- SHllP ANIIA

. HONDA

cmoo.cuoo.suoo
'oo . 125 MODEL cm2ss.c012ss.su25

 

 

. FOREWORD

This Shop Manual is published as a guide to servicing the Honda 100-125.
. It provides the service technician with complete and proper servicing in-

formation. Further, the sales personnel will also gain the technical know-

ledge which is very beneficial in his work.

The manual is separated into five sections with the respective sections

being further divided into disassembly, adjustment, and repair.

By closely following the instructions, the proper servicing can be per-

formed with greater efficiency.

The information in this manual was in effect at the time of publication.

. The information peculiar to TL125 is complied at the back of this

publication as a suppliment.

BIIHTENTS

 

 

I. PRflCEDURE 0F PERFflRMING THE WORK

. When performing an overhaul. all the parts which have been disassembled should be
separated in their respective groups so that they will not become mixed.
. All packings. gaskets and cotter pins which have been removed should be replaced with new
items when reassembling. Any snap rings which are deformed shoud also be replaced.
. All engine parts should be cleaned after disassembly. Metal surfaces which are subject to
friction must be coated with oil.
. The work should be performed with special tools for better results.
. All nuts and bolts are normally torqued starting from those of large diameter and from
inside to outside symmetrically.
. Refer to torque values shown in the following table.

 

 

 

 

 

 

 

 

UNIT: kg-rn (fl-lb)
Engine Frame
Item Torque values Item Torque values
Cylinder head |.8~ 2.0 Front axle nut 4.0~ 5.0
(ll.5~l4.5) (29.0~36.0)
Spark advance 0.8~ 1.2 Rear axle nut 4.0~ 5.0
( 5.8~ 8.7) (29.0~36.0)
Cam sprocket 0.8~ |.2 Rear fork pivot bolt 3.0~ 4.0
( 5.8~ 8.7) (2|.7~29.0)
Cylinder mount boll, 6mm l.2~ [.8 Engine mounting bolt 2.0~ 2.5
( 8.7~|3.0) (l4.5~l8.8)
Left crank case cover 0.8~ l.2 Handle mounting bolt 0.9~ l.l
( 5.8~ 8.7) (6.50~7.95)
A.C rotor 2.6~ 3.2 Steering stem nut 6.0~8.0
(18.8~23.2) (43.3~57.8)
A.C generator mounting screw 08—» l.2 Front cushion mounting bolt 4.0~ 5.0
( 5.8~ 8.7) (29.0~36.0)
Cam chain tensioner arm 0.8~ l.2 Rear cushion mounting nut 3.0~ 4.0
( 5.8~ 8.7) (2L7~29.0)
Right crank case cover screw 0.8~ 1.2 Torque link mounting bolt 2.0-- 2.5
( 5.8~ 8.7) (l4.5~l8.0)
Oil filter cover screw 0.8~ 0.4 Top bridge lock nut 4.0~ 4.8
( 2.2~ 2.9) (29.0~34.7)
Oil filter (lock nut. 16mm) 4.0~ 5.0 Final driven sprocket 2.0~ 2.5
(29.0~36.0) (l4.5~ l8.0)
Oil pump gar cover bolt 0.4—» 0.6 Seat mounting bolt 2.0~ 2.5
( 2.9~ 4.4) (l4.5~18.0)
Clutch mounting bolt 0.8~ l.2
( 5.6~ 8.7)
Gear shift drum stopper bolt 0.8~ 1.2
( 5.6~ 8.7)
Gear shift drum cam bolt 0.8~ 1.2
( 5.6~ 8.7)

 

Standard parts

Bolt hex. 6mm
Screw cross, 6mm
Nut. 6mm

Screw cross. 5mm

0.3-4.2 kg/m (5.8.13.7)
0.8~l.2 kg/m (5.8~8.7)
0.8~l.2 kg/m (5.34.7)
o.3~o.4 kg/m (2.2~2.9)

 

2

SPECIAL TOOLS

 

 

 

 

 

 

®
Ref. No. Tool No. Description
070004070] Special Tool Set for C8100 and CLl00
0700|—l l001 Special Tool Set for SLl00
l * 07001—10701 Valve seat 90° cutter
2 * 07003—l0701 inlet valve seat top cutter
3 " 07004—1070] Exhaust valve seat top cutter
4 * 07005—1070] Inlet valve seat interior cutter
5 * 07006-l070l Exhaust valve seat interior cutter
6 07007-0010] Valve seat cutter holder 5.5mm
7 07046—2l60l Valve guide driver
8 07022—2000! Drive sprocket holder
9 07072—2000] Pin spanner, 48 mm
10 070] l-0300l Dynamo rotor puller
ll 0703l—1070l Valve spring compressor

 

 

 

 

 

 

 

Ref. No. Tool No. Description
12 07047—0400l Valve guide remover
13 07054—02802 Front fork oil seal driving weight
14 * 07054—02803 Front fork oil seal driving guide (CBIOO‘ CLIOO)
15 07083-2160] Stem nut box wrench. 29 mm
16 07008—24001 Valve guide reamer
17 07086-2830l T-handle box wrench, l6 mm
18 * 07061-1070] Timing inspection cover
19 0707l—25001 Main switch spanner
20 * 07024—1070] Clutch outer holder
21 07997—05l0] Valve seat cutter case
07790—2920l Tool case

 

 

 

* These tools are newly made for use, the others are common to all series.

 

 

SPECIAL TOOLS FOR CBIZ5S, CDIZSS AND SL125

 

 

 

 

Tool No. Description
07000—3240] Special Tool Set for CBIZSS. CDIZSS and SLI25
0700l—3240] Valve seat 90° cutter
07003-32401 Inlet valve seat top cutter
07004-32401 Exhaust valve seat top cutter
07005—32401 Inlet valve seat interior cutter
07006—3240l Exhaust valve seat interior cutter

 

These tools described above are newly made for use, the others are

common to 100 series.

 

. 11. MAINTENANCE 0PERATIUNS 5

l. TAPPE’I‘ ADJUSTMENT

The inspection and adjustment must be per-

formed while the engine is cold.

I) Unscrew the two 8mm seat mounting

. bolts and remove the seat.

2) Remove the fuel tank.

3) Unscrew and remove the tappet hole caps.

4) Remove the dynamo cover.

5) Turn the crankshaft so that the “T"

. (timing) mark aligns with index mark on
the stator and the piston is in the compres-
sion stroke. The piston in the compression
stroke can be determined by feeling rocker
arms for clearance. (Fig. l)

6) Check tappet clearances with a thickness
gauge and if it is necessary to adjust. loosen
the lock nut and adjust the tappet adjust
screw. (Fig. 2)

Tappet clearances: Intake 0.05mm (0.002 in.)
Exhaust 0.05mm (0.002 in.)

When tightening the lock nut, exercise
care so that the tappet clearance wil| not
. be disturbed. Recheck the tappet clearance.

2. CARBURETOR ADJUSTMENT

Warm up the engine before setting the engine

idle speed and make the idle adjustment with

the pilot air screw and throttle stop screw.

(Fig. 3)

I) Adjust the throttle stop screw to give idle
speed of 1,200 rpm. Use a tachometer
when it is available.

2) Turn the pilot air screw in and out to locate
the position where engine rpm is highest.
Turning the screw in will provide a rich
fuel mixture, turning the screw out will

. give a lean fuel mixture.

3) If engine rpm has increased by the ad-
justment of air screw. the engine rpm
should be set to the proper idle speed by
using the throttle stop screw.

4) Turn the pilot air screw in or out
within the range of US to l/4 turn to
obtain the optium idling condition.

 

Fig. 3 Idling adjustment
LD Air screw w Throttle stop screw

 

    

 

 

 

. ' _ (D “F" aligning mark (2 Breaker arm sprin
mg 6 CD Ground Io earth 0 Bulb 3

 

‘7 ,_/' ,il-iv “r" L l‘ . u ,
Fig, 7 ® Base plate mounting screw 0 Base plate

3. BREAKER POINT AND IGNITION
TIMING ADJUSTMENT

Adjust breaker point gap. before performing
the ignition timing adjustment.

A. Breaker point gap

1)

Remove the point and dynamo covers.

Turn the crankshaft with the pin spanner
provided as a service tool until the

breaker arm slipper is on the highest
point of cam lobe. (Fig. 4)

2) Measure point gap using a thickness gauge.

The gap should be 0.3—0.4 mm (0.012—
0.016 in.).

3) If it is necessary to make adjustment,

4)

loosen the breaker arm retaining screws,
insert a screwdriver in the adjusting screw
slot, and pry to adjust to the above value.
Retighten the screw securely after setting
is made. (Fig. 5)

Check the ignition. When the point contact
surfaces are pitted or dirty, grind contacts
with a point file or oil stone to remove
transfer or contamination. If the metal
build-up on the point is greater than
0.5 mm (0.02 in.), it should be replaced.

B. Ignition timing adjustment

1)

2)

3)

4)

Disconnect the contact breaker cord (green
cord) at the connector and connect a
12V—3W lamp across the line. (Fig. 6)

Set the combination switch to “ON" posi-
tion.

Turn the rotor slowly until the lamp goes
out and check the position of “F“ mark
on the rotor against the index mark on the
L. crankcase. If they are in line, the ignition
timing is correct. (Fig. 6)

If ignition timing is required for ad-
justment, loosen two base plate mounting
screws and move the base plate. Turning
the base plate clockwise will retard the
timing and counter clockwise will advance
it. Tighten the screw after adjustment is
made. (Fig. 7)

4. CLUTCH ADJUSTMENT
"‘ Check the clutch free play at the end of the
clutch lever. The play should be 1—2 cm

(2/5-3/4in.). (Fig. 8) lf it is not within this

range. adjust it in accordance with the follow-

ing procedure.

I) Loosen the clutch cable adjuster lock nut
and turn the adjuster clockwise to make the
cable free. Then loosen the lock nut of the
clutch adjuster on the right crankcase cover.
Turn the adjuster screw counter clockwise
until a slight drag is felt and return it by
”8 to l/4 turn. Tighten the lock nut
securely. (Fig. 9) -

2) Turn the adjuster in the cable counter clock-
wise to adjust the lever end play. (Fig. 10)

3) Check for proper adjustment by starting
the engine, applying clutch, and operating
gear change. If the clutch does not dis-
engage, the engine will stall or the motor-
cycle will tend to creep.

If the clutch does not fully engage, the
clutch will slip and the motorcycle will not

accelerate in response to the acceleration “8- 9 8'13. :glnsmitw mw
of engine.

 

 

5. SPARK PLUG INSPECTION

Remove the spark plug with a spark plug

wrench and visually check conditions of

electrodes and insulator.

The standard spark plugs equipped in the

original engine are MES (NGK) or X24ES

(Nihon denso).

I) If the plug is carboned up, sooty or has
a hard deposit from the chemical fuel
additivies, it should be cleaned with a
spark plug cleaner or a wire brush.

2) Replace the plug if it insulator is cracked . .1, .4 ; -
or chipped. A, o_5:..0_'7.. '

3) Check the gap between the electrodes 1. ‘,(o‘.'025~o.ozain) ,
with a thickness gauge and if necessary, '- “ -
adjust the ground electrode by bending.
The standard clearance is 0.6—0.7Inm
(0.025—0.028in.).(Fig. ll) ‘

4) Check the plug gasket before installation
and replace if it is damaged.

 

 
 
    
    

Fig, 11 a; Electrode '

6. ENGINE OIL CHANGE

The oil change is better performed while the

engine is warm as this will expedite thorough

draining of oil.

1) Remove the oil cap and remove the drain
plug to drain oil. (Fig. l3)

2) When the oil is thoroughly drained, replace
the drain plug.
Fill with a brand name oil SAE l0W-30, in
the quantity of I lit. (1.05 qt.). Check the
level by placing the dip stick in its hole,
but not screwing it in. In this position, the
level should be within the upper and lower
marks. (Fig. 12)

 

Fig. [3 f1) Drain plug
7. OIL FILTER CLEANING
' I) Remove the muffler.
2) Remove the step bar.
3) Remove the right crankcase cover.
4) Remove the centrifugal oil filter cap and
clean inside. (Fig. 14)

 

Oil Pump Screen Cleaning

Whenever the right crankcase cover is remov-
ed, check the oil pump screen to see if dirt is
trapped. If it is dirty, remove the screen by
taking off the cap. Clean the screen by blow-
ing compressed air through it. (Fig. l5)

 

Fig. l5 ’1“ Oil pump semen

 

8. CAM CHAIN ADJUSTMENT
Perform the adjustment with the adjuster
screw. Loosen the lock nut and turn the
adjuster screw counter clockwise to decrease
the slack in the cam chain. The procedure for
adjustment is. first loosen the screw and then
tighten until it becomes heavy. Tighten the
lock nut after completing the adjustment.

(Fig. 16)

  

 

Fig. 16 (1') Lock nut (2 Adjuster screw

9. FUEL SYSTEM INSPECTION

Inspect the fuel tank. fuel cock, carburetor
and fuel piping system for any fuel leaks.
If fuel is spilled at any time during the re-
placement off uel system component, it should
be cleaned up immediately as it is a fire hazard.

10. AIR CLEANER ELEMENT SERVICING
l) Remove the right side cover.
2) Loosen air cleaner connecting clamp and
the two mounting nuts to remove the air
cleaner element. (Fig. 17)

 

Fig, 17 ‘1‘ Mounting nut (2 Air cleaner connecting clamp

3) Wash the element in solvent and then allow
to dry. Apply a small quantity of oil on
the element before installation. (Fig. 18)

Note:
Do not use gasoline to wash the filter element.

 

Fig. 18 (D Air cleaner element

 

  

  

./ .~ 1 a ' - '
Fig 20 (£1 Adjuster nut l Lock nut [‘13. 2.0—A

Adjuster nut a" Decreuse '5‘ Increase

     
 

2~3m
(91"- l Kin.)

" t .
Fig. 22 Q Adjuster nut O Decrease ® Increase

 
   

ll. BRAKE ADJUSTMENT
(Front wheel)
Check the brake free play at the end of the
brake lever. The play should be 2—3 cm
(3/4—1 -l/8 in.). (Fig. l9) lfit is not within this
range, adjust it in accordance with the follow-
ing procedure.
I) Turn the adjuster nut clockwise to reduce
play in the brake lever. (Fig. 20)

2) Minor or fine adjustment can be made with
adjuster nut on the clutch lever. (Fig. 20-A)

(Rear wheel)

Check the brake free play at the end of the

brake pedal. The play should be 2-3cm

(3/4—1-1/8 in.). (Fig. 2|) li it is not within this

range. adjust it in accordance with the follow

ing procedure.

I) Turn the adjuster nut clockwise to reduce
the amount of play in the brake pedal.
(Fig. 2|)

2) Minor or fine adjustment can be made
with adjuster nut on the brake lever.

ll

 

12. DRIVE CHAIN ADJUSTMENT
Adjust the chain slack to 1—2 cm (2/5—3/4
in.) with adjuster nuts after the axle nut is
loosened. (Fig. 23)
Note:
Both right and left adjuster nuts should be
turned equal amounts. This can be verified by
the position of the adjuster indicator plate
on both sides.

  

’7’ <%~' *

 

Fig, 23 (I) Index mark and side scale (2 Rear axle nut
(31 Adjuster nut

13. BATTERY ELECTROLYTE
INSPECTION
Remove the left side cover and check the
level of battery electrolyte to level indicator

marks on battery case. (Fig. 24)
I) If the electroyte level is low, remove the

battery to refill it.
2) Add distilled water to bring electrolyte
level to upper level marked on the case.

Note:

Over filling will cause electroyte to overflow
and result in corrosion around the battery
compartment.

14. FRONT FORK 01L REPLACEMENT
1) Remove the fork bolts and remove the
drain plug to drain oil. Actuate the fork
for complete draining. (Fig. 25—26)

2) Flush out the interior using solvent.

Note:

Do not use gasoline for cleaning.

3) Reinstall the drain plug and tighten before
refilling with new oil.(Fig. 26)

Recommended oil: SAE low-40
Capacity:

c3100, cnnss
cuoo, cmzss 130-140cc(4.4—4.7 on)

SL100, SL125 180—1900c(6.1—7.2 025)

4) Replace the fork bolt.
Torque to 4.0-5.0 kg-m (29.0—36.0 ft lbs).

 

Fig. 26 (D Dmn' pluI

12

 

Fig. 27 (1‘ Compression gauge

15. CYLINDER COMPRESSION CHECK
Low compression and pressure leak will
cause unstable engine rpm and loss of power.
Compression is checked with a cylinder
compression gauge by the following procedure.
(Fig. 27)

l) Remove the spark plug.

2) Insert the rubber tip of compression gauge
into the spark plug hole and operate the
kick starter while holding the throttle grip
fully open.

Note:

Perform the check after warming up the

engine.

3) The normal compression pressure is l2
kg/cm’ (170 psi).

(Li Low‘compression is due to one of the
following causes:

. Leaking valve.

- Defective or sticking piston rings.
. Blown cylinder head gasket.

- Improper tappet adjustment.

