CB Cl175 CB Cl125 Shop Manual 1971

- SHOP MANUAL HONDA. © 1259175 steveFOREWORD This Shop Manual is @ servicing guide for the CBI25, CL125, CBI7S ond cu7s. The Manual has been prepared using the CB175 and CLI7S os the basic models, however, the informotion contained will apply equally well to all models. There ore minor differences among the models, primarily in the engines ; these differences have been specificially noted for the CB125 and CL126. This Shop Manual is applicable to cll model serial numbers shown below cond subsequent, 125K! Engine Frame €B125K2 (General Export Type! Engine Frame CB125K3 (Genero! Export Type! cu12sk1 Engine Frome Engine Frome CL125K3 (Generel Export Type) cei7s cBI75K3 cBi75K4 cus cui75K3 cui7sKa Engine Frame Engine Frome Engine Frame Engine Frame Engine Frome Engine Frome Engine Frame No, 2000011 ~ No. 2000000~ No. 3000001 ~ No. 3000001~ No. 4000001~ No. 4000001~ No. 2000001~ No. 2000001 ~ No. 4000001~ No, 4000001~ No. 1000001~ No. 1000001 ~ No. 4000001 ~ Ne, 4000001~ No. $000001~ No, 5000001~ No. 1000001 ~ No, 1000001 ~ No. 4000001 ~ No. 4000001~ No. 5000001~ No. 5000001~ To ensure proper servicing, the special tools must be used and all repairs made to the specified tolerances. The information peculiar to CB/CLI28, 175 revised models is compiled at the back of this publication as a supplement. June 25, 1974 HONDA MOTOR CO., LTD. vice Publication OfficeFEATURES ENGINE 1. Chain driven overhead camshaft Assures quieter operation, due to the silent choin drive, ond @ more efficent higher speed engine resuiting from the elimination of power loss. 2. Dual cil filtering system Provides only highly cleoned oll 10 lubricate the moving parts of the engine to greatly extend the trouble free engine life. 3. Constant-meshed transmission gears Moke possible smooth and effortless gear change. 4. Variable venturi carburetor Provides economical operation and greater power output at all speeds. FRAME 1. The frome mein ynit is mode of welded high strength steel tubing of backbone design for lightness and rugged service. 2. Front wheel is mounted on an cil dampened telescoping fork which provides superb hondling ond good stability. Reor wheel is on a swing orm pivoted about plain bearings for increase rigidly and suspended on cushions provided with three stoge load adjustments 3. The CL models have © wide raised handle mounted on rubber for comfort. Semi raised hondle is mounted on the CB models. 4. Block tread pottern tire is instlled on the rear wheel of the CL models for good road holding on bad roads. 5. All lights are used throughout for grecter safety, and their operating switches are ‘ll mounted on the handle bar where they ore accessible without moving the hands 6. Front wheel broke is of the two leadings type for greatest braking efficiency. 7. All protruding parts ore designed with generous radius ond sharp corners have been eliminated to prevent injuries to the rider.an 32 33 CONTENTS |. SPECIFICATIONS . SPECIAL TOOLS cB175, CLI75 8125, CL125 |. ENGINE (CB175, CLI75) Engine Removal and Installation ‘A. Engine construction B. Removal CC. Reassembly Cylinder Head and Cylinder 1. Cylinder head. « A. Construction B. Disassembly C. Inspection «-- D. Reassombly a 2. Cylinder head cover and breather A. Description 8. Disossembly 3. Camshaft. A. Construction B. Disossembly . Inspection « D. Reossembly 4. Rocker orm A. Construction B. Disassembly. C. Inspection D. Reassembly 5. Valve A. Description B. Disassembly C. Inspection D. Reassembly 6. Valve seat «. A. Description B. Inspection 7. Cylinder ‘A. Construction.» B. Disassembly C. Inspection « D._Reassembly Left Crankcase Cover 1. Left crankcase cover ‘A. Construction «++ B. Disassembly C. Reassembly 2. AC generator A. Construction B. Disassembly - C. Reossembly 13 13, 15 a 18 18 18 wv 20 20 20 20 2 2 23 23 23 24 24 28 25 25 26 28 26 26 26 27 27 27 27 28 28 28 28 29 29 29 29 30 30 30 30 31 31 31 31 32 3234 35 36 37 38 3. Storting sprocket ond clutch A Construction B. Disassembly ond reassembly (Starting clutch) . CC. Disassembly ond reassembly (Starting sprocket! 4. Clutch adjuster ond neutral switen rotor A. Operation -. B. Disossembly and reassembly (Clutch adjusterl... C. Disassembly and reassembly (Neutral switch rotor) A. Construction B. Reassembly 2. Clutch eo. A. Description ond operation B. Disassembly CC. Inspection D. Reassembly Oil Pump, Filter and Seperetor 1. Oil pump A. Description jht Cronkease Cover Assembly. 1. Right crankcase cover B. Disassembly... . Inspection D. Reassembly 2 Oli iter... A. Description B. Disassembly C. Reassembly 3. Oil separators... .eeeeeeee A. Operation Crankease ‘A. Description B. Disassembly CC. Inspection D. Reassembly Crankshoft, Connecting Rods and Pistons .. ‘A. Construction B. Disassembly C. Inspection 2. Connecting rods. A. Descrpition B. Inspection 3. Piston A. Description B. Disossembly C. Inspection D. Reassembly 4, Piston rings. A. Construction B. Inspection C. Replacing the piston rings Cam Chain Tensioner and Com Chain Guide Roller..... ‘A. Operation. B. Disassembly 32 32 32 33 33 33 33 33 34 34 34 34 34 34 35 36 36 36 36 36 38 39 39 40 40 40 40 40 40 40 40 4 4 a 41 4 42 42 43 43 43 4s 44 44 45 46 48 46 46 48 48 49 493.9. Transmission... 3.10 Gear Shift .... C. Inspection «. D. Reassembly : E. Cam chain tension adjustment. ‘A. Description B. Disassembly C. Inspection « D. Reossembly ‘A. Operation B. Disassembly CC. Inspection D. Reassembly 3.11 Kick Starter. 3.12 Corburetor A. Construction «- B. Disassembly CC. Inspection D. Reostembly Constevction Function of the mein components ‘Adjustment Engine (CB125, CL125) 3.1 Engine Removal and Instollation ‘A. Engine description B. Removal C. Reastembly 3.2 Cylinder Head and Cylinder. Cylinder head, cover and breather A. Construction B. Disassembly C. Inspection D. Reassembly Comshatt .- A. Construction B. Disassembly C. Inspection D. Reassembly Rocker arm. +. A. Construction B. Disassembly . CC. Inspection « D. Reassembly Valve . A. Construction B. Disossembly C. Inspection «- D. Reaszembly Valve seat A. Description ...22+++ Cylinder <2 A. Construction «.-- B. Disassembly... 9 49 4 50 52 52 52 53 53 53 54 54 54 55 55 55. 55 56 56 58 60 62 64 64 64 65 66 66 66 66 66 67 68 68 69 69 69 69 69 69 70 70 70 70 70 n n n n 72 72 233 34 35 36 CC. Inspection D. Reossembly Left Crankcase Cover 1. Left crankcase cover 2. A.C, Generators. ee eee A. Construction... B. Disassembly C. Reossembly .... 3. Clutch lifter thread. A. Description B. Disassembly C. Reossembly 4. Com choin tensioner A. Construction B. Disassembly C. Inspection «. ++ D. Reassembly Right cronkcose cover ossembly .....06..0++ 1, Right cronkcose cover A. Construction «+++ B. Disassembly C. Reassembly os... 2. Clutch peooccnb ‘A. Description and Operation B. Disassembly C. Inspection « D. Reassembly 3. Oil pump) B. Disassembly C. Inspection « D. Reastombly 4. Oil iter ‘A. Operation B. Disossembly C. Reassembly Crankease 5 1. Upper and under cronkcase A. Description B. Disossembly C. Inspection D. Reastombly 2. Oil separator A, Description 8. Disassembly C. Reossembly Crankshaft ‘A. Construction « B. Disussembly C. Inspection D. Reossembly 2. Connecting Rods... A. Disassembly... 3. Piston 72 72 73 73 73 73 73 3 74 74 74 74 74 74 74 75 75 75 75 75 75 75 7% 78 7% 7 1” 78 78 78 78 78 78 7B 78 79 79 79 79 79 79 79 79 79 79 80 80 80 80 80 81 81 al4 37 38 39 A. Description B. Disassombly ...... C. Inspection « D. Reassembly 4. Piston Rings. ---- ++ B. Inspection «+ ++++ C. Replacing the piston rings Transmission. A. Description B. Operation C. Inspection Geor : A. Description B. Disassembly C. Inspection D. Reossembly, Kick Starter ‘A. Description B. Disossembly C. Inspection D. Reassembly 3.10 Corburetor FRAME at 42 43 As 45 46 Construction vee ese : Function of the main components Adjustment ing Handi Description Disassembly Inspection Reassembly se eeeeeeeeeee Front Cushion A. Description B. Disassembly ..- C. Inspection D. Reassembly ng Stem and Steering Hondle Lock ‘A. Construction cee 8. Disassembly C. Inspection D. Reassembly Fuel Tank. : ‘A. Construction B. Disassembly C. Inspection D. Reassembly, Frome Body A. Construction «2-5 B. Disassembly ....-. + C. Inspection «eee D. Reassembly .......+ Air Cleaner Case ond Seat A. Consteuction ....++++ Ste + 100 oo, eee i00, + 100 + 100 82 82 83 83 83 84 a4 84 a5, 85 25. 86 86 86 86 86 87 87 87 87 88 88 88 88 89 89 90 90 93 94 95 95 95 9% 7 97 7 97 98 98 99 99 998 c. D. Reassemb! Stand ; A. Construction « B. Disassembly ie D. Reassembly oes Muffler ond Exhaust Pipe... A. Construction B. Disassembly... ie D. Reossembly Air Cleaner and Too! Case B. Disassembly «. D. Reassembly Rear Fork and Rear Fender ....... ‘A. Construction « 8. Disassembly ic D. Reossembly Rear Cushion ‘A. Construction B. Disossembly 2... c. D. Reastembly Front Wheel ‘A. Construction B. Disassembly .. ic D. Reassembly Rear Wheel .. ‘A. Description B. Disassembly ce D. Reassembly 5. ELECTRIC SYSTEM Ignition Circuit A 8. c. D. E Electrical power supply A. AC. generator . Selenium rectifier . Battery se. 107 + 108 am Spork odvoncer... Contact breaker feo +126 Instruction on use ond servicing Bottery charging procedure Trovble shooting and corrective ct moOe> 101 101 101 101 101 102 102 102 103 + 103 103 104 104 106 106 107 107 107 107 108, 109 109 no no ho m m ne 22 14 4 us 6 eli + 120 2120 120 + 120 121 122 122 124 124 128 126 126 127 127 129—w— 5. Various loads 130 A. Headlight 130 B. Toil, stoplight 130 C. Neuival ond speedometer lamp =. 130 6 Starting motor wees ooo apd 13 A. Description Beepenooonc feces TT B. Disassembly a : 132 C. Inepection ==... 2.6 a tees 182 D. Reassemly «. eo : tieseeees 132 7. Service tester instruction... .e.00eeseeee — 133 6. PERIODIC ADJUSTMENT oot seeeseees 138 4.1 Maintenance Inspection 138 A. Engine Adjustment : ao 138 1. Measuring compression : : 22 138 2. Toppet adjustment... 2+ 138 3. Ignition timing adjustment... 5 139 4. Contact points ..-+20+0+ 5 140 5. Spork plug adiustmer +140 6. Fuel supply system : at 7. Fuel strainer cleaning .- 5 : 242 8. Oil filer screen cleaning, 2142 9. Air cleaner servicing. vee 142, 10. Carburetor cleaning and advsiment 143 B. Lubricating : 2143 1. Parts not Fequring periodic ol change or lubrication tees 143 2. Engine oil change. « 2144 . Drive choin agjustment fee a 144 D. Broke ediustment popceocdecha ‘i 145. 1. Front broke adjustment : 145 2. Reor broke adjustment... esses oe 145 E. Spoke torquing «.-- Bppenecoocd 145 F, Bottery inspection .....2...- 5 — 145 G. Security inspection Of parts .....ceeeseeeeesseseeeeeee ea 6.2 Periodic Inspection and Servicing... ceeseeees MB 7. TROUBLE SHOOTING i 150 1. Main engine trouble... +++ i ceererees 150 2. Carburetor trouble... ++ 5 : 152 3. Engine noise 5 dpapiorcogouecsocs see 154 4. Steering system. =... Gao — isi) 5. Clutch system « 155 6. Geor change system 155 7. Suspensions -« : Shoop opoepocaedeon 155 eoeis aan ee 156 9. Drive chain... 156 8, WIRING DIAGRAM cee 157 CBI25 wiring diagram... -e++ a cy L125 wiring diagram 158 €B175 wiring diagram 159 CLI75 wiring diogrem (General export typeb s--e+scese++ 160 CLI7S wiring diagram IU. 8. A. Export typel -..- 161—w- 9. CB/CLI25, 175K3... on 9.2 93 94 95 Dismounting and Mounting Engine 1. Dismounting engine (C8/CL175) (€8/CL128) 2. Mounting engine Engine Mechanism (e8/cL175) 1. Cylinder head and cylinder Crankcose Gear Crankshaft Transmission Kick storter mechonism Corburator (c8/cL125) Cylinder head Comsholt sce eeseeeeseeeesseeereeeee Cam chain tensioner Transmission Gear shifting mechanism Kick starter. Carburetor Frome s.ccccsseeseeeesseeee epee ceuaueqaeo0H 1. Front suspension 2. Rear suspension 3. Front wheel 4. Rear whee! Electrical 1. Chorging current measurement 2. Starting motor 3. Starter solenoid switch ...-.cccceesseteereteerees Wiring Diegram . = 190 162 162 = 162 163 - 163 164 164 . 