. HONDA " cazso-aso' . .250-350 3.2.23.3st FORIWORD Til-Mandi:-gnidctolhniupeclionandaenidnsoflheflondnmowtcych.flondn250/aso. Modzl CHM/850, (ELM/350 and SL350. 'l‘hAClJSOilunqdunhaaeforthiamupl,dwrelm. lh: photograph: Ind drawing. Ill ofthil model However. since all models are practically idenfiul, 1112 information contained will mly oqullly to the 061:: models. Thb manual, (he Minor clung: (MMC) T-hle on page 19 show! the principul modification of other models toward! 01.350 Mndgl (ha-in modzl). Great change! in conmcfion Ind 1min. mam-n are given in the me of the mnual md minor clung:- in xhon luau are omitted. Any information which are peculiar lo my of the model: will be identified to the applicable model by the me of the codes listed below: Applicabk to ' ALL CB/CLZSO, 350 modela ALL (232591 C3850 modzln ALL 01:450. C1350 model- ALL C3250. CLZSO modzla ALL C3350, CL350 model- ALL SL350 model! Code Honda 250/350 cam/350 CL250/350 CB/CLZSO CB/CL350 SL350 Service and mainvuunte procedums are outlined in detail to enable the shop pemnnel to loan: the problem: npldly and malt: repair: with much saving in time. This mum] has been pup-ted by mnjor groupl, usemblies and mum for easy nu. Further. .11 work procedure- 0:: descriptive nnd accompanied by many photognpln Ind drawing (or clnrityl Following Are the initial serial numbers 0! such modal at the time of Clause. Model ‘ Fume No. 7 1.10111 Fume No. 013250 100IXX)1~1024626 011250 1010001~1007711 cmxz 31000014025222 cmwxz ‘ zm1~m cnzsoxs 4000001~402m€17 4—7 #— CB250K4 5000001~ c1350 ‘ 1000001—1002293 CL350K2 mmwmms c3350 1000001~ CLasoxa 3001x101~3051361 cassoxz 2000001~2066494 CL350K4 ‘ 400000» 0335019 30000014103171 CLasoKs 5000001~ cassom 4m1~ —7 7 1283506 511m1~ 5L”) 1000001~ susom m1—2051561 51.350102 3000001~ HONDA MOTOR co.. no. suvucs DIVISION * ‘ ‘ 5507' - ' 63 o .i‘ -: - ” . , . . - o * O . . . . . . 0 ‘l ' I 5': CONTENTS L TECHNICAL DATA ..... . .......................................................................... l 2. ml; ML .......... 15 I. mo! KOBE]. CHANGE TABLE OFF PRINCIPAL MODIFICATIONS ...... 19 4.le 4.1 ”Faun". 29 2 é E E 52 4-8 Dhmnthxmnn‘hc 4 “autumn-(In VII'. W V ........................................................... Ducl'iplion Dill-embly 1W... humbly Dene-Hption Dilmbly hmcfion Run-embly Dmflpfion Diuuenbly Inspection.“ Rummbly Lnbflatm 5mm .. Ducfipfion Dinnembly Inlpectionm Reunmbly Demipfion ' Dislmmbly [anemia-1,. Reluemhly .- a .59.”? 905'? . q pow? - on Pow? . é s$géassaxz Dow? 4. .. e A. Deneription a. Dimsembly c. Inspecfion . D."Remembly .3 I-ll Tmi-ion............. .4 ’ 5'! aagvsw$8isslazsaea s G I! A. 53 B. 59 C. 54 D. 55 4'13 55 A. 55 B. 56 C. 56 D. 57 4-13 57 A. 57 B. Din-cm”: 57 C. Impecfiun... . 57 D. humbly . 57 ‘ 4'14 Cnllkulu . 58 A Dencripdon . 58 B. Diuuembly . 58 C. lnspecfion,. . 58 #15 mm: . 5B 3. A. Ductipfion . 59 B. Dhuembly . 60 C. lupecdon., , 60 5. M 61 5.1 61 A. Description 61 a Dig-humbly .. . . 61 C. Inspection” 62 ‘ D. Wkly 62 6 ~ 2 Fork Top Bridge ............................................................................. 63 A. Ducfiption .. 63 , B. Diaaasembiy ,. 63 ;“ C, Inxpcction" 63 D, Rummbly 63 5 - I Front Cushion .................................................................................. 64 A. Description .. . 64 B. Disassembly .. 65 C. Inspection" 66 D. Reunmbly 57 5- 4 Steering Shin .................................................................................... 71 A Deuripn'on .. .g. ~ Disammbly .. 72 £5 C. ‘4 Inspection .. ’11, Rememblv .. .. .. . i. pan; pnw?1. pomp; pap? PPS”? B. Diunembly . Inspection . Reunmbly . sum! and Bnh Padnl‘ Ducripfion ‘ Diunembly. lmpecliam Reuse-ably Exit-m Plpu Ind Madam Deltriplion Dimmbly . Inspection. Reunmbly Air Cleuen ............................ Description . Dinmmbly . Inspection, Rea-embly . Bur Fork Ind Ran Fender Description . Diuuembly . Inspection. Reulembly ............................ Reu- Cuhion ................ Description \De Cuban iy-pc. Opcrnliun ................. Description {Double lube two-way valve) .. Operation V . Dimembly . Inspection Reammbly . Front Wheel ‘ Description Dimmbly ............... a 53.051??? DSWQMII FF?» POW?5A PF???» $79!”?r- Din-embly of ellipen and mute: cylmdfl' Inspection of cll'xpefl Ind mum- cylinder" Alan”, 0! enliven Ind nun/n cylindu ., Adjustment at dink bake Ball ml ................. Deucription Dbl-ably lawman" Relmmbly Ignition Coil Description Runny-l. Impection N Runemhly Spuk Aduncet Description .. Ramon]. Inspection. Reunmbly . Breaker Point V Ducriplion . Dinnembly . Inspection Reunemhly ....... Capacitor Dcuriptinn , Remov 1 Inspection t Spark Plug .......... Descriptinn , 106 Remnvnl 107 t 107 Inlpeclion luunllntion . Nome Suppxessor , ION Description . Removal, , .. Inspection . Reimullnion . 5;; a . BPCF?»PDF?F§ 9.0!”? G OP?L a PCP?PFOF?NPOw?ré a a .>!~'.U.0.w?r- Surfing Motor 115 Description . 115 Dix-sembly . Inspection. Remembly Surfing Clutch , . ., Description 1 1,17 Diwm‘fly . 117 Inspection n1 Remembly . 111! Solenoid Switch 113 Description nu Removal.... 118 lupecu’on. 113 Rewmbly ........ H 115 119 Safety Equipment ..... Hom ‘ Description V 119 Removal. 119 Inspection . 119 Renssembly 119 119 119 Speedomem and Tachometer Description ..... '1. human swim. A Description .. f ’. Ramon}. D. Rulumhly . 2. swim Swfith A. Dencription . B. Romwul. 123 c. Inspecuon. 23 D. Rmsembly l24 3. Sum: Swim]: Button and Lighting Sw h A. Description ........ B. Removal. C. Inspection. D. Re-mmbly ....... 4. Turn Signd Cnnlrol Switch Ind Hum Control Switch A. Description . B. Dblmmbly , C. Inspection. 1). Rc-mmbly . 5. Neutral switch A. Descripaion . 8. Removal... “q 93’?“ re .1 95?; O E“:— Fofk TOD Brill. Description From Culhinn . Description Dismembly , Inspection Remmbly Steering Sign . Description . Dimemmy, a L? 90?”? no :- Inlpectinn Ramembly . Fuel Tlllk Deuripdou arm? a: .>é. m a. Disassemhly Inspection .. UHF? . Re-mmbly m .1 Seal Description Muller Description ‘ m .>£=? a: . _ELECI'RICAL cu \- 4: .>= mum's pm» Reuemhly In! O'Ha- Ducripxian Diummbly Inspection,” Reuumbly ..... Pro-I Wheel Tin Recommendation ‘1' >5 puns pop 9 n 1 Initial Coll ..... 9 - 2 Born I - 3 Spudolnewr 9 - 4 sum:- nglniu Emcmncy Switch A. Dinaumbly B. Inspection .. '8. Rguumbly .. y, WIRING DIAGRAM ............ CB’LSOKIi Wiring Dilgnm (U.K4 Type] cBasoKa wuing Dim-m (Cu .A. Type) CBSSOKA Wixing Diurnm (General Type) CL’JSOK4 ‘V'iring ‘Dilgnm (USA. Type} CL350K¢ Wiring Dilanrn (Genenl Type) SUMKZ \Vidfl'Diagram (US ’L Type) £33500 warm Diagram LL . Type) . . MAINTENANCE ............................................................................. 10.1 Mainumnce Schedule ................................................................ 15] 10-2 Tlghunlng Torque Stand-rd V .................................. 152 IO~3 Trouble Shootlng Rum-1.. “patina“. ‘ Ruuembly 7. ENGINE (SL180) ...... l Dina-Ilium” .................. 2 Romuummlu .................... a Pflmxielm 4 cmwgpn 1. 'I 1. A. Disumhly B lupecfiun .. C Run-embly ...... 7 - Whom ., A Sp-cific-finnl B. Carburetor Circuits Mk: Dmfipfion Fork Twp Bridge Delcription ..... Front Oil-Mon Dacfiplinn u Dim-emhly Inspection ,, Reunmhly ...... U ?L an n a. .2? .509"? an s Shem; Ste-I Deocripfion Diuucmbly Inspection Remembly POP? an m Fun] Tank Description ...... an at.) ane ‘ Description Diusuembly Impeclian,. , Renmmbly .......... Sell Desuiption Mailer ., Description u . . .. V . . ..... 138 vow? m 4 > m .>o'u I. TICHNICAL DA'A mi)“. K5 .- ' 1"” can mu. 1n.) cm: an. m) cum unanimous o...“ 1...“). menu mi.) mom main) 2,040... mm vim: mm- (3051:.) anon- (233m) 775nm M W W5” (mill) 105m (Illin) Llama WM 1.- 1a)“ (GE-Gin) 1312mm (5min) 1,345.... emu) cm 150m (59).) 16mm ( 51in) 1m an 7 - - cm with 1601.. (mm lb) mu; (m m) 172 u. wad). dktrlbuflm F/R m Edgy/7’” ‘b’ " 13m in (16mm lb) a high 19m 1. ml: 1,... Suzi-nimble. man Semdouble. cradle swam). am. up: Snap-Adan. (m: Tm: fork Telewopic fork Telescopic an nu ma Sumac... tar Wu: um Sinai-m Inn Swing m: ms nu: Tun vile. [foul Cam—18 (4 PR) M304! (4 PR) 315-154 PR Rib man 1—... .5... r... EH5}; 125—13 « PR) 351-154 H: mock pin-m Bub. 1mm, inin. nu 1mm) “min, 522 an‘ x 2 1..ng exp-mm, 1- m', 26.2 .q. in lawn-l um“ lfien‘ Bake. mt. lining Inn Inlemd expllllion, 51.0 um‘ x 2 Imam-J expansion, LSOm'. as Iq- in lawn-l uni-din. Ind 1r...) nap-city 12 m. (32 US 3.1., 2.61""). pl.) 12 lit. (32 us 3.1., 215 1315.3!” 11.0 In Enter uncle 81' 63' 62'” 1-,.“ m). 35mm (3.35)") 55mm (3.36 in) 92 mm ENGINE 1-",e Egg. :ziwlinder, .ip ; 2:13. :Srofllinda, Iir- 3:320:34 41mph one. Cyfinder arr-lumen! Verde-l. twin plnlld Veniul. twin plnllel Vulia! twin plrlllcl Bole Ind all-uh 55X50.6 nun (2205x139ein) SSXSLG mm (2.205X L992 in) 56.0)(5M; mm Dilplncemml 24!! cc {15,2} cu-in) ‘ 249 to (15.21 cu-in) 249 cc Communion {min 9.5 9.5 95 : l 9,500 rpm) 3.51) rpm) C-rhumor Cot-aunt velocity lype. mm.) Cam-m velocity type, mm“ Constlm veloc'uy lype 7 h,” mm 313.. driven ovnheld :lm- shim" drivzu overhead cam- Mfly mm“, 2.14 ka-m: 9,500 rpm (1:5 (145,. 2.14 kg~m19,5ll) mm (15.5 Mb. 20 ham/9.000 mm 1») Q h w CIIO (mu. m.) cm (0.x. I'm) canon 0' W BE"?1U.S. nun. Isl-1p. 2&511 U5 1m 1‘ lap. 10 lit. Lubr‘mfion um Pond-duh], Fmedudmmv Famed Ind we! out-p law—lad lanolin: with 91 m required 0m number uhou 96 0am maker Am: 90 m nub" of hm" hm void“ (lum- oil) 52:! k. unis lb) 52 kg (nu lb) 55 k. am: mm chuck Wet. muIIi-plm tyn- Wok. mum-plu- type Wax mum—plan type Tnnsminion 5 speed Inward, comm-n nah 5 spud forward, mum med: S—wud mm mesh Prim-I1 "mm 3,114 am arm a." min In 2353 2m 2500 2nd was mas 1.750 3rd was 1269 1.115 «h was was un ah 0.500 0.900 0365 ' Fun-l rtdflcfion 2.315 , 2.375 2375 ulcnlcn. *‘tgnn'm amen H-neri Emery Ind imam. mu , Junta. lylam Mum and kick Mmur .nd kick Surfing mmcrlnd kick—gum: ‘. “Elan-y cap-aw, le—l'JAH 2\'—12AH le—leI-k swk m... NGK Mas NGK HES. ND W—‘MES NGK- Bar-:5. ND mars M. u— m can (mu. 1”.) mm (11.3.; 1”.) limo“! omuu mu: mom (19.5 in) 2.025.“. (79.7 in) 0mm width momma-Ii.) insommm) Ovmll was 1090mm (423m) _ 1.1mm (43.3w) m bile 13mm (52.0“!) 132)“ (520m) Ground dunno: mom ( 8.1 in) H? 160 mm (6.3 in) cm weight 157k; 1345.41!» 169k; (372.61b) ‘ mum dimihnflon F/R suns k; (2001/2713 lb) 91/126 k. (many-1.315) mun Type ‘ swank. emu. Semi-donut. cndle Swan-ion. Eton: “7 7 Telescopic (ml: Talencopic fork ‘ Sanguine. In: W: Inn 7 Swinging arm The in. {mm 390-19 (4 PR) 7 $00-19 (4 PR) Tire lite, Ill: 350-18 (4 PR) 35043 (4 PR) Erika, front, lining In: Imam! explosion. 52.2 21;“ x 2 Intnml explain. 521 cm‘x Z Bnke, mt. lining u:- lnuml expulsion, 51.0 un'x2 lulu-m] expansion. 5L0 cm'xz Fuel cup-city Slit. (2.4U.S‘ gul‘, 2.01111p.g|l.) 9 lit. (24 U5. El... 201mg. .11.) Cum} mule Tun length 63' 63' ’ 36 mm (m in) 95 mm (3‘74 in) ENGINE Type O.H.C‘ twin cylinder, nit-coolcd 44!ka ORG, twin cylinder. lihcoukd I-urok: it; m1 stroke Displlccmenl Compression rlfio iCylindu‘ ‘mlngemem Vertical, twin plxlllel Vem‘c-l, twin pix-He] M x 50.6 mm (252x 1.992 in) 64 X 501i mm (252 x1992 in) 325 c; (193 min) 325 cc (19$ cu-in) 9.5 95 Cuburemr anve (min Mu. torque Comm: velocity type. Keihin Chuin dr'wm overhud 1:li ' 2m kg-m/Snm rpn: 7(19‘5 (Mb/8,000 rpm) Conn-m velocity type, Keihin Chain overhead camshaft 2‘69 kgm/smo rpm (193 (nth/8,000 rpm; -:\_>J _ cuu (03¢. Tm) CLINIC (USA. 'l‘ypl) on «may 2H1.(2.1U5.qun. 1.81am. gum) 21k. (2.1US.qun. 1.81m gun) Wham Fomdmdfilt-Imp Fond-advetmmp Fuel rum-ind Otuunmhrabovefis Manual-exam.” 3"" m an ' 525k; (115510) 52kg (114.110) um: mun Clutch Wu. maid-plus ups Wet, mulli.phu 1“). '1‘an 5 quad ion-Id, comm mesh 5 mad {on-rd. cont-n: mesh hm mm: 3.714 3.714 Gm mi» 1:: 2.352 2,353 7 2nd was 1.636 3rd use ‘ 1209 m. 1.036 1.036 V 50; 0.900 0.900 Fin-l ”auction 2.375 ’ 2.375 V 7 WCAL Ignition Bum-y Bum-y m Iymm Motor and kick Motor “A kick ' Elm cup-city lZV-IZAH lZV-IZAH Spnrk p1... NGK HES NGK 3m ND w—was mm“. m) “- m m Plum Ovulll bank 21)” min 79.7 in Over-II Iidlll 810mm 31.9 in Oven.“ haw 1,1me 433 in Wheel but 1320mm 52.0 in 5m high! 320mm 32.3 in Foot peg height 85mm [2.0 in Ground CW 160 mm 6.3 in Dry weight 162 kg 357 lb FRI-A Type Semidonblc null: r. Impenaim, trlch relmapic fork. mun 114.6 mm (4.5m) R. auapenaioa, travel Swing arm. navel 77.6 min (3.1 in) F. lire nine. pun-urn 100—19 (4 PR) Block pnuern, lire air pnuum La kg/cm' (26 psi) R. lire niu. mum 350-15 (4PR) Block punch}. lire .ir'p'Qmm 2.0kg/cm’ (as P“) 7 F. hnkn. lining ml Internal expanding ahoe. lining swept are. 1m cm' (26.2 sq. in) R. brake. lining an Internal expanding an; lining swept m. 150cm'(23.33q.in) Final capacity 3.5 Iii 2.2 0.5. 3.1. 1.9 Imp. 91. Fuel relerve capacity 2.0m 0.51.1.5. 3.1. 041nm pl. 1 Caller angle 63' Trail length 95 mm 3.7 in From fork oll capacity 125-130 cc (lo fill dry) 4.2—4.4 on Front {ark oil cnpncily 105—110 cl: (Io an «m draining) 3.6—3.7 m Engine Type Air-cooled. 4-atroke OHS. engine Cylind; mmgement Verticll twin ”1.11.1 Bore and Stroke 7 91.0st ll; x1992 in Diaplncemenl 325 cc 19.8 (min Compression ralio 9.5:l Valve train Chain driven over head ramshall 2.0 lit 2.] Us. pl. L81mp.ql. on capacity Luhriculion lynem Forced and wet sump Cylinder head compressinn pressure 12 kg/cm‘ (170.7 psi) Open At 10" ibeforr 10p dead renter} lnlake valve Close A: 35° {ufier hollom dead cemerl Open At 40° melon bollom dead tentell Exhaust valve —— , Cloxc Ar 15' (after my dead rumur) Valve luppcl clearance IN: 005 EX: 0.1mm 1)}: 6.002. ax: mm; Idle speed 1,200 rpm In. W m cum ’1»- Slflill M MA Mil it! 5h" in Air W mm um um Flo-t height Drive Ifl Clutch Wu, multi pin: type Tmnn'mion sawed, con-ml mesh mm uducdnn 3.714 Gm rifle I 2.35:; Ga: man 11 1.936 Gm nIio m was Gen: ndo Vl 1.036 Gear ruin V 0.900 Fin-l reduction 2375, drive Iprocket 161'. driven 381‘ Curl-hm pmem hf: loot operated mum syuem W Ilnilinn Emery and ignilion coil Surfing Iynem ‘ Surfing monk Ind kick unnu- Altenum A.C. generator 0.1 kw/5,000rpm> Battery clpuity 12V-12AH _ spuk plug NGK BEES, Now 24ES nudism Low/high 12v—25W/3sw Tuil/noplight Tail-Mop xzv-mz CP (SAE TRADE No. 1157) Turn sign-1 ugh: Front/rel: 12v-3z/32 CP (SAE TRADE fin. me) i Speedometer light [EV—2 CP (SAE TRADE No. 57) Tuhonéem light 12v—z CP (SAE TRADE Na. 57) Nentnl indicator light 12v-2 CP (SAE TRADE No. 57) Turn signll indicator light le—Z CP (SAE TRADE No. 57) 7- High helm indintor lighl 12vv2c1I (sAE TRADE No. 57) V ’P m lu- m can (mu I'm) own (mu 2,...) Mom Ovanll Inn 2910 m (792 in) 2910 “(79.1 in) Overall whhl: 775 m (305 in) 765mm (1m in) 0'12le unsm (c.3111) 1m5muuin) Wheel bus 1.320m(52mn) 13201111116201.» Gmund chum 150 mm ( 5.9 in) 150 mm ( 5.9 in) ‘ cm wei‘hl wok. (352.311,) we kg (mm 7 wan dlldbufiou FIR 96/124 kg (211.1/m41b) 13/33 k. (161/183 lb) mm: Type Semi-dmihle, emu. Semi-double. cndle Sum-ion, {rout Tcklcopic fork Tclmpic fork Sum-inn, In: | Swinging Inn Swinging um 71“ .12, {mg mus (4 PR) 3.00-13 (¢ 1m) Tile .1... m: 3mm (4 PR) # 350—1801 PR) 7 Bake. front. lining Ile- liberal! exp-mien, 52.2 cm‘x2 lam-ml expansion, 1w cm', ZGnq-in Bnke. rut, lining ml lam-all pruulan, 51.0 cm‘xZ [um-1 exp-Mimi; 150 an’, 23 u-in Fuel cup-city 125:. (3.2 US. ”1., 2.6 Imp. pl.) 12 lit. (3.2 US. 3-1.. 2.6 Imp. My Cute: ml: 63' 63' Trlil length 85mm (3.35 in) Kimm (3.35 in) , a!“ ENGINE .. 1 . Type 01H1C1 twin cylinder, nix-cooled 4-nxoke 0.11.0. twin cylinder, nit-cooled ditch: . Cylinder ujnnzemnt Veniul, twin pulllel Vertical, (win pmlm Ban And make ibilphoemenl 56 x 50.6 mm (ZZJSX 1.992 in) 35 cc (19B cu-in) 64x50.5mm (2521» 1.99211) 325cc (19.5 min) Compreslinn nfio 9,5 9.5 7 Curbunwr Cancun: velocity Iype, Keihin Con-um velocity type, Keihin Valve min Chain driven overland emu-11m l Chm driven overhead cam-hilt Mu. mm“. 2.14ks-m/9500rpm(155f91b/9,5mrpu) l 2.14kg-m/ssoo rpm (15.5ft-Ib/SMrpm) M M can (mu. 'l'nl) cannon (mu in») mm 2mmusqm 151mm“) ammusm 151mm 1;.qu qudmdmmp qudlndwatmp Fu-lmuind Datum-WIS Wanamaker-ban!) “I“ m a) 525 k. (115:. lb) 520 r. (us lb) m: nun Climb Wet. muld-plm type Wet, mum-pin: mac Tannin-ion sun-diam.th Swabmtcomm Pan-I7 ndnm'on 3.714 1714 ii Gar 1-50 m m 2353 2nd 1156 was ad men 1269 «h was was 51:: 0.900 0.000 thl admin 150 22.50 ' 7‘ sacrum Ignition Bakery Bunny W Mm: Ind kick Mom: and kink uni-fem 3* uv—IzAH 12V—12AH NGK HES ' iNGK 3431-: NI) w—zms Sui-ll! Pl“! lu- m m mm Over-ll nun 2,010 nun 791 in out!“ width no m 31.9 in Oven“ knight 1.115 In 439 in Win-I bu. 13mm 529 in Sat height 815m am in Foot ”imam 306m win in Ground clearance 150 nan 5.9 in Dry weigh: 4‘ m k. 359 lb In.» Typt Senti-dnuble cradle type F. Juana-inn. unvel Teleocapic fork, tnvel 114.6nun (c.5in) R. ounpemion. travel Swing Inn, Cruel 716mm (3.1m) F. «in tin. prelim ago-m (t PR) Rib m, fire .5: wen-um 15 kg/m' (25pm R. lire Iiu, [manure '1 350—13 «Pm Block 1mm, fire air We 2.0 ku/an' (uni) ‘ F. bake. lining «on Dill: brake, lining mm 'm 33ch (5.9 lq. in) ‘ ‘ R broke. lining an Internal expending shoe, lining wept ure- 150 cm' (23.3 min) anl u - , 11 lit 29 us .nL 2.41m.» 3.1. Fuel reserve cup-mi 2m 7 0.5 051.1. manna. Caner male 7 V Trail length 35 mm 3.33 in 1 anx (ark oil enmity lZS—lwoc (to fill dry) 12—4.”: Front fork oil cup-city 105-110 cc (to fill afar dnining) 3.6-3.7 on Engine Type Air cooled. d-Itmlte 0.ll.C. engi Cylinder urnngemenl ‘ Venicll twin pix-“cl Bore nnd stroke 64.0):505 mm 2520x1992 in 1 325 cc 1593 cu-in Dioplncement Compression ratio 95:1 Valve Irnin Chain driven over head cAmllull Oil cup-city 20 lit 2.! U.S.ql. lfilmprqr. Lubrication uyllem Forced .nd wet sump 7 Cylinder held communal): pxeuurz 12 kg/cm' 060.7 psi) Open A! 15' (before lop dead center) [nuke vnlve Close At 40' (um-r bottom hurl center) ‘ Open A: 49° {before button. dead center) Exhnual vulva , 7 W Close ‘ At 15" [liter top dead cunwr) Valve tnppel clearance IN: 0.05. EX: 0.1mm IN: ”002, Ex: 01:04 in ldlc speed 1300mm ‘ ’ ’5‘. En- m m m Typo Pinon vulve Selling wk MA Mall: in Pa: 878. 2nd [106 Slim SIR .55 Air leaving again; I,“ 2“ man Flo-t held“ 26 Drln trail Clutch Wu. mum-plan type Tnnuniuinn Squad. cult-m melh «- kinky reduction 3.714 Gen min I 2353 Gen ado 11 1.636 Gut ratio 111 1.269 Gent mtio V1 1136 Gut nfin V 0300 Final reduction 2.250. drive sprocket 151', drivzn oproclu! 361‘ Gen- nhih pattern Left (om operand return lylleln Hum Inklon Emmy and ignition coll 3min; lymm Alum-lot 51min: motui‘ Ind kick tuner A.CV gent-nor 0.1 Irv/5m!) rpm Battery capacity lZV-IZAH Spark plug NGK BBS, NDW fllfi Heldlight Low/high 12V—25W/35W TIil/noplight TIiI/Ilop lZV—3/32 CP (SAE TRADE Non 1157) Tum sign-l light From/reu- 12V-32/32 CP (SAE TRADE No, 1073) Speedometer light Tuzhomelex light 12V—2 CP (SAE TRADE No. 57) 12V—2 CP (SAE TRADE No‘ 57) Neutral indie-(or light 12V<2 CP [SAE TRADE No. 57) Tum signal indicator light IZV-Z C? (SAE TRADE Nun 57) High helm indiclior light 12-v2 CP (SAE TRADE Na. 57) ' i'Wwvg- OLE“ “I. w M ("5.4. w) W! Own“ loud: Mm (817 b) Oven]! width mm (32.71.) ' V ' Oven.“ Wt 1M m (42.9 in) Wlucl hue Gmnd dell-nee [Mm ( 7.1 in) Curb midi! 157 kc (345.4“) Weigh! Main FIR 91/lfi k1 (“J/277.8 lb) mm: Typo Semi-double. mdk Supernion. from Tale-mph: fork Sup-aim. rel! Swinging Inn Till sin, {mm (mo-19 (4 PR) The list. m: 350-18 (I PR) Bnkn, from. lining ne- Inmnnl expuuiun. 521 cm'xz Bake, mt, lininl Ire- ‘ Interval axpuuion, 51.0 cm' x 2 Fuel Clpuily . 9 1k. (24 US. 3.1., 2.01m“) Cuber Ina]: Tnil lenglh 5mm (3.7din) ENGINE Type O.H.C. twin cylinder, lit-cooled Huck: Cylinder mun-um Vem’cfl. min punllel Bore Ind nmke Disphument 56X50.6 mm (2.205 X 1.992 in) 249 cc (1521 cu-in‘, Companion ntia 9.5 Cuburewr Conn-m velocity type. Keihin ‘V-lve Inin Max, torque Chlin driven overhead tun-Ink 2.07 Imam/8,000 rpm (15ft-1b/81XD rpm) \ ~ Ml 12 I... “ mu am. Tm) on equity all (2.1 usgm Lump. gum) Luis-mu unn- loud and at any Full maid 06m: numbn- Jam 95 3W? wad, on) an. (115511.) “I" TRAIN cm» Wet, mum-plate type Tuna-ion 5 Ipud (mud, mm m Pam-I7 mam 3.114 0-: 1-69 m 2351 2nd um an! 1269 «h was 7 m 0.900 - 7' Final reduction 2375 —— fl ' mm Ignition Bunny Surfing lyillm Molar and kick 3mm equiv 12V—12AH spun plug NGK B—BES Duh. R. lining nu lime. 6.66m; inx2(fl.90q cmxz) m (133.4. In.) m (MA. I‘m) ‘ cum I...» m u m In 2.15 n. as: in M width mm mm- rmnn win o...- W 2,145.... ma. 1.115.. «ssh. thhu 1.3mm was. 1mm WV {dun 5-: hum Mun 3149i]: us.- 333'... m m high mm mm. 330-- mu. Gama Ark-sue: m all u in 2:0 mm 9.1 in c...» nun Lash mm us i. mlb wad» dhm‘htim PA! 64/1“. lax/um 11. «5/155 u lumen. run 1'". Dan“: and]: Double mdb Sum-ion. F Fm lurk Tale-«wk fork _Suupeuinn.l Swinzinalmd-wbon-mion Smmdembm-upd-inn 11y. tin. F 125—19 (4 PR) sm-n (4 m) ‘ 'nm tin. R ‘_ 4. oo-fs (4 mi N 4110-15 (4 PR) 35“» 1’! 1am. "3 . glitffl‘llflz (my-q” m'xz) $731.11“: (46 'hun'xz V Intern-J upmlin. Inmul ax 6.65I1inx2(u‘?qmaxm Lubric-u'nn Iyslem Forced prmuu Ind wet sump Engine weight (mind. oil; 47 k. 101511, Fuel mucky 941 In. {2.4 Us [-1. 2» lap, [IL 91) In. l2; U s. pL u by ’L VFuel mm. aplc'ny mm. a 05.". 3.5Inp.pk. 2.0 m. luus. ,1. 3.5 Imp c“... mm: 52- may I Tni] hank “b an 433 in fl “8 null ‘ 5.3 in mam: Tm o.H.c, twin~cylindgn air cooled. l—cynle OJ-LC. xw‘mqumx, .3: ended, Hung cylm amazement Two cylinder: in madam 7 Vania-1, twin ”and Bore ma Suck: axamum 72.52xl.992in Mxiofimm 152x135“. Dinpl-oemuu as cc \ 19.3 min 325 c: 19.3 cm. Companion min 95 95 Cnrbuum: Kgildn. W 24 7 Ka'hin, W 24 v.1". min (Sh-an drivun overhaul aw Chin driven ovzrhud mm 11...“... mm. ‘ as Iran/sow rpm 15.: run/3,000 rpm 2.5 h-m/amn rpm mm m foil up-dly 2.0m. nus.“ .15th 2.0m. My“. Forwd prawn and um lump 47 kg mums l4 "1‘: 1?. N- m (an In» sum (mu. Inn) ml rum and Mali-plan. n In. Mum-um. wet up TM I find. eon— ‘ 5 mod. all-.1 Inch mm Ind-union mu mu Gar min In use 2366 and was mo H m: “ um «h ‘ mm was all H am on ' ‘ ram m 2.500 mm Gnu mm puuym Ink loot mum m:- M uh (on: return type 17mm mum Initial: 3mm ml ignition eon Emmy ma i'nhion rail sum... Syneln 5min. molar ad ad: pod-l | Kick lune: Alma-tor AC gum-Io: AC lunerlm In!!! coldly n V.