+ SHOP MANUAL e HOND €B100.CL100.SL100 “100: 125 MODEL ¢31955.CD1255.SL125TROUBLE SHOOTING ot Corrective action ‘Troubles Probable causes Engine doesnot start | 1. Lack of compression ‘or hard starting (1) Tappet stuck open Aajusttappet clearance, @) Worn valve guide Replace ) Valve timing out of adjustment Repair (4) Worn piston rings Replace (5) Worn cylinder Replace 2. No spark produced from spark plug electrodes (1) Fouled spark plug Clean (2) Wet spark plug | clean (G) Fouled breaker contact points Clean (4) Improper point ap, Adjust (5) Ignition timing out of adjustment Adjust (6 Detetive ignition coil Replace () Open or shorted citcut in ignition cord | Replace (8) Shorted condenser Replace 3. Fuel does not flow to carburetor (1) Clogged feel tank cap vent hole Clean (2) Clogged fuel cock Clean @) Detective carburetor oat valve Replace (4) Clogged fuel tube Clean Engine suddenly stalls | 1. Fouled spark plug Clean hile running 2. Fouled breaker contact points Clean 3, Hanition timing out of adjustment Adjust 4. Clogged fue ine | Clean 5. Clogged carburetor jets Clean Engine noise 1, Tappet noise (1) Excessive tappet clearance Repair (@) Weakened or broken valve spring Replace 2. Knocking noise from piston (1) Wor piston and cylinder nose Replace (@) Carbon accumulation in combination Clean’ chamber ©) Worn piston pin or connecting rod small | Replace Cam chain noise end () Stretched eam chain {@) Wor cam sprocket or timing sprocket _L Replace or shorten the chain ReplaceCorrective action ‘Troubles Probable causes Bngine nose 4. Knocking noise from clutch (1) Looseness of clutch center spine Replace (@) Excessively worn friction dise or elutch Replace @) Distorted frietion ise or clutch plate Replace or repair 5. Crankshaft (1) Excessive runout of crankshaft Repai {@) Excesively worn crankshaft bearing Replace (@) Excessively worn connecting rod, large end | Replace 6, Gear noise (2) Worn or binding transmission gear teth Replace {@) Wor transmission spline Replace @) Wor or binding primary transmission gear | Replace Chath slips 1. Imroper adjustment of clutch (no free play) Readjust 2, Weakened cluch spring Replace 3, Worn or distorted pressure plate. Replace 4, Distorted clutch plate Replace 5. Worn or distorted friction plate Replace (Clutch disngages 1, Improper adjustment of clutch (excessive play) | Readjust improperly 2. Uneven clutch spring tension Readjust 3, Distorted clutch plate Replace Gear does not sift in | 1. Broken center gear shift fork pawl Replace 2, Broken gear shift cam Replace 43, Deformed gear shift fork Repair or replace (Change pedal does not | 1. Broken or dislocated gear shift retuen spring Repair or replace etara tots position | >, shitting spindle hits crankcase hole Repair Gear jumps out 1. Worn shifting gears on main shaft and Replace hile running counter shaft 2, Distorted or worn gear shift fork Repair or replace 3, Weakened shit drum stopper spring Replace‘Troables Probable causes Corrective action Poor engine performance | 1. Improper adjustment of tappet [Reagjst ac See 2. Poor cylinder head valve seating. Replace 3. Defective valve guide Replace 4, Ignition timing out of adjustment Readjust 5. Improper breaker contact points Repair 6, Excesive