167 167 170 170 eae 172 173 174 175 ei 180 182 - 183 134 184 185 187 188 190 190 193 194SPECIFICATIONS: 2 1. SPECIFICATIONS €B175 (U.S.A. Type) aaenton [ ove wi = cone ot Wheel bose 1.275 150.2 : 1,280 (50.39) 1,275 (50.2) Ow wei Tah ig Batik Cab woth 17g Ori ha | Gu weigh 136g GPF ane Te Bocttone Se dob rai ner Woe | Some f. erpenion, wove Telescopic fork ‘Some of att ‘Som tL mperon, nov | Evin om Oe Tone oe Sone os I Fe te, Woe 250-18 275-164 Same or tet R tire size, type 275-18 14 PRL 300-164 | Some os tft Tbe imorol expending how | Some ov oh ne tte Tera enon How tone eaeeae Tih cow wl Tar TEU ot. 2.3 mp.) TBS pl, 271m. oa Fuel reserve capacity — | — nee ee Some os ft ovr vale ro Sone oi Sone ot lt Ti iat ee 38 ene os It Soe oft exon Type 7 Air cooled 4 stroke cycle ‘Some os lef Some Cyn orongonen | ToS wd om | Ton pray OF coed song ‘Bore ond stroke 2x41 2047x1615) Some ot tot ‘Some ot lat |” Dislocoment| V7 ec 04S cuit ‘Sone oF Sane of lot | Compresion ratio 90:1 same | seme os ith ‘Maximum horsepower ~ | 90.0 10,000 rpm Some os left ‘Some os left Maximum torque 15k gem (108 ft tbs) ‘Some as left Same os leit Ot copociy 15th 82 US pt 27 mp. pe) | Some 0 lit “Some oF lt Forced presze & wet sump | Some ot lait Sane ot lot3 1. SPECIFICATIONS mt Ko T «3 Ke 10" 10° Some oF I = 0 [iE Sone oof [or 7 Sone oF lat Exhaust valve ~ 0 10" Sone os left | Vote tppet clearance | 005 (0.002) Some ot left : Some oF tet late speed 1.200 0m Some oF lt aca DRIVE TRAIN Cuten Matple wet plots Some of let Transition (Contant mashed gear | Some or let Primary redaction 3700 Some oF tat Geor ratio I 2769 Some oF fot Geor ratio I 882 Sone of lot | Geor vo Mt 1480 Sone ot leit Gear ratio co ‘Some 08 lt | Seer ron ¥ 1.000 Final eeduction 2500 2470 okt Gear shi ponern at food operated rotrn type Some oF laf ECTRICAL Ignition Battery ord ignition coil | Some os left [seme os tt Storing yam Motor ond tek ‘Some of tet Some oF lat ‘Aerntor AG generator rotor tee | Sane oF ‘Sone ot lft Bowery capociy 1av-9AH ‘Sone o lft Some oF eft Spark pug | rans, a-aars ans Sone or ltL175 (U.S.A. Type) 1. SPECIFICATIONS ew xo xe ee DinENON ‘Overall tength 1978 77.8) 1.990 178.3) Some os leit Overall width 745 (29.3) 820 192.3) - ‘Some os left Overt bah 1015 wo, Two a2 Seno os Wheel bose 1.278 (60.21 1.290 150.8) Same seo! bg e 790 ai. sone oie Grol eres | a mia om Oey weiah (or Garb woight 12449 724i | Curd weight 126K [200 rane Type | Backbone ‘Semi-double cradle tubler type | Some os left ‘suspension, trovel Telescopic fork ‘Some os loft - Some pope, ove! | Soh om see ot one fe oon We 70-18 te 300-194 Some o eh | we ae aoe a7s-18 ur 300-184 Sone ooh F. broke, Some as left - ~ Some as talt | &. bre Internal expanding shoe ‘Sone taf Sone oF tol foe Wien, imp god | Bega ont gas_| feo [ rt we oe Tt nétimon | Smee Cover re oe Sere os lit =o Tel ios we 38 70138 Sona ost Bowe Type Air cooled 4 strote eye! Some os left 7 ‘Same os left Cynder cnangenens | RRR 30" Wand Tom Tae ae Wald | Sone wt al Bore ond shake | saxar ou 1isi Same of tft | Some ot left | Displacement 174. cc (10.65 ev-in) ‘Some os left ‘Compression ratio 9000 Some =e vee tan Gia ven veto Song one ob ‘otmim honepower | 3995 10000 rom Seno oh Sone ot Moxa tre ‘stg 101 8.00pm | fone lt Sone = lh Oil copacity 1.5 lit. (9.2 US pts, 2.7 Imp. ptsl | Same os loft | Some os tet Forced posure wet me | Same ol = Wbriation estan5 1. SPECIFICATIONS trem I Ko xa Ka Opens | 10° 10" Some a a Open | 40° o Sone Exh ve | Gores | 10" 10 Sane of lit Yolve opps" eleorerce | 005 1.0021 | Some: tot Some of Io ale speed 1.200 p= Sone o lett Sone ole RIVE TRAIN Clutch ‘Multiple wet plotes Some as | Some or tet Traromision Conon! meshed ero ‘Some ot ltt ‘Some ot tat Primary reduction 3700 3700 Gear roti T 2769 [Some or tt Some oleh Gear ratio 1882 ‘Some oI Sone or loft Geor oo | (1480 ee cones [eens Gear rato 1 17 Same o lft Some Geer ratio V 1.000 Some ot ‘Sone Firat redvtion 2378 Sone or left | Sone a: ttt } Gear shit poten | ta foot operated rotrn type | Same ot lft | Sere os ti LECTRICAL Ignition Battery end ignition coi ‘Some of left T Some os left [storing stem Motor ond Yok Sone olf Sone 0 lt ‘Aerator ‘AG. generator ror hype Sane oll Bovery conociy | TaV-PAN Same 0 lst Some oF tat Spark poo Deis, x-22FS sis Sone 2 lot1, SPECIFICATIONS 6125 nh Tom Ko ll Ka Ka INENSION Overall era 1978 07-8) Sone ot lat 1980 07.98) ‘Overa width 745 2931 Soma oF lot [some oF tit ‘Overt eight 990 09.01 Some ofa 10 worn Whee! bore 1275 (5021 ‘ome of lat 1.280 (6039) Seat beiaht — 790 (307) 790 B10) Growd ceorones |S 871 Some ot taf 0 530) ‘Gob weight 119 hy 2624 ea oe tite size, type 2.50-18-4 Same os left ~ | Some os lit | R. tire size, type 275-184 ‘Some os tet Some os left F. broke Internal expanding show Same as lett a 7 2, broke Tnteroal expunding show ‘Some or left ‘Same of left aes [ns " — - 251it. (5.3US pt, 4.4 mp. pt | Some os left Fl vaerve capacity Lubriation ston Cover ane oo Some ot iat fone or Trot rah or) Some oie “Saw ot ENGNE | tee ‘Aircooled & woke erie | Some oF tot Sone oot Cylinder arongement | fetege ued Fem Sone oF lel Sein porate] 8° eine | Bove ond arate axel ODT Sone oft Some ol Dilocener 126 ce 0-57 euin Some ot tat Sone o et Companion ose | ‘9401 Sone oF lt Some oI Vee role xs cane Same ot lt Sone ot let | Movin hoaepower | _15°8/11000 9m Some or tet 1575/10 000 Meni 11008 G59 a 9,000:00 oe Bion (8 corezty 12, 25US p21 lap ps | Some os et Sone oe Tored premure & wet mp | Some oF Some ol7 1. SPECIFICATIONS tem Ko «2 Ke Open |e ‘Some oF eth Some 0 lat tnele were Gone | 90° Sone oe et ‘Sane oft = Sone oft shout vole = Some lh Sone oF lat Valve toppet clearance | 0.05 (0.0021 ‘Some ot tat Sone of lat ide toed 1.200 pm Sone or lft ‘some DRIVE TRAIN ian Matipte wot plate Sone at et Some oF lft Trini Convo mesbed goon ‘Some or lh Sone os et inary vodecion ars Some oF lth Some of let Gear rato T 2615 Some oF lait Some oF ht Gear roo T vail | Gear ratio TT 1.190 1.286 — J ‘Geor ratio V osi7 108 —_ Some ot Hot (Gear ratio V — 2880 Sane os tat “Final radeon | 280 aan Some alot Gear it perm Leth foot operated return ype | Some os lat Sone os lal LECTRICAL Iontion “Bartery ond anton coi! | Some ot lth Sone oF lat Saring astm Motor ond ek Some of lath ot ‘orton AC. generator rotor type | Some oF lal =] Boner capacity | SY-HAN | evtaan Some ot Ia ‘Spark log aH, 248s ans Some oF lt1, SPECIFICATIONS 1125 min) tem xo Ka Ka DIMENSION veal Tenth 1.700 760 Some ot lot Sane lt ‘Overall wih 30 027) Sone of et 10 181 ‘Overt hook 1040 141.0) 1005 40.6) 920 4088) ihosl bose 1270 1530 Some a Ie [1.230 10.391 Seat height = = — ‘Ground ceorance. i501 8m Some ole 1651 610 ry weight 117 eg 258 Curb weight 11589 253.6100 | Same as lait ANE Te [_fsstore ie frome Sone 0 at Seni dui code er He | F wipenion, wovel | Telescopic fort [Sone ot tft Some 0: lel spenon vovel__| Swing om 0 Sone oot Sone oi ie 8 pe 275164 [Sone os iit Sane of lt te ee are) Some wit | ‘Some ot lt F. brake ~|_tnenat exzonding shoe ‘Sone a It Sone oF lett broke Inert expanding oe | Sone 0 lat Sone oft Foe copoe aie Bae Sone oft GEBUS gol, 29 mp.gol) | 2SUSal, 2.1 wp. got foal rane eapocny | — = = ‘Caner erle g Sone oot Some oJ Tre erg we a8 Sone oft Sone oJ eon | te8 Tr coced 4 sole ele | Sone ot let Some a lit ee a Fa iat OF ales ore ond stroke [daar rsx i815) Some oF lal Sane Daplcenent Tasce 0.57 enim Some ot Sone ot | Conoresion ratio gat Sane it Same or lal Ye wal a ges wal Tse ot = ‘avown tonepower [1475/1000 rm Sone oF Masieam torque Bayes ‘Some os tof | some il (8 erect 12h SUS 2.1 mp ps | Sone ot et sone | etre & wer son Sone oft Sone ott lubrication seem7 1, SPECIFICATIONS tn tem Ke I «2 Ka s | some = itt Some oF lat tat Sone of I 0 ‘some ‘Closes Open | 35° ‘Some oI Sone ot eft Stow weve coms |_| Sone of Io Some os Felt Valve topper cloronce | 0.05 10.002) Sone o let | Some or tot tae speed | 200m [ sone oth Some os let ‘DRIVE TRAIN cae Multiple wat plter Some ot let Sone of eth “Tranenision | Constant method guare Sone ot leit Some oF lath Primary reduction 3878 | Some or tit Some oF lth Geor ratio T 2615 Sone crit «| Soma or Tah Geor roto vent ‘Some of left Sone of ft Goor ratio Hl as | Sore or Hatt | Some ot tot "Gear roto WV | os “0 [Some a: Heit Gear soto Vo | __|— Fino! rection | —8.000 Seve os tet | Gear sit poner | te oot operoed tin ype | Same or left ‘Some of fh ELECTRICAL Tanition Batery ond ignion coil | Some ot lat Some os lett ‘Storing sem Motor nd Wek ‘Sone of left “| Some oF ta ‘Aerator ‘AC. generator rior type | Some ot lat | Same ot ett Bonery capacity cones ‘Some oF tat Some ot teft Spork plea DONS, ¥-24"5 Soto crit «| Same ot alt10 1, SPECIFICATION & PERFORMANCES (urs2) waz) 988—e} ONIMVEG TVNOISNaWIG sz1aCBI75 DIMENSIONAL DRAWING 1, SPECIFICATION & PERFORMANCES RG | » 2) sia—_—+ | cue)CLI75 DIMENSIONAL DRAWING 1, SPECIFICATION & PERFORMANCES 12 (ww62) $82} (ws v2) 083}13 2. SPECIAL TOOLS (8125 +175 ENGINE 2. SPECIAL TOOLS eaeiae Tool oucpion Gy Eso Ae Cao ono @ —07902-2400000 Spanner. pin 46 mm 7 °° ee @® —07922-2350000 Holder, drive sprocket 1 fo} oe eee ao Se eee : a ee co ee ee 5 i @ —07954~-2350000 Compressor, piston ring 1 oO @ —07957-3290000 Compressor, valve spring v ° oO2. SPECIAL TOOLS 14 <___ E> 2 mm» ©8©8125 +175 FRAME 15 2. SPECIAL TOOLS Ne. Tool No. Tool Descriton ay CE CR ranerts @ —07950-2500000 em, ison 1 70. 70 @ —07757-2270000 Comprar, hock troter = 1 OO @ —o7973-7500000 Slider, spring 16 @ —07960-2400100 Cater, 90° IND 10 @ —07980-2400200 ‘Cutter, 90° 1X) 1 oO @ —07980-2400300 Cutter, fat 1 Oo @ — o7960-2400400 Cater, ot 10 @ —07980-2160500 Caer, interior ah 10 @ —07900-2160600 Cater, intron fn 1 0 @ —07980-2350100 0" 1 oO @ 07980-23500 fot {IND 1 ° ® — 07980-2350400 Catter, flat (EX) 1 oO @ —_07980-2350500 Cutter, interior {IN} 1 Oo @ —_07980-2350600 ‘Cumter, interior (EX! 1 Oo @ —07981-2160000 Holder, seat cutter 1 oO @ —_07981-2350000 Holder, seat cutter 1 ° @® —_07984~2000000 Reamer, valve guide : oO oO @ = 07797-0510100 Case, seat cutter 1 oO oO @ — 07797-2920300 Cove, spoil too! 1 0.0 @ —07999-2460000 Cove, tnng Inspection i) @ —07999-2250000 Cover, siningispacton : °2. SPECIAL TOOLS 16 @@ wownn \@ aa RT we ey @@ FS S417 3.1 ENGINE 3. ENGINE CB/CL175 Engine assembly diagram3.1 ENGINE REMOVAL AND INSTALLATION 18 3, A. Engine Construction All of the models incorporate the O.M.C. design, riven from the certer of the engine by a lightweight choin. This provides the engine with high speed ard igh power output die to the elimination of the rect procating movements mechanical losses, and reduction in weight. Further the chain is always maintained inf {2 corstanttersion by the spring operoted automatic tensioner to azure quiet operction ond precise valve tining at all speeds. © Step bor @ Sem bois ond outs The lubrication system wtilizes © plunger type oi! pump, driven through the tranamission main shaft to Fig, 3-1. Reroving the stop bar provide Wbrication under prassura to all af the primary moving par's of the engine and in coriunction, a screen ond o centiugalfter ore Incorporated in the system to assure that orly highly purified cil is circulated within the engine to. mininize the ports wear ond ‘attributing to the extended engine lie B. Engine removal (CB 175 and CL 175) ft off the fuel cock o! the fuel ton 2. Remove the step bar @ by unscrewing the two Bim rots and 8X25 bolts @ mm bolts for L175), (Fig. 3-1) Remove the mm suts fram the cylinder head ond {8X36 bol, end then the mufler can be reparoted. (CLI7S: Remove the 6 mm nut from the cylinder head and &imm nut and 6mm bol) 3, Remove the oir cleaner cover 4, Remove the oir cleaner @ by unscrewing the two L 4X12 bolts @ ard the 5X18 cross screw @. — Clutch cable @ Coed iter tread (Fig. 3-2) Fig 3, 5 Remove the lt erkcte ear over ond connect the clutch cable @ lower end from the Ciuc Wer toed QW. 93) 6, Rotate the rear wheel 12 potiion the chain joint adjacent tothe deve sprocket and disconnect the dive chain @. (Fig. 3-4) © Wont clip @ Dive chain Fig. $4, Discomectng the dive chain19 3. ENGINE 7. Disconnect the high tersion terminals from the park plug, Remove the starting motor cable, ord than disconnect oll leads. (Fig: 3-5) 8. Remove the carburetor @. (Fig. 3-6) (Note) Seporote the fuel took to facilitate the removal (of the 6mm bolts 9, Remove the engine mounting bolls and the engine con be freed from the frome, Fig. 3S Oiscomactng the electra! leads © Carburetor @ Gm bes bole C. Reastembly 1. Perform the eagine installation a the reverse order ‘of removal described In Section 31 8. 