- SHOP MANUAL €B125-160 y ASUP — " WiPREFACE ‘This maucl fas boon complied as © guide for ducssonbly end essenbly of Hooda: Models CB 125 od 160 Tho manval is divided into sx sections, each of which gives detas of ‘consucton, dlsssonbly, and astembly, Reqited hpocton ond malneronce procedkres ore aio clued, To further clarify the detcits contained orein, os mony illstrations os possible were used. This morucl, if read coretlly, will supply the techniques of corect maintenance ond the fundamental technical knowledge required of both mechanics ord soles stoi. SERVICE DEPARTMENT FOREIGN SALES DIVISION HONDA MOTOR CO., LTD.CONTENTS 1 FEATURES Il SPECIFICATIONS ML ENGINE 1 Disaszonbling end Asserbting Engine 2. Cylninder Head ond Cylinder 3. eft Cronkcase Covorsseesese 4 Crarkcose Cover Assembly, Right 5 Chatch ‘ 7 8 Oil Pump, Fier, end Seporctor Cronkese a. Girish, Comectng Rot, ond Pistons 9 Cam Chain Tightonor ond Can Choin Guide Rolle... 10 Trensmission.... V1 Goor Shift 12. Kick Stator. 13 Carburetor 47 IV FRAME 53 55 59 4 53 585 66 7 69 70 72 73 Handlebar saeecssseeseense Construction of Front Cushion Stooring Stem ond Handlebar Lock 1 2 3 4 uel Tronk 5 Frame Body. 4 fir Cleorer Case and Seat 7 8 Stand 9 ir Cleaner ard Tool Cose 10. Rear Fork ond Reot Fender Tear Caston 12. Front Wheel 13. Reor Wheelcontents J V_ ELECTRIC EQUIPMENT 1 General of Electrical Ports 2. Bloctical System Ignition Cleuit Power Source Chest SelFStartor Sofety Ports . Switch Wire Hames CG) VI INSPECTION AND ADJUSTMENT 14 126 6.1 Maintenance .. 6. 2. Periodic Inspection end Repair| FEATURES Features of CB 125 and 160 AL Engine Ider engine, ond each cylinder has special carburetor. The intoko 1. This engine isa poralel to yf ‘overhead cam for pipe is qute smooth, with low resistence, for high inoke efficiency, ond has on igh rotation and high outpu 2, The camshaft dive ie by chon, ord fs between the right ond left cylinders: and steady performance cond dilly moiatin low cylindor temperature 3. LWbricatng oll is fitering by both fitereg mesh ond © centifugal iter plunger purp to tho crankshalt, camshaft, end transmission shaft. Core has beon given 10 wear and It is forcefed by @ seizwe resistance of och uit. 1A, For power trensisson from the erarkshaft fo tbe transmission shaft, doxble spur goars ond shock “cosorbers reduce goer noise ond increase curcbilty by Increasing the proctcal effective engagement ratio B. Frome 1. The frame hos two sb-fubes which are horizontally exterded from the hood pipe and have High twist rigidity, in oxkition to strength required for « sports vehicle, 2. The fiont wheel suspension is telescopic nd tho roar wheel is of swinging crm type, with hydraulic shock dbeorbors. Superb riding comfort, steering, and stability is cbtined. front two leading" type ond rear leading, and taling type, Due to the 3. The broke unt is 0 semimetalic fring used for broke lining, brake performance is high 4A. The bondlebor of somiaised type, which together withthe lxge speedomter, encbles the rider mointoin @ notecl poste wiile cruing.SPECIFICATIONS MODEL ENGINE Cooing sytem end cycles ember of eyinder: ond aosntng oe Vives Combution chontae linger expacity ore Stoke CComresin rato Compeesson Mex. torque Min fuel conseption et fl lsd Seong Spark tining| Spare eo Model Monufotorer sor pis Monufocuee Corer Type end unter Monat ie cleorar Type Mansfatree eal tank capacty Type of of pune Type of ai fier Latrcatag ot copocty artery Model end mater Vatogelcopociy 125 ovate fete Kecooled, dros 2 eyindaet, poral 30° vp fom Overbead ype Seaispteria 01246 60 in AA 1.79% 1.61 90 10tg/aq em (141.9 psd 1510500 0, 1.07 mig 17.7 9200 em 250 ge (88 ei etic motor ond Kick ya estery sport 8°10 45" bafore top dood contr e208 29700.097 cm12 Kotwian Denk, Nihon Osseo, Hoch Sone oH Nea Totshy Tooyo | Paton valve type, 2 each 7 Kal KK) Kein Se OL itor pops Tey Eot 10.511 28US 9), 2.3m got Pump ond ps sy Wee mesh od conta eye combined {ln (27 US go 22 np gat i combined MW 3-126, 1 eock 1av 9aK co 10 Ae-coaled, 4sicke 2eytndart, portal 30° op fom forme! Overkead type 0.6 (84 il 50X41 mm (197X161 as TO fg em (141.950 165/10.000 rom 1.24.9 1,118 500 pm 250 gr 68 22)hpIe ectse motor end Kick sens conned ary spk e208 29700-097 CMI? Kolueon Dent, Niton Doro, Hock Sensi oan Nihon Totuhy Togye Piston valve type, 2 each ea) itor oper Toiyo Roll WK) 10.5 28USgo, 2.3 4ep ga Pump ond sesh system combed Wire mesh ond cantifgal system coabeed 10 (27 US oo 22 np ol MBW 3-126, 1 goch iv 9aH| sPeciricaTiOns ‘MODEL ce 125 ca 160 ‘Garang genercter Model £519 7000-024 K 107 €G19 s7000-024 107 Monatactrer oluzan Dent, Non Date, Hioehi | Koluon Der, Nien Denso, Hoch Sassi Selene Stating mortor Model cos 2¢000-111 $108 coos 22000-111 $108 Monsfoctrer ctw Ov, hon Gun, Hoc | Kalin Dil Reon Doo, Hae ower tonmision device Mactenm from engine 12 gear | Gear sytan, oor aytem Rection ratio | 200 3700 Model of ech Wot maine What mate Tronumion Model CConint engaged geor sytem Conant engaged gear system Shitting alt foot sytem Left foot system Troreiton gear rato ft 2768 270 second v8 vr thea re ey fourth row Yoo Neca ron tron davies | Che Oa Redhtion ratio 2608 2425 ‘CHAS Diners rer tngth 1947 (398 parm 1639 1 Overt wish 0745 24510 075m 24st vera baht 0390m 32519 090m 9.25% Wiheciose 277m 1608 177m (50801 road dearrce O1esm 1048 [osm cain wrest Wilot vlooded 127049 79 127049 (27911 Nanber of ere 2 2 Wolgh deduce 2 0 tons front | 40.5 1133181 40.519 11398) Foor | 6651 (1468 66549 (MG Performance Max. speed 130 yh 81 13Sknf (85 lee Fel costumption aio on povedroad | &Sbalht 40 mile/gl ‘5h 5 e/g Clnieg obty ars0" od Min twig roe 2.1201 ot 2.1200 7 Braing stereo Jo tot 38d 7m to! 35 tfn) 251 tt 22 mesh "pt Wot 22 mend steering Stoeing ole 40° ght ond te 40" ght ond tt Length of hadlebor 0.676 osrae fing ‘Csi oo oe Tal 096m wo25% 086m 1025 4 Fron! 250-18 Up 250-18 (Fy Rese 275-18 14 Py) 275-18 (Hy)vn oe eee Type of frome Tubular | Taba =MODEL CB125 | (GEAR RATIO tows 24,38. Lion ands 15.62 |e) M4 ) aed: 1158 [op a a fi . | ie ; a 7 gm i iz oda a Oe aT aH eM 5 fendine*a ptt («10009 RUNNING SPEED (Km/h) 18) MODEL CB160 GEAR RATIO low: 26.9 es Pod 2 17.2 7 is aa se ere 8 ely ie A 2 ( 7 : (mke) q ZION " 88 ENGINE R.P.M FES 0 T1000) Le EPEREL EMMETT ENGINE RPM RUNNING SPEED kn/h)ong 409y pun epig ‘do} “juoss-smala so1F rr HANDLEBAR z REAR SHOCK ABSORBER HEAD LIGHT ‘CARBURETOR éSPECIAL TOOLS FOR ce 125/160 2880289800000 146 tock mt sack ter pile Sp eng por Soap eng pers Fieon rag 09! Piton idee Past Vato ovide Feton tore Ror fork pot batt ©80808908e0 01 stone Valve soot colter se Toot fer bering pallor cringe 142217 wrench Mole swith sotor © wooden special diver 29 mm stom mut bor Foor euion From fork Tool borENGINE g e ©eeoeceeee3. ENGINE 3.1 Disassembling ond assembling engine A. Dizatsembling engine 1. Close the fuel cock. 2. Remove the right ond left exhaust pipe joints and remove the four 8X 28 bolts helding the mfler (to other with the forrest cm) and 8X38 bots holding the footrest pinion. Seperate tho paris from the engine. (Refer to Fig. 9.1 and 3.2) 3, Remove tho cir cleaner cover and the tool box. 4. Remove the igh tension terminals from the spark plug and disconnect all foods. (R 5. Remove the oir cleaner coupling ond the carbu- retor of the point of the set plate stop. (Refer to Fig. 3.4)3.1. DISASEEMAING AND ASSEMBUNNG ENGINE " & Remove the left crankcase re0r cover and sparcto the cable end together with the clutch cable joint from the cable core. (Refer to Fig. 3.5) 7. Rotate tho rear wheel and remove:the clip ot the chain joint and the dkive chain joist. (Refer to Fig. 3.6) 8. Remove the starting motor cable from the switch connecting section. (Refer to Fig. 3.7) 9. Separate the cerbwetor from the lasulator section ot the engine head side. (Refer to Fig. 3.8) {CAUTON) Bo coreful not to bond the choke rod, Fig. 9.0 Removing cobustor2 3. ENGIN 10. Remove the engine meunting bolts and seperate the engine from the frame, (Refer to Fig. 3.9) B. Assembling engine 1. Installation of the engine should be made in tho reverse order of Section 3,1 A, 2. When installing the engine mounting bol epera- ion is eosily pocformed if © Tver is employed. (Refer to Fig. 3.10) Fig. 3.10 Intalation of engine (CAUTION) ‘When coupling the chive chain joint, the joint should be set with the split of the joint clip facing the reverse side of the rotating deection of the RORNAL ORECTION OF CHAR hive sprocket. (Refer to Fig. 3.11) (2229) (One) ence OR) 3.2 Cylinder heed ond cylinder Figs 11 Gresion of drive chin joint A. Disassembly The head of the parallel twin cylinders of the four stroke 360° cronk type ie equipped with the conshatt, ‘The combustion chanber is dome shaped ord the cam chain is located on the right and left hond sides for good comiation efficiency. For cooling, consideration is made for cbtoining the some conditions en both the right ord left eylinders in addition, ¢ contact breaker is installed ot the left end of the camshaft. The cylinder heod is fed with the breather chomber and provides engine mounting. (Refer to Fig. 3.12) Fig. 2.12 Cylnder heed combson etonber2.2. CYUNDER HEAD AND CYLINDER L. Disossembly Coution required during disessembly ond cossembly ©. The work orea should be rrenged orderly ond the tollowing itens should be prepared. + One set of general standard tools + One set of CB 125 and 140 special tools + Clecning solvent, gasoline, ond ci + Measuring instrament + Gaskets and packing for the paxticular engine b. Disassembly should be performed in o systomatic & A complete veliele inspection must be made, 1. Remove the eylinder hood cover. (Refer to Fig. 3.13) 2. Remove the generator cover. (CAUTION) In the 6X18 xpoint screw for securing the generator cover, « §.5% 1.50 ting is inserted. (IF the ring is not used, oll leakage results 3, By fuming the A.C. ganerator rotor, locate the com chain joint end remove it near top dood center. (Refer to Fig. 3.14) WF @ thin sting oF wiee is attached 10 the cam chain ot this tine, later operction becomes easier. 