Q) Unusually high compression pressure is
due to excessive carbon deposits on the
combustion chamber or on the piston
head.

Engine must be disassembled for complete

inspection or repair in these cases.

III. ENGINE

 

Construction

I3

H

1. WORK WHICH CAN BE PERFORMED
WITHOUT REMOVING THE ENGINE.

 

 

 

 

 

 

Work Item l Page
1) Oil piump, oil filter W 22
_2) Clutch , 25
3) Gear shift mechanism 27

 

 

2. ENGINE REMOVAL AND REINSTALLA-
TlON

A. Engine Removal

1) Remove the exhaust pipe and muffler.

2) Remove four 8mm step bar mounting
bolts and remove the step bar.

3) Loosen the clutch cable lock nut. provide
additional cable slack and then discon-
nect from the clutch lever. (Fig. 28)

4) Unscrew the two carburetor mounting
bolts and separate the carburetor from
the inlet pipe.

5) Remove the gear change pedal.

6) Remove the left rear crankcase cover.

7) Disconnect and remove the drive chain.

8) Disconnect the coupler from wire harness.
(Fig. 29)

9) Remove nuts from the engine hanger
bolts, raise engine toward the rear. and
remove engine bolt while supporting the
engine. (Fig. 30)

 

Fig. 30 ’1“ Engine hanger bolts

l5

 

 

B. Engine Reinstallation

l) Reinstall engine in the reverse order of Direction of rotation
removal.

2) To simplify installation, use the “T"
handle screwdriver to hang the engine
temporarily followed by installing the
support bolt.

3) Temporarily install the exhaust pipe joint
and muffler and then perform the final
torquing.

4) When connecting drive chain. make sure
that the chain joint clip is properly
installed. (Fig. 3|)

 

 

 

 

Fig. 3| Direction of rotation

3. CYLINDER, CYLINDER HEAD AND

PISTON

A. Disassembly

l) Remove two 5mm screws and disassemble
the point cover.

2) Loosen two 5mm mounting screws and
remove the contact breaker. (Fig. 32)

3) Loosen the 6mm mounting bolt and
remove the governor. (Fig. 32)

4) Loosen two 6mm screws and remove the
point base. (Fig. 32)

5) Position the piston at top-dead-center,
loosen the cam sprocket mounting bolts
and remove the cam sprocket from the
cam chain. (Fig. 33)

Drop cam chain toward the side of the
cylinder.

Note:

Do not loosen the cylinder head bolts.

6) Remove four 8mm cap nuts.

 

  
  

7) Align both the inlet and exhaust cams to .7 t "‘ < x Q j] , . .
the cutout on the cylinder head and then Fig. 33 8 Cam chain <2 mm bolts 0 Cmgvrockct

. "T"Ilignin' mark @Camflnn 9
remove the camshaft from the cylinder. .,_ ., . .

(Fig. 34)

 

Fig. 34 nuhaft removal
m Cam chain (2 Camshaft

   

 

 

  
  

Fig. 36 Cylinder removal
® Cylinder

 

Fig. 37 Piston 7pm removal

(1) Piston pin clip (2 Lon] nose pliers

Cylinder bore measurement—
(D Cylinder pun @ Cylinder

8) Remove the tensioner stopper bolt and
then remove the cam chain tensioner from
the cylinder head.

9) Lift 00' the cylinder head.

IO) Remove the cam chain guide.

ll) Lift and remove the cylinder. (Fig. 36)
Note:

If cylinder head is frozen on the cylinder or
if it is difiicult to remove, tap the cylinder
base with a wooden hammer to loosen. Ex-
ercise care not to strike the cylinder with a
hard blow as the cooling fins may be damaged.

12) Remove piston pin clip and piston pin,
and then separate the piston from the
connecting rod. (Fig. 37)

Note:

When removing the piston pin clip, exercise

care not to drop the clip into the crankcase.

l3) Remove the piston rings.

B. Impection
l) lnspect the condition of the cylinder bore.

Measure diameter of the cylinder bore in
both the X and Y directions and at the
top, center and bottom of the cylinder.

(Fig. 38)

 

Item Standard nine limit

 

gag 50.50-50.51mm. 50.6mm max.
Bo SL100 (l.988|-l.9885 in.) (L992 in.)
re

diameter

 

””55 56.00-56.01mm 56.lmm max.

$322558 (21047—22051 in.) (2.2086 in)

 

 

 

 

 

 

If the cylinder bore is less than 52.6 mm,
rebore and hone the cylinder, and replace
the piston with oversize piston and the
standard clearance between the piston and
the cylinder should be 0.01-0.05mm (0.0004
—0.0020 in.) at the piston skirt. The over-
size pistons are available in the oversize
of 0.25. 0.50, 0.75 and l.0mm(0.0|0. 0.020,
0.030 & 0.040 in.).

2) Piston diameter inspection
Measure the piston at the skirt. (Fig. 39)

 

Service-bl:
Item Standard value llmlt

 

 

CB'°° 50.47—50.49mm 50.3mm

CLIOO . .
00 (1.9874988 m.) (1.980 m.)
Piston SL1

 

diameter
33112255?» 55.97—55.99mm_ 55.80mn1
(moss-2.2043 m.) (2.!968m.)

 

 

SLl25

 

 

 

Replace if beyond the serviceable limit.

3) Measure the piston ring side clearance
using a thickness gauge. Replace the piston
ring or piston if beyond the serviceable
limit.

 

Servieenhle
[tun Standard value limit

 

Piston ring 0.025-0.030mm 0.7mm
side clearance (00008—0001! in.) (0.0275 in.)

 

 

 

 

 

4) Piston ring gap
Insert the piston ring into the cylinder
so that it is normal to the cylinder axis
and then measure the ring gap using a
thickness gauge. (Fig. 40)

 

 

 

Item Standard value Service-bl:
limit
Top and 0.|5—0.35mm 0.5mm max.
second rings (0.0059-0.0l38 in.) (0.0l97 in.)
. - 0,l5-0.04mm 0.5mm max.
0" ”"3 (o.oos9-o.or58 in.) (0.0:97 in.)

 

 

 

 

 

Replace if beyond the serviceable limit.
C. Reassemhly

l) Assemble the piston ring on the piston.

Note:
The ring marking located adjacent to the ring

gap should he toward the top. (Fig. 4])

When installing new piston rings, roll the
rings over their respective piston ring
grooves to make sure that the ring side
clearances are adequate. Rings should roll
smoothly.

2) Install the piston. (Fig. 42)

Note:

Install the piston so that the IN marking

on the piston head is toward the rear.

Replace all piston pin clips with new items.

3) Space the piston ring gaps equally apart
(l20°) and then install the cylinder.

Note:

Do not forget to install the two dowel pins

in the mounting base.

17

  

t ~.z

 

Fig. 39 Piston diameter measurement
(1) Piston Q Micrometer

 

Fig. 40 Piston ring gap measurement
(1) Thickness gauge i2 Piston ring

 

Fig. 41 (I) Piston ring rnnrkina

 

Fig. 42 Piston installation
a} Piston pin clips (2 Long nose pliers

[8

 

 

 

 

 

 

 

. (I) Dowel pins r Cam chain tensioner
Fig 43 {3 Cam chain gage

  

n7 ‘ «z 7 fan“ ,,

Fig. 44 Q) Carri chain f2: Screwdriver r32 8mm up nuts

 

Fig. 45 Camshaft installation
(I) Camshaft ® Cam lobe

 

Valve timing procedure
(I) “T" mark (2 Mounting holes (3 Cam sprocket

4) Reinstall the Chain guide. (Fig. 43)
5) Reinstall the three dowel pins and 0 ring.
(Fig. 43)

6) Assemble cam sprocket on the cam chain
and then install the sub assembly on the
cylinder head together with the cam chain
tensioner.

7) Use a screwdriver to support the cam
sprocket and then install the 8 mm cap
nuts. (Fig. 44)

Torque to 0.8—1.2 kg-m (5.8—8.7 ft. lbs).

8) Disassemble the cam chain from the cam
sprocket and then reinstall the camshaft.
(Fig. 45)

Note:
Align cam lobe to the cutout on the cylinder
head and then install the camshaft. Rotate the
camshaft one revolution to bring it to the top-
dead-center position. This is determined by the
cam sprocket mounting holes being perpen-
dicular to the crankshaft.

9) Reinstall the cam sprocket.

install the cam sprocket after completing

the valve timing. (Fig. 46)

(Valve timing procedure)

a. Align the "T" mark on the crankshaft
to the top—dead—center position.

b. Make the chain taut and install the
cam sprocket with the mounting holes
at the top.

c. Mount the sprocket with the two bolts.

l9

. l0) Reinstall the breaker point base assembly
using the oil seal guide.
ll) Reinstall the spark advance. (Fig. 47)
12) Reinstall the contact breaker assembly.
l3) Install the point cover.

 

 

. Fig. 47 Advance Insullation
(1’ Pin VD Pinhole

 

 

 

 

. Fig, 48 ’3 Cylinder m Cylinder had (3 Dowel pins 0 0 ring

20
4. VALVE REMOVAL

A. Disassembly
I) Remove the cylinder head in accordance
with section 3. A.
2) Compress valve spring with a valve lifter
and remove valve cotter and valve spring.
The valve can then be removed. (Fig. 49)

 

removal

Fig. 49 Valve
1* Valve spring compressor (Tool No. 070114070”

B. Inspection

1) Valve stem clearance is measured by rais-
ing the valve ofl‘ its seat and measuring the
amount of side play by applying the dial
gauge against the valve head.
The play is measured along both the X
and Y axes. (Fig. 50)
Exhaust valve with a TIR of greater than
0.08 mm (0.0032 in.) or inlet valve with
TIR greater than 0.| mm (0.004 in.) should
have either the valve or guide replaced.

  

.e‘ ‘\

Fig. 50 Valve stem clearance masnrernent

 

 

 

 

 

 

 

' v
’1‘ Damn” Q m: Item Standard value Serviceable limit
Valve ‘lN 5.45075.465mm 5.420mm min.
stem (0.2145A0.2l50in.) (0.2I30 in.)
diameter 5.4304 5.445mm 5.400mm min.)
; (0.2l38—0.2I46 in.) (0.2!26 in.)

 

2) Valve guide replacement
Remove and reinstall valve guide using a
valve guide driver (special tool No. 07046-
2|60l). Use an oversize replacement valve
guide. After replacingthe valve guide. run
a reamer through the valve guide to assure
that the guide will be of standard diameter.
l-l ~L5mml0-043~0-°59in-) 3) Valve face dimensional check
Apply thin coating of red lead or bluing
on the valve face. press valve against the
valve seat and rotate. Remove and check
to see ifthere is a uniform width impression
of the valve face. (Fig. 51)

 

 

 

 

 

 

 

Item Standard value Servictalrle limit
Valve seat 0.7mm LSmm max.
width I (0.028 in.) (0.059 in.)

 

 

 

 

Fig. St Valve face

2!

 

If there is uneven contact, the valve seat
should be cut by first using the valve seat
interior cutter followed by the top cutter
and then finished with the 90° seat cutter.
(Fig. 52)

4) Valve lapping
Finally, lap the valve into the seat using a
fine valve grinding compound. A uniform
lap ring on the face of the valve indicates
a good seating.

5) Valve spring

 

 

 

Item Standard value Serviceahle limit
40.4mm 39.0mm
83$ 0”" (1.591 in.) (1.535 in. min.)
SLlw Inner 35.7mm 34.5mm
Free (1.406in.) (1.358 in. min.)

 

'thh 403mm 39.5mm
C312” 0““ (1.610 in.) (1.555 in. min.)

 

 

 

 

 

 

 

CDIZSS
33.5mm 32.0mm
5”” “In" (1.3l8in.) (1-259‘m- min-l
C. Reassembly

1) Clean all parts with solvent or kerosene
and perform the reassembly in the reverse
order of diassembly.

2) Reassemble the cylinder head in accord-
anoe with paragraph 3.C.

  

Fig. 52 Valve seat dressing
a) Valve yea! 90' cutter (Tool No. 07001—10101)

 

 

 

 

 

_ 53 Camshaft ® Inlet valve 0 Exhaul valve 0 0 ring 0 Valve guide Valvesurn seal Valve omen rin
m 8 Valve inner spring 0 Valve spring retainer 0 Valve cotter 0 Valve rows-nu 0 Valve rochoeramshan p '

 

 

 

 

 

 

C3100. CLIW. SLIM / CRIN, CDIISS. SLIZSS

Fig, 54 0) Oil pump gar cover (2 Oil pump body G) Oil
pump plate (D Oil rump drive our Primary
drive [ear @ Oil fi ler complete m il filter rotor
cap (3 lamm lock nut @ on pump ,mn

OPinionneu

5. OIL PUMP AND OIL FILTER

The oil pump is a trochoid type driven from
the primary drive gear through the oil pump
drive gear and supplies oil to all the rotating
components.

The oil filter is mounted directly on the
crankshaft. The impurities in the oil, due
to its heavier weight, are deposited along the
rib of the oil filter cap by centrifugal force
and only the purified oil is allowed to be
supplied to the various components of the
engine.

Discharge volume. .2.4 [per min./l0.000RPM

Lubricating system

The oil in the crankcase is picked up by the
oil pump and pressure fed through the right
crankcase where it is diverted into two routes.
In one direction, it is routed through the

“ passage in the right crankcase cover, oil filter

and to the crankshaft. The other direction, the
oil is routed through the passage in the
cylinder head stud, to the cylinder head and
then to the camshafts and rocker arms.
From the right crankcase,the oil is also sup-
plied under pressure to the transmission.

 

 

 

 

Fig. 55 Lubdutlon system
0) Oil filter Q Oil pump

 

A. Disassembly
l) Remove the right crankcase cover.

2) Remove the oil filter rotor cover.
3) Unscrew the 6mm lock nut and remove the

oil filter rotor. (Fig. 56)

4) Remove the oil pump gear cover.
5) (CBlZSS, CDIZSS, SL125)
Remove the tachometer pinion gear.

6) Remove the oil pump drive gear. (Fig. S7)

7) Unscrew two 6mm oil pump body mount-
ing bolts and then remove the pump body.
(Fig. 58)

8) Pull out the oil pump shaft, loosen two
4mm pump outer rotor mounting screws
and then remove the outer rotor. (Fig. 59)

 

Fig. 56 Lock nut removal
‘1: lfimm. T-hnndle be: wrench (Tool No. 07086-1830!)
r2 Oil filler

  
  

 

Fig. 57 Oil pump drive gear removal
(1,: Oil pump drive gear L2 Shall

,1 .- .‘

 

Fig. 58 Oil pump body removal
(D 6mm bolts a Oil pump body

 

Fig. 59 Oil pump disassembly

(1) 4mm screws

 

 

t1) I6mm lock nut

B. Reassembly
l) Perform the reassembly in the reverse
order of disassembly. Align the concave
part on the oil pump to the convex part
on the oil pump plate and install (Fig. 60)

2) Reinstall the oil pump body.
Note:
Do not forget to assemble two 2.4 x9.4 “0"

rings. (Fig. 6l)

3) Align oil pump shaft to the cutout on the
inner rotor gear and then assemble. (Fig. 62)
(CBHSS, CDlZSS. SL125)
Assemble the tachometer pinion gear.

4) Assemble the oil pump drive gears and
install the pump gear cover with the 5mm
mounting bolts.

5) Mount the oil filter rotor with the l6mm
lock nut. (Fig. 63)
Torque to 4.0—5.0 kg-m (29—36 ft-lbs).
Note:
Do not forget to install the lock washer.
6) Reinstall the right crankcase cover.

 

. 6. CLUTCH

The clutch is a multi-disc, wet type. The friction disc is bounded to heat dissipating center

plate.
The clutch consists of five cork molded disc plates, four clutch plates and four clutch
springs which are all assembed within the clutch outer.

 

 

 

 

 

Fig. 64 m CIuKEh outercomplel: l2 Clutch center ® Friction dis: @ Clutch plate 6} Clutch pressure plate ‘5) Clutch mm plate
Q Clutch liner guide pin '5) Clutch spring

. A. Disassembly

1) Remove the right crankcase cover and the
oil filter rotor in accordance with section

5.A.
2) Remove four 6mm bolts and remove the

. clutch lifter plate. (Fig. 65)

 

. 65 Clutch removal
Fig (1) 6mm. bolts

26

3) Unfasten the 20mm set ring and remove
the clutch center together with the friction
disc. (Fig. 66)

4) Remove the 20mm spline washer and then
remove the clutch outer assembly.

 

Fig. 66 Clutch outer removal
(1) Special pliers Q 20mm set ring ® Clutch center

B. Inspection
I) Clutch friction disc (Fig. 67)

 

Item Standard value Servieeable limit

 

Thickness 2.9mm (0.]l4in.) 26mm (0.I02 in.)

 

 

 

 

 

Replace the friction disc if beyond the
serviceable limit.
2) Replace the worn or damaged clutch plate.