2. The engine installation can be made easier by temporarily hanging the engine on the frame by the ute of the Tehandle cross screw driver ® followed by the installation of the engine mounting bolts ig. 3-7) DT hondle cron erow dever Fig. 3-7. Intaling the eine f (Note) When reconnecting the drive chain the joint clip should be installed withthe opening facing eppostio to the direction of the normal drive. chan (Fig. 3-8) 3. Adjust the chain tension so that there will be 1 fo 2m (040~0,80'n) slack at midpoint between DIRECTION OF ROTATION — Fig. 2-8. int clip itllation3.2. CYLINDER HEAD AND CYLINDER 20 Fig. 3-9 Vole mechonism 3.2 CYLINDER HEAD AND CYLINDER 1. CYLINDER HEAD A. Construction ‘The cylinder head is a cost alumiium twin cors. twetion of seni-spherical combustion chamber with o squish area for better combustion ffciency. The single piece overhead camshaft, ‘orm ond al Imechonism ore ll incorpora valve chamber ‘above the combustion chamber. (Fig. 3-9, 3-10) Contact breaker assembly is mounted on the left cod of the consholt od cover incorporates © breather pot the pressure buld up. 1. Drain oil from the engine. 2 Remove the tick starter pedal, right crankcose cover ond cylinder head side cover 3. Remove the gear change pedal, left cronkcose ‘cover, point cover and breaker ossembly ight Bram blied ruts @ ond 6X45 ‘ond then remove the cylinder heod cover @. (Fig. 3-11) 55. Rotate the cronishalt 20 that the cam chain joint clip @ is toward tho top of the cam sprocket tard then dliconnect the cam chain @. (Fig. 3-12) or Atoch © wire to both ends of the chain before @ Sam bind nut @ 6X45 hex bol disconnecting, this will simplify the stombly task) Gyinder head cover to Fg. 3-11. Romovig the eyinder hood cover 6. Separate the cylinder head© Con chain @ Sint clip Fig. 3-12. Daconnecing the cam coin © Cynder heod @ Bling or red lead Fig. 3-13, Checking the cinder head for warpage c 1 3. ENGINE Inspection The cylinder heod is exposed to the high pressure nd temperature resulting from the combustion of ‘he fvel mixture, further, when the head is unevenly torqued, it may develop cracks or warpage ond will cove defective sealing between the head ‘ond the cylinder resulting in got Teak, oi sucking With consequent drop in compression. The warpage of the cylinder head does not develop suddenly ond it may be overlooked, therefore, covtion should be exercited during recsonbly since the uneven torquing of the cylinder head is @ very common foul To inspect for warpage of tho cylinder head, epply © thin coat of bling or red lead on a surface plote ond wark the mating sirface of the cylinder head on the sutfoce plate the worpage can be determined by the Wansfer af the bling on to the evlider hood. (Fg. 3-13) To correct the worpoge, lop the cylinder heed on the surface plate with o $200 sandpaper, faclly finish by using @ #400 sandpaper, and then inspect ‘goin with the bling. Inspect the combustion chanber, Inlet end exhaust ports for cracks. Inspect the valve guide ond valve stom. Check the valve guide diameter at the top, center ond bottom in both the X ond ¥ axis, using © precision cylinder gouge. Check the valve stom with micro: If the valve guide inside diameter is beyond serviceable limit, it may be repaired by using 0 reamer (Tool No. 07008-00101) and replacing the valve with one of on oversize. Ounide donater —J | ounise danster Conte! face runou Ouede am shout valve Contact face rout Ince domerer Ehoust vole guide Oude diometer leevoroncs Tor2ise— 0.2062) 0.00081 EESSS1S am (oa1es~ 02171 in (0.3959~ 0.3969 i) Semacecble Ua Replace 1 under Suen 218m) 3 10.0004-0.0074 i) 56547 wi (0216070254 Teplace over ime 10.0280) 135 we ‘ih in 0.82 em 555515 nm "om65~02071 i) 008" Toplace aver 850mm 10219 id .0s5~ 10.068 103959~0.9963 m1 0104~0085 mm epic i over 00k mm (0.0099) 022m)3.2 CYLINDER HEAD AND CYLINDER 22 4. When replacement of the valve guide becomes necessary, remove and replace with on oversize Guide, use the volve guide remover Tool No. 07047-04001! ond the valve guide driver ‘Too! No. 07046-21401) for replacement operation Alter installing the volve guide, use 0 reomer to ‘obtain the proper valve clearance. D. Reassembly 1. Clean ond inspect the cylinder head Interior and extorior for cracks, damage ond worpoge, also Inspect the hood othe, valves, valve guide and spring for ttisfectory condition. Perform the head cssembly in the reverse order of disassembly. 2. When insaling the cylinder head to the eylnder, the com chain shovld be otzembled as shown In Fig. 3-14 ond attention should be given to the proper valve timing. Align the “T" timing mark on the generator to the timing index mark the piston Is at top-dead-ceater), postion the comholt sprocket £0 that the "0" matk on the face of the sprocket is et the top, ond then assemble the cam chain. The joie! clip mus! be intlled with the opening facing in the opposite direction to the normal chain movement 3. IF he cam choin tensioner pushbar isnot completely pushed in, the com chain connot be connected, (ig. 3-15) 4. The cylinder head should be tightened uniformly with the torque wrench in the sequence shoven in Fig. 3-16, [Torques 160~210 Kg. cm (11.6~ 15.21, 18) @ Genter crarihalt_@ Com chain gude roller (@ Tensioner puth rbber @. Cam chain wnsone srg © Teroner get tot” @ Tensioner push bor ® Cam chain tensoner @ Cam shalt ‘sembing the com chain Fo 214, @ Tensioner s21 bolt @ Tensioner push bot Fig. 3-18. Pushing in the tension posh bor Fig. 8-16, Tightening sequence ofthe cylinder heod23 3. ENGINE Contoct beater caver @ Contact breaker axsenbly Fig. 3-19,. Removing the contac breaker asenbly 2. CYLINDER HEAD COVER AND BREATHER A. Deser ‘A brecther chamber it incorporated in the hood cover which provide constant pressure within the Cronkcose, Further, the oll i separated (rom the got Which i: exboust ‘As the cil loden oll vopor pastes through the breather porage, the oll if separated from the Got by centrifugal force and flows down the oil pasoge. whore itis collected. (Fig. 3-17, 3-18) B. Disassembly of the spark advancer 1, Remove the contact breaker cover (, contact breaker assembly @ ond then remove the spark advancer from the camthol. (Fig. 3-19) (ote) ‘A wooden stopper block @ should be used 10 key the camshaft @ from turning, (Fig. 3-20)3.2 CYLINDER HEAD AND CYLINDER 24 2, The contact breaker point bose can be removed by lootering the four mounting screws. (Fig, -21) 3. The spark advancer canter piace serves os a bushing for the conthat. tis oiled by the oll vapor ord dose not require special lubrication. 4, Perform the ostombly it the reverse order of lisessombly 5, The evtout on the contact breaker point bose should be aligned s0 that itis at the top. {@ Contact breaker pont bore Fig. 8.21. Removing the contact breaker point bore 3. CAMSHAFT A. Construction ‘A single piece camthatt contains both inlet ord femaust cons together with the sprocket which is Imounted in the center of the camshaft The com sprocket i driven by the crankshaft at Ys the speed of the cronkshat. (Fig, 3-22) @ Ganshait @ Torpet adusing nwt @ Rocer orm @ Rocker arm shalt Fig. 3-2 ‘The com ie provided with o long gradual rise to prevent abrupt rise ond drop of the valve, thus assut- ing ¢ quer valve operation. (Fig. 3-23) © tow ciclo @ Nor con th @ Baer carve @ Con height Fig. 9-28, Com contow25 3. ENGINE |] 8 Disassembly 1, Remove the cinder head In accordance with Section 32.1. B 2 Remove the lft and right cinder head side covers, contact breaker otenbly, spark edvancer ‘ond toppet acjusing hole cop. Rotate the com- that 20 thot both rocker arms are reting ont heel of the cam. in this position, ditassembia the rocker oem from the head by removing the rac crm shol's, (Fig. 3-24) @ Vole rocker arm @ Rocker arm shot Fig. 3-24. Removing the vole rocker crm 3. Remove the comhaft rom the cylinder head, ig. 3-25) © conto 3828 r zz0s(st11m) pif eet | rt eg_ 3 } C. Inspection rc = ae ae areas 1. Comsat ig, 3-26 ot os dancer a | RI =IRREre | eaaee ode Lett side lomerer @ | your ~o7esemn) | 19-7 mm 107859 i Com bose ele [ con toion D. Reassembly 1. Screw out the toppet ousting screw and assemble the rocker arm inta the cylinder heod In the reverse order of disctsenbly 2. Adjust the tapeet clearance to 0.05 mm (0.0020 in) with a cold engine (Mote) Repair or replace the combat ifthe cam is scored or worn exesively,3.2. CYLINDER HEAD AND CYLINDER 26 4. ROCKER ARM A. Construction The function of the rocker arm is 10 tranpote the rotary mation of the camshaft fo @ reciprocating motion for actuating the valve. The rocker orm is ‘made rigid to prevent deflection and the end which ontactt the com is Grithed smooth fer surface hordoned to mininize wear. The end which operates the volvo is provides with o topper adjusting screw ‘Mot contacts the valve, (Fig. 3-27) B. Disassembly 1, Disassemble the rocker arm in accordance with Section 323. 8, . Inspection 1. Rocker orm Replace over ot Sipper si se Feploce funder esis I over 188m 1.0081 i 3. Check for proper loppet clearance, (both inlet and exhaust! should be 0.05 mn (0.002, 100 small © cleorance will alec the engine causing com prestion leok nd result In hard starting. 4, Check for proper valve fining. (Fig. 3-2-1) Refer to page 22 5. Check to tee that the com chain i not stretched, D. Reossembly 1. Inspect the rocker arm contac! sulace and repair for replace i there i scoring oF excessive wear 2. Hf the rocker arm had been disassembled, the tappet cleorance should be readlusted. Make the ‘odjusiment by positioning the piston on top-deod: confor of the compression stroke, this will foe dll of the valves. Align the "T" timing mark on the generctor rotor 1 the timing index arcaw mort on the stator 3, Check the valve loppet clearance with the thickness gouge. (Fig. 3-28-2), Vows rocker erm @ Postar orm shalt Fig. 3-27. Rocker crm and rocker arm that @ Wat vale ope 1" _@ inet valve ch @ Exhowt valve opens 40" @ Eshowst Fig, 328-1. Voie tring diagram (© Crlinder hood cop @ Adjuting srowe @ toak nut @ Theos gouge Fig. 3-28-2. Checling the vlve toppet clearanceOy. ‘@ Wet valve Eshour valve @ Volo spring seat @ Inner waive spring @ Outer valve sping © Voie spcng retainer @ VoWe cover Fig. 329. o_o HAE PS - INLET. VALVE 4 Fig. 3-31, Inet ond exo! volves ENGINE 5. VALVE A. Description The volves contral the volome of inlet gos and ‘oko the exhovst gas entering ord leaving the cylinder The diameter of the exhoust valve head Is mode smoller for better heot radiation. Inet valve i made large for greater volumetric ficiency Double spring feature prevents the volves from eating during high speed operation. (Fig. 3-29) B. Disassembly 1. Remove the eylinder head in accordance with Section 32 18 2. Disassemble the rocker orm from the cylinder hood by pulling out the rocker orm shaft. 