4. By removing the cam chain the cylinder hood can be removed from the stud bolts. (Refer to Fi 3.15) 5. Tho spark plug should be disconnected from the the high tension tominal. (CAUTION) lol Alter removal of the cylinder head, the gasket sfaco should be iespocted, (b) Corbon in tho conbusion chanber should, be refidied. (Refer to Fig. 3.16) > (el Usally, gaskets and packing cre used only once. Whoa dsastonbled, they should be thoroughly inspected: if any scor is Found, replo- coment should be mode. Fig. 3.13. Cylader Fig. 2.16 Fewoving cokes bo‘CAM CHAIN TGHTENER SPRING. powenee set 80tr ourenes POR seg ‘ch, crane SU BNy 120. Cylinder hood cover sed breather chontsr pasooe ENGINE WU. Assembly 1. A proper inspection of the cylinder head gasket, sotus of volves, end tho interior should be mado = ‘after confimation of their corcect status, assembly sould be conducted in the reverse order of isos senbly. 2. When essonbling the cylinder head, instalation Cf the com choln should be made os shown inthe figure with attention directed to avoiding deviation in timing. (Refer to Fig. 3-17) 3, The direction of the com chain joint clip at installation should be the sams os the join! clip (of the fal dive chain, with tho split facing In the reverse diection of rotation. 4, At this ime, if the com tightoner is not pushed in completely, the cam chain becomes ststchad and the joint canna be Fitted, Tho eam tightener should bbe handled properly before ossonbly. (Refer to 3.18) 55. Tigening of the cylinder head should be mode in the order shown in the figue, using @ torqve wrench, (Refer to Fig. 3.19) B, Description of cylinder head cover and breather The cylinder head cover mounted on the engine, provides a breather charnber in the hood cover and ops the interior pressure in tho crankcase constnt Oil is separated simultoneously and ganeroted gos Is exhowted. (Refer to Fig. 3.20)By sudden change of direction of the forced gos stream, the breather separates iby diference of gra vityl olf ia @ gaseous stote when the gas strikes the breather wall through contfugal force. Passing the interior pressure of the crorkcase 10 the hood vapor 2e¢ moisture by sibjecting the gas 10 high tempocs mo. (Refer to Fig. 3.20 ond Fige 3.21) Disossembly ond essembly ‘The cylinder bead includes the head cover, beck er comthalt, valves, ond side cover, in this section, sub-dsossembly of tho breather and breaker is sinply rooted, 1. Disatsombly ond cssembly of the breather separ When the nuts of the cylinder end cylinder head axe removed, the heod cover can be separated, 2. Disossonbly ond assembly of breaker advancer lol By removing the point cover, separate the break se. (Refer to Fig. 3.22) (h) Remove the spock advencer assembly from th com shaft. (Refer to Fig. 3.23) Before operation, @ rotation stop shoud be copplied 10 the cam tevocket, fel By renoving the. four 6x18 screws, the point bose is separated. (Refer to Fig. 3.24) The point base serves 0s the bearing of the can shoft without bushing. With oll grooves cut in the sliding poction, this unit is residolly ubvicated by oll from com ltrication. (d) Asenbly is the reverse order of disassembly. (el During ossombly, attention should be drected to tho cut on the contoct broaker base plate showing wpward. 3.2. CYUNDER HEAD AND CYLINDER us Fig. 3.23. Dioxonby of spor advnce 2.24 Removing pt) baseFig. 2.25 Contoft BASE CIRCLE arate FT \ cam Hersut Fig 3.20 Nanes of com pout ig, 3.28 Removing comalt ENGINE C. Description of camshaft Tho camshaft of this engine has @ can sprocket ft the center and polished cam sections at the right end left sides. The beating sections ore « logical typo which, are supported by the side cover and point base, ‘The cam sprocket Is driven by the cam chain from the gear shift at 1/2 traxzission gocr ratio. (Refer to Fig. 25) The com provides a damping cuve over @ folly lorge range between the base cecle ond the com Unit, ond damps the shock generated when the rocker Fits tho lit cxve >this provents noise. (Refer to Fig. 3.26) Disassembly 1. Remove the cylinder head, (Refer to Fig. 9.2) 2. After the point base ond the right side cover ere Femoved, remove the tappet adjusting hole cop. Remove the rocker crm to the right ond left on the base ciclo and the canshaft con be soporated from the cylinder head. (Refer to Fig. 9.27 and 3. 28)8.2. CYLINDER HEAD AND CYLINDER tl. Assembly 1. When the dusting screw of the rocker orm Is tuned back fuly, sot it to the rocker am pin ond cssonble it in roverso oxder of disassembly. 2. Tho stanard toppet cloarance fs 0.03 to 0.05 mn (0.012 to 0.020 in) wien the engine is cold (CAUTION) Conect or replace the unit when the com is scored oF worn unevenly 1D. Description of rocker rm The rocker rm i& an important unit which changes the rotating motion of the camshaft 10 reciprocating notion for the valve. The rocker arm contact surface is frsh treated efter hardening. The tappet adjusting screw is coupled ct the other end ond pushes up the valve ot the tip ‘of the serow. 1. Dissassembly 1. Refer to section C above. When tho right ond left covers ore removed, removal ean be made, (Refer to Fig. 3.30) 11, Assembly 1. Inspect the rocker crm contact suflace and replce the unit Hf there Is score. 2. When the rocker am shaft is belng assembled, the rocker cm should be matched t0 the cil poo! groove, (Refer to Fig. 3-31) ‘3. When the rocker arm has been disassembled and reassenbled the toppet clecrence (valve clearance) should be moawed ond adjusted Adjustment should be performed at the postion where the T mmatk of the A.C. gonerator rotor and the arrow tmatk of the stator are matched, (Compression top dood conte). (Refer to Fig. 3.32) Fig. 3.20 Ramoving valve rocker orm SALVE ACOH AR Fig. 3.92 Adusinart of tppot cleornce1 2 Yatve Sag sat j | vu | VALE seas Fig. 3.38 Drening waive soot ENGINE Description of valve Tho valve performs tho important role of ir Yightness in the cylinder, of intake ond exhaust for compression ond combustion, ard extensively infuences the engine output. AY the exhaust valve, the comber is small, for ob- taining better fect radiation and the clearance between the stem ond cylinder is mode largo. At the inlet valve, it is lage for incrasing the intcke efficiency ‘ond the clecrance between the stom ond the eylindor is made small for satisfying various conditions con- cerning valve. ‘A datble spring system Is employed for the volvo. (Refer to Fig. 3.33) |. Disassembly 1. Remove the cylinder head eccording to Section B21 2. Depress the valve lifter spring ard remove the ‘wo valve cotter pins with long nose pliers or woezers, the retoiner valve spring from the beod cover, and the valve frm the combustion chamber. (Refer to Fig. 9.34) Instll Before the volve is ossenbled, surface should bo inspected for woor, pitting, or caben, After coating, cil the valve stem, ond tho volvo should be inserted from the conbuton crbor sido. (Refer to Fig. 3.35) 2. Tho valve sping outer and one retainers should be fited from the cop hole of the tappet odstng hole ond be conpresed by wing the vale iter Seoe withthe valve eoter pin. I, Valve seating 1. Dressing of © volve seat is mode by using tree cutters (sch 05 «90° plane cutter, INTAKE ond EXHAUST plone cutter, ond INTAKE ond EXHAUST interior surface cuter. 2. Tho position of eat iz determined by the INTAKE and EXHAUST plane cutie ond the with of @ contact suroce Is determised by wing on INTAKE ord EXHAUST interior surface cutter. 3. Whan a soat sufoce is excessively burned, ckess sng should be performed by using 0 90° cuter so thot the sect swfoce becomes even. (Refer to Fig. 3.36)2.2. CYUNOER HEAD AND CrtiNDEt (CAUTION) (cl When the valve stem Is rectly worn, the valve ide fs usually a0 worn, Hence, whon volves replaced, it ol is dasa to replace the volve qude. AS the guide was press inserted, i is better 10 replace the guide after heating the head 10 300°C in o furnace. (G1 When the valve is essombled, the compound which was used during lapping should be com pletely removed F. Description of cylinder A cylevier sleove of special alloy is pressinserted in 0 cylinder of lightweight cast oluninim alloy. At the center of the cylinder, « clearance for the opera: tional ronge of the cam chain tightener and cam chein fs estblished. ‘The Mication oil fed fiom the oll pump passes ticough the shid holes of the rear right ond left of tho cylinder head of the gasket surfoce, Fiting of ceyliader is determined by two guido hoys. (Refer to Fig. 3.37) Discssembly 1. Remove the cylinder as i Section 3.2.1 and the 6%22 bolt retaining the cylinder : the cylinder cca be removed from the stud bolt. (Refer to Fig. 3-38) Wl Assembly 1. Inspect the eylinder and coffer confirmation of no bromalty sich as ground wear O° scors, remount a 2. Ploce packing ot the contoct sufoce with the crankcase ond insert the cylinder. 