CB250-350 250-350 CL 250-350 s 2 SL350° 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Description .. Disassembiy ..... Inspection Reassembly ... 4:12 Gear Shift Mechanism Description Disassembly Inspection. Resssembly, poR> Kick Starter Description Disassembly Tnspection Reassembly pores a 14 A B. ©. D, 15 A B e FRAME... Handlobar. Crankeases Description Disassembly Tnepection «on. Reassembly Carburetor Description Disassernbly Inspection vIn BP Fork Top Bridge . Description Disassembly Taspection poop Reassembly Front Cushion Description Disassembly Inspection Reasserably pomp Steering Stem > Description By Disassembly C.Inspeetion “D. Reassembly + ep AR Soe a. ae ae gee 22822 99984 ere e e a Cy ©& PPP PS ONwes DORE OO PPs DOR poop 5-1 (e D. 512 A B. A B B c D. 513 A B Poel Tank Deseription Disassembly ... Laspection .. Reassembly. 73 Frame Body neal 3 Description faeadens ™ Disassombly ™ Inspection n" Reassembly 4 Boat Fat 74 Description 78 Disassembly 6 Inspection . 6 Reassembly % Stand and Brake Pedal Description Disassembly Inspection 76 Reassenly 6 Eshaust Pipes and Muflers 78 Description %6 Disnscemly n Inspection. ion 7 Reassemly a Air Cleaners r Description Disassembly Inspection Reasembly Rear Fork and Rear Fender 8 Description - Disassembly 8 Inspection : » Reassembly oe : » Rear Cushion... segaggennte 0 Description (De Carbon types neunsnninnennnni gph 20 Operation » Description (Double tube trosray valve) ft Operation a Disassembly 2 tapeaion = Reassembly .. — % Front Wheel eg sip OB Description : rarpuenes 2 Disascombly ..© Inspection . D. Reassembly FRONT WHEEL (with u disk broke system) Disassembly Inspection Assembly Dissusembly of ealipers and master cylinder Inspection of calipers and master cylinder... Assembly of calipers and master cylinder .. ‘Adjustment of dis brake Rear Wheel Description Disassembly .. Tospection pouPpEpapropp Reassembly 6. ELECTRICAL PARTS 6-1 Ignition System, Tgnitioa Coil Description Removal Taspe Rensserbly Sparle Advancer .. Description Removal. Inspection Reassembly Bresker Point Description Disassembly Inspection ... Reassembly Capacitor Description je Removal... Inspection Spark Plug Deseription| Removal Inspection Installation Noise Suppressor Deseription Removal Inspection Reinstallation POD Da ONE >a ARPA DADE e OOP Pp DOPE "7 *9 9 ges % 98 9 102 a0 101 a0 su 101 1101 .. 102, 102 102 102 _ 102 a2 103 103 103 108 105 108 105 108 106 106 107 107 107 108 108 108 108 1086 OOP >p DO he POR> PRP ae DA Bh>e DO RP yp oom eE prepnmers ee Generating System Sere AC. Generator . Description Disessembly UnspeCtiON ener erernee Reassembly eserves Current Limiter (Regulator Deseription Disassembly Inspection... no Reassembly a0 Reetifying System Sih elite 210 Description... _ 9 Disessembly no Tnspection... Sane mcnctiaas vous HO ‘Reassembly air Battery .. _ Description m Removal. main 2 Inspection ne Starting System, +15 Starting Motor... amelie 2 seas Description Pe 45 Disassembly i ipa Taspeetion ase nie i i a a a Reassexbly 7 Starting Chuieh “7 Description... me nc trner en et ea Disasvembly ais gee ae Inspection 17 Reassembly 8 Sclenoid Switch nate Description uB Remavel ug Inspection 18 Reassembly ee 18 Safety Equipment. 29 Hor z eo LD Description aegaiaewasnctsice Removal S 19 Inspection a . age. 119 Reasoerbly. ‘ abies 18 Speedometer ond Tachometer eres 9 Deseription susie paisisisnvonte 11D!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—— 1. TECHNICAL DATA CB250K4, K5 ica sates (CB250 (U.S.A. Type) CBRS0K4 (U.K. Type) eB280KS IE i DIMENBIONS ver loth 220 (230 0am 02a) aoc Oven wiih Tem (O5in) Sek GD iam ‘Overall height 1075 mm (428m) 7025 mm UOdin) Tse Whe fae tien (015 725m (in 136m Gone coe 1m (590) 1 mm (87) co cae nams “ang cea) ke Gy Tike ‘wee auton FR | HGREM GEE © Tye 06/18) a wide | T8/ADke TRAME ee Sena, ene Sento erate Seber tate ae ae Teaco ok Teleco ek Tecan ok dsm sepia fae page ox pore en Sos (PR) tb8 (FR) Sie FRR pene ‘Tire size, rear 325-18 (4 PR) ee S258 (4 PR) 350-18-4 PR Block patter TI Brake, fronl, ining aes Internal expansion, 522 em*x2 Tnternal expension, 169 m*, 2ideg.ia Internal expending. 163 emt Tower expansion, SLO cm?x<2 Internal expansion, 15) cm, ternal expending, 15) cx! Broke, re, lining area ayaa Fool capacity WDlie. @2US gal, 26 1mp gal) | 12K. G2US eal, 25 mp. gil) | 1L0le. Caster angle o a = sear v4 ‘Trl lena Gmm G.Sin) 85mm (.35in) me ENGINE Typ OH. gin erlinder, air. | O.H.G. twin erlinder, a> | Air cooled Astroke OHLC. Cylinder arrangement Bore and stroke sooleel dstrle ‘Vertical, evin parallel $6506 mm (2.205% L982in) coded danke ‘Vertical ewin pelle 55X508 mm (2.05% 1.982in) Vertical owin pavalle) 580X526 mm Compression ratio 249 ce (1521 ew-in) 95 249 ce (15.21 eu-in) 95, 2100 a5: Constant velocity type, Keihin Cartureor ‘Conant velocity type, Kein | Constant velocity wpe | scissors weeded cr) Clem ur orotees Valve train cate shale ear Titeaasorem (SSE) | ikem (oa pn GBSKI| Biman | Soot) ‘S300 rpm)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ae ee (0B250 (U.S.A. Type) ‘CBRBOKA (UK. Trpe) ones0Ks 2k, 21US quar, 131 ‘2h. @1US. quar, L8imp. i Oi capacity pea ees eee “Lubrication system | Forced and wot camp Forced and set sump Forced and wet sump Lowdead gasoline witk 9 Puck required Oczane sumber above % Oouane rumher abore 99 Cie ete ie ‘Engine weight (Inelnde ot) | S25 kg (11551) ‘Ske (LTB) Bike DRIVE TRAIN Cluck Wet, malé-plae type Wet, muti-plae type Wet mubi-plate wpe Transmission 5 speed forwant, constant mesh | G apeed forward, conatane meah | Gapood consant mosh Primary reduction aia ana ‘sa Garnio te | om8 2388 2500 and Tse 1.638 ss 1730 ad [1289 [120 sis . ah ‘ae | oss nau th 0.900 900 086 Gna recon 2395 Se nfoaare: 2505. RLECTRICAL Tgrision Bastery Baers Banery and ignition coil Staniog syxem Motor aed kick Motor and hick: ‘Starting motor and kick starter Butery capacity | zva2aH | a¥-a4AH Spark plo NGK BSS NGK B-8ES, ND W-2UES NGK BYES, ND W-i4ES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)‘tee oe CL350 (US.A. Type) CLS90K4 (U.S.A. Type) Oil capacity 2lit (21 U.S. quart, 1.8 Imp. quart) ‘2lit. (2.1 US. quart, 181mp. quart) Labrication system Forced and wet sump Forced and wet sump Fuel required ‘Octane number sbove $5 ‘Octane number above XI Engine weigh ie oil) | 525k (15516) S2kg (114.7 1b) DRIVE TRAIN latch Wet, multplate type Wet, multiplate type ‘Transmission 5 speed forward, consiaat mesh 5 speed forward, constant mesh Primary reductioa 3714 ane = se Gear ratio Ist 2353 2.353 Z 2nd 1636 1.636 é ard | 1260 1.269 i tk 1036 1.036 a [ sth | 0900 0.900 ae) Final reduction 2375 2.373 = e ELECTRICAL guition Baery Battery Starting system ‘Motor and kick | Motor and ick Battery cepacity 12V-12AH_ 12V-12AH_ = = Spark plug NGK B-8ES i NGK B-GES ND W-24ES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| ‘tem Metric English Carburetor Type Seiting marke 726A Main jet Slow iet ‘i screw opening TE tome Float height Drive train | Clutch | Wet, multi plate ype Traneciation Speed, constant mesh Primary seduction a7 Gear ratio L 2359 Gear ratio TT 1.636 Gear roto HI 1250 Geae ratio Vi 1036 Gear ratio V 0.300 - al sidaetion 2275, drive sprocket 167, deiven 367 Gear shift patieon Tift foot operated return system Bleetrical | Ignition Baitery and ignition cal Starting system Starting motor end kick starter Alterastor AC. generator 0.1 kee/5,000 rpm Battery capacity VAI Spark plug NGK BSES, NDW 248S Headlight Low/high _12V-25W/35W ‘Tail/stoplight 5 Turn signal light Speedometer Hight Tachometer light ‘Turn signal High beam indicator light sdiestor light Neutral indicetor light Fromt/reer_12V-32/320P (GAE TRADE No. Teil-soy 12V-3/32CP_ (GAR TRADE No. LV-2CP (SAE TRADE No, 97) 12V-2CP (SAE TRADE No, 87) CP (SAE TRADE No. 57) 2V-2CP (SAE TRADE No. 7) WV-2CP (SAE TRADE No. 37 Ly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 L350 Tea ees C1250 CUS.A. Type) DIMENSIONS Overall Tength 2100 mm (82.7 i) ‘Overall wid 800 mm (32.7 ja) ‘Overall height 1090 mm (42.9in) Wheel base Ground clearance 180mm (7.19) re ‘Curb weight 157 leg (945.416) z ‘Weight distribution F/R | 91/126 kg (200.7/277.81b) qe Semi-double, cradle Telescopic fork Brake, {cont, lining area Brake, rear, Taternal expaasion, 522em'x2 Intemal expansion, 510 cm! x2 ‘Swinging arm = ‘Tite size, froat 300-19 (4 PR) | Tixe size, rear ‘350-18 (4 PR) Fuel capacity Caster angle Cylinder arrangement ‘Compression ratio Carburetor Yalve train Max torque Slit. (@.4U.S. gal, 20 Imp. gal 207 kg-m0/8,000-xpm (6 f-b/88000 rom) %am 7) ia) OG, twin cpliades, sircooled ‘stroke ‘Vertical, twin parallel 56x 50.6 mim (2206 x 1.992 i) 29 ce GB21 cua) 95 Constant velocity type, Keihin ‘Chain deiven overhead cemahaft12 Item = CL250 (US.A. Type) Oil capacity Blk, @1US. quart, 18 Imp. quer) Lubrication system Forced and wet sump Poel required Octane aumber above 96 Engine weight, oy | S25kg (115514) DRIVE TRAIN Cluch Wet, muliplate type “Tranamission 5 speed forward, constant mesh Primacy reduction a7 Gear ratio Ist 253 ted | 186 od ord 1.259 2 th | a8 a) a0 2 cae = Final reduction 2395 ELECTRICAL Tgaition Battery Starting system Motor and kick Battery capacity yeV-2AT e Spark plus NGK B-MES,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 Ref, No. Tool No. Description .07900-2860000 Special tool set for CB/CL250, 350 (0798)-2860100 Valve seat cutter 90° (07980-28600 Ialet valve seur top cutter (0728-2880400 Exhaust valve seat top cutter (07980-2860500 Tolet valve seat interior cutter 07980-28660 Exheust valve seat interior cutter (07022. 2870000 Drive eprockst holder orga. ‘Valve seat cutter holder ‘97984-5900000 Valve guide reamer, 7mm (07967-3290000 Valve lifter (o7302~2590100 Valve guide driving toal ‘07%42-2590200, Valve guide removing tool Fiston base (2 each) Piston tinge compressor (CB/CL250) Fiston ring compressor (CB/CL350) T-Handle dyneme rotor puller 7016-2830000 Lock aut wrench, 16mm (07401-0019000 Carburetor float gauge (CB/CL250) (CB/CL350) (07945-2360100 Bearing driving too! ‘7902 2000000 Pin spanner, 48 mm, @oanEseesseangeaeaga16 CB/CL250 + 350 Ref. No, Tool No. Description tS ® o7947-2790100 Front fork oil seal driving guide ye @ (07959-3290000 Rear cushion easembling end disasembiing tool ® (07002-2500000 Main switch pin spanner @ (7946-286)100 Front wheel beering driver attachment a 7945-2860200 Rear wheel hearing driver ettechment a 79492860000 Bearing driver handle 3S (07965-2860000 Front fork assembling tool oe (07999-2860000 Dynamo inspection cover ® 797-3230 ‘Wrench, hollow set (mma e 7910-3: Rear wheel beariug retainer adjust wrench ‘or797-2920200 Tool eate (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. Deseription e O7946-2860100 -—=«*Front and R, Rear wheel bearing driver ettachment © (07946-2860200 AL, Rear wheel bearing driver attachment @ o7a4s-2860000—-*Bearing driver handle o7948-2730100 Front fork oil seal driver guide 2 (07922-2870000 Drive sprocket holder a Rear cushion disassembling and ascembling tool @ ‘T-handle box wrench, 16 ram 2 Float level gauge a ‘o7910-3290000 Rear wheel bearing retainer adjusting wrench 5 (07954-55100 Piston rng compressor @ (7 958-25000000 Piston, base a o77e7-0510100 Valve seat cutter case orrai-z920300 Tool case o7ay7-32:30000 wench, hollow set Gm +thote tools are for use with the L350 only, the others are common to all seri.19 ae er en ‘Aye jonpoad pasos x01 _poyesedzeowy 3949029 4949] spe, yorsss doyg song Q y [Te Zend jonpoud poseatay 203 = & [pad aveag ston gouermedde pososdun 304, sounzesdd ponoaduy 204 yyenb qonposd posorduy seq uonerersut sapjoy yamyey pur eam qote9) 9028 PSU PIS pen are Saas € Rs oe" (osayan apy) 1898 pamUNT apIs ovis SPOT Wag pu Iwas | ‘aqqead sonpoad pasoudwy 40g Thirend yanpaad paxoaday) 305 ‘deo fang uado deus 7 pus days poured oy amuet) a eS ayy sue, (ang 3 oseoraD 8m oseroszeT9 2M ose-vezaD ose-osaty Wa SNOILVDISIGOW TWdISNIdd 40 318VL JONVHD THGOW YONIW “€ OSE USAIDPOPU PIS women 203, ou 289 hesy Paya ORT Watem ost-0sca9 Ost 0SeHT9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),ee aepung 80x. pue que, [eng atpeso aqnod suyaady) 9g S901 OS (5 ne ENA) 991s VOI ALY VONOH = 110 ‘ayes oa4g 2M OSeTS TH 08e 1S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spopysoad Sjaou ayojd Suyureyos ‘sx2}ou1 ay Jo ayue Surjunour jo osuey> oyp YyIM WoReuN(UOD uy Mose Io’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 piston + connecting, rod — crankshaft —+ primary drive gear — (primary driven gear) dutch outer —+ eight friction disks — eight clutch plates — clutch center —+ ‘ronemiosion maiaehalt-» mainshalt gear— countershaft gear —countershalt—+ drive sprocket drive chain rear wheel. Fig, +3) NOTE: ‘The following pacts ca be disassembled from the eagine without dismounting the engine trom the frame. + Crankease cover (both right and left), left crankease + Clutch assernbiy + Oil pump, oil filter + AC. generator asembly + Neutral switch + Cam chain tensioner holder 4-3 DISMOUNTING THE ENGINE 1, Buel tanke Tum the fuel cock to the “STOP” position; remove the fuel lines from the cocle and the fasl level tube, and raise the seat to remove the cenk. 2, Remove the mufflers. 9, Clutch cable Remove the gear change pedal and step bar, and take off the L, eraakease rear cover @ f, crankshalt_@ K, crankshaft & Tranemissin mainshatt @ Teanamiasion counterehale @ Drive sprocket Fig, 1. Drive sequence @ hich {© Electrical los connecter @ Contact breseer leads Fig. 42. Removing the electric leadsRemove the drive chain 5. Remove tbe reer brake pedal 6. Carburetor Remove the throttle control cables from the carburetor; remove the left and cight air cleaner cases and loosen the carburetor insulating bands, Unplug the electrical eable conncetion. (Fig. 4-2) 3, Remove the contact breaker cable connection. Remove the high ‘easion temmizal assemblies from the @ Starting motor cable ae ee Fig. 43. Removing the wating motor cable 10, Remove the starting motor cable. (Fig, 4-3) 11, Disconaect the tachometer cable at the engine. 