520% 1.992 Displecement 325 ce 198 cwin Compression ratio 95.4 Chain driven over head camshaft | Oil capacity Lubrication system 20 ie 21 US pe 18Tmp.at Forced and wet sump Cylinder head compression pressure Tntalee valve Exhaust valve Wleg/em* (170.7 psi) “At 10" (before top dead ¢ AL 35° (after bottom deed center) TN: 9.002, EX: (.004 inItem Metric English Carburetor Type Seiting mark 726 Main iet Slew jet Ai screw opening TH toe Float height Drive train | Clutch ‘Wet, multi pate tree Transciasion Saapeed, constant mesh Primary reduction 37 Gear rato T 2350 oe Gear ratio 1 1.636 (Gear ratio IL 1209 Gear ratio VI 1036 Ss Gear ratio V ‘0900 Final reduction 2305, drive oprocket 167, deiven 387 Gear shift patiern [Left foot operated rewumn system Biectrical | Ignition Battery and ignition col Searing system Staring motor end kick starter Alternator TA. generator 0.1 kyw/5,000 rpm Battery capacity Spark plug VA, NGK BSES, NDW 24S Headlight Low/high 12V-250/35W ‘Tai/atoplight Teilstop _ 12V-$/82CR (SAE TRADE No. 1157) ‘Tur signal light Front/rear 12V-20/32CP (AE TRADE No. 1073) Speedometer light = LV-2CP___GAE TRADE No. 67) Tachometer light LV-2CP (SAE TRADE No, 67) Neutral indiotor Hight CP (SAE TRADE No. 57) “Turn signal indicator Hight [ 12V-2CP (SAE TRADE No. 57) Hiigh beam indicator light Ly-ZCP (SAE TRADE No, 37CBS50KE Tew mee CBS50 (US.A. Type) CBBOKS (USA. Type) DIMENSIONS Overall length 2010 mm (79.20) 2010 am(79. in) Overall wide 775 mem (305 in) 766 men (30.1 jn) Overall height LOTS mm (23 in) 11.086 mma (42.7 in) Wheel base 1.520 mm (520in) 1320 mn (520m) Ground clearance 150mm ( 59in) 150mm ( 59 in) =| Curb weight 120 kg (952815) kg @7210) Weight distribution F/R | 96/124 kx (21.7/278.41) | 73/88 kg. (181/188) FRAME Type Seri-Jouble, cradle Semi-double, cradle Suspension, front Telescopic fork “Telescopic fork Suspeasion, roar Swinging erm Swinging sem | ‘Tire size, front 3.00-18 (4 PR) | 300-18 G4 PR) 5 Tine ses, reer 350-18 (4 PR) 25018 GPR) * Brake, roan Feel capacity ing Brake, front, lining ares 12lt. (@2US.gal,, 261mp. gal) Tnternal expansion, 52.2em*x2 Internal expansion, $L0em!x2 or ae a2lit, (@2US. gal, 26 lp. gal)» 85mm (.2in) ‘85mm (839 in) Internal expansion, 150.em*, 23 sain Taternal expansion, 109 em’, 26sqria Bore and stroke i Cylinder arrangement | Vertical, win parallel 56805 mm (2.205%1 992in) ‘Vertical, tia parallel ate OH. twin eylinder, airccoled 4etroke | OH. twin cylinder, air-cooled 4-Stroke 64%50.6 mm (2.520% 1.992 in) “Displacement 825 (19.8 cw-in) 925 cc (19.8 ein) ‘Compression ratio 25 95 Constant velocity wpe, Keibia Constant velocity type, Keihin Max. torque Chain driven overhead camshaft Chain driven overhead camshaft 214 kg-m/9.500xpm (155 ft1b/9,300 rpm) | 2.24 kg-mn/9,500 rpm (15.5 ft-lb/9,500 mpm)ne Mee (€B380 (U.S.A. Type) CBIG0KA (U.S.A. Type) Oil eapacity| | 2iit. @AUS. quart, 18 tmp. quar) 2k @1US. quart, 18lmp.quart) Lubrication system Forced and wet sump Forced and wet sump Fuel required Octane aumber above 9 Octane number above 99 Eagloe weights | 625ke (SSI) szokg (15.8) DRIVE TRAIN ‘Clute Wet, multi-plate type Wet, multi-plate type “Transmission 3 epecd forward, constant mech 5 opeed forward, constant mesh Primary seduction ana and Z Gear ratio Ist 2359 2363 2d 11.636 1.685 ard | 209 1260 ah | 16 1.036 5th 9300 | 0.900 Final reduction | 2250 r 2.250 ELECTRICAL Ignition | Battery Starting? pytern Motor and Kick Motor and kick See capacity 12V-12AH 12V-12AH Spark plug NGK B-865 __NGK B-SES ND W-24ES‘tem ‘Overall length Overall width Overall height ‘Wheel base | Seat height | Foot pes. height Ground clearance | Dry weight ‘Type Semidouble cradle type , suspension, travel R, suspension, travel F. tire size, pressure R, te size, pressure Telescopic fork, travel 114.6mm (45 in) Swing acm, travel 775mm Bin) ‘300-18 (4PR) Rib pattern, tire air pressure ‘350-18 (PR) Block pettem, tire air pressure 2.0 kg/em* (28 pst) 18 ka/em® (26 psi) F, brake, lining area , breke, lining area Fuel cap Dik brake, lining swept area 38 om? (5.9 sq. in) Internal expandiag shoe, lining swept are 160em? (23.3 eq. in) 29US.gal 24 1mp gal, Fucl reserve capacity 05US. gal 0.4 Imp gal Caster angle ‘Teil length # Front fork oil pacity Front fork oll capacity 7 Cylinder arrangement Bore and stroke Displacement Compression ratio Valve tain Oil capacity Lubrication system pressure Intake valve i Exhaust vee — 125-130 ee (io fill dry) 105-110 ce (to fil after dr ‘Air cooled, 4-stroke O.LC. engin ‘Vertical twin parallel Chain driven over head camshaft Cylinder head compreation Wke/em* (160.7 psi) before top dead cente ‘after bottom heed center) Open Clote Open ___At 40” (Lefore bottom daed coater) Close | At 159° (after top dead center) Valve tappet clearance IN: 0.02, EX: 0.0040 “Tale speed10 * # Item Metric English Garburetor|_‘Type "| Piston valve ‘Setting marke on Maia jet Pri #78, 2nd $105 Slow jet 0s ‘Air screwing opening 14 £94 tums Flot height 6 Drive train. | Clutch Wer, muliplate pe ‘Transmission S.speed, constant mesh, es Primary reduction 374 Gear ratio L 2.558 Gear ratio I 1.636 Goer ratio II 1.269 Gear ratio Vi 1.088 Gear ratio V [000 Pinal redvetion 2.250, drive sprocket 161, driven sprocket 367 Gear shift pater Left foot operated retura system, Tecra” nition Battery and ignition coll Starting system Alterustor jrting motor and kiek starter ‘ACC. generator 0.1 lew/5,000 pm Battery eapacits 12V-12AH Spark plug Headlight Tail/stoplight ‘Torn sigaal light Speedometer light NGK SES, NDW 2488 Low/high _12V-25W Tai/etop _ 12V-8/S2CP (SAE TRADE Front/rear 12V-82/32 CP (SAE TRADE 12V-2CP (GAE TRADE No. No. 1073) No, 1157), 51) Tachometer bitht 12V-2CP (SAB TRADE Ne. 57) Neutral indicator light 12V-2CP (SAE TRADE No, 57) ‘Turn signal indicator light 1WV-2GP (GAE TRADE No. §7) High beam indicator light [ 12-V2CP (GAB TRADE No. 57)ll 1350 70a a CL250 (US.A. Type) DIMENSIONS Overall Jengeh 2100 men (82.7 in) Overall width 830mm (32.7 ia) Overall height 1090 mm (42.9 in) ‘Wheel base Ground clearance 180 mm ( 7.1 i) i Curb weight 157 kg (946.416) “Weight distribution F/R 91/126 leg (200.7/277.818) Semidouble, cradle ‘Telescopic fork Suspension, reer Tite sie, front Ture size, rear Bore and stroke "Displacement Compression ratio Carburetor Valve train Max. torque Brake, front, lining area ‘Swinging arm 300-19 (4 PR) ‘950-18 (4 PR) Intemal expansion, 52.2cm'x2 Intemal expansion, 510m? x2 Slit. (2.4 U.S. gal, 20 Imp. gal.) Vertical, twin parallel (5650.6 mam (2.905 x 1.002 ia) 249 ce (15.21 ewin) 95 Constant velocity type, Keihin Chain deiven overhead camshaft ‘207 kg-1m/8000 xpm (15 {-1b/8,000 rpm) cylinder, air-cooled 4-stroke12 ‘ties = CL250 (US.A. Type) Oil capacity 2iit, @1 US. quart, 18 lmp. quart) Tubrication system | Forced and wet sump 5 Fuel required Octane