spark plug gap Readjust 7. Weak ignition spark (defective condenser [Replace ‘and ignition eo) 4, Improper adjustment of carburetor float level |Readjust 9, Improper adjustment of carburetor air screw | Readjust Poor engine performance | 1. Weak valve spring Replace at high speed 2, Valve timing out of adjustment Readjust 3. Too small spark plug gap Readjust 4, nition timing is retarded Readjust 5. Weak point arm spring | Replace 6, Defective ignition coil | Replace 7, Improper adjustment of carburetor float level Readjust 8. Clogged air cleaner element Clean 9, Insufficient fuel flow to carburetor ‘Clean or replenish Hard steering 1, Broken steering ball bearings Replace 2, Bent steering stem Repair or replace 3, Excessively tightened steering cone race Retighten to specified torque | 4. Low tre pressure Inflate to specified pressure Front and rear suspension | 1. Weakened main spring Replace Cat 2. Insufficient front damper oil Refill to specified amount Front and rear suspension | 1. Front damper oil viseosiy i thigh femction too hard 2, Excessive damper oil 3. Improper adjustment of rear cushion Ineffective brake 1. Worn brake Hining | replace 2. Foreign objects adhered on brake lining surace| Clean 3. Improper engagement of brake arm serration | Repair 4. Worn brake cam“Troubles Probable Causes Corrective Action Exhaust smoke from muller 1, Excessive engine oil ‘Check oil level with oi level gauge 2, Excessively worn cylinder and piston rings | Replace 3, Wor valve guide Replace } 4, Damaged cylinder Replace Tnseficent horsepower | 1. Improper adjusiment of tappet (valve stuck | Readjust ‘ore Weakened valve spring Replace Valve timing out of alignment Repair 1. Worn cylinder and piston rings Replace Poor valve scting Replace 5. Ipnition timing out of adjustment Readjst Poor breaker contact points Repair or eplace Defective plus ap Repair 9. Clogged carburetor fel passage | ome Improper adjustment of flat level Readjst Clogeed sir cleaner Clean 1. Excessive carbon accumulation on pliner head 2 Insufficient oil 3. Defective oll pump and clogged oil passage 4. Too low float level 5. Too exry ignition timing (causes knocking) Refill upto specified oil level ‘Clean Reagjust, Readjust ELECTRICAL SYSTEM “Troubles Probable Causes Corrective Action Engine doesnot start D Batery {Poor contact of battery terminals 2) Combination switch 7 Open or shorted circuit, disconnected connections Poor contact between combinanation switch wire and wire harness, 13 Tzition coi * improperly insulated high tension coil Open Sr ahoned ulin gion col 4) Contact breaker * Open circuit inthe primary coil {Dirty ground point with oll or dust {Point gap out of adjustment ‘Improperly charged condenser Recharge or replace Repair Repair Repair Replace Replace Repair Gean Readjust ReplaceTroubles Probable Causes Corrective Action ‘Batter self 1 Wiring ” Open or shorted circuit in batery oF ‘sconnected battery terminals 2) Generator ” Open or shorted circuit in stator coil or round «Broken or shorted teads { Demagnetization of rotor 23) Battery ® poor contact of battery terminals “suelo battery electrolyte 1 Shorted batery electrode Replace oF reighten Repair oF replace Repair Replace Repair ‘Ade distilled