32, Remove the 7 engiae hanger bolts and dismount the ‘engine from the right side. (Fig. 4-4) 4-4 REMOUNTING THE ENGINE Remount in the reverse sequence of dismounting. NOTE: ‘Insert the hanger bolis from the right side of the trame fand tighton sfits from the left side. Install the battery ground cable from the right side. (Fig. 4-8) +I the hanger boks do net go in emily, do not farce Find the cause and make correction When installing the bamtery ground cable, clean all rust ‘and paint {rom the hanger bolt as well as from the terminal and the {come mounting area so that good contact is assured. (Fig. 4-6) | @ Batiety ground cable @ Engine hanger bolt Fig. 4-5. Iastling the bawery ground cable 1 + Make sure that the drive chain joint link clip is facing in the corzect direction, the opening must be opposite to the direction of chain movement. (Fig. 4-6) (© Joint chp Fig. 46, Drive chain join: clip direction . +Make sure that the stecl ball has been assembled in the clutch lever before installing the left crankcase 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 ishouscd withio the cam case. Driven from the crankshaft through a loop of cam chain, thé camshsft moyes the valves through the rocker arms. ‘Thie shalt is supported at two places and ruas at 1/2 the crankshaft speed. The working Suriaces of the cams are casehardened by softaitriding (CLN) process to provide greeter wear re: eamside ends of the rocker arms are hard special alloy. The valves are stellitefaced and their seats are mede of a heatresistant steel to. minimize valve com- ponent wear, The tachometer drive is located at the right side of the camshaft and the spark advancer and contact Ibreaker at the left side 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. (Fig. 4-9) 4. Remove the rocker arm pin lock muts (both sides, 2 each), aad the side covers aad socker arm pins. (Fig. 4-10) 4. Remove the cam chaia tensioner. 5. Aliga the staisr index merk to the “LT” on the AC. enerator rotor (top dead center of the exhaust stroke) approximately 10° ATDC and then remove the sprocket sligament bolt, followed by curning the rotor © align with a point approximately 10° ATDC of the compression stoke and then remove the remaiaing sprocket setting bolt. (Fig. 4-11, 12) @ Gan chang Cam sprocket @ Camshaft © Valve rocker nem Rocker arm pia © Valve spring @ Yalvo Fig. 48, Valve mechanism, © Contact breaker assembly Spark advancer Fig. 4-9, Removing the comiact breaker spark advancer (© Rocker nem pin lock ate @ Rocker srm pi @ Sido cover @ Rocher erm Fig. #10, 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 7, oil weal & Trarsmision coumershafi @ 249mm, O sing Trersmission countersbafi only 4 6mm, hex, bolt @ 2mm, thrust wather $8 25mm, lock washer @ Brn, thrust washer B D, Reassembly Reassemble in the reverse sequence of disassembly in accordance with 4+11B on page 58. NOTE: ‘+/Make sure that che thrust washers and circlips are ia: stalled on the M4, C2 and C3 gears. + Use only new circlips and properly install in the groove. + When assembling the bearings to the mainshaft and countershaft, make sure that the bearing with the oil groove is installed oa the countershait and the bearing fwithout the oil groove on the main shaft. +The installation of the bearing set rings and the dowel pins must not be forgotten. « Assemble the left shift fork on gear C4, right shift fork fon gear C5 and the center shift fork on gear M2-M3, fand then assemble the mainshaft and the countershaft in set. (Fig. 4-111) 4.12 GEAR SHIFT MECHANISM A. Description ‘The gear shift mechanism is « linkage arranged between the gear change pedal and the shift forks and includes a shift arm @, a shift drum @, « neutral stopper @, a drum Stopper @, etc. as shown in the figure above, When the pedal is depressed for shifting, the shilt spindle rotates, Gausing the arm to rotate the drum. As the drum is so rotated, the fork is moved by the cam action of a groove Gat in the drum to shift a gear. The drum stopper is provided to prevent unintentional gear engagement. Return Epring & use to return the pedal to its original position When released aad to place it in the neutral position for subsequent shifting, @ Gens shift orm @ Shfi drum stopper @ Neuiral stopper @ Daun stopper plate 55 © Malnshafe_@ Countershafe Fig, G11, Assembling the gearsB, Disassembly 1, Separate the transmission gear assembly from the upper erankesse in accordance with 4-11B on page 83. % Remove the neutral switch rotor and then separate the shift drum stopper. 3. Remove the shift fork guide pin clip end then pall out ‘guide pin, 4, Remove the geor shift drum by lightly teppiag the case ‘on the side of the neutral switch mounting. (Fig. 4-113) © Geer shift drum @ Gece shift forks Fig. 4-113, Removing the gear shift dram ©. Inspection 1, Messure the amount of weer to the dog on the goer shift fork ‘ S Position the gear shift drum vertically on the V-block, measure the shift drum fork dog at two step points. Gig. 11) ram (ine) Vandana Valeo Serviceable Limit 2 9.1 (0004) max. oe pate © Dial eauge @ Gear shift fork —_——ons Fig. 4114. Mensiring the fatness of ear shift fork 2. Messure the thickness of the gear shift fork dog, Fig. 4-115) Ex meets) Sorvieatble Limit — A iaed Replace if wnder 2 acs) Poni ‘ B (Feed ta Replace if under ‘a mas A) GEs=0.29 Se 029 @ Miccomoter) @ Gear shife fork Fig. 4-115. Measuring the thickness of gear shift fork 4. Gene shift fork bore diameter Measure the bore with a cylinder gauge or on inside micrometer. (Pig. 116) na fas \ ST VEE se ee oe } (1.575 ~ 1.876) 40.075 (1.577) © Cylinder gage @ Gear shift fork Fig. 4116. esuring sit fork bore % A. Geac shift drum outside diameter “Moasuro the gotr shift dram using « micrometer Fig. 4-117) h) —Siaedard Valve ‘Servis Ln as~ 9975 Replace if vader 90 5 © Gear stift drum @ Micrometer Fig. £117. Messusing the oater diameterD, Reassembly 1, Assemble the gear shift drum into the upper case, At this time make sure that the location of the shift fork are in their respective positioa. The two outside and the center gear shift forks are different. NOTE; When assembling the gear shift drum, exercise care not to damage the oll seal press fitted into the crankcase. 2, Inotall the shift fork guide pin into the shift fork and lock with a clip. (Fig. 118) NOTE: § Check to make sure whether the clip is set securely. 9, Reessemble the remining parts is the reverse sequence of disassembly. NOTE: Checlet make fork is smooth. jaro that the action of the gear shift 4-13 KICK STARTER A. Description ‘The kick starter is a devive used to crank the engine for start-up, ard consists essentially of a pinion, a spindle @ end a return spring When the starter pedal is de- pressed with a full kill stroke, the spindle is rotated in the direction of arzow (counterclockwise) within the pinion and the screw threads provided on the spincle cause the pinion. stationary because of its inertia, to move in the direction of ‘arrow, engaging the countershaft low gear. Upon engage: ment, the torque or drive is transmitted through the clutch to the engine crankshaft, er@nking the engine. When the pedal is released, the spindle rotates in the reverse direction ‘Glockise), causing the pinion to move on the screw spindle away from the gear, disengeging the drive. B, Disassembly 1. Disassemble the upper and lower crankcase. 2, Disassemble the kick starter spindle €. Inspection Check the kick starter spindle and pinion, if Camaged cor worn, replace with a neo part D, Reassembly Reacsemble the kick starter components ia the reverse order of disassembly. NOTE: Do aot forget to install the 18mm circlip and the 18 mm. washer. (Fig. 4-123) ® Guide pin clip Fig 118, @ Faia pring @ Kid waver pinion © Cond Tow geor” @) ick steer spindle @ Kick starer spring @ 18mm washer Fig. 4119, idk starter mechanism 1m ctckp @ Fricion spring @ Kick surter pinion @ Kick sater spindle B Kick sterter spring @ Imm orelip Fig. 4-120, Fig. 121, ‘Component parts of kick spine @ 16mm worker _@ Kick starer spindle Tasialing the 180m vasher@ To camalal @ To crankahale @ To mainshate Fig. 4122 Upper crankcase oll posoge © Separator @ Lower crankcase Pe 1 Ol spartan @ Simm hex bolts | Fie C15. “Tightening voper crankcase © BX9T hex. bolt @ Bx 115 hex. bolt @ 8x10 hex. hot a) 656 bex. bolt @ 6x45 hex, bok 6X10) hex bolt @ 6x0 hex. bole 4126," “Tighieniny, lower crankease 4:14 CRANKCASES A, Description ‘The upper and lower crankcases are aluminium-alloy in ‘material and are case in one piece. ‘They can be separsted from cach other end are internally provided with oil passages theourh which lubricating oils fed to the crenkehat, cam shalt, transmission ete. Oil Separator Operation The lower crankcase ie provided with the oil seperator which serves as baffle plate to prevent lubricating oil from splashing on the crankshaft excessively B. Disassembly 1, Disessemble the cam case in accordance with section 4-5B on page 31 2, Disessemble the cylinder head and eylinder in accordance with section 4+5D on page 3 3. Disessemble the cylinder in accordance with section 4+6B on page 39. 4, Disassemble the cam chain tensioner in accordance with tection 4-68 on page 29, 5. Remove the R. erackease cover, oil ter, oil pump and clutch in sccordance with section 4-8B on page 45~46 5. Remove the L. craukease cover, A.C, generator rotor aud starting clutch in accordance with 4103 on page 81, 7. Loosen the two Gmm hex. bolts on the upper side, the four 8mm her. bolts and eight 6mm hex. bolts on’ the lower side, and remove the lower case. C. Inspection Check for damazes especially around mating surfaces since even a amall defect such ao scratch will cause oil leaks, Repair should be made with an oil stone.te 59 D, Reassembly ao 1, Check to make sure that the kick starter is properly exyaged in the lower crankcase. Apply liquid gasket to the mating surface of the lower erankcase. Nore: + Oil, solvent, stuck gasket should be completely removed from the matiag machine surface, + Do not permit the liquid gasket to get oa the dowel pia hole or to susfaces other thon the mating pasts. = Apply the Tiquid gasket evenly and smoothly. + Allow the Tiguid gasket to set before joining the two crankcase halves. 2. Asserable the lower case. 3, Handle the staring motor cable and dynamo cord with care so as not to damage the clamps; tighten the bolts, 4-15 CARBURETOR A. Deseription ‘The outstanding festure of the CV carburetor is « constant pressure, single barrel, compound carburetors brought about by the automatic changing of the venturi area by the vecaum pressure of the eagine. Fach cylinder is equipped with a single carburetor of this type which provides the following advantages to engines having a broad speed range fand 6 high power output. ¢ 1. Because of the variable venturi design, the (raasition between the first aud second stage is exceptionally smooth, 2, ‘The construction is very simple duc to the single barrel feature, 4, Excellent acceleration and good economy is astured. ‘The sir which passes the clesner fows through the sir inlet ®, venturi ®, throttle valve @ and enters the cylinder through the iulet port. The vacuum piston @ is prosruding into the venturi area @ aad by the action of the vacuum piston spring @, the venturi is held toward the closing side. When there is only a small amount of air bein Toto the engine, the vecuum piston @ ia in the lowered position, forming the primary venturi @. The air velocity ia the venturi area @ is maintained constent, afordiag good atomization of the fuel. With au increase in the air flow, the vacuum pressure in the venturi increases, causing the vacuum pitton to rie due to the pressure applied to the top of the piston. The venturi arca is incieased by the amouut of the rise of the piston which is in proportion to the vacuum pressure, ‘Wen the oginereeches masinam rpm, the rcaum pst reaches the 1p and becomes ibe méoaday aia to provide aulficient venturi area for maximum power ou‘pst. (Refer to Carburetor Manual for details Hig. 4.127, Sectional view of carburetorB, Disassembly 1, Remove both left and right air cleaner covers 2, Loosen the throttle cable adjusting bolt and nut, and remove the throttle cable from the carburetor. 3, Loosen the carburetor setting bands, and remove the carburetors. C. Inspection 1, Tding adjuotment 1) Adjust the stop serew @ 20 that the exhaust pressure is the same for both the right and left side. (ig. 4-128) If the engine speed does act decrease when the stop screw ia screwed out, loosen the lock aut @ and crew in the cable adjust bolt © by about one turn. ‘The engine rpm st this point should be between 1,100~1,300 rpm. (Fig. 4-129) © Stop screw @ Pilot screw 2) Starting with either the right or left carburetor, mi Fie, #128, Adjusting idling speed pulate the pilot screw @ and find the point of high rpm; the same thould be done with the opposite earbuseter, Turning the pilot screw in will give a lean fuel air mixture, turning the screw out will give « rich mixture. The pilot screw @ should be set at a point 1 (8/4 for 350) of a turn out from full close. (Pig. 4-129) 3) Alter completeting the adjustment in paragraph 2 above, recheck the exhaust pipe pressure on both the right and left sides and if necessary, readjust the stop crows as was done in paragraph L " 4) Repest the procedures from paragraph 1 through 3 ® Throttle cable adjust tole @ Lock nut several times so that the pilot screw is set to give Pig. 4-128. Throtle cable adjustment optimum mixture, while the stop screws are set to provide the specified rpm and the eame exhaust pressure oa both the right and left ses. 2. Synchronizing the throtile valve Malke the adjustment so thet the right and left chrotde valves will both move by the same amoust when the throtile grip is moved slightly This adjustment ean be made Ly placiag « head uader the carburetor and noting, the movement of the throttie lever, or by overserving. the movement while the throitle grip is slowly moved and checking to see thet the throttle levers start moving fat the same time. If adjustment is required, loosen the Tock nut @ and perform the adjustment with tho cable adjust bolt ©. ig. 4-129) ) Flost level gau Fig. C130. Ched 3, Float level check Remove the float chamber cover, position the float to the polat where the float arm berely touches the float, arm. Tn thie position, set the oat level gauge vertically on the foat (Carburetor til of 10° is normal) Gig. 4-180) 4A. Ifthe adjustment is necessary, meke the sdjustineat by using a small screwdriver to bend the float arm.ially designed with the up.to-dete engineering techniques of Honda to provide maximum riding comfor: and minimum steering difficulty. It is mounted on the fore top bridge with two clamps. A fully-raised type lebar is mounted on the CL-series machiaes aud a semi- raised type handlehar on the CB-series machines. B. Disassembly. 