13. When a piston is inserted into o cylinder, use © piston “slider ". Applying @ base between the pision and case, insert the cylinder. (Refer to Fig. 3.39) 4, Assemble the cylinder head ond heod cover unit. {CAUTION) Inspect to detornine if the crankcase packing has slipped from the cylinder lapping sxfoce. (For oie tightonoss) Valve Tining models CB 125/160 IN opens (ot Liam bf | ®.T.D.C) inyeiesares ames eee [Soe Kops (1 (| 80 BDC) Kelows (1 | PATO3. ENGINE 2.3. Lett erento ever Te kh cnkcan co, wal ste ees, bates he lf fonion a poeien a ( oF ijt coy le neeg He NC prt tn pe of eg hpecon nd chit wet ony AC. guna coarsest te crite tte nec en he noe ony e@ te AC. grr Be tne To ech coal |. Disassembly 1. Drain the engine cl or lay the engine on is side. 2. Remove the gear shift and the neutral cord from the switch, 3. When the crosspoint screws that retain the caso cover are removed, the left crankcase cover con be seporated from the cronksose, 1. Installation |. Assembly should be performed with attention ected 10 the following points + Breckage of left craskcase cover gasket + Action of clutch cable 2. Alter complete vehicle essambly and inspection, ‘odjustment of the clutch should be made with the clutch cable (Refer to Fig. 3.42) B. AC generator ‘A description of the AC. generotar. is given in ectrcal Ports (8). In CB 125 and 160, in ower to have the per formance displayed by narrowig the width of the crankcase 10. the minimum, ¢ logical design is employed With the AC gorerater located near the crankshaft fond the stotor coupled in the left crankcase cover. {Refer to Fig. 3.43) Fig, 3:43 AC goneoter ond storL. Discssembly 1. Disassembly of AC generator [ol The AC gonerator ct the left crankcase con be removed or mounted without dismounting the engine. In this section, operation is explained ‘whon the engine disneunted and tho cylinder head and cylinder ere dsatserbled. {1 Tho piston is safely socwed by the piston bose (el By removing the generator rotor bolt, dismount the rotcr from tho crankshaft by use of @ gener: tor rotor puller. (Refer to Fig. 3.44) 2. Removal of AC generator rotor (el Remove the lft crankcase cover. (Refer to Fig. 3.20) (BAC gonerator stator coupled in tho lft crankcase ‘cover can be separated by removing the three 6X28 bolis. (Refer to Fig. 3.46) 3K AL the bock of the AC generator rotor, the starting cltch is coupled tby tho threo 6 20 pan M. Instollation |L_Installotion of the AC generator rotor can be made by metching the grove at the the rotor side 10 the key sot ot the crankshaft side, Secure by rotor setting bolt (CAUTION) Whon the key is dislocated from the crankshott, 1 should be fitted by light topping on the side of the key and sligtly pressing to the set groove. 2. Following the reverse order of lsassembly, as sembly should bo mado followed by coupling of the left cronkcase cover. Starter sprocket and clutch |. Operation of starter clutch During trensmision of rotation of the stating motor {0 the carkshaft, rotation from the motor con be tronsnitied 10 the crankshaft : conversely, rotation of the crankshaft cawot be transmitted to the moter. (For detail, refer to Electrical Ports (Chopter 5) (Refer to Fig. 3.47) LEFT CUANKCASE coveR 2.47 Stoter clitch AE GENERATOR STATORChek einer a ENGINE Il, Disassembly ond installation of clutch 1, Following Section 2.3 B, the AC ganerator rotor is seperated from the left eronkease cover 2. As the starter cltch is istlled ot the back of ihe AC generator rotor by using throe 6% 20 pan screws, it con be separated by removing the screws 3. When installation is being performed, attontion should bo directed to tho following points + Smooth roller operation + Starter cltch side plate and guide. + Weak clutch roller spring treplacel. Il, Disassembly ond installation of storter sprocket 1. After separation of the AC generator ond the left crankcase following tbe previous section, the starting chain is disconnected ct the joint section 2. By removing the storting sprocket set plate 6 12screws} coupled ia the lower cerkcase, the sprocket con be seperated from the crankshaft, (Refer to Fig. 3.49) 3. The starting motor sprocket is coupled only by serration end can be extracted quite easily. (Refer 3.50) (CAUTION) The joint clip slot of the storing chain should foce opposite the direction of rotation. D. Clutch edjuster ond neutral switch rotor Operation of clutch adjuster For tronsnitting operation of tho clutch cable. to the clutch through the clutch rod, the clutch duster pushes the clutch rod nd indicates relationship in direct stort, transmission goor shifting, and stop. That is, adjustment of the clutch is generclly made ot the Clutch adjuster oxjustment; affects the vehicle perfor mance. (Refer to Fig. 3.51)I, Disassembly ond ostembly of clutch odjuster 1, Following Section 8.3 B, remove tho loft crank 2. By removing the 6% 35 bolts holding the adjuster fixing plote ond clich lover spring, the clich ad juster con be seported. (Refer to Fig. 3.53) 3. When ossembly is performed, grease should be cpplied to the clutch odjster (Grease Type HD Muitpurpose NLG! No. 2) IM, Disassembly ond instollation of neutral switch rotor 1. Remove the left crankcase cover. 2. By pulling out the 6% 12 serew holding the neutral star, remove the stator. 3, By removing the 6% 20 screw, the neutral switch rotor is separated from the goar shift drum, (Refer to Fig. 3.54) 4. Mer tha groove of the neutral switch rotor is matched 40 the key of the goor shift drum, essombly shoud be performed in reverse order of disassembly. 3.4 Crankcose cover ossembly, ri ‘A. Description of the right crenkease cover ‘The right crankcase cover, os well es the left crankcase cover, performs the role protection. The Gil fter cover is fitted to the caso cover and pro- vidos for passoge of kbicating il in both direction. (Refer to Fig. 3.54) 1. Disassembly 1. Remove the kick starter orm from the kick pinion shaft 2. By pulling out the ton crosspoint screws securing 8.4 CBANKCASE COVER ASSEMBLY, RIGHT tt cos cover, tho right crakeaso cover bree fo moved, (Refer to Fig. 3.55) 4A. After pulling cut the three 6X40. cross-point screws, the filer cover Is removed (CAUTION) Daring poration, ottention should be directed to the two 74.5%3 "0" rings fitted to tho oil fie ter cover Fig. 3.55. High eranzare cover screws2 3. ENGINE Figs 8:65 "0" sg on ol itor cover 3.5. Clutch ML. Instoltation 1. Before installation, inspection ond confemation should be conducted 0 determine that tho right crankcase cover is not broken, since a break cavses «il leak 2. After sufficiently washed, th ol iter cover should be installed with cttenion dcected so that the 74.5%3 "0" rag is nat broken. (Refer to Fig. 3.56) 3. While instolltion is performed, all tightening serows should ke tightened repeatedly ond evenly. ster ctch compote Cc fiction se Gltch plete Cutch center ee080 Clutch pase pate CGtch pate rating pate loch fiet, ‘Guteh tod 20mm set rng 6X 18hex bolt 220003.5 CLUTCH 2 ‘A. Description ond operation of clutch ‘As shown in the previous figue, the clutch is @ ‘wet multtplate type ord consists of the outer clutch, presse plate, friction disc, clutch plote, ond clutch ‘center et, For transiting rotation from tho crankshaft 10 the tronaisten, the clutch has the role to engage or dlseagoge power. It also provides for storts and stope which do not reasonably load the engine. {Refer to Fig. 3.57) When tho right crankcase cover is removed, the ‘cuter clutch complet, Is exposed. To the outer clutch complete, the cluch spring deving tho clutch pressure plate i installed, The clutch plote is installed with the chtch friction disc between the clutch confer with fou 8X18 hox bots The clutch plate has teeth cut on the ins. Those feoth ore engaged with teeth cut on the ouside, of the cluich conter. Tho clich center is coupled) 10 the transmission main shaft by spline, Hence, it’and the transmission main shaft ore essentially a single Unit. The clutch plate, clutch conter, and clutch presare plate rotcte. (On the other hand, 10 the groove cut on the ex: terior creunfererce of tho outer clutch, the clutch friction disc fs coupled by the collor entering the groove ; freewheeling rotation with the transmission tnain shaft is obtcinod. Honce, while the clutch Is ccomected, the cuter clutch center, five clich plates, five clich friction dics, and clutch pressure plate ore cessontolly @ single unit tough friction exerted by the clutch spring rotation of the crankshaft Js trons ritted to transmission system. Inside the outer cltch, the primary dtiven goor. (Refer to Fig. 3.58) When the clitch lover is gripped, the clutch od [usr rotates clockwise, the ajustment thread is pushed ‘out by the squoeheaded thvead in the cltch adjuster fitted 10 the left crankease cover ; this Is pushed out by the clutch joint through the clutch rod. The clutch spring Is compressed ond the five clutch fiction discs ‘nd five clutch plotes become disengaged. Hence, tho rotary motion of five outer clutches and five clutch dees is not trnsmitted to the clutch center. (Refer to Fig. 3.58 ond 59) Fig. 2.57 Chih ine (compote veil) 3.58 Sectonl view af cuich Tig. 8.99 Sectoral wow of chick edjiment tread2% 3. ENGINE 1. Disassembly 1. Remove the right cronkease cover. 2 By removing the four 6X18 bolts for secuxing the clutch presure plate, separate the clutch fic- ion disc ond the clutch plate. By removing the 20mm sot ring, remove the clutch center. By removing the oil fter cap ond the 16mm lock nut secwing the oil fter rotor, extract the «il fiter rotor. 