aumber above $5 Engine weight guy | 525g (118518) DRIVE TRAIN latch Wet, multi-plate type Tranomission 3 speed forward, constant mesh Primary reduction =| S74 3 Gear ratio tet 2353 and 1.936 i od) 1.280 e Sh ah | 1086 ees aes | 5 0900 = Final reduction | 2575 ees ELECTRICAL Tenition Battery | Starting system | Motor and kick Battery capacity 12V-124H a Spark plex NGK B85 Z ee13 om teen ‘SLSG0K4 (U.S.A. Type) ‘SLBS0K2 (U.S.A. Type) DMENION ] Oven eng anton sain 216 am tin Overt with ‘idm | an fan Sin Overall height 1,145 mm 45.08 in | 11% mm 463in ‘Wheel tase 1,990 mm 54.72 in 1,400 mon 2 ‘S6.lin Sa bit 0. asin am Sain Foot peg height 900 mm iigtin | 330 mm 130in Crom Gurnee |e usage aie Cab web —, ash is sm Wigs dasibs F/R |g aa use ieee FRAME | = Dasha ce Dele cil Sarat F | Tekan fe 7 | Sepa Seach tentang Sees ee a rn ra Tire size, F 9.25-19 (4PR) "300-21 (APR) Tire size, R fis 4.00-18 (4 PR) : 400-18 (4 PR) eal expending so, Tita edge, Brake, F, lining area Brake, R, lining area Gat sg.in x2 (46.9 9q,em>x2) Tateraal expanding shoe, Ttoguin tag 22) cael ee Gib oqsinn® 2g. omx2) Ssh eg: ine (2aq. cm x2) Pel capaciey oie |24US gl 20%mp el 90 i 24US gal. 2.0 mp.) Fuel reserve capacity 201i H2US.pt 35tap pe 20ke 42US.p. d6Imppt, Caster angle y oar 7 Trail length 110 mm 433 in 148 mam 5Bin ENGINE Tre OM. ewin-cylinder, sir cooled, 4-eycle OH. twin-ylincer, sir cooled, Leycle Cylinder arrangement ‘Two cylinders ia tandem Vertical, win parallel 61x50. mm 252% Loszin ore and Stroke 64x 508mm 22x 1.992 in Displacement =| 5ee ioBouia BB ce 18exin | Compcession ratio 28 95 Carburetor Keihin, PW 24 Keihia, FW 24 Vaive train | (Chain driven overhead camshaft [Chain deiven overhead camshale Maximum ome 25 kxm/8000spm | ISL Wt/So0rpm | Zokgm/AOWrm | ISATb-f/8,000rpm | Oil capacity 2olie 4208 pe 35Imp.pt 20t 42US.pt a5Imp Labrication sysiem Forced pressure aad wet sump © Forsed presoare and wot ump | Engine weigh Gnclude oi) aes wo85ib ang 103.5114 Medel eS SLSS0K1 (U.S.A. Type) SLSS0K2 (U.S.A. Type) DRIVE TRAIN lush Makiplats, wot type Muli-plate, wet expe Tiassmission 5 speed, constant mesh & opeed, consiant mesh Primary reduction ‘a7 saa Gear ratio Ist 2.388 2.866 2d 1690 800 ad | 1280 1588 ah = 1086 Tans \ Bh a 00 os Final retucion 2500 265 Gear shift stern Left foot reuen type syseem lt foot rou type system LECTIN to ey and gion ct Basu gion vo ‘Stazting System & Starting motor and kick pedal ‘Kick starter Alternator rs AC generator = AG penerstor ae cy BV-S5AH BVsAm ‘Spack plug NOK BARES, NDW-4ES NGK B-8 ES, NDW-24ES PERFORMANCE T Bs pe net nth igh sain ov ae otk ak [| he. aed 5 mph Bi kph 59 mph (85 kph a el Wolk ah | on Dao hs oh wah Pac comme Sai vsa Bh a Oech SHIT wl BS kmy/tt. at GO Eisen | 2 eeeo | Ginga = » | Turning circle weak Alm Th 213m “pig deme | kw logh | meso | haa | me Ph Sos een lydia, BYSIRW ALA.2. SPECIAL TOOLS CB/CL250 + 350 RefNo. Tool No. Description .07900-2860000 Special tool set for CB/CL250, 350 (0798)-2860100 Valve seat cutter 90° ‘07980-2860000, Ialet valve seat top cutter (07280-2860400 Exhaust valve seat top cutter (07080-2860500 Tolet valve seat interior cutter (07880-2860600 Exhaust valve seat interior cutter @sannesesgesosescea (07845-28610 ‘07002. 2000000 Drive sprocket holder Valve seat cutter holier Valve guide ceamer, 7 mm Valve lifter Valve guide driving tool Valve guide removing tool Fiston base (2 each} Fiston ring compressor (CB/CL250) Piston ring compressor (CB/CL350) T-Handle dynsmo rotor puller Lock aut wrench, 16mm Carburetor float gauge (CB/CL250) (CB/CL350) Bearing driving too! Pin spanner, 48 mm16 CB/CL250 + 350 een Y@ eS ~ oh ewe ® Ref. No, Tool No. Description ‘ @ o7947-2790100 Brant fori oil seal driving guide , a (07959-29000 Rear cushion assembling end disassembling tool ® ‘79022500000 Main switch pin spanner @ 7946-2860100 Front wheel beering driver attachment a 7945-2860200 ‘Rear wheel bearing driver attachment B o7949-2860000 Bearing driver handle e (07965-2860000 Front fork assembling tool a .07999-2860000 Dynamo inspection cover ® 7917-3290000 Wrench, hollow set 6 mm a Rear wheel bearing retainer adjust wrench Tool ease (CB/CL250, 350)S1350 7 Ref. No. Tool No. Description 07900-2860000 -—*Special tool set for SL360 © (07980-2860100 Inlet valve seat 90° cutter (IN. EX) @ (07980-2860300 Inlet valve seat top cutter ® (07980-2860400 Exbaust valve seat top cutter © (07980-2860500 Inlet valre seat interior © (97080-2860600 Exhaust valve seat interior cutter © Valve seat cutter holder, 7 mm © Valve guide reamer, 7mm ® Pin spenner, 48mm ® ‘T-Hendle dynamo rotor puller @ Valve guide driver ® Valve guide remover @ Valve spring compressor 6 Main switch pia spanner @ Roaring driver 8 79999-2884000 Dynamo inspection cover “These tools are for use with the $L450 only, the others one common to all series18, Ref, No, Tool No. Description ® 07946-2800100 “Front and R, Rear wheel bearing driver sttachment @ o7até-2860200 © #L, Rear wheel bearing driver attachment e o7gig-zg0000 “Bearing driver handle e (07949-2730100 Front fork oil seal driver guide 2 o7gz2-2870000 Drive sprocket holder a (07959-3290000 *Rear cushion disassembling and assembling tool 2 79162830000 ‘T-handle box wrench, 16 mm a ‘o7491-0010000 Float level geuge a rato. Rear wheel hearing retainer adjusting wrench 3 (07954-5910000 Piston ring compressor @ (07958-2500000 Piston, base a O7797-0510100 Valve seat cutter case 920300 Tool case 8 o7gy7-3230000 Wrench, hollow set G mm +thote tools are for use with the SLI50 only, the others are common to all seri.19 en ary en worms dois song & yBypes <9 gouernodde posorduy 40g ooweswadd anoaduar 404 a Tipenb qanpora posorduy 30g ytenb qompead pasoaduay 40 Impeg ayeag aay S207 Wag pu Iwas | wpa panodiy 30g ao eT We> jany vado dus ue diate pond oy amu) Thien onpord paxoadwy 404 2 Leg $M OfeoreaD SNOILVDISIGOW TWdISNIdd 40 318VL JDNVHS T3GOW YONIW ’E OSE USAIDPOPU PIS women 203, ou 289 hesy Paya ORT Wat#3 ose-0sce “sr osea>aT OAT PRAT Ha ES soured povoxduay 10g Aqqenb qonpoad posordut sea | ‘umieay ah ‘pesos plo WET mae one) Ds, pure diaye poraied o} a3ueyp | pav dine porujmd 0 asuey, (= Pree) 1m a 0st 19 $M 098719 2M ose'0e7T9 ose'0e7 19) waaL O01),aapuog 80x. souvavodde paxoat Syondey paw suey [eM a1pesr aqqnog ounay stuymadyy 9g Zyenb yonpead poaosdiay 10g wt a unig 2 seseszr ops Ho é GLY epuoR) anqes 924g, won p91 ye98 woot BL RS si mine ee MIME ope uopeeaduos sons | ECT 22961 —USL Sysedes [1D - rs | CL a % ‘puelt wo popuoumo:og | LV VONOH ? 