“ AH 12 v-s AH spun plul NGK B4B. Maw—ms Nox Hm. Maw-zines PIHOIIIANCI ’ Mn Ipned in .3; 1n 23mph «kph 25mph wkph ad 4051911 ‘_ «kph 40mph 7 solrph Fl 3rd 51 mph 3| kph 55mph 7 “kph «h 7 53 mph _ 100 kph — 53 mph I no kph i an: ‘ 79 mph 121 kph _ oomph ' 12; kph m1 nominption ,jf ‘E'Efifi I'l- » sin/In. n so kph f 'agdgfifi "‘- 25 Inn/m. n w kph if my“ I SEE/"£3:- “- ‘ cumin. Ibifiq 25- ao- 4 Turning am. mm 42 m 7 n 213.. A flaking din-nee am It 31 mph Hm n sohph 1 «mix. at 31 inph u... m 50kph w Wm m;u::::-.::.'h;.h MW mflzzhmm 5%: 25w V 2. SPECIAL I'OOLS cn/cuuo - m Ref. No. Description Speciul tool set {or (SB/CLEO, 350 anve sent cutter 90" Inlel valve mt top cutter Exhaust valve year lop cutter Inlet v-ive sent interior cutter Exhlufl vnlve sell interior cutter Drive sprocket holder Valve seal cutter holder Valve guide mum-x, 7mm V-lvr lifter Vlive guide driving tool Valve guide removing tool Piston lane (:1 null) Pislou mtg comprcssur (CB/cum) @@©®®®©@®®eaeee©9®e 079544510000 Piston ring compressor 1CB;CL350; (T7932 2160000 'l‘iHundlr dyn-mo tutor puller 07916 33300“) Lock nut Wrench, 1?: mm 07401430100“) Carburetor float gauge {CB/C1450} iCBJCLSSO) mmazwnm Bearing driving tool 079027mux> Pin spanner, 48 mm 16 cn/mso- an ~ '9 \ _ ‘\ ,, _, @ ® J\ / Ref. No‘ Tool No. Description 0 07947-27301“) From fork oil Bell dxiving guid: Q 07999-3290“) Rear cushion assembling Ind diuxnembling Inc] ® (TIM-m hhin switch pin lpmner @ 07946-23601“) Front wheel bunting driver alluhmenl 6 W946 3360200 Rel! wheel bearing driver Itlichmeut 8 0794wa Rating driver handle Q “7955-2860000 Front fork mmbling mo] Q 07999-28600“) Dynamo inspection (‘nver @ 079174330300 “’mnch, hollow set fimm G OTQIO-IIZEXXW Rear whet‘l homing retainer adjust wrench 07797—29203“! Tool cane (CB/C1350. 350) H Ref. No. Tool No. Description 07900-286000!) ‘Spec'nl tool let for SL350 lnlct valve mt 90' cutter (IN. EX) Inlet valve mt lop cutter Exhaust vdve lent top cutter Inlel vulva sent interior Elm-us: valve kl! interior cutter Vulve nut cutter boldex, 7mm Valve guide tamer, 7mm Pin spinner. 48 mm T—Handle dyn-mo rotox puller Valve guide driver Valve guide remove! 'Vulve spring compxeslor Muin switch pin splmlcl' Benin“ driver Dynamo impecliun cover ®®®®®GQGSQG©9®8 ‘These tools are [or use with the SL350 only, Ihe other: one common to all larles, J mmmvummuIivmwlmln» \ Refv No. Tool No. Deacfipfion 8 OTSdf’rZBGOlOU *Fwnl and R, Rear wheel benring driver attachment @ 07946’2860M ‘L, Rear wheel baring driver attachment @ 07949~2860030 'Benring driver handh- @ 07949-27le Front [ark oil mml driver guide Q Drh'e sprocket holder ® 'Rear cuuhion disassembling and assembling 0001 Q T-handlr box wrench, 15mm a; Hoax lvvrl gauge 8 Rear wlu-rl bearing rclainer ndjusllng wrench @ 0795.1- Home Pismn ring compressur 8 07955—2mlu10 Pisvon base 17, 077974LG‘UIDO anVk‘ m-al Cutler case 07 ‘ 1300 Tool r m- ill) i Wn-uclx. hollow Se! Ii mm l 7, 'Thefi- mols are for use with the Sufi] only, the (Mu-rs are common In all scrlcs, Ila—lei 2:...- EL 2:2 2:: in: :5. MR. 3:35... E1! .81... stall. 3- 3:998... .31.} 3:. 3.2:: /..»L. 5...... e... :5: €23. 5% 29:. ® has: 32.. .353... .3.» MW J» E ; u... 5!...- .P3£Ju...:.h .55. 3:5. :3. .31.! 5.8.... I‘Mwuzu. vol-ulna- ; nah 1.1010. .9131.— EoZEE EE .5590 «Em nil: is! 15...... a... £15 iii It’ll. .35 m WWW/J / xx \ :6, ‘ \_ ii... 4\ I. 3.2. :5... .5 A; 435' a! ‘08:: in 150.9. 18-... .13 109....— uflm 33:4 23w 1.5 gnaw 3!. :62. 13k! 5. £1... :3:- 153... 5. @ t, Gnu nun—B all a: I... ‘3- 3 i=5 96 .2; .3“. GI Sag a— 359 «a afiéfino demNm—U Em: ”20:30:30: .—<&.UZ-¢L no udfl 3oz .532 wit—cm 1:. .3...» a. 0333 Vol. 3.5. .5: known—5:9 2m: @WEQQ 1:. go 15 .5 25 40 :5 no ions-.1 as! 7.: .5 int-L ESQ—“Kg a!§9,flu :2: E2... nu” 5.3. .5 $2 :5; “3.5:; :3: 25:71 :5; 5:55,. $.25. 26 N: Owns—m :- cam 23,... 2'] ®® .vo—mbgn bit: «.11— uiilvu E32: 2... «a «in. 9.355! ._e 09.10 04. 5.! 13.2315... :— 5:21... 3:... a. 25 5.2.1.... «El—Ila I 3 vantage Ian..— _l.—. :5 E! in moan-.33.. al- 333308- 3 0.9.4 3.3.5:: :gkviu 3—3455”. £3 SEQ i5 21.; in e .31... 8:. 3 33.. is... i9: 259 Each»- i».— n "leg-um 333 .55. .351. aim n “303!!— mufinifin main. .3521 xuoaw .1322: ass-8 2.53:3 "3.3..- :8;- ifi .9 .15: .Scule‘hl: 1.- 3.01! 50.3; 1353 this :1 All «£5 macaw—2383 h ESQ—QED t J‘ 4. ENGINE d-l Mmmu The engine mounted on thin mowrcycle new the follcwinz lawns. - Camshak. rocker Inn, eke. Ire «unlined within the em cue fer gruur rigidity and imprvve cooling. Funher, by (hi: nonmetiun, uniting of the engine in implified. cV-lvemmclemneedjuinnentiaperformedbydierocfirumpinwhichiamcunuedcnlneeelnuie. simplifying the Idjumnt prooeu, - Heavy duty belting: ere mounted on the crunlrnhnf: Ind inn-minim: ehnlt. . Redesign of th- Ihifr drum mpplr end the neuml mpper provide imprmed gen: chnnge eclion u well .- poeidve Ihiifingl I Uu of the double Ipur gun for the primlry reduzlim he reduced the gen: no'le Ind increased the durability. 1 29 - Employment cf a dual filtering Iylteln using I mull men nniner end I centrifugll filoer vmly reduces the . wear to the engine component. - The two variable venrm-i lymm for the CV cnrburewr mum uniform fuel mixtun independently to the respective cylinders In provide mood: power output at all Ipeed rangeel (-2 POWER TRANSMISSION SYSTEM The power Ian-don quuence end in anaemia-ion to n the renr wheel for performing unful work in I: follow: Comhuuion —o paw- —- connecting rod -— cnnknhnft —- primnry drive gear —~ (primary driven gen) clutch onmr - eight friction dink: —~ eight clutch plane! —¢ clumh oenmr —~ transmission meinIhIIt—v mainsh-fr geu—~ annular-Inf: gen —~ comm-heft — drive sprocket _. drive chnin —~ relr wheel. (Fig. 4-3) NUI'E: The {ulluwinx pert: can he disassembled from the engine withoul dismounling the engine from the (rune. -Crnnl(cue cover (both right Ind lefK). left crankcue rear cover . Clutch membly . Oil pump, oil filter - A.C. generator numbly . Neuml Iwirch - Cum chain Iensioner holder 4-3 DlSMOUN’l‘lNG THE ENGINE L Fucl wnk Turn the fuel cock to the “STOP" position: remove the fuel lines lrom (he cock and the fuel lrw-l tube, and raise me seal to remove the rank. 2, Remove the mufflers. 3. Clutch ublc Remove the gcm’ change pedll and step bar. and take all the L, crankcase rear cover "’ér‘ a) L crankshlll 0 RV rnulkshalt 3 (fluid. a: Trlnsvmssiml mainshalr a; Tnmmlssion cuuulerxlulz Q Drivc lprockct Fig. 4 1‘ Drive sequence m Electricll Jud. cannccmr ® Contact breaker leads Fig. 4 2. Ramon)“; [he elk-(Ideal lend; Remove the drive chain . Remove the rent brake pedd. . Carburetor Remove the throttle control cubln from the cuburetor. remave the left Ind right lit clemer cues and loosen the cnburetor imulntlng bends. . Unplug the electrical uble connection. (Fig. 4—2) . Remove the cantact brenket cable connection. . Remove the high ten-ion tertnlnnl meltlhliu from the m Starling motnr cnhlo Ip-rk pluxt In. 4-8. Removing the Harlin. mnltll’ cable 10, Remove the tuning motor able (Fig. 4—3) 11. Disconnect the tachometer cable at the engine 12. Remove the 7 euuine hunger bolt: Ind dllmonnt the engine from the righl side. (Fig. 447 4 -4 REMOL'NTING THE ENGINE Renmunt in the revem sequence of dim-mutating. NOTE : . lnscrt the hanger bolt: from the right sltle of the harm.- nnd tighten fit; from the left side. Install the battery ground cable from the right side. (Fig 475) - It the hanger bolts do not gel ln ensily. do not force. Find the “use and make comctiou - Vthn lustnlling the battery ground cahlc, dun all rust and paint from the hunger btllt as well as from the lemllull and the lrume mountlng amt so thll good contact is assured. (Fig. 4—5) ,, a) hurry ground c-blc a; Engine hanger lml. . 11;. us. hut-Hing the lmmy ground clbl: -Mnke sure thlt the drive chain 5mm link clip is {wing in the correct diteetinn, the opening must he opposite to th- dlrectlon of chain movement. (Fig. 476‘, 0 Joint clip me. H. Um chrm ,mm rhp dlttt‘tlnn ~Mn|tc sure that Ihe steel ball has hceu assembled in the clutch lever before mslnllmg the left crankcase ten covet. LFln. d 7; “l. ’1 l ». } o Sleel hull :1 Clutch lever 0 Left crankcase rear cover m. H. Having [he sleel hull . 3?! 4 - 5 VALVE MECHANISM A. W The valve mechlnilm consist! of a urn-halt, rocker um. inks Ind nhlllfl Vllves and their related pm: Ind hhmued within the cm uIe. Drivcn [mm the crank“! Mush I loop of cum chin. Ihb cum-hall maven d1: valve: Hannah #1:: rocket Inn. This shit il Iurpponed at two plum Ind mm It 1/2 the cmhhlll speed. The working surface! of Ike cum Ire cue-budget! by Iolbniufling (CI—N) mocc- to pmvida I Mr wen relilnnce. The maid: end: of the tucker um: u: lard-faced with I mchl Alloy. The valve: In stellilelaced and their nun Ire nude of - hula-inn: neel w minimize vllve cum» pawn! wear. The m-hamam drive in loo-ml at d1: right side of die climb-i: Ind the Ipuk Adv-near and conuct breaker It the left Iide. a) Cm chain a: a... sprutkel an Cumxlmlx 0 Valve rocker Inn @ Rocker um pm 0 v.1“ Ipring «1 VAIVQ Fig. LE. Valve mechanism B. Dinmmhly ; .51. Remove eight 8mm clp mm m! remove the cylinder 1 hlld cover. ‘1 2! Rmnuve aw dyzumo com, breaker point caver..conm [11 bra-key point numbly, and the lpnxk Idvancen 1 \Fig. 4—9) ‘ a) Cum-cl hruke: “5:...th a) spun lduncer Fir. n. Removing H“ mm. mum m1 apnk Idvlncfl . s. Remov: the rocker arm pin lock nuu [both sides, 2 elch), Ind the aide covers Ind rocker arm pins. (Fig. 4—10) t Remove the cum chain lensioner. a) Rocker lrm pin luck null w Rocker Mm pin: (3) Sid: mm m? Rurkcr mm Fig. Ho. 5. Align Ihe stnwr index milk to die “ LT" on the AC. genenwr rotor (mp dud center of the cxhnusl shake) to Approxinuuly 10" ATDC and vhen remove ‘he lpmckrl nlianment boll, [allowed by lurning the rotor to align with in point approximncly 10° ATDC of Ill: comprmiou woke m! then remove the rcmlining sprocket scltlng boll. (Fig‘ 4711, 12‘; to Index mnrk a "LT" , l-‘ix. m. Line up “L ‘ NOTE: -Hoolr boll Ind the sprocket serving boll can be easily removed by using the 10mm universal b0: wrench provided in the special tool kit. Tool No. MOSS-Ml) (Fig. 4—12) - This is u specill bolt Ind therefore it‘dwuld not be losi or misplaced. It can be identified by the marking “9“ amp on the ball head. a) 10mm univuul box wrench Q Cm sprocket l 3 in. Hz. Rlllmving [he can sprockm >2 6. when removing the numb-[l from the am case, remove ‘ the camshaft from the window: {or rem ‘ the cam Ipmckex nnd cam use. which are mum provided In remove the camshaft, townrd the right hand side while planing ihe “L" mark of cum Iprocke: on the upper side as for Fig. 443, 'n. 7, Remove [he ion: 6mm cross «Elem Ind sepu-ne the Amm case. (Fig. 4-14) ém mm scmws a> c 8. Remove the spuh plug nud‘unmw the 6mm bola {mm both sides. (Fig. 4-15) .. (ms-um hex. bolu as Cylinder head _ . m. 4.15. Removing me ulmder ma .1’ ‘ , ‘ ' I ’ * 9, Separate the cylinder head from the cylinder ll), Use the valve nssclllbly and dishmmbly tool {Tool N0. 67957‘3290000) and dugalemble flu: valve cotter, vulve’ retainer. vach springs rand inlve spring «cats (Fig. 4-16) C. III-Mon l. Comma-inn pruure (Fig. 4-17) - The engine does not have to he dismounted to check the cylinder hm compnsainu pressure. Perform the \ measurement while thc engine i: ll operating tempera- ture. move the lpll’k plug. it the heed of the compression glugt: an the spark plug hole. Held it firmly no that camprcasion is not loet. . m Compression W... 3) Open the throttle snv Ind choke “1W mmemly- Pu». H1. Mn-urinx cumpteuion pressurr - A) Kick the starter ped-l repeatedly. quickly and powerlully, and rend the maximum ulna on the gauge. 5) The rated comprelsion is 12 “liq-c- ("Op“). 2. Adjusting the engine to lb: proper oomprenian pressure. . The engine muat be dismounted for: thin operation It the Column men-tire we: mtg/mm (170 pai), the combustion climber wall nnd/or pinmn head probably hnva carbon depoait. Remove the carbon clepocite (rain the combustion chamber (refer to pug: 35‘, or pistan head. it below tone/wen ([50pli), perform the following operation. 7 (refer to page 36) _ and pietnn ring: (refer to page 40). 3) Check cylhder heed gulteling “glue (refer to page 35;. I, 3. Vllve tappet dent-nee ifllpeclinn end .djunh'nenl This operation an be permuted without dimuunting the engine. Further. make the check with n cold 2 Perlonn the cheek And adjunmt in accord-nee with the (allowing procedurcrll w ,9" 1) Remove the lappet hole capt. . ‘r/ 2) Remove the Contact hruh'r cave: Ind dynuno cnver. 'f " V. J fi‘ ’ ‘ I l 3) T urn the genernmr rote; lerclockwiae Ind align the “L " timbg mark the index mark on the tutor. (Fig. 4-13) With the finger. check to make sure lhll hath rocker arm: of the kit ride in the cam use in free, this indicates till! the piston (or this glinder is ll lop- deadcenter ol the compression make. [I the valves ue tight. turn the generator (otér counterclockwise 360‘ and realign the timing mark. [nun the thick. nuns gauge between the vulva stem and rocker arm to chcch the (apps! clearance. Ii adjustment i! required. turn [be rocker llrm pin in either the right or left with the screwdriver to nhtnin the proper clearance. Alter cumpletiug the adjustment. tighten the adjuster lock nut nnd the recheck tappct rlenrnnce to assure that lht: clunmnce has not Chungt‘tl during locking. G) Index mark a: Generator rotor Fil. Ha. Align" rte mark rFig. 4719‘, mm :mthl " ‘ ‘1“.le hmmlud \‘aIIIP ' Inlet 005 20.002 Elhlmsl Ml) ’lem Rucku- «rm pin mu . X‘! dram-xt- ‘ re- 34 . '2’? NM! 1. Twa thickness gnugel of 0.05m (am in) thickness are included in the m1 kit. Such the m g-uge- when checking the upper clearance at the ethm vnlve, 2. The eccentric indium: cutout “A” of the rocker Irm pin must be rot-led so am i: in to the outside of the Icrewdriver Ila! “ B" (own: the cams: po‘um) is shown in Fig, 4-31 I This setting is the same (or ball: the right and left cylinders. Fit. C N. 4) After completing the check a! the left cylinder, mm the generator mm: counterdockwise 180° md align the “L" liming mnrk with the sutor index nnrk and perform the check md ndjusunent in ‘he urn: munner :5 described In 3 Above .- \- NOTE: sdjum'ng the kappa clearance. 01m 9 Deere-I: m. u). Rack“ um pin mung direclinn e emfig gm damn;- [I the iide Clell'lnce in exceuiveb large, noise will develop between 5,0» to 6,“ rpm. much A dill indiculox to due side of the cam sprockll and check the side clan-nee of the cumshlll. If the uide ale-nun it over 1.0 nun 0).th inlnll " 0.2 Inl'l (0.008|n) lllim which Ire Ivlillble. Theaundud aide den-me in 0.2~0.6 mu (D.008~0.024in). (Fil- 4432) (D Sm]! din! Kluge a; ( Fil. 1722‘ Chrvk‘mg camshah mic defiance 3. Cum diameter Measure the diameter using a micrometer. (Fig. 4-23) mm (inch) EV , 75mm ' fl Senna-Ah]: me lulu and 3635:; Replica .( undu exhaun um u 451- 36.68 (mm NOTE 1 Minor delecu on the cam mny he reworked using a fine oil None. E" m Hammad a Can dilmlur m. Ha. Measuring elm diuneler . &. www 'ge’fi“ mandalfimruminznd Mmhflflllndkkeodldthemm with a We (Fig. 4-24) mm (inch) ’ Sand-rd Vein Sundae-bl: Limit Eprl 21339-4138) W if under dunner (om-ones) . 21 (01162) 1. Ruck-r em pin dim Menu: the rocker um pin pivot diameter with I micro. meter. (Fig. (-5) imam.) WV»... Serviceman-nut Rodin-Inn . . . 1251-.le Resin: It nae: “In? ((1510—0511) 12. (03303)“ 8. Right Ind left cylinder held tide cover internal diameter Manure die cumin.“ mounting hole. in both the X Ind Y nu, with I cylinder [tuner (Fig. 4-5) mm (inch) Sand-Id VIII“ Serviceohle V m~ami Re In it we: (03654357) 30. (0.868) Mounting ho diameter 9. Deformetion of the guketing turiue Check the guketing surface (or delarmnlion ur wupage using I "night edge or a square bu Ind - thickness gauge. If there In! any clearance between the menu!- ing tool and the surface which is grater than 0.05am (0.002 in) the pm should be either repaired or repl-ced. (Figi 4-27) (Rapid!) Apply I thin coating of red lend or bluing on I surface plate nnd rub the painting surf-re over the surface plate to determine the ms of deformation. With a flat oiletone. lap the high area: using I figure 8 motion. Occasionally check the lapping program with the coated surlnce plate Finally check with a straight edge or square bar nnd thickness gauge. 10. Carbon rcmuvnl Remove the carbon with a curbuu remover hrush, being clreful not to Match or damage the combustion chamber luriace. (Fig. 4-25: NOTE : Perfurming this npenltinn with the vulva: installed will (militate the work and prevent the vulva seats from setting scratched, “ (D Miami-tar 0 Mounting end diameter , Hg. 0-144 Measuring dilmcler a; Micromener a; Rocker um pin Fil. us. Melsurinfi rocker um pin a) Cylinder lung: (1) Cylindu bend lam Fl; 4 as. Me-uring cylinder Ml ua. com a) Thirknae Kluge @ Stretch Fig. I 21 check... warplgr of night: turtles '.. I. (j) Wire brush (3 Combustion clumher Fix. 4728. Remnvmg xlta‘clrbon ¥ mm H m , A.“ 1.2. 11. Who nut cont-n Applynthincouingolndledorbluingonthemve out. mall the "he into the guide and mute the "iv: whila Applying a Ilight pmlllre to the vulva held. In- lpoct the imprunion ol th: coating. Mcuun the vulva (we connct width tiling I ventifl culiper. mGnch) , _We Eunice-bl: L- ’ “I?“ 30:330.: Mme; m. 4-”. Sectional view nlnlu mt '" l ‘- ‘ ~ U om - (- ) (Repair) Repair the vllva not win; n special tool vnlve nut cutten. (Fig. #30) (Ede: to lpecill tool- on plge 15~18) .. Detcri an. > Tool No. Valve sell cutm. 90' WWI“) lnkl vulva mt top calm 07980-831600 Elli-III! vulva mt top cutter Inlet vulve lent interim cutter Exhnun vulva mt lntu'lur cutter Valve nut cutter holder 0 Vllve tut ulnar n. no. Prtlominl v-lve ml with eulm a p l) Ute the 90‘ vulva mt cutter 1nd cut the lent enough to clbtlin u continuous selling surlnce. (Fig. 4—31A) $5; 1) Ute the valve sent up 2:qu wd the vulve sent interior cute: to narrow the width at the valve sent to ‘ 1'43“ (QM-0.05 ll). (Fig. 4—1413. C) Fix. 431A. Fly. 8—013. Fig. 4—SIC. a) For lapping [he "he with the vnlve sent, us: a sucker (a wait»: Cup lapping tool]. Ahet applied . slnull mnmlnt of fine lapping compound on the valve seat lace, hp the valves while holding the sucker with both Imnds. and npply a slight pruesure by upping while rotating to the tight and left. Wig. 4-32] 5 4) After completing the l-pping opention. wash off dl n‘lce of the lapping compound with kerosene or solvent. NOTE: - when “gambling the \‘nlve into the head, apply I liberul nmount of engine all on the vulva stem. - Carefully rend the lmlructinn provided with the vulva sell grinder {Tool No. 077827002m1. 5) Alter the valve szt lu. pour ll smull amount of engine oil into the combustion chamber and blast air 2kg! sq“. (23.; pull in lmm the inlet und exhaust ports. If no bubble is tlppt'art‘d on the valve heal me, it Is in indication that the valves are well suited. ,1 m Vulv: lent lapping mpl , . 4.32. venom-hp ppm ml lhpm l, J p ‘ 12r anve um denunc- lnqect the n!" into the valve guide clunuebyplncingemllldill an iii-enur- the ”£2. ) (Fig. (-33) Sand-rd vdu- unis: N“ "m fmsasmu) minim?" Exhlun 0.03~0.065 a. bee if over "In (emu—0.0022) 0435 @9035) 18‘ Vllve stem diameter Manure the valve stem :1 die rm bonus: and inher- mediate points using a micmmeter. (Fig. +34) mm (inch) Sand-rd Value Servimble Limit ans—cm kn: if nude Inlet "iv. 911541752) @2738) ' EIl'IIIfll mama line i! under valve (am-0.2144) (02730) 14. Valve guide replncement When rnplncing vulva, it is recamrnended (lint tho guidel alto be nplued, Vulve guide an be rernvved by in- :telling the Valve Guide Removing Tool (Tool No. (1794 — 2590200) from the combustion chamber side and upping lightly with u hummer. (Fig. 4415) Inltnll di: vulve guide in from die Vllvc compulment aide using I Valve Guide Driving Tool (Tool Nor 07942- 2590100], exercising cure to install the guide straight, An uvcrsiu guide (overfiize guide imcrfcrcnce of 0072- Oil mm compared to n sundnrd guide iniurfcrence of 0042-41070 mm) should he used when replacing. Alter inslnlling the guide. um a anu' Guide Reamer (Tool No. (Wm—59W] and slowly rvnm oul the guide. Per. form this operation ran-fully using sulfiuicnv. oil to prevent rcumer {mm binding: if ihe reamer stunt! no work henvy, slowly remove and clean ofi the metal shnvingx before continuing In mum, (Fig 4—36) NOTE: Upon completing the valve guide reaming. inuull the valve and check the valve clearuce, 15 Valve spring dimension Measure the ire. length of me valve spring using . Vernier Culiper :Fig. 4—37,. mm emch; Smndaaril Value Serviccnble Limu FrM length at Replace ii under finger spring 49") (1.9291 47,5 (1.2132. Free lenglh nl ‘ licplnce it under mncr \pl'iltg 39.3 ”-557! .593 .1547» 16 Valve spring force Measure :lu: mlxe spring i'nmpressiou iorce nring in spring rompression truer, , , _ ndard ‘5'3‘1‘ num spring r kg @31 mm (Ul'llpl'i-‘Nrulvt force Julio-1683M h, 1:22in) lnnLr wring 30.5mm (Q. 26 mm _r0mprusne lnrrn (G7 .77.“ 1.02m) q) anve 0 Small dill mule Fig. “I. Checking vulve guide clearance CD Micxnmer 0 V-lve nun i Flt. PM. Meuurhu vllve Item diameter 0 anve guide removing tool a; Cylinder heed Fig. 4—35. RImnving me win mini. Fig. L36. Performing naming ' 6 a) Rumer - i‘ A a) vrrnirr caliper a van am Fix. Hr Muillfi u l -, nu v urging IL-.. >E t , , @- Valve mm... @ Smller pitch Inn-um. my: spring (1) Cum spa-Mu (g) "L" muk in. us. anve timing Cumm- (:9 Cam sprocket a) Pin 1:. HI. Aslemblmg m: mun-n D. mm, 1. The vulva rpring his I dunl pinch; mike lure that. the end with the miller pitch in inst-fled toward the IIIL (Fig. 4-38) 2. When installing the cylinder head. nuke sure Lhu the two hollow pinl are inlulled in the correct locations. ‘ 3. After nslemhling the component puts inw the cylinder herd. mount the head to the cylinder with two 6mm bolt: md torque to ss-mm- (6.15~7.23lblt). 4. Do not lorget tn install the can ease guket, two guide pins. 5. Mount the cm use on the cylinder heed with (our 6mm ems: screw: and torque to so to 75an (4.34» 5.241b-ft). 