5. Remove the right primory dive geor 6 By pulling up the tun stop, remove the & mm uf securing the oil pump. 7. Remove the outer cluich Icomplete) together with tho oit pump (complotel. (Refer to Fig. 3.61) (cauTion) This i removed ot aright engle focing the trans= mission shaft. Attention should be dtected so that the tronsmision shaft is not scarred by pinching I Inspection 1. Clecrance between the clutch center ond the ‘nein transmission shaft Fig. 2.61. Removing outer cich and pp body ] Standard votie [Correction Cloaerce | from 0.03 10 | When cbove D.7emm, (0.0012 | O12 mm 1.004", to 0003") [ rotes 2. Damage, wocr, and distortion of clutch plate tooth. ‘Strderd valve | Covecton tat Detovion | Wihin O2 em | When cove 08 | Ose 109%, | corrector replace 3, Measurement of damoge, thickness, distoction ond ‘one sides contact of tho notch of the elich frl- tion de Strdord value | Correction tnt Theos Disonion | Witkin 02mm | When above 08") | 0.5mm 10.02", | epee Wah of Fi. 9.42 Meouring ‘hclwsr of etch fiton die3.6 Ol PUMP, FILTER, AND SEPARATOR 4. Fatigue of clutch spring [Storia vase] Coraction tt Free lerath Torsion te) 5. Mecsxement of clearance of the outer clutch notch end. the clutch friction disc [Smad wove | _carectin fit Geornce | Win 02mm | When above ‘Sooo | Osan a9", rope I, Assembly 1. Tho outer chtch and the oll punp should be coupled by the pure plunger and tho unit should be coupled ct @ right engle to the main transmission shoft ond the pump fitieg stud bolt. (Refer to Fig. 3.65) Tighton the oll pump rts. Install the right primary chive geo, Install the il iter roer. ‘Couple the cltch center 10 the spine oF tho ‘mein transmission shaft ond sot by the 20 mm sot tg 6. Five cltch plates end five chitch fiction discs should be placed altomately. Fit tho citch pres: sure plate and place the clutch spring; tighton thom by the fou 6X18 bolts (CAUTION) When the chich prossue plate is instolled, the Clutch joa should not bo noglocted. ‘When the tightening screws of the right cranke case cover have been tigttened, assenély of the clutch fas boon completed. 3.6 Oil pump, filter, end separator A. Description of cil pump The pump is @ phnger type. It repeats the func- tion of sucking and punping cil by the length of stroke Cf the plunger through mutual relation of reciprocating tmofion of the pump plinger ond the section valve Isleel ball, (Refer to Fig. 3.67) ia. 3.68 Coupling clth sping Fig. 2.47 03 pump and contigo fier2 3. ENGINE 1. Lubrication circuit ol FuTER conmecrise Roo ocKeR ABM en TRANSMISSION HAIN SHAFT Fig. 3.68 Ol pry Oil stored in the crankcase chamber Is ckavin up by the oil pump ond fed from tho lower crankcase 10 the upper cose through the oll passage of the off filter cover to the oll fiter. Impurities ia tho oil aro separated by centrifugal frce ot the ol fiter. Clean cil is fed from the upper crankcase to all ccokshoft bemrings for lubrication When oil enters the right ‘ond left crankshaft cuter rings, it 1S divided into two ports; one is fod to the rolor bocring and the other ‘enters the cankshaft for force ubrcating the cronk fend of conecting rod the piston ends of eomecting rods ore lubxicited by splashing ll from tho oil passage in the upper crankcase ts vided Into two in tho right and left at the rear of the cylinder stud bolt and is fed to the cylinder ond cylinder heod. At the right side, fom the ight cinder head cover fat the left side from the point bose), oil is fed t0 tho camshaft ond lubricates tho Ccanshaft rocker arm; it then falls from the clearance ‘round the com chain ot the center into the crankcase. from one side which was dlvided into two ot the left side of the upper case follows the oil pos- soge In the crankcase, enters. the min trnsmis eo @3.6 OIL PUM, FILTER, AND SEPARATOR This oction hbicotes ll free goars and the cl alls Ieto the conkers, For other goors dnd bearings, ol lm formed by ofl choot ond mist performs lubrication Disassembly Remove the right crankcase, Remove the cil for. Remove the righ! primary drive gecx Seporote te pup body together with the clutch (Refer to Fig. 3.51) 5. Byremoving the 26 mm retainer, remove the pump red coupled In the outer chich, (Refer to 3.69) 6, Extract the pump plunger pin ond remove tho plunger ot the tip of tho pump rod. (Refer to Fig. 9.70) 7. Tho following ore included in the pump. (Refer to Fig. 3.71) Intake side + Outlet valve guide (completed ..seseeeT each + 11.5x2 "0" ting, sect @0ch + Suction valve spring, 1 each + #10 steo! bal. 1 each Exhaust sido + Suction valve bol. 1 each + Suction valve bolt posting... ses} e0ch + #10 stool bal. : 1 each + Pump filler scroon, 1 each + Pump gestot 1 each ML. Assembly 1. Assombly 1s the reverse order of dlassonbly. (CAUTION) [ol Whethor or not the ol pup is operating securely is confirmed by loosening the cop nuts holding the cylinder head cover at the right ond left sides ond rec. Uf oll is visble, the condition is acceptable.) (Refer to Fig. 3.72) {by When oil circulation is not favorable, inspect the following poin's: (1) Tighnoss of oil pump. (21 Pap gosket tbroken Fig, 2.69 Removing pomp red Be roriah herr Fig. 3.71 Pomp pore Fig. 3.72 Conening 0 chesoton~ 3 ENGINE Fig. 3.73. Ot fer ‘FER ROTOR 0 cn ures cap Fig. 8.74 Of le pore Fig. 3.75. Removing the ei ter exp (8) Clearance between the purp ond plunger. (Ploy by weer! (4) Steet bail tbrokon or seized.) (51 Mesh of pump fiter screen (blocked. (6) Oil fiter or oi passage tblocked). (el Inspection should be performed with sufficient ‘attention becowse wrong librcation docroases por formance of the engine, ond causes seizwe, noize cond other trouble. B. Operation of oil filter ln ©B 125 ond 160, trouble concerring the engine cil 1s prevented by double fiteng, wie meth and fer. (Refer to Fig. 3.73) Before being sucked up by the pump, cil is fltored by the fiter screen ond cil impuitios cre eliminated by separotion filtering using contifugel fore, ‘This cil fiter ot the same time collects ot input fies at the ribs of the oil flter cap by gravity, gives collective flow to oil, ond supplies clean cil to ecch wat Disassembly For the operation condicted when the crankcase ‘cover is romoved, refer to Section 3.5.1. The following section describes the operation conducted When the crankcase cover is not removed. 1. Remove the oil filer cover. 2. By using plier, clip the rib of the ofl filer cop ‘ond full cut in parallel. (Refer fo Fig. 3.75) 3, By using « screw diver, bend the 16 mm lock washer from the groove of the lock nut. 4. Pul out the lock nut by using the 16mm lock ‘ut tool and remove the lock washer from the crankshaft, 5. Noxt, pull out the oll filer rotor.2.7 CRANKCASE Assembly 1. Aftor cleaning oll parts of the fiter and oi iter cover guide, the disassembly order is reversed for assembly. (Refer to Fig. 3.76) 2 Proper tightening of the 16:mm lock net and lock ester secwing the oil iter should be mode. 3, Assembly of the ol iter cap should be performed flatly. C. Operation of ell separator The oil separator is installed in the front section of tho lower crankcase, by the right ond left cylinder bores ond just under tho cronkshoft. It reduces the ‘mcunt of oil splashed by rotation of the covnter- weight of the crankshaft, prevents oil penetration, ond controls the el temperatuo rise. (Refer to Fig. 3.77) “Tho upper ond lower crankeases ore of lightweight alloy ond con be separated cf the surfoce which includes center lines of the crorkshalt, transmission shoft, and the Kick storter spindle. In addition. ot the left frat section of the C8 125 cond 160 cronkcare, the starting motor is supported. In the upper sxrface of the upper cronkcase, the cylinder stud bolts cre inserted. At the contact surface swith the lower crankcase, nine 8 mm stud bolts exe incerted, ln the lower crerkcase, 8mm ond 6 mm stucbolts lone each) ore inserled. (Refer to Fig. 3.78) The lower cronkcose is equipped with tho oil sopo- tor, lower crankcase cover, ond two drain plugs. (Refer to Fig. 3.79) sta Fig. 8.79. Oro plot1 losing boy from at coms Fig. 2.89 Osssombilog tating wavtor side cover ENGINE 1. Disassembly 1. Drcin oft in the crankcase. 2. Remove the cylinder ead ond cylinder 8. Soporate the, loft crankcase cover and AC gone rotor. 4. Seporote the rit cerkcase cover, oil ter, ond clutch cil pump. 5. Remove ene 8 en nut and ono é mm nut from the stud bolts ot the upper port of the upper crankcase, & Remove seven 8 mm nuts, IWo 6mm rus, throe 6X35 bolts, and two 4% 55 bolts from the lower cronkeate. 7. Aftee removing the storing motor side cover, remove the 6x22 and 6X26 bolts on tho right hand sido of the crankcase which mount the starting moter. 8. By removing the 635 bolt on the left hand side ot the starting moter which is supported by the crankcase, the starting motor may be removed. 9. While the key on the goor shift arm is raloosed from the stift chum, dismount the motor. (Refer to 3.81) NL Astombly 1. Assembly should be pocfermed with attention pold 10 the following polls: + Inspect the contact surfoce of the crankease for leaks, scars, or other domoge and odequately clean the crankeose + Apply ligpid packing to the contact sixface of the case 7 offer this is dry, essombly should bo performed. Ml, Disassembly and installation of storting motor 1. When the starting moter is dsossembled ond installed without disassembling the crankcase, clten- tion should be directed 10 dotermine if tho case is domoged. 2. For disassembly, doin engine oil and remove the left crankcase cover: disconnect the starting chain Of the joint section, 3. Remove tho starting motor cable. 4. Remove wo 5X12 pon screws securing the starting motor side cover. (Refer to Fig. 3.83) 5. Remove the 6%22 bolt of the upper ease ond the 6%28 bolt of the lower cose ot the right of the storing moter.3.8 CRANKSHAFT, CONNECT 4 Remove the 6%35 bolt of the lower craskease front section. 