110 oie sain) eure Soa Se {8 1 enn asye0 vom sea ous TH OSES mM OES OSes: WALL24 ‘rend yonpoad penoidayy 10 paweny auey 2poH PUPH Tor wD AAG FPG OL adi seq2ypue HL uey nog sumer soup ary wap pereanoay 30 yds UL AayRS 20 ss = a ue soueresdde poaorduy rag 1M OSes WALL25 @ dss VS 40) BF 427 Jo “ON G7 W991 J0 ON oF 499) 30 “ON, away) ney yous 19yINe) (401) 06 41999 30 "0X. wai doy ayeys urew g ce >) 10 ON gray IFS YS MH 208 pars @ = vay PALL pu Puosag eUS EAL 2diy SA 295 $1 W987 30 “ON 11 978 30 “ON, == 2139) JON 13eUS WORE wopssyuusTENT, auex Peompes IWBIPA OPMPA anroyy Zag aay ajanyas go ‘aenrs9q post 94/84 EONS] aayainqe9, oI oss, WaTay 19 easy g9 ‘pasuays yun) [ony sw0se70/90se9 sy08eT9/19ecu ee Sire oe Sees nae ayn Jo ayZue Zuyunow jo asue BYP OW} WIE WorToUMfueD Uy quoredowes; © 0} paSuny> soyojd [op soy} PUN pazuey> 19}2Woy>u; puE a}owopaads Jo [Fu AUENOW, aaa son19q 205 ody woreMMNyTE eyose10/90seH9 Mose 9/9Rue assay 88 onmea HO Faneipe Bande woqioeqe POIs ‘poseassuy uopjeod Zupssnfpy Lequosqe yoous s¥ax Jo soquMN, 284d i Oe -aeiomoppads pue io}amoyoe) wo2Kyaq poplucrd primary drive gear— (primary driven gear) clutch outer —» ‘ight friction diske —» eight clutch plates — clutch center + ‘wansmission mainshaft~—> mainshaft gear— countershalt gear “Scountershait—+ drive sprocket > drive chain— rear wheel (Fig. £3) NOTE: ‘The following parts can be disassembled from the engine without dismounting the engine ‘rom the frame. Crankease cover (both right and left), left crankease rear cover, + Clutch assembly + Oil pump, oil filter + AC. generator assembly + Neutral ewiteh + Cam chain tensioner holler @ f, crakshalt @ R cmkslali @ Chaich @ Transmission manshatt & Transmission countershate @ Drire sprocket Fg, (1. Drive sequence 4.3. DISMOUNTING THE ENGINE 1, Fuel tank Tum the fuel cock w the “STOP” position; remove the fuel lines from the cosle and the fuel level tube, and raise the seat to remove the ten 2, Remove the malflers. 3, Clutch cable Remove the gear change pedal and step bar, and take olf the L, eraakease rear cover (© Electrical leas connector @ Comtect breaeer leads Fig. 42. Removing the electric leads|. Remove the drive chain 1. Remove the reer brake pedal. 6. Carburetor Remove the throttle control eables from the carburetor: remove the left and right air cleaaer cases and loosen the earburetor insulating bands. Unplug the electrical cable connection, (Fig. 4-2) |. Remove the contact breaker cable connection. |. Remove the high tension terminal assemblies from the @ Starting motor cab spark plugs. Fig. £3. Remoring the starting motor cable 10, Remove the starting motor cable. (Fig. 4-3) Il, Disconnect the tachometer cable at the engine. 1B, Remove the 7 engine hanger bolts and dismount the engine from the right side. (Fig. 4-<) 4:4 REMOUNTING THE ENGINE Remount in the severse sequence of dismounting. NOTE: “Insert the hanger bolts from the right side of the frame ‘and tighten wis fom the left side. Instell the battery ‘ground cable from the right side. (Fig. 4-8) +i the hanger bolts do not goin easily, do not force Find the cause and make correction « Whea insialling the battery ground cable, clean all rust ‘and paint (rom the hanger bolt as well as from the terminal and the frame mounting area so that good contact is assured, (Fig. 4-5) | © Battery ground exble @ Engine banger bolt Fig. 4-5. Installing the bauery ground cable Make eure that the drive chain joint link clip is facing in the correct direction, the opeaiog must be opporite to the direction of chain movement. (Fig. 4-0) © Joint ckp Figs 4-6, Drive chain joint dip dicestion . + Make sure that the steel ball has been assembled in the clutch lever before installing the left crankewse rear cover. (Fig. 4-7) @ Steel ball @ Clutch lever 1 Let crankcase pear cover “ Fle. 4-7. Plocing the sect ball ss4:5 VALVE MECHANISM A. Description ‘The valve mechanism consists of a camshaft, rocker arms, intake and exhaust valves and their related parts and ishoused within the cam case. Driven from the crankshaft through a loop of cam chain, thé cemsheft moyes the valves through the rocker arms. ‘Thie shalt is supported at two places and runs at 1/2 the crankshaft speed. ‘The working suriaces of the cams are carehardened by softnitriding (CLN) process to provide a greater wear resistance. The eamside ends of the rocker arms are hard-feced with a special alloy. The valves are stellitefaced and their seats are made of a hestresistant steel to minimize valve com- poueat wear. The tachometer drive is located at the right side of the camshaft and the spark sdvancer and contact breaker at the left side, @ Gam chain @ Cam sprocket @ Camshaft @ Valve rocker arm ® Rocker arm pin ® Valve spring @ Yalve Fig. 48 Valve mechanism B. Disassembly . ML. Remove eight 8mm cap nuts and remove the cylinder head cover. 2 Remove the dynamo cover, breaker point cover;,contect breaker point assembly. and the spark advancer. 49) 3, Remove the rocker arm pin Jock nus (both sides, 2 euch), and the side covers and rocker arm pins. (Fig. 4-10) 4. Remave the cam chain tensioner. © Rocker arm pin lock nuts @® Rocker arm pins @ Side cover @ Rocker sem Fig. 410, 5. Align the staise index merk to the “LT” on the AC. generator rotor (top dead center of the exhaust stroke) {2 approximately 10° ATDC and then remove the sprocket sligament bolt, followed by turning the rotor to align with a point approximately 10° ATDC of the compression stroke and then remove the remaiaing sprocket setting bolt. (Fig. 4-11, 12) © Index mark @) “LT Fig. it, Line up “LTSNOTE: + Hook bolt and the sprocket setting bolt can be easily removed by usiug the 10mm universal box wrench provided in the special tool kit, Tool No. 07093-28601) (Fig. 4-12) «= This is a special bolt and therefore it should not be lost ot mispleced, It can be identified by the markiog “9” stamp on the bolt head, D 0mm sniversl box wiench @ Cam sprocket 1 Pig. 4:12, Removing the cam sprocket = iy, 6. When removing the camshaft from the cam case, remove.” the camshaft from the windows for remoging, the cam sprocket and cem case, which are essentially provided 10 Femove the camsheft, vowaed the right hand side while placing the “L” mark of cam sprocket oa the upper Side as for Fig. 413. @"L" mark & Cam sprocket » Big. 4.18. Placing the “T” mark on the upper sds & 7 Remove the four Gaim cross Sorews and Separate the ie ome, le. 210) ia \ ng ceoe screys all 1m hex, bolts @ Gylinder head I-18. Removing tha eslindae head & Remove the sperk plig snd ‘unserew the 6mm bolts from both sides. (Pig. 4-15) 8, Separate the cylinder bead ftom the eylindes 10, Use the valve essemnbly and slishssembly tool (Toot No, (97957-2290000) and disasxemble the valve cotter, valve retainer, valve springs and xalve spring seats (Fig. 4-10)C. Inspection 1, Compression pressure (Fig. 4-17) The engine does not have to be dismounted to check the cyliader head compression pressure. Perform the \ measurement while the engine is at operating tempers move the spark plug, it the head of the compression gauge on the spark ‘plug hole, Head it firmly so that compression is aot Jost. * © Compresion gan 3) Open the throitle grip and choke valve completely. Fle, 41, Messuring compreison presure 4 Kick the starter pedal repeatedly, quickly and powerfully, and reed the maximum value on the gauge 5) The rated compression is 12 kg/sarem (170 pail). 