water Rep ‘Winker lamp blinks 100 1 Bulb fast or too stow ks unusually fast improperty connected | Replace reny 2) Wiring nn foo fast: bul with unsuitable watage | Replace {Blinks to slow: Burnt or broken bulb Rlament | Replace Defective relay Replace ‘Winker lamp inoperative | 1, Winker lamp sich ? poor contact of winker relay Replace 1 Open circuit winker relay coil Replace 2 Bulb > gull wattage is smaller than rated wattage | Replace 3) Rely ® poor éontact of winker relay Replace “improperly connected leads Replace Horn inoperative, poor || 1) Hors [ithd or foo weak sound | Cracked diaphragm Replace 2) Hom button * Poor grounding Repair 3) Wiring * Poor contact Readiust 4 Adjusting serew out of adjustment Readiust ‘Tall ight and head ight | 1) Fuse inoperative ? Bown fuse or burnt bulb lament Replace 2) Bulb * Poor contact of lighting switch Readjust 5) Sich » Poor contact of dimmer switch Readjst 4 Wiring ‘Stop ight inoperative | 1) Bulb a ° Burnt or broken bulb lament Replace 2) Front & tal stop ht otek ® Malfunction of switch Readst 3 Wiring ” Poor contact of leads ReadjustPERIODICAL MAINTENANCE Maintenance Schedule ‘The milage intervals shown in the MAINTENANCE SCHEDULE are intended as a guide for establishing regular maintenance and lubrication periods by which the best and most safe rid- ing conditions are assured. ‘The operating procedures for individual items are described in the section of MAINTE- NANCE OPERATION. After 12 months or 10,000 km (6,000 miles) perform repeatedly all items which are described in the column at every 6 months or 5,000 km (3,000 miles) intervals. Sustained severe or high speed operation under adverse conditions may necessitate more frequent servicing. T ‘Monts or Mis, whichever ceurs frst Pint [Second] Toit | sty | Page Service Required ‘Moats ——[ 6 [| 6 | _ 12 Reterence ‘km__|300_| $000 [10,000 | 5,000 | 10,000 ‘ite [300 [3.000 | 6000 | 3,000 | 6,000 Tngine Oilshange [Overy 1,000 Mile (.00%m) | Oil Fiterclan ° o | —s and adjust oF replace oO 7 F Pointschesk oF serve © @ 3 Timing-heck or aust oto 6 Clearancecheck of adjust oT 36 3 Cam Chainadiust roo 2 ‘ir Cleane-clean O 3 _ Oo ;o 45 | carbur —_[o-fo- 5 Fuel Valve Stanerciean oo 3, 3 Fuel Tank and Fuel Lines-check a o [0 50, SI ‘Cutch-check oF adjust oo To 7 Dip Chan and Spock RINCRIIC fn Front and Rear Brakeadjust o}oTo 0 Front and Rear Brake Shoeesheek or replace o O [8.4 Front and Rear Brake Linkecheck oo 3B aI ‘Wheel Rims and Spokescheck o|-6 To 38 aL [Tres check oF replace — Tore 384i rom Fork Oilcheck and o. oO, chang 5 o [1 Sesing Head Bearingscheck oF aust © o | # [Steering Handle Lockseck for operation o of Side Stand Spring-heck ooo 3 Bajey Elewobte Lovelsieck aad plas |G | | o | o Tse Upon or adr Or ofofo 0TECHNICAL DATA Foe reserve tank 2.5US pt (L2Iiter) 25US. pt (L2iter) TEM CBi00 Cx100 ‘cLi00 DIMENSION ‘Overall length 14.2in. (1,885mm) 1,915mm) Overall width 2953in. (750mm) 31.9in, (810mm) Overall height 400in.(Lo1smm) | 40Sin. (,030mm) | 42.9 in. (1,090mm) Wheel base 474i. (205mm) | 47.8in.(1,215mm) | 49.4in (1,255mm) WEIGHT Dry weight 191. Ibs (7k) 1918s (87ke) 211.7 Ibs @6ks) (CAPACITIES Engine oil 2AUSpr (Loli) — | -2LUS.pr(LOlie) | 21US.pt (LOTiter) Foe tank 20US eal. 7.5liter) | 20US.gal.