:3an MANIJAl HON DA , 125 '175 35321132 FOR EWORD This Shop Manual is a servicing guide for the CBl25, CL125, CBl75 and Cll75. The Manual has been prepared using the C5175 and CLl75 as the basic models, however, the inlormation contained will apply equally well to all models. There are minor diFferences among the models, primarily in the engines; these diFferences have been specificially noted for the CBl25 and CLI25. This Shop Manual is applicable to a“ model serial numbers shown below and subsequent. CBTQSKI Engine No. 2000011~ Frame No. 2oooooo~ C5125K2 [General Export Type] Engine No. 3000001~ Frame No. 3000001~ CEI25K3 [General Export Typel Engine No. 4oooom~ Frame No, 4oooom~ CL125K1 Engine No. 2000001~ Frame No. 2000001~ CLI25K3 lGeneral Export Typel Engine No. 4000001~ Frame No. 4000001~ C5175 Engine No. 1000001~ Frame No. 1000001~ CBWSKS Engine No. 4000001~ Frame No. 4000001~ CBT7SK4 Engine No. 5000001~ Frame No. 5000001~ CLI75 Engine No. 1000001~ Frame No. 1000001~ CL175K3 Engine No. 4000001~ Frame No. 4000001~ CLl75K4 Engine No. 5000001~ Frame No. 5000001~ To ensure proper servicing, the special tools must be used and all repairs made to the specilied tolerances. The information peculiar to CB/CU25, 175 revised models is compiled at the back of this publication as a supplement. June 25, 1974 HONDA MOTOR C0., LTD. Service Publication Office FEATURES ENGINE Chain driven overhead camshafi Assures quielei operalion, due io lhe sileni chain drive, and a more eincieni higher speed engine resuliing lrom lhe elirninalion oi power loss 2. Dual oil illiering sysiein Provides only highly cleaned oil lo lubricale ihe moving paris oi lhe engine lo greally exlerld ihe lrouble iree engine liie, 3, Conslant-meshed transmission gears Make possible srnooih and eiioriless gear change 4, Variable venturi carburetor Provides economical operalion and greaier power oulpui al all speeds, FRAME L The lrame main unil is made oi welded high sirengih sieel lubing oi backbone design ior lighiness and rugged service. 2. From wheel is mounled on an oil dampened lelescoping loik which provides superb handling and good siabilily, Rear wheel is on a swing arm pivoled aboui plain bearings ior increase rigidily and suspended on cushions provided wilh lhiee slage load adiuslmenls. 3s The CL models have a wide raised handle mounled on rubber l0! comforl, Semi- raised handle is mounled on lhe CB models, 4, Block lread pallern lire is insldlled on lhe rear wheel oi lhe CL models {or good road holding on bad roads 5‘ All lighis are used ihroughoui ior greaier saielv, and iheir operaling swiiches are all mounled on lhe handle bar where lhey are accessible wilhoul moving lhe hands, 6‘ Frorll wheel brake is oi ihe iwo leadings lype ior greaiesi braking eiiiciencv, 7‘ All proiruding paris are designed wiih generous radius and sharp corners have been eliminaled lo prevenl iniuries lo lhe riders CONTENTS SPECIFICATIONS SPECIAL TOOLS CEI75, CLI75 CEI25,CL125 ,. . ENGINE (CBI75, CLI75I ............. 3.] Engine Removal and lnstulla A, Engine construction I BI Removal 4; Reassembly 3.2 Cylinder Head and Cylinder , I. Cylinder head ........... AI Construction .I B. Disassembly .. C, Inspection I II D. Reassembly I 2. Cylinder head cover and breather AI Descrtpnon a, Dtsassembly I 3. Camshaft I I I I A, Construction . B, Disassembly .I Q Inspection IIIIIII DI Reassembly 4I Rocker arm ,,,,, AI Construction I. B. Disassembly II CI Inspection DI Reassembly 5. Valve . , , AI Description BI Disassembly . CI Inspection , D, Reassembly 6. Valve seat A, Description B. Inspectton 7. Cylinder AI Construction H, B, Dtsassembly C, Inspection ,,,,,,,,, D, Reassembly 33 Left Crunkcase Cover 1. Le“ crankcase cover A, Construction , B, Disassembly . c, Reassembly 2. A.C generator A, Construction a. Disassembly . c. Reassembly 34 3.5 3.6 3.7 3.8 as snarling sprackel and clutch ........................ Al Canslrucllan ........................ a. Disassembly and reassembly lSlarlirlg clulchl .s c, Discssembly and reassembly lSlarlirlg sprockell 4‘ Clutch adjuster and neulral swllcn ralar . A Operalion ssssssssssssssssssssssss B Dlsassembl‘y and reassembly lClulclr aaiuslerl sssssssssssss c Disassembly and reassembly lNeulral switch ralarl Right Crankcase Cover Assemblys ll nghl crankcase cover A Canslruclian B. Reossembly 2s Clulch.,.. A Description and aperalion B. Dlsassembly . cl lnspecllan. De Reossembly on Pump. Filler and Separalar l, Oll pump A, Descripllan a. Discssembly .. c, lnspeclion De Reossembly 2‘ Oil nller, A, Descripllan . a. Disossembly s c Reassembly 3, on separalorw Al Operallan Crankcuse .s A Description s . s. Disassembly c, lnspecllan ...... D Reassembly Crunkshufl Conneding Rods and Plslans .. Al Construcvion e B. Dlsassembly cl lnspeclian .. 2‘ Connecting rods“ A, Descraillan a. lnspecllan 3, Piston ..... A, Descriplian a. Disossembly c. Inspections De Reassembly 4, Piston rings ....... A, Canslruclian .. as lnspeclion .. cl Replacing me pislan rings Cam Chain Tensioner and Cam Chain Guide Roller A. Operavlonu a. Disassembly s —]]I- C. lnspeclion .............................................. 49 D. Reassembly 49 E. Com chain lension adiusimenv. 49 3.9 Trunsmiuion., 50 A. Descripnon 50 B, Disossembly 52 C. lnspecvion . 52 D. Reassembly 52 3J0 Gear Shifl ,,,, 53 A. Operclion . 53 B, Discssembly . 53 C. Inspection . 54 D. Recssembly 54 ll] Kick Sinner. , . . 54 A. Consiruclion , 55 a, Disassembly , 55 C. lnspeclion . 55 D. Recssembly 55 3,12 Cnrburelor 56 Conslrucllon , . . , 56 Funclion of ihe main components 55 Ad|uslmenl. , H 60 Engine (C3125, CLI25) , , 62 3.] Engine Removal and Inslullmion , 64 A. Engine descriplion 64 8. Removal 64 C. Recssembly H 65 3,2 Cylinder Head and Cylinder ,,,,,,,,,, 66 l. Cylinder head, cover and brecvher 66 A. Consiruclion . 66 B. Disassembly . 66 C. Inspection . 66 D. Reassembly 67 2. Camshaft ....... 68 A. Conslruclion . 68 B, Disossembly 69 C. Inspeclion . , , 69 D. Reassembly 69 3. Rocker arm. , , 69 A. Conslruclion , 69 a. Disassembly . 69 c. Inspeclion . 70 D. Reassembly 7o 4. Valve 70 A. Conslruclion , 70 B, Disassembly . 70 c. Inspeclion 71 D. Reassembly 71 5, Valve seat 71 A. Descriplion 7x 6. Cylinder . 72 A. Consirucnon. , 72 a. Disassembly 72 3.3 3.4 3.5 3.6 La“ Crunkcuse Cover 1 . 2‘ mm crankcase cover assembly 1. 2. A. Descriplion and Operation ., a. Disassembly C. Inspecvion ,, D. Reassembly 3. Oil pump B. Disnssembly C. Inspection ,, D. Reassembly 4. Oil filver ,,,,, . . . A. Operation ,,,,, B. Disassembly C, Reassembly Crankcase . . , . ....... . . ...... . . . 1. Upper and under crankcase ,,,,,, A. Description B. Disassembly c. Inspection D. Reassembly 2. Oil separavor. Crankshaft 2. 3. C. Inspecvion ... D. Renssembly Len crankcase cover , A.C. Generalor.. A. Consurucvion ., a, Disassembly c. Reassembly Clutch Iiher thread. . A. Descripnon a. Disassembly C. Reassembly , Cam chain vensioner ...... A. Construction , B. Disnssembly C. Inspecvion .. D. Reassembly Righl crankcase cover A. Construcvion , B. Disnssembly c. Reassembly Cluvch ....................... A. Descnmion s. Disassembly c. Reassembly A. Conslruchon ,, B. Disussembly C. lnspecvion D. Reassembly Connecting Rods. A. Disnssembly Pisfon ,,,,,,,,,,,,,,,,,,,,,,,,,,,,, A. Descripiion 81 5. Disassembly 81 c. Inspection 8| D. Reassembly 52 4. Pision Rings .... 52 5. Inspection . 52 c. Replacing the piston rings 52 3.7 Yrunsmission .................... 83 A. Description 53 B. Operaiion . . . 83 C. Inspection 84 3.3 Gear shift .. .. 84 A. Description 84 B. Disassembly 55 C. lnspeciion 55 D. Reassembly 55 3.? Kick Starter. 86 A. Description 86 5. Disassembly .. 88 c. Inspection .. 58 D. Reassembly 86 (HO Carburetor ........ 87 Construction 87 Funciion oi the main componenis 87 Ad‘ustment ...................... 87 4. FRAME i 88 u Sieering Handle . 5a A. Description 88 5. Disassembly 55 C. Inspeciion ....... 89 D. Reassembly 59 4.2 Front Cushion 2222222 90 A. Description 90 5. Disassembly 93 c. inspeciipn ., 94 D. Reassembly 95 4,3 Steering Stem and Steering Handle Lock 95 A. Construction ..................... 95 5, Disassembly C. Inspection D. Reussembly . 4,4 Fuel Tank .......... . A. Construciion .. 5. Disassembly C. lnspeciion .. D. Reossembly 4.5 Frame Body ........ A. Consiruction .. 5. Disassembly ., C. Inspection ,. D. Reossembly 4.6 Air Cleaner Case and Seat A. Consiruction ........... B, Disassembly C2 lnspecrion D1 Reassembly 4‘7 Sland A1 Consrrucrion .1 Bl Disassembly C, Inspecrion , D Reussembly 4,8 Mufiler and Exhausl Pipe 1 103 A. Conslrucncn . 103 s, Disassembly 103 c, Inspection . 104 D, Reassembly . 104 49 Air Cleaner and Tool Case . . 1 106 El D1sassembly . 10.5 c1 lnspeclicn ........ 107 D1 Reassembly 107 4110 Rear Fork and Rear Fender 1 107 107 A1 Consrruclion ......... a, Disassembly ‘ . 108 C2 lnspeclicn H . D, Reassembly 108 4.11 Rear Cushion . 109 A1 Consvruclion . 109 131 Disassembly 110 C1 Inspecnon 110 D, Reassembly 11o 4‘12 Fronl Wheel 111 A. Consrrucnon . 111 13, Disassembly ,,,,,,,, .. 111 c, Inspecnon r, . 112 D,Reassemb|y H 112 4113 Rear Wheel ....... . 114 114 A2 Descriplion El D1sassembly c. Inspection D1 Reassembly 5‘ ELECTRIC SYSTEM 00000000 116 117 1. Ignilion Circuil H 120 A. |gnil1cn coil .4 4 4 120 B. Spark advancer‘ .. . 120 C1 Conlacl breaker 1 121 D, Condenser‘ , . 122 E, Spark plug ........ 122 2‘ Eleclrical power supply 124 A. AC generavor 222222 124 3. Selenium recllfier ...... 125 4, Ballery . A. Consrrucrion 2 126 B Ruling . 126 C4 |nslrucl1on on use and servicing 127 D4 Bauery charging procedurau. 2 127 E. Trouble shooling and correcme acnon ..... , 129 5. Various loads A. Headlighi 130 B Tail sloplighl 130 C.Neu1rc1| and speedomeler lamp . 130 a, SIarIing moror . 131 A. Descriplion 131 B. Disassembly . .. 132 c. Inspeclion .. . 132 D. Reassemly 132 7 Service lesier instruciian .. 133 6, PERIODIC ADJUSTMENT ........ . . . , 138 6.1 Mainlenanceinspeclion ..... 135 A. Engine Adluslmenl 138 1. Measuring compression . 138 2. Tappel odiusimenl ..... 138 3. lgnilion liming adiuslmenl. 139 4. Caniacl poinls ......... .. 140 5. Spark plug adrusimenl . 140 e. Fuel supply syslem .. 141 7. Fuel sIrainer cleaning . 142 5. Oil iiller screen cleaning. .. 142 9. Air cleaner servicing . 142 10. Carburelor cleaning and cdlusimenl 143 B, Lubricaling ......................... 143 1. Paris nol requiring periodic oil change or lubricalion . 143 2. Engine oil change ............................... . 144 C. Drive chain adluslmenl D. Brake adluslmenl . 145 I. Franl brake adluslmenl... 145 2. Rear brake adluslmenl 145 E. Spoke iorauing 145 F. BclIery inspecIion .. 145 G. Securily inspeclion oi paris 147 6,2 Periodic Inspection and Servicing.. 14a 7. TROUBLE SHOOTING 150 1. Main engine lrouble ...... 150 2. Carbureior Irouble.. I52 3. Engine noise 154 4. Sleering syslem . . 154 5. CluIch sysIem . . 155 6, Gear change sysIem . 155 7. Suspensions... 155 8. Brake sysiem 155 9. Drive chain” 156 8. WIRING DIAGRAM . 157 (213125 wiring diagram . 157 CL125 wiring diagram 158 c3175 wiring diagram . 159 . 160 CL175 wiring diagram IGenercl exporl Iypel . CL175 wiring diagram US. A. Exporl Iypel .................... 1e1 —VIII— 9. CB/CLI25, I75K3 ......... 9,1 9.2 9.3 9A 9.5 Dismounring and Mounoing Engine l. Dismouniing engine lCB/CL1751 lCB/CL125I 2. Mourning engine .............. Engine Mechanism ............................................ (ca/cum] cylinder head and cylinder .................................. Crunkcase Gear snin mechanism Cronksnoir .s Transmission Kick sicrrer . Carburetor . s [CB/CLI25] . cylinder head CamshuH ssssss Cum chain iensioner . moosewmd Transmission Gear shining mechanism Kick siarier. N?9?UN~ Carburetor . Frame 1. Fronr suspension 2. Rear suspension .. 3. From wheel 4. Rear wheels... Elecirical ...................... ls Charging currenr meosuremenl . 2, Sioriing moror 3, Srarier solenoid swirch s Wiring Diagram ......... 162 162 162 163 163 164 164 167 167 170 170 .172 172 173 174 175 177 180 182 183 184 184 185 187 188 190 I90 190 193 194 I. SPECIFICATIONS 'l. SPECIFICATIONS CI] 75 (U.S.A. Typa) mm )in) llom x o x :l x 4 DIMENSION Ovamll leagm ).975 )77.3) ),950 (70,35) L975 )77,a) Overall mm 745 l29.31 Same as len Same as Ian Ovemll helgm ),0)5 00.0) LOAD (40,94) I ),0)5 0100) Wheel base ),275 I502) l,260 (50.39) ),275 (50,2) Sea) heigm # l 770 )30.32l Same as )ell Gvuvnd clearance 145 ( 5,7) l 167 l 5.57) ‘ Same as )ell Dvy wergm ”9&9 I264 lbs) Curb WBlQN I27 kg (171 lbs) Curb wergm 136 kg )299Iasl FRAME Typa Backbone Sem) double cradle lualer lyae Same as len f. Suspenslun. Havel Talescnplc Iovk same as len Same as len R. suspensinn. Havel Swing arm lype Same as len Same as len r, fire szse, lvpe 2,5040 (4 PR) 2.75434 | Same as )ell Turn size, Iypa 2.7546 )4 PR] 300434 Same as let) 7, bloke Imemal expundmg shoe Same as hell Same as let) )2. Wk. Imemul expundmg shun Same as her) I Same as len Fuel aapaazly 32065:): I 23) H Same as lell "3'0”" . go. . mp go, l2,6USgul.,12lmp.gul.) 2.5 ‘1'. Fuel Vesarve capaclly # ,5.“ US p), “a WW” Same as lell Casner angle 54° Same as )ell Same as )ell Tvuil long") as I136! Same as lell Same as lerl ENGINE Type A" cooled A slrole cycle Same as Is!) Same as len Windy “magma” 3mg)? )rralzrred Ivom {3: 5:33;: a“ inclined Same as IE“ Bola and snake 52x41 (1.017Xl.6l5) Same as )ell Same as )ell Dzsplaaemem I74 cc llO,é5cw1nI Same as )ell 1 Same as )ell Compression ram, 9,0 ,1 Same as )ell Same as )ell Valve lraur Sgiang'm" “WM“ Same as Ierl Same as Iell Muxlmvm horsepower 20,0 PS )o,o00 vpm Same as )ell Same as )ell Maxlmum laraue I,5lg~m (H18 n. lbs) Same as lerl Same as let) on cam,” L5)", (3,2 us als, 2.7 Imp. plsl 1 Same as len Same as her) vavi liar. syslem raraed pressure L we) sump l Same as lerl Same as )en II SPECIFICATIONS mm (in) l .m l x n x a x 4 Opens 10“ IO“ Same as IeIl Intake valve Closes A0“ 30° Same as IeIl Opens 40° 40“ Same as Ien Exhaus' valve Closes 10° 10° Same as IeIl Valve mppen cleavnnca 0.05 01002) Same as IeIl Same as I." Idle speed 1.200pr Same as lell Same as IeIl DRIVE rum Clutch MualIe we! plmes Same as IeIl Same as Ien Tvnnsmission Consmm meshed gears Same as IeIl Same as I." anury veducvion 3.700 Same as Ien Same as Ieh Gem rulio I 2.759 Same as Ien Same as IeIl Gem rmio 11 Lee: Same as IeIl Same as Ien Gem ratio 111 l us0 Same as Ien Same as I." Gem rmio IV I 1.173 Same a: Ien Same as Ien Gem rmio v J LDDO Same as IeII Same as IeII hnul vaducvion 2.500 mm Sum. as Ien Gem shill pallem LaIIIood Dpevmed velvm lypa Same as Ieh Same as Ier ELECI‘RICAL lgmlion Bufiery and igmlion can Same as Ien Same us IeIl Svavlmg system Mom and luck Same as IeIl Same as IeIl Allemulm AVC. genevamv mm wp. Same as Ien Same as IeIl Bauery capucuy l2V-9AH Same as Ien Same as IeIl Spark plug D-BHS. Hm D-BHS some a: lell CL] 75 (U.5.A. Type) II SPECIFICATIONS mm (IN I Ilom I x n K a x l I DIMENSION Ovevull lengII. I l.975 um I L990 (76.3I Same as I.“ Overall mam I 745 IZ9V3I I 520 mm Same a: In“ I OvevuII neighl I l,0l5 mom Loao I415) I Same a: In“ I wneel base I ‘I.275 I502) L290 I505) I Same as I.II 5m nelgm I — I 790 l3l.lI I Same a: lo“ Glound cIenvunca 145 I 5.7l I 200 I 761 Same a: In“ my welgm 129 kg IzsAlbxl I Curb weigm I2Akg l273.4|bxl Curb walghl lSékg ISODbe) ram: 7w: auclbone Semirdouble cvudlawblar lype Sun. a: In” I, xuspanxion, "oval Talaxcopic Iork Same a: lo“ Same as lell R. suspanxlon, Irnvel Swing arm Same a: IeIl Same a: la” r, Iire xiza. Iype 15045 (4 PR) sou-IN Same as I.“ E. III: me, Iypa 2.75-Ia l4 FR) 100434 I Some a: lo“ I. bloke Inlemul expanding xhoe Sun. a: leIl I Same a: In“ Re MI. Imemnl expanding shoe Smle a: lo“ Same a: lo“ “'°' ““0" (91'55II35 I 2 II II 32.23% I l9fll II 5"" °‘ '°" I gun Ian go. . gun . Inmue ruel vexerve capucny Iii?“ F" 2,54 Imw le I Same a: In“ Cum: ungIe w Same as IeII Sun. a: In“ Inall lengln as (3.38) 90 (3.5) Same as lell ENGINE 1w. AII cooled 4 make cycIa Same as leIl Same a: lo“ Cylmd" “Hangman, Imago" IncIIned ham (1:: 5m: 5“ Inclined Sam M I!“ Bore and male 51x41 I1047xl.el5l I Same a: la“ Same as leIl Displacemanl 174cc “0‘55 cwin) I Some a: len Same as I.“ Comprexxion rnIio 9.0 I Same a: la“ Same a: lull Valve lrnln Emanfi'm" °”'"°°d Same a: IeII Sam. a: IeIl Maximum houepowav zoPs H1000 vpm Sun. a: Ian Same a: In“ Maxlmm lorqva lfikgrmllO.flII.lbs)B,5007pm Same a: Ian Same a: lo“ 0“ “penny LSIiIV l3! us an, 2V7|mpvplxl Sane as IaII Sam: a: lo“ Faced prexxwe a. wel Sump Same as IaII Same a: In“ lubvicaIiDn we". I. SPECIFICATIONS mm Vin] llom I x n x a x 5 Opera I 10" ID“ Same as Ieh Imuke valve CID“: 40“ 30” Same as Ien anrrs m 40” Same as In“ Ernausr valve Closes IO“ 10“ Same as Ien Valve Inppefi cIeuvunca I 0.05 (0002) same as Ien Same as Ien Idle speed I 1,200 ram Same as Ieh Same as leH DRIVE YRAIN Clmch I Multiple we' pla'es Same as Ieh same as I,“ Transmission I Consvam meshad gear; Same as In“ Same as Ieh Prrmarv veduchon I 1700 3.700 Same as Ien Gear ravio 1 I 2.759 Same as In“ Same as Ieh Gear ram 11 1.562 Same as Ien Same as leh Gear ram, 11] 1.450 Same as Ien Same as lell Gear rana IV 1.173 Same as Ieh Same as Ieh Gear who v Looo Same as Iah Same as lell rrrsal veduclion 1375 Same as Ieh Same as Ieh Gear sh." aanerrr lehIomDpevmedrelvm Iype Same as Ien Same as Ien ELECYRICAL Ignrnarr sauerv and Igmlion coil Same as Ieh I Same as Ieh Slurfiing Syslem Motor and luck Same as In“ I Same as lell Allernulm AC. generulD' rmor fiype Same as Ieh I Same as Ien aanerv eapaarvv 12V-9AH Same as Ian Same as Ieh D-aHs, x-zzrs n-aHs Same as lell Spark pIug I, SPECIFICATIONS CB] 25 rnrn lrnl I llonl K a K 2 K a I DIMENSION Overall lengIh I L975 I77.al I Same as leIl I330 07.95) Overall widm 745 l29.3l I Same as Iell Sarne as lelr Overall hergm I 990 (39.0! I Same as IeIl I Low I40.94l Wheel base I 1175 mm I Same as Iell I L260 (5039) Seal hergm I i, I 750 (30.7l I 790 l3l.l0l Ground clearance I us l 57) Same as lell I ND I 5.51) I Club welghl ll 9 kg (162A lbs) Iuhricarion sysrern nry weigh! I ”5kg (2516mm Club waighl llakglulflsilbsl FRAME Type I Backbone p‘lpe Irarne Same as Iell I Samldoubla cradle Iublev rype r. suspension, rrayel Telescopic lovk Sarne as lell Sarne as IeIl R. suspens.on, nayel Swlrlg arrn rype Same as Iell Same as lell r. nre Elle. rype 2.50—Ia-l Same as lell Same as Iell l2, nre size, rype 2,75-lB—é Same as lelr Smle as lelr r. prale lnrernal expanding shoe Same as Iell Same as lell R. bvulle lnrernal expundlng snoe Same as lell Same as lell r I I lo.5l.r. loom 5 ll "' “”“C'Y (2.5 USguL zalrnp gall l2.eu5gal., 22Irnp. gall “"‘° "5 9’ fuel reserye capaciry i, 2.5m. l5.3 us pr. 4.4Imp.pl) Same as lell Cuslev angle on Same as lelr Same as lelr Trail lengrn as (3.391 Same as Iell Same as lelr ENGINE Type Aiv cooled A SHOE: cycle Same as leIl Same as lelr Twln. so“ incllned Irorn Swlrl parallel, 5° inclmed Cyl.nder arrangemenr ”mm Same as leIl Wm mum Bow and snake uxn [L732XL6I5I same as leIl Same as lelr D.splacernenr m cc v.59 CIIcin) Same as Iell Same as len Compresmn rarie 9.4 I Same as leIl Same as ler Valve lvuln Chm" d'we" ”WM“ Sarne as leIl Same as lell carnsnan Maximum horsepower 15 PS/l moo rprn Same as leIl l5 PS/ID,ODUrpm Los kgsm lo.5 kg... (759 ll. lbs) Mnxlmum roraue M9,, lbs) 9mm” Same as lelr 8,500,” on capaciry IZIll. (2.5 USpIs, 2.I lmp.prsl Same as Iell Same as Iell rorced pressure as wel surnp Same as leIl Smle as lell 7. SPEC [FICA TIONS Spark plug mm fin] In... I x o x 2 x :l Opens | 5" Same as lelr Same as In“ Inluka valve Closes 30“ Same as lslr Same as Ieh Opens 35” Same as len Same as I.“ Exhaust vulva Clases 5" Smle as leh Same as Ieh Valve laaael aleararrae I 0.05 [0.001) Same as In“ Same as In” Idle speed 1,200 rpm Same as lsl. Same as Ian DRIVE "um Clutch f Mulliple we! planes Same as lell Same as In“ Trunsmlxslon Canslam meshed gears Same as Ieh Same as Ieh Primary reduclian 3.875 Same as lsll Same as lell Gear ralia 1 2.615 Same as lsn Same as Ieh Gear ralia 11 L611 L667 Same as In” Gear ralia n] l mu 1255 Same as Iell Gear who lv 0.9!7 um ‘ Same as lell Gear rulID v i 0.680 Same as In“ Final vaduclion I 2.367 3.!33 Same as len Gear shill aanern 1 LalHooloparuledvalum type Smle as leh Same as In” ELECYRICAL lgrrmon ‘ Bauery and ignillarr coll Same as len Same as leh snarling syslem Movor and Hal Same as leh Same as In” Allemulm A.C. geaeralar mlorHIQW Same as lell Same as lell aanery aaaaaily WAéAH J éV-I2AH Same as In” DAEHS. {—ms ’ near-ls Same as In“ I. SPECIFICATIONS C“ 25 mm IInI llom K o I x a I x a DIMENSION Overall lengm I 1.930 Um I Same a: lo" I Same a: lo" Overall widvh I 330 law I Same as leh I am mew Overall heighl Loan mm mm (40.6] I Loan “0.55) Wheel has: L270 (50.01 Same a: lo“ L230 [50.39] Sam nelgm — I — — Ground cleamnce I Iso ( 5m I Same a: In“ I I55 ( an Dry weigm I Il7kg lzsalbsI I Cwb weigh! llSkgl153.6lbxl I Same a: In” fRAME Type Backbone PIPE Item: I Same as lo“ I Semi double cvudla lublev lype r. xuspenxlon, navel Telechpic York Some a: lo" Same as Iell fuel cuppcny (2.6 us gul., 2.3 Imp, gum l2.5 us gq|.. 2.l Imp. gulJ R. :uxpension, "oval Swing arm me Same as IelI Same as lelI r. live size, we 1.75454 Same a: la“ Same as lelI , R. me me, lype 3.004574 Same as IelI Same a: lo" r. brake Inlemul expundlng shoe Some US lelv Same a: lo" R. bvuka INernal expanding xhoa Some US lelI Same a: lo" 10.5lil. 9.5m. Same m M. fuel mem cepecuy Same a: lelI Cuxlev angle 6A“ Same a: lo" Tvull langlh I 86 I138] Some 0: lelI Same a: lo" ENGINE Type Aiv cooled 4 xlmke cycle Same as Ieh Some a: In” Cylind e! urvangemenl Twin. 30" Inclined Irom venical Same as lell Twin parallel. a” inclmed Imm verlicul Bore and make uxal (L732Xl.6l5) Same as lelI Same a: lo" Dixplucamenl 114 cc v.59 cuVIn) Same as IelI Same a: len lubrication xyxlam Compression rulio 9.4.4 Same a: lo“ Same a: lo“ Vhlve "Gin 3:25?” ““9““ Same a: IelI Same as Icn Maximum hovxepowev UPS/10,000 [pm Same as Ien Same as Iell Maximum "mm l‘flikfiffl‘m 3.500pr Some a: In“ Same a: leIl on cupucny mm, l2.5 us pls, 2.1 Imp. pm Same as leII I Same as I." Plenum a. wel xvmp Some a: In“ I Same a: lo“ I. SPECIFICATIONS mm (IN I' 0 III K 0 K 2 I K 3 Open: 5‘1 Sum! us In" I sum: us Is" Inlule VuIVa Closes 30° Same as lull I Same as In" Open: 35° Same as In" I Sum! us Is" Exhausl Valve CIDSeS 5)" some US lull Same D5 In" Valve Iuppel cleumnce 0.05 (0.002) Same as In" I Sum! 05 IE" Idle Speed I100 mm Same OS Is" I sum: as In" I DRIVE IRAIN I Clulch ' MVIIIPIB we! plmes I Same as Iel! I Same as In" I TranSmISsion CDMIUH' mashed years I Same as In" I Sum! 05 Is" I Primaly vaduclnon I 3.575 I Same as In" I Same as IBII Gear ratio I 2V6I5 I Same as In" I Same us Is" Gem ratio 11 L5” I Same as In" Same as Ian Geuv ratio III I IVI90 I Same us Is" Sum! us Is" Gem mno IV I 0.917 I 0.680 I Same as lei! Gm mm, v — I — I — FInuI vaduclion won I 3.133 I Same us In" Geav SIM! Dullem I la" Iool Dperaled raw": Iype I Same as In" I Same as In" ELECTRICAL Ignifion I Bunny and igmlion coil I Same as I." Same a: my swung syslam I Mom and kick I same as I." I Same us In" AIIemuior I A.CV ganwa'ov rDIDV lypa I Same us Is" I sum: us Is" Baum cupuclly I swam-1 I sum. as Ian Same as lell Spalk pIug I DiSHS, Xi14f5 50‘": as In" Same us Is" 63125 DIMENSIONAL DRAWING W I. SPECIFICATION & PERFORMANCES ("If“) (“II‘GU 071* [’(W'SZHSD LN?) (50 Tu) I .975(77.Bln) (“W“) 083 745 (29.3in) IO 63175 DIMENSIONAL DRAWING II (mm) us (29.3in) ‘ SPECIFICATION G: PERFORMANCES (mm) on (may) see “IK'ZD 912 “IT!” 9161 12 SPECIFICATION a. PERFORMANCES 1. 25¢: 82‘ fi'ggc :: 1|‘_ ("162) 991—- 04811) ass—- ‘ 02.34MB ._?‘£\VA % G) Slap bar ® snim bells and nuns, rig. a-I. ihe lubricavion sysveni uiilizes a plunger iyae oil pump, driven ihrough ihe nansmission main shall io provide lubricmion under pressure io all ol Ihe primary maving pans al the engine and in conlunciion. a screen and a cennilugal lilver are incorporaied in Ihe sysvem io assure vhai only highly purified oil is circulaied wiihin ihe engine to minimize the pans wear and anribuiing lo ihe exiended engine lile. liernavrng uh. siea bar B. Engine removal (CB I75 and G. 175) l. Shui all ihe luel cock ai ihe luel ianl. 2. Remove Ihe slep bar G) by unscrewing ihe iwo 5mm nuns and 5x25 balis Q) lamm bolls lor CLI75I. (Fig. 34) Remove ihe 6mm nuis lroni ihe cylinder head and a X36 boll, and ihen ihe mulller can be separaied. lCL I75: Remove Ihe 6 mm nuvs lroni ihe cylinder head and 8mm nui and 6 mm bolu 3. Remove ihe air cleaner cover. I. Remove Ihe air cleaner (D by unscrewing ihe Iwo 6X12 balls (2) and ihe 5X16 crass screw @. a) Clinch cable ® Clinch liner lhreud (Figs 3’7) fig. 3-3. Disconneciing lhe clulch cable 5. Remove Ihe leri crankcase rear cover and dis. connecv Ihe clinch cable G) lower end lroni ihe clinch liner ihread Q). (Fig. 373) a, Harare ihe rear wheel '0 aosiiion Ihe chain ioinl adiucem io ihe drive sprockei and disconneci ihe drive chain (2. (Fig. 374) (D John cIlp @ Drive chum Fig. :4. nisconnecimg ihe drive chain 19 3. ENGINE 7. Disconnect the high tension terminals lrom the spark plug. Remove the starting motor cable, and then disconnect all leads. (Fig. 3*5) 5. Remove the carburetor (D. (Fig. 375) (Note) Separate the fuel tank to facilitate the removal of the 6mm bolts. 9. Remove tne engine mounting bolts and the engine can be need from the lrame. (D Caiauneions @ 6mm hex, bolls rig. 3-5. Removing the carburetors c. Reussembly 1. Perform the engine installation in the reverse order of removal described in Section 3.1 B. 2. Tie engine installation can be made easier by temporarily hanging the engine on the frame by the use ol the Tnhandle cross screw driver ® followed by the installation ol the engine mounting bolts. (Fig. 377) (D Tenanaie cross screw driver Fig. :77. Installing me engine (Note) When reconnecting me drive chain tne iolnt clip should be installed with the opening lacing opposite DIRECTION OF ROTATION to the direction of the normal drive chain. — (Page 3,5) 3. Adlust the chain tension so that there will be I to 2 Cm l0.40~0.80 inl slack at midpoint between the sprockets. (D Join! clip Fig, 3-3. iomi clip installation 3.2 CYLINDER HEAD AND CYLINDER 20 fig. :79. Valve machurlixrll 3.2 CYLINDER HEAD AND CYLINDER I. CYLINDER HEAD A, ConsIrucIion The cylinder head is a casr aluminium rwin cons. rrucrion ol a semisaherical combusrion chamber wirh a sauish area lor bener combusrion eliiciency. The single piece overhead camshalr, rocker arm and valve mechanism are all incorporated in Vlle valve chamber above rhe combusrion chamber. (Fig. 379, 340) Conrad breaker assembly is mourned orl rhe lelr end cl lhe camshail. Cylinder head cover incarparaies a brearher pas. sage ro prevenr rhe pressure build ua. a. Disassembly 1. Drain oil from lhe engine. 2. Remove lhe kick slarler pedal, righl crankcase cover and cylinder head side cover. Cl. Remove lhe gear change pedal, Iell crankcase cover. point cover and breaker assembly. 4. Remove lhe eighl 8mm blind nuls (D and 6x45 llex. boll ® and lhen remove the cylinder head cover @. (Fig. sell) 5. Rolale lhe crankshail so lhal rhe cam chain ioinl clip ® is roward lhe lop cl lhe cam sarockel and Vllen disconnecl lhe cam chain G). (Fig. 342) , . Anach a wire In both ends ol lhe chain belore (D 5,"... bind n... ® 6x45 i." be]. disconnecring, lhis will simplily rhe assembly lask @ Cylinder head cever larer. fig. 3-”. kemavina rhe cylinder head caver a. Separare rhe cylinder head ® Joint clip Fig. 3-”. aiscannecting the cam chain 3. ENGINE (D Cylinder head ® Blulng or red lead cnecltng the cylinder head tor wutpage Inspection The cylinder head is exposed to the high pressure and temperature resulting from the combustion ol the fuel mixture. further. when the head is unevenly torqued. it may develop cracks or warpage and will cause defective sealing between the head and the cylinder resulting in gas leak. air sucking with consequent drop in compression. The warpage ol the cylinder head does not develop suddenly and it may be overlooked. therefore. caution should be exercised during reassembly since the uneven torquing of the cylinder head is a very common tault. To inspect tor warpage or the cylinder head. apply a thin coat or bluing or red lead on a surtace plate and work the mating surlace of the cylinder head on the surface plate; the warpage can be determined by the transler ol the bluing on to the cylinder head. (Fig. 343) To correct the warpage. lap the cylinder head on the surlace plate with a $200 sandpaper. finally tinish by using a $400 sandpaper. and then inspect again with the bluing. Inspect the combustion chamber, inlet and exhaust ports lor cracks. Inspect the valve guide and valve stem. Check the valve guide diameter at the top. center and bottom in both the x and Y axis. using a precision cylinder gauge. Check the valve stem with micro. meter. It the valve guide inside diameter is beyond serviceable limit. it may be repaired by using a learner (Tool No. 07005-00101) and replacing the valve with one of an oversize. inlet valve lt em Outside diameter Contact lace runaut Standard Value 5.AB~5.AV rnm 10.1158~D.2162in1 with in 0.02 mm (0.000atnl l Setvtcenbla llmlt l Replace ll under 5.45 mm l0.2l5 inl inlet valve guide inside dameter . Outside d.amet er - lnterterence l'it 5.5~5.5l5 rnm l0.2l65~0.2|7l inl 10.055~ID.065 mrn ID.3959~D.3963 inl 0.04~ 0.055 mm l0.00lé~0.0026 tnl Replace ll aver 5.555 mm l0.2l9int inlet valve clearance 0.01 ~0.035 mm (0.0004~0.DON inl Replace ll over 0.06mm l0.ozainl Exhaust valve Outside d arneter Contact lace runout 5.Ao~5.47 mm l0.2l50~0.2l5A tnl with in 0.02mm l0.000& tnl Replace it under 5.44mm l0.2l4tnl Exhaust valve guide inside diameter . Outsde diameter rnterlerence lit . [ 5.5~5.5l5 rnm ‘0.11é5~0.1l7lin| l0,o55~ 10.065 mm (0.3959~ 0.3953 tnl 0,04~0.oo5 mrn t0.00lo~0.0025 tnl Replace ll over 5.555 mm l0.2l9 tnl Exhaust valve clearance 0,03~0.o55 mm l0.0012~0 0012 in) Replace ll aver 0.l rnm (0.0039 tnl 3.2 CYLINDER HEAD AND CYLINDER 22 4. When replacement ol the valve guide becomes necessary, remove and replace with an oversize guide, use the vaive guide remover (Tool No. 0704770400]! and the valve guide drivel (Tool No. O7046~2l60|l tor replacement operation. After installing the valve guide, use a reamer to obtain the proper valve clearance. o. Reassembly Clean and inspect the cylinder head interior and exlerior tor cracks. damage and warpage, also inspect the head gasket, valves, valve guide and spring lor satisfactory condition. Perlorni the head assembly in the reverse order ol disassembly. 