2. Adjusting the engine to the proper compression pressure, + The engine must be dismounted for this operation. If the compression méasure over 12.kg/ad-em (170 pai), the combustion chamber wall and/or pision heed probably have carbon deposit. Remove the carbon deposits from the combustion chamber (refer to page 35) oF piston head. > When jon is below 10.5 kx/sa-em (150 ps), perform the following operation. 2) Lap (refer to page 30). 2) Cheele ind piston rings (refer to page 40). ® 8) Check cylitder head gasketing surface (refer to page 35) 3, Valve tappet clearance inspection and adjustment ‘This operstion can be ‘performed without distiounting the’ engine, Further, make the check with a cold engiae. Perform the cheek and adjustment ia accordance with the following procedures, ol 1) Remove the tappet holé caps. * 2) Remove the contact breaker cover and dynamo cover. ¥ ‘ / ) Tarte geertoe 6 Gapercoctwis and alin Delt Sigg omic ifthe nie mar on the wer (Fig 2 With the finger, check w make sure that both rocker Tine of eee aden the eam ase is tee ie Shine tnt the pbs for ant tp ESEStner othe Compression wre I the tae set hn th genet ao Pig. 6-2. tgaion col © Primary rial @ High wonslon terminal @ Cove @ High tension cord @ Spueve resin @ Primary call © Bobbin. Secondary en @ tron core Fig. 6-3. Sectional view of ignition col B. Removal 1. Raise the seat and remove the fuel tank. 2. Disconnect both the right and left high tension cords from the spark plugs 3 Unfasten the wire harness clamp. 4. Disconnect-the right and left ignition coll wiring at the counectors Tolt coil: Yellow and bleck cords Right coil: Blue and black cords Discounect the condenser (mounted on the ignition coil base) wiring (yellow and blue cords) at the connector Unscrew the two ignition coll mounting bolts 1o remove the coil from the frame, (Ignition switch and hora are also mounted by these bolts) pe C. Inspection 1. Bench testing ignition ceil Check the ignition coil using the service tester by following the procedare on the next page. (Fig. 6-4) Connect the power cord to the 17V buttery and ground the bleck ground cord. Connect the ignition primary cord plug to the tester aad connect the opposite terminal end to the primary terminal of the coil. Connect red test lead {fo the black terminal of the ignition coil, and the white lead 10 the yellow cord of the left ceil (right coil to the blue cord) Connect the high tension cable (red) to the secondary coil terminal Porition the selector knob to COIL TEST, Adjust the three point spark tester to the maximum distance spark is Imaintaiued aad then avte this distance, The coil is eatisfactory if the distance is greater than Tmm (0.28in). NOTE ark condition as shown in Fig. 5-A is normal. Fig. 5-3B shows the spark condition when the test leads fare connected in reverse at the ignition coil.@ Seve rier @ Coll eat wh @ Spark exp finder © Ignition coll © Baciery g Sea om check da ee. Fig. 6%, crane Us HEAD yA " ATTACHMENT Zein PU HIGH VOITAGE CABLE TRANE OR ENGINE Fig. 66, Iguiton cell est é. Pig. 61, Spark advsncer 340 zx 20 : =10 = 2 S 123 6 $xi0000n ENGINE SPEED Fig. 6-8. Spark advancor cheracteristiex ‘Inspection with a service tester (Tool No. 07308-0010000) 1, Ignition coil This test is conducted to check the coil performance. If the engine fails to start, check the spark plug, points and condenser for condition. 1) Connect as shown in Fig. 6-4. 2) Turn the service tester coil tout awiteh to COIL TEST. 19) Observing the spark jumping across « S.point spark gap, turn che check diel and measure the jumping fistance. Tf the spark jumps more than 6mm (0:236 in) in air, the coil is in good condition, NOTE: If the sptrk appears in the form @ in Fig. 6-5, coanest the hightension eable to the tester in the reverse direc- tion and measure the jumping distance with the spark: in the form @. D, Reassembly 1, Reassemble in the reverse onler of removal 2, Spark Advancer ‘A. Deseription “The spark advancer is of a ceetzifugal type and is mounted on the camshaft, As the engine reaches a considerable speed, the fiyweights expand out, opposing the force of the springs. This redial movement of the flyweights due to centrifugal force causes the point cam to move in the direction of rota. ton, that is, in the directioa of advancing the ignition timing, to obiain satisfactory burning of the mixture under all speed and lod conditions. B, Removal 1, Remove the point cover. 2. Unscrew the two cross screws and remove the contact breaker point assembly. 3. Unserew the spark sdvencer mounting bolt and remove the eperk advancer C. Inspection 1, Check to meke sure that the govemor weights are operating smoothly, Repair or replace if they are not operating properly. . Spark advancer specification. + Crankshaft speed at start of spark advancer, 1600~2000 RPM + Crankshaft speed at full spark advs + Range of spark advance, 27~33 2 ce, 3200~3800 RPM. ‘Reassembly Perform the resssernbly ia the reverse order of removal3. Breaker Point A. Deseription - ‘The breaker point is one of the major functional parts of the ignition system, It is located in the cam cese and ‘consists essentially of a hase plate, breaker arms and two sets of contacts points, stationary and moving «5 will be seen in the figure at right. B, Disassembly 1. Remove the contact breaker 2. Unscrew the two mounting screws to remove the contact breaker arm irom the base plate, C. Inspection 1. Contact breaker point gap and ignition timing adjustment ‘Adjustment of the point gep and ignition timing should be made for both R/H and L/H cylinder at one time. To adjust, proceed as follows Contact breaker point gap Turn the generator rotor counterclockwise aad check the point gap when it ie maximum. The correct gap is 0,012~ 0,016 in. (0.3~0-4 mm) for the LIT and R/#T point. Then loosen the contact breaker plate locking screws © when the point cam @ is st maximam lift end move the contact breaker plate @, Tighten the locking screws when the correct gap is obtained. Adjust both L/H and R/H points ia the same manner. Recheck the gap after tightening the locking. screws. NOTE: Wipe the comact breaker point surfaces with clean rag i dirty. Ignition timing ‘Adjust the ignition timiag upon completing, the adjuste ment ‘of the contact breaker point gap. LH 1, Tura the generstor rotor @ counterclockwise and align LE” mark ® (oa L/H cylinder) to timing marke D. ‘The ignitioa timing is correct if the L/1 contact breaker point @ starts opening. To check the ignition timing, couaect « 12V-3W bulb asshown in the figure and observe the moment the bulb 103 Fig. 69, Coniect breaker © Pot cam © 1/ conict breaker point R/H cone: breder po © Contac beater phe Contact breaker pte locking serews Fir. 6-10. mae @ Generstor rotor Timing mark DLE mak OE mack Fis, Fig. 6-12.