6. Rnise the cm Iprocket u thown in Fig. 6-39 and inufl the cnmshnft by working it luck Ind forlhl Refer to the Section 4,7_ vnlve timing 7‘ v.1” liming l" Align the "LT" ranking on the rotor to the index mark on the match The lclt cylinder will he on top-dead-centen Z» Align the cutout of the cam sprocket rubber damper to tht- mm cm mating surface by raising {Fig 4-40: When assembling the cam sprocket uu Lhc camshnlL allghlly raise the gnvt-rnor alignment pin on the cam- nlmll lrom the right side uud make tht- uxxt'xnbly. IFig. 4 dl\ 3 8‘ Mount the cam sprocket on the Camshnll with two 11mm bolls. ’C Hm: 11m bolts need are of difierent typu. nett‘nig dowel bolt Ind tettin‘ halt. do not reverie their inmllntinn. (Fig. 4—42) 9. Infill the rocker In: on the can cue with the rocker urn pin, on both sides. 10. inn-ll the tide cover: on both tidal. ll. Amhle the spark Idvnncer nuemhly, content breaker with. end the paint cover on the left tide. 12. hut-ll the cylinder heed cover with the eight 8mm up nut- Ind mute the null unilanlllyl NUI'E: -Torque the cylinder heed tuning from the intide Ind working nut in the dingnnll quuem. Use I torque wrench end torque to 180~mkgcn| (m—lLsft-lhe). (F i(. 4-43) v’l'he two hale: on the cylinder had inlet Ade Ire oil holet. therefore, all the nut: nut-t be properly torqued to prevent all lulu. i3. lnmll the cult chtin tanninner on the cylinder. 4-6 PI.S'1‘0NS AND CYLINDERS A. Description The piston: Ire made (Him I hent-retietrnt Ilttminum nlloy and ue fitted with three rings, top, teconrl .nd nil. Their skim Ire finished to In ellipitiul thnpe. or “cit: grind“ to provide [or uneqml expuuion that occur: It upernting temper-titre. Another denign tenure that eneh piston ll net oil the center of it: connecting rod to prevent the piston thin being pressed lglinll the cylinder well by n renulmnt horizontal or side force acting at the center oi the piston pin, 3. Dinmnbly l. Remuve» the curl cm in nccurdnnce with section 4-58 on ptge :il. 2. Remove the cylinder held in Mcordnnce with section 4-58 nu plate 31 3‘ Remove the cylinder from the crnnkcnse. 4. Remove the piston clip and push out the piston pin. Disassemble the piston {tom the connecting rod. NOTE: When removing the piston pin clip, care should be ex. ercieed no that the clip it not dropped into the crunkt‘nse. (Fig. +49 C. Inspection 1. Measure the cylinder borer taper and nut-uhround with a precision cylinder gnuge. Tnkr measurements at the tap. middle and infirm in both (ii-metrical steel (Fig. 4—46) min. halt 0 Cllll tnrocket mm letting dowel bolt - y (0 Torque wrench Fig. 4 u. Tightening mime a) Top ring a; Second ring a on ring me Hi. Section] View ul Dillon tings (9 Piston pm . in ® P. r: rut. Hal Removing Ihe patio» pin clip . uploadgifingmd‘mmmfl: Di / i i': n- > ii! , ..._ AC 5. ' as _ cs/cmso m (M) mm (inch) 3- Value Limit hem Sundud Vllue Service-He Lil-it 5301:5102 gem our 3m gagging”) E‘s-{12? 53).“- W - we W r-m m2) 35mg" Duldrnand : a?“ l °"°' Onto! round {3% $Wé)"” 2. cm‘ban'ng ml honing - ' g It! cylinder. fin'uh hnning name be perfumed to pmvide 01§~I5S mrhce finish The permissible mock Wu daring the honing mention il'lmflimlhe'y 001 m (0.0004 in) b > , ‘ v 1 ‘l p‘ NOTE: 'A' -; Sudaee finl-h OBS-15$ refer: to the 115 alpine-e lnduamal‘ Standard) cute: mughneu designation. The ulue indicm the mean depth of the groove over I (lemme em end [his value ie expressed in p(micron is 1/1000 at n millme' ler). . The “S" detignnel I 115 measuring unit. Surface finish yelue OBS indicates the lvenge depth of the toughen aver I length ul 03mm perpendicular to the lay is 08nix1§ indicates lb: avenge depth of the roughneu over e-lengt’u’of wmm perpendicular to the lnyi .13: values are determined by visual complrisnn satin-t mulu Imple'. 3. Piston dimension Menu" m. dimem of the piuwu skin perp'endiculu m the piston pin. (Fig 4—47) mm (inch) 5mm": v.1“ ling“. 5591 5599 l 2.31.“ mm '2 ~ 1;)ng 559(2301 ($3.97~ .99 Replica .( undu- (2.m5~2.5193) 63.9 (251; NOTE: - The “d" dimension i: smnller than “ D” dimeuaion by 0.22 ~01! nun (0.0087 ~o.ooos in). - Oversize pislons are available in four diflerenx sizes at increments of 0425 llllll (0.009 In). a; 0mm nlinmeler luring pumn dimmer a. 4. Piston ring side clearance Measure the piston ring .id: clear e at four points. 90- 3pm using a thickness gauge. = +49: (tn/cum mm (mch; hem VSlandud Vilue Senqccuble Limil Replace .1 over 1“" A. 70,121 .0307) W sauna ‘ Rtpllcc il um ~ 1 0.165 {000651 , ( )] o.01o~ m5 Reklace ll nm- ‘ lOI‘fl'IAVIlmlS‘I u “vying; CD CLSSO mm H mm W slundard Vulut Servivenble le V "03|)~ um 1 Re In l! “‘1' v . 70:17103)" Second 0” chlnm .l 0.170 0 »@ mum ring a la . gauge 14!. mm lulu-v? and “mm. ring clenmuoe ,.l r; 5. Hanan ring end pp Meuuxe the tin. mbyinaetfingthepiuonring into thecyunduan that the ring is u rigln ugle w m. cylinder llil, the gun should be manned wid: u thick. mi nuael (Fig. 4—50) cB/cuso mm (inch) [ma sum van: 5 5mm Limit _. ans—«35 Re In a we! “W ‘4“ "P 1 (0006-01)“) I o. (Mao) CB/cuso nun (inch) _—.__-—4 hem Sunni-rd Value mm; Limit Replace if are: . 0241.4 ““5 "d I“ (om—0.0m 03 (0.032) & Pinon ring thickness Menu“ the xhickneu ol Ll): ring wing I micmmemr. (Figl +51) mm (inch) hem Sundud v.1... A Servicuhl: Limit T use-1.175 Replica a: under “P (0.067-0415g‘ _1'.¢_3§ (00564) ms~1.m Rlpllce a1 um: 5““ ; (goers—onus) 1435 (0‘05“; 7 ‘0“ ans-2,490 Replw: a under I (0,097F-0.” 1&0 [0.096 1‘ Piston pin bore Manure the piston pin bore at both ends and I! 90‘ lpu'L (Fig. 3~52) mm (inch) , ,,We___.mlie Limi'# I5“)? H.001! Re In: if uvcr (0590m- .5&)9 15‘ [05937) 8. Piston pin dinmexer Manure the pinch pin dimmer :1 ball: ends Ind center. (F #53) _ Sand-rd v.1“ Service u.994~15.ooo Replncr J un er (0590-05906 14.96 (0.5889: D. Reuumhly l. Inmll the pismn rings on 1h: piston in [he ruvcruc order uf disassembly. NOTE: - \Vheu new pinion ring is installed. a chrck slmuld be made to assure that the ring {us freely in due grom‘c. Thi» can be done by mlling the p|slon ring externally in m pislon groove, (1-33. 4—50 a) which“. gauge a Pinon ring Fig. 4-50. Measuring cud m of“ King a) Micmmeler w Piston ring in. HI. Mus-Irina Ihickneu or piston ting .\ * a) Cylindu gluge a) Pinon pin hm Fl; ‘42. Mguuring pislun pin lame a; .ah mum pin (2 Mluomnor , r z. ”a. Mequrinx pismn pul dimmer (4,) Vision ring (2 Pine" \. Fig. 4-54. Rolling'iha‘piglnn ring in t q) Mnnufutmr's mark "I. 0—“. 0 Piston pin clip 171.. 04‘. Selling Ihe piston pin clip [- at Ann! lurk (gt Pisluh m». Hr. Anemblmg the pision w l" a) cyiindnr :2 Pnrnn Fig. 4 18‘ i: i‘mnn ring h'uillprsKnN “whining rhn rylmder '1“ min ier hnhinr ionvr roller 3) Air when qr spring - The ring: rnunt no! he inlnlled upside down; this will cauu oil pumping. The top side of the ring in etched u the opening with the initill oi the mnnufncmrer’s me. (Fig, 4-55) 2. Assemble the pinton to the smnll end of the connecting rodi Only a slight hnnd preuun Ihould be required to insert the piston pin. Alwnys instill a new pistan pin clip. NUI'E: - Cover the crankcase with a rag to prevent possibility of the pin clip from dropping into the crankcase. . Set the clip in rim the opening i. Iw-y [tom the groove euiour. (Fig. 4'56) - The piston must be assembled u» (but the arrow marking ntnmpul on the pinion head is rownrd the mp when the enginl is in the normal alLiIude. [Fig #57) 3. Assemble the cum chain guide lo rhe cylinder 4. Install the cylinder, NOTE : -The ring gap of the three plslou rings should be staggered 120° apm. . 1' e at the pislun ring cumprra‘sor inni i'rrmi Nu 075154 1mm «cu ‘cusm 07954755111111 maximum fur inutalv line the cylinder \v prevent breakage of the piston ring and. lurihrr, il will simplify the work ririg. 4753i- -Chet~k to mnlte sure that the cylinder gasket and the two locating pins on the crankclse are installed in place; aleo rhuck to make sure that Lhe O ring and cum (‘Illllu gulde an: iuslnlled on the cylinder skirt. 4-7 CAM CHAIN TENSIONER (hydnulic type) A. Description The cum ('l‘Hlln lrnmouer is, as shown in the figure at lelL of n hydraulic iypc and provide: at mean of maintain- ing the cam chain ((‘nston constant ni all umes ln openn- inn pnndple. n is heard on . condition cl equilibrium .nunhr by rhe two inrccs. nnn by the hydraulic lorce and xhv mlier by the chain renslon Oil delivered under pressure rrnm the pump flaws rhrnugh orifice q) prnvirted in the upper crnnkrnst- and check valve Cr huiir in the lower seciion nf cam l‘llflln iensioner holder \i‘.nnd1hen enter: a chamber pYUVIdrll in the holder As the Oil enter: the chamber. thr- prrszure luffeau! therein imd pushes one end of innuioner push rod 1‘ and in mm lensiouer roller (3 ngninsl (am c When rhe ehnin tension overcomes the hydrnnlic Iain, the cherk he opens to reduce rhe prelsuru iu the chamber, pemnting the roller tn more away {mm the (mu chain untili the chain lPrHinn ix lulam‘ed with the trim is spring mil-”we 4—591 B. MM: 1. Gun chain tennioner holder Iflembly can be disusentbled iron: the cylinder by removing the four mounting bolts. from the (nine in not neces- cun chain tensioner (Dianna-ting of any when dime holder). ‘ 2. Disuoemhle the r from the crankcue in accord me with action 4-63 on page @9- 3. Remove the urn chain roller pin rubber which holds the cam cit-in tensioner horn die crnnltcne. (Fig. 4—60) NOTE: when disassembling. exerciu cure to thst the urn-ll urn chsin roller pin rubber will not be dmpped in the crankcase. 4. Remove the cum chain temioner Separate the cam chain tensioner from the cue. 5. By removing the cunt chain roller pin the cm chain guide mller can be removed from the Elm chnin ten- rioncr. (Fig. (—51) C. Inspection 1. lmtnem the cam chsin tensinner holder in engine oil, opente the tandem: pushxod in the direction indicated by the Arrow in Fig. 4-62 U the pressure is maintained the pushxud should hwlnulicully lock and should not move or it may move very minutely ”this indicates that the cm chnin Iennlonl‘r holder assembly is in good condition, ‘ .Cam chain tentinner (mnnusl type) The improved csIn dill“ ltnlioncr are installed on CB (CL) 250E— 1013001, CB (CL) 3505. 1079079, SLWDE- 1000001~ end subsequent. The adjustment of cum chn‘tn tensioner is pet-farmed on the following munncr. A loose cum chain will cause the vulva timing to change. resulting in poor performance, It will Also cause axe ccuive eugine noisei l) Adiuttment must be mude when the [our valves Itre cloned romplelel)’ 1nd the tlppets are (run. This pusltlon occurs 90" A.T.D.c. on the comprusrion stroke of the left side cylinder. Route the generntor rotor counterclockwise until index insrlg on the skin is 90" r\rT.D.C. tuner 90" “L‘I‘"_murk). If the VI] He still lifted, rotate the getter-tor rotor 360' rt-lltgn lame above.I.Fig. :HSZA) 2] Loosen the lock uut {D and the trnIioncr lock bolt : I? When the lock bolts is loosened. this nllowt an internal. spring loaded plunger to reposition inrll’ ur'Id nttinmlltCnll)’ provide com-ct unslon. 3.- Tighten thu lock bolt Ind lock nut. Internal plunger in position. This lock: the D. Rememhly I. After checking all the parts tor durum: and distortion. perform the mam in the reverse order ol removnl. NOTE : When installing the cam chain tensinner mm the case. the tow-rd the top their install the miter pru rubber (1) Cum thurri temwner 0 Cum clllm roller pin rubber Flt 440 Removing the am cluiI-I roller yin while: (D CIIm chain tuntmnor ‘1) Cam chsin guide roller ‘3) chain rull Fix. 4 ‘1.REIIIOVII| (D Tvnslunt‘r lItnlinitl Fig. I .62. t; I‘cumtit-r linlilrt tinting purirruri opcruhun‘ . ualt har if Trmmncr ltVK'lK halt ' Thur..." M Hill I) rtmrrmur )prng {5 Lu.“ c n Imsiuucr \fl: (Kim l‘IVttltl gnule rulli-r Fill |<52 . cutout on the M1 chain roller pin IIIIIII be positioned; up m Rocker um w L‘lm sprocket O Rocker Irm pin a) To m chain lensinner @ Plunger oil pump a; Centriluall nil mm m R. crank-Ir mm Fig. 4-53. on luhricllion system 4 -'s LUBBJCATING SYSTEM LID-aim The lubriun’ng W is of : plenum-feed type using a plunger type pump. The oil circuit. of the system u:- echemnn'eelly illumned in the figure a: left. The all 51%! 'l of n aenn-ifuunl type. A: the 07:1qu the filter and is picked up by the tpinning vnnel of the film cover, foreign mane: such u metallic dual and carbon pnrticlea nre leper-led (mm the oil by centrifuge! force. The oil polished in this manner is fed in the engine puts lhmugh the bullet pen in the cenber section of the filler cover. . The oil pump, u shown in the figure :1 left. consinu of a pump rod {drive rod) (D, 1 pump plunger w. n pump body G) and neeLbnll type suction und delivery valves. The input end of the rod is eccentric-11y mounted on the clutch outer and is driven by the cam ol the outer :0 give a re- cipl'ocnling motion to the plunger for pumping operation Delivery valve steel bill (31 is spring-loaded. B. Din—umblf ‘ 1‘ Drain the oil. 2 Remove k sum: pad-l from the kick ltll'btr . pinian 3. Remove the mounting Icre'vn mad disassemble R. crink- cm cvver. (Fig. 4-66) a) 6x' cm. wrews a (”we cross Fix. 4—“. Removmn k. cmukrfisa mm t Remove (h: cixclip Ind filter up. (Fig‘ M7) 33 Circhp a) on filvur|p m Him @ 6mm In bah Fig. 441. Removmx nu: ml rum up 5 Stnighten the tongue of the spring. washer pawls and , tcmove the 16mm lock nut by uuing the T—handle lock nu! wrench (Tool No. [TING—2830000). The filter rotor cln khcn be removed. (Fig, 4—65) 5‘ “lurk Pig. «in Rcmuvmg m. ml fihn rolor 6, Unscrew the (our 6mm bah; and remove [he clutch spnngs, pressure plnles, friction discs and dumb plums. (Fig. 4—59/ 7. Remove the 25mm circhp and dismsmnble (hr cluu-h comer, :1-‘1g, 477(1) 8. Linlnck the all pump bah locking washrr and remove the halts, ’n "bmm ark-1.“ @ mmh (emmr a Plim mg. a 70‘ Hemnvmpz me much u-mr h 0 Clutch water 0 on yump my. 4—11. Remwing the clutch uum a) on (mu cnp a: on filler opening Fig. 4-12. on an" up w a) Dnin piup rir. 4-1:. 0.1 drain plug m lA‘vt-l mp.- 4;, i‘ppui limit :7: Lowr‘i’ limit Fit. Ht. Ull iii-u] I @ Oil filter rotor (2 Lack washer G) Lock nut Fir. I 75. Clefllllliu ml filter II-i 9. Rernwe the oil pump together with the clumh outer. (Fig. #71) C. Inspection 1. Engine oil check Ind clung: The engine oil Illollld be changed the initinl 500 mile: and every 1500 km (1000 mllen). 1) Remove the oil filler cap end dnin plug an the bottom of the cnnkcue and drlin Ill the engine oil. Draining will be hutcned if oil filler cap in remuved. (Fig. +72) 2, Alter draining. retighten the drlin plug nud pour new oil into the engine through the oil filler opening 3) It the oil level is between lower and upper limits on the oil level gauge dipstick w‘th the filler up not threaded in but just inserted, it indicates rim the oil level is correct (Fig, 4773) - If the nil level becomes below the limit mark on the oil level gauge dipstick, ndd oil through the filler tip to the upper limit mark to keep the engine in good condition - Du not Dverfilling the crankcase with all otherwise, the excessive oil flows out of the lire-titer. -W’hen driving the marorcycle in unusually dusty condi‘ lion, it is recommended that oil clung: be performed a: more irequent intervals than whet is specified in the maintenance schedule; this will have a very beneficial other on the performance ind servitelblc me at the engine -Alwnys use unly the oils (‘lflfifiifltd [or A.l’,l, sen-ice MSrDli. (nudi‘nr D11.) or the use of all season SAE group zuwm oil is recommended. la . Cleaning nil filter Cl'hr oil filter rim bl: periormed withnut dismounting the rngine from lhc [annex Clean the inside oi the filler rotor and rcmuve all din, metal particles and my other (oreigu chin-m (Figr 4'75) 1) Remove the oil filler cover. uuliisren the cirrlip which mounts rhe oil filter rotor in place and pull of! the rotor cap. 2‘ “’uah all the accumulation of dirt from Within the roror with kerosene 0r >ulvcnl m: -Wh:n niuullhg flu rotor up. the rotor up van- Ilmnldbe mmhedwdngmaveondwimidew-flol dictator. (amt-73) More mulling who oil filter carver. duck to Mt am than due oil guide maul in orienting smoothly. (Fig. H7) v WI] kindling the oil filler cover. make sure to position it prapefly. (Fig. 4—78) 3. R. cnnkcue and oil filler inspection Inlpect ihe cnnkcne md oil filter cover: for cranks and ['50 [or my d-magu to the mating mxluces since they may tune oil leaks. The dun-gcd Irena may be re- worked with fine ailslone if not exceuively damaged. 4, Oil pump body bore dimension Inspect the bar: of the oil pump body [or my dnmlgu and measure the diametzr u 90' apnn m both «2,; and bottom. (Fig. 4-79) mm (inch) _ Sundud Value ‘ Servioeable Limii Repim if over Bore ‘ K6,! mm, dinmemr 5. Oil pump plunger dimension Measure sh. diameter ai [he oil pump plunger wilh i. micmmelcn (Fig. 4 30) mm (inch) _7 Sundard \‘lluc iServim bl: main 7 Plunger 15.955-- 15.270 Rc nder Iii-male: l minnow) 15. so (0.52% 0 Rami- up 0 VIII. “I. 6-". Ruhr up innallalion G) Oil guidc maul 0 oil filter raver Hz. l-TI. Chnking fluid: met-l super-lion a) Row: up a on mm mm a) on film mini... ‘é. 3 HI. Ha. on film covet inallllnluu . ‘ - } a) Cylinder inane (2.) Oil nun-Iv body rig. 4-19. Meuuring pump lvmly but: a) Micmmeier‘_ $70.1 pump )llunKPr mi «so. Manning pump pluugu l .. "A D. MW LRuuembletheoilw-rnplnthemmewoeedmm humbly 4.83 on page ‘5. NOTE : -Thl oil pump lock wuher nhould be replnced with I new item. -Thccirclipuiewlletlhedutchwntetiaoflspcchl dimension (26x15 mm) therefore exercise cure that the mnd-rdcirclipfirnlnianoltohemed. ‘ ' ' 1 k unhel- . . g glmflmfiffifio'éfifif 1:26;" 2. When mmblmg the Oil filur rotor on the ennluhnlt. III. 441. Anemhlin. oil filter rotor lock wither ulemble the oil filter rotor lock wuher, 16mm lock wuher end the lock nut in that order. The oil filter moa- lock vuher thould he unembled with the uh toward the ounide. (Fig. 4-81) 3. Make sure [but the 16 mm Incl: nut is properly torqued and locked to prevent loo-ening. Sundnd torque: ”mu-ell (21.1-23.1 10"“) (Fig. (-82) 4. Aligned filter up held to the grow: incorporated within the rotor WI“, assemble the filter enp inns“ Ind let the til-clip. a) Leek nut a: Lock wnhv in. en. Tightening the [our nut F, 4.9 cwlcn A. Manson The clutch is of I wet. multipledilc typer Al Ihown in the figure! below, clutch plate: A G), Ind B 0; ("drive plum-I"). which are capable oi tliding nxinlly nn Clutch center 0, are "sandwiched” between friction dire: G) (" driven dim”) engaged in clutch outer ®,. ln norm-l engnged condition of the clutch, pressure pllKe Q. upon which the funedehneh wring: O in string, preml the luck of the dish nd the plume: ngninrt the cluuh outer, Under this ‘ W power in tun-mined through prirnnry drive gene @A to the unnnmiuinn mnln theft. A: the clutch ' h h dilengnge the clutch. lifter rod (9 in moved in such I directimi u to pub the pressure plate nwly the dim and the plates. opposing the force of the clutch npr'mgn Now the {nu pnslul’e n the lricrion turf-cc: of the power transmitting put: it reduced to 1am, reeulting in disengagement of the clutch. a) Primary drive gear (2- Clutch tuner complete (a) Prim-ry driven gelr m Clutch omer‘ ‘ ' ‘ ' r (.l h - q) Clfllnh plum _(;m (Zlutch pm: A (5;, Clutch plate 1)) ® Clinch center @‘Clulch wringl 3 (213:1. LTSLX'LASLE” "J 0 Clutch hirer ,omv piece gm Clutch mm rod «9 no 5:ch hell 0 Clutch Jevcr @ Steel bull (clutch bill reuxner) % Clim‘uymer 0 Clutch Ithuster lock mu 9 Clutch ndjuiling an: I. . ' “l- HIB. Section! View of cluIch B. Dilutembly Dinnemble the clutch in Iccuxdance with 4-83 on page 45. C. Inspectlon L Clutch adjustment 1) Screw the clutch cable adjusting bolt A, located on the clulch lever. .11 lb: way into the clutch kver brukel (Fig. 4'84) 2) Tum the clutch cable adjusting boll 8,10cmcd on the drive chain cnver, in the direction ® to loosen the clutch cable. (Figl 4—85) a) Circul-r lock nu: ma Cluxch able alljusling bolt A Fig. Lu <0 01ml. c-ble lxljuuing bolt 1; a) Lock mu m. 4 as. 3)].oonendueluwhudwm‘ 'gmbcknutmthe clutch Idmm' ‘ new in the counterclockvhe dirunou‘ unfilllhg‘ htren’nnnuilfelt. Fromthie pawn" mm the dinning 1cm in the elocltwue' by 1/4 turn Ind the mud the lock nut. (Fig 4—88) 4) Turn the dumb cnbla dinning bolt 8, located on the drive chnin cover. in the (a directimt so tint there i: approximloely 3/4 in of free plny At the clutch lever: then lighten the lock nut. . V l ‘ Q 5) The remaining clutch lever free phy i.- olnl'tned by the (1) Clutch adjusting we}: clutch clble dinning bolt. A. Q Clutch Idjulfing screw lock nut 6) After the edit-amen: hul been nude, check to see th-t Ii L“. the clutch in not flipping or (but the clutch is properly dimly-sing. I. When the kick mner in med, doe: the engine euily ntnrt without the clutch, slipping h. After the engine sum, pull the clutch lever md shift into seer. and melt: sure that the engine does not will, nor the motorcycle nut to creep, , Grudully reins: the clutch lever and open the throttle. the motorcycle Ihould mt: lmoothly end gradually hauler-he. n 2. Friction disc dimetuion Manure the thickness at the friction dine with I vernier :4 uliper. (Fig. H1) ) E mm (inch) Sum-d anue ”Semi nu: Lit-nit 2.62—4.75 Replica if under (0.031~0.110) 2.3 (0.9%) its, \ (D Vernier caliper Q Fvirllan disk Fl]. ‘781 Meuuring thickness at friction disk 3. Clutch plate wupuc Mrs-sure the wirpage of the clutch plnte on the slut-cc plate using a thickness gauge. (Fig. 4-88) mm (inch) Smnmd V-lue Servimble Limit 0‘15mlxt Re nr re lit :1 (0,005! mi" 03 (0!“ l ,. ® - . ‘ ....- 4. Clutch spring dimension (D Thirkuw WWII“ 1) Clutch pine {is 3'1""! Pine Measure the free length at the clutch spring with a Flt. Hut Mmunng llle wupagc at clutch pl-I: Vania, “up“ in“. 4.397 . _ mm (inch) -' 7 Standard Vlluc isen'tcenhle Umit Spring rm Re . - , , plloe it under Eggg. a ‘ 395 1.390) 34.30 (1.315) ’spnng {m hi. , . , place if under 'ég‘F'é'wm “‘3 43* 303) (1.200) D. Rammhly Reassemble the clutch in the reverse prnt-cdur: of dis- m Vern'cr rniipt'r ~27 Clutch spring ' assembly 4-88 (in page 45‘ Fig. t as. Muwvrmg tire length a! clutch wring 4-10 CRANKEEAFT AND CONNECTING RODS A Mwlfll The crmkllnft is nude from high cubon steel Ind tannin: 0! three section] such u left, center md right union. and caunterweighm, which u: put together by pun-fining, It i- eupporled at four pluu by mlifriclion belfingn—rhree roller bearing: Ind one ball belting} cl helvy duty type—no dun i: is [ully h-lnnced both antic-11y end dynnmicnlly. On (hi: cunkslnh ue mourned - Inning Ipmcket, In re generuor and I cm club: drive sprocket. The connecting rod: m in mum-id chmme-molybdenum Pl; 440. Cnnkslmh end me made by die-forging, Their big end: It: Iupporud by needle roller burlap, mg. .791, on chmnnrl B. Dinuembly l. Din-unable the am case in accordance with senior: 4-33 on page 45‘ 2‘ Din-mmble the cylinder hrnd in accord-nee with section 4-58 on page 31. 