2. When installing the cylinder head to the cylinder, the cam chain should be assembled as shown in Fiv. 3-l4 and attention should be given to the proper valve timing. Align the "T" timing mark on the generator to the timing index mark lthe piston is at topedeadecenterl, position the camshalt sprocket so that the “0" mark on the lace oi the sprocket is at the top. and then assemble the cum chain. The ioint clip must be installed with the opening facing in the opposite direction to "la normal chain movement. ® Center crankshaft ® Cam cham guide roller (5) Tensianer push rubber G) Cum cham tensioner spring © Tensianer set bolt (5) iensioner push bar (7) Cum chain lensioner (5) Cam shalt re. a-u. Assembling the cam chain 3. It the cam chain lensionel pushbar is not completely pushed in. the cam chain cannot be connected. (Fig. 345) g . {l2 4" w . @ Tenxlonev set batt ® Tensioner push bar Fig. 3—15. Pushing m the tension push bar 4. The cylinder head should be tightened unilornily with the torque wrench in the sequence shown in Fig. 346. [Torquez lw~2lo Kg. cm lll.6~ ls.2lt. lbt] rig. a—la. Tightening sequence ol the cylinder head 23 3. ENGINE m rrom crankcase @ Exhauxl gas Fi . S-IB. Princrple oi bvaulhev (D Comacl breaker cover ® Conraar breaker assembly 3—19. Removing me camacl breaker assembly (D Wooden block sippper ® Spark udvuncer Fip. 3-20. Removing me Spark aovanoer 2. CYLINDER HEAD COVER AND BREATHER As Description A brearher chamber is incorpormed in me head cover which provide aonsrani pressure wirhin rlre crankcase. Funher. yhe oil is separared lrom yhe gas which is exhaust As rlre oil laden oil vapor passes rhrough rhe breayher passage, yhe oil is separmed from wire gas by aenrrirugai tome and nows down me oil passage where ii is collecred. (Fig. 347, 3—”) B. Disassembly of me spark advancer 1. Remove yhe convacr breaker cover (1), comacr breaker assembly ® and men remove me spark advanaer from me camshalr. (Fig. 3—19) (Note) A wooden sropper block (1) slrould be used in key rlre camsharr ® from rurning (Fig. 3—20) 3‘2 CYLINDER HEAD AND CYLINDER 24 2. The conlacr breaker polril base can be removed by loosening lhe [our mounring screws. (Fig. 3*2I) 3 The spark advancer cenier piece serves as a bushing ior ihe camshalr. lr is oiled by ihe oil vapor and does nar require special lubricarion. 4 Perform lhe assembly is the reverse order of disassembry. 5. The culoul m rhe coniacr breaker painr base should be aligned so ihar ii is ar lhe rap / ® Caniaci breaker paini base figs 3-2I. Removing ihe aaniaci breaker pairn base 3. CAMSHAFT A, Construclion A single piece camshalr coniains borh inler and exhausl carns rogeiher wiih rhe sprocker which is mounred in lhe cerirer of We camshaft. The cam sprocker is driven by the crankshalr a! 1,9 rhe speed ol the crankshah. (Fig. 341) ® Camshali ® Tapper adinsiing run @ Rocker arrn G) liaclrer arrrr shali . 3-222. The cam is provided wirh a long gradual rise lo prevenr abruar rise and drop al lhe valve, rhus assure irig a quierer valve aperarion. (Fig. 372:!) a; Base circle ® Max cam lih @ Buller curve @ Cum heighi fig. 3-21 Cum comm" 26 3. ENGINE Br Disassembly L Pemove lhe cylinder head in accordance wilh Section 32s]. 8. 2. Remove lhe Ieii and righl cylinder head side covers. coniaci breaker assembly. spark advancer and iappei cdiusiing hole cap. koiaie lhe carn- shall so ihal bolh rocker arms are resling on lhe heel cl ":2 com. in ihis position, disassemble lhe rocker arms from ihe head by removing ihe rocker drm snails. (Fig. 372‘) CD Valve reckar am (2) Rocker aml shall ‘7‘ 3-24. Removing me valve rocker cm. W ' _ L 3. Remove lhe camsndn from ihe cylinder head. ' (Fig. 3725) (D Camsnun Figs 3-25. Removing lhe cumsndir .5 .s E as "‘ u: 353%, 3% 7:5: 2.5 .c? 2.}, 1 l ro—un N— o.33: o3 W‘ M? =2.» #39,: 23‘ @d: o 3-26. Cdmshuli C. Inspection liern Slunduvd Value Sevvicauble lell 1. Camsnan (Fia- 346) W" 5"“ d'mm ® igfizii'riflaey‘m 73$$1H33§23m h" m dimer ® favé’lii'ri'rymfli 53'?9'3§'n.'l 73.3223 mi Cam base civcla “‘“ 2L0 mm IUV827 In] Cam haighl IN 25.057 mm (Q9665 lnl EX 24!“ mm (0.9792 lnl D. Reussembly i. Screw ovi Yhe iappei adiusiing screw and assemble ine rocker arm inlo lhe cylinder head in Yhe reverse order oi disassembiv, 2. Adiusl lhe idppei clearance lo 005mm «10020 in: win. a cold engine. (Naic) Repair or replace me camshuh if lhe cam is scored or worn exessively. 3.2 CYLINDER HEAD AND CYLINDER 26 A. ROCKER ARM A. Construction The lunction ol the rocker arm is to transpose M ® the rotary motion ol the camshalt to a reciprocating motion lor actuating the valve. The rocker arm is V made rigid to prevent deflection and the end which ® contacts the cam is llnished smooth alter surface hardened to minimize wear. The end which operates the valve is provided with a tappet odiusting screw that contacts the valve (Fig. 3-27) B. Disossembly © Valve racker arm ® liocker arni shalt rig. 3-27. Rocker arm and rocker arm shalt. l. Disassemble lhe rocker arm in accordance with Section 3.2.3. is. C. Inspection -—-L 1. Pocket arm ltem Standard Valve Servtceable llmll my sur. _ Replace il ever lace wear 0.3mm lo.ol2 ml Shah bore lo.o~la.ols mrn Replace it over dia 10.3937~0.3943tnl lD.l mm (0.40 in) 2. Rocker arm shall item Standard Valve Serviceable Lmtt _ Outside 9,972~9,9e7 mm ltealace it under d.a [U.391£~0.3933ln| 9.91am (0.3934lnl u.ol3~o.lm mm Replace .l ever “WM“ [0.0005~D.00|7in) o.oemm l0.003| lnl 3. Check for proper tappet clearance. (both inlet and exhaust) should be 005mm (0.002in), loo small a clearance will otiect the engine causing come pression leak and results in hard starting 4. Check lor proper valve timing. (Fig. 3-25-1) lRerer to page 22l 5. Check to see that the cam chain is not stretched. D. Recssemblv l. Inspect the rocker arm contact surlace and repair or replace ii there is scoring or excessive wear. ® inlet valve opens l0“ @ inlet valve closes Ac? @ Exhausl valve opens 40° @ Exhauxl valve closes 10° rip. aeze-l. Valve llmmg dlugmm. 2, ll the rocker arm had been disassembled, the tappet clearance should be readiusted. Make the adiustrnent by positioning the piston on loprdeadr center ol the compression stroke. this will lree all ol the valves Align the " ' timing mark on the generator rotor to the timing index arrow mark on the slalor 3. Check the valve lappet clearance with lhe thickness gauge. (Fig. 3-25-1) © cvlinder head cap ® Adlusling scre @ Lack nut G) Thicknexx gauge rip. 3-234. Checking the valve lappel clearance 27 3. ENGINE (D lnlel valve (2 Exhausi valve @ Valve spring seal (9 lnner valve spring © Ouler valve spring © Valve spring reiainer ® Valve caller Fig. 3—29. Valves (D Valve liller Fig. 3—30. Removing lhe valve ® 037 EXHAUST VALVE <9“? INLEIVVALVE ‘e' H. rig. 3—3l. lnIel and exhasl valves 5. VALVE A. Descriplian The valves conlrol lhe volume al inlel gas and also lhe exhausl gas enlering and leaving "19 cylinder The diarneler ol lhe exhausl valve head is made smaller lor beller heal radialian. lnlel valve IS made large lor grealer volumelric eliiciencv. Double spring lealure prevenls lhe valves lrom noaling during high speed operalian. (Fig. 3—29) is. Disassembly l. Remove lhe cylinder head in accordance vvilh Seclion 3.2 l a. 2. Disassemble lhe rocker arm lrom lhe cylinder head by pulling oul lhe rocker arm shall. a. Compress lhe valve spring will. lhe valve liller ® lTaol No. 07957732moom and aller removing lhe valve coller. valve spring and lhe relainer. lhe valve can be removed. (Fig. 3-30) c. lnspeclian l Exhausl valve (Fig. 3—3l) liem Slandard Value Serviceaple Limll m m (D 72.l5~72.45 mm Replace il under 9 l2.8405~2.6524ln1 71.75 mm luvs ml . ssoa~s.47 mm Replace il under 5'5"“ d'" ® lo.2lso~o.2l54 inl 5.44mm "12142 inl Head o,55~o.a5 mrn Replace ll under lhickness @ lo,02l7~o.0335 lnl 03mm mm is inl Cancenlriciiv ol valve lace Wilhin 0.03 mm moon lnl 2. lnlel valve llern Slandard Value [MW (D 73.35 I 7165 mm Selvlcaabla limi! Replace il under £2.687&~2.8996 inl W Sm" ® I ssoe~5.49 mm Replace il under 156~02162m1 5.46 mm losl25lnl Head os35~0.65 m l Replace ll under lhickness @ lo.olaa~o.0256inl 0.2mm lo.ooaainl ffggjygif‘j'c: wnnn mm [0.001 3. Valve spring measuremenl Ouler valve spring Ham Slandavd Value Sevvlcaabla Limil Replace ll under free Ienglh ales rnm llezsiolnl 30.6.“ (“204“") 29.5mm/7.5~a.3irg l,léllin/l6.53&~ i swing 16302 lbs) pressure 23.3mm/29,4~31.6kg "3.9173 in/64s627~ — 71363 lbsl lnner valve spring llam Slandurd Valve 5erv eaale f . Replace .l under ree lenain 30.2 mm ILIB9Dm1 29.7 mm ”mam 26.2mm/4.06~4.51kg ILOSIS ln/E.996~ — 9 67be) Spring pressure 2 l0s7992 in/uoas 26.68! lbsl 3.2 CYLINDER HEAD AND CYLINDER 28 D. Reassembly I. Belore the valve is assembled, the valve Contact surlace should be inspected tor wear. pitting. or carbon. Alter cleaning. oil the valve stem. and the valve should be inserted from the combustion chamber side. 2. The valve outer and inner valve springs and retainers should be litted from the cap hole of the tappet adiustirig hole and compressed by using the valve litter lTool No. 07?57732?0000l. Secure with the valve cotters. 6. VALVE SEAT ‘ ‘ ® Valve sear cutter ® Cylinder head A. Description Fig. 3—32. liewarlring the valve seat The valve seat is repaired with three types ot cutter. The relative location and the width of the valve seat contact area is accomplished with the seat top cutter and seat bottom cutters while the retacing ol the valve contact area is perlornied by the 90“ cutter. (Fig. 3732) Valve seat cutters am. not W Valve seat cutter 90” 0796071350‘00 flat surlace seat cutter llNi 0795072350300 flat surlace seat cutter [90 0798072360400 Interior seat cutter llNi 079E0-2350500 Interior seat cutter lEKi 079E072350600 Valve laaping operation is perlormed last. this is to obtain a leak prool seal between the valve and the valve seat. Place a liberal amount at lapping compound on the valve lace and lap the valves. applying a slight pressure while rotating the valve back and lorth with a suction cup lapping tool. Wastt all the compound thoroughly and inspect the valve seat with bluirtg. (Fivv 3*33) (Note) lal When the valve stem is greatly worn. the valve guide is usually also worn. Hence. when a valve Fig 3—33 is replaced. it also is desirable to replace the ‘ ' valve guide. Since the guide is press litted. it is recommended that they be replaced with an overe size guide. (bl When the valve is assembled. the compound which was used during lapping should be completely removed. Valve seat detail 5. Inspection l. A valve seat in good condition should have a lull surlace contact with the valve lace. Standard value l.0 mm (0.04 in) Serviceable limit in excess ol 2mm l0.05in| 2. Assemble the valve into the cylinder head so that the valves are well seated. and fill the cylinder head combustion chamber with oil. irliect a blast of air in troni the inlet and exhaust ports and it any bubbles should appear. it is an indication that the valve seats are not completely sealed. Fig. 3—34. Cylinder 29 3. ENGINE @ Upper cvankcuxa ® 6er hex aolr ® Cylinder Fig. 3—35. Removing ine cylindev 7. CYLINDER Consiruch’on The cylinder sleeve is made ol special hard sieel alloy and is press lined imo ihe lighiweigh' casi alumi- num body. A comparlmem is provided beiween ihe cylinder bores Io accomodaie ihe cam chain and ierlsiorler. (Fig. :Hu) Disassembly I. Remove ihe cylinder head in accordance with Seclion 3.2.1. B. 2. Remove lhe 6mm hex. boll a) and men remove We cylinder (2 lrorn crankcase @. (Fig. 3735) Inspection l. Measure me cylinder bore, laaer, oul.ol.round wilha precision cylinder gauge. Take me measuremenl al lhe lop. middle and boliom in bolh ihe x and V axis. (Fig. 3736) liern Siandard Value Serviceahle Limii Cylinder 52.004101 mm Repair il over hare il.969~l.9694in) 52.l mm i205l2inl cylinder Repaiv .l over a leper 0'0“ "‘"‘ “10°01“ 0.05 mm “10010 in) cylinder oul . Repair .l aver ol round 0'0“ ’“"‘ “100°: "" 0.05 rnrn "10020 in) (D Cylinder gauge ® Cylinder figs 3-36. Measuring me cylinder aore 51 55~5160 202957103150.) 51.96’ 51 93 20457434550. Fig. 3737. Pisron (D Thicknaxx gauge ® Piston @ Pisron ling Fig. 3-30. Measuring inc pisian ring side Clearance 2. The clearance belween lhe pislon and cylinder will grearly ailecl lhe engine performance. Because We aislon is ellipiical, lhe clearance is comrolled very closely. The clearance are nol me same, however, if any area is grealer than 0.1 mm (0.00400, the cylinder should be rebored and filled wilh an oversize pislon. Oversixe pisions are available in 0.25. 0.50. 0.75 and l.00rrlm (0.0], 0.02, 0.03 and 0.04m] size. 3. When removing carbon deposiis lrom me pision lop and ring grooves, care should be exercised so as lo nol cause any scralches or damages lo lhe pislon. 4. Measure me pislon perpendicular lo lhe pislon pin hole. (Figu 3*37) Siandard Value Top 5|.55~5|.60mm Ouiside l2.030~2.aal in) die 5“" 5L96~5L96 mrn i2.046~2.047 inl llern 5. Measure lhe aision ring side clearance wilh a ihickness gauge (Fig. 340) liem Slandard Value Serviceable Limil YD o.025~o.o55 rnm Replace il over F l0.001~0.0022 in) 0.1 mm [0.004ml Pisvon m, side 0.015~0,04s mm Replace il over d5", Sam“ l0.0006~0.00la.nl 0.lmm l0.00unl ance 0| 0.01~0.045 mm Replace il over ‘ l0,0004~0.00m .nl 0.lmm [0.004in) 3.2 CYLINDER HEAD AND CYLINDER 30 a. Rision ring groove liem Slandard Value Serviceable Limil . 45,9~u,o mm B°"°"‘ d'“ lls707~ Lall inl Top li.205~l.220mm Replace il ayer Graaye Second i0.047~o.o4a in) La mm [0.05I2in) width 0.] 2,504.52 mm Replace il ayer ' io ova~o.u99 in) 2.6 mm mm: in) 7. Rision rings Measure ilie ring end gap by insening llie pision ring lnlo lhe cylinder so yhal lne ring is at right angle lo ilie cylinder axis. (Fig. 349) liem Slundard Value Serviceuble Limll (D Tlnciness gauge ® Rision rina @ Cylinder To l.la5~l.lao mm Replace ii under rig. 3—39. Measuring ine pision nna end gap " l0.066~0.0466 inl l.l25mm lo.ouainl g l.l7s~l.l90 mm Replace il unaer iniciness5°“°"d [0.046~0.047 lrII lslflfimm lumuinl 2s475~1.490mm Replace it under 0" [0s097~0.098 ml 2.43 mm isms 7inl R. Top D.52~0.76kg Replace ii under $3“ Second [l.l5~ls72lbs) onla io.9zalbsl . o.72~lo.oaRg Replace ii under m" [0" [1.59~2.22 lbs) 0.53Ra ll.169lbs) . 0.15~D.4D mm Replace .l oyer Rina end aap 06~ main) DBmm( 03l5'nl 8. Check me gaskels ior damage. Replace ii any damage exists. (Nolel l. Oversile pislon rings are available in four sizes; (D Cylinder ® Pinon base @ Pinon ring compressor 0.25, 0.50, 0.75 and Lou mm 10.01. 0.02. 0.03 "W 3"“ "mm"? ”m “Wind“ and 0.04inl. 2. When making pision ring end gap measuremeni, inseri ine ring carelully inio ine cylinder io preveni scraicnes or gauges yo me cylinder wall. D. Reassembly 1. Aher assuring yhal lhere are no damages or excese sive wear no me cylinder. assemble lne cylinder in me reverse order oi disassembly. 2. Make sure mai ilie cylinder gaskel and me iwo dowel pins are insiallea. 3. During ihe inslallaiion al lne cylinder 6), use pislan bases ® yo preveni pislan movemem. also use a ring compressor ® lo preveni ring damages (Fig, 340) 4. Assemble the cylinder head and cover Imii. (Nale) Check yo make sure yhal lhe gaskeys are properly in place 3.3 LEFT CRANKCASE COVER 1. LEFT CRANKCASE COVER A. Consiruciion The purpose oi lhe crankcase is lo prolecl lhe ,v . viral componenis ol me engine. The Ieli crankcase (D tell crankcase cover nouses ine A.C generaior slaior. (Fig. :Hl, 3742) ‘9‘ 3'"~ Le" Clank“ COW 31 3. ENGINE a, Disassembly 1. Drain lhe oil from We crankcase. 2. Remove lhe gear change pedal. 3. Afler removing lhe mourning screws. "la la“ cranks case cover can be separated from We crankcase. G) Clinch Iihev lhraad ® Asc. ganevalm svaiov Fig 3-42. snaiai hound nu ma Iell crankcase cam c. Reassembly l. Perloml lhe assembly in we reverse order at disassembly. Make sure lhal me gaskels aie no! damaged or misaligned and lhal lhe clulch acnan is normal 2. Ferfcrm clulch adiuslmem. (Fig. 3-‘3, 3-44) ® Clinch udluxler (D Clvlch adlvxlev lacling bull Fig. 3-43. 344 2. A.C GENERATOR A. Construdion The delailed aesciipiion ol lhe A.C. generalor is given in We Elecmcal Seciion. The AC. generalor is mounled in me Ien crank case cover. (Fig 345) AL. genarulm moi ® All genevmor slalor 5.9. +45. AC, ganavulol volov and Slalur B. C. 3.3 LEFT CRANKCASE COVER 32 Disassembly I. It is not necessary to remove the engine to disuse semble the A.C. generator. lln this section, operation is explained with the engine dismountedt 2, Unlooserl the three screws arid remove the dynamo cover. 3. Remove the rotor mounting bolt and remove the rotor (j) with the use of the generator rotor puller (2. ”col No. 0793372160000! (Figu 3*46) 4. Unlooserl the screws and remove the left cranks case cover and the stator (j) trorn the lelt crankcase cover @. (Fig. 347) Reussembly l. AssembletheA c.generator in the reverse order at removal (Note) Make sure that the pin is ins~alled during mounting of the rotor STARYING SPROCKEY AND CLUYCH (C3175) Construction The starter armature speed is reduced by a series ol gears enclosed within the starter housing. The chain lurther reduces the speed and provides high torque to turn over the crankshalt for each starting To prevent the starter lrom being motorized alter the engine starts, an overrunning clutch is incorporated into the A.C. generator rotor. Peter to the electrical section for details. Disassembly and reassembly of the starting clutch 1. Remove the A.C. generator in accordance with sectiDri 3.3.2. B. 2. Remove three screws and remove the starting clutch. 3, Reassemble the starting clutch and A.C. generator in the reverse order at disassemblv. Check to assure smoother roller operation. Check condition ol side plate and guide. Check tor the weak or broken clutch roller spring. ® A.C. generator rotor at kator puller fig. 346. Removing the A.C. generator rotor ® A.C generator stator @ l. Crankaase cover fig. 3-47. Removing the AC. generator stator © Starting chain Fig. 3-43. Removing the starting chain 33 3, (D STorllrlg moTor Sprockel g. 3-”. Slurling molor sproclet © sxas hex boll ® 6mm hat washer @ Adtuster rising piece (9 Clutch adlusTEr ® Clutch Iiher Thread © Lelt cranlcase cover 'p. 3-51. Components or clvTcTt (D 6X12 cross screw ® Neutral switch stator @ 6x10 cross screw G) Neutral switch rotor Fig. 3-52. Removing the nevTruI switch rotor ENGINE c. Disassembly and reassembly of the starling sprocket 1. After the removal of The A.C. generator and starting clutch is completed, remove the starting chain (9 by disconnecting ot the ioinT clip. (Fig. 348) 2. Remove the starting sprockeT plate set and remove the starting sproket. 3. STorTing moTor sprocket is easily removobie from the serrated shalt. (Fig. 349) (Nora) The sTarTing chain ioint clip must be installed with The open end opposite to normal direcTion or chain movement. 4, CLUTCH ADJUSTER AND NEUIRAL SWITCH ROTOR A. Operation of clutch adiuster The lunction or the clutch is to temporarily disenr gage the transmitting ol The power between the engine and the transmission during the period or gear change. Clutch is operated by the handle lever Through a cable to apply pressure which overrides the clutch springs. The clutch adiusTer is set to provide the proper clutch action. (Fig. 3750, :Hl) a. Disassembly and reassembly ot llte clutch adiuster I. Remove The crankcase cover in accordance wiTh SecTion 3.3.1 B. 2. Remove the 6X36 boITs rrom the aaivster Taxing ploTe and then remove the cluTch lever spring To separate the clutch apiuster. 3. Apply grease to The clutch aaivster belore assembly. use grease Type HD multipurpose NLGI No. 2. c. Disassembly and reassembly of The neutral switch rotor 1. Remove The lelT crankcase cover. 2. Loosen The 6X12 screw (D and remove The neutral switch stator @. (Fig. 3752) 3. Unscrew The 6X20 screw © and remove The neutral switch roTor © from the gear shilt drum. (rig. 3752) 4. Fit the neutral switch rotor groove to the gear shilt drum key and perlorm the assembly in the reverse order or disassembly. 3.4 RIGHT CRANKCASE COVER ASSEMBLY 34 3.4 RIGHT CRANKCASE COVER ASSEMBLY 1. RIGHT CRANKCASE COVER A. Construction The right crankcase cover Q) and the lelt crankcase cover, house the engine primary components. The oil lilter cover ® is litted to the case cover and provides the passage lor lubricating oil in both directions. (Fig. 3~5:l) a. Dimssembly 1. Remove the kick starter arm lrom the kick pinion shaft. , , 2. By removing the ten screws securing the case (D pig," ”mm,“ mm ® 0.. We, cam cover, the right crankcase cover can be removed. m 3.53_ WI, mm,“ (M, (Fi 3-54) 3. Alter unscrewing the three,6><16 screws, the filter cover cart be removed. (Caution) During operation, attention should be given to the two 74.5)(3 ”0" rings fitted to the lilter cover to assure that there are no oil leaks. Cl Reassembly l. Belore perlorming the assembly, inspect the crank case and all lilter covers (01 cracks arid also for any damages to the mating surlaces since they will cause oil leaks. 2. Clean the 0 rings © and inspect for any damages replace if necessary. (Fig. 3-55) 3, After installation of the screws, tighten them Univ (D 6X32 mew: ® 4x45 3mm formly to prevent the covers from warping and Fill- 3_5‘_ mg," mm” cum mam consequent oil leaks 2. CLUTCH Description and operation The function ol the clutch is to temporarily disv engage the transmitting of the rotary motion between the engine and the transmission during the gear change and then alter the gear change, permit a smooth power transition. The conditarl ol the clutch will havea varying efiect on the efficiency of the power transmission. (Fig. $56) The clutch mechanism is of a conventional wet type muliiple disc operated by the clutch Iilter thread connected by a cable to the clutch lever. Wherl the right crankcase cover is removed, the clutch complete is exposed. To the clutch outer complete. the clutch spring driving the clutch pressure plate is installed. The clutch plate is installed with the clutch lriction disc between the clutch center with lour 6X20 hex bolts. The clutch plate has teeth cut on the inside. These teeth are engaged with teeth cut on the outside of the clutch center. The clutch center is coupled to the transmission main shalt by spline. Hence, it and the transmission main shalt are essentially a single unit. The clutch plate. clutch center. and clutch pres- sure plate rotate. On the other hand. to the groove cut on the exterior circumference of the clutch outer, the clutch lriction disc is coupled by the collar entering the groove: freewheeling rotation with the transmission main shalt is obtained. Hence, while the clutch is connected. the clutch outer cerlter, six clutch plates. six clutch lriction discs. and clutch pressure plate are essentially a single unit through lriction exerted by ® 0 ring ® oil filter cover rig. 3-55. 0 ring and oil filter cover 35 3. ENGINE G) Clutch rod ® Clutch outer camp-ere @ Clutch cerrter @ 20m set ring (5) Clutch litter .omtaiece (5) Clutch plates (3 Clutch lrictiari disc (5) Clutch alate (9 Clutch aressure aiate @ Chrtch spring ® Clutch spring retaining alaie @ 6X20 hex bolt, rig. 3-56. Clutch @i the clutch spring 1 rotation at the crankshatt is transmit. ted to transmission system. When the clutch lever is gripaed, the clutch adr iuster rotates clockwise. the adjustment thread is pushed out by the square~headed thread in the clutch adjuster litted to the lelt crankcase cover: Ihis is pushed out by the clutch ioint through the clutch rod. The clutch saring is compressed and the six clutch lriction discs and six clutch plates become disengaged. Hence, the rotary motion at six clutch alotes and six clutch discs is not transmitted to the clutch center. (Fig. 357, 3758) a) Clutch sarma ® Clutch certter @ Clutch alate ® Clutch outer © Ciutch litter rod © Ciutch iiiter iDl’tl aiece ® Clutch lrictiari disc ria. 3-5. Sectional View 0! ciutch 6) Clutch adlustar ® Clutch litter thread @ Clutch lilter rad ria. 3-53. Sectional View or clutch udlusting thread 3. Disassembly 1. Remove the right crankcase cover. 2. Unscrew the (our clutch pressure plate retainer bolts and remove the iriction disc and clutch plates. 3.4 RIGHT CRANKCASE COVER ASSEMBLY 36 3 Pemove Vhe oil IIIer rotor lock run and Men lhe oil nlrer relaining lock nul lo pull llre rolor all lhe crankshall 4, Remove rhe 20 mm sel ring G) and remove rhe clulch cenler ®. (Fig. 3759) 5, Unscrew rlre oil pump body mounring nuls and separale llie oil pump lrom rhe crankcase 6. Remove rhe oil pump assembly rogellier willr lhe clulclr ouler cover. (fig. 3760) (Caulian) Pull ofi rhe clinch unil parallel lo rhe slrall exercisr v ing care so mar llre shall is nol damaged. (D 20 mm sel ring ® Clulcri cenier 3—59. Removing me 20 mm selering cs lnspecrian l. Clulcli spring llem l Slandara Value Serviceaale limii rree lengllr 3L0!) mm (1.2224 inl 5393“": 1'] nigh] 215mm/l5,9~lfivlkg Loud lovflflfifiin/ # 35.060~39.9ll lbs) (Note) Use coil spring Iesler (Tool No. 07134<99?0H for lesling lhe valve spring lensiori. 2. Friclion aisc . (D Clinch auler ® Oil pump assembly llem l Slandard Value Serviceaale rmil . :l-eo. Removing me clurcli auler and pump body . 2s92~avoa mm Replace il under “ ”mm“ lo,lls~o.l2l ml 2.5 mm (0.0954 inl Wm a e Wilhm 02 mm Replace il over 9 9 l0.0079 ml 05 mm is owe inl 3. Clulclr plale . :Hsl) liem Slandavd Value . Sevvlcauble lell Replace il undev Thiclness 3.0mm (Dellfilnl 1.9 mm mum Replace .l aver WWW?" 0V5 mm mom in) 4. Primary drive gear llem Slandurd Value Sewlceubla eril cnordel ’ 2m; .lérzlizlim 5;”stzl' <9 ® ,"m ‘ Fig. seal. Mausuvlng ilre cluiclr plale miclness D, Reassembly l, Reassemble rlie child! in me reverse order al disassembly. 3.5 OIL PUMP, FILTER AND SEPARATOR ls OIL PUMP A. Deseriplion The oil pump is a plunger rype. operared by a connecling rod lhrough arr eccenlric cam on lhe (D Oil mm mm, ® or. pump lransmissian main shall (no. 3762) Fig. 3—52. on pump and cenlvllugal liller 37 3. ENGINE :9 Cumshuh ® Piston ® cumming rod G) Chum lenswoner G) on film (3) on pump ® Tmnsmlsxmn main shah ® Tmnsmnon coumer shah Fig‘ 3-61 lvbviculian xyslem 3.5 OIL PUMP, FILTER AND SEPARATOR 38 o Lubrication system (Fig 3763) The oil is picked up lrom the crankcase sump and routed through the oll passage to the oil tilterwhere the impurities are removed by the centrilugally operat. ing oll filter. The clean oil is then pressure led through the upper crankcase to all the crankshalt bearing. The oil is separated into two routes, one is fed to the roller bearing and the other enters the crankshatt to lubricate the connecting rod large end through the holes drilled in the crankshalt iournuls. The connecting rod small end is lubricated by oil mist. The oil lrom the upper crankcase oil passage is separated irlto two paths. one of the paths dellvers oil to the top ol the cylinder head through the cylinder stud bolts. This all is ted irlto the camshaft from the rocker arm and lubricated. The oll lubricates the cum chain on its way down to the sump. The olher oil path teeds the oil through the oil passage in the crankcase and enters the transmission to lubricate the tree gears. The other gears and bearings are lubris cated by oil droplets and mists. Disassemble 1. Remove the right crankcase 2. Remove the oil filter. a. Pemove the right primary drive gear. 4. Separate the pump body toge:her wilh the clutch. $23611 “gram?! mix: rod 5. By remoring the 26mm circlip. (D the pump rod ® can be separated lrom the clutch outer. (Fig. 3764) 6. Extract the pump plunger pin @ and remove the plunger (3 at the tip or the pump rod. (Fly. 3765) © Pump plunger (g) Pump rad @ Pump plunger pirl Fig. 3-55. Removing the plunger 39 3. ENGINE (D 26 mm circlip (g) Pump rod side washer @ Pump rod G) exao stud © Plunger pump pin (a) Plunger (3 Pump body gasket (3) Sucllon valve boll @ Suction valve boll packing Suction valve spring ® 3(5' steel ball @ Oil pump body @ Pump lilter screen @ yr steel ball @ Valve spring @ luxz o ring @ Outlet valve guide @ Pump lock washer @@ 6mm hex nut. rig. 3-66. Pump component parts 7. Component parts ol oil pump. c. inspection I. The normal capacity ol the oil pu at 10,0007pm: ii the capacityl (Fig. 3766) mp is 3600cc/minule alls below 3400cc. there is a danger or developing engine seizure. therelore the pump should be repaired or replaced. 2, Clearance of component parts llem Slandurd Value Serwcauble Limit Plunger to o.oz5~o.063 mm noustng luool ~o.0025 inl lteplace tl oval o.l7 mm [0.0067ln) D. Reussembly l. Assemble the pump in the reverse order oldisas. sembly. (Note) a. Proper operation ol the oil pump can be checked by loosening the left rear cyli nder head cap nut. If all seeps out, the lubrication is normal. b. ll lhere is absence of oil, check the following points: lat Proper assembly ol the pump. (bl Condition ol gaskels. (cl Excessive clearance of punger. lat Malfunction ol the steel ball valve. let Clogged screw. ill Clogged lilter or oil passages. 3.6 CRA NKCASE 4O 2. OIL FILTER A. Descriplion The engine oil is doubly fillered lhrough lhe ceniriluoal filler and lhe mesh screen liller lo assure clean supply ol oil lo lhe engine. (rig. 3767) The screen filler is on lhe purnp inlel side and lhe cenirilugal lilier is on lhe oullel side. Disassembly Remove ihe righl crankcase cover in accordance wiih Secllon 3.4. B. For cleaning ol lhe cenirilugol oil liller. onlv lhe removal ol lhe oil lilier cover is required. l. Grasp lhe rib ol lhe oil nlier cop (D wiih a plier and draw slraighl oul. (Fig. 3768) 2. Use a screwdrivereand unlock lIle lock washer. Remove lhe mounling rlul wilh o speciol lool. 4. Pull ofi lhe oil filler rolor. c. Reussembly l. Aller cleaning ol all lhe pans. perlorin lhe reas. sembly in lhe reverse order ol disasseblv. 2. Make sure lhal lhe I6 mm mounling ml! is properly lorqued and filler cap well sealed. 5” OIL SEPARATOR A. operalion The oil separalor G) is localed in lhe lorward secllon of lhe lower crankcase. direclly below lhe crankshall. lls primary Iunclion is lo corilrol lhe oil splashed by crankshall counler weighls. prevenls oil penelralion ond conlrols lhe oil lemperalure. (Fig.3? 6?) 3.6 CRANKCASE A. Descriplion The upper and lower cronkcases ore conslrucled oi lighlweiohl aluminum alloy and can be seporaled al lhe ceriler lines OI lhe crankshafl. lmnsmisslon shah. and lhe kick slarler spindle. In addilion. lhe slarling molor is mounled al lhe from seclion of lhe C3175 crankcase. In lhe upper surface of The upper crankcase, lhe cvlinder slud bolls ore inserled. The lower cronlrcose is equipped wilh lhe oil separolor. lower crankcase cover. and lwo drain plugs. (rig. 3770) ® Oil lillur rolor ® Asxz Oring Q) Oil lillur cap rig. 3-67. OII filler ® Oil filler cap Fig. 34:8. Removing The oil nller cop ® Oil seporolor ri‘g. 3-69. Lower cronlicosu ® Drain plug Fig. 3-70. Drain plugs 41 ® amm boll ® 6mm belt rig. 3-7”. Crankcase belt @ Startingmatar ® 6x20 hex bolt 6) 4x36 hex belt ® 6x23 trek bait rig. 3772. Removing the starttng motor rig. 3-73A. Crankshait. 3. ENGINE a. Disassembly 1. Drain oil in the crankcase. 2. Remove the cylinder head and cylinder. 3. Separate the lelt crankcase cover and AC generator. 4. Separate the right crankcase cover, oil litter, clutch and oil pump. 5. Remove 8 mm nut and 6 mm nut lrom the stud boits at the upper part oi the upper crankcase. (Fig. :Hlak) Remove 5 mm nut. 6 mm bolts and 5 mm bolts trom (Fig. :HIeB) Remove the two 5x 12 cross screws and starting motor side cover, and then remove the 6x20 and 6X18 bolts on the right hand side ol the crank. case which mount the starting motor. (Fig. 3772) By removing the 6X35 bolt on the left hand side at the starting motor which is supported by the crankcase, the starting motor can be removed. 