 

C. Reassemhly
I) install the clutch outer assembly and pres-
sure plate. (Fig. 68)
2) Install the 20mm splined washer. (Fig. 68)

   

 

Fig. 68 Spline washer installation
(I) 20 mm spline washer (2 Clutch outer

    

3) Assemble the friction discs and clutch plates
alternately on the clutch center. Assemble
the clutch plates and make the assembly
after aligning the splines. (Fig. 69)

Note:

First, align the spline to the main shaft and then

align the clutch outer spline while rotating the

friction disc.

' (t s. “h .
Fig. 69 Clutch installation
G) Clutch center (2 Clutch friction disc 0 Spline-

 

 

4) Install the 20mm set ring.

5) Assemble the clutch spring and install
with the 6mm mounting bolts.
Torque to 0.8—].2kg—m (5.8—8.7 ft-lbs).

Note:

Do not forget to install the clutch lifter guide

pin. (Fig. 70)

6) Assemble the oil filter rotor. and install
the right crankcase cover in accordance
with section 5.0

 

7. GEAR SHIFT MECHANISM
The gear shift mechanism consists of gear shift plate, gear shift drum, three gear shift forks,

gear shift cam and the gear shift drum stopper bar. When the gear shift pedal is depressed,
the gear shift cam drum rotates to perform the gear shifting. Also, a feature is incorporated

into the system to prevent gear jumping during shifting.

 

 

 

 

 

Fig. 7] ‘1 Gear shift plate 2, Gear shin cam '31 Gear shift spindle Q Gear shill drum *5 Gear shirt fork

A. Disassembly

l) Remove the right crankcase cover and
oil filter rotor in accordance with para-
graph SA.

2) Remove the clutch in accordance with
section 6.A.

3) By removing the circlip. the spring and
gear shift plate can be disassembled.
(Fig. 72)

 

Fig. 72 Circlip removal
0 Special pliers ® Circlip

4) Unscrew the 6mm gear shift drum stopper
bolt and remove the drum stopper. (Fig. 73)

5) Unscrew the 6mm gear shift cam bolt and
remove the shiftcam. (Fig. 73)

6) Remove the gear shift pedal and then pull
out the gear shift spindle. (Fig. 73)

  
 
  

mm, T-Iundle box wrench (2 Gear shill drum
® Gear shift cum 0 Gear shift spindle

B. Reassembly
l) Assemble the gear shift cam so that the
cam pin is inserted into the hole in the
drum. (Fig. 74)

2) Assemble the gear shift assembly. (Fig. 75)

Fig. 74 Pin alignment _ NOW:
m cm ”i" ‘2’ P'" m" Install gear shift return spring so that the
' ' ' end of the spring is hooked to the boss on the

case.

3) Install the gear shift drum stopper.

4) Install gear shift plate, assemble the
spring and set into the case with the
circlip.

5) Install the clutch in accordance with
section 6.0

6) Install the oil filter rotor and the right
crankcase cover in accordance with sec-
tion 5.8.

 

Fig. 75 Spindle Installation
CD Boss (2 Return Ipn'nl

2!)

 

 

. 8. CAM CHAIN TENSIONER AND A.C.
GENERATOR

A friction plate cam chain tensioner is
utilized. and a plate spring supports the‘
entire one side of the cam chain to control

. the slack in the chain, A chain guide is
mounted on the opposite side to reduce the
chain noise for a quiet operation. (Fig. 76)
The description of the AC. generator is
found in the electrical system section.

 

 

 

 

Fig. 76 Cam chain tensioner I2 Adjusting bolt
Cam chain guide

. A. Disassembly

I) Loosen four screws and remove the left
crankcase cover.

2) Remove generator mounting bolts and
remove the rotor assembly. (Fig. 77)

3) Loosen three 6mm A.C. generator mount-
ing screws and remove the generator.

4) Remove the cam chain adjuster nut.
(Fig. 78)

5) By removing the tensioner pivot bolt. the
cam chain tensnoner and the cam chain Fig. 77 Row removal

tensioner arm can be disassembled. r1] Dynamo rotor puller (Tool No.070II-0300H
«z Dynamo rotor

. (Fig. 78)
6) By removing the tensioner arm and push
rod. the tensioner adjusting bolt can be
pulled out. (Fig. 78)

 

Fig. 78 (D Boll (2 Cam chain tensioner arm

. a: Adjusting bolt

B. Reassembly

l) Install tensioner adjusting bolt from the
outside of the case, install the case, and
then install the tensioner arm rubber.

2) Assemble cam chain tensioner on the
tensioner arm pin, hook the spring on the
arm. and then install the tensioner arm
adjusting bolt. (Fig. 79)

Note:

To simplify workbook the spring only on

the tensioner arm and leave the other end

Fi . 79 Cam chain tensioner installation
8 I‘ll Spring (2 S<rewdrivcr « unattached.

‘vv

 

3) Install the rotor assembly.
Torque to 2.6—3.2 kg-m (19.0—23.0 ft-lbs).

4) Mount the A.C. generator. First install the
cord grommet, mount the generator, and
then align the screw mounting holes.
(Fig. 80)

Note:

Do not forget to install the 70 X 2.4 “0” ring

5) Install the left crankcase cover.

    

 

    

,, ‘ ‘7 _ . .7 ‘ ,
Fig. so Generator installation
(I) Stator (2 Card grommet ® 0 ring

 

9. CRANKSHAFI‘

 

   
   

   

 

 

 

Pg, 8] (D Connecting rod (2 Crank shah Q 6305 ball barin; G) Tunrnin: sprocket is; Crank pin 0 Retainer Q Key

31

 

A. Disassembly

I) Remove the cylinder head and cylinder
in accordance with section 3.A.

2) Remove the right crankcase cover. oil
filter and the oil pump in accordance
with section 5.A.

3) Remove the clutch in accordance with

  
  
  

section 6.A.
4) Remove the gear shift in accordance with

section 7.A. ,
5 v .C. o ‘n '
) Remo e the A general ri accordance Fig. 82 Cmnkmse disassembly

with section 8.A. 1i L.cr:nkcase '2 Kernnkens:

6) Remove the drive sprocket and unscrew " " '
eleven 6mm crankcase mounting bolts
(one screw on the inside is mounted on the
right crankcase). tap the crankcase with
a wooden hammer and separate the crank-
case. (Fig. 82)

7) Support the right crankcase lightly and
then gently tap the crankshaft on the right
side to loosen and then separate it from
the case. (Fig. 83)

 

Fig. 83 Crankshaft disassembly
lll Crankshafl

B. Inspection
1) Measure the runout of the crankshaft.
Support the crankshaft at bearing with V
block. and check the amount of runout
using a dial gauge. (Fig. 84)

 

 

 

 

 

Item Standard value Serviceable limit
$2)???“ 0.03mtfl ‘ 0.lmm_
left side 1 10-00l In.) (0004 .n.)

 

Replace if beyond the serviceable limit.

 

Fig. 84 Crankshaft runout measurement
Il- Dial gauge (2 V block

2) Check the clearance of the connecting rod
large end. (Fig. 85)

 

 

 

Item ' Standard value Servimble limit
Side 0~0.0lmm 0.05mm
clearance (0~0.0004 in.) (0.“)20 in.)
Vertical 0.l0~0.35mm 0.8mm
clearance (0.004~0.0l4 in.) (0.0032 in.)

 

 

 

 

 

Replace if beyond the serviceable limit.

~ "v . .
Fig. 85 Connecting rod large end clearance measure-

ment
'1) Thickness gauze

32

C. Reassembly

I) Assemble the crankshaft into the right
crankcase.

Note:

Fit the crankshaft gently into the case. Forcibly

handling or hammering may cause damage to

ball bearings.

2) Install the left crankcase with the 6mm
attaching screws. (Fig. 86)

Note:

Exercise care not to cause the packing to

“3' 86 gnsfrtflffu'jghmins shift or forget to install the two dowel pins.

  

10. TRANSMISSION AND PRIMARY KICK STARTER

The motorcycle of six mOdels utilizesa five speed transmission. Since it incorporates a
primary kick, the engine can be started with the gears engaged by disengaging the clutch.
The kick gear will directly engage the crankshaft through the primary driven gear which

rotates freely on the main shaft.

 

 

 

 

 

Fig. 8‘] (1) Kick gear 12 Primary starter idle near 0 Cnnkshnfl

 

A. Disassembly
l) Remove the cylinder head and cylinder
in accordance with section 3.A.
2) Remove the right crankcase cover, oil

 

. filter and the oil pump in accordance with
section S.A.
3) Remove the clutch in accordance with
section 6.A.
4) Remove the gear shift in accordance with
7.A.
. 5) Remove the A.C. generator in accordance _ "
with section 8.A. fig' 88 gmfl'fl’fmfif "”0““

6) Separate the case in accordance with

section 9-A- we)

7) Remove the kick starter spindle. D-\

8) Remove the main shaft, counter shaft ‘ I_©©
and shift drum all at the same time. ,

9) The shift fork can be removed by extract-
ing the shift fork guide shaft.

IO) The kick gear can be removed together
with the kick spindle and spring by
extracting the circlip.

. Fig. 89 CI: R. shin. fork t2) Cenler shift fork G L. shift fork

 

8) Shin fork guide shaft 61 4x [0 roller ® Spring

 

 

 

 

 

. 90 Kid: starter Ipindle 9 Counter shall 0 Main than Gear shift fork Bide shall L hill 1' I: Cent: hm f k
. “8 8 R.lhiflf0fk O Prim-rysurtgr m1 9 Gen shin drug a Q ’ or ® r ‘ or

' .V- . . B. Remembly
l) Assemble right gear shift fork on the
gear shift fork guide shaft. (Fig. 9|)

Note:
When installing the spring and 4x10 rollers

on the guide shaft, use a thin screwdriver or
other pointed tool to make the installation.

    
  
  

/‘ ,\ V. :1.'7
’65:}-.. .. “A

Fig. 9| at Shirt fork guide shaft ‘2 Lshin fork .5 4x10
roller 11' Screwdriver

2) Assemble the kick starter spindle into the
right crankcase. (Fig. 92)

Note:

Insert one end of spring into the hole in the

case and then hook the other end on the boss

in the ease.

 

'k In

Fig. 92 Kick starter installation
(D Hole (2 Spring (1!, Kick starter spindle

3) Subassemble the main shaft and counter-
shaft, and then assemble the subassembly
into the case. (Fig.93)

4) Install the gear shift drum

Note: .

lf neutral switch rotor is positioned in the

direction of the cylinder installatiom the instal-

lation of gear shift fork will be simplified.

 

5) Assemble the right shift fork into the
counter shaft top gear, raise the seas and
then assemble guide pin into guide groove

fi- . ' " 7 i on the drum. (Fig. 94)

 

t; 1:“ >
Fig. 94 Q R-shlfl fork

 

6) Install the center shift fork in the same
manner. (Fig. 95)

Note:

Perform installation from the counter shaft

end.

. 7) Install the left gear shift fork. align the
holes in the three shift forks and then
insert the shaft in from the top.

8) Install the crankshaft.

9) When installing the left crankcase. make

. sure that the kick spindle shaft is per-
pendicular to the hole in the left crankcase.
(Fig. 96)

ll. CARBURE’I‘OR
Float level adjustment

I) Set the carburetor on its side.

2) Raise the float lightly with the finger tip
and locate the position of the float where
the float arm and the float valve are either
barely touching or provided with a clear-
ance of OJ mm (0.003 in.)

3) In this position. the height of the float
above the carburetor body should be 24

. mm (0.826 in.) when measured at the side
of the float. If adjustment is necessary.
carefully bend the float arm. (Fig. 97)

 

Fig. 97 (1) Fuel level gauge

‘Il‘ihl‘le

.~,,‘a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F“ _ 93 (D Coll spring L2 anottle valve 3 Needle eli late
‘8 to O ring . 6 Bar clip Jet needle Q Nets; jet
(3 Needle )et holder (9 ,F oat Main n! 0 Float
chamber body 0 Arm pm 0 alve. seat 4) Slow jet
[5 float chamber washer em); 0 Cap 13 Top

wuher 0 Top 0 Cable adj 0 Rubber no

CARBURETOR SETTING TABLE

 

 

 

 

 

 

Item C3100. cuoo, SL100 CBIZSS, CDIZSS. SLIISS
Main jet 9 [to #105
Air jet 8 100
Nwdle jet 2.6¢x3.8¢ length 10
Needle jet holder 10¢

 

Jet needle

2°30”x 3 step 1495:»

2°30” XS step 2.495.?

 

Air screw

”/2: 1/8

 

Throttle valve

{2.5 cutaway width [.2

32.5 cutaway width 1.8

 

 

 

 

 

depth 0.2 depth 0.2
l 0.84? x 2
Slow jet 5 38 2 0.8¢x2 8 38 0.9¢x2 x4
3 03¢ x 2
Fuel level 24mm (0.9449 in.)

 

 

IV. BHASSIS 3.,

. l. FRONT BRAKE AND FRONT WHEEL

 

 

 

 

 

' - 0 Fm“ “M“ we <29 From when“: coll-r a 2le7x7 oil seal 6) 630m ball bearin F u wh n. b F
[“8 99 axle distance collar Q Brake shoe 8 Front brake am :3) Fronl brake Dune] 60 From bfiak?":fl ee u 6) root

A. Disassembly

1) Place an appropriate stand under the
engine.

2) Disconnect the front brake cable.

3) Disconnect the speedometer cable.

4) Remove front wheel axle nut. extract
the front wheel axle and then drop the
wheel (Fig. l00)

5) Remove the brake arm. unhook the two
brake shoe springs and then disassemble

the brake shoes from the brake panel. '- * '
Fig. 100 Front wheel removal

. (Fig. IOI) a) Front wheel mo
6) Remove the oil seal, the two ball bearings

($63OIR), and then pull out the front
axle distance collar.

  

 

. Fig. 101 Brake shoe removal
0 Brake shoe

38

 

 

 

 

 

 

 

 

 

Fig. 102 Rim nmout measurement

 

Fig. 104 Spoke retightening

8. Inspection

l) Check for bend in the front axle.
2) Check for worn bearing (#630l R).
3) Check rim runout using a dial gauge.

 

 

(Fig. 102)
Item Standard value Serviceanle limit
' 0.5mm Max. 3.0mm
5"“ “'"°“‘ (0.020 in.) Max. (snow

 

 

 

 

 

True the wheel rim by tightening the
spokes if beyond the serviceable limit.
lf damaged or excessively bent, replace
with new one.
4) Check wear of brake drum using a caliper.

 

 

(Fig. 103)
Item Standard value Serviceable limit
Inside diameter IO9.8~ l l0.2mm ll2mm‘
of drum (43229-43385 in.) (4.4094 in.)

 

 

 

 

 

Replace il‘ beyond the serviceable limit.
5) Check wear of brake lining.

 

 

 

 

 

 

ltem Standard value Serviceable limit
Lining 3.9~4.Imm 2mm .
thickness (0.1535—0J6I4 in.) 0.07874 In.)

 

Replace if beyond the serviceable limit.

6) Check spokes for damage, bent and loosen-
ing. Tighten the loose spokes, straghten
the bent spokes and replace the broken
spokes with new one. (Fig. 104)

7) Check brake panel for buckling and other
damages. If damaged, replace with new
one.

8) Check speedometer gears for wear. If
worn, replace with new one.

9) Check oil seal for damage, buckling and
wear. If worn or damaged, replace with
new one.

l0) Check both the exterior and interior of tire
for damage, and imbedding of wire and
nails. If worn or damaged, replace with
new one. When replacing the tire, fit a new
inner tube together. Measure tire pressure
with pressure gauge. Correct tire pressure
is 1.8 kg/cm’ (26 psi) for front.

ll) Check for air leaks around the valve stem
and tube. If leaking, repair or replace
with new one.

 

. ' “9

C. Reassembly
I) lnflate the tube with small amount of air
and install the tire on the rim by forcing
the bead of the tire on the inside of the

. rim (Fig. [05)

Note:

- After the tire has been assembled. inflate
with air to about 1/3 the specified pressure
and then tap the tire all around with a wooden

. hammer to relieve pinching of folds in the
tube.

- After assuring that the valve stem is in
alignment with the wheel axle, tighten the
stern lock nut, being careful not to cause leak
around the stem.

2) Apply grease to the wheel ball bearings
(f. 63OIR) and the inside of the wheel hub.
Assemble distance collar and ball bearings

into the wheel hub.

Note:

The ball bearings are equipped with a dust

seal, therefore, make sure that it is imtalled

. in the proper direction.
(Fig. 106)

3) Assemble the brake cam into the front
brake panel, hook the brake shoe springs
on to the brake shoes and then assemble
the brake shoes on the brake panel.

4) Install the brake arm.

5) Assemble the brake panel on the front
wheel. Align the recessed section of the
panel to the protruding section of the front
fork. Assemble the oil seal and side collar
on the side of the bearing retainer and then .._ _

. mount it on the front axle with a nut. Fig' 107 gfifieflfiflfir’flfiffi‘mmnut
(Fig. l07)

6) Connect the speedometer cable.

7) Connect the front brake cable to the brake
arm and adjust the play in the brake lever.