@ Base plate locking screws Base plate @ LH contact breaker plate locking screws @ R/H contact bresker plate locking screws Pig. 613, @ Timing Vight Fig. 811A. Stoct « © Tiong light @ Tachometer Fie. §-14B, Ed of spark advance 2, If the igniton timing io incorrect (Cther advanced of reterded}, align “LF” mark to the timing mark, loosen base plate locking screws {9 and slowly turn base plete unt the bulb comes on, NoTE: The ignition timing will be advanced if the base plate is tuned clockwise’ it will be retarded ifthe base plate is tamed counterclockwise, Tighten the base plate locking serews upon completion of the adjastmen "Tam the generator rotor agein and check if the contact breaker point gap of 0.012~0.016 in, (03~0.dmm) ie maintained for the L/H breaker point R/H side 3. Then connect the bulb to the R/H contact breaker point, ‘Turn the generator xotor counterclockwise 180 degcees (1/2 turn) aod align “E" mark @ with timing mark If the bulb comes on when the marks are aligned, the ignition timing is correct. [f the ignition timing io ine corzect, loosea contact breaker plate locking screws #8 fand vary the R/H point gep within the range of comrect gap 10 adjust the igaition timing, NOTE: + Ignition point gap must remain within limits of (.012~ O.016in) 0.8~0Amm afer ignition timing has heen set, If corsect timing seouls ia a point gap which Outside these limits, inezease or decresse both point caps equally to briag gaps withia limits, then retime by rota ing base plate fog. If left point gap is set at 035mm (0014 in) and Fight polut gap produces correct timing at 02 mam (a1Tin.), decrease both gaps by 0.02 mm (0.001 in), and rotate base plate to time ignition, If-both point gaps cannot be adjusted within limite, replace point assemblice, Make sure 1o turn the rotor counterclockwise, Do not revone the rotor even when it overturned. +01 mm error of contact point gap will result in 10 degree of igaition timing. + It is advisable that L/H1 and R/H contact poiat gaps be ‘eaten! in seting © Checking ignition timing with a timing light. ‘An accurate timing check and adjustment can be made by ‘using « timing light. Follow the procedure below for performing timing with the service tester. 1. Connect the power cord to the battery and ground the black ground ord, b. Set the selector knob to TIMING. Plug in the timing light cord and attach the high voltage cord to the spark plug ead artechment, 4. Siart the eagine end with the engine idling, point the timing light on the rotor mark, the left cylinder to the “LE” mark and to the “F” mark for the right cylinder, ‘The timing is comrect if the respective marks on rotor are aligned to the index mark on the stetor. IE it is necessary to make readjustment, perform the adjustinent in accordance with the procedure described ia the previous page‘Next, operate the engine at approximately 4000 9m and at this speed, if the index mark is between the two marks located 27~33° before the “LI” or the “FP” mark, the ignition timing at the full advance condition is satisfactory. Af there js malfunction with the ignition even though the RPM is constant, the fault is probably with the advancer spring or a delect ia the breaker points, therefore, the unsatisfactory parts should be repaired or replaced. .. The engine RPM is checked with a revolution counter, hhowerer, the service tester can also be used, ‘Set the tachometer switch to the ON position, insert the tacko- moter cable, place the tachometer ageinst the center of the A.C. generator rotor and then read off the engine speed by engine speed scale meter. D. Reassembly. Perform the reassembly in the reverse order of the dis. assembly, is a small electricel part mounted on the ‘ignition coil base. It provides @ means of preventing the spark plage feom fleshing over abnormally. The condenser used on the present machines is rated to 0.22~0.26uR. B. Removal Perform the removal ia the same procedure at for the Ignition coil outlined on 6+1B (page 101), C. Inspection Condenser test 1. Whea using @ battery end bulb, connect as shown ia Fig. 6-17. Ifthe bulb does not come oa, the condenser ic in good condition. 2, Whea using « radio taster, connect at shown in Fig 6-18. Li the zesisiauce is infiie ia the XI range of @ seal, 8, Iaspection with service tester (Tool No. 07308-0010000), = Coanect es shown in Fig. 6-10. + Turn the switch “LI” to "CAPACITY" (condenser cape city measurement) +Push the “CAPACITY” button and cead the scale on the tester. Specification: 0.22~ 0:3 8 105 Fig. €15. Ignition diming vert ArTacunenT SPANK PLUS HEA ZAR PLUG BATTERY TING LT (BREEN SCALE _JHOHOWETER SWITCH (ON) (s SF HMeTER Fie. 617. @ Bacery @ Bub @ Condemes Fig. 6.18. @ Swick ll" @ “CAPACITY Batery qd Condenser Fig. 5-18 ee© Gener elecirode @ Wire packing @ Gasker @ Plate packing ® Sparks gaps @® Terminal @ Inulation (with carrugation)@® Filled powder Bonding @ Hex nut @ Metalic main body @ Side clostrodte @ Length of thread (reach) Fle. 6-21. Gross-ection of spark plus. Fig. 622, Saisfactory condition Fig. 622, Excessively burat eoralion NOTE: + Upon completion of measurement, the condenser terminal should be short citcuited to discharge the charge accu. ‘mulated in the condenser. If aot, a shock may be expected to the touch. (Fig. 6-20) + Tho condenser functions to hold electricity temporasily so ‘hat when the point is opened, the current does not spark. If the internal insulation is defective or the capacity it insaficient, the secondary voltage is lowered, the plug sparking is weakened. and the ignition becomes defective 5. Spark Plug A, Description The standard spark plug used is the NGK B-8ES. The rain parts of the spark plug are the electrodes, insuletor and the plag body. It caa withstand high temperature and the insulation resistance value is high at high temperature, leak ‘proof and can withstand sudden chenges in temperature and physical property is strong agniast shock. (Fig. 6-21) Further, spark plug must be comparable with the heat characteristics of the engine, however, it is impossible to produce « plug which con be used universally. In ancther ‘word, during the operation, if the temperature of the electrode is too low, carbon or oil will form on the electrode and will cause misfiring of the plug, therefore, the tempersture of the electrode must be high enough to prevent the fouling of the plug, This i called the self clesning temperature and it approximately 450~000°C (@42~1112"F). However, if the temperature