6. the lower crankcase. 7. 8. Whiie the key on the gear shirt arm is released from the Shitt drum, dismount the motor. c. inspection 1, Check lor damages especially around the machined mating surlaces since even a small delect will cause oii leaks. ihe mating surtaces should be tiat to within 0.05 mm to.oo2ini. Measure with a thickness gauge on surlace piate. D. Reossembty 1. Assembly should be perlormed with attention paid to the ioliowing points ~ Clean the crankcase and inspect the mating sur. laces or the crankcase tor sign oi ieaks. scratches and other damages. - Aapiy liquid gasket to the mating surlaces oi the case: assemble atter drying. 3.7 CRANKSHAFT. CONNECTING RODS, AND PISTONS A. Conflrucfion The crankshaft iournais are made or high carbon steel and the counterweights are ol nickelechrome. molybdenum steel, assembled by press fitting. Crank shatt is supported by three roller bearings and one ball bearing which takes the thrust load and arelixed in place by dowel pins. Sprocket to drive the cam chain is mach:ned on the center shalt. (Fig. 3773A, B) 3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 42 a) leit cranksnalt ® 35 rnrn circllp (a) as rnrn side wasner Q L, rnarn bearing outer ring a) 4x to ralier © |.. rnain bearing raller retainer m 5mm Sealing wasner (9) tell center crank wergnt @ Axla raller @ Center bearing raller retainer ® Center crank snaltv @ R center crank Duler ring @ Right Center crank welghl @ Cannectina rad ® 2.5x“) raiier @ Connecting rod ralier retainer @6305 sr-is bal' bearing @ Right cranksnalt fig. 3-73u. Crankshalt carnalete Sectional diagram The oil outlet passage in the upper crankcase is aligned to the oil annular groove in the crank counten weight. Oil is lorced into the crankpin by centrifugal force to lubricate the connecting rod beating. There is also a separate oil route to lubricate the main bearings. (rig. 3774) a. Disassembly 1 Drain oil tram the crankcase. 2. Separate the cylinder head and cylinder. 3 Separate the lelt and right crankcase cover. 4 Separate the AC generator and clutch all pump G) Oil ® Center crank miter ring © Crank weignt . . . @ Connecting rod 5. Dlsassemble the crankcase in accordance with fig. 3_74- Crankshalt lubricatmg passage sectlan 3.63. c. Inspection 1 Support the crankshaft on V blocks at both bear. ings and measure the amount or runout. (Fig. 3-75) ltern l Standard Value Serviceable Limit Len bearing 002 liealace Dr repair web Side at id 003;“. I ll aver Total 30 rnrn rm ml ' '" 0,03 rnrn iosoim lrtI rwtoul Right hearing 00? mm Replace or repair web Side at m. 0008i I it over an mmll.3lnl ' " 0,03 rnrn ID 0032 inl (D Dial gauge ® Crankshatt complete Fig. 3-75. Measuring tne snalt runaut 43 3. ENGINE © crankshali cg Main bearing auier rina @ v block @ Dlul gauge . 3-76. Checking lire crankxhull iar verllcal clearance e e @ v block a) Main bearing auier ring ® Dial gaaae © Crankshull ria. 3-77. Checking lrie cranksnall lar side clearance a) Canneciina rad ® lialler @ Relulnar Fla. 3-75. (D Max deileclion Fla. 3-79. Checking denecnan al Ihe pisian and al lne canneclina rod 2. The clearance in lire bearing is measured by fixing lhe crankshail on cenlers and moving lhe bearing in We axial and reriical direcliorl. (Fig. 3776, 3777) llem Slandard Value Serviceuble Limil Axial wrinin 0.05 mm Replace ll over clearance llmlm inl o.l mm lo.uo4o in) Clearance o.on~o.02 mm Realace il arer narrnal ia UXIS lo.oous~o.oooa in) 0.05 mm lumm lnI When lhe clearance in irre axial direciian becomes excessive, lhe crankshail will move lrarrl side when engine is running arid araauce undesireable naises as well as causing urleveri wear lo lhe cylinder, aisian and lire liming gear. 2. CONNECTING RODS A. Deseriplian The connecling rods are of molybdenum sleel and have arl Heshaped secliorl; irre roller bearings ai lire crurlkshail erld. The crankshuii is polished ailer case hardening and mourns Vile roller wiihouv race. The roller l2.5>< IDI is held by Vile roller relainer made oi special aluminum alloy. Siaggered rollers are used in order lo increase lhe load Capacily. (Fig. 3778) a. lnspeelian i. Measuremeni al delleciian al lhe aislan erld ol irre conneciing rod. (Fig. 377?) _Ser ceuble Llrrl _ Replace ri aver llem Slandard Value i I 0mml llalinl Dalleclian 3,7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 44 2. Measurement to determine if the connecting rod ends are correctly aligned and parallel is obtained by measuring the diiierence oi inclination of points 50mm l2.0irll away item the center when a 100mm (4.0 in) bar with the same thickness as the piston pin diameter is inserted into the bore of the piston end and twisted to the right and Ieit. and when the bar is rotated fl)“ and again twisted to the right and lelt. (Fig. IFSOI 3. PISTON A, Description The piston is made from select material, an aluminum casting. This material is light and suitable for high speed, in addition to having good heat conducting property to dissipate the heat rapidly. Furthermore, the coefficient of heat expansion is small thus minimize ing the warpage at elevated temperature and permitle ing a small piston to cylinder clearance design. The shape oi the piston is an elliptical taper. The head oi the piston, compared to the skirt, is exposed to higher temperature and since the expansion is greater. it is taperingly smaller toward the top. The tapering oi the piston also tends to lessen the piston slap when the throttle is lightly snapped without the engine being loaded. (rig. seal) The piston employs a iour step taper. The piston pin boss area is made thicker thereby resulting in greater expansion at high temperature. For this reason, the diameter oi the piston skirt is mode smaller in the direction of the piston pin so that at the high oprating temperature, the piston will expand into a true circular shape, The skirt is constantly provided with flexibility to assure that no delormution will result even irom extended continuous driving. The piston pin is ofiset imm lom int from the piston centerlirte in the direction of the inlet side so that when the piston approaches the top dead center oi the compression stroke. the side load from the cylinder moves From the right side to the left. With a "O" oilset. the point will move to align with the tapedeode center oi the compression stroke. & Disassembly 1. Remove the piston pin clipand push out the piston pin. (Fig. 3753) AiflzDEGREE OF P ARALLEL ISM i Max dellecrion degree oi Parallelism rig. 3-30. Checking level ol parallel ot the piston end at the connecting rod ® Valve escape @ Piston ring grooves @ Piston pin hole rig. 3-8], Piston 1,0(0.043ll) rig. 3-82. Piston oflsal ® Piston pin clip ® Piston rig. 3-53. Removing the piston pm 45 (D Piston ring ® Piston Removing the piston ring Fig. 3—54. 5] 55~51 60 [“295 .0315Iii) 51.96~51.93 Zm§7~2 U‘ESIII Fig. 3-85. Measuring the piston outside diameter ® Thl.kness gauge ® Piston ring @ Piston Fig. 3-86. Measuring the ring groove clearance (D Cylinder gauge ® Piston Fig. 3-57. Measuring piston pln hole C. 3. ENGINE 2. Remove the piston rings from the piston by using a piston ring tool Ispecial tooll. lithe tool is not available. the rings may be removed by hand, spreading the rings at the ring opening with both hands. During the process. the ring should not be twisted or expanded more than necessary as it will cause the ring to break. (Fig. 3784) inspection 1. Before inspection. carbon adhering to the piston head or ring groove should be removed. using care not to scratch the piston. (Note) Sandpaper should not be used lor removing carbon, use a carbon scraper. 2. Piston outside diameter (Fig. 3785) Standard Value Ilem Head 5|.55~5|.6Dmm diameter i2 295~ oaitint Maior diameter i2 457~ mes nt a. Ring groove clearance when a new piston ring is litted. (Fig. 3786) item Slandurd Value Sevvlceable Limil I , o.oz5~o.o55 mm Replace it over °P ""9 loeool~o.uo In) DJ mm mum int 5mm fin 0.DI5~D.045 mm Replace .l over 9 l0.0006~0.00lfi in) in mm “1004 in) 0| . o.mo~o.o45 mm Replace it over ' ""9 luouowoeoolatnt 0.1mm l0.004m| 4. Piston pin hole (Fig. 3737) Standard Value ltem Serviceaole limil Replace it over lws mm l0.5532inl l4.002~u,oua nini 3"" l0.55l ~o,552 int 5. For oversize pistons. there are three at intervals of 0.25 mm l0.0'l inl. 3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 46 o. Reassemblv l. Assemble lhe aislon on lhe connecling rod. only a slighl pressure should be required lo inslall lhe aislon pin. Inslall lhe aislon pin relaining clip al bolh ends. (Fig. :Haa) (Nola) la: The lop ollhe pislon is marked wilh "IN" lo one side. Pislon musl be inslalled wilh lhis mark loward lhe inlel side. lb) Use lhe new pislon in clips (o Pislon pin ® Pinon 4. PISTON “"65 Fig. 3—59. Assembling lhe pislan A. Construclion The aislon rinasperlorm a vilal lunclion ol lorming a seal belween lhe pislon and cylinder. conlrollina lhe lubricalion ol lhe cylinder wall and dissipaling lhe heal lrom lhe pislon. This serves lo develop grealer power oulpul. The rings are made or special casl iron lor slrenalh. wear resislance, heal resislance and good heal conducling aualilies. Rings are given parkerizing lrealmenl lor added slrenglh, Top lwo rings are compression rings lo prevenl gas leak. lhese lwo rings are made wilh a slighl lapered surlace where il conlacls lhe cylinder wall lo expedile wearingcin, lop ring oulersurlace is hard chrome plaled lor exlra wear. The oil ring is grooved lor oil scraping a. Inspeciion l. When lhe aislon ring has been removed. il should be lilled wilh lhe gap approximalely 15mm (0.6 in) from skirl ol lhe cylinder al a righl angle lo lhe cenler line. Measuremenl ol lhe gap should be made wilh a lhiclness gauge. (Fig. 3739) llem 7 Slandard Vuluei Slaw eable I To m 0,ls~0,4 rnrn Replace il over F 9 l0,006~0.0lainl 0.0 mm l0,03l5inl r o.l5~o,4 mm 7m, a) Thickness gauge ® Pislon ring 59“” ""9 [0.006~0.016inl 0.5 mm [0.0315inl Ho- 349- Meawving me vision ling gal: OI , 0.l5~0.4 mrn Tieplace it over ' ""9 l0.006~0.oleinl 0.0 mm (0.03” ml 2. Tension ol lhe pislon ring is measured wilh a lension measuring inslrumenl. llem Slunduvd Value Serv.ceable LImil Tap, . 2~0.7Skg Replace il under Second ring l0 020~0030lbi 0.42kg loxm lbi on r... WNW-W Replace il under 9 l0.928~0.397 lbi 0.53lg ll.i69 lb) 47 3. ENGINE (D Fina-90c. Fixlon ring (om 3. Pision ring dimensions. (Fig. 3—90A, 5, c1 "'- 3'90“ Pm" ""9 New) Fig. 3—700. Piston nne (Second) No. nein ‘\ Slundurd Valve Serviceuhle Emit Mark ‘ (D oinside dla (Slunduvd) 52.00 (2.047 (m Nona omide die 0.25 (Oversixe) 52.25 (2.057 ini 25 0 Oulside die 0.50 lOvemer 52 50 (2.057 in) 50 g omide din 0.75 (menxixei 52.75 (2.077ini 75 L Ovuida dio I 00 (Oversize) 53.00 (2.0a7ini (00 o '— @ wsdm 2.3~2.5 (0.09(~0.09aini ® Thicknasx |.|65~l.15[0.046~0.0464in) (.(25 (0.0443ini (9 Angle 20'~50' (D Oumde dia (smndurdi ‘ oiiuide dlu 0.25 leavxixeY g (amide diu 0.50 [Ovevxlxel some in (op ving Z Culiide diu 0.75 (Oversixei 5 Oumde din L00 (Oversixei B ® Wldlh 2.3~2.5 (0.09(~0.090ini "7 @ Thicknexx (.(75~(.(9(0.04¢~0.047.n( (.(35 (0.0447ini (9 Angie (”~("30' (D (amide din (snundoidi omside diu 0.25 (Ovenixal (9 came die 0.50 [Ovamxal seine ax (op ring g oiiuide dla 0.75 (Oversize) : Oumda dlu (.00 lOvevsixe) 0 ® Width 2.3~2.5 (0.09(~0.095in( @ Thicknaxx 2.475~2.49(0.097~0.095.n( 2.43 (0.0957ini (4) Angie None 3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER 48 c. Replacing the pision rings l. When a piston ring is reassembled. it should he litted.to the cylinder. Inspection should be made to determine il the gap ol each ring is between 0.15 mm l0.006in! and 0.4 mm (0.015 in], ll the gaps are somewhat less. they should be dressed with a Vile. (Caution) Ial When a gap is dressed with a liie. adiustnient should be made perpendicular to the rings. (bl ii the piston ring gap is too small. seizure between the ring and cylinder occurs due to thermal expansion; if the gap is too large, oil penetration or gas leakage occurs. 0.) Pixton vine ® Piston 2‘ When pine" ring is assembled on me pm“, my Fig. 3-9i. inspection oi the piston ring by rotating around interference between the ring and the groove may prevent smooth operation, it is necessary to inspect lor clearance. when new ring is titted to the groove, by rotating the ring around the circumlerence. (Fig, 379” 3. install the rings on the piston with the piston ring tool, the rings may also be installed manuaity. install the bottom ring first. (Caution) laI Care should be exersizcd not to install the rings upside down. The top side ol the ring is marked near the ring opening with the manufacturers initials. (Fig. 3472) lb] Worn or rings which has lost its tension should be replaced. a) 4. Space the piston ring gaps no“ apart. Aligning n“ 3-92. Pm" mg oi the gaps WI” result in pressure leak. 3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER Fig. 3-93. Cum chain lenxicnev A9 3. E N G I N E I. CAM CHAIN TENSIONER A. Operalion The com chain tightener is used to tighten the cam chain from the outer side with the cam chain guide roller in between. As shown in the Figure, the tensioner push bar is automatically under compression by the cam chain tensioner spring and supports one end of the tightener. On the other hand. the tensioner roller is applying pressure against the cam chain. When the tensioner set bolt is loosened. the tensioner push bar auto matically takes up the slack ol the com chain by applying lorce lrom the spring. (Fig. 3—93) is. Dimssembly l. Separate the cylinder head and cylinder. 2. Tie a wire across the ends of the cum chain. 3. Remove the two 6X20 bolts mounting the cam chain guide roller and separate the cam chain tensioner from the crankcase. 4. The com chain guide roller is coupled to the corn chain tensioner and remove the cam chain guide roller pinand then separate the cam chain tensioner. (rig. 3-9;) 5. When the 5mm thin nut is loosened and the *- _ ~ _ tensioner set bolt is removed, the tensioner push ® C:_";:"°ga:"'c:aiflzl’qsifilcm Ch“ bar coupled to the cylinder head is separated ' together with the tensioner spring. (Fig. 3475) c. Inspection 1. Check the cam chain tensioner tor any damage or wear. ltem standard Value Sevviceable Lirnii 7"" “M" Ra lace it under Spring lree as rnrn l3.26fiin| “PM [3 HM") length . Tension 4| rnrn/u.5s~o.esig _ [L6Hin/L2)~l.talbs) D. Reussembly l. Pertorm the assembly in the reverse order ol a) Tensioner set boll ® rensianer push her disassembly. ('9) “mm” 59""9 a. Replace any worn or damaged guide or ten~ Flg. 345. Assembling lhe rensioner push uar . stoner roller. b. Assemble the tensioner push bar and spring into the cylinder head and lock with the set bolt. The push bar should be in the retracted position to tacilitate connecting the cam chain. (Fig. 3—95) E. Corn chain tension adjustment l. Loosen the tensianer set bolt and the chain will tighten automatically. 2. Reset the tensianer set bolt and laclr with the loclr nut. (Hg. 3—9.5) (D lock nut ® Tensiener set bolt Fig. 3-96. Adlusting the cam chain 3.9 TRANSMISSION 50 3.9 TRANSMISSION A. Description The transmission receives the rotary power from the crankshaft and through a series 0! gears. changes it to the desired speed and then transmits it to the drive sprocket to drive the rear wheel. All the gears are Iully constant meshed. assuring srnooth gear change. (Fig. 3477) (D not t-ls ball bearing ® Transmission mum shalt (:9 Main shalt top gear (Z) 20 mm thrust washer A ® 20 mm cinclip ® Ball bearing set ring A ® axlsq stud © IDXN knock pin ® Main shalt shilting gear @ Main shalt second gear ® 15mm bearing bush A ® Knock pin 63 5x25x6 oiI seaI @ 16mm bearing bush 3 63 Knock pin 03 Counter shalt low gear @ Counter shalt second gear 63 20 mm (Ir-clip @ 20 mm thrust washer A @ Counter shalt lourth gear @ Counter shalt third gear @ Counter shalt lop gear @ 20x52x9 TCelypa oiI seal ® Drive sprocket lléTi ® Drive sprocket liking plate ® exlo hex. boll @ IDXH knock pin ® Transmission counter shalt rig. 3-97. Transmission 1. OPERATION When the clutch is engaged, the power from the crankshaft is transmitted through the clutch assembly to drive the transmission main shalt. During the shilting of the transmission gears, the clutch is disen- gaged to stop the rotation of the main shalt. The position ot the gears will be described in relerence to the neutral gear. Neutral : ( 3*95) When the transmission is in neutral, the gears in he the transmission are arranged so that there is no .11; power transmitted lrom the transmission main shalt to the counter shalt. The fixed rnain shalt low “I 3_9g_ New”. gear (D is meshed with the tree rotating counter shalt low gear (2). tree rotating rnain shalt so 51 . ENGINE top gear © is meshed with the sliding counter shaft top gear @. sliding main shaft lhird-Iourfh gears (is) are meshed with the free rotating counter shaft- thirdfourth gears ® (a) and the free rotating main shaft second gear © is meshed with the splined counter shaft second gear 0. Low: (Fig. a—w) When the gear is shifted to low. the sliding counter shalt top gear Q) is moved by the shift fork to engage with the free rotating counter shaft low gear (2). The power from the transmission main shaft (D is transmitted through the fixed main shaft low gear to the counter shalt low gear, across to the counter shaft top gear and then to the drive sprockt ® mounted on the end of the counter shaft. Fig. 3-99. low Bear Second: (Fig. 3—100) I When the gear is shifted to second. the sliding main shaft lhifdrlounh gear (2) is moved by the shift fork to engage with the free rotating main shaft second gear @. The power from the transmission main shaft (D is transmitted through the main shalt third—fourth gear to the main shaft second gear which drives the counter shalt second gear ® and hence the drive sprocket (5) mounted on the end of the counter shalt. Fig. 3—100: Second gem Third: (Fig. 3401) When the gear is shilted to third. the counter shalt top gear ® is moved by the shilt fork to engage with the counter shaft third gear @. The power from the transmission main shaft is transmitted throughl the main shalt thirdrfourfh gear to the counter shaft third gear, across to the counter shalt top gear ® and to drive the drive sprocket @ mounted on the end of the counter shaft. Fourth: (Fig. 3402) When the gear is shifted to fourth gear. the sliding counter shaft second gear ® is moved to become engaged with the free rotating counter shaft fourth gear (:3. The power from the transmission main shalt is transmitted through the main shaft thirdr fourth gear ® to the counter shaft fourth gear (:3), across to the counter shalt second gear ® and then to the drive sprocket (5) at the end of the counter shaft. Fig. 3-I0l. Third gear Top: (Fig. 3403) When the gear is shifted to top gear, the sliding main shaft thirdrfourlh gear ® is moved by the shilt fork to become engaged with the free rorating main shaft top gear (2). The power from the transmission main shalt is transmitted to the main shaft thirdrfourfh gear C!) over to the main shaft top gear (2). across to the counter shaft top gear ® and then to the drive sprocket at the end of the counter shaft. Fig. 3-102. Fourth gear 3.9 TRANSMISSION 52 a, Disassembly l. Disassemble rne cylinder head and cylinder. 2. Separaie rne crankcase. c. lnspeclion l, Main shall )0 niain snali gear clearance. lrern Slanaara Value Serviceable lrnnl Second 0.0]6~D.045 mm Replace il oval geurll5¢l (D.0006~D.0018ln| o.lrnni (0.004im Top gear 0.0ll~D.04.§ mm Replace il over new lo.0004~o.00la inl DJ mm mom inl 2. Coumer snail lo coumer shall gear clearance. Item Slandard Valve Sevviceable Limiv Yhird. 0.0o9~0.025 rnrn Replace it over rmmh gear l0.0o04~o.o0l0inl 0.1 min (0,004inl Low 5°, D.0|6~D.045 nini Replace ll over 9 (D.0006~0.DDlBlnl 0.7 rnn. (0.004 ".1 3. Bearing clearance. (Fig. a—loa) Ham Slandard Valve Sevviceable Limil Axial Wilhln 0.05 mm Replace it over clearance (0.002inl 0.1 mm l0.oo4inl Radial D.DI~D.DZS mm Replace it over clearance l0.0004~o.00lo inl 0.05 mm (0.001 inl A. Shlll drum groove. (Fig. 3405) Smndard valu 6.1 ~63 mm l0.740~0,744 inl Serviceuble liNII': 6.4 mm (0.256 inl D. Reassembly i, Assemble rne yransrnission gears in we reverse order of removal. 2. Alva! assemblys all componems should be checked in assure lhal lhe aperalion is smoolh wilhaul any binding. 3. Inspecl lhe malingsurlaces of me crankcase for any scralcnes or damage which will be a source cl all leak. F . 3403. Top gear a) vial gauge @ searing @ v block 3404. Measuring clearance 0! me bearing 55 “~61 I z _ "“ muemluu 10.25 E lIJIAIl] UJNuI) 0.2“") 2 32.954351: (1136—4337”: figs 3405. Measuring ine snill dwm gtoova 53 3. ENGINE @ Shlll drurn slapper (3 Gear shill drurn (:9 Gear shill prrn spring @ Genushiil relurn spring © Gear shill spindle comp. Fig, 3-!06. Gear (D snilr lark gu e um clips @ Gear shill lurks Fig. a—lo7. Removing lhe shill larl guide pins (D 6x20 hex boll ® shill drurn slapper ‘ @ Slevper arrn plale - s-loa, Removing lh sh dr slapper (D Gear shill spindle ® I2rnrn sel g rig. 3409. Remaving lhe gear shill spindle F’ 3.10 GEAR SHIFT A. operdlion The gear shill lorlr is rnaved linearly by lhe ralarv mavemenl cl lhe gear shill drum. When lhe gear shill pedal is depressed. lhe gear shill spindle. rhrdugh lhe gear shill arm. causes lhe shill drum la move eilher irl lhe clockwise or coumer clockwise direction, depending upon wherher lhe forward or rear al lhe pedal is depressed. The shill ldrls are lined aver lhe shill drum and guided in irs linear mavenenl by lhe canl groove on lhe surlace of lhe shill drum inla which Vhe fclk guide pins are insened. Relation oi lhe drum shiils lhe iorks lo lhe righl or left which in lurn perldrins lhe gear shilling. A gedr shill rerurn ils normal posilion aller each gear change snake. (Fig, :Hoé) Disassembly I. Disassemble lhe ironsmission in accordance wilh seclion 3.9. B. 2. Pull dul lhe gedr shill guide pin clips and guide pins. (Fig, 3407) 3. Remove lhe nemml switch rolor and svalor horn lhe Iell end of lhe shill drum. 4. Unscrew 6X20 hex. boll (D and remove lhe shiil drum slopper (2) and slapper arm plane (:3 (Fig. 3408) 5. Draw oul lhe gear shill drum. 6. The gear shill spindle and relurn spring can be removed by removing lhe sel ring from lhe op~ pdsile end of lhe gedr shill spindle. (Fig. :Hov) 3.10 GEAR SHIFT 3.” KICK STARTER 54 C, Inspection I. Inspect the gear shilt spindle. gear shilt arm and gem shift forks '01 twist or bend. 2. Inspect the gear shilt drum and guide pin for excessive wear. 3. Check the springs for breakage and proper tension. 0. Reussembly 1. Insert the gear shilt drum at the right side ol the upper crankcase and assemble the gear shilt lork in the crankcase. (Fig. :Hlo, 3—111) 2. Assemble the shilt iork with the gear shitt lork ® 6 M I k d ‘ We “"5 “"d 9““ P‘" ""‘" (a) 652', in}. ri'n 332;; '2}: up @ or. w shilt link 3. Assemble the neutral switch rotor and the stator. G) Cm" gm mm M 6, Rig,“ 9", SN" ,mk 4. Assemble the shilt drum stopper; this completes © r3”, 5M, mm upper case assembly. Fig. 3-]10. Component parts at gear shiit drum. 5. Assemble the gear shift return spring in the lower crankcase. 6. The gear shilt spindle should be inserted together with the return spring lrom the right side of the lower crankcase. The gear shilt spindle side stoppe'i and oil seal should be inserted at the left end or the shitt spindle and then install the set ring. 7. Assemble the ciankshafl with transmission gears in the upper case and tighten the lower crankcase. 5. Complete the assembly in accordance with section 3.8. 3.11 KICK STARTER ® Gear shilt lork ® Gear shin dnml Fig. 3-1". Assembling the gear Shlh iark 4 @ 25 mm civsclip ® rrictian spring @ Kick starter pinian @ Kick starter washer (5) Kick starter spindle @ Kick starter spring (D AXls knack pin Fig. 3-II2A. Kick starter assembly 55 3. ENGINE (D 25 mm circclip ® Friction spring 6) Kick starter pinion ® Kick starter washer (5) Kick starter spindle © Kick starter spring Fig. 3-ll2a,. Disassembling the kick starter A, Construction The kick starter pinion engages with the transmis sion low gear and by utilizing the transmission gears kicking is made easy and does not require much Iorce. When the kick starter shalt is rotated by the kicking action the serrated kick starter ratchet nange is rotated simultaneously and the pawl ol the kick starter ratchet nange slides down front the kick starter guide and is pushed against the kick starter pinion groove by the pawl spring. Power is transferred from the kick starter pinion to the countershalt low gean When the kick starter is not depressed or the kick starter pedal is released alter kicking. the kick starter ratchet llange is pushed back by the kick starter spring. The pawl rests on the kick starter ratchet guide and the kick starter pinion is lreed. (Fig. 341'“, B) Disassembly I. Separate upper and lower crankcase in accordance with section 3.10. B. 2. Take out the kick starter shalt. 3. Remove the main shalt. countershalt and gear shilt drum. Inspection Check the ratchet and the kick starter pinion ratchet lar excessive wear and replace if excessive wear exists. Reassembly Reassemble the kick starter in the reverse order ol disassembly. Setting specification (c5175, CL‘75) Model ca I75 <1 lrs Carburetor type PW 22 Setting mark cs-a a Main bore 20 min my in) 22 mm i0.867 in) Main iet it 95 it 95 Air iei llloo 5100 Air bleed AB! o.e¢x4 AB! o,9¢x 4 AB 2 uadxz AB 2 o.a¢x2 A33 o.e¢><2 A515 o.a¢><2 AB 4 o.e¢x2 AB 3 own A35 oe¢x2 Needle iet l 2.e¢xa.e¢ 2.e¢xa.e¢ let needle 3°. 2.535¢-3 stage 4“, 2.535é-3 siage Cutaway (throttle valvet «2n no iWidth l.2 depth 0.5) Air screw )‘Ai‘A Ki‘A Slaw iei $35 io.7><2><3l $35440 iu.¢¢><2><2t Valve seat was 20¢ Pilot antlei clad p=e.o mm Lu,» P 5.5 innit ruel level 19.5 mm lureaini 25.0 mm ll.l inl 3. 12 CARBURETOR 56 3.12 CARBURE‘I’OR (C3175, CL] 75) A. CONSTRUCTION The cans or CLl7s is equipped with a twin variable venturi carburetors operated synchronously by a single cable iron the throttle grip branching to the two throttle valves. The choke valves are connected by a linkage. Each cylinder is equipped with an individual carburetor to provide maximum pertormance. The operation 0! the engine creates a vacuum within the cylinder and this draws the outside air into the cylinder alter having been passed through the air cleaner where the air is cleaned, through the carburetor where the proper amount ol tuol has been mixed to torm a combustible mixture and finally enters the cylinder where it is ignited to produce the power necessary to perform work. FUEL SYSYEM As the air enters the carburetor, it passes under the throttle valve where vacuum pressure is produced due to the restriction caused by the throttle valve extending into the main air passageway. The Iuel discharge outlet is located in this sorcclled venturi area so that the vacuum pressure Carl draw out the Iuel. This carburetor incorporates both the main and a slow system. Flu. 3-ll3. Sectional view at carburetor lCEl75l 57 3. ENGINE rig. 3-IH. Sectional view 0! carburetor tC1I75t A. Main syslem (“3- 3-111 3-1”) The luel posses through the main iet and enters the needle iet holder G) where it mixes with the bleed air entering lrom the bleed hole located around the needle is! holder G). The luel air mixture passes by the opening between the needle jet @ and iel needle ® and is discharged from below the throttle valve ©. It is here that the mixture is combined with the mainair and alter being atomized, is taken into the engine. Fig. 3415. ® slow .et a. Slow system (Fig. 3415) The air which enters lrom the inlet passes through the outside or the air screw where it is metered and It mixes with the fuel which enters the slow iet (D to produce a lull spray enters lhe slow iel bleed hole. This mixes with the air from that is discharged trom the pilot outlet at a point under the throttle valve. the air inlet to lorm a combustible mixture betore being taken into the engine. 2. FLOAT CHAMBER (Fig. 3-116) The carburetor must provide a proper mixture at tuel at dit‘ierent throttle openings and engine speeds; in order to accomplish this, the luel level in the carburetor must be maintained constant. The lloat chamber lunctions to serve this purpose. The luel trom the lcnk enters the tloat chamber through the luel inlet passage, between the «out valve seat (3) and lloat valve ® and fills the chamber to the level where the tloat @ rises to shul oil the now at the fuel by seating the float valve against the valve seat through the action ol the float arm ®. As the tuel is consumed, the fuel level in the float chamber, drops the float will follow the level. and the luel will start to enter the chamber between the opening at the float valve and valve seat to maintain a constant tuel level. 3.13 CARBURETOR 58 A spring is incorporated in the head at the lloat valve which comes in contact with the float arm. The purpose at this spring is to prevent the noat valve lrom oscillating so that a constant luel level can be maintained evenwhen riding over rough or bad roads. It lurther serves to prevent arty shock between the lloat valve and seat, thereby reducing the amount at 7 wear to these parts. II-‘Inll-l Overflow pipe When riding on a steep grade or when any ioreign substance becomes lodge in the iioat valve, it causes the fuel to overllow lrom the needle iet or G) “W chum“ Wm" ® new Wm the slow iet, and enters the engine causing the engine @ no“, “I” S", Q) "M, am (5) HM, oil to become diluted. In order to prevent such a pig. 3.1m condition, an overflow pipe has been incorporated . in the lloat chamber. At normal condition, the pipe opening is above the fuel level and it serves no purpose, but when the overflow condition exists and the fuel level rises, the luel will drain out ol the overliow pipe to the outside rather than into the engine. at . CHOKE (Fig. 371W) For starting in cold weather. a rich luel mixture is momentarily iequiiedt to serve this purpose. a choke valve a) is used in the carburetor. A reliel valve ® is included in the choke valve and is held ,‘s , , ' e closed bya spring. By raising the choke lever iully, ® ’C‘hm ”I“ ® RIM ”I“ the choke valve closes and the air entering lrom the “9- 3_”7' Choke Mm air inlet becomes restricted. When the starting motor is engaged with the throttle lever opened approximately 1/4. the fuel will be drawn out of the pilot outlet and the needle iet by the vac‘uum pressure. At the same time, the vacuum pressure will causesthe reliel valve to open by the proper amount to provide an ideal luel mixture to eliect and engine start. As the engine starts, the vacuum pressure' becomes greater and the relief valve is opened lurther to provide the proper luel mixture to warm up the engine. In this manner. the throttle valve movement causes the relief valve to operateand. therelore. the operation ol the choke valve is not required to warm up the engine. The choke valve is opened alter the engine warms up. FUNCTION OF THE MAIN COMPONENTS The main components ol the carburetor lunctions in the lollowing manner. 