3. Compress the valve spring with the valve lifter @ {Toot No. 07957~32900001 and after removing the valve cotter, valve sing ond the retvines, the valve can be removed. (Fis. 3-30) C. Inspection Exhaust val team © _| (Fg stm do @ | jesrigo~ 0.2154 ead | 055~085 wm Hicins @ | 16:0217~0.0835 Geneon ‘hin 0.93 ot wae face] ie, q | Wioor a 2 Inet val 73.35 17365 ‘nm (021409 03mm Gotten) Sonieeatle Un Tepace W under Lenoth © | fabora~ 28996 | 7295 mm (2872010) Stem 0 @ | fozie8~0.2162 in) | Stasmm (0.1251n Wood | 035~045 mn oplce Wander (6.0138 0.0256 it Concerti | yin 0.08 mm valve foc) Win a 001 3. Volve spring measurement Cuter valve sexing Ten] —_Siondord Vale Yength_ | 31-8 mm 1.2820 i | Bema 850 | [Seniceabie Unit Topace W order udm 12007 i) Tieitin/t6538~ — oo 183020) prone | 23Sinm/D.4~ 326g Oa w/eaazr~ — Inner valve spring Ten |_Stondord Valea —]—Seveobie Unit Free length | 902mm 1.18901) | SeP ce Harder tance a5 ost n/e.ve~ Seng ee 967 prostre | 20imm7i0.9~i2 Til (07992 n/2.03s~ — ‘pase3.2. CYLINDER HEAD AND CYLINDER 28 D. Reassembly 1. Before the volve is assembled, the valve contact surface should be inspected for weer, pling, oF ccorbos. Alter cleaning, oil the valve stem, ond the valve should be Inserted from tho combustion cchomber side 2. The valve ovter ond inner valve. springt and retainers should be ‘ited from the cap hole of the tonpet adjusting hole and compressed by using the valve liter (Tool No. 07967-32900001, ‘Secure with the valve cotters 6 VALVE SEAT © Volvo seat eater @ Cylinder hood A. Description 3-32, Fewoting the valve seat The volve seat is repoited with theee types of The relative location end the width of the valves seat contact area is accomplished with the seat top cutter ond seat bottom cutters while the refacing of the valve contact area i performed by the 90° camer. (Pig. 3-32) Valve seat cutters ‘07980-2950100 07960-2350900 Flat surfoce #00" eter 0) o77s0-2as0400 Ineror ear cater IN o79e0-2350500 Ineror 0a! cutter 1H 079e0-2950600 Valve lapeing operation is performed lost this fe to obtain 0 leak proof zeal between the volve ond the valve seat. Place @ libercl amour! of topping compound on the valve foce ard lop the valves, ‘pelying «slight pressure while rotating the valve ‘back ord forth with suetion cup lapping tool. Wosh (of the compound thoroughly end inspect the valve soot with bluing. (Fig. 3-33) (Not {a! When the valve stom is greatly worn, the valve guide ie umclly clio worn Hance, whan @ valve IF replaced, i okt it desirable 10 reploce the valve guide. Since the guide is press fied, 1 i recommended thot they be replaced with an over: size guide {by When the volvo is ossombled, the compound which wos used during. lapping should be completely removed B. Inspection 1. Avalve seat in good condition should have @ ful fueloce contact with the volve face. ‘Standard value: 1.0 mm 10.04 ink Serviceoble limit: in excess of 2mm (0,08) 2, Assemble the valve into the cylinder head so that the valves ore well seated. and fil the cylinder head ‘combustion chamber with cl, Inject @ Bast of air in {rom the inlet ond exhaust ports and if ony bubbles should appear itis on indication thot the valve seats ere sot congletely sealed.© 6mm box bot @ Cylinder Fig. 2-35, Removing the cylinder @ Upper croteote © Cylinder gauge @ Grinder Fig, 2-36. Meaning the eyindor bore 0572465} Fig, 357. Paton © Paton eng nets gouge @ Pion Fig. 3-38, Meonring tho pton vig side ceoronce on ENGINE 7. CYLINDER A. Construction The cylinder sleeve is made of special hard sleet clloy ond is press fited into the lightweight cos! olumi- tum body. 'A compartment is provided between the eYlinder bores to accomodate the cam chain ond (Fig. 3-34) B. Disassembly 1 Remove the cylinder head in accordance with Section 32.1. & 2. Remove the 6am hex. bolt @ and then remove the cylinder @ from crankcase @. (Fig. 3-35) . Inspection ourof-round 1, Measure the cylinder bore, pe! with-a precision cylinder gouge Toke the measurement at the top, middle ond bottom in both the X and Y axl. (Fig. 3-36) em —[Stonderd Volos —] —Senceatie Test — finder | $2.00~6201 mm | Fepai if over ore inpep~t enue) _| SE tm (20812) Cyndie Topo over % 2.005 wm 0008 | BI Seon 158m 10.0020) Eylindor aut ; Spade ° | 0.005 men 1.0002 2 The cleorance between the piston and cylinder will greatly offect the engine performance. Becovse the piston & elliptical, the clearance is controlled very closely, The clestance fe no! the sone, however, if eny area le greater than 0.1 mm (0.004 il, the cylinder should be rebored ond ‘ed with an oversize piston, Oversize pistons ore available in 0.25, 0.50, 0.75 cond 1,00 mm 10.01, 0.02, 0.03 and 0.04 in size, 3. When removing carbon deposits from the piston tap ond ring grooves, care should be exercised 0 a5 10 not cause any scratches or damages to the piston, 4. Measure the piston perpendicular 40 the piston pin hole. (Fig. 3-37) Tem Standard value | Sense at Fool 8561.50 me ~~ wside [72°] t2030~2001e__| ae |) S196~51.98 mm pose~2.087 mt 5, Meatere the piston ring side clearance with thickness aovge. (Fig. 3-38) a a fo Chm 00040 Se bend Obs eT [SPS lon (6.0004 ~0,0018 int | Of se 10.008 nt3.2. CYLINDER HEAD AND CYLINDER 30 6, Piston ring groove Tien Sioned Vane] Sericeable Ua TE9~ 46.0 Bonom ke | gor~ iat Top | 1.208~1.220mm | Replace F over — ond (5.047~ 0.04810) _| Imm OOSI2 [oy | 280~ 252mm | Reloce over iGore~apreim | bem loo 7, Piston rings Measure the ring end gop by inserting the piston ring into the cylinder £0 tho! the ving is ot right tngle to the cylinder axis. (Fig. 3-39) " ————— Ties J “Sienderd Vas] Serveeatio Unit @ Thicinew gauge @ Piston ving @ Cylinder T.i65~ 1.180 mm —| Boplace i unde Fig. 2-29, Meoruring the piston tng end 909 [Foe | tec4e~o.oeée m_| 1f26mm Woden) » | cotta ng TITS 190 wm ~ Rplce 7 Meer (ane Oar)_| rm (5447 5 EATS 290mm | Rotoce Tarr 01 | ‘om~ooin | Stine ware ra am [RR] USR=O78IG | Hepce I wnder fing [scond tis~i abn | Oahg 0926 ba Gi [oy | 872= 10089 | Repiace if ander force Jon | iewaares | OBig davies | Tis—adee [Rene over | mond sop | ooscooisn [Ohm acisn | 1 Check the gaskets for damage. Replace if ony omage exist (Note) Bese Ee 1. Oversize piston riage are available in four sizes; © Cylinder @ Pinion bose @ Piston ring compresor 0.25, 0.50, 075 and 1.00 mm (001, 0.02, 0.03 Fig 3-40. Insoling the cylinder cond 005 i. 2, When mating piston ring end gop measurement, Insert the ving carefully into the eylider to prevent scratches oF gouges to the cylinder wall D. Reassembly 1. After assuring that there are no damages oF exces five wear to the cylinder, ostemble the cylinder In the reveree order of disassembly. 2. Moke sre that the cylinder gasket and the two dowel pins ore istlied 3. During the installation of the cylinder @, use piston boses @ to prevent piston movemest, elo tive ring camprassor @ to proven? ring damages (Fig. 3-40), 4. Assemble the cylieder head and cover unit (Note) Check 10 mate sure that the gaskets are properly In place, 3.3 LEFT CRANKCASE COVER 1. LEFT CRANKCASE COVER A. Construction The purpote of the crankcase fs to protect the Vitel components of the engine. The left crarkease © Lett cronkese cover hovwses the AC generator tlotor, (Fig. 3-41, 3-42) Flas $41. Leth croneose cover31 ENGINE B. Disassembly 1. Drain the oil from the crankcase 2. Remove the gear change pedal 3, Aller removing the mounting scrows, the lft crank cate cover con be teparated {om the crankcase © Clutch litter thread @ AC. generator stator Fig. 2-42, Stotor hovted i the lft cronkone cover C. Reassembly 1 Perlorm the assembly in the roverse order of disastembly. Make sire that the gatkets are rot damaged or misaligned and that the clutch action ie normal 2, Perform clutch adjustment. (Fig. 3-43, 3-44) Fig. 3-43 2. A.C GENERATOR A. Construction The detailed dascrption of the AC. generator is civen in the Electrical Section The AC. generator it mounted in the let crank cose cover. (ig. 3-45) 'AG. generotor 10" @ AC. genealr solar Fig, 345. AC. generator sotor ond ator3.3. LEFT CRANKCASE COVER 32 B. Discssembly 1. Iris not nacestary to remo semble the AC. generator lin this section, operation 1s explined with the engine dsmousied) the engine to dior. 2. Unlooren the thras scrows and remove the dynamo 3. Remove the rotor mounting bolt and remove the rotor @ withthe use of the generator rofar pull @. Cool No. 07933-2140000) (Fig. 3-46) 4. Usloosen the screws ond romave the left cronk cote cover and the stator @ from the left crasicose cover @. (Fig. 9-47) Reassembly 1. Assemble the A.C. genetotor in the reverse order of removal (ote) Moke sve that the pin instlled during mounting of the rotor. |. STARTING SPROCKET AND CLUTCH (C8175) Construction The sorter armoture speed Is reduced by a series ‘of gears enclosed within the starter housing, The chain further reduces the speed ond provides high torque 10 turn over the cronkshott for each staring. To prevent the starter (rom being thotorized after the engine starts, an overrunning elvich is incorporated into the AC. generator rotor. Refer to the electrical section for details B. Disossembly ond reassembly of the starting clutch 1, Remove the AC. generator in accordance with tection 3.32. 8 screws and remove the starting 3, Reastomble the starting clutch ond AC. goneretor in tho reverse order of disatsembly. Check to ossre smoother roller operation. Check condition of side plate ond guid. CCheck for the weok or broken clutch roller spring DAG. gorerator rotor —@ Rotor pulet Fig. 3-44, Fomoving the AC. generator rotor @ AC gorerotor stor @ L. Cronkcove cover 307. Removing the AC. generator soto. @ Storing chow Fig. 348. Removing the wrting chia© Starting not @ 6X36 hex bolt @ 6mm fat wosher @ Adjter fixing pisce @ Clutch odjter ® Cueh iter head @ Lei cronkcose cover Fig. 3-51. Components of clutch 1 6X12 ciom srew Neutral sich sito @ 6X20 crom serew A) Neutral switch rotor Fig. 3-52. Bomoving the neutral switch flor ENGINE . Disassembly and reassembly of the starting sprocket 1. Altar the removal of the AC. generator ond ‘tarting clitch it completed, remove the starting chain @ by disconnecting at the joint clip, (Fig. 3-48) 2. Remove the stoning sprocket plate set and remove the starting sproke. 3, Starting motor sprocket is easly removabie from (Fig. 3-49), the serrated shaft (Note) The starting chain joint cin must be installed with the open end apposite to normol divection of choin movement 4. CLUTCH ADJUSTER AND NEUTRAL SWITCH ROTOR ‘A. Operation of clutch adjuster The function of the clutch i 10 temporarily disen (9096 the transmiting of the power between the engine ‘and the transmission during the period of geor chonge. Clutch is operated by the handle I cable 10 opply pressure which ove springs. Tho clutch adjuster is sot to provide the proper clutch action, (Fig. 3-50, 3-51) isassembly and reassembly of the clutch adjuster 1, Remove the crankcase cover in accordance with Section 33.1 8. 