7. Pull cut gontly ond ia line with the crorkcose. 8. Assonbly Is the reverse order of disassembly. 3.8 Crankshaft, connecting rods, and pistons ‘A. Description of crankshaft ‘The right ond left cronkshafts ore of carbon steel cond the counterweights ae of nickelchyem= molybdo- fm stool. Each crnkhaft is constructed by press Inserting the counterweight lato the crankshaft. The contr cronkshoft is prss inserted and coupled, The cronkshalt is supperted ot four points, ene ball bearing rd tires roller bearings. The sprocket of tho com hein it cot inthe crankshaft ond crives the cam shaft (Refer to Fig. 3.84) All bearings ore secured fo the crankcase by guide pins. In the conter crank cuter ring, on ol hole which matches the cil hole of the upper crankcase is the ‘ide : the guide isin the form of © pipe Oil punped by the cil pump is divided ot the Conter crark over Fng cil hole ; one supply Ibsicates the roller bearing ond the other is stored in the cuta- woy of the counterweight side. surface for fooding from the weight cutoway groove to the interior of the crank pin by contifugel force. This lubricates the ‘ronkshoft end of the comecting rod. (Refer to Fi 3.85) 1. Disassembly 1. Drain oll from the crankcase 2. Sepaxcte the cylinder head and cylinder. 3. Separate the loft ond right crankcase cover. 4, Soparcte the AC ganerotor end clutch ofl pump. 5. Hence, dsassonbly of the crankcase is performed by following Section 3. 5. ING RODS, AND PISTONS 2 po ceancmeicar “CentER CRIA OUTER RING 5° Creeat ots ord neau Fig. 3.90 Fort of comecng rod 3. ENGINE N. Inspection 1. Clearance of the cronkshoft 6305 special ball bearing should be measxed at the value obtained hon the cronkshaft is set on V-shaped blocks and the bearing Is moved up ond down ond 10 the right cond left ‘woraird vole | _Comecton lit ‘il ‘eae thon ‘When over hone | Dosen Oi mm Loos", oor", ‘replacement shoul be: made fad ‘Whitin 0.01 10 | When over ‘cooronce | "0.025 9m 0.05 m0 1002", ~ SEI node 2. Meceaement of crank cuter ring and loft main bearing clearance, ‘Stndord vake | Canection bat ‘eat ‘Wie 0006 to | When over ‘Seorence | “OS\d am O05 ms"1.002", 0002" 0005" | fepincemert ML, Installation 1. The upper crarkeate should be inverted and the crankshaft complete should be ploced on it, Guide holes of beorings should be matched ond the lower crankcase shoud be set on the essonbly is the reverse order of dsassenbly. (Refer to Fig. 3.89) B. Description of connecting rods The comecting rods are of molybdenum steel and have on Hshaped section; bushings are not ot both tho crankshaft end piston ends. The crankshaft. Is polished ofter cose hardening and mounts the roller Without race, The rellor (4% 13) is held by the roller rotoinor mado of special cluminum lloy. Stoggered rollers ere usod in ordor fo increase the load copacity. (Refer to Fig. 3.90)3.8 CRANKSHAFT, CONNECTING RODS, AND PISTONS Inspection 1. Meossrement of deflection ot the piston end of the comecting rod. (Refer to Fig. 3.91) Stood wae | Covection it Detection inet shel bo wmode 2. Measurement to determine if the connecting rod ‘ends ore correctly aligned end porlll is cbtcinod by measuring the dference of inclination of points 50mm (2.0°) away from the center when o 100 mm (4.0") bor with the samo thicknoss a5 tho piston pin dlometer is Inserted into the bore of the Piston end ond twisted to the right ond loft, ond ‘when the bar is rotated 90° end ogoin twisted fo the right and left. (Refer to Fig. 3.92) ‘Sordod vase | Covecion tint Level of | Les hon than) | When over poral lozem 0004") | C1 wn (047, feplaceront ‘howd be ede, Twit es ton ‘bam, L0006"% C. Description of pistons The piston Is on ovol type which is heat rected end worked offer casting with chino alloy. Tho piston, undor high temperature, swells in the pin roc tion and clearance with the cylinder ts decreased. When the piston ond cylinder ere fted, close ctten- tion should be paid to the clearance. In edsition, in the C8 125 ond 160, for increasing the compres+ sion ratio, the piston head Is cut for avoiding intor~ ference between the valve and piston. (Refer to Fi 3.93) 'V._Whon clecrence betwoen the piston and cylindor Is too large + 1. When the piston reverses direction ot the top ‘ond bottom dead centers, shock is intense ond o slapping noise resus. 2. Oil penetration to the conbuston chamber occurs, J. When tho cleorance 1s too stall: 1, Formation oF oil fim inside the cylinder doos not cccur and seizure rests. 2. Even when solzue does not occu, the output 1s decreased since friction loss is increased. (MANDERLECTION Tia, 891 Mocuranani of maxinom defection ot he ‘ison end of comecing rod Al LORGREE OF PARAUFUSH Fig. 8.92 Meomonen! of poalel condiion ot the Paton end of the Comectng vod 3:94 Macuiog clatence between piton ond eyinder6 2 ENGINE |. Disostembly 1. Remove the piston pin rotciner from the removed crankshaft and remove the piston pin, (Refer to 3.95) 2. When the piston pin is removed, attention should be directed s0 that tho ring is not twisted. (En ployment of the plston ring too! is recommended. (Refer to Fig. 3.96) Inspection 1. Before cleaning, carbon oxhering 10 the piston head oF sing groove chad be removed with out the piston being scored. (caution) Sandpaper should ot be vied for removing 2. Meossxement of ouside diameter of the piston (Refer to Fig. 3.97) Se on eins ve _[ Goin I [ihrer on Mt =| =| 5 tess wi or aaa Fig. 9.98 Mocsuing rag ereove when @ new piston 3, Moosuroment of the rag groove clearance when © new piston ring is fitted. (Refer to Fig. 3.98) ‘Stondord volue | Coxtection init a | aa Top ro | O04 19 007 mn, | When over Coorg? 100028") | 015mm C0060", Feplocament ‘hod be made, 001 10 004mm, and cing — | OBA42 O04, | Some or shove 001 10 004em, | Hoooe? sooo 08 rng Some 01 cbove (CB 125, 160)4. Macaurement of piston pin hole (Refer to Fig. 3.99) ‘Sida woke | _Coreron fet tore Wen chove sven shoud be ‘mo. 5. For oversize pistons, there are three at intervals of 0.25 mn, 6. Measurement of the piston outside dameter. Sond vole | Conecon tnt ‘cane! ee (CB 125, 1601 Wh, Assembly 1. At insolation, the row mark ot the piston head should be faced in the forward direction. (Refer to Fig. 3.100) (caution) Core should be token since reversal of direction ‘causes the piston heed to contact the valves, 2. Fer fiting of the piston pin, piston, ond piston fend of the comecting rod, @ normal temperature floot system is employed, Hance, iting should be sich that light manual pressure ot normal tom perature is sificient for insertion, (Refer to Fig. 101) ‘Avoid the use of piston rings which have lost thoie tomper : use new piston rings. D._ Description of piston rings Of the steel rings, bard chrome plating Is opplied 10 the top and second, ond paikeizing is applied fo the oil ring. The top ond second rings ore compression rings end the oll ing “Is for scroping down oil en the cylader wall, All transit piston heat to the cylinder well (11 As the top ting is expecially opt to wear die to high temperature, hard chrome plating is applied fer increasing weor resistance, 12) At the second ring, the contoct surface with the cylinder Is reduced for increcsing the tension per smooth fing is cbtoined in a short unit reo period. 19) The oil ring has on indented shape suitable for seresing oil down, 3.8 CRAN-SHAFT, CONNECTING £005, AND FISTONS Fig, 2.99 Messing piston pn tle ARROW mann Aston Fig, 8.102 Sectional view of ptm ageA 8, ENGINE 1. Inspection 11. When the piston ring has been removed, it should be fitted with the gap operoximatsly 15.mn 16") from sket of the cylinder ot o right angle to tho ‘center line, Measurement of the gop should be mode with thickness gauge. (Refer to Fig. 3.108) ‘ondord vave | Correction Bat Tép tng | O18 19 O5en, | When over {08 to 014 | 0.8mm (034, | fepacanest ‘hos be made. Bod tng | 0.15 tp 0.35 _ its? to avery | Some o# sore Ol tng | 010 10, 0.300 itgoaye ta aries | Some Fe 2. Torsion of the piston ring is measured with @ ten sion measuring instrument as shown in the fice. (Refer to Fig. 3.104) ~~ Top ring OS540.12K9 Wien over Sh Ny; game [OER [sam wane wszZ SZ o7eaarate as os orme [TREES y [soe a coe pores moTesoe I. Replacing piston rings QZ sZ 1. When @ psn ing is reseed, it oud be lao = “wercooo” fitted 10 the cylinder. Inspection should be made — to determine if the gops pf the top ond second TGS hale pe oe a, the oil ring between 0.10 00391 to 0.30 mm LONI. IF the gops are somewhet less, they should be dressed with a fle (CAUTION) {ol When @ gop is cessed with a file, oqust- iment should be made ot a ight angle due 10 right angle fiting. (b) If the piston ring gop Is 00 snail, soiare between the ring ond cylinder occurs due to thermal expansion; If the gop Is too large, cil penetration or gas leckage cous. (Refer to Fig. 3.105)3.9. CAM CHAIN TIGHTENER AND CAM CHAIN, GUIDE KOLLER 2. When piston ing is set on the piston, ony catch between the ring ond the groove may prevent ‘smooth operation. It is necessary to ingpact the stotue, when the ring i fied 10 the groove, by rotating the rigg croved the cicunference. (Refer to Fig. 3.106) \Whan th piston cng is csenbled, attention sould be drected 20 thatthe upper ond lower face OF the ing oe proves. The merufoctre’'snerk is way stonpod on the ring. (Refer to Fig. 3.107) WF ossonbly i pforned with the sppar ond lower sufoces improper, ol may be sicked up. 4. Wan tho piston rag is bong istaed, employ: innt of icon fing tol Fal ebsin proper and single operation. (Refer to Section 3.8 Ci) 3.9 Com chain tightener ond cam chain gui roller A. Operation of cam chain tightener ‘The cam choin tghtener is sed to tighten tho com chain from the outer sido with the com chain guido roller ia between. [As shown in the fig, the tightener push bar is cxtomatically pushod cut by the cam chain tightener spring end supports one end of tho tightener which performs a see-saw maton (with tho cam chain guide roller pin os © suppoting point. (On the other hand, the tightener roller is pressing the cam chain, Whon the tghterer sot bot I loosened, the tighterer push bar automaticaly stretches tho com chain by tension of the spring. (Refer to Fig. 3. 