1. Disconnect the front brake cable at the lower end by looseniag the froat brake edjusting bolt nut, move the brake arm toward the braking pesition to providing slack to the cable, and then disconnect the cable from the brake am, (Fig. 5-2, 5-3) 1 Remove the brake and clutch cables from the handlebar bby turning the slotted zing adjusting bol: so that the slots im the holder and the fixing nut are aligned. Remove inner cable and slide the end off of the handle lever. Fig. 5-4) NOTE: ‘When disconnecting the clutch cable at the lower end, remove the gear shift pedal, drive chain cover, and thea Femove the cable exd from clutch lever, 3, To remove throtle cable from the handle lever, unscrew the setting screw on the starter switch assembly and separate the two halves of the starter switch. The starter table will be exposed end can be removed from uuoie rio pipe. (Fig. 5-5) Ls 61 L © Clutch cable @ Clurch cable adjusting bolt Fixing aut @ Clutes lever Fig. 5-4. Removing cable from the handle © Throtle grip) @ Throide cable @ Suarter lighting switch assembly Fig. 5-5. Removing the throtle cable4, Disconnect the throttle cable at the lower end by loosen. ing the leck aut at the cable support arm oa the carburetor fand then disconnect the throttle cable from the carburetor. Fig. 5-6) Lode nut Fig. 5.6. Removing the throtle cable < ® Throwtle cable @ Throtle cable adj @ 5, The electrical witing for the hora, sturting motor switch and the light dimmer switch cay be disconnected by tincoupling the cable junctions from the wire harness Tecated within headlight ease 6. Remove handlebar by unscrewing the four 8mm belts from the handle pipe holder clamps. (Fig. 9-7) ® Steering handle pine @ 8mm hex. bolt Fig. 5-7. Removing the handlebar ©. Inspection 1. Inspect the theotle, clutch and front brake cable for damages to the housing and inuer cable, also check to se that the cable is operating smoothly. Apply grease before reassembly. Check the operation of the throttle grip; mek eure that the action of the grip is emooth through the eatire rene, Inspect the handle pips for twist, bends or other damages. 2 3. Inspect the hand lever operation for lightness. 4 5. Inspect the switches oa the handle for proper operation end also the lead wires for breaks end frayed covering D, Reassembly 1. Rough the electrical leads feom the hendlebar through the center hole in the top bridge and mount the hendle on the top bridge. Fix in place with the handlebar holder tend lock with the four Simm bolis Conacet the throttle cable to the throttle grip and edjust the play with the nur @. (Fig, 5-6) @ Throtde cable @ Throtile cable adjust mut “A” @ Lock nut @ Decrease Increase Fig. 58. Throtle cable play adjustment 3. Connect the clutch cable to the left band lever and the front brake cable to the right hand lever. ‘The adjustment ff the clutch cable is made at the crankcase (Refer 10 page 21), wherees, the adjustment for the front brake Eimade with aut h” and “ce” at the lower end of the front brake cable, (Fix, (© Front trske cable Fig. 6:9, Adjusting the front brake4, Connect the electrical leads from the andlebar at the heedlight case. (Fig. 5-10) 5-2 FORK TOP BRIDGE A. Description ‘The fork top bridge is mounsed on the top of the fork with two bolts and is secured to the steering stem with stem nut, as illustrated in the Syare at right. To this bridge is mounted the handlebar with euhlon rubber to resist shocks to the rider's hands, B, Disassembly 1. Remove the steering handle in accordance with section S+1B on page 61~€2. 2, Extract the 61mm lock pin and remove steering damper by pulling apward 3. Disconnect the speedometer and the tachometer cables from the respective meters (the meters may be removed from the fork top bridge by unscrewing the 6mm nuts). 4. Separate the fork top bridge from the front fork by Unserewing the two front fork bolts and loosening the steering slem aut, (Fig. 5-12) 5. Unscrew the 8mm hex. nuts and remove the front fork washer, handle cushion rubbers and the hancle pipe under holders from the fork top bridge. (Fig. 5-19) NoTE If the handle pipe under holders are to be removed, it is recommieaded that the 8 mm hex. auts on the pipe holders be first unserewed before removing the handiebar. This fs to preveat the pipe holder from the turning. (Fig. 5-14) .. Inspection 1, Inspect the fork top bridge for cracks and other damages. 2, Inspect the handle cushion rubber for damages and wear. D, Reassembly Mount the fork top bridge on the front fork, install the front fork bolts aud steering stem nut Assemble the handlebar in sccordance with section S-1B. on page b1~! 3. After completing the installation, check to make sure dhat the electrical equipments are operating properly. 63 Fig. 5-10. Connecting clecitical lends @ Swering handle @ #mm hex belt @ Handle pipe upper holder @ Cable bolder @ Handle pape under holler @ Hance cushion rubber © Handee cushion washer ® 8mm hee. nat ® Damper lock spring set bolt @ Steering damper Ieek spring @® Fork top bridge Fig. 5-12 idee © Under bandlebsr holder @ Handlebar cashion rubber @ Fork top bridge @ Haedle cushion wesher © Bim bes. nat Tig. 5-18. Component paris of fork top bridge+The models CB/CL250, 390K2 thru K5 ere provided with no steering damper. @ Handle pipe under holder @ Fork top bridge @ smn nut Fig. 5-14. Too bridge holder installing 8mm not 5-3 FRONT CUSHION (Piston type) A. Description ‘The froat fork is of « hyéraulically-damped telescopic type, It consists mainly of a fork pipe @ complete with piston @, a fork bottom case @ and s cushion spring. On “compression”, that is, when any downward loed is Fmposed oa the front fork, for example, under heavy front breking, the piston moves dowa, compressing the oil in chamber “A.” and forcing it into chamber “3” through orifices “a” in the peripbery of the fork pipe to lift damper ‘alve @ off its seat. On the other hand, the cushion spring, now compressed, exerts an upward reaction to move up the piston. The piston when so moved compresses the oil in chamber “B” and forces it back into chamber “A” through orikes “b’” te provide damping setion. On ‘full bump”, or bump overcoming the capacity of the cushion pring, the pipe is moved dowa towacd the botiom end of the bottom case, trapping the oil in the space between the pipe and tapered lock piece ® to provide maximum damping. On “full rebound”, the orifice “b” is covered by fuide @ end the cil is trapped within chamber “B”" to provide damping on the extension side. @ Front fork bottom case s ail ae Es = E BP Fig, 6-168, CL250/35065 6 26.2): som: compen te Zen 2) 18demi7 9) =a © From fork pipe compleio @ Brent fork bottom case complete @ Front fork ripe gui @ Front demper valve. @ Oi lock piece Fig. 5-160. Front cushion operation (Rod type) A. Description ‘The rod type telescopic shock absorber is the most advanced absorber ever produced—so called because the spring under seat incorporates a damper actusted by a ong rod. ‘The rod is serewed in the Lostom of the fork bolt, One of the distinguishing features of this latest unit is its higher ability to absorb shocks and vibrations. “The fork pipe is in direct contact with the cylinder ‘without piston, Fig. 5-10. The rod type @ Front fork piston consist of a lightweight aluminum froat fork bottom case with © dual action telescoping shock absorber oil damper. Coshionig travel i 907mm (3.5 ia.) on compression and 27.8 mm (1.08 i strokes, on extersion © Front fork bole 1 O-ring 1B Locke st Front fork pine 15) Front suspension spring @ Fron: fork hoot B Damper red B Sup nog © Oil seal 7A. Front fork wait @ Heléer @ Collar (@ Brom fork bovtore cate {9 Demper ease @ Axle bolder 1 Phin washer @ Spring washer NuO Fork pipe @ Ol Tosk piece @ Oil eval 1 Valeo sot spring @ Rebound stopper spring @ Second power hole @ Piston rod Compression © Piston rod guide @ Extension © Lock guide housing @ Chamber © © Valve ® Chanber B @ Psion (i Chamber A. ® Cylinder Fig. 5 178, @ Boron case @ Front fender @ 6mm bex. bolt Fig. 5-11. Removing the front fender © From fork bolt @ Bw { Freot frie assem y Fig. 518, Resoring the front fosk assembly Then. bolt Operation : + The piston, as it goes down, pushes a part of the fluid from the chamber “B" into “C”. Most fluid can flow into the chamber “A” through the valve in the piston Freely. + As the pitton travels up on its extension, the fluid is returned from the chamber “C” through the snall open ing into the chamber "A". ‘This imposes a restraint on the spring and wheel actions as acted ia the previous section + Near the end of the compression, the fork pipe is pleced ‘over the oll lock piece. ‘This holds the fork in place, thereby preventing it from dashing against the bottom Damping increases as the piston reaches the end of the extension stroke. This feature plus a rebound stop spring combine to achieve an exceptionally smooth cushioning. Rod type disassembl The models CB/CLI50, 360K4 end KS use front forks of the rod type. ‘After palling out the front fork assembly, set the fork fas shown in Fig. 5-17B. Then remove the fork botiom pipe and damper unit using a hollow set wrench. B, Disassembly (Piston type) 1. Separate the front wheel from the motorcycle in accordance with section on Page 84, 2 Remove the three 61m fender stay mounting bolts and the one Smm bolt (fender stay and front brake stopper farm atteching bolt) from the inside. ‘The fender can be separated from the fork, (Fig. 5-17) 8, Unsereve the headlight case mounting belts attaching the hheadlight assembly to the front fork Remove the 8mm bolts from the froat side of the steering. stem and slide the cushion assembly out from the bottom. ig. 5-18) NOTE: ‘The front cushion removal can be faclliaied by spreading the mounting ring of the bottom bridge by driving a welge iato the slot on the mounting ting4. Drain the oil ia the cushion by removing the drain plug at the bottom or inverting the cushion and draining the ‘il out of the top mounting bolt bole before separating the front fork pipe from the front fork bottom case. 5. Remove the front fork boot, (CB250/350: front fork under cover), front cushion spring and then remove the 44mm Internal citclip using the snap ring pliers. Pull out and disassemble the front fork bottom pipe and the front fork ‘pipe assembly. (Fig. 5-19) 6, Distsvemble the front fork pipe assembly by removing the fork piston snap ring, font fork paton,stoper ring, front damper valve, front valve stopper ring, fork pipe stopper ring, and front fork pipe guide, in that order. (Fig. 5-20) C. Inepeetion (Piston type) 1, Froat fork cil change Changing the oil in the front fork should be performed the initial 900 miles (500 kin) aad every 12,000 miles (20,000 icm) thereafter. 1) Remove the front fork bolt, drein_plug and drain the oil from the froat fork, allow euficient time to drain the oil completely. (Fig, 5-21, 22) 2) Cleen inside with oily solvent. Don’t use gasoline for cleaning inside. 2) Reinstall she drain plug and pour 200.e (12.2 eu-in) of engine oll SAB 10W (API service classification) Inspect for oil leak. JO! caks are duc to defective or improperly installed oil teal, loosening of the drain plug, damage front fork bottom case and ete, Perform the inspection of the respective arees and repair or teplace the defects, 3. Inspect front cushion spring Measure the free length of the spring with a vernier caliper. (Fig. 5-23) mm (iach) rimealle Umit Replace st under ise 4. Front eushion trucness Set the’spring up on its end on the surface gauge and measure the amouat of tlt with a squere aad vernier caliper. Petey Sardird Valve |__‘Serviseable Lim a Replace if Within 5 (02, ie @ Pls (close) @ 44mm internal ciecip Fig. € 10, Removing (4am circlip Lr (From fork ble_@ Ol filer penne Fig. 5-21. Removing the front fork bele © Front fork botiom ease @ Front fork drain phig Fig. 5-22. Removing font fork drain plug @ Vernier caliper @) Front cushion soring Fig. 5-22. Messoring lree length af cushion spring@ Front fork piston @ Micrometer Fig. $24. Meacuring front fore piston diemeter © Cinder guage _@ Fron: ‘ork boom case Fig. 5-25. Measuring front fork boom case @ Front fork oll seal driving guide @ Oi seal Fig. 8-23, Driving front fork oil seal Installing the front fork into the sieering 5, Bront fork piston diameter ‘Measure the diameter with a micrometer, (Fig. 5-25) im (inch) —sierd Valse _Serieee Tie a6 37.420 | Replace # undor 472 AAP) | ares tara 6. Front fork bottom case diameter Meacure the inside diameter of the bottom with case a cylinder gauge. (Fig. 5-25) om Cinch) Sensioesbie Limit Replace if aver 37.680 (1.464) D. Reassembly (Piston type) 1. Clean the parts thoroughly before assembling, 2, Assemble the individual components into the front fork pipe assembly. NOTE: ‘After completing the assembly of the front damper valve into the froat fork pipe, make sure that the damper valve is operstiag smoothly. 3, Taiert the front pipe sssembly into the front fork bottom ccaxe usiag the following special tools, front fork cil seal driving guide, front fork oil secl driving weight. Exercise ceare not to damage the oll seal. (Fig. 5-28) 4, Assemble the front cushion spring and the boot (CB250/ 60: front fork under cover). 5. Install the front cushion assembly on the steering stem. Fill each cushion with the following amount of automatic, trensmission Guid (APT) through fcom the front forte bolt hole and install the froat fork bott upon completing the filling. Lock the cushion it the bottom bridge by tightening the 8mm hex. bolt. (Fig. 5-27) FORK OIL, FORK OIL VOLUME,“TO | CAPACITY. MODEL FILL AFTER | TOFILLURY DEAINING ASSEMBLY 195—25 | 63~69 196-218 | 68—69 iw=u9 lis~ 10 tis~ 10 6. Install the front fender and the front wheel, 7. Upon completion of the front cushion assembi or proper operstion and assure that there is 069 A. Description (Rod Type) @ Front fork assembly @ Frone fork bole & Front fork pipe & From suspension spring / / © Cushien sprng sex © Dostaral, 853e47% 10 © Oil seal, 39-46-205 @ Front fork loom case @ Front axle holder Fig. 5.28, B, Disassembly + The rod type front forks should be dissssembled ia the same manner as the piston type up to step 1~3 on page 66, PRE VEE OW weal (€. acccews the Brim bovine wece hols vehais «Sone oes wrench (Tool No. 07917-8290000) end remove the damper tunit from the bottom case, @ Feo @ ® Danyer 3 sal 1-45-109 (@ Front fork bocom cise70 +— square Fig. 0 eee Fig 538 Oilseal @ Ol cal driving guide C. Inspection 1, Check the front suspension spring. 2. Check the fork pipe and betiom case for damage or Tooseness. 3. Check the oil seal for scratches and damage. 4. Check for excessive clearance between the shock absorber ‘piston and the cylinder. D. Reassembly 1. Reassemble in the reverse order of disessembly. Take cure not to allow dust, dirt or other foreign matters to achere to the component parts 2. Install the fork pipe into the boom case. Apply 2 coat of thread lock cement to the socket bolt and tighten it using @ socket wrench. 