2, Remove the 6X36 bolls from the adjuster Fixing plate ond thea remove the cltch lever spring tp eporate the clutch opivter, 3. Apply grease tothe clutch adjuster before ossembly use greare type HD multipurpose NLGI No. 2. . Disassembly ond reassembly of the neutral switch rotor 1. Remove the left crankcase cover 2 Loosen the 6X12 screw @ ond remove the rnevieol switch stator @, (Fig. 3-52) 3, Unscrew the 6X20 scrow @ and remove the nevteol switch rotor @ tom the gear shift drum (Fig. 3-52) 4, fit the nevirol switch rotor groove 10 the geor shift drum key and perform the osembly in the reverse order of dinoreembly3.4 RIGHT CRANKCASE COVER ASSEMBLY 3.4 RIGHT CRANKCASE COVER ASSEMBLY 1. RIGHT CRANKCASE COVER A. Construction The tight cronkcate cover () od the le crankcase cover, hovse the engine primary components. The ol filter cover @ ls fined ta the cove cover ond provides the pasiage for lubricating oil In bolh directions (Fig. 3-53) B. Disassembly 1, Remove the kick starter orm from the kick pinion shat 2. By removing the ten scrows securing the cose cover, the ight crankcase cover con be removed (Fig. 3-54) 3, Alter unscrewing the throas8x 16 screws, the fiter over ‘can be removed. (Coution) During operation, attention should be given to the two 745x3 "O° rings filed 10 the filer cover fo osture that there are na’ oil leaks C. Reassembly 1. Before performing the ostembiy. inspect the eronk care ond ol fer covers for cracks ord alto for ‘ny demages othe mating surfaces since they will oise oil Tents 2, Clean the O rings @ and inspect for any damages: replace if necestry. (Fig. 3-85) 3. Alor insallaion of the sevews, ighten them ui formly to. prevent the covers from worping abd corsequen! ol lets 2. CLUTCH A. Description ond operation The fonction of the clutch i 10 temporarily dis engage the ‘raremiting of the rotary motion between the engine and the troremisian during the goor chorge tard. then offer the gear change, permit a smooth power transition. The condition ‘of the. cluteh will fave © vatying efect on the eficiency of the power transmission. (Fig. 3-36) The dluich mechanism Is of @ conventional wot type muliple dite operated by the cltch iter head connected by @ cablo 10 the clutch lever. When the right crarkcase cover is removed, the clutch complete it exposed. To. the clutch outer Compete, the ctch spring driving the clutch pressure plate is installed, The cluch plate Is insaled wih the clich tretion dise between the clutch canter with Four 6% 20 hex babs “The clutch plate hos teeth cut onthe irsie. These teeth fe engaged wih tooth cut on the outside of the clutch ‘corter, The clutch center ls coupled 10 the troramission main shaft by spline. Hence, it ond the trarsmission ‘main shaft ore. essentially single Uni. "The elitch plate, clutch center, and clutch pres sre plate rotate. ‘On the other hand, to the groove cut on the ‘exorior circumference of the clutch outer, the clutch Friction die iz coupled by the colar entering the groove ; freewheeling rotation with the transmission froin shaft obtained, Hence, whila the clich je Comected, the clutch outer carer, six clutch plates, [Ex clitch friction discs and clutch pressure plate ore fssenilly © single unit through fiction exerted by © Bight cronkcate cover @ Oi fier ever Fig. 3-53. Nght croncor cover © 6x32 screws @ GXES cers Fig. 2-54, Hight crortease cover screws DO ting @ OW Mer cover Fig. 355, O sing ond ol fier cover35 3. ENGINE D Che od_@ Gich over conpieys Nee — a zs! Y, = bug ba ti i Fisch conor @ 20mm set ing Chich tier joint piece @ Chuch plate & @ Chtch reion dsc” ® Chsch plate" @) Chtch pronwre plate Chtch spring) Clutch seving rearing pete @ 820 hoe bal Fig. 3-56 Clateh ® ~9 the clutch spring ;rattion ofthe crankshaft is taranit- fed to transmission system. When the clutch lever I gripped, the clutch ad jester rotoles cloclwis, the adjustment throod ie pushed fut by the squore-headed tivead inthe cluch adjuster Fined to the leit crankcase cover: hs i pushed out by the clutch joint through the clutch rod. The clutch pring ie compressed ond the six clutch fiction discs Gnd’ six clutch ploter become dueagaged. Hence the rotary motion of six chtch plotes ond six clutch discs is no! Worumilted to the cltch centr. ig. 3-2 Oe D Gis sping D Chae covior @ Gatch cater @ Chih itor rod © Chach plow {© Guth titer jit plsce ) Clsteh leton dae Fig. 8°57, Sectonal view of clotch @ Guich odusier @ Chichier teod @ Gute ther ros octiral view of eich adusing teeod B. Disassembly 1, Remove the ght crankcase cover 2. Unscrew the four clutch pressure plore retainer bolts and remove the friction dise and clutch ples.3.4 RIGHT CRANKCASE COVER ASSEMBLY 3, Remove the oil iter rotor lock sul end then the cll fer retaining lock aut 10 pull the rotor off the crankahot 4. Remove the 20mm sat ring @ and remove the clutch conter @. (Fig. 3-59) 5, Unscrew the oil punp body mounting nuts ond separate the oil pump from the crankcase 6 Remove the oil pump assembly together with the clutch outer cover. (Fig, 3-60) (Coution) Pull off the clutch unit parallel 10 the shaft exerci ing core £0 thet the shaft is rot domoged . Inspection 1, Clutch spring Free erat | 31.05: 1 22min | Bee $38:060 99.911 hn Load (ote) Use coll spring teeter (Tool No, 07134-9950) for testing the valve spting tension 2. friction dite 2921.08 90 ions~o.3t in ‘Within 02 mm | 23m 0.0984 19 3. Clutch plate (Fig. 3-61) Replace it over | Srondord Vote] 3.0mm (0.118 4. Primory drive gear Tiondord Vols | —Sevieatio Unt Garde itnce | 18769~15790mm | Replace i unde soon 3 | 106208~o1a5ia) | 18739 mm D. Reassembly 1. Reastemble the clutch in the reverse disassembly order of 3.5. OIL PUMP, FILTER AND SEPARATOR 1. OL PUMP A. Description The oil pump is © plunger type, operated by a connecting rod through an eccentric cam on the transmission moin shaft. (Fl. 3-62) 1@ Clute eonter © 2am set rng Fig. 2-59, Removing the 20 nm se-ing @ Cutch ower @ Oil pune ossembly Fig, 2-40, Removing he vuteh outer ond pane body ® ©@ Vernier calipers @ Cloch plate Fig. 2:61, Maouiring the clutch pote theese @ Oi pure Fig. 3-42. Oil pune ond certntgal fier3. ENGINE 373.5 OIL PUMP, FILTER AND SEPARATOR 38 O Lubrication system (Fig. 3-63) The oll is picked up from the crankcase sump ond routed through the ell passage 10 the oil filler where the Impurities ore removed by the certlfugelly operat ing oll fier. The clean oil ie then pressure fed ‘trough the upper crontcose to cll the cronishalt beating. The oils separated into two rovtes, one is fed 10 the roller bearing ond the other enters the crankshaft 10 lubrieste the consecting rod large end though the holes dilled in the crankshaft journos The connecting rod small end is bbrcated by oil nis, The cil from the veper cronkcase oll passoge is separated inlo two paths, one of the paths delivers Cll 10 the top of the cylinder head through the cylinder stud bolts. This oll Is fed ito the camshaft from the rocker arm ond lubricated. The il lubricates the com chain on its way down 10 the sump. The other oil oth feeds the oil through the oll potsage in the crankcase and enters the transmission fo lubricate the free goors. The other gears ond bearings are libri coted by oll droplets and mists Disassemble 1, Remove the right crankcase, Remove the oil fer Remove the righ primary drive geor Separate the pump body together with the clutch, By removing the 261mm circlip, @ the pump rod ® con be seporated from the clutch outer (Fig. 3-64) 6, Extract the pump plunger pia @ ond remove the plunger @ ot the tip ofthe pump rod. (Fig. 3-65) @ em cin @ Pomp rod Fig, 3-84, Rezovng the pune rod © Pump plunger @ Pomp rod @ Pomp plunger pin Fig. 3-45. Removing the plunger39 3. ENGINE © 26mm ciclo @ Pump tod side washer @ Pump tod @ 6X36 stud @ Flunger pump pin @ Plnger @ Pune toy gost!” @ Suction valve belt @ Sucton voke Bolt packing @ Suction valve soving 3" steel ball {@ Or pump boy Purp Titer seen @ X" sol bal (9 Vole spring @ 11-5%2 0 rag A Outlet volo guide @ Pomp lock wother QB 6mm hor mt Fig. 3-66, Pump component port 2. Component parts of cil pump. (Fig. 3-66) . Inspection 1. The normal copociy of the oll pump is 3600ce/mirute 1 10,000rpm; i the capacty falls balow 3400ce, there is @ danger of developing engine seizure, therefore the pump should be repaired oF replaced, 2. Clearance of composen! poris Seniceable Gar = Slandard Val = Plrger 12 | .025~0.083 90 owing" | toot ~0.0028 mt Feoplace If over Oren tobe” i D. Reassembly 1. Astembie the pump in the reverse order of ditas- sonbly. (Note) 12, Proper operation of the oil purp can be checked by loorening the left rear cylinder head cap rut lbrication te normal W cil eoope ut, th If there i absence of oil, check the following points: (a) Proper assembly of the pump. 1b) Condition of gaskets [cl Excessive cleororce of punger (ai Malfunction of the steel boll valve, le) Clogged screw. WN) Clogged fiter oF oll passages.3.6 CRANKCASE 40 2. Ol FILTER A. Description The engine oil is doubly fred. through th cenirityge filter afd the mesh scroen filer to. otsre claon supply of cll 10 the engine. (Fig, 3-67) The screen filter is on the pump ile! side ond the ‘contfugolfiter it on the outlet sid, B. Disassembly Remove the right crankcate cover in accordance with Section 34. 8. For clearing of the centitgal oll fer, only the removal of the cil filer cover Is required 1. Grasp the rib of the oil iter cap @ witha plier cond draw siroight out. (Fig. 3-68) Use screwddiver.and unlock the lock washer. 3. Remove the mounting mut with « special tool 4, Pull of the oil fer rotor C. Reossembly 1. After cleaning of oll the ports, perform the ret sombly lo the reverse order of disosibly 2. Moke sure thot the 16 mm mounting rut fe properly torqued ond fiter cop wall seated. 3. OIL. SEPARATOR ‘A. Operation The oil separator @ is located In the forward tection of the lower crankcore, directly below the Cronlahalt, Is primary fiction is 10 control the cil splashed by crorishalt counter weigh, prevents cil Penetration ord contol the oll temperature. (Fig. 3- 7 3.6 CRANKCASE A. Des The upper and lower crankcates ore constructed of lightweight okminum allay ard con be seperated ff the center lines ofthe cronkshot tranemision that fond the Kick starter spindle, In cddtion, the stating motor is mounted at the front section of the C8175 erankcat. In the upper surface of the upper crankcase, the finder stud bolts ore inserted The lower crankcase is eqviened with tho oil separator, lower erankease cover, and two drain pls. (Fig. 3-70) @ OW fier vor @ 46x2 Onng @ OW Mer cop 1 2-67.” Oi fer 0) Fig. 2-48, Removing the me) @ Oi seporotr Fig. 369. Lower cronkcore © Drain plo Fig. 9-70. Dron plugs3. ENGINE ® ]& Disassembly [> | 1 rain ot inte rokeoe 2. Ramove the cylinder head and cylinder. 3. Separate the left crankcase cover and AC generator. 4. Separate the right crankcase cover, cil iter, clutch ‘ond oil pump, 5, Remove 8 mm out ond 6 mm nut from the stud bolts fat the upper part of the upper crankcase (Fig. 3-71-a) “gan bot @ Fig. 2714, Croskcore bolt 6 Remove 8mm oul, 6mm bolts ard 8 mm bolts From the lower crankcase, (Fig. 3-71-8) 7. Ramove the two 5X12 crost screws ond storing motor tide cover, and then remove the 6X20 and 6X28 bolts on the right hond side of the crank ose which mount the starting motor. (Fig. 3-72) 8, By removing the 6X35 bolt on the lft hard tide ff the staring motor which fe supported by the crankcase, the starting motor can be removed. 9. While the key on the gear shift orm & releated from the shift drum, dismount the motor . Inspection 1. Check for damages espectally orcund the machined ‘mating surfaces since even a small defect wil couse oil lea ‘The mating surfaces should be fatto within 0,05 mm (0.002%nl. Measure with a thickness gouge on surface plate D. Reassembly 1. Asvembly should be performed with attention paid ta the following poine + Cleon the crankcase ond inspect the mating sur- {@ 6X20 nex Bolt @ SX28 hex faces of the crankcase for sign of leaks, scrotches @ 436 hex bolt ‘and other domages + Apply liquid gasket to the mating surfaces of tho cate extemble alter drying 3.7 CRANKSHAFT, CONNECTING RODS, AND PISTONS A. Construction The crankshoft journals are made of high carbon steel and the counterwoights are of nickel-chrome- molybdenum steel, ortenbled by pros: fing, Cronk- shaft is supported by three roller bearings ond one boll bearing which totes the thust lood and ore fxed in place by dowel pis. Sproclet 10 dive the com choin is machined on the center shaft. (Fig. 3-734, 8) Fig. 279A. Cronksho,3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 42 ® a POPP DROME BER rs @ gaa i @ tot cronishah @ 361m crn G ASmm side wonhor @ L. mein bearing autor ting @ 4X10 roller L main bearing role retciner (@ Confer booring roller vetiner@) Center crank shal @ Conocing rod” @ 25X10 roller Fig, 8-738, Cronshot conplate sectonal dogrom ‘The oil outlet passage in the upper crankcase is aligned #0 the oil ensular groove in the crank counter ‘weigh, Oil is forced into the eranépin by contriugal force to lubricate the connecting rod bearing. There is bo @ separate ol rovte 40 lubricate the main bearings. (Fig. 3-74) B. Disassembly 1. Drain oil from the crarkcor. 2, Separate the cylinder head ond cylinder. 