3. Disassemble the cylinder in accordance with 4-63 on page :99. 4. Disassemble cum chain Icosioner in accordance with section 4-78 on page 43. 1» Neuunl lead mnmuon a) ma mun Fig, 4792. Removing [he mud lend rumxu’xion 5, Remove oil filter, oil pump. clutch in Accordance with lethal} 4-88 on page 45. 6. Remove me gear 5|qu spindle 7. Remove xhe neutral leml cpnneclivn from the neutral switch. aFig. +92]- 5. Remove the 1m cruukcase Coven "mu 4—93, it 1. uankmsu qu Fm 1 9.1, Krmmmg du- I. urrlnlusflxc «We! 9 Remove [hr generator rotor hy uemg a generator mm: puller v'rnnl No.0793. slamming. 4794‘ i nwmw .nmr 1 Llcnvnuur xulur puller m. n 9:. Rumun'ug m genera“)! rum! a) Sinning mot r Ipmcku a Siming spinnin- a) Suning clllln m. Ha. Removing lhz inning mach: 0 Snull dill glue 0 Cunluhnh 0 V-bloclr Hz. 4—H. Mfllunn‘ runoui of crank-hill q) Disl gnuge ® Bearing oum ucn m. l-D‘I. Menunng [he diamuruul clan-nu ® Dinl gnuge @ L’annemng rod Fig. I 98‘ Mmunng Ihl' cumming wd dumclriral clunnce (9 Thickness gnugn a) Convieciing rod Fig. us, Measuring iiie rcnnecnng 10d ddz cluunce 10. RAM“ in main: Iprocket m plue and take out the Inning sprocker together with the flirting mono: Iprockel. (Fig. 4—95) 11. sepunie an: lower crunkcm by removing '11! cu: fixing bola. 12. Unscrew the center bearing up bah: Ind remove the ennknhnh. C. Inspection 1. Meuue mount of bend supper: the crinkshah by die mm baring on V-block. Rome the cnnknhnli wid: the right nnd lei: connecting rod and measure the Imounk of runout will: I did slush (Fig. 4-96) nini (inch) Sand-rd Value ViServicubie Limit shin 0.02 (0.0098) £35}; (35155:: 73mm Rep-i: or u’pim it my" °-1° (“0‘“) over as (09122 2. Main belting dimetricul clunnce Support the cmklh‘ll on V-blocku It two point! md mature the mount a! clear-ace by setting the dill glaze on tap at the outer rune. (Fig. 447) mm (inch) Sundnxd Value Senicnnhln Lun‘u 7 ‘ 0.0124302!) ‘ Repllm il om (amo5~o.ooosz onus (0.002) c :1. Connecting rod di-meuicnl cleulnce Support the cnnkshnh on Viblock u two points, move the conntcling rod in the vertiul direction md measure the nmunin of clearance with n dial gnuge. ( ‘ as) mm (Inch) ,, 7 sinndnni Value in! W jervicenble Limli 0,00-I~D,ulz Replnce if over minim—owns; 005 mom; 4. Connening rod side clearance Measure the amount of side clenrnnce oi the connecting rod wiih n lhlckflcu gnugc (Fig, 4—99; mm (inch; 5 Adan] v.1... , SerViceaMe Limit ouiiuw Rnplncc .1 cm \0m28~4)0130; um \uu'zfl; 5. Connecting rod null and bore M:uure (h: mull and bore with - cyfinder glugc. (Fig. 4—H”) mm (inch) SW v-lue Servimhl: Limil [501645.034 Rollo: if over (0.59! ~05”) ism (0593) D. humbly 1. The dowel pin on the inning nuLer me is firmly installed into the groove: of flu cnnkcnse. (Fig. 4—101) 2. Assemble the cmklhall in Lh: revuse procedure 0! disusembly in lucid-nee with 4-1013 on pug: 51. J NOTE : ~Unilonnly lighten the four cuter bearing up bolu in I diqonnl sequence in 220-240 kg-cm (15.9~l7.4 fl-lbo) torque. (Fig. 4—102) - Tighten 1h; AC. geuenwr rotor setting bolt m 220- 240 kg-cm (15.9-41.4 I'm-lbs) torque. 4 - ll TRANSMISSION A. Descriptinn The transmiuion is of a consmumnesh Iype and provides a selection of five speed: — the flows 0; power in the respec- live epccd pusilions are illustmcd in Fig. 47109 through Fig. 4 1m. ll his Iwo sham; namely, il main shah (input shall: and a rnunu'rvhnh (ouqu shaft: on which various speed gears are spunemoumcd, mm dog cngngcmvnl I." Lb: muiu shalt secnndg‘lhlrd and fourth gens And the countershull um and fourth gain. The shafts are supported by ball bearings On the output and of \he countexshnh is mnumed the driv: sluocket B. Disnssemhly 1 Dunssemblc the cum use in accordance wnh srvtion 4-813 on page » ‘3 Disassemble thr- t'yllndl‘r head in accordance With suction 4-513 on page 31 3. Disasthlc div cylinder in accordance with «‘L‘tilln 1-68 on page :22. 4. [inassrmble the cam chain tensioncr m nuurdnncc wiih sci-{inn MB on page .13! . A 0 Connecting rod a: Cylinder gauge rs... Hon. Musuring m.“ and bore 3) Dawn] pin groove! m Upper mnkme Pin £ I01. (9 Torque wnench m. Hoz. Tightening the bearing up bolls 53 5. Disassemble the oil pump Ind clutch in Lowrance with eccn'on 4-85 on page 45. 6. Dina-enable the cranhhah in amordmce with section 4-1013 on me 52. 7. Disassemble the transmission gen shift Inembly from the upper crankcase. 3. Remove from the main IhIh. (he relpectlve needle roller benring and the M5, MZ—MB gem; remove the cit-clip and thrust washer and then remove the M4 gen 9. Remove from the countenlult the reapective needle _ . , roller herring: and the C1. C4 gem; remove the circlip m. ‘ “‘- s'm“ 5'" ‘C‘ " ""h“) thrust wulm which mum the c3 gm Ind remove (13 end C2 gem. Remove the circlip Ind thrust wuher reuining (:5 gen; remove CS seer from the lhlft. Since 26 mm thrust wuher Ind lock washer are employed in between the C2 Ind C3 gen! for engine: maul-l:- tured liter engine Ierill No. CB/CLZWE-IWW‘ or (33/01350le remove the C3 gear It fink Ind then, remove the lock washer and thrust wuher, Refer to Service Bulletin No. 012 {ai- CB/cuso & 350 Ind rum News Nor 8034 (or cam concerning the detail: of the subject nutter mi Hot. Third gelr (C4 in shifted) ' m. 4 103, Top gear 1 l! shlflrrl} rig. u-m. Fuunh gelr {ME-MS is shifted) C~ Immtion 1. Measuring hnrklaxh Hold the mulling gear so that it does not mm and lightly rock the gm hem meaxurcdi Manure Lhc amount of backlash uxillg a small dial gauge, mm llnchl hem fl , inland v.1“ Servirelhlp me mmqum ‘ Replute it over I'HlllT~U|fl32: 027101105: ume~u14 mph.» ll over 00015410055‘ OL' :UIXH‘ l Srlglfinrd Value Sch'u’ezlble Linux ‘1) Small mil gauge m w mnemnn Replatr .l over Flgr Hos. “mum he gum hhhliah ' > - 0 mammary: m gums C, R: hue il aver ‘(Hll)~0l)02l in 00039? 7 (‘w‘ (3 mm «(H234 Rrplnct ii over " lillml5~llm3 ‘ (l1 HNmTl is “fear (0 lrnnmlisdan gear Gears «her lam: period of use will dexelop war to the mull) and dug resulting m uncvcu roman whirl: pro, ducts: noise or cause [he dogs ta disengage To correct [hls mndluon. the mimug Hears must he rcplflL‘Ed m IBIS. 3 Clunrnnre hrrwl-eu gear and than Measurr (hr bore of the gel." with a cyllmlcr gauge or nu inside mirrnmerel’: mrnsurl: the shaft dlnmctcr with n micromuvr flml compuxr the clearance {Refer to the “lime table‘s t Place the geminneutrnlpotltlonnndeheclttoueure tint the dogs nre not eluhing and the respective gun It! apenfitm monthly 0) Benin. min. ring @ Benin. dowel pin 0 smslls. hell hearing a) Bxst. on ml 0mm.uedlehuring 0 mpg“! on Main-huh mud A third .m o unis. elullp 0 25mm. thnu mlm o Main-huh launh gun: a Tun-million minlhlfi a mum. needle hen-in: o Connnenhnl’t law [ear 0 Comm“! faunh gear 0 Cuultunhllt third gel! 0 Connwrth-ft umd .m o Counter-heft lop gm 9 Drive rpmku fixing phi: 0 Drive lprockm o 33x52x7. oil peel o Tun-minim: mnhenhlfi o 245 Inn. 0 tin] . Tnmmiuion enuntenhlft only 9 6mm, m1 bolt 9 20m. thrust Weber 9 25mm. lock mm: a 25mm, mm: wither a D. Ree-unbly Reuoetnble in the nvene eequenoe of dint-embly in accordance with #1113 on peg: 53. NOTE: -Mnke lure thnt the thrust wuhert and circlipt are im lulled on the M4. C2 and C3 gemt - Use only new circlipl Ind properly insull in the groove. -Wben assembling the betringt to the mainthah And content-It, mlk: sure thnt the bearing with the oil groove in ineulled on the countetthnft And the belting without the oil groove on the min nhnl‘tl - The installation of the benring net rings Ind the dowel pint must not be forgotten. . Anemhle the left shift lork on genr Cd. right shift lurk nn gear CS and the center uhil’t fork on yer M27543. end then unmhle the mninthzh and the countetshnft in set. (Fig. 4-111) 4 -12 GEAR SHIFT MECHANISM A. Description The geu shift mechanism is n linkage arranged between the gen change pedal and the sh"! fork: and include: I shift arm {2. n shill drum 1;. a neutrnl Stopper (D, a drum “upper (3, etc. as shown in the figure nbovel When the pedal is deprewd (or shifting, the shift spindle rotates, ”using the arm to rotate the drum A: the drum is so rotated. the fork is mmed by the CM“ action of a groove cut in the drum to shill n gear. The drum stopper is provided to pretent unintentional gt-nr engagement Return spring is used to tclurn the pedal to ils original position when released and to place- it in the neutral plmitinu [or subsequtrnt shifting [I 'cnr shill arm a- Ncutral mum- \ :4, sum .lmm Smpper m llrunl twp" plale 55 Hg. 4-110. Tun-million a) Mnimhllt ® Cnumrrshalt Fix. Llll. Assembling the units Fig. I—IIZ. Gfll‘ nhlft mechanilm B. Dill-ell“, ' l. Sepnum the umminion gen uni-ably {mm the upper mnkcue in accordmce with 4-113 on page 51. Z. Ramon the nun-Ii Wild) row: mad than "punt: flu shift drum lump“. 3. Rmove the UN“ {ark guide pin clip and then pull out guide pin, 41 Ramon (he gent nhih dnun by lightly upping the cue on flie tide of flu Mum! rwitch mounting. (Fig. 4-113) 0 Gear 1th drum 0 Our Ihifl {nth rig. 4-112. Removing me 5m llliil dxum C. mm 1. Manure the mount of wear to the dog on the gear thift lurk. ' Po-iiiun ch: gnu Ihifk drum venicllly on die V-biock, mount: the nhih drum (ark dog In two up poi-nu (Fig. +114) mm (inch) ' SW51“; 7_ Serv cable L our 0.1 (max) mu. mm 0 Dill gauge a) Gm Ih'ift lurk in... k1“. Melsuring “1: am“. oi zen! nhifl ioiii 2. Manure the thickness of the geu' shift (ark dog. (Fig. 4—115) mm (inch) sand-iii vim Serviggbigymix A (filled to 4.93-5.0 Rephm if Wdeii flu. 05) («MW-197) L6 (0.151) 3 (filled in 633-40 Replica if “my MZ-MB) (01233~0.236) 5!; (an) a) Mimi-mu @ Gm shiii fork 11.. 1-115. Mounting the iiiidmui 01 gel: ihin lurk 3. Gen shift fork bore dimemx Meuure the bare with I cylinder gauge or on inlide micrometer. (Fig. 4-116) mm (inch) k} dud Vllue 5:1- Repl over 40075 (1.517) a) Cylinder glugc <2) Gnu ihin fork Pi]. {4161 Muluring Ihifi fork bore a 4. Gear shift drum outside diameter “D Measure th: gear shift drum using a micrometer. (Fig. 4417) mm (inch) Slandlrd 11.11977 Sun bl: 145m 399549.975 ‘ Re [me it under (1.5689~15738) i 39 (15711 (0 Gen ihin drum (2:1 Liicromnlcr ri.‘ 47111. .iimimng Ii): uum dinmnler 13.33-3th l. MHIIM‘EIIMdnmh-Imfllumut At thisn'ntemnhrurethnttheloclfinn olthelhiftforlt erelnthdrrupectivepoohion. The two iii-hide end the center gurlhiftiorluere difierent. NOTE: Whennnemblingthegurehiftdrummxercheeuenot In dun-ye the oil seal pre- fitted into the crenltcue. 2. Inst-ll the eliift fork guide pin into the shift fork Ind lock with . clip. (Fig. 4-118) NOTE: . Check to mite .u‘re whethr the clip is m securely. at Reusemble the rem-hing pen: in the revere mum of diuuenthly. NOTE: 'nuh eure that the nation of the gar shift fork is mouth, I - 13 KICK STARTER A. Dnriptiml The kick Inner in A device med a: crank the engine lot curt-up, Ind ennui": euentinlly of n pinion. n rpindle 0 end I return spring. When the Inner pedal is de- preued with n lull kill evoke, the :pindle is muted in the direction of lrruw (counterclockw'ue) within the pinion And the screw thread: provided on the Ipindll cause the pinion. stationary hectare of it: inertit, to move in the direction of ln'nw. making the counter-halt low gent. Upon eng-ge. meat. the torque or drive in trensmitted through the clutch m the engine cnnklhllt, creaking the engine. When the pednl i- releued. the Ipindle router in the reverse direction (clockwiu), curing the pinion to move on the screw rpindle may from the gear. dieengnging the drive. 8. Diuuemhly 1. [limemble the upper and lower cnnltcue. 2, Diinssemhle the kick starter spindle, C. Inspection Check the kick starter spindle nnd pinion. if damaged or worn. replace with a new pln. D. RusaeIIIhly Rousemble the kick sinner companrnts in the reverse order of disassemhly. NOTE : Do not forget lo install the 18 mm circlip and the 13 mm washer. (Fig. 4—121) 0 sum. pill clip In. His. (9 Fri pring a) Kick inner pinion o Cmm ‘ k m Km (3 Kirk 5mm spindle a Kick sinner Bpring 1|) 115mm wuher Pl]. #119. Kick :Ilrler mech-nlsm Kyfl A (o 25 mm circlip ® Fri (5; mt tun" pinion Kirk starter spindlv an Kirk shin" epnug it in mm rin‘lip Fig. 4 120. Component pan: in! luck npindlc ‘on )pi’lng a; ll mm washer a) Kick mm spindle Fig. 4.121. lnsullmg the "limit with" \L\ (D To «mallalr Q To crmkalnh 0 Tu main-halt Hz. #121. Upper crankcase oil pus-go Ht. l-lfl. Oil flow in lhe lower crankuse 0 Lower crmkun Oil nparalcr (D 5X97 Ill-x lmll lg; 8v [[5 l'wx, boll gs; 8x150 lwx hull l: lyxsd lwxv boil 3) 8x45 lu'x hull la, MUD!) llcx. bclr iv 6x140 hex boll Fig. 47126. Ilghlrmng lower cranlxns: r4 4 - 14 CRANKCASE A. Dun-mien The upper Ind lower crank-pea In alminiumalloy in material-ndmunelncma placer Thumbs-apart“ from each other and an mutually pmvided wi‘h oi] pun-gel Ihmngh which lubricating oil is fed to die crankshaft, cum- Ihaft, trammiu‘lon etc. Oil Separator Operation The lower crankcase is provided with the oil rep-rater which serves as baflle plate lo prevent lubricating oil from splashing on the crankshaft excessively. B. Dimmhly L Dian-enable the cam case in accordance with Mctlon 2. Disassemble the cylinder head and cylinder in accordance with lemon 4611 on paxe 31. 3‘ Disassemble rhc cylinder in accordance with secllon will on page 39. 4. Disassemble lhe cam chain tensiuner m accordance will: secrlcu 4~6L$ on page 39. v. . Remove the RV crackcase cover, all mm. on pump and clutch in Mcurrlnnrt- with arctmn 4-HB on pnge 45-46. tic Remove Lhe L. crankcase cover. [\lC‘ generator rotor nnd running clutch in Accordance with 4408 an page 51 7. Loosen lllc twu filmn 1m balls on au- upper Hula, m. {our 8mm llcxv lwlhl and night 6mm llcx, bulb on the lower side, and remove the lower case. C. Inspection Chuck for damages especially mound maring surfaces Sim-v cvcu a small defect such as scratch will cause all leaks Repair ~llould he made will) an all stone, D. Bu—nhb 1. Chmknmkemthnthsmiumrkpmptrlyemdindielnwermnkm. Applyliquitlguimtn Innthgmifioeofthelowercrenhnsu. NUI'II - Oil. lolmt. stuck what should he completely re-avod from the rolling whine surf-oz. ~Donatpsrmitdteliquidgukettogetonthedowelpinhole ormsurfscetotherthsndiemnflngpsm. - Apply the liquid whet evenly and monthly. - Allow the liquid gash! to set helore joining the two ennlteut halves. 2. Assemble the lower cue. 3. Handle the tuning motor uhle Ind dynamo cord with we no u not to deluge the chmpl; tighten the bolts. 4 - 15 CARWRETOR A. D-eripfion The outstanding future of the CV carburetor' I: s content pressure, single barrel, compound urhuretors brought thout by the numeric changing of the venturi nee by the vacuum prenure of the engine Etch cylinder Is equipped with A single carburetor of this type which provides the (allowing sdvsntsge: to engines hsving s hrosd speed r ; end a high power output. . 1. Because of the vsrilble venturi design, the trunnition between the first end second “we is exuptionelly smooth; 7. The construction is very simple due no the single blue! lesture. 3. Excellent stealer-tin Ind good economy is natured. . The fix whieh pusee the cleaner flows through the air inlet G), venturi Q, throttle valve 0 And eaten the eylintles ' ‘ through the inlet port. The vseuurn piston G) is protruding into the venturi are- (D end by the union of thn v piston spring 0, the ventun is held townrd the closing side. When there' Is only I mull unount of sir ‘ into the engine. the vscuum piston Q) is in the lowered position. forming the primry venturi O 11:. dr‘vs h‘ the \enturi ares Q is mnintnined constsnt. nfinrding good stomizstion of the fuel. With In influx in the lit low, the vlcuulll pressure in the venturi incxuses, csusing the vacuum piston to rip: due to the pro-we Ippliod tn the top at the piston. The venturi Ilen is inn-cued hy the lmounl of the rise of the pimn whieh is in proportion to the vuuum pressure. ‘ ‘ m “i . when the engine resche- maximum rpm. the vacuum piston ratchet the top And beme the secondary "gig to provide suficient venturi are- for maximum power output. (Refer to Csrburetnr Mmusl (or detsils). u m. t 121. Secuonal View of rarhurelur (0 stop screw 0 Pilot screw fig. ‘4”. ti) Throttle uhle ldiuli bolt @ Luck nut Ill- 4-129. Adjusting idling Ipeed Throllle clble ldiustmem m Firm level gauge (2 Flam I'll. ii m, Checking no.“ irrrl B. Dmbly 1‘ Remove both left end right air cleaner covert. 2. Maren the throttle enble uljiuting bolt Ind nut, uId relum the throttle enble from the carburetor. 3. Loosen the cnrburetor letting binds. Ind remove the cnrhurerors. C. Inspection 1. Idling Idjusunent l) Adjust the stop screw © so that rhe exhaust pressure in the same for both the right Ind left side. (Fig. 4-128) If the engine speed does not decrease when the stop screw is screwed out, loosen the lock nut ® and screw in the cubic ndjuet bolt (D by about one turn. The engine rpm u: this point should be between 1.100~l,300rpn. (F~ 4-129) 2) Surting with either the right or left carburetor. mani- pulete the pilot screw ® end find the point of highest rpm; the same shnuld he done with the apposite carburetor. Turning the pilot screw in will give n lam luel nit mixture, turning the screw out will give I rich mixture. The pilot screw (1) should be set at I point 1 (3/4 {or 350) ol 1: turn out from full alone. (Fig. 4-129) After completeting the adjustment in paragraph 2 above, recheck the exhnutt pipe pressure on both the right Ind lelt sides and if necessary. reldjun the stop screws He Wu (lime: in paragraph 1. 3 4 Repeat the procedures from per-graph l thmugh 3 several times no tint the pilot screw in net to give optimum mixture, while the stop screws are set to provide the specified rpm and the same exhaust pressure on both the right And left sides. 2. Synchronizing the throttle vllvc Make the adjustment so that the right and lelt throttle valves will both move by the same amount when the thruttle grip is moved sliglllly. This adjustment can be rude by placing t lulud under the carburetor and noting the movement ul the throttle lever, in by m-crscrving the movement while the throttle grip IS slowly moved and checking to see that thr throttle levers start rniwing at the same time. It adjustment is required, loosen the lock nut (31 and perlorm the adjuslmenl With the cable adjust bolt (9, Win 4-129) 3. Fluul lcvcl check Remove the float Chamber cut-er. pnblnnn the float to the point where the float arm barely muches [he that arm in this position, set the limit level gauge Venlt‘fllly on the float, [Carburetor tilt at 10" is norniali. um. +130: 4. ll the adjustment is ncct‘ssary, make the adjustment by using a small screwdriver to bend the float nrm. 5. FRAME Sol HANDLEBAR A. minim: The budlebu i. Ipecinlly designed wad! the unwdne engineering techniques of Hand: to provide minimum rlding wmlorr Ind mlnimnm mering dificulzy. l: is manned on the fork lop bridge with two clamps. A (“11vath type hlndlehu i: mounted on the (ill-uric: muhinel and I Iemi- niled type bandlebu an the (DB-mic: muhinu. 3. Diana“, 1. Dilemnect die from bake table A: (be lower end by loosening the from brlke Idjuninn halt nuL move he hnke urn: mud die linking position to providing slnclr to the ublu, md than iii-connect Lb: cable from the brake Innr (Fig‘ 5-2, 5—3) I 2. Remove the link: and cluurh cables from the handlebar by inning ihe alone-d rlng ndjusling boll so that die slot: in the holder and the fixing nut are aligned. Remove inner cahle end slide the end 0“ at the handle lever. lFig. 5-4) NOTE: W'hen disconnecting the clutch cable at l1): lower end, remove the gear shill pedal. drive chain cover, and (hen remove the cable end from clutch lever. 3r To remove thronlc table lrom the linndlc lever, unscrew the sening screw on ihe starter switch assembly and suparnle the two halves or the starter switch. The miner cable will he exposed Mull can be removed from lluoule grip pipe. (“3‘ 5-5, \4”, 61 Fig. 5-1. Enema] view 0! hundlcbu Figr 54. Removing brnlre clble (g Chm-l: cable 1) Clinch cable Adjusting bolt @ Fixing nut @ Clulch lever m. 54. Removing uhle from me lilndle m Thmule grip o Throule um: ‘33 Sinner [inkling witch usemhly my 5 s. Removing the ihmule cable t Disconnect the throttle c-ble II the lower end by loo-en- ing the lock nut It the able nupport m on the carburetor Ind then dilemma the throttle table from the euburewr. (F in. 5-6) ® Throttle able 0 Throttle able Idiumr 0 Lock nut m. H Removing the throttle able 5. The electric-l wiring {or the horn. :tsrting motor switch Ind the light dimmer switch cln be dixonnected by uncoupling the cable Junctions {mm the wire h-rness lac-ted within headlight core. 6. Remove handlebnr by unscrewing the four 8mm bolt: [tom the hurdle pipe holder clumps. (Fig. 5‘7) (1) Steering hurdle pipe Q 8mm bext bolt Fig. 54. Removing the handlehlr C. Inspection 1. Inspect the throttle, clutch and front bI‘llt! cable for dun-gen to the housing and inner cable. also check lD tee than the cable in operating smoothly. Apply grease hefore reassembly. . Check the operntion of the throttle grip; melt: sure thnt the action a! the grip is smooth through the entire range. . Inspect the hand lever operation (or lightness. inspect the handle pipe for twtst. bend; or other damages. Inspect, the switches on the handle for proper operation and Ilsa the lead wires (or breaks and (rnyed covering. sue-”N D. Reassenthly 1. Rough the elechical lends from the hundlehnr through the center hole in the top bridge Ind mount the handle on the top bridge. Fix in [)1er with the handlebar holder and lock with the {our 8mm bolts. 