 

 

. Fig. 108 Brake lever phy
(I) Adjuster nut @ Lock nut

M)

2. REAR BRAKE AND REAR WHEEL

 

 

 

 

 

 

fig 109 (1;) Rar brake um ? Rear brake pannel ® Brake shoe ® Rear wheel hub 6 Rear wheel axle 6 Rent ule distance
' coll-r m Rear whee lire ® Final driven sprocket 13 llmrn (ensued Washer 19 58 mm circlip 0 6302!! ball hearing

A. Disassembly

l) Place an appropriate stand under the
engine. »

2) Remove the rear brake rod.

3) Unfasten the drive.chain link and dis-
connect the chain.

(Fig. ”0)

4) Remove the rear brake arm bolt and then
remove the rear brake arm from the brake
panel.

’ , 5) Loosen the nut from the rear axle and
Fig' "0 Dri'e chain mmmb'y remove the rear axle.

(It Drive Chlill link
6) Remove the rear wheel. (Fig. HI)

7) Disassemble the brake panel from the
wheel hub.

Remove the brake arm from the panel. pull
out the brake cam, disconnect the spring
and then remove the brake shoes.

8) Straighten the tongued washer on the final
driven sprocket, loosen the four mounting
bolts. unfasten the circlips and then remove
the final driven sprocket.

 

 

Fig. 111 Rear wheel removal

41

 

9) Remove the oil seal. ball bearings (see
below). and the distance collar from the
rear wheel hub.

Ball bearings
C8100, CD100 #62021! and 6302R one
CBIZSS, CDIZSS each
SL100, SL125 #6302R two each
3. Inspection

1) Check for bend in the rear axle.

2) Check bearing for wear.

3) Check rim runout using a dial gauge.

 

 

Item Standard value Serviceuble limit
Side 0.5mm max. -
runout “10'” in.) max. 3.0mm (0.1181 In.)

 

 

 

 

 

True the wheel rim by tightening the spokes
if beyond the serviceable limit. If damaged
or excessively bent, replace with new one.
4) Check wear of brake drum using a caliper.

 

 

 

 

 

(Fig. ”2)
Item Standard val: Savleahle Ill-1t

C8100
CL100 109.8~110.2mm

pru‘nei gBDlIZZSSSS (4.322943385in)

ins:

diameter (41min )
SL100 110.0—110.3mm ' '
SL125 [01.330743425)

 

 

 

 

Replace if beyond the serviceable limit.
5) Check wear of brake lining. (Fig. 113)

 

 

Item Standard value Serviceable limit
Lining 3.9-4. l mm 2mm
[hickness (0.l535~0.1614 in.) (0.0787 in.)

 

 

 

 

 

Replace if beyond the serviceable limit.

6) Check the spokes for damage, bent and
loosening. Tighten the loose spokes,
straghten the bent spokes and replace
the broken spokes with new one. (Fig. ”4)

7) Check the brake panel for buckling and
other damages. If damaged, replace with
new one.

8) Check the oil seal for damage, buckling
and wear. 1f worn or damaged, replace
with new one.

9) Check the tire for damage, and imbedding
of wire and nails on both the exterior and
interior. [1‘ worn or damaged. replace with
new one. The tire pressure should be 2.0
kg/m' (28 psi).

10) Check for air leaks around the valve stem
and tube. 11‘ leaking, repair or replace with
new one.

 

    

Fig. 115 Ball bearings installation
(1) Bill bearing drive:

42

  
  

/

Fig. 116 Mm] driven sprocket ammbly
(11 Final driven sprocket

 

Fig. “7 Brake stopper arm installation
(1] Brake stopper arm

 

Fig. "8 Drive chain adjustment

(1! Index marl: and side scale

(2 Adjuster nut

     
 

A31 Drive chain link

  
 
  

 

  

\ ‘0' ~ 5
Fig. 119 Chain slack and‘hrake pedal play

C. Reassemhly .
l) lnflate the tube with a small amount of air

and install the tire on the rim by forcing
the bead of the tire on the inside of rim.

Note:

- After the tire has been assembled, inflate
with air to about 1/3 the specified pressure
and then tap tire all around with a wooden
hammer to relieve any pinching or folds in
the tube.

- After assuring that the valve stem is in
alignment with wheel axle, tighten stern
lock nut being careful not to cause leaks
around the stem.

2) Apply grease to the wheel ball bearings
and the inside of the wheel hub.
Assemble distance collar and ball bearings
into the wheel hub. (Fig. “5)

3) Mount the final drive sprocket on the
rear wheel hub, install the tongued washers,
and nuts. After torquing the nuts, bend the
tab on tongued washer to lock it. Finally.
install the circlip. (Fig. llé)

4) Mount the brake panel assembly on the
rear wheel hub.

S) Assemble the right and left side collars on
each side of oil seal and then install rear
wheel on the rear fork with the axle.

6) Mount the rear brake stopper arm on the
rear brake panel. (Fig. 117)

7) Install and connect drive chain, and after
completing the-adjustment. tighten the
rear axle nut. Chain should be adjusted so

that there is 1-2 cm (2/5—3/4 in) slack in

the chain (Fig. 119).
Note:

The chain joint link must be installed so that
the cutout is pointing in the opposite direction
to the direction of rotation. When chain is
finally adjusted, the chain adjuster indicator
on both right and left side: should be at in-
dentical locations. (Fig. “8)
8) Connect rear brake rod to the brake arm
and then make brake adjustments.
Note:
The play in the brake pedal should be 2—3 cm
(1/4—1-1/8 in.)_ (Fig. "9).

43

 

3. STEERING UNIT
A. Disassembly

l) Disconnect the front brake cable from
brake lever.

2) Disconnect the clutch cable at the handle
clutch lever. (Fig. 120)

3) (SL100, SL125 USA. Type)
Remove the combination headlight control
and emergency switch by unscrewing two
mounting screws. (Fig. I21).

4) Disconnect the throttle cable from the
throttle grip.

5) Remove the headlight and disconnect the
wire harness in the headlight case. (Fig. 121)

6) Loosen four 6mm bots and remove the
handle bar upper holder and handle bar.
(Fig. [22)

7) Remove the front wheel in accordance
with section LA.

8) Remove the headlight case and front
fender.

9) (C8100, CL100, CBIZSS, CDlZSS)
Remove the fork bolt, loosen the steering
stem mounting bolt, and then drop front
fork out the bottom.

(SL100, SL125)

Remove four fork top and bottom bridge
mounting bolts and drop front fork out
the bottom.

l0) Loosen the steering stem nut and remove
the fork top bridge. (Fig. l23)

 

Fig. 120 Clutch cable removal
(I; Gulch cable

Fig: 121 Emergency switch removal

(D Mounting screws :2 Wire harness

l

.L

Fig. 122 Handle bar removal
:I‘ 6 mm bolts :2 Handle but upper holder

1

Fig. 12.} Pork top bridge removal
(D Fork lop bridge L2 Steering stern nut

(.4 r . { - &

  
    

 

 

Fig. 114 Steering stem removal
(D Steering stem

B. Inspection

I) Check the condition of both inner cable
and easing of the control cables for opera-
tion, action and damages. If the cable
does not move smoothly, apply grease or
replace with new one. If the outer cable
is damaged, repair with the plastic tape or
replace with new one.

2) Check the operation of the throttle grip.
If the throttle grip does not move smoothly,
apply grease to the throttle hinge. If worn,
replace with new one.

3) Check the condition of the handle bar for
bend and twist. If bent or twisted, straight-
en or replace with new one.

4) Inspect the steel balls for wear and cracks.
lf worn or damaged, replace with new one.

5) Inspect the steering top cone, bottom cone,
and the other ball races for galling and
wear condition. If worn, replace the cones,
races and steel ball together.

6) Inspect the steering head dust seal for wear
and damage. If worn or damaged, replace
with new one.

7) Check the steering stem for bend and twist.
lf slightly bent or twisted, repair with the
press. If badly bent or twisted, replace
with new one.

8) Inspect the threads for damage and de-
formation. lf damaged, replace with new
one.

9) Check the action of the handle lock return
spring. If it does not work properly,
replace with new one.

ll) Loosen the steering head top nut and then
drop steering stem out the bottom.
(Fig. l24)

When removing steering stern. exercise
care not to drop and lose the steel balls
(2| pcs. each).

l2) Remove the two 6mm bolts and separate
handle lock from steering stern. Insert
engine key into the lock. turn counter
clockwise and remove the lock piston.

C. Reassembly

1) Mount the handle lock on the steering
stem.

2) Apply grease on the ball races and on it
set the steel balls, Insert the steering stern
into steering head and assemble the top
cone race and head top nut.

Note:

- Wash the cone race. ball race and steel
balls, and apply new grease on the friction
surfaces. When assembling parts, exercise
care not to drop the steel balls.

 

. To. adjust the head to top nut, first assemble
the fork top bridge. front fork, headlight
case, front fender and the front wheel in
that order; tighten top nut so that the steer-
ing handle is neither too tight nor too loose
when it is moved fully to the right and left.

3) Install the fork top bridge. front fork and
wheel.

4) Reconnect the throttle. clutch and front
brake cables.

5) Route the wire harnesses and control
cables through their respective positions
and then install the steering handle.

Note:

Check to make sure that the harnesses and

cables are not binding when the steering

handle is moved fully to both sides.

6) Reconnect all wire harnesses.

7) Adjust the play in all the cables. (Fig. l25,
126)

Throttle cable
(twist grip to full travel) 90°—100°
(play) 10°— 15°
Front brake cable (at end of lever)
2—3 cm (3/4—1- 1/8 in.)
Clutch cable (at end of lever)
1—2 cm (2/5—3/4 in.)
4. FRONT SUSPENSION

   
  

Jonah 1 Kin.)

Fig. 125 Brake cable play adjustment
:1) Adjuster nut (2‘ Lock nut

l~20rn

 

Fig. 126 Clutch cable play adjustment
0) Lock nut (2 Adjuster nut

 

 

(C3100, CBIZSS)
G)

  

 

 

 

 

 

Fig. 127 C3100, CLIOO

 

9 Front fork bolt (2 Front fork upper cover <3 Fork cover lower seal packing a: Fork cover lower seat 6‘ Front
0

rk under cover (CBlOO). Front fork boot (CLlOO) 0 Front fork sprin

guide (2) Front fork spring ® Front fork pipe

Q) 37 mm circlip (9 Front fork oil ml 0 Front fork pipe guide a) i‘ront fork piston 13 Front fork bottom pipe

46

 

© (1D A. Construction
It is of a telescopic design with bottom case

made of alluminium alloy to reduce unspring
weight. The long stroke provides good sta-
bility and handling on rough roads.

The oil damper is filled with SAE low-30.

 

 

 

 

 

 

 

 

 

 

 

 

[ten cum, cams

cuoo 5““ cuius' 5””

222.22 62222 woo-""2 222.2-

mg. m a? 2222: 4222.222“? “earmarzwa'asr <- "M‘- mN- m-H- m

 

up ring Jlx43xl0 oi seal ‘D Front fork plpe
SL100 guide @gront fork spring ® From fork pipe
10 Front fork piston 0 Front fork bottom case

is i  ~» 2/

 
 
  

 

B. Disassembly

I) Remove the front wheel in accordance
with section LA

2) (C3100, CL100, CBlZSS, CDIZSS)
Remove the headlight case, disconnect the
turn signal connector within the case and
remove the turn signal. (Fig. l29)

3) Loosen the headlight case mounting bolts
from both sides and remove the case from
the fork upper case.

4) (C8100, CL100, CBIZSS, CDlZSS)
Unscrew four fender mounting bolts and
remove the fender from the fork.

5) (C8100, CL100, CBIZSS, CDIZSS)
Remove the front fork bolt, loosen the
steering stem fork mounting bolt and
then remove the fork. (Fig. I30)

‘ ‘ (SL100, SL125)

. '3 Loosen the fork top bridge and steering
" r’ 'I stem front fork mounting bolt and then
Front fork removal
(11 Front fork bolt @ Fork mounting bolt remove the fork out the bottom.
' .v‘ 6) Loosen oil drain plug from the bottom

case and drain oil.
7) (C8100, CL100, CBIZSS, CDIZSS)

(D Remove the front fork under cover or
front fork boot, circlip (37 mm dia.),
and then disassemble the fork bottom case.
(Fig. l3l)
(SL100, SL125)
Remove the dust seal, circlip (44mm dirt),
and then disassemble the fork bottom case.

Fig. I29 (I) Turn signal connector

 

  

fig. 131 Circlip removal
(1) Circlip

 

47

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C. lrspection
l) Front fork spring. (Fig. I32)

ltan Standard uh: Sauce-hie limit 7
c3100 184mm 160mm x 5
Cum (7.2440in.) (6299201.) 5 i
z .
48¢me 460mm “‘ 3
Fm SL100 (19.0mm) (l8.ll02in.) .L‘ 1'
length g l
cmzss 205.5mm isomm my
(:01sz (8.0905 in.) (1.0866in.) l
482.3mm 460mm ‘

5“” (18.988! in.) (18.II02 in.) —

Fig. IJZ Spring free length measurement

Replace if beyond the serviceable limit.
2) Wear of front fork piston.

 

Sada-bl:
Iter- Studml value “I“

 

C8100
CLIOO 30.936—30.975mm 30.9mm

CBIZSS (l.2l74-l.2l94in.) (l.2l65in.)
Outside CDIZSS

d‘m‘“ suoo 35.425—35.450mm 35.4mm
suzs 03946-13956 in.) (1.2937 in.)

 

 

 

 

 

 

 

 

Replace if beyond the serviceable limit.

3) Check the front fork oil seal for damage. } r n or D om I, . ' 15°“
Ir damaged. replace with new one- “3' ”3 9:9 552': $1;sz it éfimrfrciifezfilm.

4) Check the front fork pipe and bottom
case for bend or crank. lf badly damaged,
replace with new one.

D. Reassemhly

l) Assemble piston stopper and piston on
the front fork pipe.

2) Fill front fork bottom case with SAE
low-30.

C8100, CL100, CBlZSS, CDIZSS:
130—140ee (4.4-4.7 ozs)
SL100, SL125: l80—l90cc(6.l~6.4on)

3) (C3100! Cle’ CBlzss’ CDIZSS) Flg. '34 fisogrtorfrgrkngfiembg Front fork bottom pipe

Insert the front fork pipe assembly into
the bottom case, install the oil seal and
circlip. and assemble the front fork spring
into the fork pipe so that the end with the
large pitch is at the bottom. (Fig. l34)
(SL100, SL125)
Place the large pitch end of the front fork
spring into the bottom case. insert the front
fork pipe and assemble the oil seal and
circlip.

4) (C3100, CL100, CBIZSS, CDIZSS) .
Attach the front fork upper and lower Fig. l35 Front fork Installation
covers or fork boots. and install the front a Fm" rm °“""

fork as a unit. Tighten the front fork bolt
and mnllntino hnlt A'tm‘h lhe- from fpnrlpr

 

 

 

43 O
(SL100, SL125)
Attach the headlight case stay between
the fork top bridge and steering stem and
install the front fork as a unit.
Tighten the front fork mounting bolts.
5) Install the headlight case. .

5. REAR SUSPENSION

 

C31”. CLIW, (231258, CD158
CD Rear shock absorber
(2 Rear shock absorber upper
case
3 Rear shock absorber upper

seat
Rear shock absorber spring
Rear shock absorber spring
Rude

0 ear shock absorber spring

seat

Q Rear shock absorber under
mt

0 Rear shock absorber bottom
metal

SL100, SL125

0 Rear shock absorber
Q Rear shock absorber spring

seat stopper

0 Rear shock absorber spring
upper seal

8 Rear shock absorber spring

Rear shock absorber spring
End:

6 ear shock absorber spring
adjuster

Q Rear shock absorber end

use
0 Rear shock absorber bottom
metal

   

 

 

 

 

 

l.
Fig. 136 C5100, CL1W. (331158, 012$ SLIM, SL125
A. Disassembly

l) Remove the rear wheel in accordance with
section 2.A.

2) Unscrew the two rear shock absorber
mounting cap nuts and remove the shock .
absorber from the frame and rear fork.

3) Remove the rear shock absorber bottom
metal and then separate the spring and
upper case (Fig. I37)

4) Remove the chain case.

5) Loosen the rear fork pivot nut, extract

 

. 137 R shock absorber disusembl .
Fix wagon”: ml y the rear fork pivot bolt and then remove

the rear fork.

6) Remove the cotter ‘pin and nut and then
remove the rear brake stopper arm from
the rear fork.

~89

 

 

B. Inspection
1) Rear shock absorber spring.
Serviceable
ltu Standard value m .

 

CBlOO
CLlOO 180.9mm 160mm

CBIZSS (7J2!!! in.) (6.2992 in.)
CDIZSS

 

Free length
cuoo l90mm 170mm
SL125 (7.4803 in.) (6.6929 in.)

 

 

 

 

 

 

Replace if beyond the serviceable limit.

2) Check the shock absorber for oil leaks.
If leaks from inside of body. replace the
body with new one.