3 Separate the loft ond right crankcase cover 4, Seporate the AC generator and clutch oll pump. ‘5. Dizaxonblo the croskcase in oecordance with ection 3.68 C. Inspection 1. Support the cranishalt on V blocks of both beor ings and measure the amount of runout. (Fig. 3-75) Soriaab coor] Torat | 30 mam 3 ny ©-0008 1) al a ee 30.mm'1.3 inl = 0.08 mm_ (0.0032 in} @ Sem seolng worer @ Leite Comectng 10d rlereetainer jor crane weight @ 4X13 “@ f contr crank outer ting @ Bight canter crnk weight {® 6205 SHS bol bearing GH High cronahoh DOT G Caner cok ones ing @ Cok wage @ Comecting roa Fig. 2-74, Craniholt Mbvicating potage @ Dial gouge @ Crankhah complete43 3 © Crise @ Main bearing ovter ring @ ¥ block © Oral gouge ‘Checking the cronshal for vert = ee @ Moin bearing outs ring @ Dil gouge GD V block @ Croat Fig. 2.77, Checking the crnkshott for side clearonce @ Comecing vod @ feller @ Retainer Fig. 978. @ Wax defect Fig. 3-79, Checling defection ot the piston end ENGINE 2, The clearance in the bearing is measured by fixing the crankshaft on centers ond moving the bearing (Fig. 3-76, in the axel and vertical direction 277) Sndorg Vane rad Within COSmm | Fapiace over {lecronce | 8012~0.0T mm —| Resace W over ermal fo-ove | 1.0005 0.0008 | O45 mo 10.0020 ‘When the clearance in the axial direction becomes excessive, the crankshaft will move from side. when fengine le running and produce undesireoble noes os well 0: cousing uneven weot to the cylinder, piston ‘ond the fining. geor. 2. CONNECTING RODS A. Description The connecting rods ore of molybdenum steel ona hove an H-shoped section: the roller bearlags et the cronishatt end. The crankshaft is polished fer case hordening ord mounts the coller without race. The roller (25% 101 is held by the roller retainer mode of special aluminum olloy. Staggered rollers are vsed in ‘order 10 increase the load capaciy. (Fig. 3-78) 1. Measure the connecting rod. ction at the piston ond of (Fig. 3-79) Detector || Some3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 44 2, Measurement to determine if the connecting rod tends are correctly aligned ond parallel is obtained bby measuring the diference of inclination of points 50mm (20in| away from the center when a 100mm 14.0 in) bar with tho some thickness as the piston pin diameter i ingered into the bore of the piston fond ard twisted 10 the right and felt, and when the bor Is rotated 90" ond agoln twisted to the fight ond lef. (Fig. 3-801 3. PISTON A. Description The piston is made om select material, an eluminum costing. This moterial i light ond suitable for high speed, in oddtion 10 having good heat conducting property 10 dissipate the heat rapidly. Furthermore, the coeficient of act expansion i smal thus minimiz ing the warpage ot elevated temperatore and permit ing a small piston to cylinder clearance design. The shape of the piston ison elliptical oper. The head ff tho piston, compored 10 the skit, is exposed to higher temperature and since the expansion is greater, 184s toperingly smeller toward the top. The tapering fof the pistan liso tends 10 lessen the piston slop when the throtle is lightly snapped without the engine being loaded. (Fig. 3-81) The piston employs @ four step taper. The piston pi bose area is made thicker thereby resulting in greater expansion a high tompercture. For this rason, the diameter of the piston ster is mode smaller in the direction of the piston pin so thot of the high oprating temperature, the piston will expand into a tive circular thope. The sit is constantly provided With Nexbity to assure thot 20 deformation wil esult ‘even from extended continuous driving The piston pia i offset mm 10.040 from the piston conterlne in the dizection of the inlet side so that When the piston opproaches the top dead center of ‘he compression stroke, the side load from the cylinder moves from the right side to the left. With o "O" (offs, the point will move to align with the top-dead, center of the compression sire B. Disossembly 1. Remove the piston pin clip and push out the piston pia. (Fig. 3-83), ——fir— EGREE OF PARALLELISM, TD Wax dofecion degree of Porlelion Fig. 2-80, Chectng level of parle! ofthe pion end of the comecting od @ Volve excape —@ Pinon ring roover @) Paton Fn ale Fig. 3-81. Paton 7.0(0.04n) Pion ofier "© Piston pin clip @ Piston Fig. 2-83, Rowovieg the psion pin45 3. ENGINE 2, Remove the piston ringe from the piston by vsing © pision ring toot pecial tool), If the tool hot avilable, the riage may be removed by hand spreading the ringt ot the ting opening with both ands. During the process, the ring should not bbe twisted or expaded more than necessary os 't will couse the ing t0 break. (Fig. 3-84) Fig. 9-84, Removing the piston ing fC . Inspection 1, Before inspection, carbon adhering to the piston head or ring groove should be temoved, using is care nat t0 #erateh the piston (Note) ‘Sondpoper should not be used for removing carbon ie @ corbon scraper 155-8100 ea 4 2. Piston outside diometer (Fig. 3-88) Siandard Val Bi5E~51-00 am Sus 20296~ 2031 i) 4872045 Fi me (2.0457 ~ 20465 il 3, Ring groove clearance when a new piston rng is fined. (Fig. 3-86) Tan] Stoned Vote] Sortavabie nl 7 (25~0.085 ma Replace i over ep tra | Yooo1~000 | OF mm (0.004) Second ang | 00150045 mn Replce | so.c006~0.0018 in | ote 008 nd _ 0.010~0.045 mm] Ropiocs if over Ot eng | 10.0006~1.0018 it | 0 mm 10.008 & ss on Fton rng @ Paton Fig. 3-86, Mooring the ring groove ceoronce 4, Piston pin hola (Fig. 3-87) Tee Glondord Value Sewicsobe Uni 14:002~14.008 wm | Raploce Hover = (O'S5t—0.582in) | 1408 en 08892 in) 5, For oversize pistons, there are three ot intervals of 025 mm (0.01 in © Cylinder gouge @ Piston Fig, 8-87, Measuring pliton in bole3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS D. Reassembly 1, Assemble the piston on the connecting red, only fo sligh! pressure shovld be required 10 instal the Piston pin, neal the piston pin retaining clip ot both ends. (Fig. 3-88) (Nor (al The top ofthe piston it marked with "IN" 10 one side, Piston must be instoled with this mark toward the inlet side (6) Use the new piston In clips 4, PISTON RINGS A. Construction The piston rings perform @ vital function of forming © t00l between the piston end cylinder, controling the lubrication of the cylinder wall and disipating the heat from the piston, This erves to develop groater power out ‘The rings ore made of special cast ton for strength weor retistnce, heat resistance and good hoot conducting qualities. Rings ore given patterizing treotmnt for added strength Top two rings ore compresion rings 10 prevent ‘gx leak, thete two rings ote mode with a slight tapered surface where it contacts the cylinder wal to expedite wearing.in, top ring outer sutlace is hard chrome plated for extra wear ‘The oil ring is grooved for ail sroping B. Inspection 1. When the piston ring hot been removed, it should be fitted with the gap approximately 15 mm (0.6 in) from skit of the cylindet ot 0 right engle to the center line, Mecsutemen of the gap should be mode with @ thickness gauge. (Fig. 3-1 Tie see ae Top rma | faonsote Second rg | Goose Sts _| Om 055 1 Ot e09 feoeca stain | On ost it 2, Torsion of the piston sing is measured with a torsion measuring insirumont [Santora Vana | Sereabie nt foom~eosdm | Oalg G26 OF ing 10.028~0.397 tb)_| 0.53 bg (1.169 tb) 1@ Paton pin @ Piston Fo. 3-88. Asanblng the piston © Thickness govge @ Piston tng Fig. 3-89. Meaning the paton 9 90°a7 3. ENGINE Fie, 3-900, Peto tng [Toot Fig. 3-908, Pion rng (Second Figd-90G, ton tag 3, Piston ring dimensions, (Fig. 3-904, _ Trea D | Sands do Geos] a200 a007 a lL 2 | | omve so ost croncer | 5250 orm ® %| | Cte ao 028 eres | $278 tor w 3 SC rs st 100 ree | $300 asi __ 8 ey wan 23-26 woni~Om) | thaws | csc Nemo coceti 1.128 wus (al se ena To] omits a toc || ons de 028 Oren | @ || Snes go 00 tremens | Sone wtp oe 2| | Sen ee 2 |_| Ones 30 00 reece 2 |_| ownte oo 100 oer | _ - § fe) won Wasa Gon ~OaH | | Thickness 1.17S~1.19 10.046~0.047 in} | 1.135 (0.0447 in) [@] Aro 11830 | O] Gwe de Bonar Owns da 028 wae See 2} | oven aie 075 verze) & | Sits So nao mea 5 Te] wen 2328 @or1~O07E 3] tae paver 2e9 0077 -00M a) | 243 0087 Wd @| Arce None’3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER 48 C. Replacing the piston rings 1, When piston ting it reessembled, it should be fitest0 the eyinder. Inspection should be made to. determine i the gap of each ring is between (0.15 mm 10.006 in) nd 06 mm (0.018 in if the (opt are somewhat less, they should be dr wih le. (Ceution) al When a gop is dressed with fle, adjueiment should be made perpendicular to the rings. (1 If the piston ring gop is too smal, selure Between the riag ond cylinder occurs due to imal expondion if the gop is 100 lorge oll natration or gas leokoge occurs Fiion tag @ Inspection of he piston ring by rotating oround isto ring is ostembled on the piston, ory Fa. 3-91. nee between the ring and the oroove t smooth operation. Iie necessary to Inepect for clearance, when naw ring by itted to the groove, by totaling the ting around the circumference, (Fig. 3-91) 3, Install the rings on the piston with the piston ring tool, the ‘ings may abo be instlled marully Install the bottom rng fr. (Ceution) (o} Core should be exerszed not to install the rings Upside down. The top side of the tng i morked feat the ring opening with the manufacturers ints. “Fig. 3-92), 1b) Worn or singe which has lost its tension should be replaced, 4. Spoce the piston ring gaps 120° apart. Aligning of the gone wil revit in pressure leak. 3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER Fig. 3-92. Piston cng Fig. 3-95. Cam chon tensionao 3. ENGINE 1. CAM CHAIN TENSIONER ‘A. Operation The com choin tightener is used to tighten the com chain from the outer side with the cam chain (vide roller in between, ‘As shown in the figure, the tensioner push bar it futometicall under compression by the cam chain tensioner sping ond supports one end of the tighener. ‘On the other hand, the tensioner roller is applying pressure against the cam chain. When the tensioner fot bolt is lootened, the tensioner push bar auto: matically totes up the slack of the com chain by ‘ppiving force from the spring, (Fig. 3-93) B. Disassembly 1. Separate the cylinder heod ond cylinder, 2, Tie @ wire across the ends of the com chain 3. Remove the two 6X20 bolts mounting the com chain guide roller ard separate the cam choin tensioner from the crankcase 4. The cam chain guide collar is coupled to the com chain tensioner and remove the com chain guid roller pin and then separate the cam chain tension (Fig. 3-94) m 5, When the Smm thin not iz lootened and the ian tensioner set bolt is removed. the tensioner push © Com chon pide rer @ Com cha bar covpled to the cylinder heod is seperated ee ee together with the tensioner spring. (Fig. 3-95) C. Inspection 1, Check the com chain tensioner for ony damage Tom | — Sida [ Senieeabie iat Tensioner pace if under pmng ree | 620m a.260mm | Replace if ander Tensor | Lana D. Reossembly 1, Perlorm the assembly in the reverse order of lsctsemby 12. Replace ony worn oF damaged guide of ten. sioner roller . Astomble the tensioner posh bar and spring Ito the cylinder hood and lock with the set bolt. The push bor should bein the retracted postion to factitate compacting the com chain (Fig. 3-95) £. Cam chain tension adjustment 1. Loosen the tensioner set bolt and the chain will tighten avtomtically 2. Reset the tensioner set bolt and lock withthe lock rut. (Fig. 3-96) © tock wut @ Tensioner 21 bot Fig. 3-96. Agusing the com chain3.9 TRANSMISSION 50 3.9 TRANSMISSION A. Description The tronamistion receives the rotary power from the crarlshalt ond through a series of gears, changes It 10 ‘he desited speed ord then froninits it to the drive sprocket to drive the rear wheel, All the gears are fully conetont meshed, astiring smooth gear change. (Fig. 3-97) © 6904 HS ball bearing @ Troneinion main shat GD Main salt