1. MAIN JEI (Fig. Bills) The function of the main jet is to control the luel discharge and to provide the proper luel air mixture at the higher range ol throttle opening (driving at maximum speedl. However, the main is! will also have a varying degree ol eliect in the vicinity of l/2 throttle opening. The main iets are numbered. so that the larger the number. bigger the opening and cone sequentlv a richer fuelruii mixture. lg. 3-ll3. Main ist 59 3. ENGINE 2. AIR JET Al full throttle opening, the iuel~air mixture has a tendency to become rich, and in order to prevent this condition, a bleed air is added to the fuel through the needle iet holder. The purpose ol the air iet is to meter the amount of this air; the larger the air iel, more air will be added to the fuel mixture and a leaner fuel mixture is provided. Also, by mixing the air with the fuel, better atomization will be assured. 3. NEEDLE JET (Fig 34]?) At full or intermediate tniottle opening, the needle iet will regulate the fuel which had been metered by the main iel. This control is accomplished together with the jet needle which will be described in the following paragraph. The hole of needle iet is made very accurately for precise control. Fin. 8—]!9. Nudlo I" 4, JE1’ NEEDLE (Fig. 3—]20) The iet needle together with the needle iet dese cribed in the previous paragraph, meters the discharge of the.fuel mixture in the l/4 to 3/4 throttle range. The long tapered needle is suspended within the needle iet opening. The iet needle moves up and down with the throttle to control the Iuel mixture proportionally to the throttle opening. There are three grooves on the head of the iet needle by resetting the set clip toward the lower groove, a richer fuel mixture will be provided. rip. 3-l2o. Jet needle 5. YHROTTLE VALVE (Fig. 3—l2l) The throttle valve regulates the amount of fuel air mixture taken into the engine to control the output and speed of the engine. In addition, it serves a very important function in that it controls the fuel mixture There is a cutaway on the throttle valve at the air inlet side which afiects the vacuum pressure that controls the function ol the needle iel. The use ol the throttle valve with diflerent size cutawav will control the discharge rate ol the fuel, which at‘iects the fueleair ratio. The larger throttle valve cutaway number provides leaner mixture, however, this is only eflective within the lower range ol the throttle opening and has no eflect above 1/2 throttle opening. There is also a throttle stop screw which sets the idling speed. Turning this screw IN will raise the idling speed, and lowers the speed when the screw is turned OUT. Throttle valve 6. SLOW JET (Figu 3—]22) The slow iet controls the fuel at slow speed and at idling by regulating the air entering from the air bleed to produce a fueleair mixture which assists in the atomization ol the fuel. The slow iet. like the main iet. provides a richer fuel mixture when a is! ol larger number is used. (D Siow .er Fig. 3-122. stow tel 3. 73 CARBURETOR 7. AIR SCREW (Fig. 3423) The air screw reguloies ihe oir emering rhe slow sysieni by conirolIing rhe piIoi hoIe. Turning ihe screw IN wiIl richenihe niixnrre and iurning rhe screw our will lean ihe mixrure. . FUNCTIONAL RANGE OF THE RESPECTIVE COMPONENTS In summorizing lhe descriplion slored above. lha funclionol ronge of lhe respeclive components ore as follows; Ironi lull close lo we rhrorrle opening Air screw : Thronle valve cutaway; 1/8 ro I/4 rhronle opening lei needle: l/4 io 3/4 rhronIe opening Main ie': 3/4 io lull ihronle opening ADJUSTMENT 1. HIGH SPEED ADJUSTMENT During driving. il rhe speed increases when rhe choke voIve is closed inghrIy. ii is an indiconon rhor ihe IueI mixvure is Ieon. In which case. repIoce rhe nloln iel progressively wllh lhe nexl lorger size unlll properly odinsled. The nioin ier sizes doove moo are#105.#110 and «us end lor sizes below 33100 are 4:98, W5 and :92. In ihe opposile cose. il rhe speed should loll on when lhe choke valve is closed. lhe moin iel size is proper, or else. il moy be loo large. In which case. lolIow lhe procedure below ro make the deierminavion. A. Properly sel When. aller replacing lhe main iel wilh one or o smaller size and il ii is round ro cause o drop in speed. and an increase in speed when rhe choke is slighlly closed, ii is on indicolion rhol rhe nioin iel is loo smoll. The replaced iel con be con. sldered lo be 0! lhe proper size. a. Main an Ice large When rhe iei is loo large. progressively replace ihe iei wiih one ol a smaller size nniil ihe cone diiion in porogroph A above occurs. and make rhe odiusrmeni accordingly. . INTERMEDIATE SPEED ADJUSTMENT (Fig. 3425) The odiusrmeni wirhin I/B ro 3/4 ihrorrle opening is made by ihe changing rhe posinon oi ihe clip on rhe ier needle groove and rhe repIocemeni oi rhe rhroirle vaIve cumway. However. ihe rhronle volve curowdy wiII olieci ihe lueI niixrure beiween idling and 1/4 ihronle opening. In ihe inrerniedioie speed range. ir is recommended ihoi rhe ier needIe be odiusred wirhin ihe range ol good occeIerorion as rhis will prove ro give hener fuel economy. Fig. 3-I23. Air screw (D Thronle slop screw (3 Aiv screw g. 3424. Adlusllng (afbuvemv (D rloai volve @ flool rig. 3425 ® rleai arm (:9 mm gauge 61 3. ENGINE A. Jel needle ll) When excessive black smoke is emiiled lrom lhe exhuusi during intermediate speed. ii is an indicalion ot rich tuel mixture, therelore, lower the iet needle by one groove. t2l During driving, it the engine misses or bucks, raise the is! needle one groove. B. Cutaway of lhe thronle valve The throttle valve with a larger number stamped on the cutaway will give a leaner mixture. Throttle valve will ailect the perlormance ol the slow speed as well as the intermediate speed. therelore, the range afiected should be considered when making the adjustment. 3. SLOW SPEED ADJUSl’MEN‘l The tuel mixture adjustment between idling and 1/8 throttle opening is accomplished with the air screw and the cutaway ol the throttle valve. A. Air screw The mixture adjustment at idle is made by the air screw. Turning the screw clockwise will give a rich mixture and turning in the opposite direction will lean the mixture. Not only is the idling screw used to make the idling adiustment but it also should take into consideration the mixture condition at the point where the throttle starts to open so that there is a smooth transition rrom the idling speed to the start of throttle opening speed. a. Adiusling with the throttle culuwuy As a point we throttle opening. the air screw may no longer be efiective in adiusting the tuel mixture In sucha case. replace the cutaway. It the mixture is too rich. replace the cutaway with one ot a larger number and it the mixture is too lean, replace with one ot a smaller cutaway number. C. Idle udiuslmenl (Fig, 3424) ldle cdiuslmem is made by the use or both the throttle stop screw and the air screw by the lollowing procedure. in Use the throttle stop screw to set the engine to the proper speed. l2! Manipulate the air screw back and lorth slowly to obtain the point ol maximum speed. l3| Reset the throttle stop screw to bring the speed back to the normal. l4| In lhis position, recheck lhe air screw lo assure lhul lhe selling is correct l5l Alter completing the idle adiustment, check the engine response by snapping and accelerating the throttle, Perrorm this check between 1/8 to 1/4 throttle opening. 4. FUEL LEVEL ADJUSYMENY (Fig. 3425) The float level is specilied by the height ol the lloat "h" shown in figure 3425. The float adjusting procedure is described below in coniunction with hgure sens. C3175 . h_ 9.5 mm (0.768inl cu7s. =2a.o mmtl.linl a. lnvert the carburetor. in this condition, the weight ot the float has caused the lloat arm to bear against the tloat valve and the spring is compressed into the valve. This is not the normal tuel level position. b. Next. set the carburetor as shown in the figure with the float arm pin toward the top. tilt the carburetor so that the float is on the bottom with the lloat arm in the position so lhul it is just about to separate trom the end ot the tloat valve and set in this position. (the arm will separate trom the end ol the valve when the carburetor is raised approximately 70", theretore. about 10“ lrom this point is sumcient. i.e., where the arm is not compressing the valve endl. c. In this position, measure the distance the bottom ot the float is lrom the body nange area with the gauge, this is the height h. The tolerance is 1 mm. the float may be depressed lmm or there may be a clearance ol l mm between the gauge and the float. This much to lerance will not adver selv aflect the operation. If the “on! is pos' ioned in excess ot this amount, make the adiustment by bending the lip of the float arm. There is a spring ncorporated in the end ot the lloat valve which will permit the end ot the lloat valve to submerge and will give and erroneous reading, theretore, exercise care when determining the point ol contact. lmproper measurement and adiustment will not give the proper tuel level. 3. ENGINE ENGINE-CB/CL'I25 Engine assembly diagram (Fig. 3-125) 3. ENGINE 63 3.I ENGINE REMOVAL AND INSTALLATION 64 3.] ENGINE REMOVAL AND INSTALLATION A. Engine Descri Iion The motorcycle pertormance characteristics are determined by the engine which is used Primary requirements oi on engine are high power output, light weight, compactness, ability to withstand rough handling and low mainlenunce cost. Furlher, the engine must be designed so that it harmonizes with the styling of the lrame to give it a well balanced appearance. All Honda motorcycles are engineered to provide these features. The extensive use oI aluminum alloy gives a good weight to power ratio which attributes to high pen Iormance. It also provides good engine cooling. OHC driven by a lightweight chain makes possible higher engine speed, greater power output and quiet operation. Long lite ol the engine component and trouble iree maintenance is assured by the employment or dual oil filtering in the pressure lubrication system. . . A 7 @ Munler ® Exhalm pipe setting boll @ 5x20 hek. boll Fig. 3-I28. Removing the muliler ICL|251 W B. Engine removal (CB 125 and CL l25) l. Shut oh the luel cock at the fuel tank. 2. Remove the mutiler by unscrewing the tour 6mm .m ‘ nuvs‘al the cylinder head and the two 8mm bolts. ® bxlohexv bolts ® sxlécraxs screw To remove the mufller (D ICL 125l, unscrew the Fig. 3429. Removing me air cleaner four 6 mm nuts at the cylinder head, exhaust pipe setting bolt ® and exit) bolt (:3 at the rear oi the seat. (Fig. 3428) (Note) Remove the exhaust pipe protector to facilitate the remayal or the exhuusl pipe setting bolt. 3. Remove the air filter covers. Unscrew the two 6X12 bolls mend 5X15 cross screw ® av Hie air cleaner connecting tube and remoye the air filter (:3. (Fig. 3429) 4. Disconnecl Vhe high Vension lermirlal Irom Vhe spark plug and all electrt.al leads. (Fig. 3430) 445.1%. a) clutch cable (3 Cluich liller thread Fig. 343‘. Dtscennocting the clutch cable 65 3. ENGINE 5. Remove lhe drive chain cover and disconnecr lhe clulchcableend ® ironr lhe clulcn Iiher lhread @. (rig. 3431) 6. Disconnecl lhe chain ioinl clip © and remove rhe drive chain ®. (rig. 3432) 7. Remove rhe 6mm HMS ® mountind lhe carburetors ® lo lhe cylinder head. (rig. 3433) 8. Remove "is four 8X25 bolls av lhe underside or lhe crankcase and remove lhe slep bar. 9. Unscrew lhe (our engine maunling nuis. Place a suppori block Under ine engine lo preyenl drope ping. push oul ine rnounring balls and rhen lhe engine will be lreed irarn rhe iranre. (D J m clip (7: Dnye cna. rig. 3432. Remowng ihe dnye (hum c. Reassembly 1. Perform rhe engine insrallarion in lhe reverse order A ,. ‘ . . [2) 6mm hex. nuts or removal described in Secrion 3.1 E. G) Carbureirs F‘V' 3"”- R°’"°“"‘9 "‘° ‘°“’“"'°” 2. The engine insiallarion can be made easier by reniporarily hanging lhe engine on lhe frame by lire use or a Tehcndle cross screw driyer (D followed by lhe inslallalion or lhe engine maunling bolls. (Fig. 3434) (Note) When reconnecring lire drive chain. lhe ioinl clip should be insialled wiln lhe opening lacing opposiie lo lhe direcrion or lhe normal chain rnoyenrenl. (Fig. 3435) 3. Adiusr ihe chain iension so «her rhere will be i lo 2cm (040~0.80in) slack in rhe chain (D rehandle (ms: screw duvet Fig. 3434. lnsialirng rhe engine [DIRECTION OF ROTATION G) loin: clip Fla. 3435. Join! (lip inxlullulion 3.2 CYLINDER HEAD AND CYLINDER 66 3.2 CYLINDER HEAD AND CYLINDER l. CYLINDER HEAD, COVER AND BREATHER A. Construction The cylinder head is a cast aluminum ’WlVl head construction of a semirspherical combustion chamber with a squish area (or better combustion efiiciency. (Fig. 3436) The single piece overhead camshelt. rocker arms and valve mechanisms are all incorporated in the valve chamber above the combustion chamber. Cylinder head cover incorporates a breather pas. sage for dissipating the pressure build up. F‘ Disassembly i, Drain oil lrom the engine. 2. Remove the 8mm blind nut and five 8mm hex. nuts. and then remove ihe cylinder head cover. (Fig. 3437) 3. Remove the Ielt and right cylinder head side covers by unscrewing the long bolt lrom the left side '4, Rotate the crankshaft so that the cam chain ioint is toward. the top ol the cam sprocket and then remove the cam sprocket mouuting bolts. 5. Attach a wire G) to both ends ol the chain ® ® 5mm hex rum ® amrn blind nut and then disconnect the cam chain. this will simplify Fla, 3437. Removing the cylinder head cover. the reassembly task later. (Fig. 34 3s) 6. Separate the cylinder head irom the cylinder. c. Inspection l. Disassemble and clean all the parts belore inspec- tion. Carbon, should be removed with care. using a carbon scraper to prevent damaging the head. (Fig. 3439) 2. Reler to section 3.2 c on page 21. 3, Inspect the combustion chamber, inlet and exhaust ports lor cracks. 4. Inspect the valve guide and valve stem. Check 6) w” (,3 Cum (Mi the valve guide diameter at the top, center and r g_ 3.135. Alluchirg the wire to Iha corn chain bottom in both the X and Y axes, using a precision cylinder gauge. Check the valve stem with micrae meter. Fig. 3-137. Scraping carbon irom combustion chamber 67 3. ENGINE l ltem l Standard Value l Serviceable limlt . . 5.4a~5.49 rnrn Replace ll under 0"""‘° d'“'“'°' (D.1l.§&~0.1l61inl 5.oenirn lo.2l5inl lnlei valve . Contact lace runout< w"“‘" 0.02 ’“'“ «3.0003 inI mm diam”, . 5.5~5.515mm Replace il over l0.2|65~0.1l7l ml 5.555 mm (0.219in) . . . lo.D55~l0.065 mrn lrilei valve gulde Ourside diameter ~ (0.3959~D.3963inl o.o4~ 0.06.5 mm ""°"°'°"“ "' ‘ IO.DOI6~0.0016lnI law ”I“ damn“ o.m~o.035 mm Replace ll over lo.oom~o.oouml anamm lama ml . _ 5.4e~5.47 mm Replace ll under 0"""‘° d'°’“°"' io.2l5o~o.2l54inl 5.44 mm lo.2l4inl Exhaust valve . c ' H ' wirhin 0.02am on ac ace runou moses ml Inside dummy 4 5.5~5.5l5mm Replace il over (0.2165~0.217l inl 5.555 mm (0.2l9irl) . . lo.u55~lo.os5 mm Exhauxtvalve gulde cuiside dlametev - (0.3959~0.3963ln| lnierlerence lit - °'°‘~°‘°°5 ’“"‘ (0.00]6~0.0026 ml “hound“ mam“ o.oa~o.o55 rnrn Replace il ever Io.ool1~5.0021 ml 0.1 mm (0.0039 in) ll tlle valve guide is beyand serviceable limit, it may be repaired by usinga reamer (Tool No. 0700570010“ and replacing the valve wiih one at an oversize. 5 When replacement or tlle valve guide becomes necessary. remove and replace with an oversize guider use rhe valve guide temover liaal Na. 0794273290l00l and rhe valve guide driver lTaol Na. 0794273290200) lor replacement aperarian. ® "0" mark fig. 3 40. Installing the cam spruclei ® Cylinder head cover gaxket na. 34“. Alter insralllng llle valve guide, use a reamer lo oblaln the proper valve clearance. D. Reassernblv l. Reassemble the cylinder head in the reverse order ol disassembly. (Novel lal Belore installing tlle cam chain. the valve must be limed in relerence ra rhe pasirian al rhe crankshalt. To do lhls. l‘irsl, paslriari rhe crankshaft so lllal rhe knock pin at rhe tapered shalt end is an rhe cylinder centerline and toward the cylinder head. Then align the "0" mark slaniped an rhe cam spraclel to tlle index mark on the cylinder head [both inlet and exhaust valve should be closed. if not, rotate rhe cam 180".l In rhls posllian, connect lhe cam drive chain. (Fig, 34‘0) Check rhe condirian ol tlle gaskets. It is recom mended that a new gaskets be used rhroughoul, especially rhe head gasket. (Fig. 37m) lb [cl ll rhe carri chain tensiorler push rod is not screwed in camplerely, rhe carri chain cannai be connected. 3.2 CYLINDER HEAD AND CYLINDER 2. Tigmeri me cylinder head cover nuis uniformly in me sequence shown: (Fig. 3442) Torque: lBO~230kg. :rri (13.0~16.7h. lbs) 3. iriseri me boll in ihraugi. me cenier bali hole on me leri side caver, assemble and iigmen me rigm side cover 2. CAMSHAFI A. Construction A single piece camshan camains boil. inlei and exhausi carris rogeilier wiili ihe sprackei which is mounved a! We Ieh end. (Fig. 3*]‘3, 144) The cam sproclei is driven by Me crankshch an M lhe speed. The com is designed will. a long gradual slope lo prevent abrupl rise and drop of me valve, lhus assuring a quleier valve operaiion rig. 3442 Fig. a-ua. Camshal: \ r"- H # __-_--‘-_______-_ l a) Cumshuh ® Cylindev head @ Cylindev head rgiir side cove! Fig. a-m. oil passage diagram 6) Cyllndev head Ieli side cover 69 3. ENGINE a. Disassembly I. Remove the cylinder head in accordance with a Section 3.2.1 B. llall\“°““ 2. Remove the tappet adiusting hole caps and loosen ’ the tuppet adiusting screw5_ I “lll‘wil‘ll‘t‘w‘ll‘“lllt shalt stopper and pull out the rocker arm shalts, and the locket arms can be removed from the cylinder head. 4. Remove the camshalt lrom the cylinder head by sliding out the left side. 3. Remove the 5 mm hex. bolt holding the rocker orrn t ll‘h ”Hill c. Inspection l. Valve timing (Fig, 3445) 2. Checlr the cam tor excessive wear or scoring. 3. Camshatt (Fig. H46, 3447) Item Standard Value Fer ceuble L . l9.953~l9.964 mm eiplace ll undev ”We” d'""‘°"'® o.7ss7~o.7sol inll9.93rnmlo.7sAeinl . 32.927~32.94 mm Replace it under ‘5" "d d'“”‘°'°' ®lL1963~L1965inl31.907mmll.2955ln) Cum base circle 210mm (0.82a8lnl on legs. WA— 4. Cam sprocket root diameter (0 lnlet. valve oaens. 5"BTDC Standard value¢59.a7~59.99 mm (2 lnlet valve closes» 30°ABDC [1355..2364 int @ Exhaust valve opens» 5°EBDC G) Exhaust valve closes» 35°ATDC Fig. 3445. Valve timing diagram D. Reassembly I. Screw a'ut the tappet adiusting screw and assemble the camsholt into the cylinder head in the reverse order ol disassembly. 2. Adiust the topper clearance to 0.04 to 0.06mm l0.015 to 0.023 int with a cold engine. 3. ROCKER ARM Construction The lunction of the rocker arm is to transpose the rotary motion of the camshalt to a rec procating ‘ .7 motion tor actuating the valve. The rocker arm is ‘9 ”5‘1“Effiegmfigmflfflmm made rigid to prevent dellection and the end which contacts the cam is finished smooth alter surface hardening to minimize wear. The end which operates the valve is provided with a tappet adiustirlg screw that contacts the valve. a. Disassembly I. Disassemble the cylinder head in accordance wilh Section 3.2.1 B. 2. Remove the tappet adjusting screws. 3. Rotate the camshaft so that the locket arms are resting on the base circle oi the cam lthis can be set by aligning the "0" mark stamped on the _ 7 . cam sprocket to the index marlr on the cylinder no. 3 H7. Camshalt dimensions head Is“ my“ flange). 3.2 CYLINDER HEAD AND CYLINDER 70 4. Remove lhe boll holding lhe rocker arm shall slopper (D and pull our lhe rocker arm shall ®. lhe rocker armcarl lhen be removed. (Fig. 37145) To facililale lhe removal, use the snap ring plier. (Fig. 3449) c. inspeclien I. Clean all pans, especially make sure lhal lhe all holes are clean. 2. lnspecl lhe rocker arm cam conlacl surlace and repair or replace it lhere is. scoring or excessive wear. @ Rocker arm rlralr ”“Cke' °"" rig. 3-l43. Removing rhe rocRer arm shalr lrem srandard Value Serviceahle lell " Slipper l Replace il aver surlace wen! 0.3 mm "1012 ml snail hora lo.oo~lo.ol5mm Replace il aver dia l0.3937~0‘3943 lhl lo.l mm io.40inl Rocker arm shail llern Slandard Value Serviceaale Llrnii 9.972~9.9a7 mm Replace il under lo.3926~l13933 ml 9.92 mm lo.393¢ inl Clearance o,ol3~o.043mrn Replace it over lo.ooo5~o.ool7 inl 0.03 mm IUVOOSI irll Oulslde dlu (D Rocker arm shall ® Flier Fig 3-IA9. Removmg lhe rockel arm shall Check lor proper lappei clearance. bolh inlel and exhaust should be 0.05 mm ID DOZinl, loo small a clearance will cause ilre valves lo remain parrly open. causing compression leak and resulls in hard slarling. o, Reassembly Reassemble rne valve rockev arm in rlre reverse order or disassembly. A. VALVE A. Conslruclion Reler ro secrlon 3.2.5 on page 27. B. Disassembly l. Remaverlre cylinderhead. Relerra Secrion 3.2.l A. 2. Disassemble rhe rocker arms and camshair lrorn rne cylinder heaa. Reler ro Secrion 3.2.3. is and 3.2.2. B. 3. Compress rhe valve spring wlrli rhe valve lifler (Tool No. 0795773290000] and alrer removing lire valve coner, valve spring and rerainer. rne valve can be removed. (Fig, 345i) (D Carn shall (2 Valve Rocker arm @ Plsmn a) Cranlshan © Cum chain guide roller © Carri chain lensioner roller (7) Cum chain rensianer Fig. 3-lso. Valve mechanism. 71 3. 6) Valve Irller ® Cylinder head Fla. 3451. Removing llre valves INLEY VALVE C. ENGINE lnspeelien I. Exhausl Valve (Fig. 3457) Slandard Value Sarvlceable Lirnll (D 5.46~5.47 mm Replace ll under o.215o~o.2l§4 inl5.u mm IDJHZ ln) lleln Slem diameler 6|.6~6I.B rnnr liealace .l under ”"9“ ® l2.4152~2.433| inlelJrnrnluow in) Head mime“ @ o.a~o.a rnnr Replace .l wide! llslnl Concenmclly ol valve lace g) lnlel Valve (Fig. 3452) l Slanaara Valve l Servic ale mm (D 5.4s~5.«7 rnnr Eeplace il wide! lD.l764~0.l768ml .46mml0.2|50 in) ® 61.2~62.4mm Replace .l wide! i2.uaa~usa7 in 61.8 rnrniuaal in) .l~o.a mm Replace il under ‘ (0.DISB~D.0136 "no.2 rnrn ID.DO79 in) llhln 0.01 mm c.0005 .nl llerrr Slern diameler Lenallr l-leaa llriclness @ Cancenrricrlv ol valve lace 2. Valve spling rneasurernenl (Fla, 3453) Ouler valve spring ha. 345: Valve dlrnerlslon 5) Valve iesler ® Valve fig. 3453. Measuring valve ienslan ria. 3454. Valve seal deluil llern I Slandard Value Serviceable Llrrlil , Replace ll under free lenalll 32.! rnrn “.2638ln) 31.0 mm ”1105i", 20.3 mm/W~2| la tension l0.7?9 In/4|.S‘75~ — 46.305 Ibsl lnner valve spring llern Slandnrd Value Servicenble lirnll Replace il undev lree lewll. 26.1mm ”.0176 ml 256mm “mm,” ls.arnrn/lo.45~ 1 . ”.55 lg °""°" (0.6142 rn/23.o42~ i 75.668Ibsl Reessernblv l. lnslall llre auler and inner valve spring lrarn llre lappel aaiusllng hole and compress llre springs wilh a valve liller and reassemble llre valves wilh valVe coners. VALVE SEAI Descriplion The valve seal is repaired wilh llrree lypes of CuHer. Tlre relalive lacaliarr and llre wiallr al lhe valve seal conlacl area is accarnalislrea wilh llre valve seal lop “We! and valve Seal bonom only while We relacina of llre valve canlacl area is perlorrnea by llre 9o“ caller. (Fig. 3454) 3.2 CYLINDER HEAD AND CYLINDER 72 Valve lapping operaiion is performed lasi. This is m oblain a leakrproof seal belween the valve and. lhe valve seai. Place a liberal amouni al lapping compound on rhe valve lace and lap ihe valves, applying a slighi pressure while roraiing rhe valve back and lorih wivh a suciion cup lapping iool. Wash of? rhe compound ihoraughly and inspeci ihe valve sear wilh bluing. (Nole) lai When rhe valve siem is greaily worn. ihe valve guide is usually also worn. Hence, when a valve is replaced, ii also is desirable la replace ihe valve guide. Since Vhe guide is press lined, ii is recommended rhai ihey be replaced wiih an over- size gu'de. lbl When lhe valve is assembled, lhe compound which was used during lapping should be conipleiely removed fig. 3455. Cylinder CYLINDER A. Conslruclion For improved cooling efiecv and weighv, reduction. ihe cylinder is made ol aluminum alloy wiih a press fined special cosr sieel cylinder sleeves. (Fig.3ei55) The com chain guide roller is incorporaied al ihe Ieh hand side of Vhe cylinder. (D 6mm mils rig, a-isa. B. Disassembly Removing ihe cylinder 1. Pemove the cylinder head. Refer lo Secvion 3.2 B. 7. Pemove Vhe Owe 6mm hex. runs and lhe cylinder from Vhe crankcase. (Fig. 3456) c inspeclion I. Measure rhe cylinder bare, raper, ouleofrrowid wiih a precision cylinder gauge. (Fig. 34 57) Take the measuremenl al ihe mp, middle and bonom in bovh lhe X and Y axes. iiern Slandald Value Serviceaple iinui B u.o~u.0i rnrn Repair ll aver °“’ li.7323~i.7327ini Au rnrn (1.7362inl Taper. 0005 mm '0 00mm Repnlr il over gs; ‘.. . aunoi-raund 0.05 rnrn iciouzoini ® Cylmder gauge (3 Wind“ 2. The clearance beiween ihe pisron and cylinder Fig. 3-!57. Measuring lhe cylinder uare will greaily alleci rhe engine perlarmance. Be cause rhe pisron is ellipiical. rhe clearance is canirolled very closely. The clearances are nol ihe same. however. ii any area is greaier ihan o.i mm (0.004 ini, rhe cylinder should be rebored and lined wiih an oversize pision. D. Reasserribly I. lnsiall ihe gaskei beiween ihe cylinder and crank case and inseri rhe cylinder aver ihe siud bolrs. 2. Make sure ihal lhe cylinder gaskel and vhe vwo dowel pins are insialled. :1. During ihe insrallaiian or the cylinder, use a hard wood pision base m preveni pision movemeni. Also use a ring compressorio preveni ring damages. (Fig. 3458) (D cylinder (3 Vision @ Piston base. rig. J—ISB. insiaiiing ihe cylinder ng compressor 6)) Pisron 73 3. ENGINE 3.3 LEFT CRANKCASE COVER (D 6mm hex. bot ® Stator rig. 3-159. Removing the dynamo stator. a) Spark udvuncer (2) Dvnomo rotor setting ball @ Washer rig. 3-lw. Spuvk odvoncer a) Generator rotor puller ® Ganavntov rotor rig. 3-]6‘. Removing the AC. generator rotor (D clutch tiltar rig. 3461 ctvtch litter thvend tnstullutton 1. LEFT CRANKCASE COVER The purpose ol the crankcase cover is to protect the vital component ports ol the engine. The contact point is mounted on the lett end ol the cronksholt. AL. GENERATOR Construction The detailed description ot the AL. generator is given in the electrical section. Disassembly A.C. generator can be disassembled or reassembled without separating the engine trom the trame. How ever, this section describes disassemblv ot the AC. generator lrom the engine which had been separated lrom the trame, and the cylinder and cylinder head disassembled. l. Remove three screws and take oh the contact breoker cover. 2. Disconnect the primary lead lrom the breaker ossemblv terminal and remove the two contact breaker plate screws to remove the breaker assembly. 3. Remove the lett ercnkcose cover. 4. Remove the three bolts holding the A.C. dynamo stator and AL. dynamo stator can be separated. (Fig. 3459) 5. Remove the bolts holding the A.C. generotor rotor and the spark advoncer assemblv con be removed. (Fig. 3460) 6. Remove the rotor trom the cranksholt using the AC. generotor rotor puller. (Tool No. 079337 zoooooot (Fig. 3461) c. Reossembtv 1. Align the dowel pin on the flywheel when reaSA sembling the AL. generotor rotor, set in the crank Stunt! with ttle groove on the rotor and insert the rotor. Install the spark odvoncer over the rotor and tighten the rotor setting bolt. 2. Reassemble the cronkcase cover, etc. in the reverse order at disassemblv. 3.3 LEFT CRANKCASE COVER 74 3, CLUTCH LIFTER THREAD A. Description The clutch Iiltet thread is located between the clutch lever and the clutch lifter rod. It transmits the action of the clutch lever to the clutch rod during starting and changing at the gears. In other words, the clutch litter thread regulates the function of the clutch mechanism. and therefore, it indirectly aflects the perlormance oi the motorcycle. (Fig, 3462) B. Disassembly l. Remove the left crankcase cover. 2. Remove the bolt from the adiuster l‘ixing piece and the clutch lever spring. The clutch liiter thread can then be disassembled. (Fig, 346:) c. Reassernbly 1. Apply grease to the clutch Iilter thread belore assemblying. Use HD type mum-purpose NLGI, No. 2. 4. CAM CHAIN TENSIONER A. Costruction An automatic Cam chain tensioner has been employed to simpliiy the maintenance and eliminate the adiustttlent oi the cam chain. This is done by automatically applying pressure against the tensioner push rod by means at the cam chain tensioner spring. The force is applied by the push rod to one side of the "seesaw" type. tensioner to maintain proper tension to the cam chain at high speedt further, the location at the guide roller has been engineered to minimile the chain noise. In addition. a manual adiusting ieature is also provided to correct any stretch in the chain as the result of the centrilugall orce from extended riding. (Fig. 3464) a. Dixossembly l. Remove the breaket point cover, point terminal lelt covet, AC Generator rotor, and then dise assemble the AC Generator stator base. 2. Remove the Cylinder head and disassemble the cylinder. 6) Clutch adwstet Dckmg ho (2) mm was er (3 Adiustet l‘lxing piece ©‘Clutch adluslar (5; Clutch lilter thread (3) Clutch lave! spring rig. 3-!63. Cpmpanent parts at clutch adluster ® tensioner roller ® Tensioner arm (3) Timing sprocket © Crantrcase G) Adlvsl screw lock nut © Tensianer udlust aolt ® Tensianer pushrod head at tensianer pushrad ® tensioner spring (3 Oil damper chamber 3464. Construction at the cam chain tensipner >t (j) tensioner adiust bolt (3 tensioner pushrad (3) Cam chain tensioner spring ® Cam chain tensioner (a; Tensioner set plate B (3) rensianer set plate A (0 Cam chain tensipner roller rig. :Hes. Campanent parts at the cam chain tensioner @ Tensionar sci plola A (2 Tensronerser ploi. a (5) 6Xl6 cross screw rig. 3—156. kemoving lha lensioner sci pioies (i) Tensionar adiusl boll ® Lock nui rig. 3-l67. Adiusiing me cam chain iension (D Oil lilier cover ® Righi crankcase cover Fig. 3—153. kighi crankcase cover (i) kighi crankcase cover ® 0 hirer cover (5) ouxz o ring rig. 3—169. Componenl paris al k. cvankcuse cover. 3. ENGINE a. Unscrew lhe lhree lensioner sel plaie rnounling screws. (Fig. 3466) 4. Loosen ihe lock rm lrom ihe cam chain adiusler screw and aller removing ihe circlip irom ihe adlusler boll wilh a plier, ihe iensioner pushrod and lhe iensioner spring can be disassembled. c. lnspealion Check lhe cam chain lensioner roller ior damage. dismrlion oi ihe paris, and replace any deleciive parls. Cam chain iensioner spring hem Slandard Value serviceable limil . kapiace il under free iengih 68.7mm l2.7osini 663mm .159an T . zomm/la5~2l5gr °"“°" l0s787in/B.6~loox) D, Reassembly I. Perlorm lhe reassembly in lhe reverse order oi disassembly. 2. The lensioner adiusiing boll should lirsr be screwed all ihe way in and lhen gradually backed olT unnl lhe proper iension is achieved. Make ihe adluslmenl by applying a screwdriver lo lhe upper porlion ol ihe boh head and lighien lhe lock nul aller complerion. (Fig. 34.57) ll lhe adiusiing boll is loosened, lhe cam lensioner will be auiornarically iighlened. a. Align lhe “1" rnarking on lhe AC Generalor rolor lo Vhe arrow making an lhe slalm and Se! Vhe crankshan on Voprdeadecemer oi compression slroke. 