3. Apply 1 coat of Honda ATF to both sides of the oil seal fand install it using a front fork oil seal driving guide (Tool No, 07947-2730100, CB, CLI50 » 350 models), (07940- 2730100 SL350 model) NOTE: Dao not forget to install the snap ring. + Replace the removed seal with a new one. 4. Apply a.coat of thread lock cement to the threaded part cof the damper. ‘Making sure that the & mm lock nut is completely screwed ‘on the threaded part of the damper, tighten the fork belt. Capacity refer to on page 68, Remove the front fork bolt and pour a epecified « mownt of Honda ATE into the front fori pipe. 6. Install and tight the front fork bolt. 7. Route the front forks through the holes in the fork top bridge and tighten them with the &mm setting bolt and 10 mim setting bolts, NOTE: Remove oil, if any, from around the front forks. 8 After reassembling, check the froat forks for smooth movement, Also check if oil leaks from the oil seals,5-4 STEERING STEM A, Description ‘The steering stem is in # sense between the front fork and the frame, ball bearings at its upper and lower ends and pivocs in the frame head. A steoring damper is provided to adjust the stem for diferent riding or road conditions ~ the adjustment ‘can be made by means of steering damper knob @. Turning the kncb clockwise will increase the friction betreen damper plates © to “tighten” the steering, and vice versa. In this tem ie built the handleber lock. B. Disassembly 1. Separate the handlebar in accordance with section 5+1B fon page 61~62 2, Remove the front wheel in accordance with section 5-19B on pege 84. 3. Disessemble front cushion in accordance with section 5-3 on page 6. 4, Remove the top bridge 5-28 0a page 62, 5, Remove the steering stem top thread and withdraw steering stem out of the heed pipe. being careful not to drop the steel balls, (Fig. 5-05) plate in accordance with section C, Inspection L. Inspect stee! balls for cracks, wear and other damages. 2. Inspect the cone and ball races of both the top and bo:tom for aay wear or damages. 3, Inspect the steering head dust seal for wear end damages. 4. Inspect the top end of steering stem for damaged threads 5. Inspect steering handle lock for damages or defects, D. Reassembly 1. Mount the steering handle lock on the steering stem. 2, Mix the 1/4” steel balls (37) im grease, lay into the lower G9) end upper (18) ball xaces, aad carefully insert the stem into the heed pipe, exercising care not w drop the balls. ‘The top thread should firet be hand.tightened fully end then be backed off wbout 34 vurn, Tightening it exces- sively will eause a hard steering and backing it off ex- cessively & loose steering wheel (Fig, 5-26) n @ Storing damper Knob © Damper lock spring setting bolt Steering demper lock sping © Front fk top beige) Steering stem @ Secrng damper oA @ Searing me as rcering damper spring nut ® Stesing dampers Sa ig. 5-94. Sectional view cf steering sem @ #8 Steel balls @ Steering stem Fig. 9-35. Remoring the steering sien. 48mm pin spanner @ Steering head top thread @ Sesing stom Fig. 6 96, Reaombling the steering tom© Steriag head top thread @ Steering stem Pig. 5-31. Check of stem operation © Feel tank front cushion @ Foel tank rear cushion Fig. 5-38. Schematic view of wale ubber cushion sembly @ Joine mat @ Feel tank ving the fuel coke assembly NOTE: Special aucention is required to tighten the top thread. It must be tightened in conjunction with the steering stem ‘aut and the froat fork bolt. If the stem nat is properly tightened, the steering estembly will turn to the locks under its own weigh assisted only by @ slight initial force. Further there should not be any looseness of the stan in either the verticel or the horizontal directions. (Fig. 5-37) 8, Assemble the top bridge front cushion and front wheel. 4, Tnstall the steering handle end damper kacb. 5. Adjust the play of the clutch, brake and throttle cables. 5-5 FUEL TANK A. Description ‘The fuel tank is made by press-working and is mounted, on the half frame (upper member of frame body) with rubber cushions ws shown la the figure at lef. ‘The models CB250/ 350KI thra KS are provided with no knee grip rubbers Knee grip mibbers ere attached to the tank mounted on the (8250/30 machines B. Disassembly 1. Unlock the seat Intch located on the left front of the seat side, 2, Position the fuel cock lever to STOP position aad remove the fuel tube from the fuel cock. 3, Remove one end of the fuel level tube end apply « clip on the tube to close off the fuel tube, Install a rubber cap or a plag on the taak fitting to prevent the fuel from draining. Detach fvel tank from the fuel tank rear cushion and enrefully remove to the rear side. (Fig. 5-40) 4, The fuel cock assembly can be removed from the tank by loosening the joiut nut and unscrewing the fuel cock assembly. (Fig. 5-41)C. Inspection 1, Taspect the fuel tank for leaks. NOTE: Normelly an air prossure test ie performed by immersing the tank in water, However, exercise precaution since ‘excessive pressure will cause repture et the tank seam. 2 Inspect for clogging of the filler cap vent hole 3. Inspect the front snd rear cushion rubbers for detetiore- tion, wear and other damages. 4, Inspect for damage to the valve cock packing and the screen. (ig. 5-42) 5, Taspect the fuel line for defects, Reassembly 1, Tnstall the fuel cock assembly on the tank, 2. Fit the front and rear rubbercushions to the frame body. ‘The front rubber cushion should be inserted by pushing the fuel tank from the reer, Install the fuel tank resr bracket oa the rear cushion, (Fig, 5-49) NOTE: When installing the tank, particular attention should be given to the condition of the wires and their routing 4. Install the two fuel lines using fuel line clips, eleo connect the fuel level tube to the tank valve. 4, Install the seat and secure with the seat larch. 5-6 FRAME BODY A, Description ‘The frame body is of a semi-cracle, double-frame type. It i rigidly fabricated with high-strength steel tubing to carry the weight of the propelling machinery and the rider and 110 to provide free steeriag movement of the front wheel while maintaiaing the reer wheel in accurate alignment with the enter plane of the machine. The major components of the frame body aré as shown in the figure at left 73 @ Joint nvt_@ Joint nat packing @ Fuel cock body @ Screen @ Cack packing @ Feel strinee cep © Poel tank Bir. 5-88. @ Hal fame @ Head pipe @ Hall pillar @ Front down tube @ Sub tube holder © Lower cross member Fig. 8 14, Schematic view of frame bodyCaer 6 igiioa ol © 1 RPGS Moune pornos f cecal fens @ Selenium rectiier @ Fuse @ Magnetic starter switch ® Winker clay @ Pointless regulator @ Battery Fig. 5-46, Mountiag positions of electrical itsme @ Wooden drift @ Hesd Fig. 547, Removing the bs © Dall race driving cool q) Head pipe Fig, $:48, Dring the ball rice @ Double seat Fig. 13. Set B, Disassembly 1, Dismount the engine from the frame in accordance with section 4-3 on page 29. 2, Remove the seat and fuel tank in accordance with sections 5.5B and 5-78 on page 72. 3. Remove the air cleaner in accordance with section 5+10B on pege 77. 4. Separate the handlebar in eccordance with section 5+1B on pege 61. 5, Disussemble the front wheel in accordance with section 5+15B on pege 83 8, Remove the top bridge in accordance with section 5+2B op page G3. 7. Disassemble the front cushion ia accordance with section 5+3B on page 66, 69. 48, Remove the stcering stem in accordance with section 5-4B on page 7. 9. Disessemble reer fork, rear fender and tool box in sc- cordance with cection 5-11B on page 78. 10, Remove the electric equipment from the frame body. (Fig. 5-45, 46) UU, Detach the main stand in sccordaace with section 5+€B fon page 63 and then the frame can be disassembled. 12, Knock out the ball races from the head pipe by using « wooden drift. (Fig. 5-47) CC, Inspection 1, Inspect the weld joints for aay breaks or cracks. 2. Tnopect the stecring head pipe for twist, bende and mise. ligament. 2, Inspect the top and bottom steering head ball races signe of wear and scratches. NOTE: ‘The ball races should be fitted to the steering head pipe with light driving and must be bottomed securely. (Pig, 5-48) 4, Inopect the frame paint costing for any chips and rust spots D. Reassembly Perform the assembly in the reverse order of disassembly, 5-7 SEAT A. Deseription A double seot is mounted, ‘This seat is sponge rubber. padded to provide aa optimum padding thickness under the average rider. Its center and rear sections are paced thicker to prevent the rider from sliding oa the seat when rapidly starting or accelereting. The covering is easy-to-clean, high- strength vinyl leather im material, ‘The seat is hinged at the rear end so that it can be reised by ualatching at the front left side for servicing of the battery or other elecirical parts.B. Disassembly 1. Raise the seat and remove the two 8mm hex. nuts at the seet hinge and separate seat from the frame. (Pig. 5-51) 2, The seat stay can be separated from the seat by unscrew. ing the two 6 mm nuts €. Inspection 1 Inspect the seat covering for wear, cracks and tear. 2, Tngpect the binge and the rubber seal to insure that they are not damaged or eracked. Reassembly 1. Bolt the seat stay to the seat with the wo 6mm nuts. 2, Mount the seat hinge to the frame, 43. Assure that the seat front end is properly hooked by the latch. 5-8 STANDS AND BRAKE PEDAL A. Description ‘A main stand @ and « side stand @fabricated with steel tubing are used, The former stand is mounted oa pivot shaft @ fitted to the lower cross member of the frame and is spring-loaded to provide an “ over-dead center” action when rected or folded, The foot plates welded to the botiom ends of the stand provide a hetter “ footing ” for stable machine Support. The latier stand is mounted on the pivot screw @ ‘The brake pedal @ is mounted on pivot bolt @ located just in front of the main stand pivot shaft. Brake pedal @ Beake potel spring 2 Rear brake pivor bolt. © 14mm washer © Brake rod joint pin @ 1.6«2 cotter pio Rear brake rod.) Rear brake rod spring Rear brake arm int @ Reer brake adjusting net f@ Main sane spring $2 Main stand pivot pipe @ Main wand stopper rubber (CL250/350 {25:00 cotter pia @ Main esand (@ Side stand sping @ 10mm hex. aut ft Sie stand pivot ssrew gy Sie stend B, Disassembly Main Stand) L. Raise the front wheel off the ground by placing a block andemeath the engine, 2. Remove the stand spring from the right side. 3. Aiteroosening the two 6 mm hex. nuts, remove the cotter pin from the left side, slide off the mzin stand pivot pipe And remove the main stand. (Fig. 5-53) @ Scat Itch lever @ Seat Fig. 5-60. Unlatching the seat latch lever © Seat_@ 8mm hex. nuts Fig. 6-51. Kemoving the seat Fig. §-62. Exploded view of sland and brake pedal © 6mm hex, nat _@ Main stand Fig. 5-58. Removing the min stend(Rear Brake Pedal) L. Remove the rear brake adjusting nut. 2. Unhook the brake pedal and stop switch springs. 3. Rear brake pedal can be removed by unscrewing the rear brake pivot bolt. 4A, Rear brake rod can be teparated from the beske pedal by removing the brake rod joint pin. (Pig. 5-48) A @ Rear bake rod @ 16x12 cotter pin 1 Rear rake pecal Pig. 6-64. Rear brake pedal (Step Bar) 1, Unscrew the four 8mm bolte and remeve the step ber. (ig. 5-25) 2, ‘The side stand is mounted on the left side of the step bar snd is removed by disassembling the side stand spring and side stend pivot sezew. @ Step tar_@ 8mm bols @ Side : Fig. 5-55. Removing the siep ber C. Inspection 1. Main stand pivot pipe Measure the main stand pivot pipe diameter with a vernier caliper, sm Cinch) = [_Seviesabie Cie ——— Haat", Replace if under (aer7~6581) rds srs) 2. Rear brake pivot collar Measure the brake pedal pivot collar with « vemier caliper, ram (inch) ‘Saandard Value ieviosabla Cont Taam ite Replace if over (a5s5~0.500) 145 (0.265), ‘3. Inspect the stand, step and brake pedal to insure that they fare not bent or deformed 4, Inspect all springs for breakage or lost of tension D. Reassembly 1. Clean all pasts and grease all shaft arces, Fill dhe inside of the pivot pipe with grease. © Eahaval pipe @ mem hex. nu 2. Perform reessembly in the reverse order of disassembly Exhaus! pipe joist @ Cylinder bead . & Exhaus: pipe joint colle @ Exhaust pipe geskes NOT Fig. 5-57, Cross-secioh of exhdust pipe and nut Do not over-torque the 6mm bolts. (Fig. 56) Tightening torque: 80~100kg-em (8~8 ft-1b) 5-9 EXHAUST PIPES AND MUFFLERS A. Description Two exhavst lines, one for each cylinder, are employed. Fach line is made up of a dual.wall type exhaust pipe and amoffes, Piping layout for the exhaust lines and design of the mufflers are specislly made to damp the exhaust pressure waves and the resulting cise mere effectivelyB, Disassembly ‘Unscrew the four 6 mm (K1: 6mm, K2~K6:8 mm) ex- hhaust pipe ange joint nuis and the tvo 8mm mufler flange bolts on the left side end remove the exhaust muffler ig. 5-58) (On the CB250/950, unscrew the four 8mm muffler flange nuts on the inside of both right and left side to remove the exhaust muffler) ©, Inspection 1, Inspeet the muffler gasket for damage. ChRLER 2. Inspect the muffler for execks, dents and other defects. Fig. 6-53. Removing the mufor D, Reassembly: 1, Install the exhaust pipe gasket on the cylinder head and temporarily tightea the pipe joint with the collar and 6 mm 2. Alter completing the mufller installation, tighten the ex- hhaust pipe flange nuts. (Fig. 5-59) NOTE: If the exhaust pipe dange joint auts are tightened first, it ‘will be difficult to install the muffler. 5+10 AIR CLEANERS A, Description ‘Two air cleaners, one for each carburetor (cylinder), are arranged ia “ side-by-side” fashion and are located at the Center of the frame, Each closner uses « replaceable paper filtering element to “polish” incomimg air. As shown ia the figure at lef, both cleaners are ecnmunicated with each other bby a central air passage. This design and « large capacity of the filtering elements assure constant supply of clean air to the engine even if any one of the elements is clogged. B. Disassembly L, Remove the air cleaner cover. When remosing the air cleaner case from the Jet side of the CL290/350, the mufler must be removed first 2, Remove the air cleaner case by removing cleaner clement setting nut. (Fig. 5-61) 3. The air cleaner element can be separated from the frame by removing the air cleaner consecting tube clamp and the 6mm belt, © 6X16 hex. bolt @ Aic cleaner jeaner element seting aut @ Air cleaner cov Fig. 5-61, Removing the air clanar case C. Inspection 1. Dustoa the sir cleaner element can be removed by tapping lightly and blowing off the loose dust particles with ‘compressed air 2 Inspect the air cleaner element to make sure that it is aot damaged or clogged by soilage. 