108) |. Disassembly 1, Separate the cylinder head ond cyngor. 2. Apply 0 thin wite guido to the com chain 3. Remove the two 6X18 bells mounting tbe cam chain guide roller ond separate the cam chain fightener from the cronkease. (Refer to Fig. 3.109) fig. 9.108 lnpectng ton rng by rolang cro Fis. 2.107 Confing veper ond lower surface ofthe ce rd cay cians She Ee ch GHAR TIGHTENER Fig. 8.108 Cam chan tihtenor ig. 2.107 Removing com chain til” 3 ENGINE 4. The com chain guid erller is coupled to tho eam choin tightener. (Refer to Fig. 110) + Com chain guido roller + Com chain guide roller pin + 12m set Fg 5. Whea thé 6mm thin nut is leosenod ond the Tightener sot bolt Is removed, the tightener push bar coupled to the cylinder is seperated together With the tightener spring from the cylinder. Ml Installation 1. spect while istalling end assemble In a reverse order of dsossembly. (el) Damage and deformation on the eam chain guide roller ond the com chain tightener salle. 2. The tighioner pwh'bor should be losered together ‘with the tigktener spring fully Into the eylindar ond tightened by the tightener bolt. IF the tightener push bor protudes excessively, the cam chain Is stretched ond joining of the chain becomes lfc. (Refer to Fig. 3.111) MI. Cam chain adjustment 1. Tho T mark of the AC gonerator rotor should be mmotched to the exrow mark of the stator at con Pression top deod center. 2. When the 61mm nut ond the tightener sot bolt ‘ero loosened, the can chain is automatically stretched. 3. The tightener sot bolt should be tuned in and soared by tho rut. (Refer to Fig. 3.112) Fig. 3.112 Adstog com chin3.10 _ TRANSMISSION 3.10 Transmission a 8X 25X8 oll seal 15m bearing basting A Nain tat fouth geo ein shatt third geor 20am se tng vn ach 20. test washer Awnn2 00h Main shft sacond goor Treanion min shaft £6904 bot Beating fall bearing 2 fing Aov2 0008 @8e0900080 ‘A. Description of transmission The transmission of the constent mesh type, fou speed forward, employs the linit type reciprocating system. The performance of the tronsmssion is very. lar portant at it transmits power from the crankshaft though the clutch, with the relfionship betwoon the reqped torque and speed corresponding t0 the load condtion. @e899e8909 ext hex bath Drive plot fing pate 167 dive sprocket 20x82%9 Mods TC oll sal Trani coustrsatt CCouneshft thed gear complete Counters! second goor CCounteshftlow gear tconpete! 15mm boaring bashing 8 ‘nm guide ln2 3 ENGINE B. Transmission system 1. For neural C1 gacr end C3 goor on the countertholt ond M2 gear and M 4 geor on the transnisson min shaft ‘ee all froo in tho rection of rotation Rotation transmitted from the clutch canter to the transmission is transmitted by the main shoft ond M 3 ‘gear to the C1 gear ond C3 gecr, fee at the comer shaft side, However, C2 ond C4 gears transmitting rotation of the countershaft side are not coupled by dowels; rotator is not tronsmitted 10 thom. Hence, the countershaft does not rotste and power Is not trasmitted 10 the chive sprocket. (Refer to Fig. 3.114) 2. For low {fest speed) By stifling operation, the ft fork of the gear shift sum couples the C2 gecr on tho comtershalt to the C1 goor-by dowel. Power is transitted to the C1 (scr From the transmission mein shoft end by dowel through the cauntershaft ; the dive sprocket is (Refer to Fig. 3.114) 3. For seccnd speed M3 goar on the main shaft is connected, by oper: ‘ation of tho shift fork in shifting, t0 the free M2 goar by dowel ond drive is tronaitted from the main shaft trough the M3 oor, M2 geor, and the comer: shaft to the dive sprocket, (Refer to Fig. 3.115) 4. Fr third speed The C2 goor on the countorthalt is dowel con: rected 10 the free C3 gear by operation of the Sift fork in shifting : dive is tronsmitted from the ‘moin shaft theough the order: M3 geer, C3 geor, comtershaft. (Refer to Fig. 3.116) ig. 3.118 Trosmision of the thd spued3.10. TRANSMISSION 15. For the fourth speed ‘Tho M3 gear on the main shaft is, by eperation cf the shift fork fa stifting, dowel connected with the free M4 gear and dive is transmitted from tho rmoin shaft through M3 ond M4 gears to the coupled comtershaft (C4 gear omitted. (Refer to Fig. 3.117) 1. Disassembly 1. Following the same erdor os for the crarkshaft [Refer to Section 3, 11), separate the upper ond the lower erarkeose ond remove the trersission nit. (Rofer to Fig. 118) Inspection 1. Measurement of clearance in tho axiol and radial rections for the transmission main shaft ond countershaft bearing. (Refer to Fig. 3.119) ‘Standard vate | Covecton fit ‘eal et thon When over ‘Georonce | 805m Dm L004", voz" replacement, seal be made, Raat 001 te 0.026 m | When over ‘learonce |" C0004" Yo 001%) 0.05 mm L002", teplocenoat tout be. made 2. Moosuring ploy on the geor teeth surfoce of the tronaission unit. (Refer to Fig. 3.120) ‘Stndord vale | Covection lint Tey 1089 19 0.1780 | Won over (0034710 0074 | 0.2m L0078"), teploconent shoul be made 33 Fig. 8.118 View of tronaniion with lower eronase parsed Fig. 2.119 Meartog-Searonce of the arson th beorng Fig. 2.120 After the ranuniien ond eretshalt ore Coupled, the lower eretcazo ould be etched“ 3 ENGINE UL, Assembly 1. Clean cll trarsmission geors ond inspect for do- mmoge or soas. Subassomble, (Refer to Fig. 3.121) Fig 3121 Ale noun od coil 3.11 Gear shift othe A. Operation of gear shift ‘When the gear shift pedal is dopresied, the gear Shit spindle is tuned and the geor sift orm presses the goar shift dum pin ot the right end. of the goor shift dum by the tip of the notch; the dum rotates. ‘A groove is cut of the conter of ‘this shift dum cand the shift fork guide pin fitted to the geor shift fork is inserted in this groove. Hence, according ta See rototion of the chum. the gpar sift fork moves tothe moving the shift gece: The geor shift spring functions to rotun the sift pedal 10 the orginal postion and prepares the pedal for the following operation. (Refer to Fig. 3.122) 1. Disossembly 1. Following the sone operation os that of trans mission disossombly, divido the cronkcase into. the Upper ond lower ports. 2. Pall up the ear of the lock washer of the gear shift coupled to the upper-crankease and remove ‘he shift fork quide pie. (Refer to Fig. 3.123) 38. Remove the shift chum guide screw and the shift ‘mm guide collar ot the upper surface of the upper crankcase. (Refer to Fig. 3.124) 4. Remove: the neutol switch rotor and stator coupled to tho loft end of the shift: dum. Fig, 2.124 Removing shit rum gue sowRemove the 6% 18 bolt of the shift dunn pressing the shift cum limit step plate and remove the liit. (Refer to Fig. 3.125) Remove the shift drum lathe dtecton of tho right cronkease cover sido. (The gece shift chum lint plote ts seowed by 6314 pon scrws.) At the lower crankcase, the goor shift spindle togatter with the gear shift return spring ond the geo" shift spindle sido lint ore coupled. Hence, by removing the set tng with snap ring pliers, tt con be removed toward the right side of the caso. (Refer to Fig. 3.126) ‘or removing the gear shift reken sering, @ wrench cor a deep box wrench should be employed. ‘Assembly Insett the gpor shift dum at the right side of the upper crorkcate ond assemble the gear sift fork in the coxkcase with cltetion directed to. the division, (Refer to Fig. 3.127) Mount the chum with the shift guido collor ond Azzemblo tho shift fork with the gear shift fork tide pin ond postion the ear of the lock washer. (Refer to Fig. 3.128) ‘Assenble the neutral switch roter ond the starter. ‘Assonble tho shift drum limit; this completes upper core cxsombly. ‘Assonble the gecr sift return spring inthe lower crankcase. ‘Tho gee shift spindle should be inserted toge- ther with the return spring ct tho right side of the lower crankense, The gear shift spindle sido init should bo inserted ot tho left side and the 12 mm sot ring should be employed for securing. 5 ean suet Fig. 2.127 Divilon of-ae0r eft fork Fig. 3.128 Anenbing of alt fork ude pa“ 3 ENGINE ich Toor 8 SHIT Fo cine rr oni oul eh RUM stor ‘GEAR SFT Fac ls my Oe uM ST0e PLATE Lo Se oho cube scaew) iu OM SURE COU Fig. 3.127 Gear aft crm fork line TR eae i : aie ecg sane hex sianten SNe! leg stanre Fig. 3.130. Kick sorter Fig. 3.131 ice wovtr exenbiy Fig. 3.132 Auonblng lek starter sng 8. Assomblo the cronkshoft with tronsmision gears in the uppor case end tighten the lower cronkeate. 9. Hence, ossonbly can be made according 10 the ‘sembly order of tho crankshaft. (CHECK THE FOLLOWING) + Beat gear sift + Uneven wear shift guide pin + Woar and play of stift guide roller + Fatigve of goar shift spindle rotun spring + Tighinoss of retun spring pia 3.12 Kick storter A. Operation of kick starter As shown in Fig. 3.130 and 3.131. tho stortor ‘xs @ pinion ratchet system which engages the pinion with the goor and ekivos through the Kick starter ratchet. (Refer to Fig. 3.130 ond 3.131) ‘When the foot is released from the kick starter, the kick stoter ratchet retuns by the forco of tho kick starter pinion sot spring ond is stopped by tho kick starter spindle bushing the pinion rototes regardless Of the kick starter spindle. 