3.4 RIGHT CRANKCASE COVER ASSEMBLY L RIGHI CRANKCASE COVER A. ConsOrucfion The righi crankcase cover and lhe leil crankcase cover, house ihe engine primary cornponenls. The oil filler cover is ruled lo lhe righl crankcase cover and provides lhe passage ior lubricaling oil. (Fig. 3468) a. Disassembly I. Remove lhe kick slarier arm lrom lhe kick pinion snoli. 2. By removing lhe len screws securing lhe case cover, lhe righi crankcase cover can be removed. a. Aller unscrewing lhe lhree 6X16 screws, lhe nller cover can be removed. (Caution) During operalion, alienlion should be given lo lhe iwo 64.5)(2 O ring Filled lo lhe filler cover lo assure lhal lhere are no oil leaks. (Fig.37l69) C. Reussembly I. eelore periorming lhe assembly, inspecl ihe crank- case and oil filler cover lor cracks and also lor any darnages lo ihe maling surlaces since lhey will cause oil leak. 2. Clean lhe o ring and inspecl lor any darnages; replace it necessary. 3. Afler inslallalion ol lhe screws. lighien lhem unilormly lo preveni lhe covers irom warping and consequenl oil leak. 2. 3.4 RIGHT CRANKCASE COVER ASSEMBLY 76 CLUICH A. Description and operation Wheri the right crankcase cover is removed the clutch complete is exposed. To the clutch outer. the clutchspring driving the clutch pressure plate is installed. The clutch plate is installed with the clutch friction disc between the clutch ceriter with lour 6X20 hex. bolts. The clutch plate has internal teeth which fits over the machined grooves cut on the outside ol the clutch center. Clutch center in turn is mounted on the trans mission main shalt by spline. Hence, it and the transmission main shaft are essentially a single unit. The Clutch plate, clutch center, and clutch pressure plate rotate. On the other hand. to the groove cut on the exterior circumlerence of the clutch outer. the clutch lriction disc is coupled by the collar entering the groove: lree wheeling rotation with the transmission main shalt is obtained. Hence, while the clutch is connected. the clutch outer center, four clutch plates, lour clutch friction discs. and clutch pressure plate are essentially a single unit through lriction exerted by the clutch spring: rotation of the crankshaft is transmit ted to transmission system. When the clutch lever is gripped, the clutch adiuster rotates clockwise. the adiustment thread is pushed out by the squareeheaded thread in the clutch adiuster fitted to the left crankcase cover; this is pushed out by the clutch ioirit through the clutch rod. The clutch spring is compressed and the tour clutch lriction discs and tour clutch plates became disengaged. Hence. the rotary motion ol lour outer clutches and lour clutch discs is not transmitted to the clutch center. (Fig. 3470) Disassembiy i. Remove the right crankcase cover. 2. Remove the tour 6X20 bolts © securing the clutch pressure plate. separate the clutch lriction disc and the clutch plate. (Fig. 3-l7l) 3 By removing the 20mm set ring ®, clutch center © can be removed. (Fig. 3—l72) 4. Pemove the oil Filter cap and extract the oil filter rotor. Remove the 16mm lock nut securing the primary drive gear. 5. By pulling up the turn stop. remove the 6 mm hex bolts securing the oil pump. ® Primary driven gear ® Clutch outer @ Oil opening (1) Clutch spring © Clutch pressure plate © Clutch iiiter lolnt piece fig. 3-170. Sectional View ai clutch assembly (D 6X20 hex. halt ® Clutch assembly rip. :H7l. Removing the clutch assembly (i) 20 mm set ring @ Flier @ Clutch :ariter Fig. 3-172. Removing the clutch center 77 3. ENGINE (D Clutch outer ® O'll pump rip. 3—l7a. Removing the all pump (D Clutch outer (2) Oil pump Fig. :t-m. on pump (D Cam eham guide roller ® Cam ehair. idle roller @ Cam chain tensioner G) Camshalt (3) Oil nlter ® Oil lilter screen r. 3475. Oil lubrication diagram 6. Pemove the clutch outer together with the alt pump. (Fig, 347:) (Nate) This is removed at a right angle lacing the trans mission shalt. Care should be taken so that the transmission shaft is not damaged. 7. Remove the right primary drive gear. Inspection 1. Measurement ol damage, thickness, distortion and anecsides contact of the notch ol the clutch lrice tian disc. Item Standard Value Serviceable Limit Thickness 3.5 mm mun ml Width ol I3J~llfl mrn Replace ii under claw l0.539~o.543 inl I15 mm meals in) 2. Fatigue al clutch spring. ltem Standard Value Serviceable Limit . lieplaee it under free length 3L7 mm n.2teoinl 31.0 mm ”mm“ 2i mm/15~l6kg Tension tuna in/33.075~ 35.18 lbs) Cl. Measurement ol clearance ol the clutch outer notch and the clutch friction disc. Item Standard Value Serviceable Ltmtt clearance 0'2 N 0'35 "‘"‘ (0.0079~0.DI38 lnl Reassembly i. install the primary drive gears. 2. The clutch outer and the oil pump should be coupled by the pump plunger and the unit should be coupled at a right angle to the transmission main shaft and lhe pump fitting stud bolt. Tighten the two oil pump bolts. install the right primary drive gear. install the oil iilter rotor and oil pump cap. psi-e.” Couple the clutch center to the spline ol the trans mission main shaft and set with the 20 mm set ring. 7. Four clutch plates and lour clutch friction discs should be placed altemately. Assemble the clutch pressure plate. the clutch spring and the 6X20 bolts. (Note) When the clutch pressure plate is installed, make sure the clutch iaint is in place. 8. Install the right crankcase cover and screws. 3.4 RIGHT CRANKCASE COVER ASSEMBLY 78 3. OIL PUMP (Fag. 3475, I76) The oil is picked up lrorn the crankcase sump and routed through the oil passage to the oil ltlterwhere the impurities are removed by the centrilugally operate ing oil l'llter. The clean oil is then pressure led through the upper crankcase to the right crankshalt bearing. The oil which enters the right and lelt crankcase outer rings is separated into two routes, one is fed to the roller bearing and the other enters the crankshalt to lubricate the connecting rod large end through the holes drilled in the crankshalt iourrlals. The connecting rod small end is lubricated by oil mist. The oil from the upper crankcase oil passage (D ,0 “mum" (2 TO K mm” com is fed to the top of the cylinder head through the ® Ta quad” head ® Um,” crankcase @ Oil cylinder stud bolts. This oil is led into the camshatt n" a-lu. 5mm“. view 0, 0;, mg and lubricate: the rocker arm. The oil lubricate: the , , cam chain on its way down to the sump. The gears and bearings are lubricated by oil droplets and mists. The normal capacity ol oil pump is 3.700 cc ”96 cu int at 7,200 rpm. a. Disassembly l. Remove the right crankcase cover. 2, Remove the oil I'llter rotor 3. Separate the pump body together with the clutch. 4, By removing the 26 mm circlip. (D the pump rad ‘ . ,, r. (2) can be separated lvom the clutch outer ® Oil litter rotor washer (g) Oll litter cop (Fig. 3764) @ 50.5Xl.5 a nng (9 all filter ratar Fig. 3-177. Oll filter 5. Extract the pump plunger p;n @ and remove the plunger (D at the tip ot the pump rod. (Figaeosl c. Inspection Reter to section 3.5.].C on page 39. D. Reussembly l. Assemble the pump in the reverse order or disossembly A. OIL FILYER A. operation The engine oil is doubly hltered through the centrilugal lilter and the mesh screen lilter to assure clean supply al oil to the engine. (rig. 3477) The screen filter is on the pump inlet side and the centrilugal filter is on the outlet side. B. Disossembly l. Remove the oil filter cover. 7. Remove the Iour 4X l6 cross screws and oil lilter cap 3. Pull ofl the oil lilter rotor. c. Reassembly l. After cleaning ol all the parts. perlorm the reas sembly in the reverse order ot disassembly. 79 3.5 CRANKCASE 3.5 CRANKCASE l. Upper and under crankcase. A. Description The upper and under crankcases are constructed of lightweight aluminum alloy and can be separated at the center lines at the crankshaft, transmission main shaft and counter shaft. (Note) In the upper surface of the upper crankcase. the cylinder stud bolts are inserted. (Fig. 347B) The lower crankcase is equipped with the oil Fig. 3475. Upper crankcase separator and two drain plugs. (Fig. 3479) s. Disassembly l. Drain oil in the crankcase. 2. Remove the cylinder head and cylinder in accor. dance with 3. 2. IB and 3. 2. as. 3. Separate the right crankcase cover, oil litter. clutch and oil pump in accordance with 3. 4, l, 3. 4, 2 and 3. 4. 3. A. Separate the left crankcase cover and AC generator in accordance with 3. 3. l and 3. 3. 2. 5. Remove the gear shift spindle. 6. Remove the bolts from the under crankcase. and the upper crankcase can be removed irorn the under crankcase. (Fig. 3480) Fig. 3*]79. Under crankcase c. inspection keler to section 3.6.C on page 4t. 0. Reassembly 1. Assembly should be performed with attention paid to the following points: . Clean the crankcase and inspect the mating sur. faces of the crankcase for sign of leaks, scratches and other damages. - Apply liquid gasket to the mating surfaces at the case: assemble after drying. (D Under crankcase (2) Upper crankcase . ria. 3-IBO. Removing the under crankcase 2' 0" “Pam'o’ A. Description The oil separator is located in the forward section at the lower crankcase. directly below the crankshaft. Its primary function is to control the oil splashed by crankshaft counter weight, prevent oil penetration and controls the oil temperature. a. Disassembly Oil separator can be removed by pulling out the oil separator set bar. (Fig. 345i) c, Reussembly a) on separator ® Oil separator set bar rip. 3-lal. Removing the oil separator Assemble the oil separator in the reverse order or di.assembly 3.6 CRANKSHAFT 80 3.6 CRANKSHAFT A. Construction The crankshall iournals are made al high carbon sieel and lhe counierweighis are al nickelechromee molybdenum sieel, assembled by press lining. Crank shan is supporied by a roller bearing and a ball bearing which iake ihe ihrusi load and are lixed in place by dowel pins. Sprockel io driye lhe cani chain is pressrfilled on lhe leli crankshaii. The oil is forced inlo lhe crank pin by cenlrilugal iorce lo lubricaie lhe conneciing rod bearing. There is also a separale oil roule lo lubricale lhe main bearings. (Fig. 3452) a. 3-!82. Crnnkxhall asxembly laid iypel Disassembly l. Drain oil lrom ihe crankcase. 2. Separaie ihe cylinder and cylinder head in accore dance wiih 3. 2, IB and 3.2. 63. 3. Separaie ihe righl crankcase coyer, oil f'lllerr cluich and ail pump in accordance wirh 3. 4. Ir 3. 4.2 and 3.4.3. 4. Separare lhe len crankcase coyer and A. c. generaior in accordance wiih 3. 3.1 and 3. 3. 2. 5, Remove ihe gear shill spindle. 6. Remove lhe lwo 8mm and a 6mm hex nuis lrom lhe upper crankcase and remoye ihe liye 6mm hex bolis, rwo nuis and 8mm hex and blind nuis ironi lhe under crankcase. 7e Sepulale ihe under crankcase lrom lhe upper crank. case, ihen lhe crankshaii can be remoyed. c. lnspeciion (1| Suppori lhe crankshaii on v blocks ai bolh bearings and measure lhe amounl ol runoui. (Fig. 3453) hem m Seryiceable limir Len healing Replace il oyer web side ai m’ug‘gw 0.06 mm ioial 30mm(1.3in) ' 10.0032 inl runouv Righi bearing Replace ll oyer web side ai 0.02 "‘"‘. 0.08 mm . - 26mmll.0 in) “10°05 "" (D 32ml — _ (D Crunkxhnh ussy. Q) Did gauge l2) The clearance in lhe bearing is measured by rig. 3403 Measuring ihe crankshali run our. Fixing the crankshall on llie cerilers and moving lhe bearing in llie axial and veriical direclion. liem Siandard Value Seryiceable Limit Axial Wiihin 0.05 mm Replace il oyer clearance (0.0020inl 0.l mrn lo.004 in) clearance Wiihin 0.05 mm Replace il oyer narmal Io axis l0.0020in) 0.l mm mom in) When lhe clearance in lhe axial direciion becomes excessive, lhe crankshail will moye lroni side lo side when engine is running and produce undersirable noises as well as causing uneven wear lo lhe cylinder. pisian and lhe liming sprockel. D. Reussembly Assemble ihe crankcase in ihe reyerse order a! disassembly. 81 3. E N G I N E 7. CONNECTING RODS A. Description The connecting rods are or molybdenum steel and have an Hsshaped section; The roller 12.5X8.5mml is hold by the roller retainer made or special aluminum alloy. Staggered rollers are used in order to increase the load capacity. 1. Measuring the deflection ot the piston end oi lhe connecting rod. Refer to section 3.7.23 on page 43 and 44. 3, PISTON A. Description tieler to section 3.7.“ on page 44. B. Disassembly Reier to section 3.7.3.5 on page 44. C. Inspection I. Before inspection, carbon adhering to the piston head or ring groove should be removed, using care not to scratch the piston. (Caution) Sandpaper should not be used for removing carbon, use a carbon scraper. 2. Piston outside diorneter. item Standard Value Serviceaole limit t-tead 43.50~43.55 mm Replace il under diameter tl.7la~l.7l5 int 414 mm “.7057 inl Ma.ar 419B~44.0mm Replace il under diameter ll.732~ L732 inl 43.9 mm ”.7283 i. i 3. Ring groove clearance when a new piston ring is titted. ltem Standard Value Serviceaale Limit . o.ols~o.045 mm Replace it aver 7"" ""9 (0.0006~0.DDIE inl 0.) mm l0.004 inl . 0.DI5~D.045 mm Replace it ever 2"“ ""9 (0.0006~0.DDIE inl 0.) mm roman.) O“ (in 0.0] ~o.oc5 mm Replace it over 9 tu.ooot~o.oole in) 0.) mm lacuna) 4, Piston pin hole. (Fig, 3454) ltem Standard Value Serviceaale limil \ _ H _ Em lS.DOO~ll006mm Replace it aver “ . to.5lla~o.5l20 in) 13.05 mm (0.5m int r¢ Dlul gauge (g) Paton —— Fig. 3-154 Mausuvmg plslon pin hole 3.6 CRANKSHAFT 5. There are three types ol oversize piston at intervals of 0.25mi“ £0.01 in.) D. Reossernbly 4‘ B. Reler to section 3.7.3.0 on page 46. PISTON RINGS Reler to section 3.7.4. on page 46. inspection I. When the piston ring has been removed, the gap should be measured. It should be inserted ape proximately l5rnm l0.6i .l lrom skin or the cylinder at right angle to the center line. Measurement of the gap should be made with a thickness gauge. (Fig. 3455) itent l Standard Value Sevv'lceuble Li it To fin 0.15~o 35 mm Replace it over F 9 059~ELO|38in| 0.5 rnnt l0.032ini 0.I5~D,35 rnnt Replace it over “CW“ ""9 l0.0059~0.0|35 int 70.3 rnnt lo.032 in) o o.ls~o,4o rnrn eplace it over ’ 0059~00155 int 0.3 mm tom: in) _ 2. Tension or the piston ring is measured with a tension measuring instrument. itern Standard Value Sevvtceuble llmtl . To . D.34~D,63 kg Replace it under P ""9 (D,750~l.3&9lbl 0.24 kg (0.529lbl . o.2e~o.s7i Re lace it under hm" ""9 l0.6l7~l,25%lbl D.2pkg IDJU lbl O" my . o~o.30ip Replace it under ll.l03~l.764 lb) 0 4 kg tusz Ibl Replacing the piston rings I. When a piston ring is reassembled, it should be fitted to the cylinder. Inspection should be made to determine if the gaps of the top and second rings are proper. If the gaps are somewhat less, they should be corrected with a File. (Caution) lat The gap should be liled perpendicular to the ring (bl ll the piston ring gap is too small. seizure between the ring and cylinder occurs due to thermal expansion; if the gap is too large, oil penetration or gas leakage occurs. 2. When piston ring is assembled on the piston, any interlerence between the ring and the groove may prevent smooth operation. It is necessary to inspect lor clearance. when new ring is fitted to the groove, by rotating the ring around the cir. cumlerence. (Fig. 3456) 6) Thickness gauge ® Piston ring rip. 3—ias. Measuring the piston ring gap 82 @ Riston ring @ Piston 3-!86. inspection ot the piston wig by (Dialing around the piston 83 3.7 TRANSMISSION 3.7 TRANSMISSION A. Descripfion The transmission receives the rotary power from the crankshaft and through a series of gears, changes it to the desired speed and then transmits it to the drive sprocket to drive the rear wheel. All the gears are fully constant meshed, assuring smooth gear change. 3. Operation Low: (Fig. 3—157) ‘ The power from the crankshaft is transmitted “9- 3"" “W 9“” through the clutch to the spline fixed driven gear on the transmission main shift (D. The power from the transmission main shaft (1) _is transmitted from the main shaft drive gear to the counter shaft low gear ®. However. the counter shaft second gear (:3 which is splined to the counter shaft and is moved against the low gear Q) by the shift fork and is locked by means of a dog, forming an single unit with the counter shaft to transmit the driving force to the drive sprocket © mounted on the left end of the counter shaft. Second: (Fig. 3—488) The main shalt third gear ® which is spline slide lttted to the main shalt (j) is moved by the shilt fork to lock with the second gear (:3 by means of a dog, thus permitting the transmission ol power from the main shaft to the counter shalt (D by meshing the main shalt second gear with the splined counter shaft second gear (5) hence to drive the sprocket Third; (Fig. 37189) The power from the transmission main shaft (3) is transmitted to the counter shaft third gear (:3 by meshing with the main shaft third gear ®. The counter shalt second gear (9 which is spline slide litted is moved by the shift fork to lock with the free rotattng third gear Q) by means of a dog. this causes the counter shalt (5) to rotate and in turn drives the sprocket (5). Top: (Fig. 3490) The main shaft third gear ® is moved by the shift fork to lock with fits; free rotating top gear Q) by means ol a dog, thus permitting the transmission of power from the main shalt (j) to the counter shaft by meshing the main shaft top gear (:3 with the fixed counter shaft @ ltop gearl to drive the sprocket (5). rig, 3488 Second gear rig. 3-!89. rnira gear Fig. 3490, rap gear 3.8 GEAR SHIFT 34 Neutral: (Fig. 349]) The gears are not locked. The main shaft low gear G) is meshed with the counter shaft low gear (2 and the main shaft third gear © is meshed with counter shaft third gear (9, however. the counter shaft gears rotate freely and therefore, no power is delivered to the sprocket (5). c, inspection i Main shalt to main shalt gear clearance. ltern Slunduvd Value Servlcanbla lirnit Second gm D.0ll~0.053 nun_ Replace if over to.ouo4~o.oozl tnt DJ nun (0.006 In] A Fig_ H” Newa‘ o.ole~o.oos rnrn Replace if over T°P 9"" i0.0006~0.0ola int DJ mm (0.004 inl 2. Counter shaft to counter shaft gear clearance. ltern Standard Value Serviceuble Limit Low 9", D.0|6~0.045 rnrn Replace if over (0s0006~0s0015in1 0.1 min l0,004 int 0.0ll~0,05:l rnrn Replace if over Third gear .o.uoo4~o.ouzi in] 0.1 mm iu.0o4inl 3. Bearing clearance. (Fig. 3492) Item Standard Value Serviceuble Lirnit Axial Within 0.05 min Replace if over clearance "3.001 int 0.1mm “3.004 int Radial 0.0l~0.015 rnrn Replace if over clearance l0.0004~0.00l inl 0.05 mm (0.002inl _ m nearing ® Dial gangs 4. Shift drum groove (Fig. 3493) rip. 3-lR2. Measuring clearance of the aearing Standard value: 6.0~6.15 mm 10.136~0.742 inJ 6~615mm 6~6.15lml (0.236~0.242in) (DJSBNDJdZin) 11t956~113umm (0.4707~0.1718In) 3395~33.S7SWI| (13356~l.3376ln) 3.8 GEAR SHIFT 3—173. Sectional view of gear shift drum A. Description As the gear change pedal is depressed, the gear shift spindle is rotated and the gear shiit pawl on the end of the gear shift artn engages with the gear shift pin on the right side of the gear shift drum and causes it to turn. A groove is machined on the surface of the drum, forming a cam, and as the drum is rotated. the shift fark riding in the groove is actuated by the contour of the groove to perform the gear shifting action. Further, there is a gear shift return spring which brings the pedal back to the original position and prepares for the next gear aperating sequenceu (Fig. 34%) 85 ® Gear shilt spindle @ Gear snitt drum © Gear snitt fork 9) Gear shilt returm spring Fig. 3-i94. Sectional v w ot gear shilt macho sm @ snrtt drum stopper plate ® Shitt drum stepper Fi 3-ts's Removing the shirt drum Stopper. ® l2mm Sal ring ® Gear shilt spindle rig 349.5. Removing [he gear shilt spindle 3. ENGINE B. Disassembly 1. Separate the crankcase to the upper and tower hall by following the procedure outlined for the disassembly of the transmission. 2. Remove the shilt fork guide pirl clip installed on the shift lork and separate the guide pins. 3. Vemove the neutral switch rotor arid stator installed on the right side ol the shift drum. 4. Remove the shift drum stopper arm pivot which holds the shift drum stopper plate and then remove the stopper. (Fig, 37195) 5. the gear shilt. gear shilt return spring, and gear shilt spindle side stopper are all assembled by a circlip. therelore. by removing the circlip with the snap ring plier, the spindle can be disassembled. (Fig. 34%) 6. Remove the gear shift return spring with a spanner or with a deep walled socket wrench. 7. Loosen the gear shilt forlr guide screw in the upper crankcase and remove; at the same time, remove the shift drum guide collar. 8. Pull out the sHtt drum from the side of the crank- case. (Fig. 3497) c. Inspection l. inspect the gear shilt fork tor bend. 2. Check the gearshift guide pirl tor excessive wear. 3. Check the shift drum stopper for looseness due to excessive wear. 4. Check the gear shift spindle return spring lor loss at tension. 5. Check the return spring pin tor security. D. Reassembly 1. Insert the gear shift drum lrom the right side ol the upper crankcase and assemble the gear shilt fork within the crankcase being careful that the gear shilt lork is centrally positioned. 2s Assemble the shift lork with the gear shift fork guide pin. Make sure that the gear shift fork guide pin is inserted in the correct position. 3. Assemble the gear shilt drum stopper. 4. Assemble the neutral switch rotor and stator: check to make sure that the switch is making contact in the neutral position. 5. Insert the gear shiit spindle lrom the right side and then assemble the gear shift spindle side stopper torm the telt side and lock in position with the circlip. 6. Assemble the cranksha't and the transmission gear assembly into the upper case. Assemble arid bolt the lower crankcase. 7. finally, assemble the crankshalt in accordance with the assembly procedure. 3.9 KICK STARTER 86 3.9 KICK STARTER A. Description The kick starter is designed to prevent the ratchet noise following the start of the engine; it is ol the same design as the C50 and C65. As the kick starter pedal is depressed, the kick starter spindle will revolve, causing the rathet to more along the spiral groove in the drum due to action of the ratchet spring. and with the pinion to transmit _ , 0.9“ the action to the counter shalt low gear, main shaft % primary driven gear and then finally rotates the crankshalt which is directly driven by the primary drive gear. (Fig. 3499) When the engine starts. and as the pinion speed exceeds the spindle speed: the ratchet due to the rotation at the pinion will turn in the lelt hand direce tion in relerence to the spindle. Because of the lelt hand square thread action of the set spring, the ratchet will separate from the pinion. ® Gear shilt lark @ Guide pin Clip @ Gear shilt drum rig. 3497. liernoving the gear shitt drum. The kick starter spring returns the spindle to the original position. disengaging lrom the pinion and is poised for the succeeding kick starter operation. a. Disassembly I. By lollowing the disassembly procedure lor the transmissian, the upper and lower crankcases can be separated permitting the disassembly ot the kick starter spindle. (D Gem shilt lark ® Guide pin (llp rig. J—IVBs installing the gear shiit drum 2. Remove the kick starter spindle. ‘6 c, inspection Check ratchet and the gear teeth of the pinion ratchet for excessive wear. D. Reassembly rertarm the assembly in the reverse arder ol disassembly. 3 6) Kick starter spindle ® tl9. Insialling the lront [01k D. Reassembly L Assemble the from damper valve and Iron! Iork piston on the front fork pipe, and lock with the front pipe rings. (Fig. 447) 7. Fill the Iron! Iork with SAE IOWSO hydraulic fluid. [1 35 cc~145 cc : 8.26~B.B7 cu inl 3. Insert the front fork pipe assembly into the fork bottom case artd push the front fork oil seal into place, being carelul not to damage cod then set the internal circlip. (Fig. 445) 4. After completing the assembly, install the Iront lork into the steering stem. (Fig. 4719) 5. Assemble the front iork to the top bridge. Assemble the steering handle to the top bridge in accordance with section MD. Install the headlight case, connect the electrical leads within the case and then assemble the light unit. lnstall the front lender on the Iront Iork. Assemble the front wheel to the front fork. Connect the speedometer cable to the gear box and connect the front brake cable and complete the adiustment. Connect and adiust the throttle cable. 4.3 STEERING STEM AND STEERING HANDLE LOCK A. Construction by The steering stem is mounted by the bolts to the front fork through the top bridge plate and supported upper and lower sets of ball bearings in the steering head on which it pivots. (D Steering head stern lull ® Steering steni washer © Steering head tap thread @ Steering top cone race (5) Steering bottom cone race (3) Steering head dust seal (‘2) Steering head dttxl seal washer © Steering stem (9 5x32 hex. bolt @ Handle lock spring ® Handle lock ® t-tanale lock case cove! @ 3mm llal washer ® 3X8 cross screw Fig. 4—204. Steering stem and steering handle lock lCB/CLIZS] 4.3 STEERING STEM AND STEERING HANDLE LOCK 96 @ Damper Ipcl rprinp remng poll {3 Steering damper locking xpring a) Slearing head xlem nul G) Sleerlne slam washev © Sleevlng head lop lnread © Sleevlng lap cone race ® Sleeving bollom cpne race @ Svaenng head dun seal ® Sleevlng head dun seal washav @ Sreerlnp elem @ 5x32 hex. ball @ Handle lpcl spvlng @ Handle lpcl @ Handle lock cuxe covev 69 3mm nal washer @ 3x5 cvou screw @ Sleermg damper lmaa ® Sveering damper plale A @ Sleevlng damper rhcrian dixk @ rrcrlan dlsk anchar hall @ Sleerinp damper plale 3 @ Sleenng damper spying @ Sleering damper rm @ 6mm snap pln Fig. 4—20—1 Sleerlng slam and sleering handle lack lCB/Clwsl Be Disassemble l. Separale me steering handle pipe in accordance wivh section 4.13. 2. Remove Vhe from cushion in accordance wivh seclion 4.25. 3, Remave lhe sleering slem lap lhrepd and draw lhe sleering slem ® cm of lhe head pipe (D. being careful nol lo drop lhe sleel balls (2). (Fig Aezll ® Head plpe ® sveel bull @ Sleering elem aanpm cane race © Sveerlng Slam 4-2l. llemavlnp rhe rreering rrem (D Steering stern ® Small dlul gauge @ Magnetic v block 4—22. Measurement at the steering stem bend (D ca type luet tank rg. 4—23-I. fuel tank a) CL type tuel lunk rig. 44342. fuel tank @ t-targht gauge FRAME C. Inspection I. Insaect steel balls tor cracks. wear and other damages. 2. Inspect the cane and ball races or both the top and bottom Ior any wear or damages. 3. Inspect the steering head dust seal for wear and damage. 4. Inspect the steering stem tar twist and bend. (Fig. 4722) llem Standard Valuei Within 005 mm to.002 In) Serviceable Limit Band 5. Inspect the thread end or the steering stem for damaged threads. 6. Inspect the spring on the steering handle lack tor breakage. Reassembly I. Mounl the steering handle lock on the steering stem. 2. Mix the as steel balls I36 total in grease and lay into the lower and upper ball races and carelully insert the stern to prevent dropping the balls. Tighten the steering head tap thread. (Note) Special care is required to tightening the top thread. It must be tightened in contunc'ion with the steering stem nut and the Irant lork bolt. When the stern nut is properly tightened. the Irant wheel should move to either lock under its own weight when a slight Iorce is applied. further there should not be any loaseness in the vertical or the horizontal directions. 3. Assemble the tram cushion and hon! wheel. 4. Inslull the steering handle. 4.4 FUEL TANK A. Construction The lueI tank is placed on the frame body directly above the engine and is installed on the lrarne body through the fuel tank cushion. The knee grip rubber. as well as the tank mark. lrtted with the tank side cover, is installed on the Iuel tank. (Fig. 4723) 4.4 FUEL TANK 98 a, Disassembly l. Loosen the two seot mounting bolts. 2. Position the fuel cock lever to 570? and remove tne fuel lube (z) from the fuel cock. (Fig. 4724) @ ruel cock ® ruel Iced lube Fig. 4724. Removmg tne luel lead lube 3. To remove the fuel tank ©, pull it Upward toward the rear and exercise care so as not to domage the fuel cock. frag. 4725) @ ruel tank 4. After the emblem is removed. the 6X5 bolt is rig. 4-25. Removing the fuel tank loosened, the side cover pushed lorwurd and lhe side cover can be removed. 5. To remove the fuel cock 6), unscrew the fuel cock cup. remove the O ring and fuel slruirler screen and unscrew the mounling screws (rig. 4726, 27) (2 Inspection I. Inspect the fuel tank for leaks. (Caution) Normally a woter test is performed at a specilted (D ruel cock 6;”. rent pressure, However, exercise precaution since he 4-21» Remuvmg the final cock excessive pressure will cause rupture at the tank seom. 2. Check for clogging of tire filler cop vent hole. 3. Check the front and rear fuel tank cushion rubbers for wear and damage. 4. Check the fuel cock fixing packing, strainer cup packing and fuel liller cap packing for wear onu damage. 5. Check lhe fuel tube {or wear and breakage. (D 6X25 cross screw ® fuel cock body (:9 fuel tank fig. 447. Removing the fuel cock aodv 99 4. FRAME n. Reussembly I. Install the fuel cock. 2. Install the side cover. (Fig. 4728) (Caution) The side cover ® is hooked to the clip ot the rear 0! the fuel tank G) arid the forwald end is attached to the tank by 6X5 hex. bolt. Make sure that the bolt is ot the proper length to prevent puncturing the tank. (Fig. 4729) L G) Clip @ ruel ionk xlde covet n 4723. installing tonk ride covet 3. Fit the lront and rear rubber cushions to the (mine body. The (rant rubber cushion should be inselted by pushing the fuel tank iron the rear. Install the fuel tank rear end by placing it under the rear trarne. (Fig. 4730) 4. Fit the tuel line to the carburetor ond secure it by the clips. ® fuel tank side covet ® 6X5mm hex, bolt (:9 fuel tank Fig. 4-29. Sectional View oi side covet retaining ooh (D Fuel tonlr 4-30. lnxlulllng the luel tank 4.5 FRAME BODY A. Construction The frame body is the main structural member around which the motolcycle is assembled. It mounts the engine and is supported on the front and rear wheels. The frame is made strong to support the weight ol the engine. rider and carrier lood ond in addition, it must be substantial to leceive the dynamic reaction imposed by the road and riding conditions undel the load. The lranie must be rigid to provide good steering characteristic and at the same time lightness is de. siruble lor lose in handling and tor good riding fiv- ‘4‘— Frume bodv parlor-hence. (Fig. 473]) 4.5 FRAME BODY 700 a. Disassembly I. Remove the engine from the Irame in accordance with section 3.13. 2. Remove lhe steering handle in accordance with section 4.13. 3. Remove the hon! cushion in accoidance with section 4.13. 4. Disassemble the steering stem in accoidance with section 4.33 5. Remove the seat and fuel tank in accordance with section 4.43. 