3. Also inspect the bonded section ta make sure that the joints are not cracked or open. D. Reassembly Mount the air cleaner with the 6 mm bolts, install the air clesner connecting tube on the carburetor with the clamp. NOTE: + After completing the installetion of the air cleaner, check to make sure that the right and left air cleaners are inter. Connected. ‘Ii there are aay leaks ia the system, wofltered air wil be drawned into dhe eylinder cnd couse rapid soar to the cylinder walls. -Tnstall the air cleaner case and the air cleaner cover.8 Hn toe, sting nie A Ste am ta, ‘cushion ruber ne ole sete wash A 0mm tinued ase Rear fender @ Rear bumper @ Drive chain case © Drive chain @ Dsive chein joint @ 6mm fet washer 6x8 hex, bolt @ Emm fet washer @ Rear fork pivot bush qb Rear cushion under bush Rear beaks stopper arm bolt. @ 10mm spring washer @ 8mm fai washer @ 8mm thin aut @ 2x18 cotter pin car brake stopper arm @ mm lock pin @ Omm hex. nat §@ Roar breke stopper bolt @ Rear fork center collar car fork dast'seal cap. @B 14X26 washer @ 14mm self lock nut @ Grease nipple @ Rear fork yivor bolt ‘5-62. Exploded view of rear fork and rear fender @ Rear forke complete @ Drive chain case Rear cushion assembly @ Resr fender Fig. 5-62. Reer fork and rear fender @ Ame self locking nut @ Rear fork Mig. 5-61. Removing the rear fork D Tead connecior @ Reae winker setting belt @ Kear fender Fig. 645. Removing the rear fonder 5-11 REAR FORK AND REAR FENDER, A. Deseription ‘The rear fork is constructed as illustrated in the figure above. The frout end of the fork is pivorally mounted om the boss provided on the half pillar of the frame body with pivot bushings and the rear ends are similarly joined to the ‘bottom ends of the rear cushions with bushings. This pivéting- fork design permits free outof-tha-horizontel-plane moveme of the rear axle (rear whecl). The rear fender is @ pr worked part and is bolied to the frame body. ¢ B. Disassembly (REAR FORK} 1. Remove the rear wheel in accordance with section 4+14B (00 page 58: 2 Disassemble the 4-124 on page 55. 3, Remove the 14mm self locking nut from the rear fork pivot bolt aad eatract the pivot bolt: the rear fork can be separated from the freme, (Fig, 5-64) 4. Lightly tap to remove the rear fork center collar from the rear fork. 5, Seperete the drive clitin case cover en the reer breke stopper arm from the tear fork: (REAR FENDER} 1, Ralge the seat end disconnect the wiring for both the rear winker and taillights. 2, Unserew the two resr winker setting bolts and pull off the fender from the rear fender setting rubber. (Fig. 5-65) 3, Tool bog can be separated from the frame by unscrewing the four 6mm mounting bolts 1s cushion in accordance with sectionC. Inspection 1. Rear fork pivot bushing Measure the inside diameter of the bushing with a cylinder gauge or iuside micrometer. mm (iach) a 000~20088 Replace if over (one? —7e0) 2018 (0.795), 2, Rear fork pivot bolt Place the pivot bolt on a V-block, rotate the bolt and measure the amount of bend with a dial gauge. ‘mim (inch) andar Within 002 (00008) FIR. D, Reassembly: (REAR FORK) 1. Drive in the pivot bushing and the center collar. Insert the rear fork dust seal eap. (Fig. 5-66) 2. Insert the pivot bolt through the side bracket and assemble the rear fork to the frame. Install the rear wheel. Inetall che drive chain. ‘When the assembly is completed, adjust the rear brake pedal and the drive chain tension, 6, Install the drive chain case. 7, Install the torque link. pee (REAR FENDER} 1. Perform the reassembly in the reverse order of disassembiy. 9 © Frame body @ Center zipe bash @ Rear fork dust seal cap rubber.) Kear fork pivot bush, @ Rear fork dust-seal cap, @ Rear fork pivot bolt @ Gretse nipple @ Rear fork conte colar “@) Rear fork Fig. 5-06, Crosssection of the rear fork pivot portion5-12 REAR CUSHION A. Description (De Carbon type) ‘The reer cushion features a “De Carbon” type demper. This damper is, as shown in the figure below, « double- ‘acting’ type single cylinder in which aitrogea gas and oil are ased to give an optimum demping performance under all fambiag and sebounding conditions. Over the damper is installed a dual-piteh spring which absorbs a wide range of Mimkiks or shocks aad maintains the unit in accurate alignment Another design feature is that the cushion is adustable for diferent riding, loading and road conditions. 12-40) ‘aml pis el eg ai pms anata @ Jeint rubber @ Spring seat siopper @ Rear cushion upper case @ Rear dager astembly @ Rear cushion spring Fig. 5-61, Seotional view of rear cushion. B. Operation ‘Simple type of a construction the heat rediation is good. therefore, performance being especially good at low speed. Further, vibration stabilizes very quickly ‘Air and cil mixture will not occur and function will not ‘be deteriorates even when operated for extended period over adverse road condition. The diference ia pressure between the front and rear of the valve is small; since form does not form, noise is mini mired; deterioration of the damping force is prevented. Fig. 6-67 eer ano as ‘The rear cuthion employs dual pic spring, the section Tig with the larger pith absorbs the large vibration. while the ‘ection with the smaller pitch absorbs the staler vibration Compras ‘This provides for exceptionally smooth cing. Further, there ore three ranges of adjustment incorporated in the rear cushion, making it possible to adjust the cushion to the different riding, loading and road conditions. Fig. 5-688. ‘I Rear suspension adjustment The rear cushion @) has theexange of adjusiment in spriag teaion and into be adjusted to mect the diflerent {ype of rua 0: riding conditions. poxkion iy for normal Fling, ‘The damper spring strength increasing. proses. Svely fom Il we Hf, and ts t9 be used for hewily loaded Gondition or when operating 0a bad roads. (Eig. 5-09 @ Rear cushion assembly Fig. 6-68, Rene cushion adjustmenta1 A. Description (Double-Tube two-way Valve) CB350G/CLI50K5 ‘The rear shock absorber assemblies feature the telesgopic type oll dampers with bottom vaive to give an optimum Gamping performance ade: all bumping and rebounding conditions. The damping performance on the extension side ie well matched with that oa the compression side, providing maximum damping. Bottom valve Piston vaive @ o Operation Each oil damper is equipped with the piston valves A. ‘and Band bottom valve. On the extension side, the damping ction it provided by means of the piston valves. While, on the compression side, the damping action is provided by means af the bottom valve On extension side: ‘The oil in the chamber [2) flows into the chamber ( through the orifice {) in the valve A (sheet metal). By the resisting force of this oll, the damping action is provided The valve A is overlapped with the valve B (leaf spring) which covers the half of the orifice, ‘The damping action is regulated by the deflection of the valve B, Under such a Condition, the bottom valve is opened and the oil in the ‘chamber 2c) flows iuto the chember [b] smoothly to prevent air bubbles from being produced On compression side : ‘The oil in the chamber [b] fows by amount of il equivalent to the volume of damper rod into the chamber fe] through the orifice in the bottom valve. By tho resisting force of this oil, the damping action is provided. At this time the piston valvee are opened and the oil flows from the chamber [b” into the chamber [a] smoothly. (D Rear shock absorber spring 2 Damper red ® Damper piston ® Damper eylindar Fig. 5-10, f iH (Bottom vaive side) = Oil flow on oxtonsion === Qi1 flow on compression © Onifoe @ Chamber @ Valve “At Chamber “2” & Valve “8” Boom valve @ Piston Orifice (Il) © Chamber “a” Fig.© Simm ber. bolt @ 10mm hex. cap nut @ Rear cushion assembly” @ 30mm her. bolt Fig. 5-72. Removing the rear cushion assembly © Speci tool _@ Rear cushion assembly. ® Spring seat stopper Fig. 8-73. Distssembling rear cushion (© Rear cushion danger assemtly_@ Rear cations ® Rear cushion upper case @ Spring seat ae Fig. 6-74. Component pare of rear uthion © Vernier caliper @ Rear curhion spring Fig. 5-15. Measuring rear ceshion spring B. Disassembly 1. Remove the 6mm bolt from the forward end of the side aip, loosen the 10mm cap nut, 10mm bolt and remove the rear cushion assembly. (Fig. 5-72) 2. Compress the rear cushion upper case by using a special tool and remove the rear cushion seat, lift off the upper case and thea remove the cushion spring. (Fig. 5-73) NOTE: DO NOT DISASSEMBLE THE REAR CUSHION DAMPER ASSEMBLY, IF POSSIES A HAZARD SINCE IT CONTAINS COMPRESSED GAS. C. Inspection . Rear cushion spring Measure the free length of the spring with « vernier caliper. (Fig. 5-15) sam (inch) Bander Vase [Seventies 235 2. Roar cushion spring trueness Set the spring up on its end on the surface geuge and Mdattie The meunt of it with a aquare and. Vernier Caliper men (neh) —Sandard Value] Serviceable Limit —}— Replase $f over Within 5 (02) Bato |. Taspect the cushioa damper to iasare that there is n0 fluid leskeage 4A. Inspect the damper case and rod to insure that they are not damper or deformed, Taspect the reer cushion stopper to insure that it is: not camaged or deformedNOTE: + Upon completing the assembly, actuate the cushion assem- bly by hand to make sure that they are not binding. Fig. 5-77) 2, Tastall the cushic (Fig. 5-78) NOTE: ‘After installing the cushion, check the alignment of the right and Jeft cushion and also the alignment of the cushion mounting bolt for both right and left sides. in the reverse order of disassembly 5-13 FRONT WHEEL A. Description ‘The front wheel is constructed as shown in the figure at left. Referring to the figure, the wheel bub and brake ‘panel are aluminum-alloy casting and contain the front brake Components and speedometer drive gearing ‘The internal surface of the bub serves as a frietion surface with which the brake shoes come in contact when expanded by the action ofthe car, The front axle is supported at its both ends by ball bearings which are held in place by axle distance collar. The speedometer drive gear which is in mesh with the i is mounted on the axle, just outside of the bearing. © Front wheel asle @ Front wheel side collar @ Oil-seal 60OER ball bearing Frost asle distance colar © Gilseal Speedomecer gear @ Speedometer pinion @ Front wheel able sleeve 19 Front brake shoe @ Front breke cam B@ Front brake cam @ Front wheel hui (@ Brake arm spring @ Front brake arm A @ Rear cushion assembly Fig. 5-71. Checking operation of cushion © 10mm cap nai @ Sie grip Special washer © 10x:2 hex. bolt @ Rear cushion Fig. 5-78. Moneting bolts end nuts of rear cushion Tig. 6-70, Crove-aeciion of front heal© Front brake stepper arm tole @ B2mm tongued washer @ Fi Fig. 6 89. Removing the beak 1 © Front wheel axle @ Froat wheel axle sleeve @ Front wheel tre Fig. 6-41. Removing the front wheel axlo © Front wheel tire @ Oilseal Fig. 5-82. Removing the oil-seal @ Front brake shoe @ Front brake penal & Front brake cam Mig. 5-88. Removing the front brake shee Fig HOG Messen, i fue B. Disassembly. 1. Place 2 suitable support block under the engine to raise front wheel off the ground, 2, Disconnect the front brake cable, the speedometer cable from the speedometer gear and the brake stopper arm, (Pig. 80) 3, Remove the 8mm nuts which support the lower axle holder on both the right and left sides. The wheel will then drop away from the fork, 4, Tnsert a bar into the hole on the sight side of the front wheel axle and remove the shaft on the left side with a 17mm wreach, Brake panel ean be separated from the front wheel. Gg 5-81) 5. Remove the panel, oil seal, two 6302R ball bearings, and front axle distance collar. (Fig, 5-82) 6. Remove the front brake arm and pull out the froat brake cam; the brake shoes can be removed from the penel by spreading the shoes apart by hand. (Fig. 5-85) 7. Separate the tire and tube from the rim with the tire lever, . Inspection 1. Front fork rim ranout Insert the axle through the wheel hub and support it on two V-blocks. Set the dial gauge against the side of the fim and rotate the wheel. (Fig. 5-84) mm (inch) Sandard Valse —__]_Sevicaabie Timi: (05 (002) THR Renae seplee if oer2. Front axle bend Place the axle on a V-block, rotete the axle and measure the amount of bend with « dial gauge, (Pig. 5-85) om Goch) Standard Value] —“Servicwable Limit Within Replace if over TIR 05 (0.002) THR, 02 (G08) & Radial clearance of 6302R ball bearing, Place « dial gauge against the bearing outer aad measure the clearance, pe Ge. © Dial gauge @ Fron: wheel axle @ V-1 Sande Var Se La Fig. 6-8 Checking he font als Weed Gl— 0.015. ace if over x {G.000i~0.0007) 005 (a2) 4, Front brake drum inside diameter Measure the diameter with a vernier caliper. (Fig. 5-86) a Gre) Tae ie Seite ime eo 1803mm————~CReplace if over (agi ~7.0890) 5. Thickness of brake lining Measure the lining thickness with « vernier caliper. mum Gnct) . @ Vernier caliper @ Front wheel bub Sandaed Vanwe ee Fig. 5-86. Measuring fcont brake drum inside diameter (oan? 02) Check thickness of front brake cam Replace if excessively worn or worn ia steps. Taspect auchor pin for bend. aspect and tighten any loose spokes. ‘Tightening torque: 20~25 ky-em (1.4~1.8 ft-1b) Check for air leak by submerging the tube ia water 40, Cheek the tire for damage 10 casing, both ine and 11, Balance wheel assembly. D, Reassembly 1. The tube can be easily mounted by inflating with small amount of air to make the tube Simi. (Fig. 5-87) @ Tie levee @® Front whesl rim @ Front wheel tre Fig. 6-87, Installing the tre Nori + After the tre [s mounted, inflate with approximately 1/3 the designated pressure and lightly tap around the tire with « wooden hammer to eliminate aay pinching of the tube. (Fig, 9-88) Wooden hammer @ Front wheel tire Hig. 5-98. Topping awa the ar86 @ Valve stem Fig. 689, Valve angle @ Hammer @ Bearing driver @ 6102R ball bearing Fig. 5-90. Deving the bearing ® Front brake arm A @ Front brake arm 8 | Front brake penel Pig. 6-01: Inetlling the brake erm [°@ Decrease g Increase Fig. 5-22. Front brake cable adjustment = The valve stem should be position poiating towerd the axle 10 prevent damage to the tube. (Fig. 5-89) + Tnflate the te to the specified pressure, For normal riding: 1.8 kg/sa. em (25.6 Iho/aq. in) For high speed riding: 2.0 kg/sq. em (28-41hs/s. in) 2, Grease the 6302R ball bearing and pack the inside of the front wheel hub with grease, and inser: the distance collar. Drive in the ball bearing using the front whee! beariag driver (Tool No. (7945-2860100 and 07946-28520). (Fig, 5-90) NOTE: ‘The 83028 ball bearing incorporates a seal on the outside, therefore, make sure that the bearing is not installed in the inverted position. 