top geor @ 20m that washer A © 200m cic @ Ball bearing st tng A.D 8X162 stud @B 10XI4 brock pin @ Main shalt siting guar (@ Moin salt cecond guar GD 15am bosrng bush A @ Krock pin (9 8X25XB ol sol @ U6 Leaing buh B 1 Kock pin Courter shal low gear @ Couter sho second gear GY 20mm circip G@ 20mm thast washer A @ Counter shlt fourth guar 2 Counter thf tied gear. @® Cainer shalt top goat GB 20X42X9 TCiype ol ea) {8 Drive sprocket 161)" Dive sprocietUxing plate @ X10 hex. bolt @ 10X14 dnodk pin @ Tronmason counter shalt 397, Tromiion 1. OPERATION When the clutch is engaged. the power from the cranlshalt is transmitted through the cluich ossembly to dive the troremission main shalt, During. the shiting of the tronemission gears, the clutch i dicen: {209ed to stop the rotation of the main shaft Tho postion of the goors will be described in reference to the neutral geo. Noutral: (Fig. 9-98) When the traemission ie in neutral, the gears in the trarmission ore orranged So that there Is no power tararitied from the taramission main shaft fo the counter shaft. The fixed main shaft low “fig. S98, Neural ger @ ls meshed with the free rotating counter shaft low gear @, free rotating mein shaft51 3. ENGINE ‘101, hed goo ig 9-102, Fourth goor top goer @ is meshed with the sliding counter shaft top geor @, sliding main sholt thirdtourth goare @ fore meshed’ with the tree rotating counter shaft thirdFourh gears @ @ ond the free rotating main shott second gecr @ it meshed with the splined Counter shalt second gear © Lows (Fig. 3-99) When the gear is shifted to low, the sliding counter sholt top gear @ is moved by the shift fork to engage with the free rotating counter shaft low gear @. The power from the transmission mata shaft’ @ ls tranemitted through the fixed main shaft ow gear to the counlet shalt low gear, across to the counter shalt top gear and then tothe drive sprockt @ mounted on the ond of the courier shaft. Second: (Fig. 3-100) When the gear is shifted to. second, the sliding main shot thir-ourth geor @) is moved by the shift fork to engage with the free rotating main shot second gear @. The power [rom the tronemission tmain shaft @ is traranitted theough the main shot third-fourh gear to the moin shalt second gear which drives the counter shalt second gear @ and hance the drive sprocket @) mounted on the end of the counter shel Thirds (Fig. 3-101) When the gear is shifted to third, the counter shoft top gear @ is moved by the shit fork to ‘ongoge with the covrter shalt thd geor @. The power from the troremision moin shalt ig transmitted throught the moin shot thied-fouth gear Yo the courte thal thd geor, across to the counter shalt top gear @ end to drive the dive sprocket @ mounted on the end of the counter shaft Fourth: (Fig. 3-102) When the gear is shifted to fourth gear, the sliding couster shaft second goor @ is moved to become engaged withthe free rotating counter shaft fourth gear @. The power from the transmission main shalt i¢ transmitted through the main shot third fourth geor @ 10 the counter shaft fourth goor @, cross fo the counter shaft second gear @ ond then to the dive sprocket @ of the end of the counter shot Top: (Fig. 3-103) When the geor i shifted to top gear the siding tmoin shaft third-fourth gear @ ls moved by the shift fork to become engaged with the free rorating main shaft top geor @. The power from the ‘rorsmission main shaft is fronsnitted 10 the moin shaft thdsfourh gear @, lover to the main shalt top gear @, across to the courter shaft top ger @ ond then 10 the drive sprocket @ of the end of the counter shaft3.9 TRANSMISSION B. Disassembly 1. Disassemble the eyinder head end cylinder. 2. Separate the cronkease C. Inspection 1. Main shaft to main shoft goar clearance. Wen | —Siendars Vas | —Sericoot int — Second | 0016~0.0t6mm | Replace it over fer 1156)| 16.0006~0.0018 my _| Of mm 20000) Top ovat | 0.011 ~0.045 mn rover 28g" | inoooe~o.0teiny | ort am 1.004 2. Counter shalt 10 counter shalt gear clearance, Sandor Vale] —Sevieabio Unit — hid, [009 ~0.028 wm | Replace it over Fourth gear 16.0004—00070 in| Of mm 10.004) i 8.016~0.045 9m ow eet | oo006~ 00018 a) | OF mw 1.04) 3, Beoring cleoronce. (Fig. 3-104) Tem Sandord Vetus] —Servieatio Unt Real Win 005mm | Replace over ‘osrance | 0002 Or mein Kecicl—001~0.075 mm | Replace i over Heoronce | 10.0004~0.0070 i) | 0.68 ym (0.002 in 4, Shit drum groove, (Fig. 3-105) Standard valve: 6.1~6.2 mm (0.240~0.244 int Serviceable init; 6.4 mm 10.256 int D. Reassembly 1, Astamble the transmission geats in the reverse forder of removal 2. Alter astombly, oll components should be checked to omire that the operation is smooth without any binding 3. Inspect the moting surfaces of the crankcase for ony tcratches oF danage which will be 0 source of oil look. Fig. 9103, Top geor Diol gouge @ Bearing GD ¥ block Fig, 2104, Meosvring cleoorce of the Bearing Fig. 3-105, Meourng the ait dum groove53 3. ENGINE @ Sui dna Vopper —@ Gear wah an {@ Gear sit ore tring @) Gears Geer shit send. como. 37106, Gear shit orm a lps @ Geor shit fore Fig. 3-107. Removing the ait fort guide pin ba “Shift drum stopper Stopper orm pote © Geor sit seine D 120m sat Fig. 3-109. Removing he geor ahi spindle 3.10 GEAR SHIFT A. Operation The gear shift fork it moved linearly by the rotary movement of the gear shit drum. When the gear {hilt pedol i deprattad, the gear shift spindle, through the gecr shit arm, courer the shift dum to move titer In the clockwise or counter clockwise direction, ‘depending upon whether the forwatd or rear of pedal iz depressed, The shift forks ote fited over the shift deum ond guided in its linear movement by the cam groove on the surface of the shift drum into Which the fork guide pins are inserted. Rotation of the drum shite the forks to the right or left which In tur performs the geor shifting, A gear shit return ite normal postion offer each geor change stoke, (Fig, 3-106), B. Disossembly 1. Disassemble the transmission in accordance with section 3.9. 8. 2. Pull out the gear shift guide pin clips ond guide pins. (Fig. 3°107) 3, Remove the soutrel switch rotor and stator From the left end of the shift drum 4. Unscrew 6X20 hex. bolt D and remove the shift arom stopper @ and stopner arm plate (Fig. 3-108) raw out The gear shift spindle and return spring can be removed by removing the set ring from the op: posite end of the goor shift spindle. (ig. 3-109)3.10 GEAR SHIFT 3.11 KICK STARTER 54 . Inspection 1. Inepect the geor shit spindle gear shit forks for twist oF bend 2, Inspect the gear shift drum ond guide pin for excessive wear 3. Check the springs for breakage and proper tension. D. Reossembly 1. Inert the gor sit drm ot the right side ofthe tpect conesse ond osentle the geor ait for inthe crnicos.. Fig, 3-110, 2-111) 2. Asonble the shit fork wih the gear shit fork ease eee eee EIN fon use sin clo Lot over af 3. Aasanbla the retal sich rotor end the stator. © Som sit fon gue a ie bt ea 4 Astomble the shit-drm stoppers this completes Gear sit um vpper cose otenbhy Fa, 8.10. Component prs of ono hit dom 15. Ruemble the goo shit return spring in the lower crontcoe 4 The goor shit nde shouldbe irted togther seth he cour oping om the ight ade ot the Tower eroneate, The. geor shit spindle side oppst ad oll teal shoud be inserted ct ho lft rdf the sit pnd ond then ita the string 7. atemble the crrkshatt wih trramsion geors in the upper esa ond tighten the lower cronkease Complete the osonbiyin accordance wih secion 38 3.11 KICK STARTER ® Geor shit fork @ Gear hit dram Fig. 3-111, Avombling the gear ait fork © 25am ci-cip _@ Fiction spring @ Kick sare pinion @ Kick torer washer @ Kick sorter spindle @ Kick storor sing D AXIS baock pin Fig. 112A, Kick storer osemblyBam cick @ Kick starter wosher © Kick tortor sing Fig. 3-1128.. Ozosenbling Fiction sping @ @ Kick ster spindle 6 ick stoner Corburtor pe Seting mark Moin bore ie il ‘ie ble Needle jet Jet needle Garowoy Hirota volved 3. ENGINE A. Construction “The kick starter pinion engages with the trons sion low geor and by uiilizing the transmission gears Leking is mode easy and does not require much force. Wheo the hick starter sholt is rotated by the Aicking action the serrated Lick starter ratchet fonge Is rotated simultaneously ond the pawl of the tick Sorter ratchet flange sides down from the ick stortor wide ond is pushed agolst the lick sorter pinion groove by the pawl spring, Power Is transerred from the hick starter pleion to the countershalt low ger When the lick starter isnot doprested or the ick storter peda is released citer Licking. the kick storter ratchet flange is pushed back by the kick starter spring. The pawl rests on the kick slerter ratchet {guide ond the kick storter pinion it freed, (Fig. 3-113, 8) B. Disassembly 1. Soporate upper and lower crankcase In accordance with section 3.10. B 2. Toke out the lick storer shot 3, Remove the main shalt, countershatt ond gear state dom, . Inspection (Check the ratchet end the hick tortor pinion ratchet for excessive wear ond replace if excessive weer xis, D. Reassembly Reassomble the lick starter in the reverse order of dsassombly, Setting specification (CB175, CLy75) cB 175 aus Pw 20 Pw 22 ae ® ~ 20 mm (0.787 i 22mm (0867 0) 495 298 F100 ic per | oapxe a1 | osxe 482 | 08gx2 452 | 086x2 183 | o.6gx2 n315 | 086x2 aaa | o4gx2 mes | ose mas | oopx2 26h x9.69 269x368 . 3°, 25356-3 soge 1°, 25356-3 stage ne Galo Wah 1.2 dapth 0.51 ee Be #55 07 x2x3) $58~ Ho 1069x221 208 P=800m 1.08 P=8.5 mat 195mm (07689 28.0 U1 nt3.12 CARBURETOR 56 3.12 CARBURETOR (CBI75, CL175) ‘A. CONSTRUCTION The CBI7S or CLITS is equipped with o twin vorioble venturi carburetors operated synchronously by «tingle cable from the throttle grip branching to the two thrahle valves, The choke valves are connected by a linkage. Each cylinder is equipped with on individual carburetor to provide maximum performance The operation of the engine creates a vacuum within the cylinder ond thie draws the outside alr Ito the cylinder after having been posted through the oir cleaner where the oir is cleaned, through the carburetor where the proper amount of fuel has been mixed 40 form e combustible mixture and finally enters the cylinder were i i ignited to produce the power necessory to perform work 1. FUEL SYSTEM [As the oir enters the carburetor, it pastes under the throtile valve where vacuum pressive is produced dh to the restriction covsed by the throttle valve extending ito tha main ait passageway. The fvel dischorge outlet Is located in this so-called verter area 20 that the vacuum pressute con draw out the fuel, Thi carburetor incorporates both the main ond @ slow system, Fig. 3-112, Sectional view of carburetor 18175)7 3. ENGINE Fig, 2-114 Sectional view of carburetor (CLI78) ‘A. Main system (Fig. 9-113, 9-114) The fuel passes through the main jet @ ond enters the needle jet holder @ where it mixes withthe bleed air ertoring from the blood hole located ‘round the needle jet holder @. The fuel air ‘misture poze: by the opening between the needle jet ® and jet needle @ ond is dischorged from below the throttle valve @) It i here that the minture is combined with the main or and offer being atomized, is token leto ‘he engine Fig 3115. @ Siow oh B. Slow system (Fig. 3-115) The clr which enters [rom the inlet posses through the outside of the air screw where it is metered ond femers the slow jo! bleed hole, lt mixes with the fuel which enters the slow jet @ to produce a full spray that is dchorged from the pilot outlet ot © pola! under the throttle valve. This mixes with the ir from the oir inlet 10 form © combustible mixture before being token Info the engin 2. FLOAT CHAMBER (fig. 2-116) ‘The corburetor must provide @ proper mixture of fuel of dillerentthrotle openings ond engine speeds in forder to accomplih ths, the fuel level in the corburetor must be moletained corsiant. The floot chanber