3) Check the main damper body for damage
or deformation and damper action. If
damaged or shock absorber action is not
satisfactory, replace with new one. The
shock absorber cannot be disassembled
and repaired.

4) Check the shock absorber case and stopper
for damage. Replace if damaged.

5) Clearance between the rear fork pivot
bushing and bolt.

 

Item Standard value Serviceable limit

 

0.1-0.3mm 0.5mm

 

 

 

 

 

 

 

0m“ (coon—om IS in.) (0.0196 in.)

 

Replace if beyond the serviceable limit.

6) Check the pivot shaft for bend or damage.
Straighten the bent shaft and check with
the dial gauge. lf damaged, replace with
new one.

7) Check the rear fork swing arm for bend.
twist and crack. If slightly bent or twisted,
straighten with press and check the swing-
ing arm with the dial gauge. If damaged,
replace with new one.

C. Reassembly
1) Install the rear brake arm stopper on the

rear fork.

2) Insert the grease coated pivot bushing into
the rear fork and install this on frame with
the rear fork pivot bolt. (Fig. I39)

3) Install the chain case on the rear fork,
join the rear shock absorber complete
to the frame and fork, install and tighten
cap nuts.

4) Install the rear wheel.

 

_ Rur fork '2 Rear fork pivot rubber bush
Fig '38 8 Rear fork piv‘ol bolt @ Rear brakestopper arm

    

 

 

Fig. 139 Rear fork assembly
:3 Rear fork (2 Rear fork pivot bolt

 

Fig. 140 Rear shock absorber assembly
0 Bottom metal r2: Sprin guide
9 Shock absorber spring ’4) hock absorber body

Note:
. When assembling the rear shock absorber

complete, the large pitch end of spring goes
toward the top. (Fig. I40)

- After completing imtallation, adjust the
tersion of drive chain and the rear brake.

 

 

6. FRAME BODY

A. Construction
Half frame. half pillar, is made of high
strength press steel sheet. The CBIOO, CLlOO,
CBlZSS and CDIZSS are designed with the
aim for light weight. It utilizes a diamond
frame. The SL100 and SL125 are designed
with a sporty double cradle frame.

B. Disassembly

I) Remove the engine in accordance with
section engine removal and installation.

2) Remove the steering handle in accordance
with section 1A.

3) (C3100, CL100. CBIZSS, CDIZSS)
Detach the sub—carrier and then remove
the seat. (Fig. 143)

(SL100, SL125)
Loosen the seat mounting nuts and re-
move the seat.

4) Position the fuel cock lever to STOP
position, disconnect the fuel tube from

 

 

 

carburetor, and then remove the fuel tank
by pulling toward the rear and slightly up-
ward. Remove the strainer cup. take out
the strainer screen and packing and remove
the mounting screws to detach it from the
fuel tank. (Fig. I43)

 

 

 

Fig. 142 SL100, SL125 Double cradle Inn:

5) Disassemble the air cleaner and tool box.
(Fig. [44)

  

Fig. :43 Seat and fuel rink removal
’1 Sub-carrier mounting bolt

  

F58. I44 Air cleaner nd tool box removal

6) Remove the front wheel and front sus-
pension in accordance with section LA
and 4.8.

7) Remove the rear wheel and rear cushion
in accordance with section 2.A and SA
and then remove the rear fender.

8) Disassemble the electrical system.

9) (C3100, CLIOO, CBIZSS, CDIES)
Extract the cotter pin in the main stand

pivot pipe, pull out the pivot pipe and
remove the stand from the frame. (Fig. 145)
C. Inspection

1) Inspect the welded joints, crack, damage
or twist to the pipe. Straighten the minor
dent or twisting, weld the crack and paint
the worn or scratched parts. Replace
twisted or badly dented frame with new
one.

2) Inspect the top and bottom races for
damage and wear.

Note:

The ball race can be driven out easily by using

a wooden drift from the inside. Exercise care

when installing the race so that it is driven in

straight and to the full depth. (Fig. I46)

3) Check the angle of head pipe and lock for
any damage. If damaged, replace with
new one.

4) Check damage to the seat leather up-
holstery. If damaged, repair or replace
with new one.

5) Check for fuel tank leak. clogged fuel
filler cap vent, damage or deformed cock
valve packing. strainer cup packing and
aging or damage to the fuel tube. Flush
out interior of the tank with clean gaso-
line.

6) Clean the air cleaner element by blowing
off dust with compressed air or wash in
soap water. (Fig. 147)

7) Replace any exhaust pipe gasket which

is damaged.
Check the mufiier for cracks and defor-
mation. If badly damaged, replace with
new one. Remove the carbon from the
diffuser pipe and clean.

8) Check the stand spring for deformation
and damage. If the part has lost tension
or damaged, replace with new one.

Fig. 145 Stand removal
(I) Cotter pin 0 Main stand pivot pip:

Fig. 146 Ball race removal

 

Fig. 147 Air cleaner clement cleaning

5]

  

 

52

 

D. Reassembly

l) (C3100, CL100, CBIZSS, CDIZSS)
Mount the main stand and brake pedal
to the frame together
(SL100, SL125)

Mount the brake pedal on the main stand
pivot pipe.

2) Mount the rear fender on the frame and
install the electrical equipment.

3) Install the rear fork, rear shock absorber,
and rear wheel.

4) Install the steering stem. front fork and
the front wheel.

5) (C3100, CL100, CBIZSS, CDIZSS)
Install the fuel tank, seat and sub—carrier
on the frame.

(SL100, SL125)
Install the fuel tank and seat on the
frame.

6) Mount the engine on the frame.

7) Route the respective control cables, and
wire harnesses through the specified posi-
tions and complete the connections.

Note:

Adjust the brakes, clutch and drive chain

slack and check the steering operation.

V. ELECTRICAL

 

l. GENERATING SYSTEM
The charging system is an A.C. generator
(magnetic single phase A.C. generator) which
consists of the stator and rotor. The AC.
generator is rectified by the selenium rectifier
and is used to charge the battery.

 

 

 

 

Fig. 148 a) Rotor Q Stator

 

 

 

 

 

Fig. 149 :1) LC. nnentor a Selenium rectifier is Battery to Fuse is) Combination switch a; lat-man coil ® Baker points
® Condenser at Lighting switch

A.G. GENERATING SPECIFICATIONS

 

Type & manufacturer Rotary type. Kokusan Denki

 

 

 

or Nippon Denki
Output 6V50W (at 5,0“) rpm in night)
Battery voltage 6V-6A
Changing rpm 500-12900 rpm

 

Polarity of ground 6
weight L45kg (3.20 lbs)

 

 

 

 

 

 

 

 

 

 

 

fi . 150 Chargi t3!
8 (D Red/lame wire harness Q Ammeter

® Voltmeler 0 Battery

2. CHARGING SYSTEM
A. Charging test
I) Use the ammeter-and-voltmeter.
2) Measure the specific gravity of the electro-

olyte in battery. If it is below l.26 (cor-
rected to 20°C.), recharge the battery. Its
normal value is l.28 (corrected to 20°C)
Perform the following test.

3) Disconnect the red/white wire harness

terminal from the ® terminal of the
battery and connect it to the 9 terminal of
the ammeter. Connect the $ terminal of
battery to the 9 terminal of ammeter.
Connect the red/white wire harness to the
(+3 terminal of the voltmeter and ground the
6 terminal of the voltmeter to earth.

4) Start the engine and perform the following

two tests in both the day and night opera-
tion mode. (Fig. 150)

5) Measure the battery voltage and charging

current. If they are less than values shown
in the following table, check or replace
the stator, selenium rectifier, ignition coil
and condenser with new one.

 

 

 

 

 

 

 

Selenium reciifeier 3) Volume meter 6 Ammeter ‘3) Battery 6V—6AH m Ignition

 

 

 

 

 

 

 

 

Fl“ 15' mfg E“??? Q ‘93:“? mm break
co r ' ' '
0 Highberm Pil:llli$l gamiwfligliimieuMuer‘iighP Headlight hifll beam 0 Hudllghl low beam 0 Dimmer switch
Initial charging mun. 5000 um. I
mum «in: Dinner twitch mun. 3.4.3: 23m; Buttery Venue
100m Day OFF OFF 1000 r.p.m. 6.8 V 1.3 A 7.8 V
sen“ NU“ ON HB (high beam) 3500 r.p.m. 6.8 V 1.3 A 7.8 V j
I
0N LB (low beam) 2200 r.p.m. 6.8 V Li! A 7.2 V
1250:: Dry OFF OFF 1000 r.p.m. 6.8 V 1.1 A 7.9 V |
5"“ Night ON i LB (low beam) 2000 r.p.m. 6.3 v 1.3 A . 7.8 v

 

 

 

 

 

 

 

 

 

55

 

. B. Inspection

l) Stator coil test
Perform a continuity test on the three
stator coil harnesses (orange. white, yellow)
with a tester to determine the condition
. ol‘ the coil and also inspect for exterior
damage. Replace with new one if there is
not continuty or damaged. (Fig. l52)

  
    

Note:
Do not test on a metal bench.
2) Selenium rectifier test 7
. . . . F“ . 152 Stator co’l test
. Check the contmunty in the normal direc- lg l1» Slatorcloil

tion and also in the reverse direction by
applying tester lead probes to green and
pink leads, pink and red/white leads.
green and yellow leads, and yellow and
red/white leads respectively and alternate-
ly as shown in the figure. The rectifier
is in good condition if continuity exists
only in one direction. If there is continuity
in both directions or no continuity in
either direction when tested, the rectifier

is defective and should be changed. (Fig. ,
Fig. 153 Selenium rectifier continuity test

. I 53-I 54) r1) Selenium rectifier
@ or @

 

 

e°f®

 

 

 

Fi , l :1) Omen and ink lends P' k (1 rod ' '
g 54 5‘ Tester lends v w in In [white lads ® Green and yellow leads ® Red/wlulc and yellow lend-

. 3. IGNITION SYSTEM
l) Ignition coil test
CD Perform functional test of the ignition
coil to determine its condition. When
poor starting is experienced, the cause
may also be found by testing the spark
. plug. contact breaker points, condenser,
etc.
a) Check the ignition coil using the
service tester.
(3) Connect the battery power source to

the tester and ground the grounding
. lead. (Fig. l56)

 

5@

      

 

 

 

Fi , |55 Secondary coil terminal Ignition cord
3 8 Secondary coil Q) Primary ctgil (5) Body 0 Care

 

 

 

 

  

(fl-0.08 in)

  
  

0.1~0.2mm

(0.004-01D8 in)

 

 

Fig. 157 (1) No.1 electrode <2 No.2 electrode

0 No.1 electrode Q) Spark

 

Fig. 158 Condenser test

m Condenser

 

 

 

 

 

Fig. 159 Battery construction

0 Separator plate (2 Cathode plate 0 Separator
plate 8) Calls: mat is Anode plate

14' Connect the ignition primary cord to
the tester and connect the opposite
terminal end to the primary terminal
of the coil. Connect the white lead
with (M) type plug to the blue terminal
of the ignition coil (primary side) and
the red tester lead to the black terminal
of the ignition coil. (Fig. 156)

(5) Connect the red tester high tension cord
to the high tension cord of the ignition
coil.

(6) Turn the slector knob to the COIL
TEST position.

(D Adjust the three point spark tester to
maintain maximum distance of spark
by turning the control knob while
observing the spark condition and then
measure the spark distance.

(8) If the spark plug distance is less than
6mm (0.24in.), the spark plug is un-
serviceable.

2) Condenser test (Fig. 158)

I) Connect the 6V battery power source
to the tester.

2) Turn the selector knob to the “CON-
DENSER" position.

3) Apply one of the tester lead probes to
the condenser body. and then read the
meter indication. If it measures between
0.21—0.26/1F, the condenser is satis-
factory. Condenser indicating less than
0.2I/1F should be replaced.

4. BATTERY

A. Construction
The construction and name of the component
parts are shown in the figure. The type of
battery having the specifications shown below
is installed in these models. (Fig. 159)

 

 

 

Type 6N6-313
Voltage ! 6V
Capacity 6AH (at 10 hr rate)

 

Changing current 0.6A

Specific gravity of 1260—1180 at 20°C (68°F)
electrolyte (when
fully charged)

 

 

 

 

 

57

 

8. Inspection and Servicing

I) Measure the specific gravity of the bat-
tery electrolyte with a hydrometer and if
it is below |.200 (corrected to 20°C). the
battery should be recharged. The specific
gravity is calibrated on the stem of the
float and the reading is taken at the fluid
level with the float buoyant. (Fig. I60)

 

 

Fig [60 '1‘ Eye level :2 Hydrometer ® Battery electrolyte

 

2) If any cell is found to be below the lower

level mark on the battery case, add dis- g moo
tilled water to bring the level up to the a :%
upper level mark. If the electrolyte eva- g 33
poration rate is unusually great. the 3, .2200
charging system should be checked for not) H23
pOSsible malfunction. If the battery case Hg:
is cracked or damaged. replace with new mac I0 20 30 w so so 70 so so m
one. Residual cap-city
<%)

 

 

 

Fig. 161 Relation between specific gravity of battery
electrolyte and electrlml apathy

 

3) Check the poor battery connection due to
corrosion of the connector and terminal,
flaking of the paste from vibration and
sulfation. The flaked paste remains on
bottom remarkably. replace with new

one. (Fig. 162)

 

 

 

 

 

 

 

 

 

 

 

C. Battery Charging
l) Quick-charge method of charging the

battery will seriously effect the battery
service life. therefore. it is recommended
that this method not be used. When the
rapid charge is required, the battery should
be recharged at a rate of 0.2 AH.

2) During the charging process, hydrogen gas
will be generated. therefore, open flame
should be kept away.

3) After the recharging is completed. the
battery should be washed with water to
remove spilled electrolyte and the ter-
minals coated with grease.

 

 

 

Fig. [62 11‘ Flaked paste r2: Bottom r3; Cathode plate

 

fig. 163 Battery charging
II) Ballery charger

53

 

“"l‘i‘T'I'ELG ”’8’

Rapid charge

 

 

Charging current rate

0.6A H

2.0AH max.

 

Checking for full charge

(I) Specific gravity:
l.260—l.280 (20°C: 6801:) maintained
constant

(2) 0.2AH—~0.6AH

(3) 7.5V--8.3V

(I) Specific gravity:
l.260- I .280 maintained at 20"C(68°F)

(2) Voltage: When large volume of gas
is emitted from the battery (in about
2—3 hours for fully discharged bat-
tery), reduce charging rate to 0.2A.
Battery is fully charged when a volt-
age of 7.5V is maintained.

 

Charging duration

By this method, a battery with specific
gravity of electrolyte below 1.220 at 20°C
(68“F) will be fully charged in approxi-
mately l2-l3 hours.

proximately l-2 hours.

By this method. battery with specific
gravity of electrolyte below l.220 at
20"C (68"F) will be fully charged ap-

 

When the charging is urgent, quick

 

 

 

 

 

Remarks
charging method may be used. how-
ever, the recommended charging current
rate should be under 2.0A.
Note: Battery should not be charged near open tire.

Terminals should be cleaned with clean water. Apply grease.

5. AUXILIARY ELECTRICAL EQUIP-
MENT
A. Inspection
1) Combination switch (Fig. I64)
If continuty exists in any other leads than
those shown below, first make sure the
wiring harness is connected correctly. lf
the wiring is correct, the switch is defective.
Check by the testing condtictivity of
wires with the switch in each positions.
Replace with new one if the conductivity
is not correct.
C3100. CL100, CBIZSS, CDIZSS,

BAT [Gr 10: HO SW WLi
0 0—0—0

0N o—o—o 0—0

2) Front stoplight switch (Fig. I65)
Check the front stop light switch for con-
tinuity by applying the tester lead probe
to the black and green/yellow-grcen switch
lead and depress the brake lever. If
there is no continuity. the switch is de-
fective.
Also check the action of switch manually.

Note:

- Check brake lever for excess play.

- Light should only operate by the brake
lever.

SL100, SL125
WL: BAT lG

 

 

 

o——o

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig 165 ’1‘ Switch case (2 Shaft ® Contact plate
Gt Front Slop switch

3) Rear stop switch

4)

Check the rear stop switch spring for dis-
engagement. Apply tester lead probes to
the green/yellow and black lead to check
continuity.

The light should come on when the brake
pedal is depressed 2cm (0.78 in.),

Turning the adjuster nut clockwise will
delay the switch engagment. (Fig. I66)

Horn

Connect a 6V battery to the horn to test
its operation.