3 Hook the spring on the front brake shoe and then install the anchor pin and breke cem. Assemble the unit to the front brake panel. NOTE: ‘Punch marks on the brake arm and brake cam must be aligned. (Pig, 9-91) 4. Assemble the panel together with the side collar to. the front wheel. 5, After tightening the froat axle, mount the front wheel on the forke coanect the front brake stopper arm and assemble the frost axle holder with 8mm nuts 6. Connect the speedometer cable to the speedometer gear. 7. Connect the front brake cable to the brake stopper arm tend adjust the free travel. The specified froe travel is 15~0 mm (0.6~1.2 im). Loosen the nut ® and make the adjustment with outs ©. Pig.FRONT WHEEL (with a dise brake system) 1 fi ? x e 488 A. Disassembly No. Disassembly procedure Note! Place wood block(s) under engine Speedometer cable a 1 2 2 | Axle holder attaching nut 2 4 Frost axle shaft Front wheel bearing reteiner 3 Hold engine wih jack and remove front wacel Remove dust seal from front wheal | esting sotsiner cri jemove auts ad Took plate an 3 eeoice bs Front wheel bearings 10 | Gear box and retainer cover “1 Disconnect the speedometer cable ly removing Suan oval head screw and disconnecting cable. "2. Using the 1wo screwdrivers as shown, remove the axle rut and remove the axle shaft. (@ Atle shaft © Ando mat Big. 6-95, "3 Remove the front wheel bearing retainer fom the wheel hab and the dust seal from the bearing retsicer @ Beating ceainer Fi.4 Straighten tabs of washers remove the nuts and lock plate and remove the front brake dice from the wheel. Remove the gear box and retainer cover from the other side, . Inspection + Measure the brake dise Place the brake disc on « level stand. Using a dial gauge, measure the brake disc at several points a8 shown, If the face runout exceeds 0.3mm (0.0118in,), replace the dive Measure the dite thickness. If the thickness is below ‘6mm (0.2362in,), replace the disc + Cheek the wheel rim for lateral runout and radial clear Rotate the wheel and check the wheel rim for lateral runout and radial clearance using « dial gauge. Units mm Gn) ‘andard Repair Bie Tarcal Hane G5 OO187), max. Radiat clearance 20 @aTaT, min 20 (OTST), in 89, @ Dial gauge Fig. 6-68. @ Brake dae 05 (00187), max, + Measure the front wheel ball bearings Units mm Go) [__ Standard ‘Repair iit ‘Axial clearance Gor (0.0028) 01 (0.0009) Raill clearance | 008 (0.0001) ‘3.08 (0.0020) Check the spokes for looseness, Check the tire tube for leaks, Check the tire for entry of foreign material or damage, ©. Assembly ‘Install the 61022 ball beatings to the wheel hub, + Install the dust seal to the beating retainer and then inatall the bearing retainer in place heel hub. Install the O-ring to the Dial gauge @ Ball bearing Fig. 5-10. Bearing driver Fig. 6-101@ O-ring Pig. 5-102 @ Lock nae Fig. 5-103. © Gear box retiner @ Speedometer gear box Fie 04 a “7 Gi akaas sick? @ lets woah Fig. 508. 5106. + Fit the tab of gear box retainer in the recess in gear box sctainer cover properly and inatall them to the wheel hub, + Install the brake dise to the whee! NOTE: Alter tightening the nuts. lock them by bending the tabs ‘of the lock plate. + Inetall the specdlometer gear box from the right side and install the front axle, + Install the front wheel to the front forks and tightea the axle holder bolts and nuts properly, NOTE: Be sure the speedometer gear box is installed correctly To tighten the azle holder bolis and nuts, begin on the left side (disc plate side) ones first + Connect the speedometer cable to the gear box + Check the wheel for balance . Make chalk marks on the cireumference of the wheel and slowly rotate the wheel two or three turns. b. If the wheel is unbslanced, it always stops rotating when the same parts (the heaviest part) comes to the bottom . To eebalance the wheel, install ¢ balance weight to the part opposive to the heaviest part 4. Install the balance weight to a spoke. Rotate the wheel two of three turns to check for balance. If the wheel stops rotating when different parts come to the bottom, itis balanced, ‘The balance weights are avatl able in four diflereat weights, 5 (017602), 10g (0.353 ce,), 15 ¢ (0.529 02) aad 20g 1070502 . The front wheel balance should be checked with the brake disc installed. Front disc brake +The dise brake system mainly consists of the brake lever, lipers ened bake dite‘A. Disassembly of calipers and master cylinder Disassembly precautions 1. Clean dirt and dust off the paris. Take care act to allow the foreiga materials 10 enter the parts 2, Set aside the disassembled component parts ia ‘eroups to faclitare assembly. No. | Disassembly procedure Note i [tiect eel 2 Drain brake fluid from master cylinder a 4 | Coles AcdB 8 | 5 Holder seting belts [3 6 Boot stopper Le bee Rees Dimi andar 2 Pee Se eee ees 6 1 Remove the oil joint bolt and disconnect the brake hose: +2 Remove the three caliper attaching bolts and one adjust ing bolt ond remove the calipers A and B as an assembly. *3. Remove the two caliper setting bolts and separate the Celiper assembly into two parts A aad B. =Remove the pad A and picton from the caliper A. «Remove the pad B from the caliper B. © Joioe Brake hose @ Boks @ Adjusting bole © Calter A @ Cabper boles Fig. 5-108 4 Flan) Piston seal Fle. 6-108, 192 @ Maste: cylinder body @ Joint bolt @ Brake hose @ Sexing boies Fig. 5-100. @ 18mm enap sng Fig. 5-101. “4 *s *6 Loosen the master cylinder joiat bolt and discounest the Drake hose, + Loosen the master cylinder bolts and remove the master cylinder from the hundiebar, = Disassamble the muster cylinder Remove the 18mm internal snap ring using the special tool. ‘Remove the 10.8 1mm washer, piston, primary cup, spring end checle valve in this order. ‘To remove the primary cup easily, direct compressed air of 2~3 kg/cm! (28~431h/in') in pressure to the cylinder union (brake hose joint), Unless the check valve is damaged, any other tool may be used to remove the primary cup.93 (© Lever cap @ Braker lever 1 Boot sm internal seap ving 1 Piston 1B Secondary cup Spring {@ Chock valve 9 Cap {% Masier eylinder place & Masten cylinder body § Master eybrnder holler @ Germ bors 1% Oi bolt washers @ Brake hese Fig. 5-113. Master cylinder disassembled NOTES 1, Wash all disastembled metal parts in trichloro. ethylene or equivalent uid and dry them throughly. 2. The check valve must be washed in brake fluid, 3, Never wash the brake paris in mineral oils such ‘as gasoline and cleaning fluid B. Inspection of calipers and master cylinder NOTES: 1. Cheek the piston for wear or damage and replace if necessary 2. Check the inside surface of the master cylinder for scores or scratches and replace if necessary. 3, Check the epring for crecks or any other damage and replace if necessary. 1, Check the brake disc pads for wear Red lines ore scribed in the pada A and B. If the pode wear dowa to the lines, replace them with new ones, Trstall new pads so that the brake dise 10 pad clearance Js 0.1mm (00059in.). To adjust the clearance, tucw the caliper adasting bolt counterclockwise until the ped bears fon the disc. Then back off the edjasting bolt 1/2 tor fad tighten the lock aut & Stopper washer 103mm washer @ Primary eww ® Handlebar lover joint bele & Diaphragm @ Spring washers @ Oil bok. ‘| @O® : sem — © Pad B 2 Brake dsc Big. 5-11. @ Pal A© Master cylinder @ Cylinder gavge Wig. 5-105. © Caliper cylinder @ Cylinder groze @ Micrometer Piston Fig. 5-116 OGlprb Oras g@hdd @ Caliper A ig. B17 @ LXIS dowel pin, falsized @ Amply ereaso to ercas markel (x), Quantcy of greace ‘About 1g (0.0059 01)/nit (equivalem to 1125, dowel pn) Fig. 5-118, 2. Measure the caliper cylinder and piston Using « cylinder gauge, measure the cylinder bore and piston OLD. If the clearance between the two exceeds 0.1mm (0.0043in,), replace Usits_mam Gin) [Repair line = 38215 gain Zis020, (0505) SB.115~ 38.08 B10 C2008=15150), (340) Cylinder bore Piston OD. 3, Measure the master cylinder and pistion Using a cylinder gauge, measure the cylinder bore and pltton OD. If the clearance between the two sxceeds 0.1 mm (0.0048 in.), replace, Bai si Ge) Cylinder bore Platen OD. C. Assembly of calipers and master cylinder To assemble, reverse the dissssembly procedures. Calipers Install the pads A and B. NOTE When installing the pads, apply a cost of grease to the calipers to prevent entry of dirt or water. When repair- ing, apply a coat of grease to the sliding surfaces and tear faces of the calipers and peds and to the dowel pin as shows, + Install the caliper assembly to the front forks. Master cylinder Assembly preeaution ‘The brake system is the most important for the safe riding. Especially, rubber parts play a critical role Whener any demaze or deterioration to the rubber parte is noted, they must be replaced immediately. Take care not to allow foreign muterigls to enter the brake parts when assembling.+ Wash the component parts and thoroughly dry them using, compressed air. + Apply a coat of breke fluid to the inside of the cylinder, + Install the check valve 10 the return spring and install them in the cylinder as a unit. When instaling. be sure to install the spring with a end having a larger dia, ia ward. ‘Take care not to allow the cbeck valve to come out of the spring. + Applying a thin cost of brake fluid to the outer surface ‘lthe primary cap and install it, taking ence not to damage itby fingers. Be sare that the cup is correctly positioned in the cylinder. Install the secondary cup to the piston, + Install the 18mm snap ring and rotate the snap ring to check for proper ft + Tnstall the boot ‘NOTES 1, Connect the brake pipe 2, Install the cylinder to the handleber. Bleed the brake lines. Road-test the motoreyele to check for air or cil leaks and for operation, 5. Check the brake fuid level D, Adjustment of dise brake When the brake is disassombled, it must be adjusted and led completely 1 week the brake lever frve play The lever feee play ie specified to be 2~5 mm (0.0787~ (0.1969 in.) at the tip of the lever. If the free play is out cof specification, check and replece if necessary Check the brake Aid level Fill the master eylinder oil reservoir up to the level line CAUTION Do not allow the brake fluid to come in contact wi painted sur the si, rubber parts end instrumen's 95 @ Chek valve Fig. 6-119. @ Panay ep Fig. 6 © Diaphragm Master eylinder ® Brake fie Fig@ Dapiaem @ Cap @ Beake lever Fig. 5-128, Diedra Ope eGlan Fig. 5124 5-14 REAR WHEEL A. Description 3, Bleed the brake lines In the hydraulic brakes, sic rapped ia the brake lines will reduce the braking efiect to result in dangerous riding. If the brake lever ie felt epongy when it is squeczed oF ifthe brake flaid level lowers excessively, bieed the brake lines, To bleed, proceed as follows a. Fill the master cylinder oil reservoir up to the level line, Install the diaphregm to prevent the fluid from splash. ing. © Pata pipe on the blevder serew located to the caliper. Prepare aa oll cen, 4. Squeeze the brake lever and operate it several times until a resistance is felt, With the lever squeezed, Toosen the bleeder screw about 1/2 tura. As soon as the lever bears oa the hendlebar pipe, tighten the blesder terew. Continue the bleeding operstion until air bubbles are no longer noted in the Muid fowing ‘out of the bloeder hole NOTE: While bleeding, add brake fiud. ‘The rear whee! is in construction similar to the frout wheel described in the preceding par, the difference being that the drive sprocket is bolted to the left side of the hub and that the axle is movably mounted for drive chain tension Adjustment, The insullation or arrangement of the major components is illustrated in the figure below, to which reference fan be made in studying the construction of the wheel. {D490 couer pin} 1mm casle mut _@ 165%90 washer @ Rear wheel side collar €mm extemal circin B fmm washer, @ Wmm thia nut, @ 10mm tongued wisher @ Final driven sprocket @ Driven sprocket fixing bole 4 Rear whee! hearing retsiner @ Dustseal @ 63012 ball bearing. §@ Rear axle distance collar B Rear acl distance collar A. §§ 63032 hall bearing @ Rear wheel collar h Rear wheel axle @ Rear brake shoe @® Kear wheel brake panel @ Rear wheel heb Fig. § 125. Cross-section of rear wheelB, Disassembly 1, Remove the drive chain j (Fig. 5-84) 2. Remove the rear brake adjusting nut; separate the brake rod from the brake arma; remove the reer brake stopper bolt and separate the stopper arm from the panel. 