6. Disassemble the rear wheel in accordance‘with ® Plum home, ® Wood @ Head We seclion “35- Fig, 4-32. Removing ball race 7. Remove the rear custtion in accordance with section 4.113. a. Disassemble the rear fork and rear lender in accordance with section 4.103. 9. Remove the air cleaner and tool box in accoir dance with section 4.63 and 4.93. lo. Detactt all electrical components Irom the Irarne. ll. Remove Itte stand in accordance wittt section 4.73. c. Inspection 1. Inspect the weld i nt for any breaks and cracks. 2. Inspect the steering head pipe for twist. befids “d '“iwligmem' ® t-lcrnrnar ® lnxavllon taoI @ Steering head pipe (Note) tip. 473:. Driving hull race The ball races should be fitted to the steering head pipe with light driving (interterence lit- 0.01mm~o.05mm/o.ooo4~'o.oozinl and must be bottomed so that it is not cocked. (Fig. 4732, 33) 4. Inspect the lrame paint coating for any chips and rust spots. D. Disassembly rerrortn the assembly in the reverse order oI disassembly. 4.6 AIR CLEANER CASE AND SEA'I' “'— A, Construction The air cleaner case is a stamped metal plate and protects the air cleaner. The motorcycle is equipped with a tandem seat tor double riding; the Iront section hooked to the frame and lhe rear section bolled lo the Vrame. The seat consists of sponge padding and vinyl leather covering. A hundrhold strap is installed across the seat for the rear rider. (Fig. 4734) fig. 4734. Seat 101 rig. 4-354. Renoying rne sec! x _ 6) Ar cleaner ® bxlz hex. ball (:9 5le cross screw fig. 473572. Removing rne air cleaner (D Main sland ® snapper rubber in lypel Fig. 4736. a. Disassembly 1. Remove lhe air cleaner case by pulling il lrorn lhe lrarne body. 2. Ta remove lhe seal (D Irarn lhe Irarne bady lcal75l. laosen lhe lwa 5X16 ® seal maunlina bolls (CL175: 5X16 and 8X10 balls! and pull lhe seal lo lhe rear. (Fig. 473571) a. Remale lhe air cleaner a) by unscrew lhe lwo 5> Type (V) rate “"9" 9"“;‘61 required fully charged at lAHl IA! “'68,.“ lor lilling 20%: I65“Fl llitersl _ MBwaelzc [Used on CB/CLI75l l2 9 0.9 1.260 0.7 1.250 ,W \,, _ 33676 (Used on cs/cmsi 6 6 0.6 L260 0.26 1.280 The charging time for a new battery is determirled by the length ol time in storage since the date ol manulacture. lDate of manulacture is printed on the back ol the specilication booklet. enclosed with motor. cycle batteriesl. The table shows the approximates charging times. D r , ' Less than 6 to l2 Over l2 ”'° ‘°” ° ”“99 6 months. months. months. Durotion ol charge lo to 20hrs. 20 to so hrs. ' Over so hrs. Mar.) 1. During the charging operation, ii the battery temperature exceeds 45"C lll3"FI. discontinue charging or decrease charging current to l/2 ol the specified value until the temperature lalls to a sale level. In this case, charging time must be increased. 2. Be sure to charge the battery at the speci ed current. 3. ll the electrolyte level lalls during charging, rel‘lll with distilled water to the upper level line Ito the level indicator in hard rubberrcaie batteries). Near the end or the charging period, adiust the specific gravity to between l.27o and 1.290 lbetweeri 1.250 and 1.270 in tropical areasi. and continue charging for two to three additional hours. 4. Explosive hydrogen gas is discharged from the cells. therelore, do not charge batteries near any open lire. Always turn charger ofi belore connecting or disconnecting batteries. 5. After charging. add distilled or battery water to the cells to bring the electrolyte to the upper level line Ito the level indicator in hard rubber case butterlesl. Tighten cell caps lirmly and wash all with clean water any acid spilled. 6. The battery is now ready to install. When installing a motorcycle battery, be sure not pinch the battery vent tube. Explosion may result if the exhaust tube is blocked. 3. Preventative Maintenance The battery is being recharged all the while the engine is running. Further. while running, the load such as the use or the winker, horn are placed on the battery ldischargadl. as the result, the battery is being dise charged at the same time it is being recharged. In the long run, the discharge and the recharge is in balance. The system has been designed in this manner. Under certain condition when the balance is upset, then trouble develops. To obtain maximum lile from the battery, it is necessary to locate this trouble and take the appropriate action early. The trouble to the battery are muirlly external such as cracked case. broken terminal, disconnected lead wire. The battery condition, trouble. corrective action are shown in the following table. 729 5. ELECTRIC SYSTEM E. TROUBLE SHOOTING AND CORRECTIVE ACIION Trouble Frobable cause Correct action A. Sulfufion The electrode plates are covered with white layer or in spots Charging rule is too small or else excessively large. The specific gravity or the mixture of the electrolyte is improper. Battery lelt in a discharged con- dition tor a long period. llelt with the switch turned onl. Exposed to excessive vibration due to improper insulation. Motorcycle stored during cold season with battery connected. When motorcycle is in storage, the battery should be recharged once a month even though the motorcycle is not used. Check the electrolyte periodically and always maintain the proper level. In a lightly discharged cond ion performing recharging and dise charging several times by starting the engine may be sufficient. a. Self discharge Ea‘tery discharges in addie tion to that caused by the connected load. Dirty contact areas and case. Contaminated electrolyte or elece trolyte excessively concentrated. Always maintain the exterior clean. . Handle the replenishing electrolyte with care. c, Large discharge rate Specific gravity, gradually lowers and around Line. the winlrer and horn no longer function. The fuse and the wiring is satise lactory, loads such as winker and horn does not function. In this condition the motorcycle will operate but with prolong use, both ® and 6 plates will react with the sulfuric acid and form lead sullide deposits, isullationl making it impossible to recharge. When the specific gravity lalls below moo (20"C:65“Fl, the battery should be recharged ime mediately. . When the battery lrequerltly be. comes discharged while operating at normal speed, check the gener. ator for proper output. ll the battery discharges under normal charge output, it is an indication of overloading, remove some of the excess load. D. tligh charging rate The electrolyte level drops rapidly but the charge is always maintained at 100% and the condition appears satislactory. A condition which is overlooked. ISpecinc gravity over l.260t The deposit will heavily accumulate at the bottom and will cause internal shorting and damage the battery. Check to assure proper charging rate. When overcharge condition exist with the proper charging rate, place an appropriate resistor in the charging circuit. E. Specific gravity drops Electrolyte evaporates shorted lnsuflicient charging Distilled water overfilled Coniaminated electrolyte Perform specific gravity measure ment. If the addition oi dislilled water causes a drop in specific gravity, add sulluric acid md adiust to proper value. 5.5 VARIOUS LOADS I30 5. VARIOUS LOADS A. Headlight The headlight is to provide sale riding at night and. theielore. il should always be mainlained at proper adiustment. 0n the CB/CLI75. a sealed beam type lamp unit is used. whereas. a semi sealed type is used on the Ca/Cles. On these types. deterioration rate ol brightness is relatively low. (Fig. 57197172) a. Malfunctions l. Broken bulb hlament ‘ (D t-lead light rim (2 Head light unit Primary causes are: Fig. 5497]. Component Davis 0! head light lCB/Cl I75l Excessive voltage applied Excessive vibration due to bad roads or high speed riding. Delective material. 2. Delective contact. Contact points making poor contact a. Taillight, Stop light A combination light bulb is used lor the taillight and the stoplight. The bulb rating is 6Vi18/5w. lCB/CLVS: avezs/BWl the stop lamp is IBW lCB/CLVS: 25W) and the tail lamp 5w lCB/CLI75: 8WI. The glass enclosure is a pear shaped bulb lCB/CL l25l (Fig. 5720; a) t-tead light rim (2 t-tead light bulb @ t-tead light Soclucl a) Socket supporter @ Ecol F: 541942. Component puns cl head light lCB/CL l2sl bx lnspcction l. Broken lllament The main cause ol broken lllament can be attribs led to excessive vibration resulting from riding over bad roads or excessive voltage. howeve. tn a rare case it can also be caused by d.lective material used in the manulacture ol the bulb. Remedy: Replace the bulb. 2. Defective CONGCI Bulb contacts making poor contact r itn the socket. 3. Broken Cord Cause: Break at the terminal due to vibration , from Iiding ovei rough loud (D Tall Ilglll hose (3 Tall Ilghl bulb @ Tall light lens Remedy: Peel back the insulation ol the cord and G) ”<45 crux: screw Fi 5720. Component Pails ol tail light resolder the wire to the paper terminal on the socket or connector. c. Neutral lamp and speedometer lamp This lamp is to indicate the gear change to be in the neutral position and is located within the Spe~ edometer. Lamp rating is aviaow. Peter to section l.2 lar remedy in case ol delectiye operation (Fig. sezll (D Neutral lamp bulb (z Sockel Fig. Ht. Components parts oi neutral lamp 131 5. ELECTRICAL SYSTEM (5. SYARTING MOTOR A. Description CB 175 is equipped with a starting motor mounted on the lorward section of the crankcase. a kick starter can be used as an auxiliary starting method. When the starter switch is depressed, the powerful series wound electric motor incorporating a planetary reduction gear drives the crankshaft by means of a chain and sprockets. As the engine starts, the speed or the crankshalt exceeds the starting motor, however, the starting motor is presented from being motorized by the In addifion overrurlning clutch mounted on the driverl sprocket. The starter magnetic switch is installed in the starting circuit to permit a large current to flow to the starter when the starter switch is depressed. Sfarfer specification Rated voltage 12v Rated output 0.35 KW Rated loading time so sec. Reduction ratio 5.45 Direction ol rotation left hand. viewing the sprocket Battery 12V 7 9AH Weight 2.5 kg rnax. Starter Performance at sprocket shalt without load with load i at been locked Voltage li.sv 9.4V J 6.7V Current 28A max. 100A 240A Torque — l7 l.5kg. m min. RPM 2000 rpm min. 500 rpm min. . Power output — 0.33 KW rnin. —— Brush spring tension Carbon brush 550 1 55 gr. 5.85~5.95mm>< 12.2~11.4mm>< l I ~12.5mm Clearance, in rotary direction 0.1~0.45mm in axial direction Brush holder 6.15~6.3X12.6~11.8mm 0.2~0.6mm 5.6 STARTING MOTOR 132 ENDED ‘D a) o ring (2) Sprocket shalt © Gear cover G) lirng gear ® Planetary gear (5) Rubber gasket :2) 0illess metal D «1) End bracket A (E Drive sprockel @ Oillcss metal c (D on seal @ liarar shalt ® oziless metal A ® Oilless metal a rig. 5-22. Construction at starting motor B. Disassembly a. Removal of starting motor 1. Disconnect the electrical power cable Irom the starting motor terminal. Remove the two 5x12 cross screws and starting motor side Covelp Remove leIt crankcase cover. Remove the starting motor sprocket by removing the starting chain. Remove the three starting motor mounting bolts and separate the motor from the engine. 9‘???" c. inspection Check the commutator lor wear and if necessary, repair. Check wear at the brush. it worn excessively, replace. Check tension of brush spring, if there is loss of tension, replace. Check the reduction gears Ior wear and damages, replace it necessary. Check the driven sprocket. overrurlrling clutch spring and roller lor wear and damage. Replace any delecv 5"???"7‘ tive parts. 6. Check all ball bearings and bushings for wear and damage, replace it necessary. ’. Check the operation ol the starter magnetic switch by applying battery power to the primary terminal while grounding the solenoid body. A click will be heard for a solenoid which is in good condition. It the starting motor does not operate properly, the solenoid contact points may be in poor condition. Disassemble the solenoid and clean the points with a line lile. o, Reassembly Reassetnble the starting motor and averrunning clutch in the reverse order or removal. (Note) Apply a thin coating or silicone grease to the overrunning clutch rollers during assembly 133 7. SERVICE TESIER INSYRUCIION 5. ELECTRIC SYSTEM Item Power Direction for Use Connect the test leads to the "X" terminals and attach the ends ol the test leads to the part to be tested. If there is continuity, the red ”Continuity" lamp will be lit. No lighting indicates that there a m is no continuity. 2 7', Examples: ; K: 1. Light bulbs, shorted or open electt:cal circuit. 3 — 2. Many other electrical continuity tests can be L5) 3 Pe"°"“°d' 6) Continuity lamp (2) rower l6V or l2VI ® Continuity ® 8: turn the switch oil @ Test lead Short out the ends ol the test leads connected to the "x" terminals and adiust the indicator needle l ol the resistance meter to "O" by the adiusting knob. Attach the ends ol the test leads to the (1‘ points across which the resistance is to be measured g %' and read the meter indication. ; > Examples; 2 f: 1. Secondary ignition coil. 5,Dooelo.000ohm Q a l__—_>@ g 5 2. Selenium rectifier normal direction, 5e40ohm @ 5‘; o 3. Selenium rectifier reverse direction. 6000hm ® Blackfcc'e mm (9 Aarusting knob 4. In addition. measurement ol resistance across @ Power ‘6‘“ 0' ”V: the points and many other uses. @ RSSiS'We @ Turn the switch ofi (5) Test lead '3 Short (Adius' the needle to "0“) Short out the ends ol the test leads connected to ® the ‘ " terminals and adiust the indicator needle ol the insulation meter to "o" by the adiusting knob. Attach the ends of the test leads across the points to be measured. the insulation value is indicaled on the meter. ® @ Examples: 7 “ ls Condenser insulation value: + ‘3 Ti; Under lM ohm . . ..delective : ) Over 5M ohm . . . . satisfactory .9 E 2. Various insulation tests may be perlormed. a _ (D Black scale El 0 ® Adiusting knob ‘ " (:9 Power lav or lel («9 Insulation @ Turn the switch all, discharge alter the measurement (5) Condenser. Short out the terminals to discharge Over 5M ohm ...... satisfactory Under lM ohm ...... detective Condenser 5.7 SERVICE TESTER INSTRUCTION I34 Item Power Direction tor Use With the initial resistance adiust the indicator needle : @ ol the meter to "o" by the adiusting knob and (9% , position the switch to "Conderaer". Attach the E ends ol the test leads to the test condenser ®“0 3 ,, terminals and read the capacity on the meter. 93"? § § Range ol measuring value: o.3~o.3,ur 8 N c '— 6: e E 6 @ © :9 “’ ® Red scale 8 (2) Adiusting knob (33 Power l6V or l2Vl @ Condenser (3 Turn the switch Attach the red test lead lrom the "x" terminal to the 6-) side and the black lest lead lrom the "x" E terminal to the 6 side ol the test part and read 3 the measurement on the meter. 3 .5 Examples: 5 g L Battery terminal voltage E 3 2. Measuring the output ol the DC. dynamo E, 5 fl = a e) e 9 Z @ uj ® Blue scale 0 (2) Battery ® D.C. voltage @ Turn the switch oil Connect the D.C. current measuring leads to the D.C. Current terminals. When the current flows from the red terminal to the black terminal, the indicator needle on the meter swings to the normal direction. It the indicator needle swings in the reverse direction, the connection at the D. C. connection must be reversed. (D (Caution) '0 II the Connections are reversed, [use U5Al will be 6') .2 blown. When the indicator needle ol the meter E § does not swing. inspect lor luse. 5 Z Example: ‘1 2 L The charge or discharge condition ol the ® Yellow scale g. battery. © D D. Current 2. Measuring the current consumpiion ol the llasher, horn, light, etc. (3) Cha'ge @ Discharge ® Yum thr switch 0H Swltc' ® Selenium rectifier Battery Mounted on chassis 19 mi tuse I35 5. ELECTRIC SYSTEM ltem Power Direction lor Use Attach the (9 test lead lrom the ' terminal to z the (B side ol the dynamo lA.C.t either day or 2 night operation and the 6 test lead to the e g 1: side or to the chassis and measure the voltage ‘5; 9 with the engine running. 5 r} (Caution) g, k Do not run the engine at high speed. Measure at Ti: g a speed below 2.000rpni. f (D Blue scale (2) AL. voltage Q (:9 Turn the switch ofl < @ Day © Night Chassis ® Dynamo lA.C.) Plug in the timing light attachment into the timing recep‘ucle. Next, attach the timing light high tension cord to the hex bar installed on the head ol the spark plug. Position the switch to "Timing". start the engine and the timing light will start llashing. Point the , _2 light to the flywheel adiacent to the case -iming 37' 2 index mark. The ignition timing and spark ad. 2: g yancing can be inspected. E \. £1 0 ® Earth (2) Power 6V orlZV ‘° @ Timing C4) The switch may be turned either ON or OFF (55) Hex bar (l3) Engine @ Plug cap Timing light S2 Ignition timing alignment mark .19 Rotor Plug the crow foot plug into the crow loot C.) G) receptacle to connect the primary coil, and connect (D the red test lead to the (B side of the primary [C] E coil and the white test lead to the 9 side. Then. £75 connect the high tension cord from the upper RH corner ol the pocket in thetester body to the high Q tension secondary coil. a Position the switch to "Coil Test“ and the spark a s will iump across the three needle test gap. ® @ 3 Measure the spark gap by turning the adiustment a T; knob. ® Black :0 S (Caution) (2) Ground ‘ D 3 5 Ground the black cord in the upper LH pocket ol @ PM” “0' 6V ““51 “9 ,0 the tester body to avoid possible electric shocks "59 6" PWE’ 0"" _ “(my me um use 12v power lor 12v corisl For 6V coils, use 6 volts power and 12 volts power @ P'ima'Y C0" @ C°" '95’ for IZV 50k The switch may be turned either ON or OFF 6) High tension secondary [For simule taneous ignition) Coil ® Primary coil @ For common use ® Red ® White ® Normal ® Reverse 5.7 SERVICE TESTER INSTRUCTION 136 Item Power Direction [0! Use Use the transistor tachometer unit attachmentinthe H— ® —> . timing test started above lor measuring the [evolur Q g _ tion ol the engine, the revolution for the charge 3 E, 3 starting and the revolution lor the governor advance 5.5 .5 ing. etc. 0~6.000rpm. X G) (D s g g o o o o 1: n c 5 ‘~ 2 e a ‘2 5 Z S ,_ ® Tachometer (2) Turn the switch on The shunt unit attachment is used lor measuring the ® starter current. the current under no load and for testing the sellstarting motor performance 6 e ‘ 0~60A E (a) 717 '5 3’: a e; : a a g ~° (3, 'F: - 3 Z0 ® Shunt 5 ® Wiring diagram for starter current in measurement ® Starter cord («9 Turn the switch OH (3 Battery I. The service tester shall be opemled with Cale and the switches turned off when not in use. SERVICE [mm 2. When the power indicator lamp is not lit with the battery connected. °~v = the probable causes of the trouble are either blownluse or delective .2 vibrator. Inspect the parts. s 6 3. When using the timing light. ii the service tester is operating but the timing light is not lit, the bulb (xenon tube) is probably detective and should be replaced. ® Power indicator lamp MEMO 6 6.1 6.1 MAINTENANCE INSPECTION 133 PERIODIC ADJUSTMENT MAINTENAN CE INSPECTION reriodic inspections should be perlormed at regular schedule and designated mileages in order to obtain salisfac'oly service as well as lo extend Ihe usehll lite at the motorcycle. ENGINE ADJUSTMENT MEASURING COMPRESSION A low compression pressure will result in a cor. . . . u) Compression gauge responding dropinthe engine power output. Pressure . , , _ Figs 64. Measuring compression pressure leak lrom any cause may etiect the engine speed adiustment at low speed and create engine stall Condi'ion. a. Remove the spark plug. b. Insert the end or the compression gauge into the spark plug hole and hold lirmly to prevent pressure lrom leaking. (Fig. 6—I) c. Operate the kick starter repeatedly several times with both the choke and throttle in the lull open position. (Note) 1. Make sure that the throttle and choke are fully open, or else, a lower pressure indication will be registered on the compression gauge. 2, The cylinder compression pressure indication will gradually increase with each kick, therefore. continue kicking until the pressure stabilizes at the highest point. 3. To obtain a true cylinder pressure indication. the measurement should be made alter the engine attains operating temperature. Check lor the proper operation ol the valves. Make sure that the compression gauge is lirmly titled in the spark plug hole to prevent pressure leak. The normal cylinder compression pressure is lokg/cm2 (142.3lb/in3t. In case the compression pressure exceeds 12kg/cmZ ll71lb/inzl, it is an indication of heavy carbon deposit accumulation on the cylinder head or the piston. The deposits should be removed by disassembly- ing the cylinder head from the cylinder. l. When the compression pressure registers less than 8kg/crnz (Il4lb/ln"). it is an indication ol pressure leak. First check the tappet adiustment and see it the condition can be corrected. disassemble the engine and inspect the condition or the valves. the head gasket and piston rings. 99-9"? TAPPET ADJUSTMENT The tappet clearance will have a great deal ol ellect on the valve timing. it the clearance is too small, it may prevent the valve trom lully closing and result in pressure leak at the valve. 0n the other hand. an excessive tappet clearance will produce tappet noise and result in noisy engine operation. The tappet clearance will also have a varying degree ol ellect on the engine power output, engine operas tion at slow speed and engine noise. I. Valve clearance a. Remove the lelt crankcase cover and align the (D “my mm mm "T" timing mark on the A.C. generator rotor with w H. Aligning We . the timing index mark on the stator. (Figséi2) b. Unscrew the tappet adjusting cap on the cylinder head and check the clearance between the adiust. ing screw and the valve with a thickness gauge. (Fig. 673) 139 6. PERIODIC ADJUSTMENT . . a. (D lhickness gauge: 0.05 mm i0.002inl ® Lacking mu (9 Admsling screw rig. o-a. Adrbsling lapael :[wmnco rming Index mark r . (H. Aligning lhe - a) Breaker poinl udlusling screws (2 Conlaal breaker @ Conlaal base plale screws (9 Conlaal hase alale rig. .575. Adlus ng lhe ign an liming (D Service lesler ® gallery i3; riming iighl ® Card rig. deb. ll lhe valve is being aclualed by lhe rocker arm, rolale lhe AC. generalor rolor one complele lurn lo sel lhe pislon al tapsdeadscemei of lhe cums pression slroke. and lhen perlorm lhe check. 2. Adiuslmeni Loosen lhe adiusling screw locking nul and make lhe adiuslmenl wilh lhe adiusling screw lo oblain lhe slandard clearance ol 005 mm (0.002 in) for bolh lhe inlel and exhausl valves. Tum screw clockwise for closer clearance. (Fig. 673) (Nola) l. The adiuslmenl musl be made wilh a cold engine and lhe clearance measured wilh a lhickness gauge. 2. When locking lhe adiusling screw locking nul hold lhe screw lo prevenl ils lurning. 3. lnspeclian a. Check lo make sure lhal lhe iappel clearance is wilhin slandard lolerance. Too small a clearance will cause lhe valve lo slay open wilh a cansee auenl pressure leakage which will resuil in hard slarling or no slarling al all. b. Check ior improper valve liming. c. Check for slrelch in lhe cam chain. IGNIIION YIMING ADJUSIMENI Ari improper ignilion liming, regardless of lhe accuracy of lhe valve liming or lhe proper compress sion pressure. will nol realize a salisiaclory engine peifmmarlce, Ignilion liming oul or adiuslmem will seriously aliecl engine power oulpul as well as lhe luel consumplion. l. Alignmenl of lhe mark a. Remove lhe leil crankcase cover and align lhe "r" marking on lhe generalor rolor lo lhe liming index mark on lhe slalor. Check lo make sure lhal lhe spark is produced across lhe spark plug gap al lhis poinl. (Fig. 674) Perlorm lhis lesl by removing and placing lhe spark plug on lop of lhe cylinder head wilh lhe high lension case connecled. 1. Adiuslmenl Make lhe adiuslmenl ii required, by loosening lhe conlacl breaker adlusling screws. 0 When lhe ignilion liming is relarded, move conlacl breaker ioward lhe righl. Q When lhe ignilion li ing is advanced, move lhe conlacl breaker loward lhe leil. 3. Breaker poinl gap, 0.3 in 0.4 mm (0.012*0.016in,) max. Improper ignilion liming will resull in combuslion lo lake place al lhe incorrecl poinl oi compress sion, making il impossible lo oblain smoolh engine operalion lhe lhrollle grip will require grealer opening, conseoueunlly, lhe ruel consumplion is increased. 6. I MAINTENANCE INSPECTION 140 Results of retarded ignition timing: l. Drop in power output. 2. Drastic increase in tuel consumption. 3. Engine overheats with a possibility ol piston seizure. Results ot odvanced ignition timing. l. Produces knocking and drop in power output. In severe cases. damage to piston. connecting rod, crankshalt may result, therelote. periodic inspection should be petlormed. 2. Upon completion or the point gop and ignition timing adiustment, check lor proper operation ol the spark advancer by the use or a timing light. Checking the operation ol the spark advancer with a tachometer. Reler to section service tester on page 123. (M) .8 4. CONTACT POINTS Inspect the surlaces or the contact points; it they ® we burn? or pil'ed. dTess the surface with an oils'one or a point dressing lile so that the points are making parallel contact. (Fig. 677) Alter the points have been dressed. wash in gasoline or trichloroethylene to remove all trace ot u) Normal (2) Worn contact point © side contact paint a) Dirty contact point Fig. 5-7. Breaker point contacting condition oil. lnsutlicient breaker point gap. a. The spark tends to linger, that is the interruption ol the primary circuit is not completed at the points, therefore, the secondary high voltage build up is reduced. b. The closed duration or the points is longer, producing heat and resulting in damage. c. In coniunction with (5) above. the points will be late in opening with a consequent delay in the ignition timing-, this will cause a drop in power output. Excessive breaker point gap a. The duration that the points are closed is too short to allow tor sutlicient current tlow in the primary circuit with a consequent low voltage bulldeup in the secondary high voltage circuit. This condition will cause poor engine starting. ignition missing at high speed and resulting in loss or power. b. Engine overcheais readily. c. The ignition tinting is advanced. 5. SPARK PLUG ADJUSTMENT A dirty 0! damaged spark plug or plug electrode which are eroded will not product a good strong spark. theretore, the spark plug should be inspected periodically and cleaning and adiustment made. Spark plug with sooty wet electrodes, or electrodes covered with deposits will permit the high tension voltage to bypass the gap without sparking. l. Cleaning a. The use or the spark plug cleaner is the recomc mended method ol cleaning the plugs. however, a satislactory cleaning can be perfoimed by using a needle or 0 iii“ wire lo remove the deposils ® Spavk plug ® Spark plug cleans! and then wash in gasoline tollowed by drying Fig. 5-5, Cleaning the spark png with a mg or compressed air. (Fig. H) 141 6. PERIODIC ADJUSTMENT a) ibickness gauge c7) Spurll plug Fig. 679. Adiusling me spark plug gap A G) Fuel cack 5- 510? ii. RESERVE Fig. a-uo. Fig. 6—”. Secrianal View al Ihe luel rank cap b. Adiusl lhe spark gap alrer cleaning. Sel lhe gap lo 0.6—0.7mm (olozieomaiml by bending lire eleclmde on lhe ground side. (Fig. 647) Spark Plug lnspeclion a. Check "19 spark inlenslly produced belween lhe gap or r‘lre ground and me cemer eleclrodes by observlng lhe color. Good condilion Poor condilion Blue spark. Red spark . Cause due lo: l. Low supply vollage 2 Delecliye ignilion coil 3. Deleclive spark plug 4 Absence oi sparking may also be due ro compression (Nola) i. Do not rernoye lhe deposils by burning. 2. When inslalling lne spark plugs. clean lhe sealing area free oi oil or foreign malls! and insiall ringer ligiu belore lorquing wiin a plug wrench. 3. The spark plugs can be lesied uller adiuslmeni with lhe plug lesier. Willi me high lenslon vollage mainlained conslum. vary lhe iesi chamber pressure and inspect lhe condilion al lhe spark. FUEL SUPPLY SYSYEM Resiriclion in lhe luel supply syslem will preyenr suiiicieru luel llow lo lhe carburelor and cause engine lo spuner during acceleralion m lhe engine may stall all high speed. a. Check ior suiiicienr supply ol luel in lire iank. b. Dlsconnecl lhe luel reed lube irom iiie carbureror and check lire luel now wirii lne luel cock in We ON or lhe RES posilion. (Fig. 640) c ii iiie luel now isinsuilicieni. remove lneiuel lank lrom lire body and clean inlernally. When lhe llow is srill inadeauare, remove lire luel cock. disassemble and clean. [Novel 1. lhe insufficieru luel llow may be caused by me plugged venl hole in lhe liller cap as well as me reslriciion in lhe luel line. (Fig. sell) 2. The luel cock is swilched lo RES lreservel lrom lhe ON posilion when lhe luel lank becomes emply. The reserve luel supply conlains approxi. maiely. CB/CL'I75: Lee (3.3 U. s. pis, 3.2 Imp. pH.) CB/CLIZS: LsZ (3.2 u. 5. pm, 2.6 imp. pis.) a. . Fuel slrainei cleaning The accumulation of dirl and waler in lhe luel cock slrainer cup will cause a resiriciion in luel now. iesulling in drop in engine speed and mallunc» lion ol lhe carbuiemr. Clean lhe cock. sliainei and lhe lillei screen a! periodic inlerval. 7. :0 6.7 FUEL STRAINER CLEANING ihe loreign substances contained in the luel passes through the luel line from the luel tank and enters the strainer- cup. The loreign substances and water, it not arrest in the strainer cup will enter the cylinder and causes engine malfunction. I. Cleaning a. Set the fuel cock lever to the STOP position. b. Remove the strainer cup. c. Clean inside the strainer cup and liiter screen. (Fig. 642) OIL FILTER SCREEN CLEANING The engine oil is filtered through a syslem ol double lllters, the Centrllugul rotor oll filter arid the pump niter screen belore being supplied to the various parts of the engine. When the impurities have ace cumulated in the lilters to prevent its proper lunction, the oil supply to the various parts are starved and eventually result in seizure and damage to the engine. It is therefore, important that the filters be cleaned periodically. 1. Cleaning Remove the right crankcase oil filter cover to get access to the rotor oil filter and lor access to the pump filter screen, remove the right crankaase cover. Clean the units in gasoline. AIR CLEANAR SERVICING An air cleaner clogged with dust restricts the tree passage ol inlet air.and result in power loss or drop in acceleration. therelore, to assure proper pers lormance, periodic cleaning ol the air cleaner should be made. 1. Removal Remove the seat to get access to the air cleaner. Reler to section 49 B on page lie. 2. Cleaning Tap the air cleaner lightly to loosen the dust and then blow dry compressed air lrom the inside or use a brush. (Fig.