1. Disassembly ond ossembly 1. When the upper ond the lower carkone ae separced by following tho dsassonbly order of tho transmission, the bck srt spindle Is exposed. 2. AF essonbling, especially of the Kick starter spring, operation is easly performed if raforence is mado 10 the figue. (Refer to Fig. 3.132)2.13 caRbureror 3.13 Corburetor Fig. 2.193 Sectional vow of eoburstor A. Description of carburetor 1, Main system ‘ir from the cic cloner Is fed from the intake through the tote valve ond main boro, and is sucked into the engine. By ths cir how, a negative presse is produced ot the needle jet ond the fuel of the float cater posses through the moin jet ond enters tho needle jot holdor. It thon passes through the oie jot ont is mixed with the air entring through the hole round the eed jt olde, passing through he cleorance between the need jet ond tho needle, ond under the throttle valve. Here it is mixed with the oir and tuned into vopor for engine inthe. (Refer to Fig. 3.134) 2. Slow speed system (Pilot system) ‘The cir from the lntoke passes cutsido tho. ir screw; itis adjusted by tho oir screw. It enters tho slow speed je! from tho holo of the slow speed jet ‘ond is mixed with fuel coning from tho fuel hole at the lower part of the slow speed jel, becoming a densely mixed gos. The mixture posses to the bottom (of the throttle valve ond Is mixed with the main oir from the intoke for engine intake. Adjustment of tho the mixture ratio ofthe slow speed system is generally bioined by ocusting the cir sew (a heavy mixture by turing clockwise ond a thin mixture by tring countor- clockwisel. When a wide range adusment is required, the slow speed jet should be chenged, obtaining a heavy mixture by a larger number ond a thin mixture by @ smaller number. (Refer to Fig. 9.135) OS ae elt SS FEE UE one sonra 8 ATES Fig 134 Man sysom Fig. 2.195 Sow weed eytem« & ENGINE Fig. 2.197 Chote Fig. 3.138 Main jt pesoue ser) esous ier woLoER—~ ig. 8139 Needs [or 3. Float chomber As previously stated, the carburetor produces mixed {905 suitable by opening ond closing the throttle for cll speeds of the engine. Hence, it is necessary 10 oop the uel level constant; the feat chamber plays this role. Fuel fed from the tonk passes though the passage between valve ond enters the float camber. The floct becomes buoyant os fuel enters and pushes p the valve through the foot cam ; when tha valve Contacts the voive seat the flow of fuel stops. When the level decreases die to consumption of fuel, the float crops conesponcing to the change and the valve ‘opens for allowing fuel to enter the float chorber. By repeating this operation, the fuel level is held constant. (Refer to Fig. 3.136) 4. Choke ‘As shown in the figue, tho choke valve closes at the postion where the choke lever is pushed up ond ‘pens at the postion where the choke lever is lowered. (Refer to Fig. 3.137) B. Operation of component parts 1. Main jet The main purpose of this unit ollows adjustment of the mixture ratio by controling the flow of fuel with ‘he throtle fully opened. However, the jet infuences tho mixture ratio, not only ot ful role, but clso ot other points. (Refer to Fig. 3. 138) 2. Air jet For insuring thot the mixed gos does not become ‘excessively heavy at fully thottle ond high speed, ‘ond that it does not become excessively thin at redo: ced throttle and low spoed, bleeding cir is fed into the needle jet holder. The air jet contols this oncunt Of cir. At a certain throttle opening, © larger cir [et produces o sraller diference of fuel flow between igh ond low speed: the flow decreases. 3. Needle jet ‘This unit reodsts the odusted fuel by the main [et of full thottle and medium speed. Adjustment is sivultaneously performed with that of the need Tho hole diometer is highly precise, (Refer to Fig. 3.139)4, Jot needle The jot needle, with the needle jet, adusts the rixture rotio ot midthrotle. The jot rood with long taper section is float fited ot the canter ole of the throttle valve ond the toper ct the tip enters the neede jet. According 10 the position of the throttle valve, the flow amount fuel Is increased or decreased ttrough the toper ond @ sueblo flow coneant (@ sitble mixtve is cbtoined. The [et needle has five grooves for postoning, Lowering the pos tion from the fest sep to the fifth, donsity of the rrixure becomes heavir. (Refer to Fig. 3. 140) 5. Throttle valve Tho throttle valve adjusts the cir fed to the engine for setting spocd end output. In adition, it also codjusts the mixture. There Is @ cutawoy at tho oir intake side of the throttle valve ond by changing the size of the cutaway umber) the negative presse is changed the fuel flow and mixtu ratio is changed, Howover, the cutaway range covers mainly from iding to oround 1/4 throttle, with tle influence above 1/2 throttle. (Refer to Fig. 3.141) 4 Slow speed jet The sow speed jot controls the fuel Now at ing cord low thottl, and produces @ mixture with the cir ‘coming from the oir breeding hole ; it vaporizes tho fuel. (Refer to Fig. 3.142) 7. Air screw The cir screw conkols the cir flow entoring the slow speed system. By odjesting oir mixed in fuel coming from the slow speed jt, it produces a propor rrixure ond ejects the mixture from the tip of the slow spood jet. (Refer to Fig. 3.143) 2.13 canbueeToR Fig. 2.140 Jet node Fig, 2.141 Thole valve 312 Sow speed [at ® © 1B Ke stowarmors stor scxtw pan scxew Derone vave ENGINE Adjustment 1. Adjustment of high speed In the range from full throttla to 1/2 trotle, oo iusiment of the mixture rotio is made by the main fet. (Refer to Fig. 3.144) Determination of mixtue density is obtainad by the following methods. 6. At fuel thottl, ifthe spoed is eeduced by sightly closing the choke, tho mixed gas is 100 thin la such caso, the main jet should be replaced with a lauger one end a conction check mad. b. If speed is rediced by closing the choke, the imcin jat is suitable oF is too large. Determination Js mode by the following methods (11 When the main jot is suitable: When a smalie nnoia jot is employed and speed dacraates, ond when the choke is slightly closed ond spood ie creases, the new main jet (smaller crel Is too small. Honce, the original one is suteble. (2) When the main jet is 100 large: Gradblly smcller main jats should be employed in replace ‘men! vntil the status daserbed in section (I rails 2. Adjustment ot mid-throttle Adusiment of the mixtue in @ range from 1/8 to 1/2 throttle is mainly obtained by the jot nocd stops fond the cutaway of the throttle valve. However, as the cutway of the throtle volve infuences the range below 1/8 throttle misadjustment is apt to ocaw. For meciom speed adustrent, os long as accelora- tion chxactersics are maintained, employment of smallor jot needle is mote practical. (Refer to Fig. 3.145) det neade (1) If ctnormal bla&k -sncke is ejected during ‘operation at modlum speed, the mixture. Is too heavy: the jet need shoul be pulled yp one step 12) During engine broking after accelerating oF ‘citing when the engine sounds rough, the jet redie clip should bo lowered by ene step. b. Cutaway of throttle valve When the tvottle cvlowoy with a larger number Js employed, the mixture becomes thimer and vice versa. Tho throttle vovle covers not only medium speed, but also low speed in the range of adjust ment: token while odjsting (1) Except for special coses such 0s racing, rop- lacement of the cutaway is not requted,3.13 CARBURETOR 3. Adjustment ot low speed The mixture covers the rage from 1/8 throttle to ‘ding. Adjustment is mado by the or scrow cutaway aed the tote vol. (Refer to Fig. 3.146) Air scow ‘Adusiment of the sixtue ot iding 1s made by tho oir serow. Ifthe screw is tuned clockwise, the mish becomes beaver if th sexow Is timed cainterclockwise, the ixive becomes. thinner However, the dfusimet of the eit scrw shuld be rrado with atlontion dectod nt enly 10 icing bu dio to stating ond ecceleration. Ako obsowve runing porfornence in relation 10 density of the mixture oF the poiet whee the thy open b. Throttle valve cxoway Noor 1/8 tote, the density of the mixture semetines comot bo compensated by only the cir szzow, In sich cox, ifthe mint is 100 heavy, 4 valve with @ lage ctawoy number shoud be employed (or vico varcl. This adjustment of tho ci screw is obtined. + In CB125 nd 160, rploconent of the screw valve is not reqited since the cxtawoy Is com- pletely dusted et A. Adjustment of stondard fuel I As shown in Fig. 3.145, the fuol level Is. estar bilished at hoight th) from the main Lore bottom ; it is diferent for every engine, It is rather cific to measre the actus! fuel level Hence, ths is determined by the float height. Ad: justment of float. (Refer-to Fig. 3.147) 10. The carburetor should bo turned upsido down and slid hexizontally. By pushing the foot vertically and lihily with the tip of a fiager, find the postion where the tip of the floct valve and the float am contact slightly & The diflecence between the height of the tip of the floot ond that of the carburetor body is equal to h. If this height isnot acceptable, edjustment should be obtained by carefully bending the floot bof Pw22 9.5mm 678") Fig. 3.147 Moorrng andor Tol level2 3. ENGINE (CAUTION) Tho spring sot ot the tip of the float valve is eprossed easly into the valve by pushing. This ccbscures the position where the valve essentially closes. Hence, careful attention should. be pod hon observing the contact point of the float erm nd the floot valve, Adjustment of the throttle opening of the Fight ond left carburetors Two cxburtors ove employed. The adjustments of both must bo tho samo, Adjusiment should be made Cot © pot somewhat cbove full close (approximately Timm). Hence, the openings of both the right ond loft corburator become the sane. ‘Adjustment should be boned, ofter the carburetor is removed from the engine, with the slow speed jet screws on tho right and left sidos. (Refer to Fig. 4.148) Fig. 3.148IV FRAME 4.1 Handlebar ‘A. Construction of handlebor Tho complate handlebar is mode of pipe ond is iestlled on tho front fork top bridge by the pipe holdor. The fork top bxidge is mounted onthe front cushion by 10 front Fark bolts. In. adiion, every Wite unit is expoted for moking handlebar replacement cary. (Refer to Fig. 4.1) B. Disassembly 1. Tools required for disassonbly ond ossombly of tho bandabar. (Refer to Fig. 4.2) 2. For dsossenbling the front broke cable, tu the front brake am ceunterclockwise (where the brake is effective), ond remove the end of the cable. (Refer to Fig. 4.3) 3. For disassembling the cuich cable, loosen the tives small coss point sceews of the dive chain cover end remove tho end of the cable from the Clch adustnent thread. 