becomes too high the electrocie will be heated to the point that it will cause the fuel mixture to ignite and result in pre-ignition. This temperature is called pre-ignition temperature and is about 750~850°C (382~1562°F), Be ‘cause of this, the spark plug should be selected so that the heat rating is higher than the self cleaning temperature but lower than the pre-ignition temperature, To designate the heat characteristics, the term heat range refers to the operating condition of the plug. The higher ‘umber designation of the plug is use for high speed driving or when normally bearing a heavy loed. Conversely, when the plags with the smaller number indicate that it i @ ot ‘ype lug. Asan example, if there is a tendency for the engine to overheat caused by burning of the electrodes or pre.ignition, while using the NG& 7ES plugs, the spark plugs should be replaced with plugs of « higher heat range such as the B-SES, ‘On the other hend if the plugs appear to be sooty, replace the spark plugs with those of a lower heat range ‘such as the BEE, “The standard NGK B-BES spark plug has a thread dis. meter of 14mm and a resch of 19 mim (0.784 in), Fig, 6-24. Sooty condition (dry)B, Removal 1. Remove the high tension cord from the spark plug. 2. Remove the spark plug using a spark plug wrench. ©. Inspection 1, Spark plugs should be periodically inspected. If « spark lug is used for # long period of time, the electrode gradually burns and the sparking efficiency lowers The epark plug efficiency can be detected with a spark plug ene.” Inspect the sparking contin, by changing the tester intemal pressure, with the rated voltage epplied. 2, Ibis best to use « spark plug cleaner for cleaning, how. ever, when cleans is not avaiable, scrap with a piece of wire or needle, end wash with gasoline end wipe off with a dry rag. (Fig. 6-27) 3, After cleaning, adjust the spark gep. Adjust with @ thick fess gauge so that the gap is between 0.7 mm~0.8 mm (0.028~0.082 in). (Fig. 6-23) D, Installation 1. When reinstalling spark plug, wipe off oil and dust around the sperk plug hole oa the cylinder head. 2. The spark plug should first be screwed in finger tight and then torqued with the sperk plug wrench until tight, about 1/2 to 3/4 tum. 4 enim len get we) ‘ een Hiaasen) Vette wel Fie. 6-25, Compatison of hea: characteristics @ ® @ Resch ia covrect_@ Reach is to0 Tone {@ Reach in t00 short Fig. 6-28. Spark plug reach © Spork plug Fig. @-27. Spark plug cleaning 07~08 mm (0428~032 in) Fig, €28 "Spark gep measuring29, Noite suppressor cap @ AC, genersior rotor @ AC. generator stator Fig, 680, AC, generator ‘AC VOLTAGE fe BLUE SCALE DAYTIME pone TME FRAME (AC. vallige messarement 6. Noise Suppressor A. Deseription To preveat the oscillating curreat which contains the high frequency radio wave produced by the high tension ignition cireuit, the spark plig is firted with * suppressor. ‘The suppressor consists of a resistor cap and housed in the shielded cover, B. Removal 1. Remove the noise suppressor eap from the spark plug. 2, Remove the cap from the high tension cord. C. Inspection Parts which are cracked will cause a short circuit when driving in inclement weather, therefore, it should be replaced, D. Reinstallation Perform the instalation in the reverse order of the re. moval. NOTE: ‘The high tension cord carries the high voltage to the spark plug, therefore, it should be inserted securely into the cap. Further, do not put a sharp bend im the high tension cord or route it oo that it is binding against the frame, 6-2 GENERATING SYSTEM 1, Alternatd¥(A.C. generator) A. Description ‘An alternator having six poles is used. The rotor of the generator is key-mounted oa the left crankshaft and the stator is bolted t0 the crankcase cover. The arrangement of the poles is as shown in the figure at left B. Disassembly 1. Remove the left crankcase cover, 2. Remove the AC. generator rotor with a rotor puller (Poo! No. 07933-2160000) 3, Remove the stator from the left crankcase cover C. Inspection 1. Check the stator coil for open or short circuit The check is performed with the service tester by_ mes suring the resistance value of the cail. A good coil will show a resistaace value shown in the table below, however, if unusually low resistance or an infinite resistance indicates, that there is « short or an open circuit in the coil. Further, a low resistance indicates a layer short, ‘Standard Resistance Values 2 AG, voltage measurement Rotate the selector nob on the tester to the A.C. VOLT. AGE position and connect the (+) side of the tester lead to the yellow lead (day operation) or the white lead (night operation), and grouad the (—) lead to the frame, Start the engine and perform the voltage measurement.3. AC, generator performance characteristics (reference) [eS eae Direction of soraton ems Speciation Normal 300~ 11500 gine apecd (RPM) 15,000 ele hand rotation (Wiewing from the left side) 12Y-12AH bawtecy and two ail catia pee ignition eal i “Matte | ORS Lemp 3, Tightime pa, one TOF lamps and the day tine loud Charging cherecternics | Daytime Under 1400 RPM ci gbauerye12eV) | Nighuime | Under 2,000 RPM fo: Dea eeae ae 12-258 Under 4A Under 4A, Yalow D, Reassembly OTE 2, Silicon Current Regular A. Deseription To prevent the battery from becoming over-charged, @ nousdjuting SCR (ilicon current regulsior) regulator ic used. This wil produce a very stable curput voltage without any need for adjesting, On the HONDA 250 and 850, a pointless type regulator, ZROD6 {12V) is mounted on the boom of the battery box. When the battery voltage is low, the regulator does not function and whea fully charged or when approaching full charge, the regulator wil {unesion to ground the excess current. Ia this way, the hattery is prevented ftom becoming overcharged. B, Disassembly Disconnect the wiring at the connectors and unscrew the two mounting botts. NOTE: Do not remove the rubber cape on the bottom side of the regulator, do not turn the under the rubber cap. Color of lead wires | Nighttime White Orange Perform the reassembly inthe reverse ond ot ie ae Before installing the rotor on the crankshaft, cléin both taper surfaces. @D AG. generaion @ Hosdlighe switch &® Selenium reciler stack @ Combination switch Pointless regulator @ Battery Load Fig. 62% Pointless regulator circuit diagramFig. 624. ACG. generator battery charging characteristics (Without the pointless regulator) 35, A.G. generator batery cherging characteristics ‘Fig the pointleas regulator) © Genesaing coil @ Batery & Load Fir. 6-38, RESSTANCE BLACK SOME SEALE ADUSTER Snot Ge BATTERY Pig, 629. Selenium seer wack C. Inspection 1. Charging current measurement Conncet an emmeter betweoa the’ battery (+) terminel and the SCR, end check to see if the values obtained are in cecordance with the stenderd specifications listed in the chart below. Fig, 6-34, 35 shows the battery chergiag performence when without the rezulator. 