2. Connect the throttle cable to the throttle grip and adjust the play with the rm: (2, (Fig. 578] ® Throttle able (2‘ Throttle able Id;ust nut “A" (3) Lock nut 8 Drrn‘axc 0 Increase Fix. a a. Timur rsblt- play ad‘ualmem , 3. Connect [hr clutch cnhlc lo the left hand lever and the front brake cable to the right hand lever. The adjustment of the clutch table is made at the crankcase (Relet to page 21), where-s. the ndjusuncul for rhr (rm-it hrnke is mndt with nut “b" and “ c" M Lhe lower end of the iron: brake cnth. (Fig, 579} GI, Frnnt brakr culil» Fix. 5 9. Adjusting thr- from brake 4.Connouthndnmicnllendsfmmthehnndkhnrltthe heldlight ecu. (Fin. 5-10) 5 - 2 FORK TOP BRIDGE A. Description The {orlt mp bridge is lnounwd on the top nl the fork with two bolt: In! in secured to the steering turn with stem nut, u illnmted in the figure It right. To thin bridge in mounted the handlebar with cushion rubber to resist shock: to the rider'l handl. B. Din-unbly 1r Remove the nearing hmrlle in accordance with section 5-13 on page rib—62. . Exmct the 6mm lock pin nnd remove steering dunner by pulling nprrnrd. r Disconnect the rpeedometer md the tachometer cnbles ham the rupective meters (the meters may be removed from the fork top bridge by unmrewing the 6mm null). . Separate the fork bop bridge (mm the front lurk by unscrewing the two front lork bole- Ind loosening the “Bering stem nut. (Fig. 5—12) . Unscrew the 8mm hex. nuts and remove the front fork washer, hmdle nurlnon rubbers aid the handle pipe under hold". from the fork top bridge (Fig. 5-”) NOTE: C 1. 2. If the hxndle pipe under holders are to he remmed. it is recomln‘cndnd that the li mm hex. nuts ml the pipe holders he first unscrewed befnre removing the handlebar. This is to prevent Lhe pipe hnlrler from the turning. (Fig. 5H4) . Inspection lnsptct the [ark (up bridge for cracks nnd other (Inn-Anger Inspect the hnndlr cushinn rnhhrr for damages and wear. D. Reamembly 1 2 . Mount the furk tup bridge on the [rum lurk. install the front fork bolt: and angering stein nut. . Assemble tht- handlebar in accordant‘c will: nccuou soul all We 6l~ 2. :1. Alter Compltllug lhe lnsmllnlltln, clinL‘k lo make sure tit-t the electrical equipments are opvrnting properly. (1) Steering lumllc 0 Bmm llu. halt a) Hmdle pipe upper holder a; Cnble hulder 6 “until: pipe undrr holder 0 "ladle cushion ruhber Q 8 mm hex. nul a; Handln mhlnh wuller Fit. 5 ll. (D From lurk bolt 0 Steering :Iem nut g) Damper lock spring sel bolt @ Sleenng dnrnper lock spring @ Fork mp bridge l-‘ix. Hz. Remnvlnl the inrlr (up bridge as tinder hrhdlehtr holder .3 Handlebar cushinn rubber a) lnrlr rnr. bridge '3) Handle cuilllun washer :5, 8mm hr-x nul Fig, 5 13. rumpnnem pnrls ht inrl mp llrltlgr -The model: cB/cmo. 350m dint K5 ue pmvided with no fleeting dmper. 0 Hendh pipe under holder 0 Perl: top bridge 0 8 mm mu ’1'. ‘4]. T09 bridge holder inmllin; 5mm nut 6-3 FRONT CUSHION (Pi-ton type) A. Description The front lot-it il cf 1 hydnuliclllydunped telescopic type. it consists nuiniy of a fork pipe G) complete with piston 0, a fork button can Q end a cushion spring. On “compulsion ”, [hit is, when my dawnwud loud it imposed on the Iron! lorlt, fat example. under huvy {tom halting the piston move: down, compreuing the oil in climber "A " and forcing it into chamber “ B" through orifice: "I" in the periphery of the fork pipe to lift dlmpex vulva 0 0E it tell. On the nth: lllnd, the cushion Ipl‘lng, now compressed, exem In upwud reaction to move up the pinup. The pinhon when so moved commenc- the oil in chamber "B" Ind force: it buk into chlmher “A" lhlvugh orifice "h" m pnwide (limping union. On “ M1 bump”. or bump overcoming the clpecily oi the whim Ipring, the pipe is moved dawn toward the hollum end of the bottom cm, trapping the oil in the space between the pipe and tapered lock piece (I) no provide muimuln dunpinzt On "lull rebound ", the orifice “h“ is covered by guide Q end the oil il flipped within climber "B“ to pmvirle dumping on the extenaion side. ‘9' a) From lurk pipe 0 From [ark m (cum/350) m From lork bottom clue m. 545. Front (nth lucmhly W251») mum) M lvUT Mum Stu-M, ( mg). lmflmin) Fl]. 5718A. CUSO/‘JSD It. 1-1.]. (2350/1550 0 Front (ark pipe complete 0 Fran! (ark hmroln cu: tomplzle 0 From {ark pip: guid- 0 Front Iork piucn 0 Front damper vulva 0 Oil lock piece m. 5-100. Prom cushion operation (Rod W) L Denalpdon Th: rod type uleuopic rhock Ibrorber is the man advanced Absorber ever produced—so called became the spring under seal incorpontu I damper Iclulled by I long rod. The rod in rcrewed in the bottom of the fork balm One at the diltinguilhinx («cum 0! this latest unit in it: higher Ihility to nbnorb shocks nnd vibration. The lork pipe in in direct cam-ct will: the cylinder widmut pinion, m». Hon. The rod iypc unil con-in of n li‘imnilin duminuni from lurk bottom cut with I dun! nation talc-coping lhock nlmzrber oil dumper. Culhionili‘ and in ”m (35:11.) on compulsion Ind 27.6 mm mm in‘) on enennivn It“) er. Fig. G—I'IA. Frunl fork unit (i) From fork bolt ‘2 U-ring fl) Lark mu 9 From lurk pipe 3 Front xuspensmu spring Vg From lurk ham :3 Dumper rad @ 3"... ring a nil mil .3 Holder «3 Collar 42 From lurk bonam cm 53, 0mm mm: M Axle holder go man washer @ Spring washer Q Nul a) Fork pipe to Oll luck piece 0 on “.1 a viiiv. m min. ® Rebound .Iloppet Ipfin‘ 8 Second power hole © Pinon ma 9 Camprealwn a7 Piston rml guide a Exit-mica in Luck guide hnusing @ Chamber c m Valve «1 Cllllttlwr B m Pinon in Chamber A w Cylinder Fig. 5 nn. 0 Bottom cm (f, hunt (under (I) 6 mm hex. bull Fig. 547. Removing the front lender ‘ l-‘rnm lurk bolt (3) 8mm litx. bolt l" :ii lurk :ie mliiy Fig, 54H, chmimg ilw li'm’ll lurk Asiemhly - The piltnn. u it you down, Pulhel n pen of the fluid from the chamber "B" into “C”. Molt fluid can flow into the chamber "A" through the vulva in the piston lreely. -An the pinton trnveh up on its extension. the fluid is returned from the chamber “C" through the null open- ing into the chlmber “A". Thin imposes e run-lint on the Ipring end wheel lctions as noted in the previmu tectiun, - Nee! the end of the compression, the fork pipe is placed over the oil lock piece. This holds the fork in pine, thereby preventing it from duhing n inst the bottom. - Dumping increases In the piston niches the end of the extension Quake. This lenture plul n rebound stop spring combine to achieve an enceptionnlly lmoalh cushioning. Rod type disusembly - The models CB/CL250, 350K! nnd K5 use front forks ol the rod type, Alter pulling out the {rant fork nucmbly. set the fork as shown in Fig. 5—178. Then remove the lurk bottom pipe and damper unit using I hollow set wrenchi B. Dinneeetnhly {Piston type! 1, Separate the lruntwheel [mm the motorcycle in accordance with section on Page 34. 2. Remove the three 6mm lender stay mounting bolts and the one 8mm bttlt {lender stay and front brake stopper arm attaching bolt; from the inside. The tender run he separated from the lurk. iFig. 5—17; 3, L'usttew the headlight rare mounting bolts attaching the headlight assemhly to the lrnnt fork. erovn the N mm bolts from the front side of the steering stern and slide the cushion assembly out from the bottom. (Fig. 5718) NOTE : The iron! cum." tt-mtnul can be [nutllulletl by spreading the mouuriug ring ut tlu- lmtlotn bridge by driving it wcdgr into the slot on the mounting ring. 4. Dninrheoilintheeuhionhymovinathedninplug ntlhe homorinvenin‘ thecunhionnnddnlnlngthe oil out of till top mounting bolt hnlc belore leper-ting the Inn! lork pipe from the front lurk bottom care. & Ila-nave the hunt lurk boot, (Cm/350: front fork under manta-ant cubicn spring end then remove the “min intend eirdip lining the lnlp ring pllen. Pull out and diunentble the front fork bottom pipe and the front fork pipe noel-ably. (Fig. 5—19) 6. Dlxunanhle the {rent lurk pipe I-unbly by removing the fork pint-m mining. front fork pimn, ring. front dunner vllvethm: valve Imppcr ring. ‘0 pipe stopper ring. end from fork pipe guide. in that order. (Fig. 5-20) Cr Inspection (Piston type) 1. Front fork oil change Changing the oil in the front fork Ihould he perlur-rned I: the initial 300 milee (500 km) and every 12,000 mile- (20,000 km) therenller. 1) Remove the front fork bolt, duh: plug and drnln Ihe oil from the front fork. allow mfl‘icinnt lime to drain Lhe all completely. (Fig. 5—21, fl) 2) Clean inside with oily Solvent Don‘t use gasoline for cleaning inside. 3) Reinuml] the drnin plug and pour 200:: (12.2 en-ln) of engine oil SAE low (API service classificnn'on), 2, Inspect (or oil leak lOil eulu are due a: deleetive or improperly inst-Had oil scul,looeening ol the drain plug. demege (rant lorlr bottom any: and etc. Perform the inspection of the respective Area: and repair or replace the defects, 3. Inspect imnr cushion spring Measure the free length of the spring with n van-tier “up". (Fig. Hz» mm (inch) ‘ MW“ 7 M 310 L337; ‘ Repllt’e it under ism (7-72? 4, Front cushion trucncnr Sal the spring up on its end on the surlace gauge and measure the nmounl of ult wilh a square and vcrnier cflllpcrv mm (inch) Suindnrd Value l Servictnhlc lell ‘7 . Renlnt‘t‘ lf om r‘ n “min-i 9 ion, 5 .uJL’: a: Plier- (dooe) o urn-i imam-l circlip Hg. no. Removing «nun drelip Luise M32:- rig. s 21. Filr 5722. (D Front fork bolt Q Oil filler opening Removing the [mm fork halt V ('0 Frmu ("in mun". (Inc q, me lorlt dram plug Rum...“ lrunl fork tllmn plug ‘ \ir-ininr ciiiipu ri From main." \pnnp hm a 23. Mrmur Hg lrrc lrnmlt u! tl:~:ilnn sprint: 5. From fotk pinton dinmeter Measure the diam: with I nit-tomcat. (Fig‘ 5—25) nun (inch) Stud-rd Value l Service-hie Limit 37395~37w R line if under 1.4724473 3:585 (L472 a) hunt tori pinion 0 Micron-met ". PM. Manning (rout {all piiton dinnmu s. ant lurk human: cue dimmer Measure the inside diameter of the bottom with use I cylinder gauge (Fig. 5-25) mm (inch) Stlndnrd Value serviceable Limit 371m ~375Ml Re lace ll over 1476 ~ 1.47! 37‘ (X ‘84 D. Ben-embly (Pi-hm type) . \t ' ‘ l. Clem the pun- thoroughly before assembling. , r i a m fifili'g' fiflflz [33' 1.31‘ bout: .3: 2. Assemble the mam-m components am the from fork pipe Assembly. NOTE: Afte: completing the unemhly of the front dunper vnlve into the iron! fork pipe, nuke sure the: the dunper vnlve is operlllng smoothly. 1 Insert the front pipe memhly into the (rent fork bottom cue uling the following specill tools, front fork oil lell driving guide, front fork oil seal dxiving weight. Exercise cue not an dun-3e the oil MIL (Fig. 526) 0 Front [or]: oil nul drivinl weight 0 From lurk nil Iell driving guide O Oil ml 4, Assemble the from cushion spring And the boot (CEZSO/ 350: from lork under cover). 5. lnetnll the front cuehlon membly on the steering stem. Fill ench cushion with the followmg nmounl of nummnlic trummixelon fluid (AFT) through from the front fork boll hole and insull Lhe from lork bolt upon completing the filling. Lock the cushion it the bntmm bridge by tightening the 8mm hex bolt ~ " ' l! the exhaust pipe flenge joint nuts are tixhtened first, it \' 2 r. . will be djiicult to install the mutfier. 0 6mm hex. nut 42 Exhlull pipe Fig. 5 5., Installing the exhaust pipe 5-10 All! CLEANERS A. Description Two air cleaners, one for each carburetor (cylinder), Ire armed in " side-by-aide ” fashion and Ire located at the center at the frame. Each cleaner urea a replncenhle paper filtering element to "polish” incomin-lg air. A: ahown in the figure at lair. both cleaners are canmnnicated with each other by a cenn'll air plunge. Thin deaign and n large capecity of the filtering elemenu anure constant supply of clean air to the engine even il my one of the elementa it clogged. B. Dian-emu] l, Retrieve the air cleaner cover. When removing the air cleaner case from the left Side of the CL250/350. the mufilrr must be removed first. to , Remove the air cleaner one by removing cleaner clement setting nutl lFig. 576le 3. The air cleaner element can be separated from the frame by removing the air cleaner connecting tube clamp and the 6mm bolt. (9 6x16 hex, huh a) Air clranu case a: Cleaner elemenl scum mu @ Air clcnncr mm Fig. 5 st. Removing mi air cleaner m: C. Inspection L Dust on the air cleaner element can be removed by tapping lightly and blowing 06 the loose dust particles with compressed air. 2, Inspect the air cleaner element to make sure that it is not damaged or clogged hy milnge. 3, Ala!) inspect the bonded section to make sure that the joints are not cracked or open. D. Russelnbly Mount the air cleaner with the 6mm bolts, insmll the air Cleaner cunncctiug tube on the carburetor With the clamp‘ NOTE: - Alter complain the installation of the air cleaner, check to make sure that the right and left air cleaners are intern connected. If are are nny lenke in the system. unfiltered air will be drawncd intu the cylinder and cause rapid wear m the cylinder walls. - Install the air cleaner cnsc and the nit cleaner covcr, 78 MI! hum: utlmg mm A snow um IJI rum MM Hum helix mm mm A 10mm “wind I“ a) Re" lender @ Reu- bemper 0 Drive ehnsn me 0 Drive chnin o Drive chlin jaint @ 6mm net wnher a 5x8 hex. bolt a) shun flat wuher 0 Rant fork pivnl bush 9 Rear etuhion under bush 9 RM: brake Hopper mi bolt 0 10 mm epnng wtther 0 8mm an: mher s 3 mm thin nut (a 2x13 cotter pin 9 Rear brnke Mapper Irm qt 3min lock yin @ 3 mm hex. nut 9 Rear trike Hopper bolt 9 Rent for]: center call-Ir a Rat lurk dultrull up a 14x26 wuher a 14 mm Ielf lock nu! 9 Gran: name 9 Rear lurk pivot bolt Fig. 5-5:. Exploded View at tux lorlt Ind mt fender 5-11 REAR FORK AND REAR FENDER A. Description The rear fork is constructed u illustnted in the figure nhove. The front end of the fork is pivutally mounted on the hosa provided on the half pill-r of the {rune body with pivot bulhings and the rear enda are similnrly joined to the bottom end: of the felt cushinns with bushing; This pivdling- fork design permits free out-of-the.horiwntnl-plane movement of the rear axle (rear wheel). The rear lender is n pren- worked part And is bolted to the {rune body. a) Beer fork complete a; him till?" use at Rm which Ilsembly 9; Rent tender m Ha. Rear lurk and rent render B. Dianeaembly [REAR FORK] 1. Remove the rear wheel in accord-nee with section 4-143 on page 5x. 2. Disassemble the rear cushion in nccordnnce with acution mm on page 55. a. Remit-e the 14mm self locking nul train the nu fork pivot bolt and extract the pivot halt; the rear fork can be separated (mm the frame, lFig 54143 4. Lightly up to remove the rent fork center collar [mm the rear fork. a) 14 mm self loch“ m“ a Re" {Mk 0. St-panitu the rlrive chain rue cnvcr and Ihe rear brake Fig. 544. Removing the rut fork WW" "“1 “’0'“ ”1° '9“ {Wk- [REAR FENDER] 1. Raise the seat and disconnect the wiring for bath the rear wiukcr and taillights. 2. Unscrew the two rur winker setting bolts and pull ah the lender from the rear lender setting rubber. VFig. 5 as; 3. Tool ho; can be separated from the frame by unscrewing the lour 6mm mounting bolts. at -. (D Ind cannectur a3 Rut wmker setting bolt m Rnnr («mint Fig, 5765, Remnvmg ihe "at {endnr chancello- 1. Rmforkpivmbunhln; M‘heimidadhmdthnhuhmwilhecyfinder page“ inhuman. nun (inch) Stank!!! Vdnl Sonics.“- Unit mm W il an: (MEI-m) n 8 (0‘7”) 2. Rent fork pivm holt leedQIpimholIMIV—bbchmmlhnholllnd wrethnmoumofheudwithedhlpuae. mm (inch) sombrd v.1... Serving“: Limil Within 002 nghfl il our mm m n. (0,002) mi D. Bun-ably [REAR FORK] l. Drivein Ihlpivol Inn-hing Ind the seam- coll-r, [nun ch: rut fork dun an] up. (Fig. 5—66) Insert due pivot bolt enough the ride hacker and ensemble the rut lurk In Lha fume land! the tar wheeL Install the drive chain. When (in auntth in complemd. Idjuu die reu- hnke pedal Ind the drive chain union. lnmll the drive ehu'n an . Inn-ll Lhe torqu: link. (REAR FENDER] 1. Perform the ruuemhly in the raven: order of din-umhly. p «9- mp.“ 79 0 Frame body g, cm" pipe bush 0 Km 1m dun-ml nip mhher 0 Run- (ark yam hell 0 Ru: lurk dun-led up 0 Rm lolk pi'm bolt (3 Gran nipple o Rmfm mm cell" a Minx-k ml. 5 u. Crmuctim at m m: {ark pim wnion $.12 REAR CUSHION A. Descriptionme Cnrbon type) The reucuehion future- I “De Carbon" type du-npert This dunper is. u shown in the figure below, e double— aetiu‘ type tingle cylinder in which nitrogen us end oil are used tn give an optimum dnmptng performence under ell humping end rebounding condition. Over the dmper in inetnlled e dual-pitch Iprina which theorize I wide rage of War-done or lhopk: end meinuitu the unit in ucunte elignntent Another delign feature in diet the cuhion is adjustable for diflerent riding, loading and road conditions. “502. 40) ‘ imam "(M INJUM” .m) i it: WIDE}: mum co Joint rubber o spa... Int name a Rm cunhion upper can a) lien damper unmbly @ Rent cull‘iion rprin‘ rig. tau. Section! View nl mt cushion B. Opentiun Simple type oi a construction the hut radiation in good, therelore, performance being especinlly good at low rpeed. Further, vibration stabilizes very quickly. Air Ind oil mixture will not occur and function will not be deterior-ter even when apereted (or extended period over universe told condition. The difierence in pressure between the front and tent of the unit): is small; since form does not (arm. noise is mini- mixed; deterioration of the dumping force is prevented, (F ig. 5457) V. l I» Rm; The rear cushion employs e (lull pitch spring, the section 9:33:33 m with the llrger pitch Ibwrbs the llrge vibration while the section with the smeller pitch ehsorbs the smaller vibration. mansion This provides for exceptionnlly smooth riding. Further. there ere three ranges of adjustment incorporated in the rent cushion. making it possible to ndjust the cushion to the dilierent riding. loading and road conditions. I a) Pinion Q Velve Q Rod Pig. $688. Rear suspension adjustment _ The rear cushion (9 has threenhgr oi adjustmrnt in spring tension and is to lu' adjusted to meet the different type of rand or rtdiug conditions I position s to: normal riding. The tlumpcr spring fitrt‘ugll) increasing prams sively (tom 11 m I". and l: m be used for heavily ltmtletl condition or when upcrnuug on had roads LFin, 5769: m Rm cushinn assembly Fig. 5 59. Rear cushion emu-uncut A. W (Donia-hie mm Valve) “EM/CW“ The rear Ihoelt ahaorher I-omhIiea feature the telercopic typeoildantpuawithhntmntvaheooniveanopn'mnm damping performance under all bumping and rebounding auditions. Thedmpingperfomanoeonthe extenaion aide iawalltnalchadwith thaton the comm-ion aide, providing nnflntnnt dainpinu. 81 Piston valve Bottom valve (I) (I) (3) (I) E Operation Each oil damper ia equipped with the piston velvet A and B and bottom valve, On the extension aide, the damping nction is provided by means oi the piston valves. While, on the comprellion ride, the damping action is provided by means of the bottom valve. 0n extension alde : The oil in the chamber [-3 flown into the chamber Lb; through the orifice (I) in the valve A (sheet metal). By the restoring force of rim oil, the dumping action is provided. The valve A il overlapped with the valve B (leaf spring) which cover! the hall ol the orifice. The damping action is regulated by the deflection of the valw B, Under such a condition. the bottom valve is opened Ind the oil in the chamber Cc: flows into the chamber Lb} tmoothly to prevent air bubble: (mm being produced. 0n comma-ion aide : The oil in the chamber [h] flows by amount a! nil equivalent to the volume of dumper rod into the thamher [cJ through the orifice in the bottom valve. By the retisting force of this oil, the damping action is provided. At this time the piston valves are opened and the oil flows from the chamber Vb: into the chamlx-r [a] smoothly. CD Rut ahoclt absorber spring 0 Damper rod 0 Damper piston o Damper cylinder nu. Ho. Com pression Extension (5) (5) u) ,4 l ' <1) i 7(1) u) l . i" (.i) (Piston valve aide) (Bottom valve side) ‘— Otl flow on extension “" 011 How on compression (i) Orifice ’l) :9 Chamber “h" Q; Valve A" 5) Chamber “c“ (5) Valve “B" 3; Hanan. Valve a: Ptstun cm orifice \u; (5 Chamber "a" Fig. 5 7t. 82 a: 6mm in; boll 010mm hex. up III]! 0 Rear cushion numb]: 0 10 mn bu. bolt I'll. 5-11. Remain. the nu- (which umbiy G) Speci-I lool Q Rear cmhion Immhly Q Sprin. nu: Mower mg. 5.1:. mummbnn. mr culhim‘ a) Rm tulhion damper usembly @ Rur cushion min. (3; Rear cushion upper are L; Spring rut "app“ 11.. ML oompmm guns at rear cushwn (i) Vernier m‘iper a) Run cushion spring Fig. 571;. rile-nun.“ 1'ch cushmn spring N Inhale-My L Rmthesmbohfmm flu {um-dead of the aide Kfipr loosen the 10mm Clp nut, 10mm bolt end remove the I!!! culhion unmhly. (Fig. 5-72) 2. Compreu the reu- cushion Upper use by using I special real and remove Lhe mt cushion mt, lifr off the upper use and then [Imuve the cushion lpl’ing. (Fig. #73) NOTE: DO NOT DISABSEKBLE THE REAR CUSHION DAMPER ASSEMBLY. 11’ P085153 A HAZARD SINCE l’l‘ CONTAINS COHPWED GAS. C. Impection 1, Rear cushion spring Measure the {rec length n! the spring with a vrmier caliper (Fig. 5-75; mm :mdr) 5"“d‘r“ VL : nmbn Limui 201.3 “391:“? “rude! 115. .i r anr cushion spring Irucncss Ser 0m spring up on iis end on the surface gauge and measure ihe Mmoum oi rili wuh a square and vernicr caliper, mm (influ finnilnrd anue , Sewircuble Lumr Repln it n r An [0111 \‘Vithin 5 ‘l‘ : Ii“ 3, Inspect ihe cu3lfiuu damper (u in>ure rhm there is no fluid leakage. Inspect the damper case llnd rod in insure rimL they are not damper or deformed, 3. Inspect the renr cushu-n sloppcr to insure that it is no: damxgul ox deiormed. non. -Upunconph1hgthenenhly.mubelhecuhhnnm hlyhyhnndmmhemdnuhnymnathlnding. (Figs-77) 2.1m.“ Ihl cushion in the muse alder d din-nomhly. (Fig. 5-78) NUI'E: After ill-ailing m: cnnhinn, check (In dinmenpof the right udlefi cushion Ind Illa (he Ilium”!!! of [hi cnlhion mounting bait for both right and left lid“. 