The sound volume can be adjusted with
the adjusting screw provided on the back
of the horn. (Fig. I67)

5) Horn button switch

Check the continuity of the switch by
applying the tester lead probes to the light
green cord within the headlight case and
to the handle bar. Continuity should exist
when the button is pressed (Fig. I68)

6) Turn signal siwtch

Disconnect the turn signal switch leads
in the headlight case and check the conti-
nuity by connecting the gray switch lead
to one of the tester probes and appling the
other tester lead probe to the blue and
orange switch leads alternately and operat-
ing the switch. if continuity exist in both
positions, the switch is satisfactory. How-
ever. if there are continuity in the position
other than shown on the chart. the switch
is defective. if the both turn signal lamps
on one side do not light up or if all lamps
on both side light up. the switch or wiring
is defective. If the switch and wiring are
not defective and no turn signal lamps
turn on, the relay is defective. Replace the
relay with new one. (Fig. 169)

59

 

Fig. 166 Rear stop switch
1‘ Adjuster nut

 

Fig. l67 Ham

‘1‘: Volume adjusting screw

 

 

 

 

 

 

 

 

 

 

Knob position Blue cord Gray cord lOrange cord

 

 

Right side oaio I

 

 

Left side 1 0+7 0

 

 

 

Fig. I68 ‘Ii Horn bultun swilch 2| Horn button switch lead
:3 Handle bar

  

. A"

Fig. 169 Turn signal switch eontinuty test
‘1 Gray land 2. Blue lead

7) Lighting and dimmer switch

Check the continuity of switch with the
tester in accordance with the table below.

 

 

 

 

 

 

 

 

 

 

 

 

 

(Fig. I70)
H TL L [G DY SE
Ofl'
Low o——o——o o——o
(N) o——o——o——o o——o
High o——o o O o 0
Color of Blue Brown While Bllclt :13:er Yellow

 

 

8) Emergency switch (SL 100 U.S.A. Type).

Construction

The emergency ignition switch (kill button)

is provided to insure safe riding and shut-

ting off the engines operation when the
motorcycle is overturned or when trouble
develops in the throttle system. (Fig. I7l)

Disassembly

(D Loosen two switch mounting screws
and separate the upper and lower
halves. (Fig. I72)

’3 Disconnect the throttle cable from
the throttle cable connector on the
bottom of the switch housing.

(3) Disconnect the wirings within the head-
light case and remove the switch ass-
embly.

Inspection

Start the engine, first make sure the en-

gine can be stopped by switching off the

emergency switch, If the respective switch
positions are not functioned properly,
Fig. I72 Emergency switch removal the switch or wiring is defective.
'DSwilch mounting screws n. the wiring is correct, check by the
testing conductivity of wires with the
switch. If the conductivity is not correct,
replace with new one.

 

 

 

 

Reassembly
‘9 Perform assembly in the reverse order

of disassembly. Check switch operation.

 

 

 

 

 

 

Operation
The operational principle ol‘ lhe emer-
gency ignition switch is shown by the

Fig. 173 Emergency switch operation illustration. Even if ignition switch is

. 5 E nc witch (2) Main switch ’3 Ignition . . . . .
clail 'W'sgparyk splus ,5, Contact breaker .5 Con. ON. the primdry cureutt can be opened

denser t7; Fuse ISA 8* Battery b\’—6AH by operation of ll‘lC switch. (Fig. l73)

 

 

 

 

 

Gl

 

TROUBLE SHOOTING

 

 

 

 

Troubles Probable causes Corrective action
Engine does not start I. Lack of compression
or hard starting (I) Tappet stuck open Adjust tappet clearance.
(2) Worn valve guide Replace
(3) Valve timing out of adjustment Repair
(4) Worn piston rings Replace
(S) Worn cylinder Replace
2. No spark produced from spark plug electrodes
(I) Fouled spark plug Clean
(2) Wet spark plug Clean
(3) Fouled breaker contact points Clean
(4) Improper point gap Adjust
(5) Ignition timing out of adjustment Adjust
(6) Defective ignition coil Replace
(7) Open or shorted circuit in ignition cord Replace
(8) Shorted condenser Replace
3. Fuel does not flow to carburetor
(I) Clogged fuel tank cap vent hole Clean
(2) Clogged fuel cock Clean
(3) Defective carburetor float valve Replace
(4) Clogged fuel tube Clean
Engine suddenly stalls I. Fouled spark plug Clean
while running 2. Fouled breaker contact points Clean
3. Ignition liming out of adjustment Adjust
4. Clogged fuel line Clean
5. Clogged carburetor jets Clean
Engine nolse I. Tappet noise
(I) Excessive tappet clearance Repair
(2) Weakened or broken valve spring Replace
2. Knocking noise from piston
(l) Worn piston and cylinder noise Replace
(2) Carbon accumulation in combination Clean
chamber
(3) Worn piston pin or connecting rod small Replace

 

end

. Cam chain noise

(I) Stretched cam chain
(2) Worn earn sprocket or timing sprocket

 

Replace or shorten the chain
Replace

 

 

 

 

Corrective action

 

 

 

 

 

 

 

Troubles Probable canes
Engine note 4. Knocking noise from clutch
(l) Looseness of clutch center spline Replace
(2) Excessively worn friction disc or clutch Replace
(3) Distorted friction disc or clutch plate Replace or repair
5. Crankshaft
(I) Excessive runout of crankshaft Repair
(2) Excessively worn crankshaft bearing Replace
(3) Excessively worn connecting rod, large end Replace
6. Gear noise
(I) Worn or binding transmission gear teeth Replace
(2) Worn transmission spline Replace
(3) Worn or binding primary transmission gear Replace
Clutch slips 1. Imroper adjustment of clutch (no free play) Readjust
2. Weakened clutch spring Replace
3. Worn or distorted pressure plate. Replace
4. Distorted clutch plate Replace
5. Worn or distorted friction plate Replace
Chad: W l. Improper adjustment of clutch (excessive play) Readjust
hnwoperly 2. Uneven clutch spring tension Readjust
3. Distorted clutch plate Replace
Gear doe- nnt shift in 1. Broken center gear shift fork pawl Replace
2. Broken gear shift cam Replace
3. Deformed gear shift fork Repair or replace
Change pedal does not 1. Broken or dislocated gear shift return spring Repair or replace
"m '° in W 2. Shifting spindle hits crankcase hole Repair
Gear limp: out I. Worn shifting gears on main shaft and Replace
while running counter shaft
2. Distorted or worn gear shift fork Repair or replace
3. Weakened shift drum stopper spring Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

Troubles Probable causes Corrective action
Poor engine performance I. Improper adjustment of tappet Readjust
at low speed 2. Poor cylinder head valve seating Replace
3. Defective valve guide Replace
4. Ignition timing out of adjustment Readjust
5. Improper breaker contact points Repair
6. Excessive spark plug up Readjust
7. Weak ignition spark (defective condenser Replace
and ignition coil)
8. Improper adjustment of carburetor float level Readjust
9. Improper adjustment of carburetor air screw Readjust
Poor engine performance 1. Weak valve spring . Replace
at m spud 2. Valve timing out of adjustment Rendjust
3. Too small spark plug gap Readjust
4. Ignition liming is retarded Readjust
5. Weak point arm spring Replace
6. Defective ignition coil Replace
7. Improper adjustment of carburetor float level Readjust
8. Clogged air cleaner element Clean
9. lnsuflicient fuel flow to carburetor Clan or replenish
Hard steering I. Broken steering ball bearings Replace
2. Bent steering stern Repair or replace
3. Excessively tightened steering cone race Retighten to specified
torque
4. Low tire pressure Inflate to specified pressure
Front and rearsuspension I. Weakened main spring Replace
M0“ too weak 2. lnsutfiicient front damper oil Refill to specified amount
Front and rearsnspension l. Front damper oil viscosity is too high
function '°° m 2. Excessive damper oil
3. Improper adjustment of rear cushion
Inefl'ective brake I. Worn brake lining Replace
2. Foreign objects adhered on brake lining surface Clean
3. Improper engagement of brake arm serration Repair
4

 

. Worn brake cam

 

 

 

 

 

Corrective Action

 

 

Troubles Probable Causes
Exhaust make from I. Excessive engine oil Check oil level with oil
mailer level gauge
2. Excessively worn cylinder and piston rings Replace
3. Worn valve guide Replace
4. Damaged cylinder Replace
mam horsepower I. Improper adjustment of tappet (valve stuck Readjust
open)
2. Weakened valve spring Replace
3. Valve timing out of alignment Repair
4. Worn cylinder and piston rings Replace
5. Poor valve seating Replace
6. Ignition timing out of adjustment Readjust
7. Poor breaker contact points Repair or replace
8. Defective plug gap Repair
9. Clogged carburetor fuel passage Clean
IO. Improper adjustment of float level Readjust
ll. Clogged air cleaner Clean

 

 

 

. Excessive carbon accumulation on
cylinder head
2. Insufficient oil

—-

3. Defective oil pump and clogged oil passage
4. Too low float level
5. Too early ignition timing (causes knocking)

 

Refill up to specified
oil level

Clean

Readjust

Readjust

 

ELECTRICAL SYSTEM

 

Troubles

Probable Causes

Corrective Action

 

Enginedoeanotstart

 

 

”gammy
- Poor contact of battery terminals

2) Combination switch

- Open or shorted circuit. disconnected
connections

- Poor contact between combinanation switch
wire and wire harness

3) Ignition coil
- Improperly insulated high tension coil
- Open or shorted circuit in ignition coil

4) Contact breaker

- Open circuit in the primary coil

- Dirty ground point with oil or dust
- Point gap out of adjustment

. Improperly charged condenser

 

Recharge or replace
Repair

Repair
Repair

Replace
Replace

Repair
Clean
Readjust
Replace

 

 

 

 

 

 

 

 

 

 

 

Troubles Probable Causes Corrective Action
Battery sell I) Wiring
- Open or shorted circuit in battery or Replace or retighten
disconnected battery terminals
2) Generator
- Open or shorted circuit in stator coil or Repair or replace
ground
- Broken or shorted leads Repair
. Demagnetization of rotor Replace
3) Battery
- Poor contact of battery terminals Repair
- lnsul’fiicient battery electrolyte Add distilled water
- Shorted battery electrode Repair
Winker lamp blinks too 1) Bulb
fast or too slow - Blinks unusually fast improperly connected Replace
re ay
2) Wiring
- Blinks too fast: bulb with unsuitable wattage Replace
- Blinks too slow: Burnt or broken bulb filament Replace
Defective relay Replace
Winker lamp imperative l) Winker lamp switch
- Poor contact of winker relay Replace
- Open circuit in winker relay coil Replace
2) Bulb
- Bulb wattage is smaller than rated wattage Replace
3) Relay
- Poor contact of winker relay Replace
. improperly connected leads Replace
Horn inoperative. poor I) Horn
send or too weak sound - Cracked diaphragm Replace
2) Horn button
- Poor grounding Repair
3) Wiring
. Poor contact Readjust
4) Adjusting screw
- Out of adjustment Readjust
Tail ligbtmrl bead liglrt l) Fuse
inoperative 2- 840;? fuse or burnt bulb filament Replace
) u
- Poor contact of lighting switch Readjust
3) Switch
- Poor contact of dimmer switch Readjust
4) Wiring
Stop light inoperative l) Bulb
- Burnt or broken bulb filament Replace
2) Front & tail stop light switch
- Malfunction of switch Reodjust
3) Wiring
- Poor contact of leads Readjust

 

 

 

 

65

 

Maintenance Schedule

PERIODICAL MAINTENANCE

The milage intervals shown in the MAINTENANCE SCHEDULE are intended as a guide for
establishing regular maintenance and lubrication periods by which the best and most safe rid-

ing conditions are assured.

The operating procedures for individual items are described in the section of MAINTE-

NANCE OPERATION.

After 12 months or 10,000 km (6,000 miles) perform repeatedly all items which are described
in the column at every 6 months or 5,000 km (3,000 miles) intervals.
Sustained severe or high speed operation under adverse conditions may necessitate more

frequent servicing.

 

Months or Miles, whichever

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

occm first
First Second Third Rig”, 3'3, Page
Service Required Mouth — 6 12 6 12 Reference
Inn 300 5,000 10,000 5,000 10,000
Mlle 200 3,000 6,000 3,000 6,000
Engine Oil-change 0 Every l,000 Miles (l.600 km) 8
Oil Filter-clean O O O 8
Spark Plug-clean and adjust or replace 0 O O 7
Contact Breaker Points-check or service 0 O O 6
Ignition Timing-check or adjust O O O O 6
Valve Tappet Clearance-check or adjust O O O O 5
Cam Chain-adjust O O O O 9
Air- Cleaner-clean O O 9
Throttle Operation-check O O O 45
Carburetor-check or adjust O O O 5
Fuel Valve Strainer-clean O O O 50. SI
Fuel Tank and Fuel Lincscheck O O O 50. 5|
Clutch—check or adjust O O O O 7
Dnzgfiggnortfipigockets-adjust and O O O 0 ll
Front and Rear Brake-adjust O O O O )0
Front and Rear Brake Shoes-check or replace 0 O 38. 4|
Front and Rear Brake Links-check O O O 38, 4|
Wheel Rims and Spokes-check O O O O 38, 4|
Tires-check or replace 0 O O 38. 39.4]
Front Fork Oil-check and O 0 ll
change 0 O H
Steering Heed Bearings-cheek or adjust O O 44
Steering Handle Lock-check for operation 0 O 44
Side Stand Spring-check O O 0 SI
Baitftery Elecgolyte Level-check and replenish O O O 0 II. 56-58
Lxggsago‘mofltzjsgeedomter-check for O O 0 58—60

 

 

 

 

 

 

 

 

TECHNICAL DATA

 

CthIO

 

 

 

 

 

 

 

 

ITEM C3100 CL100
DIMENSION
Overall length 74.2 in. (1,885mm) 71.6 in. (1,820mm) 75.4 in. (1,915mm)
Ovenll width 29.5 in. (750mm) 32.5 in. (825mm) 31.9 in. (810mm)
Over-:11 height 40.0 in. (1,015mm) 40.5 in. (1.030mm) 42.9 in. (1.090mm)
Wheel base 47.4 in. (1,205n1rn) 47.8 in. (1,215mm) 49.4 in. (1,255mm)
WEIGHT
Dry weight 191.8 lbs (87 kg) 191.8 lbs (87 kg) 211.71bs (96 kg)
CAPACITIES
Engine oil 2.1 US pt (1.0 liter) 2.1 U.S. pt (1.0 liter) 2.1 US. pt. (1.0 liter)
Fuel tank 2.0 US 91. (7.5 liter) 2.0 U.S. gal. (7.5 liter) 2.0 U.S. gal. (7.5 liter)
Fuel reserve tank 2.5 US pt (1.2 liter) 2.5 U.S. pt (1.2 liter) 2.5 U.S. pt. (1.2 liter)
ENGINE
Bore and stroke 1.988 x 1.944 in. 1.988 x 1.949 in. 1.988 x 1.949 in.
(50.5 x 49.5mm) (50.5x49.5mm) (50.5 x 49.5mm)
Compression ratio 9.5: 1 9.5: I 9.5: 5
Displacement 6.04 cu in. (99 cc) 6.04 cu in. (99 0c) 6.04 cu in. (99 cc)
Horse power ll.5ps/ll,000rpm ll.5ps/ll.000rpm Il.5ps/11,000rpm
Contact breaker 0.012~0.016 in. 0.012~0.016in. 0.012~0.016 in.
point gap (0.3~0.4mm) (0.3~0.4mm) (0.3 ~0.4mrn)
Spark plus up 0.024~0.028 in. 0.024~0.028 in. 0.024~0.028 in.
Valve tappet (0.6-0.7mm) (0.6~0.7mm) (0.6~0.7mm)
clearance 0.002 in. (0.05mm) 0.002 in. (0.05mm) 0.002 in. (0.05mm)
CHASSIS AND
SUSPENSION
Carter 64" 63"40' 61.5”
Tnil 2.95 in. (75mm) 3.07 in. (78mm) 3.7 in. (95mm)
Tire size. from 2.50~IB (4 PR) 2.50-18 (4 PR) 2.75-19 (4 PR)
Tire size, I'd!“ 2.75~18 (4 PR) 100-18 (4 PR) 3.25-17 (4 PR)
POWER
TRANSMISSION
Primary reduction 4.055 4.055 4.055
Final reduction 2.857 3.071 3.142
Gar mic. lst. 2.500 2.500 2.500
2 nd. 1.722 1.722 L722
3 “1- 1.333 1.333 1.333
4 th. 1.083 1 .083 1 .083
5 1h. 0.923 0.923 0.923
ELECTRICAL
Battery 6V-6AH 6V—6AH 6V-6AH
Generator A.C. generator A.C. generator A.C. generator
Fuse 15 mp 15 amp 15 amp
LIGHTS
Headlight 6V-35/25W 6V-35/25W 6V-35/25W
Tw/stoplidtl 6V-5.3/I7W 6V-5.3l17W 6V-5.3/l7W
Turn sierra! light ov-rsw 6V-18W —
Meter liuht 6V-l.5W 6V-1.5w sv-t.5w
”l3?! indicator 6V-l.5W 6V-l.5W 6V-l.5w
Tum sisal! 6V-1.5W 6V-1.5W —
indicator light
Hidl beam 6V-l.5W 6V-l.5W 6V-1.5W

indicator light

 

 

 

 

 

 

61

68

 

ITEM

C3138

C0138

SL125

 

DIMENSION
Overall length
Overall width
Ovenll height
Wheel base

74.8 in. (1,90011'Im)
29.5 in. (750mm)

40.0 in. (l.0l5mm)
47.4 in. (1,205mm)