4. Fee disossbling the throttle cable, loosen ond remove the carburetor cop : the tixotle valve con bo pulled cut. Remove the cable end from the throttle vole. (Refer to Fig. 4.4) 2 Fig. 41 Tuning te tonlbor Vda T TYPE BOX MRI sao 1014 DOUBLE OFEN ENO SPANNER | Fig. 4.2. Toot requted for iaenbly ond sembly Fig. 44 fomovag cele end from the thot valvea For dsczzenbling leod wives of the horn ond immer, remove the heod lop assembly ond dis- connect the connector, with the wire homess, in tho lamp case. 4. Remove the clip under the steering stem and the steering damper knob. 7. When four 8X 32 hex bolts ore loosened ond # eluTo the handlebar holder is removed. the complete handlebar can be removed from the fork top bridge. Then remove the wires together with it. (Refer to Fig. 4.5) 8. For disassembling tho clutch cable and brake cable from the hondlebor, loosen the cluich cable adjuster ond remove it from the handabar lover. Also remove the cable from the handle lever. (Refer to Fig. 4.6) 9, For disassembling the throttle coble, loosen the 5x14 and 5X22 smell cosspoint screws ond remove the flasher switch case ; remove the wire from the handlebar orp. Inspection 1. Inspect condition ond operation of tho throttle ‘xble, clutch cable, ond inner end outer cable of the front brake. 2. Inspect the operation of the throttle grip. 3. pect the operation of the handlobor lover. 4. Inspect the handlebar for steighiness 2 Assembly Install the throttle cable, clutch cable, ond front broke cable on the throtHe“grip ond hond levers 2 Pais every cable ond lead wire through the handlebar holder by 8X32 hex bolt. Instoll the steering damper knob, Connect all cable ends to the front broke am, throttle volve, ond clutch adjustment thread, 5. After installation, adjust the play of each cable. {Refer to Fig. 4.7 ond 4.9) Throttle cable (twist grip angle! 9 10 10 degrees Front broke cable lever endl 30 to 10mm (1.17% to 39") Fig. 4.8 Adjustment of broke cable pl eee eae * fey 20 to 30mm (78" to 1.17)4.2. CONSTRUCTION OF FONT CUSHION 5 6. Clamp coupling of oll lead wires (Refer to 4.10) (CAUTION) ‘When oll wires ore placed in the dosignated posions, the handabor should be free 10 tun 10 the right oF lft. When the handlebar is installad, the wire should not be clamped by it. 4.2. Construction of front cushion A. Description The Front cushion ond rear cision should not be separated, The stalus ofthis suspension end damping device gives direct influence to the steering perfor mance ond stability of tho vehicle. The front fork, in caddtion to dereing vertical vibration of the front wheel, should miata strength during operation, s9p- porting the front wheol and encbling steering The front exshion sprig employs the spring with uneven pitch. The oll shock absorber contains 170 cz (04 US gal, .037 Inp.gal) of No. 3 operation olf Aidomitss Kozan) ond its maximum stroke is 94 mm (2.76", (Refer to Fig. 4.11) Fig. 410" ood whe clamp To BAN COR PACING goer fp onc sor a rota onto os mt — pace, (PS Vet oe an ee Ce ane, CCE rn Fm Ut Cv om SA A A Fo = ee el ae ge ‘ONE acy tee USO SINE vc ron tr cee’ Figs A) Oisorsnbing of front cuton B. Disassembly Beene 1, Tools required for dsossenbly and osionbly of tho front cihion. (Refer to Fig. 4.12) 2. Remove the handlebar according to Soction 4.1 8. Fig, £12 Tools wed of Gaoenby ond ossebly of7 3 Fig. 415. Renovng fren! wel 4.15. Removing speedometer (CAUTION) 1 Loosen the speedometer cable cop ond remove it from the gear box. At disossonbly of the speedometer, Insure that, when the cap is loosened and removed, the inner Pertion Is not chopped. Whon enly the wheol is femoved, the goar box ean be removed of fitted to the speedometer cable, ‘When a proper bench is placed under the engine, the front brake torque bolt is removed, the 3x28 spring cotter pin is straigtened and removed, the front wheol axle mut Is loosoned, ord. the frost wheel cxlo Is pulled cut; the front wheel con be removed. (Refer to Fig. 4.13) Loosen fowr 8X10 hex bolts and remove the front fender. (Refer to Fig. 4.14) Remove the head lonp rim, the hood lonp sealed bboan init, ond two 5 mn hex auts; remove the speedometer ossombly. (Refer to Fig. 4.15) Loosen two 8X20 hex bolts ond remove the hood lamp body.4.2. CONSTRUCTION OF FRONT CUSSHON a 8. Loosen the stesting heod stom rut. (Refer to Fig. 4.16) 9. Loosen two frent fork bolts end remove the top bridge ond the front fork upper cover, 10. Loosen two 8x32 hex bolts and remove the front aishion in a downward direction. (Refer to Fig. 4.17) 1. Loosen the front fork seal hovsing ond remove the front bottom cose, Remove the front cushion spring 0s wall os tho oil in the bottom caso. 12. Disassemble the front pipe limit ring, front fork piston, end front cbsorber valve from the front fork pipe (complete). (Refer to Fig. 3.18) A power narea ._ Inspection cea rncron one 1. Measxement of the font cshion sping. Sea bad race Sgro ‘Soniod woke i ‘ formation ion | Cratos om od was loo Bua aha io lesen ate L2G Bete Ste] usw sz6Is ne) aos24\g wabeaaet 7024209 A921 Fa OTS O73, fe aa fo 1437", Beer low 05 1019") 2. Measurement of the ouside doneter ond bend Of the front fork pipe. Seda vole | Covrection tnt [oie dome | Tze e 128 Ow ‘low 02 Tope ielow 02 Detection eiow 02 3, Measirement of the front fotk piston ‘endo vole | _Cowection it S1asU ie 57Eaa ide dometee 47) az Ova Below 0.02, Teper slow 0.02FRAME ROT FORK TON Fig. 4.20 Front for lpn osonby Fig. 4.21 Assembling of font cikon SOME Aste ‘Sordid valve | Corection tt Oval fatow 02 ‘Outer Ganeter| Tere Below 02 D. Assembly 1 2 3 4 5, 6 7. 8. 9. 10. Couple the front absorber valve and front fork piston ond install it on the front fork pipe (con plotel by the front pipo limit rng. (Refer to Fig. 4.20) Apply 170 cc of No. 3 operction oil tldenitas Kosonl in the front fork bottom case Put the front cushion spring with the shorter pitch In the bottom case ond inert the fren! fork pipe (completel. Tighten the front ferk soa! housing (Refer t0 Fig. 4.21) Alter the coupling of the front cushion is fished, insert it in the designoted poston of the steering stem together with the front fork lower cover Tighten by the 8x32 hex bolt, (Refer to Fi 4.21) Secixe the frent f6tk top’ bridge. Following Section 4.10, install the completo handlebar on the front fork. Install the head lamp body and istall the sealed bbeom unit on the body. Instoll the front fender. Install the front wheel on the front cushion and ‘just the broke. ‘Adjust the throttle ond the cltch enbies4.3. Steering stem ond handlebar lock ‘A. Construction of the st The steering stom is supported by 8X 32 hex bolts ‘on the front cushion, The stem, with the cone race inside, i¢ on inporiant unit for stooing since it is rotation axis with the frame head pipe othe center To the steering ster, the storing cbsorber is istlled cllowing for odjsiment according 10. the status of ood operation, and load. ‘When the steering cbsorber knob is tuned clock: wise, the steering cbsorber sping nut goes up ond the stecting absorber plate A and 8 tighten the stering bsorber friction disc: hondlebar operation becomes stiff, IF the storing absorber knob Is tumed cownter- clockwise, the steering damper spring ut comes. down, producing ops between the steering plate A, steering ‘brorber plete B, ond the friction disc; handlebar ‘operation becomes free. The handlebar lock consis (of the support unit which is @ single unit consisting (of the stesring orm and the steoring stem. ing stem B. 1, Tools required for disassembly ond assembly the steering stom end handlebar lock (Refer to Fig. 4.24) sembly 2. Following Section 4.1 8, separate the handlebar. 3, Following Section 4.28, separate the front cxsticn Loosen the steering head top thread (complete) by spenner ond remove the steering stem in a downward direction (Refer to Fig. 4.25) 5. When the 3X8 small crosspoint secew is re moved, the cop of the handlebar lock con be separated, When the engine key Is inserted ond fumed counterclockwise, the lock pston is separated from the steering stem. (CAUTION) When the steering stem Is removed, core should be token so that the 1/4 steel bolls ore not opped or lost. 4,3. STEERING STEM AND HANOLESAE LOCK (gnc reo expen TEA te FS pcron one Fig. 423. Sectional vow of steering Fig. 4.24 Toate requted for csonbly cad esenbly (of soorng stom end hodebar lock