5 ~ 13 FRONT WHEEL A. Description The from wheel is constrained us than in dis figure It hit. Referring to the figure. the whul huh Ind hnke panel In AlumlnuIn-nlioy outing and contain vhg from hnh components and upecdommr drive gearing. The intern-1 urine: of the hub me: u a friction Induce with which Ihn brake lime- came in contact when expanded by the main of the cm. The hunt ul: it supported I: in both end: by bdlbeuing: which an held in plane by Ix]: dilunce coll-x. The lpeedoxneur drive gel: which is in mall with Ihe pininn 11 mounted on the lee, just onlaide of khg hunting. 6) From wheel nxle 0 From Wheel :ide will! a Oil-tell 0 630211 hull bearing 0 Front len dilunu Colin 0 (final :1) Speedomn [an o Speadnmm pinion 0 Front wheel nxla .Ime 0 From hula shoe {3 From huh: cm B 9 Fun" hnkt cm 9 Frvm wheel hub g Brill: Inn wring (u Frnm huh Irm A 0 Ru: m m; mhly Hg. iJn. Checking million of cushion a) 10 mm up nut q> Side pip o Spain] wuher 0 I0x32 hex. bolt 0 Rent nuhion PI‘. 5-13. Mnumina holu Ind nut: ol nu cuah'wn Fix. 5-79. Emulation cl from whesl V m From bnlu: stoypu Inn halt a; 3.2 mm Ionzued wuher a> From brllre stopper Irm rig. Ho. Removing the bnlre nopper Irm All a) From wheel me a» From wheel axle sleeve 0 From wheel Iin HI. Hr. Removmg 0.. (mm wheel m. (D From. Wheel lire (I: Ollie-l Fl]. #82. Removmg (he oilqell ® Front hnke shoe 1;; Front hrnlu: plucl 5; Fun“ lxr-ke mm Fig. 5 as. KEmDvmx m- from brake rim Fig. 5 u .‘vlrznunng mm mm B. [humbly L Place I Iulllble lupporl block under the engine to mine from wheel all the ground. 2‘ Disconnect the from brake cable, the epeedmneler able from the Ipeedomeler gen and the brake mapper Inn. (Fig. 5-30) 3, Remove rhe 8mm nut: which uupporl the lower lxle holder on bod'l the right and left sides. The wheel will then drop away from the fork. 4. Insert n bar into the hole on Lhe right side of the from wheel axle Ind remove the shell on the left side with I 17 mm wrenche Brake plnel cm be separated from the from wheel. (Fig. 54““ 5. Remove the panel, oil seal, rwo 6302K hull beuings, Ind from lee disleuce collnrr cFig. e821 6‘ Remove the from brake arm and pull oul Lhe front brake am, (he brake shoes can he removed from (he [and by spreadlng the shoes rpm by hand. uF‘rg 5 831 7. Separate rhe fire had lube from rhe rim wirh the tire leverv C. lnapectiun L From fork rim runuul Insert the axle lluuugh Ihe wheel huh and suppurl it. nu :wo \Lblocks. Sun the dial gauge kgmnal the side of 1h: rim and rotate lllc wheel +1.; 5 m: m... (inl-h‘ Sumlud Value \ 05 1002'; TIR Serncrnblu Lunu Kepalr or r9>lxce ,4 (war 2,0 {0 08m T R 85 2. Front uh bend Film the axle on a V-block. tome the mile Ind mum-re the mount oi bend with I dill guise. (Fig. 5-85) mm (inch) Sum Vllue Service-bl: Limit Widl'm Raphoe il ova: TIR 0&5 (04W) TlR 0.2 (0.008) 3‘ Rudinl clearance of “ZR ball bearing Flue I dill gauge against the belting outer and manure the clemnce. mm (inch) Sundud VllM i Selvicnbl: Limit OMB-0.016 ‘ if over (n.0wl~o.oon7) 0. (BID?) 4. From bnke drum inlide dinmeler Mguun the dinmeter with a Vernier clliper. (Fig. 5—86) m Dial page 0 From wheel "in m vim ck in. Ha. Chum... an {mm nxlcf ‘1 mm (inch) Smudud VIII-e Service-hie Limit 190- was run R cc if over (7137—17139 in) 15‘;( .17) 5. Thick»: of brake lining Measure the lining thickness with a veniier caliper. 0‘ mm (inch) (1) g, , r 0 F ‘ n. b . V . ernler a we: mm W at u Smndud VIII-e Senna-bl: Lumt F13. 5736. Musunna imnx link: drum inside dinmeler Replace a! under 55~ 5.1 (0217-0224) 3.010.113) 6. Check thicknen of from bnke cum Replnce if exceuivcly worn or worn in slaps. 7. Input anchor pin for bend. 8. Inspect and Lighten any loose spokes. Tightening torque: 20~25 kx 6 Boot stopper , *7? ' 18 mm snap Eu; --~ 77 g Priréary cup «a V ‘1 Remove (he ml john bah and disconnect the brake how a; 1mm Q on ‘oinl mu :v Brake hose l-‘ig. 5-101. *2 RemoVe the fines calipcr ullaclling buns and one adjust- ing boll mm “move the campus A and 1; as an nssrmbly. «v Mn 1, Arum“ ban 5» Caliper a ‘4 ”mm A ‘5 Lu\1:.,.:rl,..:u > Fig. 5 ms. ,3 Rmmw an- MD calmer armng bolls and scparmc |he ‘ , 9 “up" mmmy mm Iwu purl: A mud n ‘ , -erm’: the pad A and piston (mm m ”up” A / W - Rpmu»: {he pad H mm (he caliper Br " K, (l PM I! i‘ Pa-l \ ‘4 rm" 1 I'm-m WI Fig. 5 we, cylinder body 0 Iain halt a: Sada; bola m 15 mm "up ring Fill Bill]. Q) Primry cul' n‘. Luz. '4 Lumen the mute! cylinder join! bolt Ind disconnect llu: brill: howl - Loosen the mum- cylinder bolls Ind remuve the master cylinder from the hmdlebnr. - Dina-emble lhe mullet cylinder. ‘5 Rgmove the 13mm intern-l Inn]: ring using the special wall ‘6 Remove the 10.5 mm wuher. piltan. primary cup, spring and check valve in this order. To remove the pximnry cup easily, direct comprrssed nix al 2~3 kg,’cm‘ (2.8~43]l)/’in‘) in pressure to die cylinder union (brake hose jointE. Unleu the check vllvc is damaged, my other tool may be uud to rel-now the primary cupi 93 u m Lem cap a; Bnker lever (3 slow" wlsher a». Bout @ 18mm intern-l mp rm; :3 105111111 wuher m Plltun @ Seconder Cup or, Primary cup 3 Spring 531 Check vulva q; Hundleb-r 1m. joml bolt a Cu: to Mister nylindzr plate 95. Duphrlfim 8 Mn... mind" body {9 Mum mum" holder a Spring washrn a 6mm but“ 9 on bolt washers a 0.) bolt 9 am. hone Fly. 5 113. Muster cylinder diunembkd NOTES: 1. Wash all disassembled metnl putts m tnchlum- ethylene or vqnlvnlent flutd and dry thcm thoroughly. ‘1. The Chel‘k \‘nlve must be washed m litulfl' fluitl. 3 Never wash the brake pans in mineral oil: suth as gasoline Ind cleanmg fluid. B. Inspection of mlipers and must/tr cylinder NOTE: L Check the piston for wear or damagv and replace .t nr -ssury. 2. Check the insidr surfm- ol the master cylindur lor scores or snatches and replace If necessary. ll. Check the spring (or crack or any ulhvr dunking: and rkplflt‘t' I! m-cessary. 1. Chuck t1): brake dust padk fur Wl‘flr Red hues are scribed in the pads A and Ll. If the pads wear down to the ham. replace thcm with new ones. Inst-ll new pads 50 (but 1lw brake disc to pad clcarnuce “1.7mm; \s ,.15 mm Mum!) m -. To udiusl the L'll'urunt’l‘, Lum lhu caliper adjusting bull couulvrclockwise until the pad hour) {9 Pad B L? Pad A ‘ on the dust: 'I‘lu-n back off the adjuuttng lml: 1.2 tun. 511K Hgtklrlilm' 4, Srn'wc .mut mus-s z. 7 . and ughun tht» lmk nut. 0 Cylinder page (2 Cylinder [lull © Pislon G) Caliper cylinder 0 Micrornmer I" 5*“5. r ‘1'} M 2 a l i (D Callpnr E (Z 1’“ B 37 Pm] A c, Caliper A PII. F117. r17 lixlS dune! pin flill~rized @ Apply grelst .0 "L45 marked m Qunnlixy .71 mm, Ahaul lg (04155.: or Lulu! {minulnm m 11x15 dowel pm:- Fix. 5-]!& 2. Meuure the uliper cylinder Ind pinion Using I cylinder gauge, meuure the cylinder bore and piston 0D. If the dunno: between she two exceed: 0.11 mm (QM in.), replica. Unii: mm (in) Standud Rl‘plir limit , 33.15am) as 5 fl ‘1‘“ VVEEBfiflLWQL—L, . 38.]is~38.lfl 53.105 P'm“ 03' (1.5(116~l.5150) ; (mm) 5" Meuure the master cylinder Ind pinion Using 1 cylinder gauge. measure the cylinder bore And piston 0D. 11 the clear-nae between the two exceeds 0.11 mm (0.000! in), rephoei mm (in) nndard w . Nib-Mt .9 Cylinder hare @5512,me V 13.957~13.9M Pmon 0.D. «(”5495N055‘m) C. Assembly of alipern Ind master cylinder To assemble, reverse the disassembly procedures. Caliper- - Install 1hr paid: A and B. NOTE: VV'hrn iIIIMHIHg the pads, apply a con oi grease 10 (hr: cnlipcrs :o prevent entry of dirt or wrierr When repair- ing, apply n cont 0‘ ground: to the sliding nurfncer and renr faces of the calipen and pudn and 10 die dowel pm as shown, - Install lhc cilipcr uscmbly ID rim from forks. Minter cylinder Annemhly precaution The brake syslcm is rho most imponnn! fur the nip riding Exporially. rulnhrr pam pm . cmicm role. \V'hcncr any dnmage or deterioration (o the rubber pans 13 noted. they musr he replaced qunrdiulcly. Take care not ‘0 allow foreign mnmrinls lo mm 1hr brake pnris whcu “mum“ - th the component plm Ind thoroughly dry them “ling compressed air. - Apply ncolt of halts fluid to the inlidc of the cylinder: - lutnll th: check valve to the return spring rind install than in the cylinder as a unit. When installing, be sure to inn-ll the spring with I end having a larger dia. in- wnrd, Take we not to ttllow Lhi: check vulvc to came out at the tpring. - Applyluu A thin cont of links fluid to the outer aurlnc: of lltr prim-ry cup Ind inst-ll it, inking am not to damage, it by fingers, Be sure that the cup in correctly pusilium'd in the cylinder, Inmll tht~ k‘L‘OfldIY)’ cup to the pistnn. - Install the 13 mm llllp ring md route the map ring m check {or proper m. - lnfllll the bout, NOTES: L Connect the brnke pipe. 3‘ Install the cylinder to the lmndlcbar. 3‘ Bleed the brake liuest 4‘ Roadtest the molart‘yclr to chuck [or fllr tn ml leaks and for opt-ration V (‘ht-clt \lll‘ llrlilu' fluid lt-wl. :n D. Adjustment of disc brake VVl'wn [hr brake is dtsnsnemitlcd, ll must be adjusted and bled completely I (:l’u‘Lk (l1: brnltu let-ct lrt‘t' play The luvcr ltt-t- play is sperthml In 1;: 2~£>mm rUU7dT~ 0196mm“ the ill) ol the levpr If tht- {rt‘u play it out of fipkk’llll'flllllll. chrck and replm‘e ll nt-crsanty t‘ht-(k mt brake fluid lt-wl Fill mt» muslrt‘ mud” ml mun-m up u. m.» tot-.4 1m CAUTION: lJu nol allow tltt llffllu‘ lluul tu mm: in routacl wllh lllt' Pml‘tled aurlflktflt [\llllx‘r 1mm and lunlulncllli 95 m Chuck valve “L 5419. to Primary mp Fix. 5 12». (1‘ mm rt.. 5 12L 5» Diaphragm at \hu lylml'r‘r mg. 541' 1' Hraku fluid 3r Bleed the brake lines In the hydraulic hrnhee, air trapped in the bake linen will reduce the linking elieet to remlt in dengerom riding. it the brake lever is felt spangy when it in rqueeeed or if the link! fluid level lower: excessively. bleed the hreke linen. To bleed, proceed It follows: I. Fill the master cylinder ail reservoir up to the level line. b. Install the dinnhrlgin to prevent the fluid l'I'om splnslh lug. Di h Ca 9 Brllre Ieve (pl-L :13?!“ ® p I c. Put A pipe on the bleeder screw located to the enliper. Prep-re In all cent d. Squeeze the brnke lever and operate it several times until I reliltlnce is felt. With the lever queen-ml, loo-en the bleeder screw about 1/2 turn. As soon as the lever bears on the hundlcblr pipe, tighten the hleeder screw, Continue the bleeding operation until Air bubbles ere no longer noted in the fluid flowing out ol the bleeder hole. Nm: While bleeding, add brake fluid :9 Bleeder rcrew q; Pipe a: on an Pig. nu I - M REAR WHEEL p LDaaIptin l. The relr wheel in in con-truetion Iimllu tn the {rent wheel described in the preceding VAL, the difference being that the drive sprocket is bolted to the lei: side of the hub and thnt the (title in movlbly mounted for drive cluin tension abutment. The inunlletion or lrrnngemen: of the rumor component: is illustrated in the figure below. to which releretlce no he nude in studying the construction of the wheel. :9 4x30 mun pin a; ")qu mu: nut a; 16.5)(30 millet 1r Rm wheel mic collar a: 69mm external circlip G 70 mm wither m 10 mm thin nut O ll) mm tongued washer (2‘; Final tlrlvrn sprocket N Driven sprochel fixing halt a; Rent wheel bearing mm" a Duil-seal 0 53042 ball bearing 0 Rear mt distant? collar is an Rm uh: an...“ coll-r A a 63032 hell belting q; chr whtel coll-r @ Rear wheel tlxle «'9 Rear bake shut: @ Rear wheel brake plnel :9 Rear wheel hull Fig. 5 125, Cross-”Clio“ nl rear wheel EDh-embly 1. Remve the drive chzin joint, Ind discernment the chin. (Fig. 5-84) 2. Renwve the nu bflk! Idiueu'ng nut; am“: the tank: rod {rum the bnke Inn; remove the rear breke stopper bolt Ind tepur-te the newer mm (mm the pmeL 3. Extract the cotter pin from the axle 4. Remove the rear ule nul Ind extrut the reu wheel ule. Tilt the motorcycle and meme the rut wheel. (Fin. 5 1271 5. Remove 69mm extent-l circlip, Ind 70 mm wuher, straight- en the 10mm tongued wuher, and remove 10mm thin null. The final driven sprocket can then be sepnraled Iron-t the reu wheel huh, (Fig. 5—1158) 6. Remove the reuwheel beating retainer hy using bearing retainer Lightening wrench. a'l'ool No‘ Myturaztxxm: Pull out the 6: “Z and 63041 ball bearings. and rent Axle distance collar. lirig 5429-): 7‘ Remove 2X15mm Cutlrr pin and anchor pin washer Separate the brake arm from the panel in order to extract the rear brake shoe. Fig 571:1» <9 Drive min ,nam am a; pm: chain Pip 5-125. Removing m2 drivt’ rlmin Jam (1" Rear wheel HI. 5 127. erm-mg I'm: rent wheel from Ihc (rem: a; mm... I'nm mm g Nmm hmguml \nlshu ‘3 mm ({rLVu‘. Tynan 1‘ mm. mama unllp l-‘i‘. semie Kemuuug lhr 0mm dmcn :pruthfl tit new.m «mm Mnlflrmng wrt'nt'h i‘ Itmnm: hm .r Fig. 5 129. km. mg Ilu- mum; mam" tit "\ 1:. m-Ut-t m 1 r' gm mm; wa<3= 36A). "3 A. the battery .pprwhe. the hill charge condition, 3.. I will be releued from the electrolyte, At thi- time, check ! the hem electrolyte to see if the Ipecific gnvity is up ,: to the mad-rd vulue at 1164-428, and the ermine! voltage it up to the ItIndnrd vllue of lie-:16“ Perform the dunk-glinnfnrmminntneudegtininnnhour, and if {or die three checln the vnlm ue count. the buttery ‘- fully charged end the chnrging can be her- min-lect (Fig. 6-49) 5 NOTE: \ it during the chuging procee- the temper-true of the 35 5 ID 15 Al electrolyte should nine .heve 45-c (113?) or if the gun ' in being role-led iron the electrolyte in nbund-nce, the —CHARGING ClRRiNT clinging rhould be stopped temporerily or the clinging current reduced to e lower rate. Pig. H). Quick chnrger Quick abuser nhould not be on hnttery which ha been fully dischuged. Further, quick chnrging method should not be frequently med. However, when it is inevitable and quick chuging must be performed. the following 'thenu Ihauld be uburvedt For quick charging a 12AH battery, une the chnrging current rate of 12A. A battery which is 30% discharged, npproxitnntely 30 minutes ahauld be ndequnte to chime the buttery. However, if during the charging prone-a the electrolyte temperature should me nbove 50°C (122'F), the charging should be temporarily stopped or the charging current rnte reduced. - Other precaution - II the electrolyte level (Ills during charging, refill with distilled water to the upper level mnrlt. - lnflnmmhle hydrogen gas it discharged from the cells, thctelore. do not chug: batteries nent any open fire. - After charging, add ditdlled or battery Wlter to the cell: to bring the electrolyte to the upper mark. Tighten cell ups firmly and Wash 05 with eleen waver it may acid spilled. - The battery is now ready for intulletion. When inttnlling a battery in the motorcycle. be sure not [0 pinch the buttery vent tube, Explosion may result if the exhaust tube is blocked. 1M S. 6. WWKM Chuck III: tannin-l WG‘WI No. moomooo) Thhnerymmiulwklgemhechuhdwkhu Isa-vice (an. The mud-Id bunny veins: in 12V. homer, ungainly the: alumina, the voltage will be at 15-16V. Setthovolt ubctonw‘nchtotbeDC. VOLTAGE paidon ludmthe(—)luninllofthcblnerylndxudtbe vols-ac all 0h: blue uh. When performing buttery ell-triumrdumhb-mnhug'mgmdm onpln 112. (Fig.6-50) .Onthiamaddmmxcydenvuuumudddryghugedbgmyhund. Thhhlmrydoesnot require uninitial chug. Haw-vqudzeluloutheb-mhfaudmbe lope)dunnmdlnflinlchr¢in¢nhculdbeperfotmad. olfdumnmydeilmhepl-udhmmefwl broken (d1: bunny will be low in the plutic unva- period, dz: lend: to flu buttery should be diwonnecmd mdhhncommenddthnhcb-mbechnedome-munthtominninitingoodcundifion. HWY mum SEWING AND com: ACTION "5 {or n In; paind. On“ with the Iwitdt turned on). .meoflmdn minim haul-lion. Monaural-t noted during cold tee not: with boner] connected. Trouble Probehleanu Correctnefion Am LChnrlin‘t-ntoinoounfllorolu 1.Wl-imreyt:hhinnorqe,the fin nhcflu‘h phi- I‘ll Mahler". wmuhwml covmdwilllwllilnhyu'or lm-Mde‘mn‘umn Mnnthmtdtlhlmuwmdl inlpotl. dtheohmlyuisinm. ilnotnoed. 3. Wmhlmfimfifiufl I. CIt-‘k the demolyu WW1! nndalvnytnmn' mn' film“ I. . Ii‘hlly dildurnd pabrmiug recur-Ii" end iii-gin. 'in‘ men! tins hy lllflil‘ the enfine my be nfidmt. £an ”ammunition to the: tainted by the nan- Imdlond. may cont-u ueu end use. Germain-ted electrolyte or cloc- t-rnlytn nnn—iuly mint-ti. .— . Alvin Ionian-in the undue cit-n Bundle the nplnhhlng electrolyte with nlxI end one dun cont-inter. C. Ill-la m m Spa-int mull! lower: and around 1.xoo(s.c). the winker .nn hm no longer function. .‘l'hnfneenndthevirlngitmil- foam, loud: unit In winker Ind horn does not (tn-anion. In thin condition the motorcycle will opente but with malnn‘ tree, both $andephmwillteeuwiththe "Kittie Idd Ind lam lad lulfide depodfl. (Ittllntion) mkinl it impol— Iible to tech-In, D. inn elem-l nu The Electrolyte Imt dmpl min], but mt charge a. tiny: mninuined u 100% mi the condition nppenu ntilfncwry.Aconditionwhich in overlook-d. (Specific mvity over ma) . The depnlil will he-vily ucumulnoe nt the bottom and will «no: intend lltorting Ind an.” the battery. . When the npeeific unity lulln below tmotao-c attach-mitten“ he "charged lmnedillely. When tn: amt, frequently be. Daniel «ii-chimed while opening it nomll we, check the “mum for prayer output. . It the him, clinch-nu may nannnl charge output. it in at in diution of outlawing. remove tome of the «nu loud. . Check to nut-re prover chum me. . When overcharge oonditinn ettiu with [he proper chm-gin] nlc, pin: on npprnpt-Ltte resistor in the cit-rm ciltlliL E. End!!! gravity drop- Eloetraiyte evlpornm. rvnr shamed tmntnciuit cit-mind Diltilled water overfillnd Conumimted electrolyte . Pet-torn npeeihc .rnvity manure ment. . II the addition of drrtillrd wltu cut-e) . drop in specific nutty, .nn “mum ncid Ind him In proper vllug, 6-5 STARTING SYSTEM 1. Shrfinz Motor A. Description The tuning motor complete with n planetary reduction gear is mounted on the front tide of the cnnkcaur When tuner switch a) on the handlebar it pruned with ignition switch (2 closed, current flow: from the battery to encintion coil (plungcnholding coil) (1) of the solenoid switch to push. This results in the closure of paints to permit current to flow into the surfing motor. mm mm sun-r lal Itltm G) 5mm button switch (3 ignition mitt». a) Cnntlrt mm «1} Excilmmn mil (in Plunger Q) Pole FL Bruslt O Armature ® Field coil in. e-stt Stnvm' rtrcu‘rt diagram "6 ‘l'heplnnetnryroduthngenr,oonmwhdunhownin hfi‘metnuhgpmvidelnmdthfimete- duofionzthenmdmeredmkmomplfledbythe Mendelian. Ebb-emu! L Rmdtaldtmokcmruremnddimnneetthe nmttrlllud. LRmovetheleftmnkm-eoom. 8. Ram" the generator rotor ur'ntg n rotor puller (Tod No. mam-2160000). 4. Remove than running sprocket net pine and then remove the starting sprocket and the tuning motor lpmcltet together u no unit. 5. Disconnect the flirting motor. 6. Unscrew the two main; motor mounting bah: turd move the Inning motor. 7. Unscrew the two 5m crou- screwr Ind remove both of the end buckets. 8. Unmet! the 3mm harsh lend mounting mews Ind the bnnhel from the brush holder-I. (Fig. 6—53) 0 Ban mu m- 0 Cuban bum. 0- W0“ "3. Ha. Darwin; when brush 1. Check the wear of the bull] lry mourning the length of the brush with n vernier caliper. ”at ....... m (huh) 51mm vnu. Serv' rue um;- 12.5 (arias) 531’:ng; “‘4“ Further, check to see that the brush it not truck within the lamb holder Ind preventing the hrurh from oontnct- ing the commutator. I 2. Check the commutator mice undercut condition. Measure the mount of mint undercut. (Fig. 5-54) mm (inch) to Comm-um o Mic: ' Stlndud Vlluz Servjouhle Limit Fig. 6-“. Commit-tor correction 1.2.th if under- 0.6 (0.024) l as (0.012 It is difficult to repuir the undercut oi the communmr‘ therefore, this work should be performed lay I Ipecinliet. NOTE t If the commutator he: been rep-incl, the rhnrp edge- and burnt which is left should he removed. 3. Artnnture insul-tion test Perform a continuity check between the commutator Ind the shaft mounting urea. If n short is indicnted. a defect in in the armature nnd therefore, it should be replaced. 4. Mensure the rmrting current The rurtiupz current oi the starting motor cnn be checked by mounting the externol shunt on the term- current and the will permit maximum check up to 60A. Mount the external shunt box securely on Lhe D.C. current oi Lhe tester mntn unit; connect the two cards shown in Fig $55, 1) Tighten the shunt on the teller DC, current 2) Remove the primary starter cubic, connect the red shunt cord to the starter terminal and connect the mg. 0.55. Strning motor currcm mnsurement black shunt card to the removed cnhlcr 3) Turn switch [0 the DC. current (vi-J. push the star-m- button, and not: the state! current. um: -thulhmtilinfl.llndmtllehuer,dlhnfirnly. Whnthmmhhm,thl nonunion itmdm‘efnn.thementehnuldbepen- formedhyehngingthewitchtnneptive(-)poeition. -SinoetbeIl-ner mmnkinlcunelt Inuhetthlnm thInIt-tnehlinehouldhed'noonnected whmmnrkingthir hut. lithium-.memufludodcun—til matured. 5. Starting motor IpedfieIn‘on (releunoe) H7 Ill. 0-“. Sterling mo: Chlnlfllfilfifl D. humbly Perform the reusembly in the reverse order al diureemhly. 1. Sterling Clutch A. Melon hm. Speeifiatiant Ema mime 12v Rated output MKW opentim . so "mad. Munion nt‘to . an Direction nl ruuuan i Clockwise (Viewing into the pinion) Without Sullin ‘ Withlold [“1 131“" ix .3...“ to“. W Max. . RPM u Iprocket torque 1,700 Min. 500 Min. 0-7 in: 14! -m (n Stirling clutch mm“ 0 102x115 mun (5-05“ '5' “3&th a: Itc. mum rotor P I . m.” 6.44:! , , in». 6-57. Sumng clutch Sounder, mat-man rItio 2,77 : 1 Tnul reduction ruin mm The muting clutch is of I tme-wny type Ind in conItruehed in one piece with the genentor rotor. A: drive is transmitted {ran the motor to sprocket Q. roller: (l) are moved within clutch outer @ in web I manner It tn provide a “wedge Ietion” between the sprocket (now raving u I drive member) Ind the clutch whet. Now the clutch is mixed Ind the drive is transmitted through the clutch outer to the engine cnnltthnlt. After the engine um and begin. to “drive" the tprocket, the rollers Ire returned by centrifugtl {one Ind no longer act as the Wedge! to disengage the clutch (the drive) B. Diannembly Perform the disassembly in accordance with section 6—5—3 on page 115. C. Inspectjol 1, Mount the starting sprocket on the generator rotor, mute the sprocket and check the condition of operation. As shown in Fig. 67:39, thc sprocket will lock when minted in the A direction but it will be free to rotate in the B directinn. u the above condition is unsulislIctury. chuk the lunch and the roller springs. (g) Starling chain :3 Starling spvockck (1; Roller I}; chm-h uuler :5; Ron" spring (up (u Rallcr spring ‘11; Left crankshaft ® 31 mm builllflK Fig. 6 53. HO 0 O OCtn-‘pointheldme' ©Woodruflhy .l‘ftcnllhhlh ozlmhuhiu .Beltingholdu [LR-MI! mien-lily Mmtheruuemhlyinthermnrderoldil n-unbly. um: Whenmemblinxtherollennndmlletwrimintothe Mocdutehnmbly,elltheputsehnuldheeom~ plelelydeenod. I. Starter annefle Swlnh A. Motion The netting motor, become of in chumtefiltim, drum I large entrant that exceedl the capacity of I path-button nutter switch of the type currently used when mg. This is the moon why the solenoide twitch is pllced in the inner circuit end the circuit i- so denigned that the owilch is controlled by the unlit-button witch Thin twitch in an electromagnetic switch having I upeeity large enough to operate utinlutorily in the sum: circuit and is con- structed as shown in the figure below. 