74.3 in. (1.900mm)
29.5 in. (750mm)

39.4 in. (1,000mm)
47.2 in. (1,200mm)

78.5 in. (1.995mm)
31.9 in. (810mm)

44.3114. (1,115mm)
50.2 in. (1275mm)

 

WEIGHT
Dry weight

202.0163 (9| .5 kg)

196.2113! (89 kg)

209.5 1135 (95.0 kg)

 

CAPACITIE
Enginc oil

Fuel tmk

Fuel reserve tlnk

1.0 US. qt. 0.9 lmp.
qt (1.0 I)

2.0 U.S. pl. 1.6 Imp.

gal. (7.5 I)
1.3 US. qt. 1.1 Imp.
qt. (1.2 I)

l.0 U.S. qt.. 0.9 Imp.
qt. (1.0 l)

2.0 US. 381., 1.6 Imp.

gal. (7.51)
1.3 U.S.qt.. l.l Imp.
qt. (1.21)

1.0 US. qt.. 9.9 Imp.
qt. (1.01)

1.8 US. pl. 1.6 Imp.
311. (7.0 I)

0.4 US. gal. 0.3 Imp.
pl. (1.5 l)

 

 

 

 

 

 

ENGINE
Bore and stroke 2.205 X 1.949 in. 2.205x 1.949 in. 2.205 x 1.949 in.
(56x49.5mm) ($6x49.51nm) (56x 49.5mm)
Compression ratio 9.5: 1 9.5: I 9.5: 1
Displmmcm 7.44 on in. (122 01:) 7.44 cu in. (122 cc) 7.44 cu in. (122 cc)
Horse power 12.0 psl9,000 rpm 12.0 ps/9.0w rpm 12.0 psl9.000 rpm
Contact breaker 0.012~0.016 in. 0.012~0.0|6 in. 0.0l2~0.016 in.
point up (0.3~o.4mm) (0.3 ~o.4mm) (o.3~o.4mm)
Spark plus up 0.024~0.028 in. 0.024~0.028 in. 0.024~0.028 in.
Valve um (0.6~0.7mm) (0.6~0.7mm) (0.6~0.7mm)
clearance 0.002 in. (005111111) 0002 in. (0.051001) 0.002 in. (0.05m)
CHASSIS AND
SUSPENSION
Caster 63°45’ 63°45' 60°
Trail 3.15 in. (00mm) 3.15 in. (80mm) 3.15 in. (00mm)
T10: size. from 2.75-18 (4 PR) 2.50.13 (4 PR) 2.75.21 (4 PR)
Tue size. rear 300-17 (4 PR) 27548 (4 PR) 325-18 (4 PR)
POWER
TRANSMISSION
Primary reduction 4.055 4.055 4.055
Final reduction 3.267 2800 3.267
Gar ratio, 1 st. 2.500 2.769 2.769
2 nd. 1.722 1.722 1.722
3 rd. 1.333 1.272 1272
4 th. 1.033 1.000 1.000
5 01- 0.923 — 0.815
ELECI'RICAL
Battery 6V-6 AI-I 6V-6 AH 6V-6 AH
0M0! A.C. mentor A.C. actuator A.C. generator
Fuse 10 1111p 10 mp 15 mp
LIGHTS
Hadliuht 6V-25I25W 6V-25l25W 6V-25/35W
Tail/staplisht 6v-3/10w 6V-3/10W 6V-5.3I17W
Tum sin-l light 6v-sw sv-sw -
Mcter lizht 6V-1.5W 6V-1.5W 6V-l.5W
NEE-‘1 indiator 6v-1.5w 6V-1.5W 6V-l.5W
t
Tqrn stun! 6V-18W sv-1.5w 6v-1.5w
Indicator light
High bum 6V-l.5W 6V-1.5W 6V-l.5W

Indicator light

 

 

 

 

 

69

 

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TL I 25
0 TL125 SPECIAL TOOLS

(ENGINE)

 

 

 

@
@l
(9

75

 

m
(9
m
®
CD
Ref. No. Tool N 0. Description

 

07900—3550000
07902—2000000
07908— 0010000
07915— 2160000
07916— 2830000
07922— 0300000
07923— 1070000
07933— 2000000
07942—2160100
07942—3290200
07957— 3290000
07984—0980000

wowmqmm-c-ww—

I-nu-o

 

 

 

Special tool set

Pin spanner 48mm
Wrench. tappet adjusting
Wrech. stem nut 29mm
Wrench, locknut 16mm
Holder, drive sprocket
Holder, clutch outer
Puller. roter

Driver. Valve guide
Remover. Valve guide
Compressor, Valve Spring
Reamer, Valve guide

 

 

 

76

 

(FLAME)

 

 

 

Ref. No. Tool No. Description
12 07917~3230000 Wrench. hollow set 6mm
13 07947—3550000 Driver. fork seal
14 07957—3290000 Tool disassembling (Rear cushion)

15

 

07967—1180100

 

Holder. spring attachment (Rear cushion)

 

 

I . MAINTENANCE OPERATIONS 77

. l. TAPPET CLEARANCE ADJUSTMENT
Tappet clearance check and adjustment should

be made the with engine is cold.
1) For adjustment. refer to page 5.

. Remove the ACG caps A and B to ob-
serve whether or not the T mark is lined

up with the index mark on the left crank-
case cover. Specified tappet clearance:

 

 

(Fig. I) Intake 0.002in (0. 05mm) ‘ ,
. Exhaust 0.002in (0.05mm) Fig. 1 ® T mark (2) mm-zx mark
® AC6 Cap A. (4) A60 Cap 3
2. CARBURETOR ADJUSTMENT - Ii]?
1) Refer to page 5.
(Fig. 2)
. 3. BREAKER POINT AND IGNITION

TIMING ADJUSTMENT
1) Refer to page 6.

. 4. OIL FILTER CLEANING
1) Drain the engine.
2) Remove the kick starter pedal.
3) Disengage the clutch cable from the clutch
lever.
4) Remove the right crankcase cover.(Fig. 3)
. 5) Remove the oil filter rotor cover.
6)Clean any sludge off the center of the oil
filter rotor. (Fig. 4) Reassemble the filter.

Fig, 4 ® Oil litter rotor cover ® Oil filter rotor

78

 

 

4- ,2"

Fig. 7A ® Fuel cock (2) Carbon-tor (3) Fuel pipe

   

L

Fig, 6 ® Air cleaner connecting band ® Nut
, ® Air cleaner element

5. ENGINE OIL CHANGE

Start engine and run until the normal operat~

ing temperature is reached. This facilitates

complete and rapid draining.

1) Apply the side stand. With the oil filter cap
removed. operate the kick pedal several
times. Use caution to avoid dropping the
screen on the floor while operation.

2) Check both the screen filter and spring for
presence of dust and dirt; if necessary,
clean in solvent or gasoline and dry with
compressed air. (Fig. 5)

3) Replace the cap and refill with fresh oil up
to the upper level mark on the dip stick.
Specified oil viscosity: (Fig. 6)
General, all temperatures SAEIOW-40
Extreme, high temperature SAEZOW-SO

Capacity.........ll(l.05 qt)

 

 

 

 

Alternate:
Above 59° F SAE30
32° to 59° F h SAE20W
Below 32° F SAEIOW

 

 

 

   
 

 
 

6. CAM CHAIN ADJUSTMENT

1) Refer to page 9.
(Fig. 7)

7. FUEL SYSTEM INSPECTION
1) Refer to page 9_
Note:
Do not spill gasoline on the floor since it
is highly flammable and may catch fire
very easily. Place oily rags or waste in con-
tainers provided for them.

8. AIR CLEANER MAINTENANCE

1) Remove the right side cover.

2) Unfasten the band securing the cleaner to
the carburetor. Remove three nuts and take
out the filter element. Clean the element
in solvent or gasoline and dry with com-
pressed air. Refer to page 9. (Fig. 8)

79

 

9. CLUTCH WIRE ADJUSTMENT
1) Fine adjustment is made by looseninglock
nut and turning the adjuster in or out until
the proper play is obtained at the lever tip.

To decrease play...Turn clockwise
To increase play ...Turn counter clockwise
(Fig. 9)
The normal play at the tip of clutch le—

ver should be: 10~20mm (0.4~0.8inl

Note:

Check the adjustment of the clutch with
the engine running. If there is excessive
play, even full movement of the clutch le-
ver will not release the clutch fully. re-
sulting in engine stall or creeping of the
motorcycle. Also check to be sure that the
lever operates smoothly.

10. DRIVE CHAIN ADJUSTMENT

1) Check the tension of the drive chain. This
is done by moving either of the top or
bottom side of the chain up and down with
fingers midways between the sprockets.
Drive chain tension should be adjusted
to allow apprOximately )4" inch vertical
movement at this point. (Fig. 10)
Rotate the rear wheel and check drive
chain tension throughout its length.

2)To adjust, remove the cotter pins from the
axle nuts on both side of the rear fork and
turn the adjuster plates in either direction
until the specified chain tension is obtained.
The adjusters on both side must be in the
same setting. To secure it, tighten the nuts
to specification and install the cotter pins
securely. (Fig. 11)

3) Should you experience difficulty in rotating
the adjuster, holdit with a hand and rotate
while tapping on side of the tire with the

other. (Fig. 12)

 

Fig. 9 (1) Adjusler A® Lock nut CD To decrease play
(i) To increuse play 5 Nut © Adjuster
C) To decrease play 0 To incrense play

. ,rx‘v

Fig, H (D To increased tcnswn @ Tn decrease tension
@ Stopper Q) Axle nut @ Adjuster © Cotter pin

     

 

ll. FRONT BRAKE ADJUSTMENT

1) To make free play adjustment. loosen the
lock nut and turn the adjuster in or out
located at the frontwheel. Minor adjust-
ments should be made on the adjuster at
the handlebar. Do not rotate the adjuster

without first loosening the lock nut.
(Fig. 13)

I g N / .
0 To decrease ylly To increase play

9 Adjuster @ Nut 5 To decrease play
0 To increase play ® Adjuster Lock nut
"‘ . 2)Free play at the tip of the brake lever

tip should be 20~ 30mm (0.8~ 1.2 in)
(Fig. 14-),
Note:
To avoid brake lever breakage in case of
an accident, the tightening torque of the
ignition and brake lever braket is a little
less than the standard torque limit to
allow it to slip.
Make sure to use the specified torque.
Tightening torque ................. 0.2kg-m
(1.4lbs-ft)

12. REAR BRAKE ADJUSTMENT
1) Rear brake pedal free play. measured at
the tip of the rear brake pedal (D. should
be maintained at 20~ 30 mm (0.8~ 1.2 in).
Free play is the distance the brake pedal
moves until the brake starts to engage.

(Fig. 15)

 

Fig. [4 ®ZO~ 30mm (0.8~l.2 in)

 

2) Adjust the pedal free play by turning the
rear brake adjusting nut @. Turning the
adjusting nut in direction (2 will decrease
the brake pedal free play and turning the
nut in the direction (D will increase the

play. (Fig. 16)

  

@To increase plly
® Adjusting nu!

 

8|

 

l3. BRAKE PEDAL HEIGHT ADJUSTMENT

1) Brake pedal height can be adjusted to suit
an individual rider. To adjust, loosen the
lock nut and turn the stopper in or out as
required. (Fig. 17)

Note:
Always make pedal play adjustment after
the pedal height was changed.

14. GEAR CHANGE PEDAL HEIGHT
ADJUSTMENT
l)The gear change pedal can be also ad-
justable in height to suit the riding posi~
tion of an individual rider. This adjust-
ment is made by turning the adjuster after
loosening the lock nut. After adjustment.
tighten the lock nut firmly. (Fig. 18)

15. FRONT SUSPENSION SPRING

ADJUSTMENT

1) Front suspension spring tension can be
adjustable to meet the rider's weight or
different road condition. Use the following
procedure.

2) Remove the rubber cap from the top of
the front fork.

3)Using a screwdriver. adjust the spring
tension.
To obtain hard suspension. turn the
adjuster clockwise. and turn counter-
clockwise to make it soft. (Fig. 19)

16. FRONT FORK OIL CHANGE

1) Regular oil change is required to keep the
front suspension operating efficiently.

2) Remove the suspension spring adjuster
from top of the fork. Loosen off the drain
plugs from each fork leg and pump the
fork several times to encourage oil to
drain thoroughly. (Fig. 20)

 

Fig. [1 (D Raise ® Lower @
(D Stopper

    

Fig. 13 (D Gear change pedal ® Lock nut (lefthand
thread) (3 Adjuster © Raise 6) Lower 6) Lock nut

 

 

 

 

Fig.

 

    

l i

Fig. 20 (D Suspension spring adjuster

82

 

 

Note:
The fork should be flushed using an approv-
ed solvent. Do not use gasoline to avoid
damaging rubber parts.
3) Reinstall the drain plugs and relill with
fresh oil. (Fig- 21)

Specified oil ............ (automobile automatic
transmission oil)
Quantity .................. (4,4 to 4.770 025)

130 to 140cc

Note:
Tighten the plugs firmly to prevent them
from being turned out during operation.

17. CYLINDER COMPRESSION
INSPECTION
1) Refer to page 12.

II. ENGINE 8“

1. ln-motorcycle service items

 

Items to be serviced l Page

 

1. Oil filter and oil pump 22
2. Clutch 25
3. Gear shift mechanism 32

 

 

 

 

2. ENGINE REMOVAL AND INSTALLATION

A. Engine Removal
1)With the aid of a suitable Hollow set

wrench, loosen the bolt at the muffler
band securing the muffler to the exha-
ust pipe joint. (Fig. 23)

2) To disassemble the exhaust pipe. re-
move the two exhaust pipe retaining

nuts. (Fig. 24)

3) Separate the carburetor from the air
cleaner.

4) Take out the seat.

5) Remove the fuel tank.

6)Remove the throttle valve from the

carburetor. (Fig. 25)

 

Fig. 25 (D Throttle valve

7) Loosen the clutch wire lock nut and
adjusterjust enough to slacken the wire;
disconnect the wire from the clutch

lever. (Fig. 26)

8) Remove the noise suppresore cap.

9) Remove the left side cover. Disconnect
the drive chain by removing the clip
from the master link. Take out the chain
from the motorcycle. (Fig. 27)

10) Disconnect the coupler from the wiring
harness.

11) Remove the primary wire.

12) Remove the nuts from the engine hanger
bolts. Lift the rear of the engine just
enough to remove load from the hanger
bolts: pull off the bolts. (Fig. 28)
Place the engine on a clean surface or
work bench.

B. Engine Installation
1)To facilitate installation. line up eye on
the cylinder head with holes in the top
hanger bracket on the frame. Install a
T-screwdriver with the end through
these holes. The hanger bolts can then
be installed easily. (Fig. 29)

 

2) Tighten the exhaust pipe joint to the
muffler in two steps: first fingertight
and then to the specified torque using a
suitable torque wrench.

3)ln installing a drive chain. note the
direction of the master link retaining
clip.

4) Adjust the clutch as per the instructions
described earlier in this manual.

    

:ru 4 / " -“

Fig. 29 ©T-screwdriver © Retaining clip and master link

III. ENGINE, CHASSIS Allll ELECTRICAL 85

O ENGINE

l. CLUTCH
In the clutch assembly of TL125, [our friction discs and four clutch plates are incorporat-
ed. each one plate less than those of CB/CL/SLlOO and CB/CL/SL 125 S models.
The following shows an exploded View of the clutch so that the relative positions of the

parts can be seen.(Fig. 30)

  
   

Fig. 30 ® Friction disc ® Clutch plate ®Clutch pressure plate CC Clutch outer (5) Clutch liltcr rod
@ Clutch Iiitcr guide pin Cl) Clutch litter plate Clutch spring (9 Clutch center ® Disc spring seat

®Clutch spring disc Q) Set ring (82.5mm)

Removal

1) Remove the kick pedal and right crankcase
cover in the order in (Fig. 3).

2) Disengage the clutch wire end at the crank-
case cover.

3)Remove the split pin: take out the clutch
lifter cam. clutch spring and clutch lever.

(Fig. 31)

 
   
   

Fig. 3] @Clnlch levcr®C|mch spring
® Clutch filter can: ®Split pin

 

4) Remove the clutch lifter rod. Follow the
items listed on page 25.
Reverse the order of the removal to install
the clutch lever.

B .
Fig. 32 ® Clutch lifter rod

 

2. TRANSMISSION

The transmission used on TL 125 is essentially the same as those used on CB/CL/SLIOO
and CB/CD/SL 1255 except for the gear arrangement on the main shaft and the resultant
changes in the shift drum groove. (Fig. 33)
Disassembly, inspection and assembly procedures will not be shown here since these are
identical to those of C8100. See pages 32 thru 35.

