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    7 views179 pages

    Honda cb350 PDF

    Uploaded by

    Alejandra Geribon

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    ©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

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