(7Slite) | 20UL. gal. (75 titer) 25US. pt. (12Iite) tndeator light ENGINE Boreand stroke | 1.988% 1.944in. 1.988 1.949 in 1.988%1.949 in. (60.3%49.5min) (60.8x49.5mm) (60.3349.5mim) Compression ratio | 9.531 9s: 95:5 Displacement 608 cuin. (99.2) 6obeuin. (99 ce) 604 cuin. (99) Horse power 11.5 pl11,000 rpm 115 pe/t1 000 rpm Contact breaker | 0.012~0.016in. 0.012~0.016in, point sap (0.3~0-4mm) (0.304mm) (0.3~0.4mm) Spark plug gap | 0.024~0.028in. 0.024 ~0.028 i. 0.024~0.028 in. Valve tappet (0.60.7) (0.6~0.1mm) ‘en ‘learance 0.002in. (0.05mm) | 0.002in. (005mm) | _0.002in. (0.05mm) CHASSIS AND ‘SUSPENSION Caster 66 oa" ous Trail 2.950, (15mm) 307 in. (78mm) 3. in, (95mm) Tire sie, froat 2.50~18 (4 PR) 250-18 (4PR) 2.75.19 (4PR) Tire size, rear 275~18 (4PR) 300-18 (4 PR) 3:25:17 (4PR) POWER, “TRANSMISSION Primary reduction | 4,055 408s Final reduction | 2.887 3071 Gear ratio, 1st. | 2.500 2.500 and. | 172 im. 3d | 1333 1333 4th. | ros 1083, sie | oss 0.923 ELECTRICAL Battery 6V.6AH 6v-6AH 6v.6AH Generator AC. generator A.C. generator A.C. generator Fuse 1Samp Samp 1samp LIGHTS Headlight svs2sw 6.35/25 ev.as2sw Tailstopight 6¥-53/17 6V-5.3/TW 6v-s.3/17W ‘Tur signal light | 6V-16W 6v-16W Meter light v.15 ove SW ev.sw Neutral indicator | 6V-1.5W ova sw ev. sw ov.sw ov.sw - ov..sw ova.sw orTEM cans cons SEs DIMENSION ] ‘Overall length 74.80, (1,900mm) 74.80, (1,900mm) | 78.Sin, (1,995mm) ‘Overall width 29.5in. (750mm) 29.3in, (750mm) 31.9in. (810mm) Overall height 40.0in. (015mm) 39.4in.(1,000mm) | 44.in,(1,115mm) Wheel base 474%, (1,208mm) | 47-2in. (1,200mm) | 50.2 in. (1,275mm) ‘WEIGHT | Dry weight 202.0 bs (91.5 ks) 19621bs (89g) | 209.5ibs (95.08) ‘CAPACITIES: Engine oil 10US.qt.091mp. | 10US.¢t,09Imp. | 10US.a1, 0.9Imp. (lon at. (0, at 0 Fuel tank 20US.ral 16Imp, | 20US. et. 16imp. | 18US. sal 161m. ea 3) wal (51) ‘wal. (01) Fuel reserve tank | 1.3US.gt. timp. | 13US.gt,11Imp. | O4US. gal. 0.3 img was ada el dsh ENGINE Bore and stroke | 2.208 1.949n, 2.2081 949 in, 2.208x1.949 in, (S6343.Smm) (66x49.3mm) G6x43.5mm) Compression ratio | 95:1 9st 9. Displacement ecu in (12208) 7d cuin, (12260) | 744 eu in. 12260) Horse power 12.0 19,000 rpm 12. psf9,000 rpm 12.0 ps9,000 rpm Contact breaker | 0.012~00016in. 0.012~0.016in, 0.012~0.016in, point ap (0.3~04mm) (0.5~0.4mm) (O3s~ 0.4mm) Spark plug exp | 0.024~0.028 in 0.024~0.028in, o024~0.02 Valve tappet (.6~0.imm) {0.6~0.7mm) (0.6~0.7mm) ‘clearance 0.002 in. (005mm) | 0.002in. (005mm) | 0.002in, (.05mm) ‘CHASSIS AND SUSPENSION Casier ous’ o o Trail 315 in. (60mm) 31Sin. (80mm) | 3.18, (Ommm) Tire size, front 2.7518 (PR) 2.50418 (4 PR) 275.21 PR) Tire size, rear 300-17 (PR) 2.75.18 (4 PR) 325-18 @PR) POWER, “TRANSMISSION Primary eduction | 4035 40s 4.085 Final eduction | 3.267 2.800 3267 Gear ratio, 1st. | 2500 2.769 2369 2nd. | ima i 12 ard. | 1333 12m. 12m 4th | 1083 1.000 1.000 sth. | ozs = oats ELECTRICAL ‘Batery 6V-6AH 6v-6 AH 6v-6 AH Generator AC. generator ACC. generator AC. generator Fuse 10amp 1oamp Samp GTS Headlight ev-asr2sw 6v25)350 Tailstopliht 6V-3/10W 6v-S3TW ‘Tum signal ight | 6V-5W 5 Meter light 6v-1sW ov1sw Neutral indicator | 6v-t 4 cua sw ovis Turn si Ps gat, | OV I8W ov sw ‘High beam ov1sw ovsw ngicator light