3, Extract the cotter pin from the axle, , and disconnect the chain, lip @ Drive chain 36. Removing the drive chain yoint 4, Remove the rear axle nut and extract the rear wheel axle, Tilt the motoreyele and remove the rear wheel. (Big. 5-127) @ Kear wheel Fle. 5-127. Removing the rear whee! from the frame 6, Remove 69mm external citelip, and 70mm washer, straight. en the 10mm tongued washer, and remove 10mm thin rnuts. The final driven sprocket can then be separated from the rear wheel hub. (Fig, 5-128) © 10mm thin sure @ ene tongued washer & Final driven sprocket @ 69 mmm extercal dlp Fig. 6-128, Removing the fal riven sprocket 6, Remove the rear wheel bearing retainer by using bearing retainer tightening wrench. (Teo! No, 07910-8290000). Pull, ‘out the 63062 and GOD4Z ball bearings, aad rear axle distance collar, (Fig, 5-129) @ Bearing/retainer tightening wrench @ Bearing reac Fig, $129, Kemoving the bearing retainer ee Soe oe on tae aot oes w oe deter pater ig £100) ® ® @ \ t 1 @ 2x18 coiter pin like shoe selting washer ear brace shoe “@) Rear brake panel 12D. Removing the rene brake shoe8 Using tire levers, remove tire as illustrated in(Fig. 5-131) and remove tube, (Fig, 5-131) @ Tire lever @ Rese wheel vim @ Rear wheel tire Big. 6181. Removing the rear-wheel tire C. Inspection 1. Rim runout (Fig. 5-84) Insert the axle througis the wheel bub and support it om the two V-blocks. Set the dial yauge against the side of the rim aad rotate it, ram Gn Sraiard Vale See Cia Dil raat win Fevlace or ros 5 (0.020) Bo (e0ro) 2, Rear axle bend Place the axle on the V-block, rotate the axle and measure the amount of bend with a dial gauge. (Fig. 9-92) ‘mm finch) anand Vaire __]_——Servieabie ini ‘Witkin Replace if over 1908 (0.000) THR | 08% @08) TH 43, Radial clearance of the 69082 and €2042, ball bearing. Place a dial gauge against the hearing outer and measure the clearance. mm (inch) © Dial gauge @ Rear wheel axle V-block Pig, 5-192, Checking tho ronr axle for bend inane Vato | Serieeatie Limit an 001 ~0018 Replace if over z @a0i~00007) _|_ 9.08 (O.00)” ‘0.005 ~0.0020 piace if over fod (oum~oncas) | 0.06 coca23) 4, Rear brake drum inside diameter Measure the diameter with a vernier caliper. (Fig. §-123) ram (inch) Sandard Value ~Senviveabie Limi 1i00~ 160.3 Replace if over (E00~8.12), 162 68) $ 5. Thickness of broke lining @ Verwler caliper @ Rear wheel hub Measure the lining thickness with a vernier caliper. ensuring rear brake drum inside diameter im Gach) Replace if under 50018) 6, Check the anchor pin for bead. 7. Inspect sn tightan oil loosen spokes Tightening torque: 20~25 ky-em (L4~L8 (tlh) Inspect tube for air leak: by inflating end immersing it in 9 Inspect the tire and tube for eny demege on the inside and outside, (Fig, 5-134) __ Gato: 2) Kear wheel ig. 5-131, Inspecting the inside of treD. Reassombly 1. The tube can be easily mounted by inflating with small amount of air to make the tube firm. NOTE: + Aiter the fire ia mounted, inflate with epproximately 1/3. the designated pressure; lightly tap around the tire with ‘wooden hammer to eliminate any pinching of the tube, + The valve stem should be pointed toward the axle ‘Inflate the tire specified pressure. For normal riding: 2.0 kg/em (28.4 Ibe/in*) For high speed riding: 2.2 kg/em® (81.3 Ibe/in?) 2. Grease the 63042 ball bearing and pack the rear wheel hhub with grease. Tusert the specer aud diive the bearing into place using the rear wheel besring driver (Tool No. ‘07946-2800200 and 07949-2860000), (Fig. 5-135) NOTE: ‘The 62032 and 63047 ball bearing incorporste 4 seal on the outside, therefore, male sure that the bearing is not inverved, 3. Mount the final dri the sprocket reti (Fig, 5-138) sprockei on the drive dange with ing bolts, aut and tongued washer, 4, Assemble the rear brake shoe to the brake panel and install the spring to hold the shoe in place. Install the resr brake cam and brake arm on the penel. ‘Asiemble the brske shoe setting washer and lock with the cower pin, (Fig. 9-137) NOTE: When installing the brake arm on the panel, align the punch macks oa the brake arm and brake cam. 6. The chain joint clip setting thould be cerefully mode by paying attention to the chain driving direction. (Fig. 5-138) 6 Astemble the panel on the rear wheel and mount the ‘wheel assembly on the frame. Install the drive chain and make the proper edjustmext before final torquing of the ear wheel axle, NOTE: Adjust the chaia 20 that there is 1 to Zem (0.4 to 0.8 im) fof slack aad make sure thet the chaia adjasters on both sides ere in the same relative position, (Fig. 5-139) © Hammer @ Besring driver ‘5-195, Installing the bearing © Final driven sprocket @ 69mm external aclip @ 10mm tongued washer @ 10mm thin rut "Assembling the final driven sprocket @ Rear brake shoe @ Rear brake shoe spring @ Brake shoe vetting washer @ 2.15 cotter pin Fig. 6-181, Iasalling the brake shoe @ Chain driving direction _@® Chain jeim clip Pig. $198, Sting the chain joint clip © Relerence Fig. © 199,7. Install the rear brake stopper arm to the rear brake panel. 8. Install the rear brake rod to the brake am. Set the rear Drake pedal on ie side and odjust rear brake play. NOTE: The free play of the rear beake pedal should be from 2 to Sem (08 to 12Zin.) (Fig, 5-140, 141) 9, Install the chain case (© Rear bake pedal Fig. S140, Keat brake pedal play (© Rear brake erm @ Rear brake edusting nut ® Increase @ Decrease Fig. 5-141, Adjusting the rear brake101 6. ELECTRICAL PARTS 6-1 IGNITION SYSTEM A “‘battery-coll” type ignition system is employed. A. schematic layout of the components of this system is shown in the figure at right. The ignition coil @ which is simply a transformer has its primery circuit opened at soguler intervals by a eet of ‘contact points (breaker points) @) operated by a cam, Open- ing aad closing this cireuit causes the magnetic field to expand @ Bastery @ Foss @ Ignition coll @ Breaker point ‘and collepse, inducing an ac voliage in the secondary wind: @ Condenser @ Spark plug ing. This high yoltage’is fed to the spark plugs @ and Fig. 1. ignition syscem ‘causes them to fash over and ignite the fuelair mixture. 1. Ignition Coil A. Description ‘Two independent ignitioa coils, one for each sparks plug, are used. Each coil has the primary and secondary windings wound on aa iron core. The former winding hae 200 to 00 turns of 0.6mm (0.024 in) dia. enameled copper wire and the later winding 10,000 to 20,000 turns of 0.08 min (0.003 in) dia, wire of the same type. These windings are inductively ‘coupled together and are synthetic resin-molded in one and the same case with two terminals extended. Fig. 2, Ignition coll © Peimery terminal @ High tension terminal @ Case @ High tension cord @ Synthetic resin @ Primary coil © Bobbin ® Secondary coil @ Iron core Fig. 6-8. Sectional view of igaiden call 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, Unlasten the wire bamess clamp. 4. Disconnect-the right and left ignition coil wiring at the connectors Left coll: Yellow and black cords Right coil: Blue and biack cords ‘5. Disconnect the condeaser (mouated on the ignition coil base) wiring (yellow and blue cords) at the conacctor Unscrew the two ignition coil mounting bolts to remove the coil from the frame. (Ignition switch and hora are also mounted by these bolis) ©. Inspection 1. Beach Chek the ignition coil using the service testor by following the procedure on the next page. (Fig. 6-4) Coanect the power card to the 17V battery and ground the blsck ground cord, Connect the ignition primary cord plug 10 the tester and connect the opposite terminal end to the primary terminal of the coll, Connect red test lead fo the black terminal of the ignition coi, and the white lead to the yellow cord of the left coil (right coll to the blue cond Connect the high tension cable (ced) to the secondary coil terminal Position the selector knob to COIL TRST. Adjust the three point spark tester to the maximum distance spar is Inaintsined and then avte this disteuce. The coll is setifectory if the distance is greater than T mm (0.28 in) 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. «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 cf the ignition system, It is located in the cam case and ‘consists essentially of a hase plate, breaker arms and two sets of contacts points, stationary and moving 8 will be seen in the figure at right. B, Disassembly 1. Remove the coatact breaker 2. Unserew the two mounting screws to remove the contact breaker arm irom the base plate. C. Inspection 1. Contact breaker point gap and ignition timing edjustment ‘Adjustment of the point gap and ignition timing should be made for both R/H and L/H cylinder at one time. To adjust, proceed as follows Contact breaker poiat gap Tum the generator rotor counterclockwise aad check the point gap when it is maximum, The correct gap is 0,012 0,016 in. (0.3~0-4 mm) for the 1./H and R/H point. ‘Then loosen the contact breaker plate locking screws © then the point cam @ is at maximam lift and move the Contact breaker plate @, Tighten the locking screws when the correct gap is obtained. Adjust both L/H and R/H points in the same manner’ Recheck the gap after tightening the locking screws. NOTE: Wipe the contact breaker point suriaces with clean if dirty Ignition timing ‘Adjust the ignition timing upon completing the adjuste mment‘of the contact breaker paint gap. L/H ‘urn the generator rotor @ couatorclockwise and align LE” mark @ (oa L/tl cylinder) tw timing mark ©. ‘The iguitioa timing is correct if the L/H contact breaker point @ suats opening, To check the ignition timing, connect « 12V-3W bulb as shown in the figure and observe the moment the bulb 103 Pig. 8, Contact bresker © Point cam © 1/H contact breaker point © R/H comast breaker point & conc breakers Contact breaker plate locking screws Fig. 6-10, Sra imag mark F mark Fig. 6-12.B. Disassembly 1. Disconnect the froat brake from the brake arm and the clutch cable at the lower end. Disconnect the throttie cable at the carburetor and the wiring harness located ‘within headlight cese, Remove handlebar by unscrewing the four mm bolts rom the handle pipe holder clamps 2. Remove the front wheel 3, Remove the top bridge plate. 4, Remove the steering oil damper (option) irom the bottom bridge plate end the damper bracket with hora. Sores ll Saris beste @ Seeing il damper 6, Remove the baaigh aod ont fork: fora) Fork bottom bridge Pili Seatepan tates inns 6. Remove the steering stem top nut @ using « hook ze tat ee spanner (Tool No. 07902-200000) and pull the stem oat the bottom. (Fig. 8-12) NOTE: Do not drop out the steel bells during the steering stem removal. @ Steering stem top nut @ Hook spanner Fig. 818 €. Inspection 1. Check the steering stem for tny bead or deformation. Straighten the beut stem with the press and then check it with a dial geuge. If badly damaged, replace with new one 2 Check the steel balls for wear and eracks. If heavy steering is experienced while riding, it is probably due to either the worn steel balls or the broken balls, Replace the balls to correct the trouble, 3, Check the steering oil damper for dents, damage or Guid leakage. If dofective, it must be repsired or replaced. D, Reassembly Perform the reassembly in the reverse order of dissavembly, hewever, epaciel attention must be given to the following points, NOTE: 1, Use sulficient grease when installing the steel balls of 1/4in (6.25 mm) dia. into the bell races (18 for the upper and 19 for the lower races), Whea removing the stecring stem, care should be taken not to drop any steel ball 2 When mounting the steering stom, the ateering stom top aut should be tightened co that only slight pressure is applied end there is no slackness in the steering cones. To check tightness of the steering, tlt the frout wheel tovither side slightly and let the handle to start moving by its own weight. If the handle does not move by itself or there are gape between races, readjust the steering stem top aut8-5 FUEL TANK A. Deseription ‘The fuel tank is mounted on the frame body directly above the engine and is installed on the frame body and through the fuel tauk rubber cushion, Stripe lines are painted on both sides of the tank. A flip open type of tank cap is used to facilitate refusling. Removal and installation procedures are identical to the C350, therefore, refer to the section of CB, CL250-350. Fig. 8:18. Fuel tanke 8-6 FRAME ‘A, Description The frame is of a double cradle tubular steel constrac- fn, “This design fs parclriy sited for rough roud. fender stay is fon the rear extension of the half frame for mounting the rear fender. © Head pipe @ Main pipe @ Reer fender stay © Sab tube holder © Front dowa tube © Lower cross member Fig. 82 B. Disassembly. 1. Engine dismounting Reler to engine dismounting section on page 127, 2 Seat Unlock the seat latch, open the seat land remove the two lock pias and bolts et the ceat hinge, Then separste seat from the frame. 3, Fuel tank When dismounting the engine, the fuel tank is alio removed at the sume time. Refer to page 12 4 Air cleaner Remove the two oir cleaners as described on page 138, 5. Steering handle, front suspension and wheel Remove these parts as described oa page 132~185, 6, Rear wheel Remove the rear wheel ae described on page 141 7, Rear ewhion Remove the rear cushion as described on page 10. 8. Rear fork Remove the rear fork aa deseribed om page 159.138 C. Inspection 1 Inspect the weld joiats for any breaks or cracks and the steering pipe for twist and bends, Weld the cracks, straighten the minor deuts or twisting, 2, Check the frame paint costing for rust spots. Paint the worn or scratched parts. D, Reassembly Perform the assembly in the reverse order of disassembly. 8-7 SEAT A. Description The center of the seat is made into a depression changing greduslly from a flat suriace to a series of ridges covered with viny! leather, This provides good sext holding ‘on rough roads: also, the sponge rubber cushion used ia the seat absorbs shock and vibration for more comfortable riding. The seat is unlocked and raised toward the right side for access to the battery, selenium rectifier and the winker @ Seat latch relay for iaspection. Refer to the 250-350 Shop Menuel Fig. #21 relay for inspection 8-8 MUFFLER y a A, Description ‘The exhaust pipes are mounted to their respective eight ‘and left cylinder head with exhaust pipe joints and 8mm holts and nuts. “The muffler and the exheust pipe are an integral unit which is mounted to the units on the mafler bracket with a 10mm hex. bolt. A US Forestry Service approved spare arrester is installed within the maffler to prevent the emmis- sion of hot sparks when riding through forest and mountainows regions, Refer to the 250-350 Shop Menual for removal, inspec- tion and installation procedure. NOTE: Disconnection of the muffler and exheust pipe or dis- ‘assembly of the muffler cannot be done. @ Exhaust pipe joint Mange @ Exhaust pipe joint caller @ Mulllr eacombly Mig. 8-22, 8-9 AIR CLEANER A, Description Two sir cleaner elements are attached, one on each side of the frame. Both elements are mede of uretan form ‘which requires cleaning at specified intervals. B. Disassembly 1. Remove the air cleaner cover by pulliag off at che rubber mount, 2, Unscrew air cleaner fiiag bolts ©, @ and connecting @ Ai cleaner fixing Yols @ Air cleaner fixing bolt & Connecting tube screw ra) ani Wie. 628, frame. (Fig. 8-25) tube screw @ and then withdraw the cleaner from the139 C. Inspection 1, If the element is dirty, wash it in solvent or gasoline ‘and allow to dry throughly. Then follow by squeezing ‘out the excess oil and assembling it into the air cleaner case. It broken ot damaged, replace with new one. (Fig. 8-24) 2, Check the air cleaner case for crack or other damage. If badly damaged, replace with new one. (Fig. 8-24) D. Reassembly Perform the reassembly in the reverse order of dis- assembly. @ Air cleaner element Hig. 8-24. 