Functions 10 serve this purpose. The fuel from the fork enters the loot chamber through the fuel inlet possage, between the floot valve saat @ and float valve @ and fils the chamber to the level where the foot @ sues 10 shut of the flow of the fuel by seating the oot valve against the valve seat though the fection of the float orm @. Ae the fuel fz coneumed, the fue level in the foot chamber, drops the Noa! will follow the level, ond the fuel wil sort to enter the chomber between the opening of the float valve and valve seo! to maintain o constant fuel level3.13. CARBURETOR 58 A spring it incorporated in the head of the float valve which cones in contact with the float orm. The purpose of this spring is 10 prevent the oat valve from oscillating 40 that @ constant fuel level con be nointoined even when riding over rough or bad roads. In further serves 10 prevent any shock between the oot valve and seat, thereby reducing the omourt of wear to these ports Overflow pipe When riding on @ steep gtade or when ony Foreign substance becomes lodge in the float valve. it causes the fuel to overflow from the needle jet oF the slow jet, and enters the engine causing the engine cll to become divted. In order to prevent such condition, on overfow pipe hos been incorporated in the float chonber. AY nosmal condition, the pipe Opening iz above the fuel level ond it server ro purpose, but when the overflow condition exists ond the fuel level rises, the fuel will drain out of the ‘overfow pipe tothe ouside rather than into the ening, 3. CHOKE (Fig. 3-117) For slotting in cold weather, 0 rich fuel mixture 'e momerarily required; to serve thie purpose, © chote valve @ is uted in the carburetor. A reliel valve @ is included in the choke volve and is held closed by © spring, By raising the choke lever fly the choke valve closes ond the cir entering from the dlr inlat becomes restricted. When the stating motor Is engaged with he throttle laver opened approximately 1/4, the fvel wil be drawn out of the pilot outlet ‘ord the noodle jot by the vacuum pressure. At the some time, the vacuum pressure will causesthe reli valve 10 open by the proper omount to provide an ool fuel mixture to eflect ond engine start. A the fengine stort, the vacuum pressvre becomes great ‘ond the relief valve is opened further to provide the Proper fuel misture to worm up the engine, In thie ‘manner the throttle valve movement covses the reli valve to operate ond, therefore, the operation of the chote valve Is not required 10 worm up the engine. ‘The choke valve is opened alter he engine worm vp. FUNCTION OF THE MAIN COMPONENTS. The main components of the carburetor functions in the following manne. 1. MAIN JET (Fig. 3-118) The function of the moin jot i to control the fuel achorge and to provide the proper fuel oir mixture a the higher range of throtle opening Idrving ot rmoxinum speed. However, the main jet will also have a varying degree of effect in the vicinity of 1/2 throttle opening. The main jets ore rumbered, £0 that the larger the number. bigger the opening and con: sequertly © richer fue-ait mixture, D Foot cantar wore Foo! valve soot D Fost vare @ Foot arm Flost (© Grote valve @ Relief valve, Fig. 3-117, Choke valve el ae Fig. 34118, Moin Jot59 3. ENGINE Fig. 35119. Nowe j Fig. 3120. Jet needle & Fig. $121. Throttle valve © Siow jet Fg. 3122 2. AIR JET At full throttle opering, the fuel-cie minture hos 1 tendency to become rich, and in order to prevent this condition, ¢ bleed alt Is added to the fuel through the needle [et holder. The purpose of the ir jet js to meter the amount of this olf» the largor the fir (ot, more alr will be added to the fuel mixture ford a leaner fuel mixture ie provided. Also, by mixing the it wih the fuel, better otomizotion will be assured, 3. NEEDLE JET (Fig. 3-119) ‘A ful or intermediate tnrotle opering, the needle {et will regulate the fvel which hod been metered by the main jet. This control is accomplished together with the jet needle which wil be doscribed in the {ollowing poragraph. The hole of needle jet fe made very acewotely for precise control 4. JET NEEDLE (Fig. 3-120) The jot needle together with the needle jet dos- rived inthe previous paragraph, meters the discharge (of the Suel mixture In the 1/4 to 3/4 theolle range. ‘The long taperad needle is expended within the noedla [et opening. The [ot noodle moves up and down with the throttle to corral the fuel midture proportionally to the throttle opening. There ore three grooves on the head of the [at needle by reseting the set clip toward the lower groove, @ riehor fuel mixture wil be provided. 5. THROTTLE VALVE (Fig. 3-121) ‘The throttle valve regulates the amour of fuel air inixture token into the engine to control the output ‘and speed of the engine. In addition, it serves Very important function in thot it controls the fuel “There is @ cutaway on the throtle valve at the of tnlet side which affects the vacuum pri thot controls the function of the needle jet. The use Of the throttle valve with diferent size cutaway will Control the discharge rote of the fuel, which affects the {velit ratio. The larger throttle valve cutaway umber provides leaner misture, however, this is only fective within the lower range of the throtle epering Grd has no effect above 1/2 tote opening. There Irak a throttle stop screw which sels the idling speed. TTuroing this serew IN will raise the Idling speed, and lowers the speed when the screw is turned OUT. 6. SLOW JET (Fig. 3-122) The slow jet controls the fuel at slow speed and a idling by regulating the oir entering from the oie bleed to produce a fusloir mixture which oss In the atonizotion of the fuel. The slow jet, Ike the Imaia jet, provides a richer fuel mixture When © jot fof longer number i used.3.13 CARBURETOR 60 7. AIR SCREW (Fig. 3-123) The ot screw regulates the sir ertoring the slow system by controling the pilot hole. Turning the grow IN will richen the mixture and turing the screw’ OUT wll Tean the iste 8. FUNCTIONAL RANGE OF THE RESPECTIVE COMPONENTS: In summarizing the description stated above, the functional raage of the respective components are ax follows: from fill clote to 1/8 throttle Ae screw Throttle valve eutawey: 1/8 to 1/4 throtle opening Jet needle: 1/4 to 3/4 throttle opering Main et: 3/4 to full throtle opening ADJUSTMENT 1. HIGH SPEED ADJUSTMENT During driving. the spead increases when the choke volve is closed slightly, tis an indication that the fuel mixture is lean In which case, replace the rnain jet progrestvely with the next lorger size until properly adjutied, The main jet sizer obove $100 fare £105, #110 ond £115 and for sizes below $100 core $98, 495 and 92. In the opposite cate, the speed should fll ff when the choke valve it closed, the main jet sze is proper, oF else, it moy be 100 large. In which caso, follow the procedure below to make the determination A. Properly set When, after replacing the main jet with one of 0 mollo size and if i is found to cavse a drop in speed, and on inereare in speed when the choke lightly closed, # fen indication thatthe main [et i t00 small, The replaced jet can be con: sidered 10 be of the proper size B. Main jet too large When the jet i too large, progressively replace ‘he jat with one of a smaller size until the con: dion in paragraph A cbove occurs, ond make the adjustment accordingly. 2. INTERMEDIATE SPEED ADJUSTMENT (Fig. 2-125) The adjustment within 1/8 to 3/4 throtle opening fe rode by the changing the position of the clip on ‘he jet needle groove ard the replacement of the ‘Wrote valve cuteway. However, the throtle valve cutoway will ofect the fuel mixture between idling and 1/4 throtle opesing. la the intermediate speed Tange, i is recommended that the jet needle be ‘adjusted within the range of good occeleration os this will prove to give better fuel economy. 1@ Throtle sop screw @ Air scr Fig. 3124, Adjusting carburetor Foot vole Fig. 3-125 @ Float orm @ Floot gouge @ Fost61 3. ENGINE A. Jet needle II) When excessive black amoke fs emitted from the exhaust during Intermodiate speed, it Is an indication of rich fuel mixture, therefore, lower the jet needle by one groove. (2) During driving, the engine misses or bucks, role the jet needle one groove, B. Cutaway of the throttle valve The throtlo valve with a larger number stamped on the cuteway will give @ leaner mixture Throttle valve wil affect the performance of the slow speed os wel os the intermediate speed, therefore, the range flected should be considered when making the edlustmert 3. SLOW SPEED ADJUSTMENT The fuel misture adjustment betw the cutoway of the throtle valve 1 idling ard 1/8 throtle opesing is accomplished with the oir screw ond A. Air serew The mixture adjustment ot idle te made by the oir screw. Turning tho scrow clockwise will give a rich risure and turning in the opposite direction will lean the mixture. Not only is the ling screw vsed to teke the idling adivstmen’ tu! it olzo should toke into consideration the mixture condition at the point ware the throttle stots to open 20 that there i smooth trarsition from the idling speed to the stor! of throttle opening speed, B. Adjusting with the throttle cutaway ‘As 0 point 1/8 throtle opening, the air screw may no longer be elective in acsting the fuel mixture Insuch 0 cose, replace the cuteway. M the mixture Is 100 rich, replace the cutaway with one of « larger umber and if the mixture to0 lean, replace with one of @ smaller cutaway number. C. Idle adjustment (Fig. 3-124) Idle adjustment is made by the ure of both the thvole stop screw ond the air screw by the following procedure 0) Use the throtle stop screw to set the engine to the proper speed. 12) Manipulate the ir screw bock ond forth slowly to obtain the point of maximum speed (3) Rete! the throtlle stop screw to bring the speed back to the normal Ui In this postion, recheck the cir screw to assure that the selfing is correct 18) Alter completing the idle adjusiment, check tho engine response by snapping and accelerating the throttle, Perform this check between 1/8 to 1/4 throttle opening 4, FUEL LEVEL ADJUSTMENT (Fig. 3-125) ‘The floot level is specified by the height of the float “h” thown In gure 3-125. The Moot adjusting procedure is described below in conjunction with figure 3-125. CBI75:h=19.5 mm/0.768ie) CLI7S:h=28.0 mm 1, 1in) 1, Invert the carburetor, In this condition the welght of the foot har caused the float orm to beor against the Mloat yolve end the spring is compressed Inta the valve. This if rot the normal fuol level position . Nex, get the carburetor os shown in the figure with the foot arm pin toward the top, tit the carburetor s0 thot the float Is on the bottom with the float arn in the potion 20 that Its just about to separate from the end of the float yolve and set in this postion. the arm will separate from tho ond of the valve when the carburetor is raked approximately 70°, therefore, about 10° from this point is suffclon, Ley Where the arm i not compressing the valve endl. «. In this postion, meature the distance the bottom of the float is from the body Nonge area with the gouge this isthe height "h. The tolerance is nim, the foot may be depressed 11mm or there moy be « clearance ‘of Imm between the gauge ond the oat. This much to letance will not adver sely offect the operation. If the float ie positioned in excess of this amount, make the adlusiment by bending the lip of the foot axm. There is @ spring incorporated in the end of the foot valve which will permit the end of the foot valve to sbmerge ond will give ond erroneous reading, therefore, exercise care when determining the point of ‘contact. Improper meoruremen! and agustment will no! give the proper fuel level

CB Cl175 CB Cl125 Shop Manual 1971

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CB Cl175 CB Cl125 Shop Manual 1971

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