&|3) (Caution) 'l. The air cleaner is made ol paper and it torn or damaged, will cause dust to enter the engine cylinder. resulting in increased cylinder wear.tllere~ lore. replace with a new element. 2. Oll or water on the Cleaner element will render it inel‘lective by restricting the now ol air and causing a drop in power. MAINTENANCE INSPECTION 742 @ Fuel strainer cup (D o ring @ Screen Fig. 6-”. Cleaning lhe luel strainer a) Air cleaner element @Air gun rig. 643. Cleaning lhe air clesner element I43 6. PERIODIC ADJUSTMENT 0. CARBURETOR CLEANING AND ADJUSTMENT A dirly corburelor or carbureror oul or adiuslnienl will cause poor engine perlornionce. As an example. a carburelor sel lo a lean luel air mixIUre will cause lhe engine lo oyerheol while o rich mixlure will cause engine lo run sluggish. Furlher. oyerllowing ol luel lroni lhe carburelor is a possible lire hazard, lherelore, periodic cleaning and odiuslnienl should be perlornied. l. Cleaning o. Disassemble lhe carburelor ond wash lhe parls in gasoline. b. Blow oul lhe nozzles wilh compressed air and aller cleaning ond reassembly, rnalre lhe adiuslnienl. 2. idle adiuslnrenl The idle odiuslrnenl is perlornied wilh bolh lhe lhrollle slop screw ond lhe air screw by lhe lollowing procedure. (Fig. sell) a. Bolh carburelors niusl be adiusled siniullaneously. b. Sel lhe vhronle slop screw lo lhe specified idling speed (ITOO~I300'pm). c. Nexl. adiusl lhe air screw by Nrnirlg slowly in bmh dIrecIions m obtain lhe highesl engine speed. Turning lhe screw in will produce a rich luel mixlure. Turning lhe screw oul will produce a lean luel mixlure. d. Reduce lhe engine speed which has gone up in lo lhe specified RPM by regulaling lhe lhrollle slop screw. e. Al lhis lhrollle slop screw selling, recheck lhe carburelor adiuslnienl by nionipulaling lhe air screw. .Mler lhe idling odiuslrnenl has been compleled, check lhe carburelor by snapping lhrollle and also check lhe lhrollle response. (D 1hroille slop screw ® All Screw e—u. Adwsling lhe carburelor (Note) 1. All odiuslnienl should be made oller lhe engine has allained operoling lemperarure. 2. Adlusl bolh carburelors allernaVer lhrough each or operolions. I. LUBRICATING The purpose ol Iubricalion is lo prevenl direcI surlace lo surlace conlacl or lhe nroying parls by providing a film or oil belween lhe surlaces ond lhereby, reducing lriclion ond preyenling wear. ll also serves lo cool lhe parls lrom lhe heal produced by lricllori. Furlher, lhe lubriconl penelrales belween lhe pislon and cylinder lo form an oil film thcIl ucl as a seal lo mainlain lhe cylinder pressure. 'I. PARTS NOT REQUIRING PERIODIC OIL CHANGE OR LUBRICATION There are some parls which only require lubrIca~ lion whenever lhe parls rre disassembled lor repair or replacemenl. Sleering slern sleel balls and cone race lhrallle grip Grease Mam stand (D Droirl plug rig. e—ls. Removing rhe drain plug 6.1 MAINTENANCE INSPECTION 744 2. ENGINE OIL CHANGE Clrange oil al inilial 300m (185m) and al every lOOOkm (620 mi) llrerealier. l. Oil Change a. lzemoye lire ail cap and drain lire engine com~ aleiely or oil by unscrewing lhe plug al lire bolioni al lire engine. (Fig. 645) (Nale) The oil should be drained wlrile lire engine is slill warni. ilris will save lime and assure.proper draining. b. ine proper oil level is indicaled by lire oil level markers on llre gauge wlren clrecked willraul screwing llre cap down. (Fig. 6716) (D on level gauge (2 Upper level mark (3 kawer level mark Fig. 646. Oil level gauge Oil capacily CB/cu75rl.54 l3.2 U.s.ai, 2'.7lnipall CB/Cles r L24 12.5 us. an, 2.1 Imp. all Oil Brand and Grade Tire grade or oil lor lire season is slrawn an lire upper crankcase Use lire ail corresponding la MS. DG in lire A. P. l. service classillcaiian. (Fig. 647) Under 0”C 132"?) SAE 10W 0“~15"C132°~60 H. SAE 20W Ovev 15"C (60"F! . SAE 30 (Nale) l. Oil plays a prominenl role in lire lile and lire Irouble lree perlorniance al an engine. llrerelore, ii is very imaorlanl lliamire oil clrange be pep lormed periodically and relrain lroni using dirly oil over a long period. The more lreauenl lire ail clrange. llie belrer il is lor llre engine. 2. When relilling or adding ail, il slrould nol be lilled above llre specified level. Overlilling will cause ail pumping willr conseauenl louling al llre spark plug. 3. Use only recommended oil ol proaer grade. rig. .s-i7. oil viscnslly C. DRIVE CHAIN ADJUSTMENT An excessively sla'ck driye clrain will cause clrain Io whip, whereas an overJerlsion condllion will produce resislance. resulling in lowering lhe powel (D D W chain ouipul ai lhe rear wlreel. Always mainlain ilre clrain pm ML mm,“ dm mm mm" al lire specilied lensian. i. iensian Checking Procedure a. cneck Io see it lhe ioial veriical slack al lire clrain ai lire mid poinl is beiween Hem (0.407030 in). (Fig. 645) . Perlarm adruslnienl by loosening lire axle nul and ilren adjusl willr lire adrusling balls. (Fig. 649) Turn Io lire riglu Io decrease clrain slack. Tum lo lire lell lo increase clrain slack. (Nole) Tire adruslers slrould be ai lire same alignmenl marks lar boll: lire riglu and leli sides. . Periodically clean and lubricale lire chain. a) Allgnmenl rnari @ Adluxllng bull @ lack nur Lack al oil will cause lhe chain links lo bind and G) Adluxlei ceuse undesirable eiiecr on me sprocker. s—lv. Adrusnna me drive chain a- n l45 rig. 640. (D Lock nut Fig bezl. C2) Adlusting nut Adiuslmg the lront broke lever © rree play oi the pedal © Adlusling nut Fig. .543. Adlusting the rear brake pedal 6. PERIODICA DJUSTMENT '1 BRAKE ADJUSTMENT Brakes are the llle~|ine ol the rider, therelore do not neglect to perlorm the periodic inspection. daily inspection and pre.riding inspection. FRONT BRAKE ADJUSTMENT L Lever free play a. The tree play of the brake lever, that is. the distance between the normal attitude and the point where the brake starts to take hold should be 2*3 cm (0.73ilul2 in). Aaiustment can be made at the cable adjuster at the brake lever, by loosening circular lock nut and screwing the adiuster in to increase the lever play and screwing the adiuster out to. decrease the free play. . Adiustmeht is also made by the adiusting nut. (Fig.672l) Turn to the right to decrease the free play. Turn to the left to increase the free play. v REAR BRAKE ADJUSTMENT I. Pedal free play a. The tree play ol the brake pedal. that is the distance between the normal attitude and the point where the brake starts to take hold should be 273cm (0.787I.I2ifl) (Fig, 6*22) b. Adiustnient is made by the adjusting nut. (Figeeza) Turn to the right to decrease pedal play. Turn to the left to increase pedal play. c. When the braking stroke is small. the lollowitig condition is apparent. I. Too small a clearance between brake panel and shoe. 2. Loss of tension in the brake spring. 3. Brake lining damaged due to overheating. SPOKE TOROUING Riding with loose spoke will place an ununilorm loading on the rim as well as on the remaining spokes. therelore. the spokes should be inspected liequetilly and retoraued when they become loose. Raise the wheel 0“ the ground and check each spoke lor tightness. arty spoke which are noticeably loose should be torqued to the same value as the remaining spokes so that the spokes are all ol unilorm torque. Use the spoke nipple tool and torauing wrench. BATTERY INSPECTION Loss ol battery electrolyte occurs after long use and should be replenished periodically. When the electrolyte level drops to the point where the plates are exposed, it will result in rapid discharge to the battery. The battery should always be maintained at the proper electrolyte level. 6.7 MAINTENANCE INSPECTION 146 l. Electrolyte Level 0. Remove the air cleanet covet disconnect the battery cable item the battery, remove the battery setting bolt and then remove the battery. The standatd battety used is the MEWSiIiC (CB/CLUE: 33676! Mg. by Yuasa Battety Col 0' . Always maintain the electrolyte level above the lower electrolyte level marking on the battery. When replenishing, add distilled water to raise the electrolyte level to the upper matklng (Fig. HA) Replenish by unscrewing the battery cap at the top and add the distilled water. All three battery cells should be filled to the same level. n 2. Damaged and Dirty sallery Cable Connector inspect the connectors lor cleanliness and damage. Clean the dirty connectors or replace damaged connectors belore making connection and apply a coating of grease at yaselirte an the connectors to prevent corrosion. 3. Specific Gravity Check the specilic gravity or all three cells or the battery with a hyarometer. it it measures below 1,200, the battery should be charged. A tully charged battery should indicate a specitic gravity al’ L180 at electrolyte temperature ol 20"C (68"F). The specific gravity will vary somewhat with the temperature at the rate or 0.000l7 specilic gravity variation tor each I“C ll.8“rl charge in temper. ature. A rise in temperature will cause a decrease in spec Ic gravity and vica versa. (Fig. 6725) (Caution) 1. Do not add any sulturic acid to the distilled water when replenishing. 2. When the drop in electrolyte level is excessive, check the discharge rate or the battery. 3. Exercise care not to pinch the battery cable when making the battery installation. 4. Also, make sure that the vent tube is not pinched. 5. When the temperature drops. the capacity ol' the battery will lower and cause hard starting. In such a case, store the motorcycle in a warm place. (D Upper level rnarl (a) Lower level rnarl rig. .5724. Batlevy electrolyte level (D Hydrometer (2 Battery Fig. e—zs. Measuring spectttc gravity 747 6. PERIODIC ADJUSTMENT G. SECURITY INSPECTION OF PARTS Fig. 672:: ® Handle Ins'alluvion nm l50~250kgrcm llD.l~lB.l [lesl (2) s:eering svem nm 900~1.200kgrcm 165.1~86.81le51 @ From axle um 700~900kgrcm k50,6~72.3h.lbst (9 Rear axle nu! 9oo~1,loo kgrcm [65.1495 n. lbs) © Wheel spokes 15~2o kgrcm u 0~l.5h lbs) @ Rear cushion upper and rear nuis 200~350kgrcm llAS~25e3ftlbsl (3 Real «om pivol boll 500~600kgrcm 136.I~43.4h.lbs) Engine hangel bol's 8mm 200~300kgrcm l15~2L7VI lbs) 10 mm v 300~400 kgrcm 121.7~28.9 M. lbs! (9 Real brake iolque boll nu! 150~250 kgrcm K10 B~IB.1 (Libs) (Fig. 6-25, 27) 6,2 PERIODIC INSPECTION AND SERVICING 148 6.2 PERIODIC INSPECTION AND SERVICING A. Daily inspeciion ll is ol uiniosi irnporiance lo periarrn periodical inspeclion and servicing so Ihal lroubles can be prevenled and ihe nioiorcycle niainlained in lhe besi oi operaiing candiiian. The inspeciion is classilied inlo lwo lypes. namely, the preridina inspeciion periorrned by lire rider daily and me periodical inspeciion which is periorrned a] a regular schedule eiiher by ihe rider or ihe service shop. Fig. 5—23 The following ilems oI- inspeclion should be performed daily as a money of habit. (D Check lor excessive looseness or sway oi lhe handle. ® Check ior proper iree play ol lire clulcli lever ® Check ihe iunciion oi ihe headliahi. iailligiii, slop. Iighl and Wm signal ligiiis. 8) Check lor looseness and oil leaks in lhe lroni and rear cushions , (5 Check Iuel auaniiiy. CBIZS/CBWSv lo 5 z (28 v.5. gal. 2.3 Imp. gal.l Cllzs/cms 9.52 (2.5 us. gal., 2.1 Imp. galJ (Fig. 6728, 29) @ From lire air pressure 1.8 @7ch 125.6lbs/inzl .® Rear lire air pressure zokg/cm2 l28.5lbs/in=l Check me horn lor sound and loudness. (9 Check lor proper play oi lronl brake lever @ Correcl level and condiliorr ol engine oil CE/CLI75: l 52 (3.2 U5. p 2.7 Imp. pl.l CB/Cl.l25 1.22 (2,5 U.s. p 2.l Irnp.pl.l @ Check lor proper play ol llre rear brake lever 149 6. PERIODIC ADJUSTMENT (Nate) After inspecting the above items, attention should be paid to the iollowing points when riding. I. After starting. warm up the engine for two minutes at low speed. When the engine is cold. the viscosity ol the oil is heavy and does not permit adequate lubrication to all parts 2. Do not race the engine needlessly. Refrain from sudden acceleration or braking. tight cornering. 4. Check battery electrolyte level weekly without fail. Under the following conditions. checks should be made at a more Ireauent intervals. 9’ a. Riding in mountainous area. b. More frequent inspection is necessary when riding at high speed. Periodic Inspection Periodic inspection and servicing should be perlorrned in accordance with the Iollowing table. \ |ntervals by tire-1W9” 300 ‘LDOD‘ 2.600 3.000 4.000 5.000) 6.000 7.000) 8.000) 9..000/l0000 H.000 11.000 \, "‘ "‘ (I00) (620] (1.240) (1.560)‘ (2.480) (3,100). (3.720) (4.340) (4.950) is seolimool (6.520) 7.440) Items Change engine ail O O I I O O O O O Adiust ign Adiust valve clearance O Adiust cant chain 0 Adlusl clutch O IAdiusr carburetar Adiustdrive chain 0 O O Adiust lront and rear brake . . Clean spdvk plug clean ail litter 0 Clean air cleaner clean luel strainer O Clean rnulller Check tightness al spake: O Retighten um: and bolts “Adlusl lighting equipments and ' . ,.... ho checihattery [O O O O O O 7.1 ENGINE 150 7. TROUBLE SHOOTING ll is mosl imporlanl lnal lne cause or any lrouble be localed as soon as possible and lbe proper correclive aclion loken so llial lne serviceable lile or live engine will be exlended. Lisled in lne Iollowing lables are live lroubles. probable causes and live correclive aclions. 1, MAIN ENGINE YROUBLE Troubles Probable causes Correclive acilon Engine will nol conlinue l. Clogged luel cock. Clean and inspecl. running. 2. Plugged venl hole in fuel lank cap. 3. Improper lappel clearance. 4. The carburetor lo imake manllold cons necling lube damaged or leaking air al llle ioinls. 5. Improper oil level Engine mallunclions aller l. Deleclive spark plug 1 Overhealed spark plug. replace wormsup. 2. Deleclive ignilion coil willi plugs olcorrecl heal range 3. lncorrecl lloa' level Excessive smoke al nign l. Oil being pumped inlo llie combuslion By diagnosing lne noise. rebore engine speed. lollpumps chamber due lo excessively worn or and/or replace llie parls as ing condilioni damaged cylinder. pislon. rings and required. burned during combuslion. Noise produced near llle l. Worn pislon and cylinder l. lnspecl and rebore cylinder and lap of lhe engine The clearance belween lhe pislon and replace worn parls. cylinder is increased causing llie pislon 2. Replace connecling rod. large skirl lo slap againsl cylinder wall during end bearing and crank pin. combuslion. 3 Adius' lo proper specilicalion. 2. Worn connecling rod large end produces knocking 3. Tappel naise Overnealing engine 1. Carbon deposil accumulalion l. Disassemble and clean 2. Dirly or louled spark plugs 2. Clean.aryrouled plugs. lnspecl 3. Improper lype spark plugs or gap carburelar if plugs conlinues lo 4. lnsullicienl lubricalion lo drive chain or foul. chain lension loo lighl. 4. Aaiusl periodically, lubricale 5. Oil level loo low, poor or improper 7. Adiusl periodically grade oil 6. Improper dislribulor poinl gap clearance. dirly. burnl 7. Excessive carbon accumulalion in come buslion cnarnber Engine does nol slarl l. roreign obiecl cauglil belween valve 1. Disassemble and clean Ilack ol compressionl and valve seal 2. Adius! 2. Tappel sluck open 3. Adiusl Ignilion liming oul or adiuslmenl 4. Replace new luse .‘w Blown luse 151 7. TROUBLE SHOOTING Engine suddenly stalls l. Clogged Fuel cock 1. Disconnect tlle fuel line and while running 2. ruel passage in lhe carburetor clogged check the luel llow 3. Dirty spark plugs lheary carbon deposil 5. ll lhe Iuse is blown. lhe pllols or wet plugl lamps will not light up 4 Ignition liming oul of adiustmerlt 5. Blown luse Oil becomes emulsified l. Water mixed with oil 2. Use Honda Ultra Oil or equivae lespecially during wlnlerl 2. Use or improper type oil lent oils 3. Clogged brealner pipe (Caulian) The oil. even though clean in ape pearance, may decomposed due to extended use and become lhin, resulting in loss of lubricate ing properties. Should be replaced. l. Clogged air cleaner Service air cleaner element Increased ruel consump- . lion. (Related symplomsl 2. Distributor point gap out oladiustment, 2. Adiust gap clearance. rework - Law exhaust noise. dirty. burnt or replace burnt points low back pressure at 3. Excess accumulallon or carbon in cylin~ 4. ll ignition liming is relarded, the muIller der exhausl port or inside murller. dislrlbulor points will open ailer - Low compression 4. Ignition timing retarted the timing mark "F" has been noliceable when kick Worn cylinder, pislon, piston ring. passed. slarling. Adiusl lo proper selling lnsuilicienl engine rpm. 1. Fuel passage clogged 1. When the fuel passageincloge 2. Delective spark plug llouledl ges. the spark plugs will be dry. 3. Clogged mulller 4. ll the air cleaner is clogged. 4 Clogged air cleaner engine will not derelop high 5. Ignition timing out ol adiustment RPM and the exhaust smoke becomes dark. Clean the air l'llter element periodically. Poor throttle response I. Clogged air cleaner. lcheck I'lrst to see man 2. Clogged exhaust port or exhaust pipe llie throttle cable is pro- 3. Ignition liming out of adjustment perly adiustedl 4 Tappel clearance out or adiustmerlt Distributor points burnt l. Points covered with oil The condenser by method described 2. Improper ignilion liming below. 3. Delective condenser ‘ 4. Condenser in poor condition Condenser Test Metllod Aller taking lhe resistance value willl the manager. g, use a copper wire lo shorl across lhe lerminals. a 0 V 0 good slrong spark should be produced at the instance 9 the leads are contacted. Condenser Measurement Wilh the distributor points open. measure the resislance belween lhe primary lerminal and lhe outer 9 Shell, a good condenser should measure at least 5 M Q resistance al slandard temperature. The condenser is defective if it measures below (3 l M :2 (D Serwce tester (2) Spark ® Condenser Delermine the condition of the condenser by the rig. 7-l. Measuring condenser capacily above memod_ (Caulian) A loosely inslaIIed condenser or dirly terminal will cause ignitiorl lo mallunclion. 2. CARBURETOR TROUBLE 7.2 CARBURETOR 152 Trouble Probable cause Corrective action 1. Fuel overllovv l. Contaminated luel 1. Remove noal cnamcer cover lrelaled symptoms] o. Remove locking clip and disas- . p90, idling semble the float cnamber ~ Poor perlormance in all speed - Excessive luel consumplion - Hard slarling ~ Low power outpu" ~ Poor occeleralion b. Check lor any dirt lodge in the valve seal, remove dirl by blow. ing with compressed air or by unscrewing the valve seal. and clean. c. Reussemble aller cleaning in gasoline. Damaged valve or valve seal 2. Replace both the valve and valve seat with new parls. Punctured "out 3. Remove the float chamber cover. take out the float and check tor fuel in the "out. iCheciing procedurel - snake the floor - Immerse lne floor in hot waler was C U947263“Fl lor approximately 60 Sean onds. bubbles can be observed it the lloal is punclured. Float arm lip benl 4. Straighten the arm lip ii benl and use llie luel level gauge lo oblain llie proper luel level. Frobable cause Corrective action 2. 3. 4. Trouble 2. Poor idling l. lrelated symplomsl - roor perlormance at slow speed ~ Poor speed lransislion ~ roor response lo throttle snapping . Poor perlormance at Air screvv improperly odiusled I. Turn the air screw lightly lo lull close and cneck to see it the air screw was properly adjusted. Back oli lfiiyg turn lrom lull close. Start lne engine and lurn the air screw in both direction not mote than i tum and Set ol the poinl where lne engine rpm is nignesl lsmoollil. medium speed 2. Throttle slop screvv oul or adiuslment 2. Back off the throttle stop screw all the way and check for proper operation at the throttle, lurn the stop screw in until the proper rpm is obloined. 3. Clogged slow iel lincluding pilol iell 3. Unscrew lne plug. remove the pilol iel, check tor any dirl. blow oul vvilli compressed oir it dirly. Remove the slow jet and clean in the same manner. 153 TROUBLE SHOOTING (D Thvollle slflp screw (2) Air screw rig. 772A Adivsling idling lCB/CL I75) Trouble Probable cause Corrective aclion 3‘ Poor perlormarlce al inlermediale speed lrelaled symplomsl - Flal spol - Poor acceleralion - Excessive luel cone sunlplion - Poor speed lransillon Clogged slow iel linclud'e_pilol iell Same Correclive aclion as for poor idling Jel needle al improper selling Improper luel level Adiusl lo me proper sroge l3 slagesl Replace worn iel needle willl new purl. Use me luel level gouge and adiusr lhe level by bending me noal arm lip. Clogged air venl Clean oul lhe air venl Trouble Probable cause Corrective aclion 4. Poor high speed perr lormance lrelaled symplomsl . Loss ol power ‘ Poor acceleralion . Block exhausl smoke ~ Poor engine perlormonce P‘?‘.“’.'°." Loose main iel or clogged with dirl Clogged air venl lube Choke closed Fuel cock improperlv posirioned Loose iel needle Remove main iel and clean, irlsloll and lighlen securely. Clean oul venl lube Open ll‘le choke lo lull OPEN posilion Posilion lhe luel cock lever lo lull OPEN posilion. ll iel needle locking clip is broken, replace wilh a new parr. 5. Hard slarring Excessive use or cnoke Fuel overllow Fuel cock in closed posiiion Slarl engine will. choke valve lullv open lcleon spark plugl Same correclive aclion as l above open luel cock 3, ENGINE NOIICE 7. ENGINE 154 1rouble Rrobable cause Correclive aclion l, 1oppel noise L Excessive lappel clearance l. Adiusl lo proper clearance 2. Worn lappel 2. Repair or replace 2. Rislon slop l. Worn pislon, cylinder 1. Repair or replace 2. Carbon deposil in combuslion chamber 2. Remore carbon 3 Worn pislon pin bore. connecling rod a Repair or replace small end 3. Com chain noise 1. Tensioner oul or udius'mem l. Readiusl 2. snelched chain 2. Replace 3. Worn leelh on corn sprockel, liming 3. Replace sprockel 4. Clulch knock l. Worn clmch lriclion disc oulev lab areo l. Repair or replace 2. Worn clulch cenler spline 2. Repair or replace 5. Crankshan noise 1. Crankshafl end play i. Repair or replace 2. Worn cranRsnoll bearing 2. Repair or replace 6. Engine noise I. Challno belween kick arm and oil seal I l. Repair (magnem noisel 2. Breaker poinl noise. deleclire slipper 2. Replace A.C. generamr surlace assembly 4. SIEERING SYSTEM Trouble Prob‘uble cause Correclive oclion l. l-landle operoles l. Overloroued sleering cone race 1. Readiusl heavy 2. Domeoed sleering sleel bolls 2. Replace 3. Benl sleering slem 3. Repair 2. From or rear wheel 1. Loose bearing in lroni or rear wheel l. Check lor wear and replace as 2. aenl rim on lronl or rear wheel required 3. Loose spoRe 2. snoiohien byloosening or lighl. 4. Worn rear lorl pirol bushing enlng lhe spokes. 5. Twisled lrame 3. Replace il uncorrecloble 6. Drive choin adiusler om or adiuslnieni 4. Replace 7. Defec'ive line 5. Repaiv or Iepluce 6. Adiusl lo proper value 7. Replace 3. Rulls lo one side l. Rignl ond lell cushion nol bolanced. 1. Replace lronl or rear. 2. Replace 2. Misalignmem ol lronl and rear cushions 3. Repair 3. aenl lronl fork l 4. Repair 4. Benl rear fork 5. Repair 5. Beni lronl axle 6. Repair 6. Loose componenl in sleering syslerr 155 5. CLUTCH SYSI’EM 7. TROUBLE SHOOTING Correclive aclion Trouble Riobable cause i. Clulch slips l. Loss or lension in clulch springs ll Replace 2. Worn or warped clulcll plale 2. Replace 3. Worn or warped clulcll lriclion disc 3. Repair or replace 2. Clulcll will nol l. Excessively worn clulcll lriclion disc 1. Repair or replace disengage 2. lrnproper adiuslrnenl 2. Adiusl lo proper specirucalion 3. Clulcll oul ol l. Warped clulcll plale or lriclion disc l. Repair adiuslrnenl 2. Uneven lension ol clulch spring 2. Measure lension and repair or (engine slallsl replace 6. GEAR CHANGE SYSTEM Trouble Probable cause Correcllve aclion l. Gears will nol l. Broken lug on shill drurn l. Replace engage 2. Broken lug on shill arni broken 2. Replace 3. Unsrnoolh morernenl belweenshill drum 3. Repair and shill lork 4. Replace 4. Broken shill lork 5. Replace 5. Broken Iug on counler sllall second 6. Replace and lhird gear 6. Broken lug on rnain shall second and lllird gear 2. Gear cllange pedal l. Broken shill relurn spring l. Replace nol relurning 2. Gear sllill spindle rubbing againsl case 2. Repair or cover 3. Gear iump oul ol 1. Worn lug oncounler shall second and L Repair or replace engagernenl 'hird 9w 2. Repair or replace 2. Worn lug on rnain shall second and 3 R . . eplace lhrrd gear 4 R 3. Worn or benl shill lork . ”We 4. Broken or loss ol lension ol shill drurn slopper spring 7. SUSPENSIONS Trouble Probable cause Correclive aclion l. Soll suspension l. Loss ol spring lension l. Replace 2. Excessive load 2. Hard suspension l. Inefieclive lronl cusllion darnper 2. Inelleclive rear cushion damper 3. Suspension noise 1. Cushion case rubbing l. lnspecl cushion spring and case 2. Inlerlerence belween Cushion case and 2. Repair spring 3. Replace 3. Damaged cushion slopper rubber 4. Replace 4. Insuiiicienl spring damper oil (lronl and rear) 8. BRAKE SYSI’EM 7. FRAME I56 sprockel Trouble Probable cause Correclive aclion i. No range ol l. Worn brake snoe l. Replace adiusvmem 2. Worn brake cam slipper 2. Replace 3 Worn brake can 3. Replace 2. Unusual noise when l. Worn brake shoe l. Replace applied 2. Foreign obiecr lodged in brake lining 2. Rernove loreian obiecr 3. Riued brake drum surlace 3. Repair 4. Worn brake panel bushing 4. Replace 3. Inefiecvive braking l. lnoperarive lronr brake cable l. Rernove loreign obiecr iron 2. Loose brake rod cable and inspecl lor bends 3. Improper shoe coniacr 2. lnspecr and repair 4. Din or vvcrer inside Vhe brake 3. lnspecr and repair 5. Oil or grease on brake lining 4. lnspecl and repair 5. lnspecr and repair 9. DRIVE CHAIN Trouble Probable cause Correcrive aclion 1. Drive chain slreicli l. Excessive load applied ro chcin l. Correcr riding recnniaue rapid lduring riding or gear change] 2. Rerlorni proper lubricarion 2. Due ro oil leak. excessive lubricarion periodically 2. Excessively vvorn 1. Driving wirn worn sprocRer l. Clean sprocRer area 2. SprocRer rnalllned ro drive chain 2. Replace vvirli proper sprocker C3125 WIRING DIAGRAM LIGHTING DIMIIER SWIIEII ARRANIIMEII T Mam" Tuknsalclw um ‘i m or; 'G "5 H L“ ”V 5‘ GE— "5‘ N B o 0 9 ® nu “ 0'0 0'0 5mm spzznamzn l 0—00 00 av sAN NEIHRAL momma LAMP sv 15w FUSE smnwmn m LAMP 6V aw LELIII Inn—CAN. 1 _,_ l/Tmncul qu WIRE HARNESS MEAR TURN SIGNAL IIGNT 5v InW TAIL AND STOP LIGN'I /5w “gm um LIMIT .9” a.“ .TuL—r av 25/zsw @L _ K ARRANGEMEN'I CUMBINATIUN SWITCH cGMaINATIGN SWITGN In u. OFF an In TLthzi O--O 1 I: New auTTnII THEN SIGNAL SWITGN L.FRON1 TURN SIGNAL IIGIIT 6V InW GGIITACT BREANUI (CONDENSER) F. 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LGH Um I..." . mm W . an “my.“ nah: mu: m v 3mm .m m. 5.. m4 Mow Ins: surVnEssoR "I w Niumn 5mm. swam mm: L mum mm mm um “I" mum uww ‘nmN aw‘smm’n mm Baum A : mama '9 WVEISVIO SNIHIM 951 C5175 WIRING DIAGRAM LIGHTING-BEAM-STARTER SWITCH R n m_ EARTN R FRONT TURN SIGNALWLAEM; 7 m mu 3mm “M n " T N 000 00 e 93‘ JJ m M 0—0 00 BATTERY SPEEDMETER ~ _ RREAR TURN SIGNAL LANR m/aw A o -o 00 12v 9AM STARTLR MAENETIC NEUTRAL mmcnon LAMP SWITCH—@umm/m IzV/zw «mu em mchToR LAMP lZV/3W r m TURN SIGNAL IchAToR MP IUSE 1” LA _ , N mm: _ _ NINE HARNESS . sums * \~ ~ L 1"“ ' "‘él‘ia'h “a.” 4 ,4 TAILANDSTDPLAMP HEAD LAMP 12V/35/25w H, H—"” L" I 12v zmw nu: F k I ’1»— 1. ‘ #W _. u — 7 in F' I .T u. cuNmuATmN squcN mwmem k .u Kl! M MIMI LREAR TURN SIGNAL LANP lZ‘I/ZSW WI | | mp 11 o 0 mm, men swncN WIRING DIAGRAM [2 CT RREANLR TENSIW nI—ahe Br —Bmlm ‘ can“ u: L h R Rd — mum — a r_ _‘ mus: SURPRESSOR V—Velow TAR—em 5 I W“ NEUTRAL swchu 5-0!" P 4"“ PLUG w — Whit: Gr — Gray LFRGMT TURN SIGNAL LAMP Lev/25w “mm mm" mm °‘°"“l° ““4"" m — SIGINAL 3mm 51’ ' V/R—Vdow/Red "(TIN _ MOTOR 3%: GIIIII/IIm/M A.c GENERATOR 691 WVHS VIG ONIHIM ‘9 C“? «Emu mmcnon 4‘ LAMP 12 "um SIENAL wmcnon LAMP 11v 3w CL] 75 WIRING DIAGRAM (General Export type) Lloumn BEAM swncnmc ARRANGEMENI Mm LAMP 12v 35/st LFRom YURN R.FRDN12JUZR:WSIGNAL LAMP m we TL m m s:‘ 1 u "g or? 1 ' 71 N 040-0 00 e @F swzzununzw LAMP J a" 00 5mm ””ng 5mm srmomzm \zvawxz L 0Q] 12v 9AM lZVst a rusz 15! u ““Di‘cffo‘ "‘ I = 1 WIRE muss 7 , ; LAMP lzvaw TL; A“ W. S A AND 510? . .w-(‘D’waf— . 1 IL I “In—6v 31—.14' _\ ‘ L: LAMP IZVZSI'BW w . g — ‘ “ fl " fig) Egr—I__—.'.-E;"= “ . C.‘ u—O-w C. m A. /v—' j r— J a H. mm-mmnnuswncu mm-mmnuu SwchN swncnme ARRANGEMEI LREAR mm SIGNAL ‘3 W Iclmmz} 5m? swncn WI? W 25" ‘0?“ ‘1 \ l mow} EM - WW" ‘ «:1an NW. ‘ rpm suvrnzgsun . 1mm BLUE R‘ u; IGMI mm m » um Min MD m 57‘” PL“ ‘ wv~ WMI'VE AND YELLOW smu L , M ,BREMR wn- YELLUW mom A ' cu um ; a / mwu AND mm: H, UMP lZVZsW mum auswvmréuwm mcwuzn HEMHAL swncu i/w- an; MD wmvz W 5'5"“ o/v- min Ann YELLOW . w. wnnz an men to Minnow WVEISVIG SNIHIM ‘9 091 R FRONT TURN STGNAT CL'I75 WIRING DIAGRAM (U. S. A. Export type) LIGNTINE BEAM SWITCHING ARRANGEMENT m HE 1L LB‘DV SE T HEAR TURN STGNAL LAMP III/13W TAN AND STOP 12;?" mm Izmw/sw ummmw Orr ‘ f M H 0.00 00 0mm? T N _ smqunm LAMP an 3—3 03 12v 9AM >15 mm svzwomnm 1zv3wxz lI '0 9* 1 mem muml mmmm T W )E LAMP xzv 3w , 7 ms: 15A v ” 1 H GH BEAM wan 5mm mmmop mmmon wm: mums m “ [AMP 12V3W LAMP 12V3W _|_‘ V a L I Hymm-mm . L 4 L, +1 HEAD LAMP 12v ss/zsw v—-1 __4 l —q\—E=I= II “—0—; LREAR TURN SIGNAL LAMP IZVIBW MAIN- MAIN IGNIT‘DN SWITCH T IGNITION SWITCH an we m m‘ HORN aufiou J 0+0 o-o‘ TURN SIGNAL SWTTCN , NOISE SUPPRESSBR , I mm \C: 'g‘LgaNnmsm 3' *1 CONTACT EREAAER r . I CONTACT-BREAKER INCLUDED / A C.GENERATOI STOP SWITCH \ NEUTRAL SWITCH :41 .m | , ) “”3233“ J” fin) LFRONT TURN STGNAL LAMP lZVISW Blue GI WIN: Ev Velmw [BI Gray Bmwn [91 ’9 WVHOVICI ONIMIM 9. ca/cuzs, mm 9. CB/CL'IZS, 175K3 9.1 DISMOUN‘I’ING AND MOUNTING ENGINE l. DISMOUNIING ENGINE [CB/CL] 75] l . 12. Remove the step bar, kick starter pedalana gear change pedal. . Remove the mulfler. Remove the spark plug caps Irom the spark plugs. . Remove the cylinder head R side cover and remove the tachometer cable by unscrewing the setting screw. Remove the seat. Shut ON the (Uel cock and remove the two luel tubes from the carburetors. . Uncouple the electric leads connecting. (Fig. 94) . Loosen the air cleaner tube bands and remove the remove the throttle valve from the carburetor. Remove the L. crankcase rear cover and remove drive chain at the ioinl clip. . Remove the clutch cable from the clutch lever. (Fig. rH) . Remove the stater magnetic switch. KCBI75| Pull out the engine hunger bolts i9 each) and remove the engine to the right side. (Fig. 973) G) Clutch cable ® Clutch lever Removing ciurcn cable (D lornrn bolt (2) arnrn halt rig. 9-3. Removing engine hanger halts 162 163 9.7 DISMOUNTING AND MOUNTING ENGINE [CB/CLI25] l. Remove Ihe siea bar, kick slarler pedaI and gear change pedal. 2. Remove lhe mulller. 3. Remove lhe spark plug caps lrom lhe spark plugs. 4. Remove lhe lachomeier cable lrom lhe righl side ol ihe cylinder head. 5. Remove lhe seal. 6. Shul on lhe ivel cock and remove lhe lvel lube: lrom Ihe carburelors. 7. Uncovp'le lhe eleclrical leads ai lhe conneciors. (Fig. 974) 8. Loosen ihe air cleaner connecling lube and ihronle valve irom lhe carburelor. (Fig, 9—5) 9. Remove the L. crankcase rear cover and remove lhe drive chain. 