1. Open the tent end remove the sir clelncl on the right side. 2. Dimnnm the decried lend: [tom the binder mugnotic twitch. 3. Unmet: the two mounting bolts end témove the Inner magnetic switch from the (nine, (D MIgnelic Cali (primary mil} (2; (‘nnllct (upcnlmg tide: ca Plunger r9 Relum spring a Comm relunt spring to Terminal: m Contact (fixed tide) I’ll. («51. C. Inspection I 1. When the nutter switch is depressed I "clic " in the Inner solenoid is helrd; thit indicates the movement 0! the plunger Ind closing of the terminal contacts. a Alter I long period at use, the contact points will be. come pitted end worn, Ind increasing the retietnnt: to the current flow. when Inch condition develop, an. assemble the solenoid switch and clean up the point content urea: with 1 file or so emery paper. 3. Other causes which will tcaull in the malfunction of the etnrter solenoid switch. - Poor cunuct within the key switch. - Defective mngnetic coil. - Improper action ol the moving core. D. Reununhly Petlorm the reassembly in the reverse order of die. assembly. NOTE : 1f the switch has been disassembled, ldhesive cement should he applied to the muting surf-cue to prevent moisture Iron-i entry into the switch. 6-0 SAFETY EQUIPMENT The following equipment: stein-mulled onthemotolcycle minnneule riding. Allotmludetl Ire theeontrolntn uncut-“01m: IHm-n - Spam/tachometer I Vnrinul lighting equipment (Inch u the headlight. mil/mp light. turn Ii‘nnl lights. cue.) . Kill lelch Lam-n LD-erlpflal Autrlingtypehtrrnwnnmmedulhowninthe figure a left in used. Referring tn the figure. it includee A metal dlnphngmlotnnuntedinnmthntit vihntu heck end forth an the nugnule field produced by the electrcnnngnet (em-um) v-rle- In uncouth. Thh vlbntion takes plue unimt the air to produce the sound wevee, II. Benton! 1. Reine the lent nnd remove the lull tank 2. Disconnect the horn lead: and unscrew the two horn mounting bolts. NOTE : The horn is neeuntely ndjumed to produce the desired sound, therefore, die horn Ihould not be disassembled il it in operating properly. C. Inspection ll than: in n chnuge in pitch of the sound or H the loudness he: decreued. check the horn by connecting it to n lully churned battery. 11' the quality 0‘ the sound is still poor, remove the horn cover and ndjusl by turning the Adjusting screw. Tuning the screw to the right will increue (he loudness. D. humbly Perform the reluembly in the tevente order 0! removal 2. Speedometer and Tachometer A. Description The speedometer incurpontiug the odometer is driven from the front wheel through A flexible shaft and the u- chometer is similarly driven from the c-mshalt. These meter: are constructed as shown in the figure at tighl. B. Removll Unscrew the flexible that coupling uul (mm the heck of both units and then unscrew the mounting uuls to re‘ move nut units. C. humbly Perform the reassembly in the reverse order of removnl. 119 a: Carlin. horn o Dinphruln a) Pole n m Arm-lure :9 Pole A a Case a Core phle o Coil m Contact "many «9 Coupler (hlnult) 0 Hum amp 9 Cuvn rig. Lu. Horn construction m Tat-1 Q 5th gear a 41h [ell a} 3rd gear a) 2nd shalt 0 1a .llllll (magnet ehnfl) Fig. 3-65. (n Pmnlct @ Dill a: Bukmg mechnnism <4) Bum“ mam a; Stnppcr (91 Palmer buying a) Pointer shall 0 Braking spring @ Induction disk 0 Mum a) Cm c Mum. bearing a Magnet man mg, em 120 s. Renting-ht A. Description The headlight is of I semi-eelled beam type. Its bulb can easily be removed from the socket fur replacement or inspection. The types and ruling: of the bulbs tiled in the headlights of Lhe current models are u follows: Country of US: Headlight Bulb Rating USA geranium xiv-$552511 Brit-in And Gem-inny 12VA35/85W Fringe lZV’SS/SGW B. Removnl 1. Remove the headlight rim from the case by removing the screws loaned It the bottom of the headlight rim. 2. The socket is twisted to the left nnd removed [mm the reflector. at Pm. the bulb inwntd ma twist towud the 1.1: to dis- englge the mint pin m then remove the bulb. a) Headlight bulb a) Headlight rim a) Unit holder mew g; Headlight unit 0 lludliuhi mum at Beam nuiun mew 61> Bcnm Adjust spring O it'ubcr m Beam adjust m m. M1. a) Headlight mm a: Headlight bulb in ”taillight nm Pin «48. m. t 60. C. Inspection 1. Beam adjustment (USA type; Horizontal adjusllnenl of the headlight is made by the adjusting «crew at the (mat of the headlight. Turning this screw clockwise will more the beam toward the left of rider. The vertical adjustment is made by loosening the belt which mounts the headlight assembly Headlight ‘is normally mljmlcrl in the vertical direction so that the center of lhl‘ lu'tlm iritz‘mt‘t‘ta the ground at the paint 50mm AiG-t it‘t‘t‘ in [mm hi the mrimrcycle with the motorcycle in the ruling altiltulv . w. a», Adiunmg scrrw rm Headlight rriutlnlillg bolt n5, Ho. llunilliglit 1U.S.A. typo; iljencral export type! The general export lypc can lii- I‘llju\CL'd in the vertical rlirw‘lion, the adjustment being mnrlc with tlir ntljuxdug st'rr‘w. . nun. replacement to ll tlu- headlight bulb is muperitlivc. rvmmt- the litilli and check for limkcu filament either visually or with a tester, 1f the filamrnt is broken, replace it with . hulh of the specified min; 3 Ah” chuck the conditmn of the wiring and if they are ‘5 """W ”I; ' ‘1'.” r i m dimmed or frayed, mm i. "1)..” or replace the wiring Fig. 6 7|. c-v m‘ll Vrl.9V:| up“: a, ,- D. MW Purlorln the mmny in the reverse order of rumor-l. N0“ : When mulling the socket unmbly into the nfiector, ch: “TOP” or the W marking should be It the top. I. Tail/Stop Light A. Dalma- Tbe nil/pr light in n tingle light having t double filament Ind i: oontrumd a shown in the figure At night. The typ. Ind ruling: of the bulb- uud in the mil/Imp light of lb. current model: are u lullawl: Co 3t Ute nil/5m L351» Bulb My U France. Hakim ml general 12V-25/7W flfl—/ lZV-SW ml “mm“ l lZV-llW((I\<)7p) B. Ream-l 1. Remove the twa germ retaining the nil/amplightlens. Z. Preu the bulb inwnrd ® and twist ta the left (3, and the bulb can be rammed 0, (Fig. 6—13) C. Inspection 1. Whan the bulb doe: not operate, remove the bulb and check for broken filament visullly or with a team Ind if found defective. replica the bulb wilh one that in of a rpecified rating, D. Rmhly Pufon'n the reusemhly in the revem order of removal NOTE: When inslnlling the nillight lam. do not overtighten the Isms, u this any damage the leml 5. Winker Lights A. Description The turn sign-l lights are constructed as shown in the figure at right. The bulb is contained in 3 housing with reddish-yellow lens. The types and ratings of [he bulhr. used in the turn signal lights of the current models are In; lollowu: (tinny nl use l Turn gull lehr Rm...“ USA 7 .Vr w me ml geut‘lnl ”V40“, 7 mm Germany IZVJISVV 12] a; Number mm bruket a Cord (p Trilhght hm parking @ Talllight hue (p Taillight lens parking w Tailfstoplighl bulb a) Tallliglxl lens Fig. 6-71. Cross«lchion of mlmop light m Tailhloplight bulb Q Tail lighl bulb Nelle! Fig. 6-78. LblBG (I) Turn sign-l light lm a) Tm :ignnl lug)“ bulb 1:) Fun mew {g (ml mew @ Lent packmg 1!! Socket holdcr (1, Socket Aublllul’l 4; Turn «gnu llglll hm qr. Turn Signal llghl socket I“,~ e 14, cm» ficllnn nl mm signal Ilglu 122 B. Maul The removal woo-dun is flooded with tho: of lheuil/mp light ducn’bed in 1214—8. 6 . hm Ila: bulb in hyper-five, roam the bulb Ind check {or broken Glam! And it found no he Mauve, replac: bulb with we of tpecifiod ruling. heck the wiring {or loan: comm hr break in the wire- Ind il found ddective, rep-Er or replace. 5,; p O D. Rel-embly Perform the run-embly in the men: order of r-ovnl. 6. Wlnku Belay A. Ducrlpfion 0n the current model: except for the “US" one, - cup-Aim type flasher Kelly in used Ind an (ll: " US ” modal. Singlesul 142” rel-y Ibwn below. ln Lb: c-pmitor (own-circuit) type rally. the Contact m_ u", nut.“ "by point ore repelhedly cloned to permit the current to flow from lhe cup-aim! lo the flasher bull: intermittently. §——-ll|l' Hz. 6-H. Ignition l'l‘llCh (CS) cloud 171'. 6-15. Signal-rm fluher rel-y S A. l— B. Removnl iws Open the sen Ind disconnect the flasher uni! leads I! : SIGNAL STAT the connector and then remove lhe fluhcr unit. H C. lnlpech‘on FLl PI. FL: 1. Mnke sure tbnl the turn sign-l lighr bulb of the proper rating is used. If bulbs of different "ting are used, the :1..th rat: will be uflectedr "1‘ “5- “ms “8"” 0‘ "8"“ “m 2, Check lb: uperruon of lb: flusber relay, when the turn signal light flashing rate u not whom, the flasher relay should be checkedr Disconnect the leads (rem the left terminll of the telly m couuccl ir Io alZV—lO or 18 or 25w hulb. If lhe flushing ram is between 65 m 90 cycles per minute. the relay in bills- factory. NOTE: During 1h: lest make sure llm llle flasher is properly ground. ll Swilch on me mm signal swilch and il (he lamp stays on runlinllmlsly nnd accompanied by a buzzing noise in the relay. check to make sun: lllal the relay is properly ground or lhnl the ground lead is not broken. 4. When Lbc flasher swlrch is lurned on. and the lamp does not flush, flasher bulb is probably defecllve. Check the bulb immcrlinluly, D. Relaxemhly Prrfurm llle lusmllalion in the reverse order of remavnl. 6-1 swrrcnm 1. ignition Switch A. Mm Thin Mitch mural: Ill electricnl circuits of the mlchine. indudinz lighting cimuiu, ind is apex-ted by a key innemd into it. The ponitiom Ind opentionn of thin Iwitch m ll outlined below: Fix. wt. ignition Iwitch EAT [G 11.1 ‘ < , (mi) , (bl-ck) fhmwniwhile) (hrnwn) “""W" 1 K" "mm" Eleclncnl rqulplnnné . u: inopnrnltve .n 0"? m: engin: mm b. lllflcd, Electriul equi mm I O——C O——O are upel’flltve. \2 Not ngmmll jngine will Illrl. l PIrkinK light in n Q—+———C upcr-uve, engine Removnl cannot be finned. kaovll l7 _, B. Bentonl l, ()an lh: nut Ind remove the (uel tank. 2. Dilconnect the ignition twitch lend: II the coupler. 3. Remove tho ignition switch mounting nul nnd remove the ignition switch. C. Inspection ll Continuity tut Forlorn n continuity check to determine if there in n lire-k in thc switch lend or defective condition of the Fig. «so. Continuity tnt oi the ignition switch contacts. Insert th: lands into the X terminal of the tesur, turn the selector knob to the continuity position And then turn the ignition switch to the ON position using the key. Apply the test lrnrht across the points to be checked; if the red continuity lamp is lit, Lh: continuity condition is satisfactory. if the llmp does not come on, it indicates an open circuitt D. Rmuamhly Perform the installation in the rewarse order of the removal 2. Stoplight Switch A. Description Th: stoplight switch is n pullvtype switch operated by the brake pedal :Fln 6—81} B. anovnl Discnnnect the wiring and remove the stoplight switch from the hrarket, C. Inspection 1. Adiuiting the position of the stoplight xwitch operation. 1) Fim, check the Idjusunenl ol the run broke pednl in , accordance wnh me procedure on page mu m maltn sure 1 that the brakes are properly adjusted, 2) Turn on the Ignition kzy (ignition position ”Red " dot} ii) Adjust the stoplight swnrh (I) so that the staplight will q) Stoplight Witch (3 Duck m" come on when the brake pedal is dcprcunui to the point H!— 6’51- whrrt- the brake pm! starts take hold. ll the stoplight swuch is Intr in switching ON the stoplight. srrew in (A) the swnrh 1m run, and if the stoplight comes on 100 early, screw out {p the switch lock nut. 13‘ D. Beeuemhly Perimtheinmllntioninthemmenttherenwvnl. 3. Starter Switch Butts-i sad “thing Swilrh A. Description The m which button Ind lighting switch (headlight control switch) are built in the right hurdle bracket. B. Remote! o .0", . '0 "w m; u l. Rana" the front hnke mounting bolts ml remove the 0 may. hull" polition w Headlight wntml Iwitch ‘mf huh 19'"- . Starter button 2 Unscrew the two twitch mounting screws and tepsnte HI. L82 the upper end lower twitch hslves. & Disconnect the throttle csble end from the throttle control end remove the throttle cable connector from the switch lower side. 4. Disconnect the wiring connectors within the headlight C. Rees-emu] Perlonn the mmmhly in the reverse procedure of d'w assembly. NOTE~ When installing the switch lower he]! on the handle, Innke sure that the pin is inserted into the handlebar stop hols Ind it fighmed together with the switch upper half. 5 » ' ' a) "hit turn sin-I" G “Right tum tisnsl” 0 Turn signs! annual twitch a) Hunt button 11.. m. D. Inspeetlon 1. Checlt to nuke sure thnt the respective switch posilionl are functioning properly. Turn the ignition key to in. ON position end at the headlight control Iwitch to the red dot ((D position); the headlight Ind taillight will not be UN. lll the L position (® position), the hesdlight will he ON low benm; in the H position ((9 position) the headlight high been: will ON. Further, the millight will be ON in both the H and L positions. 2. Push the stnrter button and :heck to see if the surting motor turn over. 4. Turn Signs] and Horn Control Switch A. Description The turn sign-l null horn oontrol switches Ire built in the right end of the right hmrllehnr. The upper button controls the turn sign-l switch and the lower one the horn control twitch. B. Din-embly l. Unscrew the clutch lever mounting bolt end remove the clutch lever. 2. Unscrew the two twitch mounting screwu utd disassemble the switch upper and lower halves. 3. Disconnect the electrical connectors located on the wiring within hesdlighl me. C. lupecfion 1. Turn the ignition switch to the ON position and set the turn signal control switch to the L position (G) petition). The turn .lgnnl light on the left tide should be flushing and when the twitch to the R position (a: position), the right hand turn signll light should he flashing. 2. Set the ignition switt‘h to the ON positionnnd when the horn button is pressed, the horn should operate. D. Rectumhly Periorm the renssemhly in the reverse oi thy: dissssemhly. NOTE: When nssen-lhling the switch lower half on the handle, make sure the: the pin is inserted into the hnndlebnr stopper hole and then tighten together with the switch upper half. 5. Neat“! Switch A. Mm The neutral switch which final-m that the gar change pain] in in neuxrll polition in mounted on one end of the gen shift drum. I: clean Ind openl the circuit (a the neulnl pilot lump. B. Inspection 1. Cluck In nuke lure that the green neuml pilot come- ml when the (a: is shifted inn) the neutnl position by the gar chme pedal. 2. Check the openfion and condition of the nwml switch. C. Renml 1. Remove the 1:1: crlnkcue reu cover. 2‘ Unmcw the neutral twitch mounting 0cm: Ind the lwhth can he rammed from the gen shift drum D. Ree-sembly Perform the inn-linden in the reverse order of the re- maul. Fig. 0-54. Neum! uwildl lrig. 5415. warm diagram lad color summon m Lam great/Red Nculml p.10: lump w VVhileg'Yelluw/Tuhe Lighting dimmer swllch g; Yellow 1.13mi"; dimmer Iwitch a; Yelloijed 5mm: luluon switch a) Grlly Wink" maul] w Black nghlirlg dlmmel’ SWllch neuln| pilol lamv m Bruwn;‘\Vhlte waetlomeln Ilmp llghzing dimmcr smell a Green High 1mm hmprlxend l:ll\p.!mnl winkel- limp (g,- Blue R. {mm winklzrlnlnp wlllkcx swllcll‘ mnkcr pilot lump 3 nghl green Hum bum," ‘iWHL’lI g; nrmgc ll, lmm winker Inmp‘winklvr ,wlmh/ wink" plinl lamp a; Red . , l g Effcwkmw‘"? lgnlnon switch coupler {a Bzuwn a ngm green Horn [)3 “lurk Holnsignitlnn mu lad onlur Yclluw \Vhile Pl L3. green ‘Red Black _ arm, Vfillnw W @063 @4383 Green 9 Red Unhwhlle; 8 Ycllow Rul 59 Elm 5 Green a Blue :9 Orange .3 “(own 3 CmenaYellnw a Green 1 Connection Hm. generator Loupler I i 7 Slop swuch amp swuch Pomlless regulamr Wlllker relay Regulator Emery lermlnnl Bauer)! lamina) 5cm...“ mum-r coupicr sum solenoid mm. kacr why (at 5019.1th Tallhuht hast R. Rum wmku Imp L. rear wmker lamp Taillxlllp blnp muh W'lnkm’ relly mm for SIGNAL-STAT wlnhcr rclny) no twain!»— AW mthhwmmmmmmunmmdem-mmn EM 1. Omduwumdnnmlhefuelunk. 2. WuhMth-ddicmfiemhdcmwhhhdwhuflightme. a DWd-ninifiunimh-ndnhhnncfifierbdxnthamplu. 4. Whleldscouplerumfnmcceuwr. 5‘ Dicnmrhaludlnlhcmiendn. E. fiawhemumbewvedfmhfnne. 0.1mm 1.Abraham-adminincheoover‘ngalthzclecuicdwixingmymdntheelunkdeq' aminope d , Mmaheckmnllhltlhenuenodmdwidn‘. mpm nv: 1 Nuwmnhqu-ter‘indIndnflhhucheckwmetumthnthccmxcfipnluewund. D. Mu: Palm III. instill-lion in the raven: order of flu dinuunbly. 7. ENGINE (SL350) GENERAL DWON OF THE SL350 with the exception at the primary kick mechnnjnnt, the urhuretor netting end the (ll-mounting and rernounting proadum. the engine in idenu'ul to the CB/CIJSO Aerie: 7-1 DISMOUNTING THE ENGINE 1. Drain the engine oil by moving both the drain plug and the sin: up. 2. Turn the fuel cock to the STOP position. Disconnect the fuel line from the cock. Reine the sent, move the tank to the mar tn dilengnge it from the fuel innk reu' culhion, and then eepente the tank from the {mine by removing it tau-rd the rear. 3. Remeve the gear chunge and kick mter pednls. Re- move the mufilen and take all the left rear crankcase cover. (Fig. 7—1) 4. Dimmect the drive chitin at the connecting link. (Fig. 741) 5. Remove the carburetor: by loosening the carburetor insulating bend screws. (Fig. 7—2) 6. Diiconnect the wire hurneu. 7. Remove the contut breaker cable connection and the high tenrion tannin-l unembliea from the spark plug. 8. Disconnect the tachometer cable It the engine. 9, Remove the nine engine hunger bolt: (at the bottom a! crankcase, on top of cylinder head. at. the top tenr of crankcase) and than dismount the engine from the right ride, :1 2 REMOUNTING THE ENGINE 1. The engine can be easily remnunlcd by sliding the rear of the engine in place lram the crnnkcase side 2. lnnmlling the rear upper crankcase mounting bolt fin! will permit enty alignment of the remaining crankcase mounting bolts, first the lower ind [hen the cylinder head upper moundux bolmi NOTE: Torque all engine hanger lmln in 25.3~ lt-lbs (154» 350kg-nm). 3, The insmlleliun details (or the engine remounlinu are performed in the reverse order ol the rcmovnl procedure. NOTE: 1. The drive chnm joint clip (9 should be facing in the correct direction, the closed end of the imk clip should point toward the direction of the nanml clnun rotation. (Fig. 7—4) 2. The steel ball (D must be in the clutch let-er (3.4 [musing when installing the lelt crankcase rear cover. iFig. 775) nu. 1-1. Removing the muffler “I. 171. m. H. Ermine hing" linlis m pm. mm. ,mm n1”. Fin. 7 4. ii Sull lull ‘2‘ Hum. lrinr Fin. 7 5. ‘7 @— ® 0 Kick surm- rubber m Kick sinner Hopper Ipring 0 Kick Inner knuckle spring @ 18 mm, circlip a: Kick curler mm 0 Kid: mm spindle compIete a: Kick inner pinion 0 Friction min. 0 Kiek spindle mm o '20 mm, :51ch 0 Kick mm: idle gel! 9 Kick mmr gen! 0 20mm, clip 1-1.. 7-6. A. Din-anemhly 1. Sepunbe die upper and lower ernnkcase and then remove the kick tuner spindle. 2. Remove dmlips Ind dimumble the kick Inner spindle. B. Inspection 1. Inspect the gear teeth 1nd kick spindle mapper {or wear or dnmlge. I! dnmlgcd. rcplue with new one. C, Remmbly Reusemble Lhe kick starter components in the reverse order. NOTE: Do not forget to assemble 18mm nnd 20 mm circiips. Wprw—r. 1-4 cm AW WWMmm-fidbelov. Forfurlluinfntmnfionnfldjimut. —\ lulu \\Mflh‘ $1.350 Sun». m A Venturi bore din 240mm (03“ in) M]. (Nil! )0!) .120 AJ. (Ail Ft) .150 IN. (1.: needle) 2515 m (0.099 in) row Thrutde vdve Zfixlsxolz 5.x (Slaw in) 1 AB. 0.5 mm (o.oznn>x2 no AB. 05mm (0023 in)x2 AB, ' 0.6 mm (0023 in) x 2 Float height I 25m: B. Carburetor Circuit: 1. Stirling dreuit when the cw in lulled while it in cold. - richer fuel-Air mixture it required. The choke vllve in provided for thin purpose. Reine the chub: let/ell and the choke v-lve iI closed to reduce the mount 01 incoming Air. cunning the richer mixture to he drew-n into the engine cylinder. A relief vdve is llluhed tn the choke valve in prevent the engine from mulling or carbon deponils due to excel-he fuel. The relief valve i| controlled by the neglfive proliure ere-led by air to be drawn into the ruin bore. The choke lever should be rliud when mining the engine mad he returned to the origin] poultion when stopping the engine. 2. Low-speed circuit The law-speed circuit ii designed to supply the proper amount of mixture {or the engine at idle Ind exrremely low speedl. The fuel in the float dumber enters Lhc slow jet. The fuel metered by the slow jet is mixed with the nit bled by the Alow nit jet in the flow jet The mixture in jetted into the ruin here through the by-plu. a) Needle in a) Slow jet a, Needle ,n holdnr @ Mush 3a a Air anew .3 Mm air jet :1) Slow air 5m 3 wt: sen @ Hutu um 60 Flult ® Choke um 3 Jul needle @ 'nlmllln valve lug. 1-H. 130 ©Slowair'p QMrum QSlowjet run-m 3. Main circuit The main circuit ildetipedto aupplythepraper tumult: otnrlmrelortheenfine at mediumandhish speeds. Thefuellntheflonchnmberententhemninjet. The Mlmndhdnminjflilmixedwflhthelirbled bythemainairietintheneedlejetholder. Themixture iljettedinwtheminbonthrouahhetweentheneedle jet-ndjetneedle. Thelmrpartoftheietneedleie llplredwregululednlmoumolmlxture, 4. Fleet circuit In order to keep the operating charmer-lulu at the mbu. retor sad it: nwmhfion of fuel In nearly canal-at as ponible. it il “till that the level of the fuel in the jet in Ilvlya maintained It the lame level. Thin ia n:- eomplilhed by new of I float menu or circuit. The fuel flown inta the float chamber (mm the fuel tnnlr thraugh the fuel joint and the cleuance between the float vulve and lent. Al the fuel level rilei. the flout moves up on the fuel. when the float valve cum“ in com-ct with it: ten, the mpply of fuel in rhut all On the other had, at the level drop, the flout mover down and again the fuel eaten the float chamber between the vulve Ind aeat. Hy repelting thin cycle, the level of the fuel in the flout chamber la alwayl maintained It the rum: level. a; Throttle vllve ® lat needle ‘3) Needle jet @ Mlin llr jet (5'; Needle jet ltultler O Mlin jet I'll. 1-9. Carburetor Adjuttmenu q; Float a; Float um .3 v.1" m. a) Flat lip 3 F1...