   

0

a? ”Q

® Countershaft idler gear (BOT)
® Countershall low gear (3ST)
® Countershaft 3rd gear (30T)
© Countershaft top gear (21T)
© Countershaft 4th gear (25T)
© Countershaft
@Counlershaft 2nd gear (341')
6) Primary starter gear (IQT)
® Main shaft
® Main shaft 3rd gear
@Main shaft top gear
®Main shaft 4th gear
®Main shaft 2nd gear

Gear shift plate
@Gear shift spindle
3 Right shifter fork
® Center shifter fork
0} Left shifter for]:
@Gear shift fork guide shaft
Q Gear shift can:
® Gear shift drum

Fig. 33

87

 

O CHASSIS
l. BRAKE ARM
After putting the brake panel assembly on
the wheel hub. install the brake arm on the
brake camshaft. aligning the mark on the
arm with index on the shaft. (Fig. 34)

2. HANDLEBAR
Be sure and keep the punch mark on the
handlebar flush with the top face of the
holder as shown. (Fig. 35)
Note:
After making sure that the punch mark and
top face of the holder match up, tighten the
holder firmly. starting with the front toward
the rear.

3. CABLES AND LEAD WIRES
All cables and lead wires should be posi.
tioned as per the instructions given in Figs.
36 and 37.
Note:
Be sure that cables and wires are not bind-
ing or stressed when the handle is operated
between two extremes.

 

Fig. 36

Fig. 35 (D Punch mark

 

 

4. FRONT SUSPENSION

 

 

 

 

 

 

 

 

stroke damping force
TL125 152mm 15~ 20kg/0.5m/sec
Fig. 38
® Spring adjuster ® Piston ring
® Fork bolt ® Under seat
(39 Front cushion spring "A" ® Front fork pipe
© Front cushion spring “8” 0 Oil lock piece
© Front fork dust seal fl Front fork bottom use
© Inner snap ring (45mm) (3 Fork bolt cap
® Oil sell (3| x43 x 12.5) (9 Front fork Assy

Fig. 39 (D Front fork boll ® Clamp bolts

    

l

A. DISASSEMBLY NOTES

1) Remove the front wheel. For details. see
page 37.

2) Before removing each front fork, remove
the fork bolt and drain bolt.

3)Move the front fork to drain the oil.

4)Loosen the upper and lower clamp bolts
and pull the front fork down.

 

5) Separate the bottom case from the front
fork pipe by removing the fork bolt cap.
To remove. use tool "Hollow set Wrench
07917- 3230000."

6) Remove the dust seal. Remove the snap
ring by using plier. (Fig. 40)

7) Separate the fork pipe from the bottom
pipe.

8) Separate the under-seat from the front
fork pipe.

9) Remove the oil seal.

B. INSPECTION

1)Examine if the front fork piston ring is
not worn.

2) Check the suspension spring for free
length and as-installed tension.

3) Inspect the front bottom case for wear.

4) Determine if the fork pipe is not cracked
or damaged excessively beyond use.

C. ASSEMBLY
”Wash all parts thoroughly in cleaning
solvent.
2) Slide the under seat into place in the
fork pipe; insert the suspensions spring.
(Fig. 41)
Note:
Before installation, apply Automobile auto-
matic transmission fluid.

3) Assemble the fork pipe with the bottom
case.

Note:
Use suitable sealer to the fork bolt cap

4) Drive the oil seal into place in the bottom
case. Use tool “Oil Seal Installer.
07947-3550000. (Fig. 42)

5) Place the snap ring in the groove in the
bottom case. Make sure it seats properly.

6) Pour the specified amount of HONDA
automobile automatic transmission fluid
oil in the front fork. (Fig. 43)

Specified quantity ............ 4.4~4.70025
(130~ 140cc)

Note:
The fork should be filled with the fluid be-

 

 

 

 

 

Flg. 41 @Front fork bottom pipe
® Bottom pipe ® Fork pipe

 

 

 

 

Fig. 42 G) Oil seal installer

 

 

 

 

 

 

Fig. 43

 

0 ELECTRICAL SYSTEM

 

 

 

 

 

 

 

 

Fig. 44
® Ignition coil
G) Condenser

© Spark plug

Referring to the illustration above. the ignition system consists of the generator, ignition coil,
contact breaker. condenser, spark advance mechanism and spark plug to ignite the air-fuel

mixture in the engine cylinder.

Technical Data

 

Ignition coil
Spark plug

Contact breaker
Condenser

Spark advancer

 

Spark length (3-needle)
Type

Gap

Point pressure

Point gap

Capacity

Insulation resistance
Advance angle

Camshaft rpm at 1' advance
Engine rpm at full advance

7mm min @ 500 rpm

D-8ESL (NGK) X-24ES (DENSO)
0.6 to 0.7mm

800 i 100g

0.35mm:l:0.05mm

0.24;:F

10MQ(by1000V Megger)

8.5° :l: l.5°

11001: 100 rpm

20001100 rpm

 

(D Generator coil
(3 Contact breaker

© Spark advancer

 

91

 

1 . GENERATOR

The generator is fundamentally an A.C. generator. with the rotor built in the engine flywheel.
The design is essentially the same as that used on SLZSOS. Current available at the generator
operates the ignition system to supply high-voltage surges to the spark plug in the engine
cylinder.

2. A.C. GENERATOR

 

Fig. 45

® Flywheel

® Oil seal

@ Primary coil

© Left cnnkcase cover

© Leh crankcase rear cover

92

 

A. Removal
1)Remove the two crankcase covers. front
and rear, from the left side of the engine.
2)Remove the stator by loosening off the
attaching bolts.
3) Remove the primary co_il by loosening off
the Stator mounting bolt (Fig. 47)

‘ ' . 4) With the help of tool “Flywheel Extractor
‘ V 07011-20001." remove the flywheel while
lightly tapping it around with the right
hand. (Fig. 48)

B. Stator Inspection

When failure to start is due to broken stator
coil. this can be checked with a tester. To
make this check, disconnect the stator cord,
black stripes on white ground, at the wiring ‘
connector. Hold a test prod against the con—
nectar. and the other against the metal part
of the stator. If continuity exists. it indi-
cates the stator coil is not broken or dis—
continued.

 

O INSPECTION OF ELECTRICAL
ACCESSORIES

1. MAIN SWITCH
If the engine fails to stop with the ignition
switch in OFF. the likelihood is that the
switch is internally short-circuited. The
ignition switch test is made by first discon-
necting the primary lead (black/white) and
that of the neutral switch and then checking
continuity between the leack with a tester.
If continuity exists when the kill switch is
turned on. it is probable that the switch is
defective. calling for replacement.

    

Fig. 49 ®Blaclt/Whitc ©Green @Mainswitch

 

 

TABLE OF OPTIONAL PARTS

 

 

No Part Name Description Application Remarks
1 Rear wheel tire ”New. wider tread tire with ”Chain case to be Off-road
special tread pattern (about removed use only
10mm wider than standard
specification)
2) Tire size same as standard
type
3) Featuring more bite on 2) Trial race only
swampy underfoot conditions
or on slope in trial race
2 Tire gauge (psi) 1) For measuring tire pressure
in pound-inch system
2) Gauge dial: 5 to 35 psi
3 Air pump ”Portable air pump to inflate
tires to standard pressure
when driving on public road
after racing
4 Air pump l)Air pump lower bracket 1)Tightened with left upper of
brackets 2) Air pump upper bracket engine hanger plate
2) Fastened with 12mm bolt along
with frame body downtube
5 Front fork l)To improve structural rigidity (Mounting location)
stiffener of front fork for higher trial Left of bottom bridge on the bot-
racing torn. and right of top bridgeon
the upper, as viewed from front
of motorcycle
6 Zechin plate 1) For number or code assigned 1)Fastened with band to front
during race fork stiffener
7 Zechine band l)Tightened to front fork stif-
fener with two 6mm bolts and
zechine plate
8 Direct type gear For use in higher class trial 1) Directly attached to gear

 

change pedal

 

racing

change pedal spindle in place

 

of link type pedal

 

 

 

MAINTENANCE SCHEDULE

authorized Honda dealer. unless the owner
has proper tools and is mechanically pro-

The maintenance intervals shown in the fol-

lowing schedule are based upon average

riding conditions.

severe use, or ridden in unusually dusty
areas, require more frequent servicing.

Machines subjected to ficient.

Items marked with' should be serviced by an

Other maintenance items are simple to per-
form and may be serviced by the owner.

 

 

 

 

O ENGINE OIL—Change. O DRIVE CHAIN—Check, lubricate,
0 'CONTACT POINTS AND IGNI- and adjust if necessary.
TION TIMING—Clean. check, 0 BRAKE CONTROL LINKAGE—
INITIAL and adjust or replace if necessary. Check linkage and adjust if neces-
SERVICE 0 ‘VALVE TAPPET CLEARANCE sary.
PERIOD —Check and adjust if necessary. 0 TIRES—Inspect and check air
0 'CARBURETOR—Check and ad- pressure.
FIRST WEEK just if necessary. 0 ALL NUTS, BOLTS. AND OTH-
OF 0 THROTTLE OPERATION—1m ER FASTENERS—Check security
OPERATION spect cable. Check and adjust free and tighten if necessary.
play. 0 'WHEELS. RIMS, AND SPOKES
O 'CLUTCH—Check operation and —Check. Tighten spokes and true
adjust if necessary. wheels if necessary.
0 ENGINE OIL—Change. O 'CAM CHAIN TENSION—Adjust
O SPARK PLUG—Clean and adjust (only initial service).
EVERY gap. or replace if necessary. 0 THROTTLE OPERATION—
30 0 'CONTACT POINTS AND ICNI- Inspect cable. Check and adjust
OPERATING TION TIMING—Clean. check. and free play.
DAYS adjust or replace if necessary. 0 'CLUTCH—Check operation and
O 'VALVE TAPPET CLEARANCE adjust if necessary.
NOTE —Check and adjust if necessary. 0 DRIVE CHAIN—Check, lubricate.
Change oil 0 POLYURETHANE FOAM AIR and adjust if necessary.
every 30 0 FILTER ELEMENT—Clean and O BRAKE CONTROL LINKAGE—
operating days oil. Service more frequently if Check linkage and adjust if neces-
or operated in dusty areas. sary.
every 3 months, 0 ‘CARBURETOR—Check and ad. 0 TIRES—Inspect and check air
whichever just if necessary. pressure.
occurs first. 0 ’WHEELS, RIMS, AND SPOKES 0 ALL NUTS. BOLTS. AND OTH-
—Check. Tighten spokes and tire ER FASTENERS—Check security
wheels if necessary. and tighten if necessary.

 

 

EVERY YEAR

 

0 FUEL FILTER SCREEN—Clean.
O FUEL LINE—Check.

O FRONT FORK OIL—Drain and refill.

O ‘OIL FILTER SCREEN—Clean.

O ‘CENTRIFUGAL OIL FILTER—Clean.

O 'FRONT AND REAR SUSPENSION-Check operation.
0 ‘STEERING HEAD BEARINGS—Adjust.

O 'BRAKE SHOES—Inspect and replace if worn.

O 'CAM CHAIN TENSION—Adjust.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
Item English Metric
Dimension Overall length 78.5in. 1.995mm
Overall width 33.!in. 840mm
Overall height 43.1in. 1.095mm
Wheel base 50,4in. 1.280mm
Seat height 30.7in. 780mm
Foot peg height 13.2in. 335mm
Ground clearance 10.2in. 260mm
Dry weight 194lbs. 88kg
Frame Type Semi double cradle
F. suspension. travel Telescopic lork. travel 6.0in. (152mm)
R. suspension. travel Swing arm. travel 3.7in. (94mm)
F. tire size, pressure 2.75—2_1 (4PR). Semi-Knobby. tire air presure 1.5kg/cm2 21psi
R. tire size. pressure _4.00—18(4PR). Semi-Knobby. tire air presure 1.5kg/cm2 21 psi
F. brake. lining area InteilaLeitpanding shoes. swept area 13.4sq-in (86.4 sq-cm)
R. brake. lining area Internal exmdiug shoes. swept area 13.4sq -in (86.4 sq-cm)
Fuel capacity _l.2 U§ gal. 4.5 lit.
Fuel reserve capacity 0.1 US gal 0.5 lit.
Caster angle 61" 30'
_ Tra_il length 4.1in. 105mm
—Engine _'l:ype Air cooled, 4-stroke OHC engine
Cylinder arrangement Single cylinder 15' inclined from vertical
Bore and stroke 2.204 x1.949in. 56.0 x 49.5mm
7.44 cu—in 122 cc

Displacement

 

 

Compression ratio

8.0:]

 

Valve train

Chain driven over head camshaft

 

Maximum horsepower

3.0 BHP/8.000 rpm

 

Maximum torque

5. 55 lb-ft/4,000rpm

0.83 kg—m/4.000rpm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil capacity 1.1 US qt. 1.0 lit.
Lubrication system Forced and wet sump
£ylinder head compression pressure 12 kysq-cm at 1.000 rpm
Opens BTDC 0'
intake valve Closes ABDC 30'
Opens BBDC 35'
Exhaust valvc Closes ATDC 0'
Valve uppet clearance 0.0002 in. 0.05 mm
Idle speed 1.300 rpm
Drive train Clutch _ Wet, multi plates

 

Transmission

5~speed constant mesh

 

Primary reduction

4.055

 

 

 

 

 

Gear ratio 1 2.769
Gear ratio 1] 2.125
Gear ratio III 1.578
Gear ratio IV 1.000
Gear ratio V 0.724

 

F inal reduction

4.000, drive sproket 15T. driven sproket GOT

 

Gear shift pattern

Left foot operated return system

 

Electrical

 

 

 

ignition Flywheel magneto
StartinLJystem Kick starter
Alternator A. C. generator

 

 

Spark plug

 

NGK D BBS—L or ND X 24ES

 

 

TL 125 WIRING DIAGRAM

 

wu_£s>\xom_m ...... >)\xm Ill

:35 ...... o .=oo zo_tzo_.o.< In.

P on: 52mm
3%: 43:35: I 1..
mohémzuoo<
13.5% 8528
5.5 355

3.5

  

 

 

BEE

 

>>\xm

 

10:26 z_<2

 

 

_ A _
Adjust ignition timing ...... 6, 77
—valve tappet clearance. . 5. 77
—cam chain ............. 9, 78
——carburetor . . . . . . 5,35. 77
AC. generator ............ 53, 91
Air cleaner ......... 9.50-51,78
._ B—
Battery ................ 11.56.58
Brakes ............. [0,37,40,87
Brake drum ............... 38. 41
Brake liming .............. 38. 41
Brake lever travel ............. 10
Brake pedal travel ......... . .10
Bore and stroke ............... 67
Bulb ......................... 67
_ c _
Cam chain tensioner ..... 9.29.78
Carburetor ............. 5 . 35 , 77
Camshaft ................. 15. 18
Change oil and oil filter ........ 8
Charging system ............... 54
Clutch .................. 7,25,85
Compression ratio ............. 67
Contact breaker ............... 6
Crankshaft ................... 30
Curb weidit .................. 67
Cylinder bore ................. l6
Cylinder head ................. 15
_ D _

Displacement ................. 67
Drive chain ............... ll. 42
_ E—

Engine installation ........ 15, 83
—oil drain plug .............. 8
—removal .................. 14
Electrical ................ 53, 85
Emergency switch ............. 60

_ F _

Final reduction ................ 67

Front hrake ................... 37
Frame body ................... 50
Front suspension .......... 45, 88
Front wheel and tire ........... 37
Fuel tank capacity ............. 67
Fuel tank ................. 50. 51
Front fork oil change ..... 2 . . . .81
Front Suspension S pring
Adjustment ................. 81
_ G _.
Gear change pedal ............. 27
Gear ratio .................... 67
Gear shift drum ............... 34
Gear shift drum stopper ....... 28
Gear shift fork ................ 27
Generator ................ 53, 91
Gear shift mechanism .......... 27
_ H .-
Headlight ..................... 46
High beam .................... 60
Horn ......................... 59
_. I _
Idling speed ................... 5
Ignition timing ................ 6
Ignition system ................ 55
Ignition coil ................... 55
_ K _
Kick starter .................. 32
_. L _
Lubrication system ............ 22
_M_

Main ignition switch ........... 58
Maintenance ................. 5
_ N _

Neutral switch ................ 34
_ 0'—

Oil filter ................. 8. 22

 

———screen .................... 8
Oil pump ...................... 22
Oil gauge ..................... 8
_ P _
Piston ........................ 15
Piston pin .................... 15
Piston ring ................... 17
Primary reduction ............. 67
_ R _.
Rear brake ................... 40
Rear shock absorber ........... 48
Rear fork ..................... 48
Rear wheel and tire ........... 40
Rocker arm ................... 21
——shaft ..................... 21
_ s _
Service air cleaner ............ 2
—battery ................... 11
—spark plug ................ 5
Spark advancer . . . . . .......... l9
Spark plug .................... 5
Special tools .................. 2
Stop switch ............... 59, 59
_ T _
Tail/stop light ................ 67
Technical data ................ 67
Torque table .................. 1
Turning circle ................ 67
Timing the valves ............. 6
Tire size ..................... 67
Transmission ................. 32
Turn signal switch ............. 59
/born switch .............. 59
_ v _

Valve ........................ 20
Valve timing ..; ............... 6
_ w—

Wiring diagram ........... 69 -74