2, When the battery charge is low, the cause may be in the AC, generator, selenium rectifier or the defective wiring. D. Reassembly Perform the reassemble in the reverse order of disassembly. NOTE: Exercise care not to make an error in the wiring when connecting the pointless regulator, as postible demage to the regulator, as well as to the battery may result + Use the ZR906 (12V) pointless regulator, 63 RECTIFYING SYSTEM A. Description I fs often necessary to convert sltemating current inte direct current for specific needs such as battery charging. ‘This process of custent conversion is known as rectification and the device which performs this function is called a rectifier, ‘The rectifiers used in the CB/CL250, 350 machines are of = gelenium type. Fig. 6-36 shows a schematic layout of, the fall-wave rectifying circuit using four reetifiers, in which both sides of the A-C cycles are rectified, G es oo @ Dickecsic costing @ Antvelectode @ Selenium @ Sheet Poritive dzection Hig. 6-31, Construction of selenium rectifier sym, B. Disassembly Reise the seat, unserew the mounts nuts and remove the rectifier. C. Inspection 1. Measuring the current flow in both directions Connect the battery to the tester and rotate the tester selector kaob to the RESISTANCE position. Shert the tester leads and adjust the gauge to “O”.‘The standard resistance values of the selenium reetiier in the normal direction are shown in the table below. Connection Resistance Value ‘Test lends | Rectifier terminal Yellow Hethite Fink poet Babe | Sahay i es SP eeeen 6500 oe Green cir renisance measurement Gree Vig. 6-40, Recife ‘The resistance valve in the reverse difection is measured by reversing the tester lends, ‘Standard valies are. shown rafieicalr wie ee oe La ae a J io a as , Rea/whi ‘Satisfactory if over wa red white: @ eR is [ae | aca Tee = Pak Fig, 641. Recifer wiring diagram A simple test can be performeil without the use of a 4 tester by following the diagram shown ja Fig. 5-41. For tein ite bona ditecfon, comest the (+) aie ofthe * battery to the yellow or the piak lead of the selenium rectifier end the (—) sde to the red/white lead. Ifthe bulb lights wp, it indicates satisfactory condition. Ta this manner, ime perform the complete test in accordance with the test con: hections shown in the table above for the normal direction teat, For testing in the reverse direction, connect the (—) side of the battery to the yellow or the pink lead ond the (+) Fig, oa, fide ‘of the battery to the red/white lead of the rectiier a ‘The ecleniam rectiier is satafactory if the bulb does not ‘ = eureny light wp. Nore: Applying reverse current to the rectifier for a long period will weaken the rectifier, there, testing ia the reverse direction should be kept at the minimum, 2 The service life of the selenium rectifier is affected by temperature, therefore, it should uot be expoged to lange cearrent for a long period. Further, the wafers should not be bent or scratched. D. Reassembly Perform the reassembly in the reverse order of dis estembly, 6-4 BATTERY A. Deseription ©. A battery meeting the specifications shown below is used on all current models Them Stecifeation YUASA NDA A © (Vaccum scted cy charged batter) ® Bue volaze | BY Glimcty'atne | BAN speste gravity | 1.25—128 a NC (°F) @ Poke BO Termioal @ Negnive pave Besta : @ Soyaraor and gies mat G Centiner ‘opacity O72 19US el ® © Terma Postve phate Fig, 6 48. Barery constructionuz B. Removal 1, Raise the seat and disconnect the black ground cable and the green ground lead from the (—) terminal of the battery. “From the (+) terminal, remove the red and the red/ white leads, 2, Remove the battery from the battery cate €. Inspection 1. Check the battery electrolyte level Reise the seat and observe the battery electrolyte level @ Upper Level mark @ Lower level mark @ Battery marking on the side of the battery to make cure that the @ Yellow Biller caps tlectrolyte level is between the upper end lower marks. Fig. 644 Battery inspection Ifthe level is below the lower level marking, add cistilled water to the battery. \ @ NOTE: ‘When adding distilled water, do not fill sbove the upper = fevel mark, @ 2 Check the specific gravity of the battery electrolyte The specific gravity is measured with a hydrometer, the type shown in Fig. 6-45, When making a reading of the measured value, the electrolyte level ia the hydro- Fig, 6-45, Meneuring the specific arevity meter should be held at the eye level and the scale read atthe fui level. Temperature of the electrolyte can be a fnemured by vied Germometee. Fig, 15) a The relnion betwoss the batery capa and the apecife i rity Gevdval capacity) i sbowa ia Fig. 646. When i Se apesiie gravity = 189 220°C (BPE) (eee than 52) He the reidal espacty mall and Hf coninucd to be used ne im such a contin, wil eventvaly lead to trouble at i" Mell as shortening the baiery Hi, therfore, she batery A10C To 20 30 at 5080 70 80 30 105 should, under such condition, be recharged as soon as penile. ig. 646) ® The slectrlyte wied in the bastery must be comprised ee OR) Of pure sults aid diuted to the designated specie Fags, Speife gravy ood rte copay chart Gravity. The specibe gravity will vary withthe tempera ture, therefore, the specific gravity index ic based on the electrolyte temperature of 20°C (68°F). The temperature correction formula should be used to derive at the proper apecifie gravity for the measure temperature af the electrolyte. Sx Where: 240.0007 (¢=20) $20=Specific gravity of the electrolyte corrected to 20°C (68°F) St =Specifie gravity of the clecwolyte mexsured temperature, °C t =Tempersture of the measured electrolyte 2, Battery charging, procedure «There are two methods of charging of « battery, namely, the constant current method aad the constant voltage method, In the constant current method, the batiery is charged at a constant curreat throughout the charging period, This method is taie and is recommended for initial charging of the bettery In the constant voltage chergiag method, a constant voltege is applied during the charging period, In this method, the charging period can be shortened by applying a larger currant, however fone drawback is that if too large « current is applied, the battery will overheat, — + charger hooky @ Battery charger @ Baitery y Connect the positive terminal (+) and the negative battery ig. 47)113 When more than one battery is to be charged at once, they should be connected in series, as shown in Fig. 6-47. Series Comection for ‘The charger voltages must be the sum of the battery voltages. For example, to charge three 12V batteries, the charger must have