“ lrm Flt. 'I 10. - Baler: adjusting the rnrhuretor. check to be sure that the engine and electrlcnl syslctn m in good condttiurt. - When dis-summing nnd cleaning the carburetor for adjustment. take care not to low. mntnminutu. tltop or give a hammer blow to any componcul parts. Remtwv dirt and dual from the para using Cttmprrsscd |ir. 1. WWW mWhmbymdfihedrm-nd macaw“. 1)Fuflymmlholiflauwillldtheahnckllofllho spedfigdmormn 2)Suntheeugimnndmthnthmtlewmlo ahninlhnlpedfiedldlcwd. 3) Undnlheoondilionclhun.mn‘ha Air-anvil: uhhndinctiantoohulnthemninum-peeduwhié Ihcu‘iucummomhly. OBmklhethx-‘mhmncmoflmomdmlpgdfid HI: 5) Tumthzhitmineithnrdirecflonw chgcktolee ihhe engine nuunnoothly without unylign of Harlin]. 2. Flock level aim-m Incorrect loll lzvel my mull in war ucekntion, ex- ce-ive fun] consumption. m. If many, Adina the don level in the following procedure. 1) Baum: lhe flout chllllher body And plug the carbu- relm' u Ihmvn. 2) Finger-move the float and find the podium: when the float vulva pin cone: in cont-ct with the flan lip. In Inch I paiu'on, measure "H" with - mummmem am. 3) II the “H" II on of rpecificnion, dial: the float lip I0 than i! in I: fight mg]: to the flour vdvel CAUTION : Since I spring il “lubed to the tip of the float Vllve. this muluxemgnt should be awfully mulc. l3! rlch loan 1.0 I/B 1/4 1/2 _7 Ht. 1—“. Q Flo-l "he [in I) Float O Vllve [ell 0 Flat! vdn 0 Flu: lip O Man-mm! nun lit. 1-“. a) [die (peed mm a Air um Fix. 7-13. 132 8-1 HANDLEBAR A. Description Thehudlehuillllddzrtypeuimillrm that med on the (1350. A. die lent height in 2.36 (60 mm) lower than 1969 model. it in duigned slightly lowered for me especially suited to on end ofl roed riding and roleaenridingf-figue from long road work (Fig. flrl). Renwvel, inspection. end install-non ere rho nme for the CL350, therelore, refer to nation of CE. CLEO-350. 8-2 FORK TOP BRIDGE A. Deueription The fork lop bridge and the handle pipe upper holder m puimed flat black to prevent umoying reflection. Further, to provide good mering stability on rough roads, the lurk (up bridge is need In chmp the top of the from fork. m fork lap bridge i. nude Inger, incorporating a) Fork mounting bolt Q Sluring mm swing bulk two mounting bolt holes end I steering stem setting hick m. a z, Fm lop bridge hole. (Fig. 8-2) 8-3 FRONT CUSHION A. Description (Pinon velve type) 'The from fork in neembled into I complete unit by the fork barium bridge, ule end the fork lop bridge and their rerpeciive mounting bolt». This Kline-paint mounting design provides - highly rigid unit (or good liability. 'Hu [mm cushion in e heleacopic type widi e 6.7in (170 mm) rmge of cruel. W39: 726. ° m From cushion spring (A) a; Fm.“ uushinn spring joinl piece a) Fran: cushion ipring (B) a: Front lurk pipe I: From lurk dust ml g Imam-l snip ring m From inrk oil m1 ([7 From {ark pipe guide a; mu. fork bounm use up Fork pmon flapper ring (9 From (m pisiun a; Fork pawn. mp ring 11;. H. Srclinn-l View or lroni cushion B. Disassemhly 1. km the from wheel 0H the gruund by placing a support under the engine. 2. Remove the (mm brnke and speedometer able; from the front wheel paueL 3. Rcmere the (mm wheel. a. Remove the headlighx mounting holu Li). {Fig 8—4) 5. Loosen the Iron: fork fixing bolts ® and remove the from fork assembly (rum 01: frame. (Fig. 841) h. Remove the from [ark lap bolt and drain the oil. (I) Headlight mnunnng bolh 12) Front fork fixing lwulii Fig. EH. 7. Remove the from ioxk dust seal. &Remveonchfork&unnal,amlmemzl ' manila-L "9"“ lehMMfly-hmhlmtfwkbm an. 10. Rmovedukomhrkm Glam Ifomlotkbomoue Duck (w ouch and W Th- cylindn' an. hmiquifi-cyfiwmd). (Figs-7) ll 01‘) [Ill W VIE:- mbh llnh Cylink 375-87559 37w diam (um-.147”; (W) Ruplmiquondthnmicubhlimh. G) From (ark bottom cue 0 Front lork culhion wring (B) O From 1me uni-inn sprin' (A) 0 grout :0: piston 0 Front [ark pip: 0 mm o oillul mm H Rd 0 From fork bolt on or u“ ml HI. H. Component plus of [mm {mu 2. anl {ork inlon Check d1: pi-mn (D {or war Ind IcnIdL Manure [he pishon din. with l micmmr w. I! won or dun-sad. teplm with new on. (Fig, 5—8) mm (inch) 1 Standard who ‘7 Servimble 1mm P'uum 37.396~37.02 37.355 dimmer (xx/22-1.4132) (117g) D. humbly Portal-m the reassembly in the revel-u: alder of dis- lucmbly. NOTE: 1, It is rocommendcd that In 5“ rings, snapper rings and snap rings be repllced with new imam 2. Apply petrolcum xesism: grease human the main Ind dun lips of the from oil In]. Install the cine-1(1) into Lhe front wheel bottom use with the oil seal driving (ml No. 07947—2730HKD and weigh! (3) iTool guide ‘3) No. 07797-29201MXI\,. [Fig 8-9) Gluten-l ' s - “(J-I. III-pun. O peddphzn 0 Cylinder “use Ill. 54. I33 (D Fork piston (z Micromcmr Fig. 8—5. (0 on and a) on m1 drivmg weight Fix. a s. a on ml driving guide I34 3. lumllhm-pn'upodfiulyinbfienhiur groove. t Mblelhemnhionqarlnginmlluuu. 5. Murinnnllingthclxwtfmkondufim,fllchelod cylinder will: ll~ll_6 cu-in (13)~19m cc) 8A3 low-a0 oil of good (ride. 6.1! the Iron! lurk mountain. in mil-land. the «am; will pull to on: Me; diction, Hon installing din mmbmhkm ulsholuby'uuerfinun-luh Mud: lb. Axle halal. (Fug. 8—10) lk. I40. Aligning bod: [ml ale hula O. FRONT FORKS (free vulva type) a: From culhinn spring a, From fork dust sell a anl rebound spring a) Oil 10¢ put: a Buuom p|pc a Fork pipe (1 PM." my a ham um holder o 35—4541 m1 seal {1; Bunum an m 1mm! 4:; mm omny mg. nrn. Disluembly The {rue valvu lypc from (mks should be disnmmblrd in [I]: sum: manner as [he piston lype up «1 step G, 1 Wuh Ihe from fork bouum use held in 1: Vin“ remove cud) 50*]er bok mlh the Hulluw so! Wrench (Tool Na, 0791 300002 Thrn svpurulr [ht {rum [urk pipc [mm «hr fork bouom case a) Hollow m Wrench 9 From lurk bollom cm Fit. 8 ll intestateeuhlrontlnrkdmtuehflmnintuulmp rin‘ndoflull. W l. Checktln hunt fork pinton flu! for weer. 2. Chuk the front Ihnck nheorber Iprinp A and B for tendon. Also menu: the spring {roe length. 3. check the (ark bottom cueo for weer, moron. untchel or crack. 4. Check the front fork pipes for weer, scam watcher. creek» or run. If rust farm-lion is noticed on the piper, completely remove it with a fine emery cloth. 5. Check the oil rule {or nearer, tcretchet or lire-liege. Ammbly - To euemlie. reverte the disurembly procedures. 1. AI Ihown in Fig. 8-“. install each front fork pipe to the fork bottom one find tighten it with the locket holt securely. When tightening, Ipply a cont 0! locking Ienlnnt to the socket bolt. 2. Apply I cont of grease to each oil sell lipr Then insert the oil seal with the fork reel driver (Tool Nor 07947~ 3290000), Do not {target to install the snap ring. 3. Fill the fork pipes with premium quality Intern-tic trans- miuion fluid (ATP) up to the specified level. (See page 68). 8-4 STEERING STEM A. Description 135 at man instill mp ring a From fork at... all m. Ha. n— o qut (ark human use 0 Front fork pipe a) Bottom pipe © Fruit tuspeneiou wring: to From fork bolt Hg. 3-“. (D Hollow m wrench mg. 3.15. Q Front {ark bmtnm are (1) Fork sell driver m Oil teal Fig. 5 is. The steering stem is mounted into the frame head pipe supported by the upper and lower steering bells. An oil damper bucket which mounts the optional steering oil damper is installed on the right side of the lorlt bottom bridge together with the horn. its function its to improve steering, prevent handle vibration, and dampen shock when cruvelling on rough roads. A handle lock l! incorporated into the fork bottom bridge, idenn'cal to the C1350. and it can be removed no u complete assembly by inserting the key. turning countertlockwise and pulling. When per. lorming the instullution, do not forget to install the handle lock spring. I“ B. Din-em”: 1. Disconnect the from bnke from the hnke Inn end the clutch able at the lower end. Disconnect the throttle ceble II. the carbureror And the wiring lumen lac-led within heldlilht use. Remave hnndlebu by unscrewing the {our 8mm boll: {ruin the handle pipe holder clempe. 2. Renew the from wheel. 3. Remove the top hridge pine. 4. Remove rhe steering oil damper (option) from die bottom bridge piece and the damper hmker with horn. 5. Remove the headlight end from fork 6. Remove the steering stem wp nut (0 using I hook winner [Tool No. 07902-2000000) and pull lhe elem our the helium. (Fix. HPlZ) a) Sleerinl oil Jumper tar-elm a: Sreering oil dlmpe-r a; Horn © Fork bmmm bridge 71.. 5.11. Sreermg orl demper (uplmn) NOTE: Do not drop out the steel bull: during d1: steering stem removll. (9 Steering nur- lop mu 9 Hook spanner 71.. Ha. C. lnepeetion 1. Check the Ibeering slem (or any bend or delarmdon. Straighten die bent slem with the pres: And then check it with a dill gauge. if hedly demeged, replace with new one. 2. Check rhe steel halls for wear and cracks. If heavy steering is experienced while riding, it is probably due to eilhex the worn sleel hulls ur [be broken bells. Replece the hell: to correct the trouble. 3. Check the steering oil damper fur dents, damage or fluid leakage. ii defective. it must be repaired or replaced. I). Reneeemhly Prrlorrn the reassembly in the reverse order ol dismemblv. however, special attention must be given lo the (allowing points. NOTE : 1. Eu suflicienl grease when handling the steel balls of m in (me: mrrn die into the hall rncoo (18 [or the upper and 19 for rhr. lower racesl. When removing lhe smearing stem. care should be taken not ro drop any sleel ball. 2. W'lieu mounlrng the sleering stem. the steering mm lop nut should be tightened so the: only slighr pressure is applied and [here is no slackness in the steering cones. To check Lighineg oi the steering. nlr die front wheel to elll'ltr side slighrly and let the handle to start moving by its own weight If Lhe handle does not move by ‘nseli or there are gape between races, readjust rhe slecring stem [0p nul. 8-5 FUELTANK LDucrlptlon The (In! tank in mound onmfimbodydirecdy lbcveflneugiumdilwulonhhml bodylnd annual: the fuel tank rubber mam. Stripe lines It: plintndnnbovhnidsollheunk. Aflipapcntypeofunk «pin-adminiflm “hiding. Rum-11nd noun-don prudun-midenfiulwtha (1360. amnion, refer to this medal: of GLOW-350. 8-6 FRAME A. Dachau:- The inm- il 0! I double crud]: mbulu Incl construc- tion. This denial is pnnicul-fly euiled for rough told. A funds: thy i: weldnd on dag mt exunaiun a! the hit (me for mounting the nu fender. 0 Rent Iender say 0 Sub tube 0 0mm pipe 0 Sub \ube holder Q From dawn tube 0 Low-x cmn member 3. Din-embly 1 Engine dismounling Refer to engine dismounfing sectim: on pig: 127 2. Sent Unlock the seal lane-h, apen flu- seal 1am] remove due two lock pins and bah: n the lam hinge. sent {mm the fume. 3. Fuel unk Pk. 5-10. Fuel tank 137 Fig. 8 20. When dismounting Lhe engine, the (uel rank is also rcmoved at the same time. Refer to pun: 1‘27. 4 Air ole-net Remove 1}): two air cleanexs As described on page 133, 5 Steering handle, from suapcnsion and wheel Remove these put :3 described on page mums, 6. Renr wheel Remove the ten wheel as described on page In 7. Rear cushion Remove the rut cushion a: dcscribed on page 140. 8 Rear {ark Remov: ChC mar fork as described on page 139. Then sop-rue a“: 138 - C. Inspection 1 hupect the weld joints for any break: or crack: and the floating pip: lot twin and bend-L Weld the creel“, Int-tighten the minor dent: or twining. 2. Check the [nine paint coating lot rust spots. Pnint the worn or scratched pub. D. Ree-embly Pet-lorm the mmbly in the 1’8ma order of dituoembly. 8 - 7 SEAT A. Description The center of the tent is made into a depression chenging gredunlly from n lint surface to I caries of ridge: covered with vinyl lenther. This provides good seat holding on rough tends: also, the sponge rubber culhlon used in the tent theorhc shock and vibration {or more comfortable riding. The seat is unlocked and mixed toward the right side for Access to the battery, selenium rectifier Ind the winket 0 5“. llllch relay for lmpection. Refer to the 250-350 Shop Manuel m. Ht. relay (or inspection 8-8 MUFFLER A. Description The exhaust pipes are mounlm‘l to their respective right end lelt cylinder head with exhaust pipe joints Ind 8mm halts and nuu. The mulfler and the exhnust 1)po era an integral unit which is mounted to the units on the tnumer bucket with n 10mm hex. bolt. A us Futcslry smite approved tput utelter is installed within the muffler to prevent the emmis- sion of but spnrks when riding through forest end mountainou- regions. Refer to the 250.350 Shop Manual [or removal. inspec- tion end insull-tion procedure. NOTE : Disconnection of the muffler and exhnust pipe DI’ dis- Lssernbly of the muffler cannot be done. (D Exhnufil pip. 50am flange (2 Ext...“ pip: yum cullar (m Muffler assembly F12. 8722. 8 - 9 AlR CLEANER A. Description Two air cleaner elements are amchetl‘ one on each side of the frame. Both elements are madt‘ of uretan form which Inquirer. cleaning at specified intervals. B. [Homembly 1, Remove me All cleaner COKEr by pulling off at (ht: mum mount 1: [inn-n.“ nir cluumr fixing hnlm { l2 and connecting :9 Air t‘lcflnrr fixing 1qu V . , V l. . , - 'enner in |h~ r1: mnnmlw “me me“, tnht lY w :U (I tlu n \Vlll’ldlfi“ ll’ll tl t m i Fig. N 23. immc ‘Flg 8 33‘ av Au clonncr fixing mm all-pude- 1.1fthnd-nentiedirty.wnnhi1inlolventarwliu Indellawtudrythrvuhly. Theanowhyeqn-dna omdanmofludn-embliuitintomenirclnw em.lfhmhnordemued.nphuwidunewune. (“3.8-1“) luaecktlullrelunueluforcmkorotherd-mue. Ubdkdnmgeinplooe with new one (Fig.8—24) D. MW Mmthereeaemhlyinthemenenrderoldir ”ably. Br 10 m FORK A. Duripfiun The rear fork support: the wheel end pivon utthe rent (ark pivot hall to provide I [wing nion. n h eon-Inland of and tubing (or greater ntrength end dmhility end mounted through: pivot bur-hing on lock aide end lubricated wide grease for smoofi open-Irina. EDI-rum“: 1. Flue I block under the engine to mile the ten wheel on the pound. 2. Remove the chin, the tar wheel end the drive chnin guard. 8. Pull out the mr fork pivot bolt G) Ind remove the rut lurk Q. (FI‘ 8-19) C. hupectlon 139 (D Air dell-er element Pk. I—u. (9 Eur fork pm: hall a) km fork 71.. Ha. L The rear fork rhould be inspected [or distortion. inert the rear fork pivot bolt through both pivot hole: in the rent {Mk Ind check the rear link for Alignment. 2. Mann the inside dinneher of the reu fork pivot bushing Ind replace if beyond the eervicelble limit. mm (lath) Item Sand-rd vdue ‘ halide dimmer at 20,000~mma ‘ burhing ‘ (0.787~0.789) Sen icenhle limit 20.18 (0 795) D. Bee-embly 1. Apply e lihenl mount of urea-e on the pivot collar end memhle it into die renr t'nrk. Insert the pivot bolxtrom lb. right nick, and then inn-ll Ind tighten the 14mm eel! lock nut. Tightening torque is IE.O~79.5lb-ft {900~ W Ira-cm). 2. lnlull the drive chein gunrd end the rear wheel. 3. Inmll the drive chain. the re-r brake pedal and drive ehnin tension". 140 8-11 BEAR CUSHION A. Ducrivfim A De Cnrbnn typed-mm cont-inn); nitrogen an underhixhpre-ureiscontainedwithinthecylindertominuin spec-m spin-nth: oil. . Thin prevent- bubbles from beinu produced in the oil during compression. It Insure: poeitive damping fiction. Nipringioraunbosdiuued Inthret poun'nnsscmrdina manning loud andridinxcondition. 'l‘hestrokeof the men-him in 3.62inr (921nm) UMTiMM a) clip (:2 Rear shock spring mt stopper 0 Rex nhock Iprinz upper mi 0 shock eprin' 0 Rear lhock spring guide o Rm shack spring lower ml (2 Rear shock dunper unit Fig. 54'. Sections] View of rel! suspension B Diuaaernbly 1‘ Remove the blind nut from the upper mounting ball 0‘ ennh renr shock spring. Remove the lower mounting bolt Ind withdrew the rear shock spring. 2. Remove the spring Q from the shock spring unit by using the renr suspension disusembling sud Insemhling tool (Tool No. 07959-32311”) @- (Fig. 3‘27) Turning the handle of the upecisl tool clockwile will gradunlly compress the spring. permitting the removnl of the spring upper seat. As the handle is turned counter clockwise, the special tonl can be separated from the cushion spring sllowing the damper unit to be disassembled. m Rear shock spring up Suspensmn drmsemhlinu and nrsemblmg tool Fir. 8—21. C. Inspection 1. Check the body of the damper for dents or damage, {or fluid leakage or lack oi dumping effect. If any of they: defects are found. replace the whole unit as the damper is not repuiruble. CAUTION: The cylinder is pressurized by nitrogen gas to upproximswly 568,8 psi (40 mm), therefore, nu attempt should be and: to disassemble the cylinder. 2. Check the free length or the spring a) with . Vernier caliper 1;. (Fig. 3 28» w a: muslin-s less than the spenfied value. the Spring that-Id b. replaced. Item , 5m rd . rinu tree gth 3, Dumping force connot he meuured. therefare the real is performed by compressing the rear damper unit by hand; normal operating condition is indicated by n grater resistance on the extension stroke than on the compres- sion stroke r17 Km suspcmiun spring q; Vernier caliper Hr. H43. I). Inn—Hy “hummingonlohmdflnw nfltwfllduhplududdhwflmhw Witnmoduddk-Imbly. die-oldleu—mrnhckmdth «hurl-tutor”; Pnihmnunlnnnnsl. 0 Rear sulpmninn r set! smppcl a; CI p 0 Run lulpension l upper an o Rnr :unwuion Iprin' @ Rur damper uni! Hg. 8—10. Compullnnl pm: oi rur cushion 8-12 “0“me A. Dam-infi- Pnficllly all of the pun "th u m whnel hearing, whul hub. hnke bucking plug, link: drum and rhoen. mohudmnmdnmeuthnufm‘thncm. ‘l'lu Innior diflerenn- m in the hobby fixe- (35~19—4 PR) used on the SL350 for better honlding when tnvelling on: rough rods. The pmndun for din renwul nnd install-non of the from wheel unmhly, bearing removal, mice-bk limit of hmm.hnkauhmlndfirenpluemnuue dielameulnrtheumzufordnodiernrieumdzhouldbe [finned an in 250'360 Show Mnnunl. B. The Macadamia: Th: following «in in recommended {or use with [he SL350. Brnnd Maul-chalet Size Air pmaur: (cold) From: 35. mm wing Bridge-ton: Tire Cd, 1.,” ‘ 3.5.49 215 psi ' Rant: as. Tnil wing Bridge-mm Tire C0,, Japan 4.oo~1s 215,»; m an m. Ipecinlly developed for the SL350 and (mum superior told holding In! both oH-ihe-roud Ind on the high my 8- 13 REAR WHEEL A. Ducrlpflon Similu Io flu (mm whenl, din pm (or the rent wheel Ir: me an: u that: uud on the CL350 widi the exception of the knobby tire and rim designed for chei mull-(ion of we had Ipueru for ofl-Ihe-rnnd riding. For disluembly, inspection, rep-if and reassembly, refer to the Lire (hinge is the same as [or the from wheel Ind should be referred to in the section of tire rccnmmcndltlon. and 5” . mm K r. m. A ml. 10-30. Tube nir vulva hula and bead spacer holes 142 9. ELECTRICAL GENERAL DESCRIPTION Allpemu-edintheelectricnl mmmthenrneuthentneuthneeuaedinthecuso,with the exnepu'on of the ignition coil. horn end Ipeedatneter. A: nefety end emergency tenure. the ignition circuit in expo-ed Ind I kill I’W‘ll‘th hat been incorponted to shut oi the engine. Description of the special pent. 9 - l IGNITION COIL The wire: in due hat'neu connecting the (me. condenser and breaker point: one of I larger fine. 9 . 2 HORN The center dintanee of the horn hreeltet mourning hole- ha: been made greater to permit the used of the name bolt: fomonhting the fleeting damper hmltet. 9 - 3 SPEEDOMETEB The decign ol the dinl plnte has been changed to indiute the rpeed ranges for on-the-roed riding, however, the speedometer main unit in- not been chenged. Refer to the 250-350 Shop Manual {or information of the diluetnhly, inspection Ind rueemhly of the respective component, 9-4 STARTER LIGHTING EMERGENCY SWITCH The mm: lighting emergency twitch ia located on top of the right handle hraclret‘ (Fig. H) A. Dinnemhly 4‘ l. Super-ate the twitch bracket by removing the two switch mounting urewn (D. (Fig. 9-2) _ I 2. Diaonnnect the throttle cable. 3‘ Dieter-meet the wiring harness within the head light case and remove the switch uternhlv. B. Inspection 1. Start the engine, fim make lure the engine cnn he flopped by switching ofl’ the emergency twitch. II the respective switch positions are not functioned properly, the switch or wiring in defective. If the wiring is correct. check by the teating conductivity of wires with the switch. if the conductivity in not cor rect, replace the switch with new one. 2. Switch on the nnin key twitch and check to me that the hendlight control switch is functioning properly by netting the respective twitch positional If its position: are not functioned properly. the twitch or wiring is defective. I: both the wiring Ind conductivity are comet. replace the switch with new one. a: Emngmy ward. at. Headlight control switch In, 9.1. C. Reunembly l’ertorm the reassembly in the reverse order at dia- usemhly‘ NOTE : W'hen instnllinu the switch lower housing on the handle her, make sure am the hodling pin is mind mm the bundle bar chop hole Ind is Lightened together with the switch upper housing. {l} S ’ m. mounting tin-w m, 9,2. I43 v WIRING DIAGRAM go: Ebm §§S§LJ Emma! u 010 page , _ W6, 9.010 . M 0.6 pm a J. g a. 4. x 55823... :85 8‘58 38 ngflfia 44;: v kg y Erin s: 31: 8:3 to; in ¥Y>«. l-SK. 2352 , 323$“— 5:4! 235 .35 5:8: 3! V3: 5.5. .33 5:2! gm EB , 5?»: .31. émgufim 1 1 325 as.) fipflficfl a. .I: 50. Bus... :39. i3 «335: 4.5:! 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