8-10 REAR FORK A. Description ‘The rear fork supports the wheel and pivots at the rear fork pivot bolt to provide a swing setion It is constructed of steel tubing for greater strength and ‘end mounted throught pivot bushing on lock side ‘and Tubricated with grease for smooth operation. B. Disassembly Bi 11 Placa blook, anor he:angine t rain the seer wheal jig Jerk rt bole @) Ber fort off the ground, 2 See ‘the chain, the rear wheel and the drive chain ua 3, Pull out the rear fork pivot bolt ( and remove the rear fork @. (Fig. 8-19) ©. Inspection 1, The reer fork should be inspected for distortion. Insert the rear fork pivot bolt through both pivot holes in the rear fork and check the rear fork for ligament 2, Messure the inside diameter of the rear fork pivot bashing and replace if beyond the serviceable limit. ‘am (inch) tem Stendard value Serciceable limit Inside diameter of 20000 ~20.088 20.8 bushing (0:787~0.789) 0795) D, Reassembly 1. Apply a liberal amount of grease on the pivot collar and assomble it into the rear fork. Insert the pivot bolt from the Heh ie, end then imal nd ighten the 14 meal Jock au ‘Tighelag tree 65.0~795 bf (90~ 1200 leg-em). 2, Install the drive chain guard aad the rear wheel. 3. Install the drive chain, the rear brake pedel and drive chain tensioner.140 8-11 REAR CUSHION A. Description 'A De Carbon type damper containing aitrogen gas under high presure ie contained within the cylinder to maintain 4 pressure against the oil Rae eerie abil from being produced in the oi daring compression. Tt amures postive damping ction “The ing force can be tdjusied 0 thee postions according 1o caring load aad siding condiGon, The stroke of the sear cushion fs 362i. (2 mm). unt: mM ireeraaa ST 207-4 Bro st 202.4 @ Clip @ Rear shock spring seat stopper 6) Rear shock spring upper seat Rear shock spring @ Rear shock epring guido © Ross chock «pring lower seat @ Rese shock damper unit Wig. #28. ‘Sectional view of rear suspension B Disassembly 1. Remove the blind mut from the upper mounting bolt of each sear shosk epring. Remove the lower mouating olt and withdrew the rear shock spring. 2. Remove the spring ® from the shock spring unit by ‘Tuming the hendle of the special tool clockwise will ‘gradually compress the spring, permitting the removal of the spring upper seat. ‘As the handle is tumed counter clockwise, the special ‘tool can be seperated from the cushion spring allowing, ‘the damper unit to be disassembled. © Rear shock spring 1 Suspension gisassembling and assembling tool Pig. BT. C. Inspection 1. Check the body of the damper for dents or damage, for fluid leakage or lack of damping effect. If any of these defects are found, replace the whole unit as the damper is not zepeirable, CAUTION: ‘The cylinder is pressurized by nitrogen gas to approximately 5688pei (40 atm), therefore, no attempt should be made to disassemble the cylinder, 2. Cheek the froe length of the spring @ with « vernier caliper @. (Fig 8-28) If st measores less than the specified value, the spring should be repleced, sam (inc) Trem Standard value | Servieable Tait Spring free 2.9 217 ies am, as 4. Damping force connot be mensured, therefore the test is performed. by compressing the rear damper unit by and; nocmal opecnting condition i indicated by 8 ester eateice on Une cxtountos rvs then ax tha Gorge: © Rear ‘sutpention spring, @ Vernioe caliper sion stroke, ie. 635©. Inspection 1. If the element is dirty, wash it in solvent or gasoline ‘and allow to dry Then follow by squeezing ‘Out the excess oil and assembling it into the sir cleaner cate. If broken or damaged, replace with new one. ig. 8-20) 2, Check the air cleaner case for crack or other damage. If badly damaged, replace with new one. (Fig. 8-24) D, Reassembly Perform the reassembly in the reverse order of dis- assembly. 8-10 REAR FORK A. Description ‘The rear fork supports the heel and pivots at the rear fork pivot bolt to provide a swing action. Ih is constricted of steel tubing for greater strength and durability and mounted throught pivot bushing on lock side ‘and lubricatad with gresse for smooth operation, B. Disassembly 1, Place a block under the engine to raise the rear wheel off the ground. 2 Rameve the chain the rear wheal sod the dive chein guard. 3, Pall out the rear fork pivot bolt @ and remove the rear fork @. (Fig. 8-19) . Inspection © Rese fork pro: bolt @ Rear fol Pig. 8-25. 3 ie 1. The rear fork should be inspected for distortion. Insert the rear fork pivot bolt through both pivot holes in the reat fork and check the sear fork for alignment 2. Measure the inside diameter of the rear fork pivot bushing and replace if beyond the serviceable limit. mm (iach) D. Reassembly Standard value 20,000~ 200038 2018 (0.787~0.789) Serviceable limit (0795) L Apply a Uberal amount of grease on the pivot collar and eacomble it into the rear fork. Insert the pivot bolt from ‘the right side, and then install and tighten the Ldmm self lock nut, Tightening torque is 65.0~795Ib.{t (900~ 1200 leg-cm). 2 Install the drive chain guard and the rear wheel. 2 Tastall the drive chain, the rear brake pedal and drive chain tensioner.140 8-11 REAR CUSHION A, Deseription Ae Caron spe dpe otisingsogen gu onder ish rear ened iin nner msn a prenore apo the of vee prascus bubbles from being produced in the oi! dering compremion. It asures postive damping sction Thin fio Tees ram twadjacnd wo thee poniioas ectondiog © caiiung Weed ad ‘ding oman. ‘The etcke of the wer cushion i 262ia. G2). UNT: Ma ax 302 ist ser2ig4 uN 250 BAD set 207 # Sno Set 202.4 tip @ Rear check spring seat stopper @ Rear shock spring upper seat Rear shock spring Rear shock apring guides @ Rear chock spring lower sest Rear shock damper unit Pig. £26, Sectional view of sear suspension B Disassembly 1. Remove the blind nat from the upper mouating bolt of exch rear shock spring. Remove the lower mounting bolt and withdraw the rear shock spring. 2, Remove the spring ® from the shock spring unit by using the rear suspension disassembling and_assembling tool (Tool No. 07959-3290000) @. (Fig. 8-27) Tuming the handle of the special tocl clockwise will gradually compress the spring, permitting the removal of the spring upper sei ‘As the handle is turned counter clockwise, the special tool can be separated from the cushion spring. allowing the damper unit to be disessembled, © Rear shock spring @ Ssspension disessembling and assembling tool Tig. 21 C. Inspection 1, Check the body of the damper for dents or damage, for fluid leakage or lack of damping efiect. If any of these defects are found, replace the whole unit as the damper is not repairable. CAUTION: ‘The oylinder is pressurized by nitrogen gas to approximstely 5A88psi (40.atm.), therefore, no attempt should be made to distssemble the cylinder 2 Check the free length of the spring @ with a vernier caliper @. (Fig, 8-28) If it measures less than the specified value, the spring should be replaced ram. finch) Tem Sandard value | Servisable Tit Spring foe 229 27 iene am a) 3. Damping force connot be measured, therefore the test is performed by compressing the rear damper unit by Jhand: normal operating condition is indicated by 2 greater resistance om the extension stroke than on the comps © Reer suspension epring @ Veenior eaiper sion stroke. Fig. 8Reassembly Testall the rear suspension spring onto the rear damper unit with the tapered end of the coil toward the ton. Perform the reverse oder of disassembly “Phe model SL250K2 uses rear shock absorbers of the double tube type. For the operation see paxe 81. @ Rear suspension spring seat stopper Clip @ Rear suspension spring upper seat @ Rear suspension spring @ Rear damper uait Fig. 8-29, Component pert of rear cushion 8-12 FRONT WHEEL Deel Pratically all of the paris such es the wheel bearings, wheel hub, brake backing plete, breke drum and shoes, apokes and ete,, are the same as those for the CL250 ‘The major diflerences axe in the knobby tires (9.25~19-4 PR) used on the SL350 for better houlding when travelling over rough roads. "The procedure for the semovel and installation of the frent wheel assembly, bearing removal, serviceable limit of the drum wear, brake shoe and tire replacements are the same as for the same as for the other series and should be telerred to the 250-350 Shop Manuel. B. Tire Recommendation ‘The following tise is recommended for use with the SL350. Brand Manufecturer Size Air pressure (cold) Front: BS. Trail wing Bridgestone Tire Co., Japan 325~19 215 pai Rear: BS. Trail wing Bridgestone Tire Co., Japan 4@~18 215 psi “This tire was specially developed for the S150 and features susperior road holding for both off-he-road and on the high way. 8-13 REAR WHEEL A. Description ‘Similar to the front wheel, the peris for the cear wheel are the same 2s thote used on the CL350 with the exception of the knobby tire and sim designed for thei nstallation of so bead spacers for off-road riding. a For disossembly, inspection, repair and reassembly, refer to the tire change is the same as for the froat wheel and should be referred to in the section of tire recommendation, Fig, 6-90. Tube air valve hole aad bead spocer holes142 9. ELECTRICAL GENERAL DESCRIPTION |All parts used in the electrical system are the same as the same as those used in the CL350, with the exception ‘of the ignition coil, hom and speedometer, As safety and emergency feature, the ignition circuit is exposed end a Kill switch has been incorporated to shut off the engine, Description of the special pasts. 91 IGNITION COLL ‘The wires in the harness connecting the fuse, condenser and breaker points are of a larger size. 9-2 HORN ‘The center distance of the hora bracket mounting holes has been made greater to permit the used of the same bolts formouating the steering damper bracket. 9-8 SPEEDOMETER ‘The design of the dial plote has been changed to indicate the speed ranges for onthe-road riding, however, the epeedometer main unit has not been changed. Refer to the 250+360 Shop Manual for information of the diassembly, inspection and rassembly of the respective components, 9-4 STARTER LIGHTING EMERGENCY SWITCH “The starter lighting emergeney switch is located on top of the tight handle bracket. (Fig. 9-1) A. Disassembly 1, Seperate the switch bracket by removing the two owitch mounting screws @. (Fig. 9-2) 2, Discomuect the throttle cable. 3. Disconnect the witiag hernese within the heed Tight cate end remove the switch assembly. B. Inspeetion 1. Start the engine, frst make sure the engine can be stopped by switching off the emergency switch. If the respective switch positions aze not functioned properly, the switeh or wiring is defective. If the witing ie correct, check by the testing conductivity of wires with the ewitch, If the conductivity is not cor- rect, replace the witch with new one 2. Switch on the main key switch and check to see that the headlight coatrol switch is functioning properly by setting the respective switch positions. If its positions are not functioned properly, the switch or wiring is defective If both the wiriag and conductivity are correct, replace the switch with new one, C. Reassembly Perform the reassembly in the reverse order of ds assembly. ® Emergency switch @ Headlight contral switch Fig. 1. NOTE: ‘When installiag the switch lower housing on the handle bar, make sure thet the hodling pin is inserted into the handle bar stop hole aad is tightened together with the ‘switch upper housing. @ Switch movating screw Fe,143 WIRING DIAGRAM i 4 roa x HEM MS Naru NTA prrae Irpnorav/satees (944, “W) WVADVIC ONTALM PyoszaD144 fais“145 OLOW SNLVIS. woIvuaNR® “oy 3441 YoLoM Fs HOLS TaLnay * ‘MOEAZE ANON TNDKS NUML erate yee ita acrowe ae ex Se lls wave fz] chewed ae : ngwewen rom Ed awvas Mig] Rome sore be Eh Se oh s ay na voiked fais wil tan Are auth we N = 7 = ath t HE) ncosener | be i C= i ASS eee mea aon MEE S is = en | 5s ghee Sanam at se eee} oe G oro oe puns warea|| | CSOGSORT] ‘OUaNoW SLES wai ujno) = eal pereeht ig cs | = OFaE TOT WBE HN SIO ALVES ONTO helt ah SMHOHIMS sous rows olin FOUINGD TroridYan Yous OM (oday, ye20u29) WVAOVI ONTUIM FHOSCAO146 Walon onsms| ft EERE Hans NEAL ANNE aa yazan SEO) ona =a 1 iB a o1voiaw Wi LOH, a (Ge se HOBO HOT TnoIs: ma, INOS eS Frouns roxuro HOURS ToaLNIO sneroWaHONOYaHNeLNG wales \ (e441, -V's'0) WVADVIC ONTAIM PHOSETO147 9m woyeh/anay 500A, o 28 oF is wand av0ws7 Nansen ENS TOA ouey rea rava Nolin as (ed4y [819U2D) WYADVIC ONAIM FHOSETO148, : er . a149) au si) (Qigey Sf am L/@® = Bee ost sn bist {one van wos wa 98H Ina a eo pa L saw ane ent md ve ayo ‘a8 mt tod tok ao WVUOSVIG SNIAIM D0s8d010. MAINTENANCE 10-1 MAINTENANCE SCHEDULE “Perform the periodic inspections on the scheduled mileage shown in the chart to maintain the motorcycle in the peak of condition and be assured of extended trouble free service. MAINTENANCE SCHEDULE INITIAL, SERVICE REGULAR SERVICE PERIOD Perform. at every indicated month, o Pailop : This mainenance schedule is evel upon average Hing roleage iaterrl, whicbever cies rst. cnditons Machines reed to severe se, or Felden Teaco ce inunasnly oaty aves, require more fequee verviing soo | morta | monihs | months | montas sities [sto "B10" [3000 ON sie | sie | hee | mite ENGINE OFL—Ghengs. e oO CENTRIFOGAL OIL, FILTER—Clem. aS OIL FILTER SCREENGiesn le SPARK FLUGS—Clas cad adjunt gap oF rerace neeseary = CONTACT POINTS AND IGNITION TINTING Clean, check, and odjust or replace if necessary. = o | SALVE TAPPET CLFARANGECheck, and adiust if necessary e ° TAM CHAIN TENSION Adjust. ° i ° PAPER ATR FILTER ELEMENT Clean =a 5 PAPER AIR FILTER BLEMENT—Rerlace. operated in duety arene © CARBURETORS Cec, and adj i nacooary. ° ] ° THROTTLE OPERATION— Inspect cable. T T . Check, ond adjust free play, e 2 FUEL FILTER SCREEN Clean | o FUEL LINES—Check o SCUVTCHI—Check operation, and aunt necessary, . | a DRIVE CTIAIN Chock, Inbricte, ond adjust ness ° BRAKE SHOES —fospec, and replace if wom, = —BRARE-CONTROL LINKAGE™Check aap, a= aes Seapets ply if names e la oA ES—Chedk Tighe 9 ant tue weds, e “TIRES pest and check air prenere fle FRONT FORK Oil-—Drsin end refi ry 1 S TRONT AND REAR SUSPENSION Check opeition. e a REAR FORK BUSHING —Gresse. Check for excesive Tocent o *STEERING HEAD BEARINGS—Adiust. a BATTERY Check slecialjte val and ald ener © necoary e o LIGHTING EQUIPMENT Chock aad odjas if noconary e [0 a ‘ALE ROTS, BOLTS, FASTENERS =Check weary | 3 = mdigher denen. | @ | © Items ~wackid) * should be serviced by an authorized Honda dealer, unless the owner has proper tools and is mechanically proficient Other wnintenance item ars simple to perform and may he serviced by the owner, ‘ INITIAL SERVICE PERIOD 200 MILES. ‘e¢ INITIAL SERVICE PERIOD 1.500 MILES,