an ourpat voltage in excess of 16, (15 (15)+16 (15)+16 (15) or 48 (or 45) volts, 4. Charging A fally discharged battery will require charging rete that is 125 higher than the normal charge rate of the battery. ‘As an cxample, © AH battery wil require 15AH charging rate (IZAHX125=15AH), There is a defiaite relationship between the charging cucrent and the charg- ing time. This is shown in Fig. 6-49, The charging curreat should not be greater than three times the 10, hours curreat rate, (For a 12AH battery, L2Ax3= 3.54), i ‘As the battery approaches the full charge condition, gas tull be released from the electrolyie. At this time, check g the batiery electrolyte to ace ifthe apecifc gravity io up = to the senderd value of 1.25~1.28, and the terminal elinge ir up to the standard value of 19~16V. Perform ho | the check again after 30 misuzes and egaia ia an hour, tnd iffor the three checks the values are constant, the tatery We fully charged and the charging cat be tre minated. (Fig. 6-49) 5 NOTE: ie | If during the charging process the temperanure of the costclyio should sive above 4StC (LIS"P) or if the ges 365 10 TSA) is being released from the electrolyte ia abundance, the —— CHARGING CURRENT charging should be stopped temporarily or the charging curreat reduced to @ lower rate, Fig. 608. + Quick charger Quick charger should aot be on battery which has been fully discharged. Further, quick charging method should thot be frequently used. However, whoa it io inevitable aad quick charging must be performed, the following itome should be observed. For quick charging a 12AH battery, use the charging current cate of 128. A batiery which is 90% discharged, approximately 30 minutes should be adequate to charge the battery. However, if duriag the charging process the electrolyte temperature should rise above 50°C (122°F), the charging should be temporarily stopped or the charging current rate reduced. + Other precaution If the electrolyte level falls during charging, ro6ll with distilled water to the upper level mark, = Tnflammable bydrogen gas is discharged from the cells, therefore, do not charge batteries near aay open fr. + After charging, add distilled or battery water to the cells to bring the electrolyte to the upper mark Tighten cell caps firmly and wash off with clean water if any acid spilled + The battery is now ready for installation. When installing a battery in the motorcycle, be sure not to pinch the battery veat tube. Explosion may result if the exhaua: tube ia blocked.14 Fig. 50. D.C. voluge measurement 6, Other important items 5, Cheek the terminal voltage (Tool Ne. 07308-0010000) The battery terminal volage can be checked with « service tester. The standard battery vollage is 12V, however, immediately after charging, the voliage will be at 15~16V. ‘Set the volt selector switch to the D.C. VOLTAGE position fon the tester and clemp the (+) tester lead to the (++) terminal of the battory and then connect the other tester lead to the (—) terminal of the battery and read the voltage off the blue scale. When performing bettery charging, refer to the battery charging section on page 12. (Fig. 6-50) * Ox this model motoreycle a vacuum sesled dry charged battery is used, This baitery does not require on initial Ghurge, However, i the seel oa. the batiery i found to be broken (ihe battery will he loose in the plastic enve- lope) the normal initial charging should be performed. If the motorcycle is to be placed in storage for a long period, the leads to the battery should be disconnected ‘and it is recommended that the baitery be charged once a month to maintain it in good condition,BATTERY TROUBLE SHOOTING AND CORRECTIVE ACTION 15 ‘Trouble Probable cause ‘Correct action The ‘A, Sulfation covered with white layer or . Charging rate is 0 small or ese excessively lage. ‘The specie gravity or the minture electrode plates are - When mocoreycle Is in storage, the tattery should be reckarzed once a month even though the motoreycle The tnd Battery discharges in ation vo tha caused by the con ected load. ©, Large discharge rate . Mich charving rate rapidly bat the charge is Always maintained at 100% 's overlooked, ‘Specie gravity over 1260) Specie gravity drops Contaminated electrolzte or elec: uolyte excessively concentrated . The fuse and the wiring 18 sats. Specific gravity gradually factory, loads auch an winker and fowersandazound 1.00(8G), | horn does no: function. the wiskeraad hor no longer In this condition the motoreysle will function | operate bar widh prolong use, bodk ® and S plates will react with the sulfuric acid end form lead sulfide deposits, (sulfation) making it impos- | able to recharge. ‘The deposit will heavily accumulate atthe botiom and will use internel shorting and damage the batery. clecicelyie level drops ‘the condition appears factory, Acondiion which Shorted Insufficient charging Disilled water overflled Contaminated dectealyre in spots. of the electrolyte is improper. ‘ot used. 2, Battery left ina discharged condition 2 Chock the slacirelyte periodically for a long period. (Left with the ‘and always maintain the proper level, ‘esitch tamed on). A Tn a lightly discharged condition, 4. Exposed to excessive vibration due performiug recharging and dischar- to improper insulation ‘ging several times by starting the 5. Mowroycle stored during cold sea engine may be sulicent, son with battery connected. B, Self discharge 1, Diety comact areas and case, 1, Always maintain the exterior clea, Handle the replenishing dlectrolyie ‘with care and use clesn container |. When the specific gravity falls below 1.0(00'C: 68°F), the battery should bbe recharged immediaey. Whea the battery frequently be. comes discharged while operating at normal speed, cheek the generator for proper outpet. 3. If the battery discharges under normal charge ouipat, it ig en i fication of overioaning, remove tome of the exenss los. 2. When overcharge condition exist wih the proper charging rate, pase fon appropriate resstor in the charging drcuit - Perform specific gravity measure- If the addition of eisilled water causes + drop in specific gravivy, add sulfuric acid and adjust to proper value 1. Check to assure proper cherxin 65 The gear is mounted on the front side of the crankcase. When starter switch @ on the handleber sith ignition switch 2 closed, current flows from the battery t> exe switch 10 push, This results ia the closure of points to STARTING SYSTEM 1. Starting Motor A. Description starting motor complete with a planetary reduction pressed tion coil (plunger holding coil) @ of the solencid @ Sarier button switch @ Veriton evitch mit current to flow into the starting motor. @ Cone uni @ Excaation col Phnger aS “ a G Pole @ Brush @ Armature @ Field cal Fig. 6-51, Startor revit ages