10, Remove ihe clinch cable lrom ihe cluich lever. (Fig. 94>) ll. Remove lhe slarling molor cable irom ihe slarier magnellc swilch. (Claim 12. Pull am he erlglrle hanger balls (9 eachl and remove lhe engine lo ihe righi side. (Fig. 977) (D 1hralile valve fig. 7- Removing lhranle valve 2. MOUNTING ENGINE PerIorm lhe mourning in ihe reverse order oi removal, however, exercise care on Ihe iollovving polnls. 1. Remove lhe corrosion lrom ihe slariing molor cable back io ihe specilled localion belore movnilng vviih a boll. 2. The drive chain ioilil clip should be inslalled so lhal lhe open end will lace opposile lo llie direclion of relation. (D clvlch cable ® clvlch lever V Fig. 7-4:. Removing clinch cable G) IOmm boll ® 8mm bal Fi 9-7. Removing engine hanger bolls 9.2 ENGINE MECHANISM lCB/CLI75) 164 . 9.1 ENGINE MECHANISM [CI/CLI75] L CYLINDER HEAD AND CYLINDER A. Disassembly 1. Drain oil trom the engine. 2. Remove the cylinder head tightening nuts lsix nuts and two cap nutsl. tightening bolt and cylinder head cover. 3. Rotate the dynamo rotor so that the cam chain ioint is toward the top or the cam sprocket and then disconnect the cam chain. . Attach the wire to bolh ends of Ihe chain before disconnecting. 4. Remove the cylinder head. 5. Remove the cylinder setting bolt and remove the cylinder. Bl Inspeclion Reler to poge 21. Cd Reassembly l. Push the cam chain tensioner. mounted on the cylinder head, all the way in and lock in place with the lock bolt. (rial 979) 2. Install the cylinder head on the cylinder. (Figi 9710) (Note) Make sure that the (our dowel pins are installed into the top or the cylinder. two 0 rings and the gasket are properly installed. 3. To install Ihe cum Chain, lurn the generator 90 . A ' align the ”T" mark on the rotor to the index @ °°W°' 9'" ® 0 ""9 © Gm“ mark on the stator. The will position the piston ”9- ‘7'”- to the Ioprdeud-cemer. Position the "0" mark on the cam sprocket to the top position. connect the chain with the ioint clip. The position or the clip must be in the position shown in Fig. 9-5. (Note) When both sides or the cylinder head cover are removed, install the cylinder head side covers betore connecting the cam choin. Loosen the valve tappet odiusteroelore installing the side cover. ® 0" mark 5 . v-ll. Installing cam chain 165 9.2 ENGINE MECHANISM lCB/CL175) G) 6mm boll r 9-12. er tightening sequence G) cansnalr ® Knack pin Fig. 943. Removing knock pm 4. Install the cylinder head cover and tighten the mounting nuts. lEighr cup nuts and one hex. boltl (Nola) Perlorrn the torauing in a diagonal pattern, start. ing from the inside and working outward. Torque to 160~210kgr¢m (I1.6~15.2flrlhs) s. Loosen the cam chain tensioner lock bolt and then relighlen: followed by setting the lock nu! lTo tighten the cum cnaint a. Adiusl the valve tappei clearance Adius' R) 0‘05 mm (one: in.) cold selling Camshaft When removing the camshait Imm the cylinder head, first remove the pin at the righl side or the camshalt and then remove lrorn the cylinder. 9,2 ENGINE MECHANISM (cs/cum) 166 a) Valve celle. ® Valve veluinev © Oulel valve swing ® lnnel valve swing @ llmel seal © Valve slem seal cap (7) Valve slelll seal @ Slem seal vubbev cusman ® Valve swing seal 5 @ Ethm valve guide @ o ting @ Exnavsl valve ® Valve swing seal ® lnlel valve gvlde @ Valve guide clip @ lnlel valve @ Valve lapael adlvslmg lock nal @ Valve laaael aalvslel @ Raclel aim @ Roclel aim shall ® Knack pin @ Camshuh @ Cum chain @ Dowel pm fig. 944. Valve Assemble lhe inlel and exhausl valve assembly componenls in accovdance wllh Fig. 9-H, exevsile (are no! lo mismcich Cylinder Wllen assemblylng lhe cylindev, inslall one each dowel pin on lhe righl and lell side, 167 9.2 ENGINE MECHANISM (CB/CLI75) 2. CRANKCASE A. Disassembly l. Remove me cylindel head and cylinder in accor. dance will. 9.] on page 164. 2. Remove me L. crankcase covel. AL. generarar. and siariing sprockei in accordance wiin seciian 3.3 an page 32~33. 3. Remove ine R. crankcase cover. clinch, oil pump in accordance wiili seciion 3.4 an page 34~3a 4. Remove Ihe gear shin spindle and kick siarier spring. 5. Loosen Ihe crankcase sening nui and bolts and separaie me lawer crankcase. (Note) Crankcase iighiening boll is insialled under me oil drain plug. ihererare, do nai lorgei to remove ine boll. (Fig. 946) B. Inspection G) arrrn ball ® 6mm hull @ 8mm can run rig. 946. nenanng lower cvanllcase Reler Io seciion 3.6C on page 41. c. Reassembly Assemble me crankcase in we reverse order oi disassembly wim aneniion paid to lhe lollowing palm. Clean me crankcase and inspecl me rnaiing sub races al lhe crankcase lor sign oi leaks. scraiclres and ailrer damages. Apply liquid gaskei lo Ihe rnaiing surlaces al Ihe crankcase. assemble aher dlying. Make sure Ihal lire iwo dawel prns are insialled on Ihe uppel crankcase. (D Dowel pin Fig. 9—l7. 5” GEAR SHIFT MECHANISM To prevenr Ihe gear snin arrn lrorn disengaging will. gear shin drum. a proieciian is provided on me uppel crankcase Io linrii iumpirlg ol gear shin arm. Funher Io laciliraie shining inlo me neuiral gear, me neuiral siopper is made to lii lire drum direcrly. (Fig. 948) (D Gear snrli arm (2 Praieciian rig. 9—15. 9.2 ENGINE MECHANISM lCB/CLI75) 168 A. Disassembly Remove the cylinder tread and cylinder in accore dance with 9.27121 on page 164. Remove the R. crankcase cover. Remove the clutch and oil pump in accordance with 3. 4.2.3 on page 35~3a. . Remove the L. crankcase cover. A.C. generator, and starting sprocket in accordance with section 3.3 on page 32~33. Remove the upper crankcase in accordance with section 9.2A on page 167. Separate the transmission gears from the upper crankcase. Remove the gear shitt drum stopper, neutral switch tram the gear snilt drum. (Fig. 949) Remove the strilt lork clip, shilt tark knack pins and pull out the snitt drurn. (Fig. 9720) inspection I . R Measure the thickness of the gear shift fork tip. Use a Vernier caliper. (Ft 9721) Sew eable ‘ Standard Value Um” .L and center i o.2ll~o 2l42 Replace it under shilt tark i [5.36~5.44l 0.203 lim 2. Measure inside at the gear shilt lork. Use a cylinder gauge or inside micrometer. (Fig. 9723) Standard Value se’yice‘m" irrnit l339~134o Replace it over I34 o~34 025) L342 04.075) shilt tprl (D Gear shilt drurn stopper ® Neutral stepper .g. 949. ® Gear shilt lari ® Gear shilt drum rip. 9720. Removing gear shilt drum (D Gear shilt tori ® Micrarneter rip. 9721. Measuring gear shilt tari tip (D Gear shilt tark (2) Cylinder gauge Fig. 9722, Measuring inside diameter 169 9.2 ENGINE MECHANISM (ca/cu75) 3. Measure oulside diameler oi lhe gear shiil drum. Use a micromeler lo make lire medsuremenl. (Fig. 9723) c. Reassembly Reassembly is periorrned in me reverse order oi lire disassembly procedure, however, special diieniion should be given Io me loilowing iiems. G) Gear shin drum (2 Macramerer rig. 9-23. Measuring auiside diameier l. When assemblying rhe gear shiii iork inio me upper crankcase rhe shih lork should be assembled irorn me ieii side in ihe order oi ihe siarnped markings R "C" and ”L" so ihdi ihe leners are iacing Io ihe leii. (Fig. 9724) 2. Make sure rhar me shiii lork guide pin is insiailed and ihen properly sei lire clip. 3. Check ihe shih lork to assure ihai ii is operaiing smoorhiy. @‘Gear shiir rork (2) Clip rig. 9-24. 4. Ailer assemblying lhe gear shill spindle move il as shown in Fig. 9725 and check lo make sure lhal ii posilively relurns Io normal aosilion. (D Gear shin arrn F 9—25. 5. Make sure ihai me gear shih spindle is posiiiveiy sei wiih ihe washer and circiip. (Fig. 9726) G) Circlip ® Washer rig. 9-25. . 9.2 ENGINE MECHANISM (CB/CL175) 170 A. CRANKSHAFT When assemblying lhe crankshali inia lhe cranks case, give proper alleniion lo llie following poims. l. lnslall rhe dowel pins inra rhe upper crankcase and posilively align rhe dowel pin holes in lhe crankseall bearings ra rhe dowel pins. Work will be simpliged by aligning lhe scribe line arr rhe bearing ourer la "la parling surlace al rhe crankcase. (Fig. 9—27 and 9—23) 2. Reler lo page “~43, secrian 3. 7. . (D Dawel pin ,7. 9—27. 5. TRANSMISSION Srspeed, consrarrl niesh lransnrissian is rnaurrlea. Reler la seciian 3.9 page so~52 lar derails pl rhe respeclive gears. A, Dimssembly Reler to section 4. SB. B. lnspeciien 1. Measuring backlash Hold ihe maling gear so ihal il does noi move and lighlly rack lhe gear being measured. Measure rhe aniaunr al backlash using a srnaii dial gauge. (Fig, 9-29) (D Crankshalr (a) Scribe line © Upper crankcase g. $725. “‘3 Slundard Value semcwble + Replace rl uyer ‘3' m‘w’ o.oole~o.oos Replace il over an and 5m gears mural“, 0.005 lo 2) 2. Gears when used lor a lang periad will develop wear la lhe reelh and dags as well as resulling in side laading al lhe gear leelh. This becomes rhe cause of gear noise and in severe case. gear disengagemem. Gear which are excessive warn should be replaced in sels. 3. Measuring gearrshah clearance a) Small dial gauge . Measure lhe bore pl rhe gear wilh a cylinder "9- “1 Checking 9"" back'ash gauge or an lnlernal micromeler. measure the shall diarneler wilh a rnicranieler and carnpule lhe clearance. (Fig, 9—30) Slandard Value swicwb" [mm M J o ooos~o.ooz4 l 02 0621 Replace il cyer ‘ o 006 cola 0004 (0.]! "‘5' C' l00l6~0045l ’ ooale~o.ooa Replace il over C 7 C3 lo.o¢~o.oazl 0.0047 mm G) Gmr (2) Cylinder gauge ® snail @ Micrunrerer rig. v—ao. Measuring diamerer 171 9‘2 ENGINE MECHANISM (CB/CLI75) (D 20 mm sel Vlng @ Tmnsmissinn ccvnlev shah © 5304 HS radial ball bearing ® Ball heaving sei vIngA ® 20x52x9 ail seal ® Drive sprackev ® Drive Sprocket rim plave ® axle hex bah © Guide pin @ 16mm hearing bush 5 ® 16mm mrusv wushev @ Cannier snan law gear I35 1) ® Ccumev shah mp gear asn ® 20 mm nrrusv washer n ® Coumer shah raurm gear (271i ® 20 mm nrrusi washev ® 20 mm mrusi wushev n @ Coumev shah mira gear (29 n ® Coumev shah second gear [321) ® 1ransmissian main siraii ® Mainshaii rap gear I25 n @ Muinxhah shining gear I231 as 20 n @ Mainshaii second gear @ Bearing hush A Q? sxzsxa an seal rig. 9731. 9.2 ENGINE MECHANISM (CB/CL175) 172 c, Reussembly Perform lhe reassembly in lhe reverse order ol disassembly, however, special allenlion should be given be la lhe lallawing ilems. l. Da nol use lhe circlips which have been removed. use only new parls. 2. lnsiall all gears, washers. and circlips properly as shown in lhe Fig. 94L 6. KICK STARTER I. When inslalling lhe kick slarler assembly inlo lhe ‘ ' . F . upper crankcase. align lhe kick slarler spindle pin Ea‘fig'm'“ “Md“ ® "“"m‘ 59""9 © “W“ 9'" graave lo lhe dowel pin in lhe arankaase. and ' ‘ pasi ‘vely sel lhelriclion spring lo lhe case groove @, 7. CARBURETOR A pislon valve lype variable venlvri carburelors are mounled one la each cylinder. A. Disassembly l. Remove lhe carburelor mounling boll, laosen lhe air cleaner aonnecling lube alamp. 2. Posillon the fuel cock Io OFF, and remove lhe luel lube (D ThmMe slap scvew rig. 9733. 3. lhe carburelar can be removed aller removal of lhe lhrollle valve. B. lnspeclion l. Idle adivslmenl lhe carburelars musl be adiusledarler lhe engine has warmed up la operaling lemperalvre. Furlher, balh lhe righl and lerl carburelors musl be adius'ed al lhe same lime. (Fig. 9733) a. Adivsl lhe engine idle speed la l,200rpm wilh lhe lhrollle slop sarew. b. Manipulale lhe air screw back and lorlh and sel il la lhe poinl ol highesl rpm llhe air screw should be sel la ”41% lurn per lram lull closed posilionl. a) fuel level gauge (2 floor @ Carburelar rig. 9734. a. Readiusi lhe idling speed lo lhe proper selling wilh lhe lhrollle slop screw. 2. Hoal level adiuslmenl Remove lhe noal chamber cover and check lhe posilion ol lhe noal wilh lhe lvel gauge, as shown in Fig. 9734, al lhe poinl where lhe llaal arm ivsl comes in aonlacl wilh lloal valve. lCarburelor is lilled approximalely 10"). Adiuslmenl is made by bending lhe llaal arm wilh a small screwdriver. The luel level gauge is Toal No. ouoromoooo. 173 9.2 ENGINE MECHANISM (CB/CLIZS) ENGINE MECHANISM [CB/CLIIS] I. CYLINDER HEAD A. Disassembly 1. Remove lhe k. side coyer lrom the right side al the cylinder head and breaker point coyer lrom lhe leti side. 2. Unscrew the two contact breaker setting screws and renioye lhe contact breaker assembly. (Fiv. 9735) (D Contact breaker assembly @ Spark adyancer ® Contact breaker setting screw 3. Unscrew the spark adyancer mounting bolt and remoye lhe spark adyancer lroni the camshaft. (rig. 9735) 4. Unscrew the three cross screws and disassemble the point base. 5. Unscrew lhe Iwo Cam sprocket mounting bolts and renioye lhe sprocket lram the end ol the camshatl. 6. Disconnect the chain being caretul not to drop the ioinl clip into the cylinder. and then. with a piece at wire lhe bolh ends ol the chain. 7. Loosen lhe six cylinder head anaching runs In remove lhe head. (D Cap ml! ® Hex nut Fig. 944:. Nut tightening sequence a. inspection keler to section 3. 2. l c on page 66~67. c. Reassernbly l. Tighlen the cylinder head cayer nuls uniformly in the sequence shown Fig, 9736, 2. The mounting ol the cam chain can be simplilied it the chain is reassembled prior to the installation or the cam sprocket left and right bolts are ol difierent sizes. therefore. exercise care that they are not installed in reverse order. (Fig, 9737) (D 0" mark C2) Knock bolt @ brnrn hex bolt rig. 9‘37. 9.2 ENGINE MECHANISM (CB/CLIZS) 174 3. Assemble the chain ioint clip so that the open slit is lacing in the direction opposite to the chain movement. (Fig. 943) 4. Align the "1" timing mark on the AL. generator rotor to the timing index mark on the position. the piston is positioned to the toprdecdrcenler. rosition the "o" timing mark on the cam sprocket to the top and mount on the camshalt with the two bolls. (Fig. 9—37) 5, When assemblying the point base. make sure that the oil seal is properly installed on the camshaft. (Fig. 949) 6. Make sure that the dowel pin in the cumshuh is properly litted to the spark advancer setting groove. (Fig. 949) 2. CAMSHAFI A. Disassembly l. lieler to cylinder head disassembly procedure on page I73 2. Remove the tappet hole caps. 3. Loosen the valve tappet adiusling screw. 4. Remove the rocker arm stopper and pull all! the rocker arm shalt. (Fig. 940) 5‘ Remove the camshafl from (he cylinder head. 3. Inspection Measure lhe base circle and cam heights wilh a micrometer. (Fig. 9w“) I Standard Value Cam base circle I ‘3089256:21‘ng) 7 . mammal Replace it under $1135?“ 'N i26il57~26il97l um (26m . I.0l3~ on Replace ii nude! 5 l t m w” E‘ l25.72~2s.7el LOOB (25m c. Reassembly lieler to cylinder head reassembly procedure. ® Julnl clip C2) Cum chain Fig. was. ® Oil seal Fig. 949. k . . ® Racket arm shalt Fig. 940. stopper ® Racket arm shalt ® Cam shalt C2) Micrameter fig. 941. Measuring cam height 175 9.2 ENGINE MECHANISM (CB/CL125) 3, CAM CHAIN TENSION The design has been simplified, making iv periorni wivh high degree or reliabilivy and also providing easy adius'mem. ; % ® © Cum chain lensione' push vud ® Tenslun Spring @ Tensions! swing A @ Luck inn @ cdin Venslunev adnm Fig. 942‘ A. Disassembly 1., Remove me genem'ol rolor by using me rolor puller Wool No. o7933~2oooom. (Fig, 943) (D Generuvur Yule! (2 Halo! puller fig. 9-43. 9.2 ENGINE MECHANISM (CB/CL725) 776 2. Remove ihe L. crankcase cover by removing ihe cam chain odinsi boii and eighl 6mm screws. (Fig. 944) 3. Remove Ihe siariing sprockei sei plate and Ihen remove Ihe siariing choin Ioge'her wiih sprockels. (Fig. 945) 4. Remove ihe cam choin Iensioner sei oiaies and remove Ihe cam chain Iensioner. (Fig. 947) 5. Inspection Cam choin adius'menl con be made in accordance wiih ioiiowing procedure. a. Remove ihe dvnamo cover. b. Roiaie ihe dynamo roior counlerclockwise nniii ihe "T” mark on ihe rolor lines up wiih ihe liming index mark on ihe sioior. This adius'mem mus! be made when Ihe oisions are on ihe iop or Ihe compression slroke. This conoiiion can be oeierminea bv shining ihe lope pels wiih iingers. N the lappe's are 'ree. ii is an indication Ihal ihe pisions are on Ihe iop oi Ihe compression slroke. c. Unscrews ihe cam chain iensioner adius' boh and roiaie ihe dynamo roior connierciockwise one inrn. a. Screw Ihe cam chain iensioner odinsi boh and Ihen iiohien ihe lock rim. c. Reassembiv Check to make sure ihoi Iensioner operules smooihiy in ihe direciion indicaied bv ihe orrovv in Fig. 947. ® Cum chain adiusl (3 6mm screw Fig. R—u. .{a . ‘s a) srarring sprecker ser piare © Slarling spracker (D Cam chain Venxicmer (a) 1ensioner ser plaie Fig. 9—46. \ s. Fig. 947. 177 9,2 ENGINE MECHANISM (CB/CLI25) 4. TRANSMISSION The CB vype Is equlpped WM: 0 Srspeed transmission while model CU25 Is equlpped wnh a 4rspeed vransmission. Fig. 9—49 A‘ Fig. 948 a. 2nd gear (C, shined) fig. 748 C‘ an gem \C. shined) a V V m gear (MM shlhedl Fig. 9-4“. 5m gear ww, shined) Fig. 943 o. A B. 9.2 ENGINE MECHANISM (CB/CL125) 178 Disassembly Disossemble lhe cylinder head in accordonce with seclion 4. l.A or page 173. . Remove lhe cylinder. . Remove lhe L. crankcase cover generolor rolor, slorling sprockel and cum choin lensioner. . Remove lhe R. crankcase, oil filler. clchh, oil pump and geor shin soindle. Remove Ihe 8mm and 6mm bolls lrom lhe uaper crankcase. (Fig. 949) Remove Ihe 0mm ond 6mm bolls lrom lhe lower cronkcase ond separole Ihe upper cronlcose. (Fig. 9*50) Separale lhe lransmission gears. Inspedion Measuring backlash Hold lhe mallng gear so lhol il does nol move and lighlly rock Ihe geor being measured Mea. sure Ihe omovnl ol backlash uslng a smoll dial gauge. (Fig. 975!) / Slanduvd Value S“‘i“7°b‘° lnml 0.00l7~o.0052 Replace il over ""1“ M 9“" l0 ou~o.l33l 0.005 lull o.00l 005 Replace il aver "“ “"d 5'” 9"" lo.042~o.lzel 0.000 IOJ) 2. Gears when used lor o long perlod will develop wear lo lhe leevh onci dogs as well as resulling in side loading or Ihe gear Ieelh. This becomes lhe cavse ol dlsengagemeni. Geor vvhlch are excessive worn should be replaced in sevs. ® 0mm boll ® .smm ball rig. 9-40. (D 6mm ball (2) 0mm boll rig. 9-50. ® Small dial gauge rig. v-sl. Measuring gear backlash 179 9.2 ENGINE MECHANISM (C3/CL125) 3. Measurlng geareshirl clearance Measure lhe bare of lhe gear wilh a cylinder gauge or an inlernal micromeler, measure lhe shall dlarneler wilh a micromeler and campme lhe clearance. (Fig 9752) Semceable Slandard Value Um" o,ooos~o.002¢ M‘ "3324.052: Replace .l over osooos~o.ools 0.004 loll! M 5' C' l0,0|b~0l045) c2, c3 0,00]6~0s003 Replace .l over (limb—101362) @0047 (OJ?) (D Gear (2) Cyllnder gauge (3 shall @ Micvomelev 9-52. Measurlng diameler G) Knock pin, 6X95 ® ISmm bearlhg bush B @ Counler shall low gear G) Caunler shall lourlh gear (5) 20 mm sel ring 6) 20 mm lhruxl washer A ® Couhler shah lhird gear ® Counler shall my gear 63 Counler shall lop gear ® Bull bearlng sel rlng B @ 620$ HS bull heaving @ 20 mm 0 ring ® Tlansmlsxlon couhler shall @ 28x4a><7 oil seal @ Dvlve sprockel ('3 Drive sprockel mung alale @ ex ID hex boll @ Tvanxmission main xhuh ® Main shall laurlh gear @ Mam shall second a. lhlld gear @ Mum shah lop gear ® 15mm bearing bush A @ sxzsxa OII seal rig. v-sa. 9.2 ENGINE MECHANISM (CB/CLIZS) 180 c. Reaxsembly Perlorm Vhe reassembly in me reverse order oi ssembly. however, special aNemion should be given Io lhe following ilems. l. Do noi use me circlips which have been removed, use only new pans. 2. lnsiail gears, washers, and circlips properly as shown in one lollowing ligures. (Fig. 9753) 3. Posivion all me gears in neuiral and rovuve by hand lo assure ihav ilie dogs are noi nining and inai ine gears are all roiaving smooinly. 4. Alier assemblying lhe gear assemblies imo lhe uaaer crankcase, make sure inav lhe sei rings and dowel pins are properly insvaiied. 5. GEAR SHIFIING MECHANISM To areveni ine gear shin arm lrom disengaging wilh gear snindrum, a proieciion is provided on lhe upper crankcase lo limii iumping oi gearsnili arm. runner io laciliiaie shining inio lhe neuvral gear, ine neuiral svopper is made vo iii ine drum direciiy. (Fig. 9*54)‘ A. Disaxsembly l. Remove Ihe cylinder head and cylinder. » . x - - ' (D Gear s H arm ® Praieciion @ Neurrai siaaaer ball 2. Remove me L. crankcase cover. generoior rovor, H} 9_5‘_ siarving sprockev and cam cnain iensioner. 3. Remove ine R. crankcase cover, clnicli. oil pump and gear shin spindle. 4. Separaie ine lower crankcase from lhe uppercase. 5. Separale lhe iransmission gear from me uaaer crankcase. 6. Remove ine shin drum siopper, neuiral siopaer bell and neniral swi ch. 7. Remove lhe shin rork sening clips and guide pins. 5. Remove the gear shin drum from the crankcase. (D Gear snili lurk ® Micramerer I. Measure ine inickness oi ilie gear snin iork iip. “9- 9'55- “"5”“? 9°” 5W" '°'k "F .~___,.1 a. lnspeclion Use a vernier caliper. (Fig. 9755) Serviceable Slandard Value irnil Riglu, Ieli a. cehrer 0.2II~D.2IS Replace il under shill lark l5.35~ .45) 0.1955 (5.05) 2. Measure inside diameter of Ihe gear shill fork. Use a cylinder gauge or inside micromeier. ( 9756) 6) Gear snilr lark (2) Cylinder gauge Fig. 9-55. Measuring inside diameier 781 9.2 ENGINE MECHANISM (CB/CLIZS) Slandard Value se'lice‘fl’” lmil . L339~L340 Replace il over 5""' '°'k 13$.0~3éi025) Lan [34i075I c. Reassembly Reassembly is periormed in lhe Ieverse order ol lhe disassembly procedure. however. special allenlion should be given lo lhe lollowing ilems. l. When assemblying lhe gear shill iork oi lhe cs lype (Sespeed lransmissionl inlo lhe upper cranke case lhe shill lork should be assembled lrom lhe leil side in lhe order at lhe slamped markings (D R shill lork ® Came! shill lork @ Guide pin clip rig. v-57. ”",5 "C” and ”L” so lhal lhe Iellers are lacing lo lhe lell. (Fig. 9757) 2. Make sure lhal lhe shill lork guide pin ‘s inslalled and lhen properly sel lhe clip. 3. Check lhe shill iork lo assure lhal ii is operaling smoolhly. 4. AHer assembly lhe gear shill spindle move il as shown in Fig. 9758 and check lo make sure lhal il posilively relurhs lo normal posiliorl. s posilively 9759) 5. Make sure lhal lhe gear shill spinal sel wilh lhe washer and cilclip. (Fi (D Washer r . 9-59. ® Circlip 9,2 ENGINE MECHANISM (CB/CL125) 182 o. KICK SYARYER When me kick svarver is operaled, lhe kick slaner pinion moves lovvdrd vhe rignl and engages will. llie coumer snarl low gear lo lrdnsniil lne lorce lo Ihe pislon thugh lne rndin shall. This causes lne engine lo slarl. As me slaner pedal is released, lhe lorce of lhe kick slaler spring rolales Ihe spindle and relurns Ihe pinion m Ihe nov't-al posilion. (Fig. 9760) (D Law gear [2) chk slarvcr spindle © Clvclip ® friclian spring 6) Kick Xlarler pinion 6) Kick svarver spring Fig. 9-60. A, Disassembly neler Io page 79. a. lspeciion Check lo make sure man we aclion ol lhe kick sVarVer spindle is srnooln. c. Reassembly Reassembly is perlorrned in we reverse order ol disassembly procedure, however. special anenvion should be given lo llie lollowing ilerns. l. When insialling lhe kick scarier assembly inlo llie upper crankcase, align llie kick scarier spindle pin groove lo we dowel pin in llie crankcase. and posmvely sev inelricvion spring lo we case groove. (D Dam] pm ® Gm“ rig. Hi. 2. Assemble llie kick slarler spindle and check lo assure inal ii is operaling properly. 783 9.2 ENGINE MECHANISM (CB/CL725) 7. .CARBURETOR A, Disassembly Reler to page 5a~al. a. Inspeclion l. Idle adinsinieni The carbureiors rnusi be adiusied dlier ihe engine has warmed up V0 operming lempemlure. Further, baih ihe righi dnd ieli cdrbnrevars rnnsi be ddinsved a! file same lime. (Fig. 9762) . d. Adiusi ihe engine idle speed la I200 rpm will. 9 Tgrcgzlle slap screw ® Air screw me ”Home “op mew '9' ' b. Manipulaie me air screw back and lonh and sei i! m ihe paim ol highesi rprn Iihe air screw should be set lo 1%:% mm open lrom lull closed pasivionl. c. Readiusi ihe idling speed V0 me praper sening wiih ihe vhronle slop screw. 2. Float level ddiusiniern Remave me liaai chamber caver and check ihe posiiian ol ihe naai will. me luel level gauge, as shown in Fig. 9763, di me poini where he nadi arrn iUsI carnes in camaci wiih ihe liaai vdlve. . lCarbureiar is iilied approximmely ID“). Adiusi. nienv is made by bending ihe liaai drrn will. d srnall ® "’1 'm' 9m” ® “W © C°'h""'°' screwdriver. The luel level gauge is iaal No. Fig. 9-53. 0740170010000. 9.3 FRAME 184 9.3 FRAME l. FRONI SUSPENSION Reler to page 9o~?5 or this Manual lor the inlorrnation on the lront suspension ol all other models. CLI75: The front cushion compression stroke £53m [llSmml while the extension stroke is L38 in [35 mm) Ior a total travel ol 5.9l in (ISO mm). 35mm(l.3£i"l ssmm(5.l5in)—/ [345 all @lID (D from tori bolt (2 2t nnn washer @ o ring a) front lovk top budge (5) front cushion Sprlng @ Front lurk bottom budge ® Front lovk pipe (5) rrant lark dust seal ® “with internal circhp @ Fvont [ark oil seal ® rrant lovk pipe gulde ® rrant piston stopper vlng @ fork valve stopper 7mg @ rront dumpev valve a; fork ptston stopper rlng @ Fvont lovk piston @ Fovk pistan snap ting @ Front larl bottom ease ria. 7-54. A. Disassembly l. Disconnect the trout broke cable and the speeds ometer cable from the front brake panel. 2. Remove the [rent wheel torque bolt. 3. Place a block under the engine. remove the front axle and separate the wheel lrom the lork. 4. Loosen the headlight mounting bracket bolts. 5. Loosen the Iront Iork top bolt and the 3mm lork bolt which mounts the lront fork and pull the Iront Iork out the bottom. [Figs 9*65) 6. Remove the [rent lork dust seal and remove the internal circlip using the circlip pliers. (Fig, 9766) 6) mm lav tap boll ® Headlight bracket semi-a ball _ © snrn bolters . 9—65. 7. Draw the lront lork plpe assembly out ol the bottom case. 3. Inspection l. Check lront lork damper otI ldisossembly is not necessaryl. It the oil is dirty or the level low. change or replenish the oil. C) Group (2 Pliers Fig. 9—66: 185 9.3 FRAME Remove the lront lork top bolt and drain plug on the damper and allow oil to drain loliawed by stroking the damper several times to get complete removal. (Fig, 9767) Replace the drain plug and fill with I55~I65 cc l9,5~lo,lcu-in) ol good grade SAE gloweso or equivalent. 2. Front lork piston Measure the diameter ol the piston with a microme eter to check the amount of wear. (Figs 9768) Serviceablc Limit L3No~l 3955 Replace it under iasrns~asu45l 13937 (35.4) Standard Value a) tram fork drain plug ®'Frorit tori tap bolt PM," diam”, rig. 9-57. c, Reussembly Perlorm the reassembly in the reverse order at the disassemblv. however, particular attention should be given to the following points. 1. First insert the axle through the lork axle holes to make sure that the lelt and right lorks are level before tightening the 5 mm front fork mounte ing bolt. (rig, 9769) 2. When installing the front lork oil seal. apply a liberal amount ol the grease between the main seal lip and the dust seal llp (petroleum resisting q) no", ion 9mm. [2; ”imam,” greaset and exercise care not to damage the lips. Fig. 9-68. Measuring diameter or lark piston Use the dust seal dri ng weight to drive to the seal. (Fig, 9770) 3. It is recommended that the fork piston stopper ring and the circlip be replaced with a new item. The old part may have lost its tension or may have become distorted during the removal. 2s REAR SUSPENSION The rear suspension utilizes a De Carbon type shock absorber. Compressed nitrogen gas and oil is sealed within the cylinder and during contraction and extension the oil llows back and forth through r r k r K 4 the orifice incorporated in the piston; the function G) :1?” ® '0'" “9 ol the valve which controls the llow pertarm the dampening. D lorce ”W“ Extension Contraction l 5W“ 2.64 in' “‘75 5°ks/o.5 m/sec is was m/sec W m) CB/CLI 25 335 in cars as kg/O.5 m/sec 12 ig/os m/sec '65 W (D rront lork on seal driving weight (2) rront torlr on seal driv.ng guide rig. we. 9.3 FRAME 186 mans mum STRME 67 m an 1715 mom 1525 mm 1515 imam cRs 2 8 4 7 8 5 6 (D Sprrng seai siopper (23 Rear cusirian spring (3 Rear damper assembly (9 Rear cusian upper case @ Rear cusnau sprrug guide (5) Rear cushion bollom case ® Spring adiusrer (3) Under sear carnpieie rig. 9-71. cB/cuzs MAX SWrMIN NZ STROKE 6 [ST SET l . ZND SET I68.5 3RD SET [53 5 NITROGEN GAS 4 a) Rubbei ioinl (23 Spring sear srapper @ Rear cusnian upper case (9 Rear darnper assernaiu (5) Rear cusnian spring (3) Rear cusiuau spring gurde rig. 9771. cam MAXJSOMTNZIS STROKE XS 151' SET 200 P‘ , 2ND SET I95 3RD SET [90 NITROGEN GAS (2) (D Spring sear siopper <2) Sprrng upper sear @ Rear cushion sprrug (5) Rear darnper assembly G) Rear cushion spring guide rig. 9—73. CLI75 187 (D Rear cvshlcn ® liear cushion disassembling a. assembling lopl rig. 9474‘ (D Rear cuxhlcn spring (3 Vernier caliper Fig. 9-75. (2 free play (D from brake lever rig. 9-76. 9.3 FRAME A, Disassembly l. Separale lne rear cusnion assembly from lhe lrame. 2. Remove lhe rear cusnion spring by using lne rear cushion removal lool. (Fig. 977‘) (Nola) The rear damper canlains nilrogen gas under pressure, lherefore, it should not be disassemhly due to the extreme hazard. B. lnspeeiion l. Rear cushion spring (Fig, 9775) Measure lhe lree lengln ol lhe rear cusliion spring using a vernier caliper; replace ii is beyond lire serviceable limil shown below. The spring compressive lorce is also shown as re'erence. 5p rig lree lengrlr Model Slandard Serviceuble Compressive larce Value llmil cans 7.257 Rem“; i' 615307 iii/32 lbs Cll25 llfl4.3l ”93 ”70) (173l5mm/Nnikgl Replace .l 71507 5.3307 in/ul lbs cans under ”853) ”so ”m was mm/20kgl Replace .l girl. :i’illlizii ‘ 7.284(185I ‘ 9 c. Reussembly Reassembly is perlormed in lhe reverse order ol disassembly. lnslall lne spring so inal lhe end wilh lne smaller coil pilcli is lovvard lhe lop. 3. FRONT WHEEL The lronl brake ulilizes llie lwo leading lype brake snoes lo provide superior bralring perlormance. Reler lo seclion 4. 12, page ill or lliis Manual lor llie descripllon of lhe compdnenl pans. A. Disassembly Reler lo seciion 4. in. page or inis Manual for lhe disassembly procedure, B. lnspeeiion l. From bralre pedal adiuslmenl ldisassembly is nol necessayl. a. Place a black under lhe engine lo raise lire lronl wneel ofl lhe ground. b. Spin lne wheel by hand slowly apply lhe brake lever unlil lne brake slarlslo lake nold. measure lne amounl ol lever lravel al lhe lip. The slandard lever lravel wees/tin ll~2eml (Fig. 9—76) 9,3 FRAME 188 c. reriorm ihe odiusimeni by lhe loosening ihe lock nul oi ihe ironi brake arm and iurriing lhe odiusier run. For minor adivsimenl. lhe coble odivsier on ihe ironi brake lever may be used. (Fig. 947) 2. Brake drvm vveor The weor oi lhe brake drum is checked by lhe measvring lhe inside diomeier oi ihe brake drum wiih o verhier caliper. (Fig. 945) Slandord Value Sevvlceahle Limir ~ ~ lleplace .i over 6.30 6.3] (I60 I603) 635 ”w — a) Loci mil ® Cable adiusler 3. From brake shoe wear pm 9.71 Measure ihe ihickhess oi ihe brake shoe wiih o vernier caliper and ii ii is worn beyond ihe specie lied serviceable limii shown below. lhe shoes should be replaced. srandard Value Serviceobie Limir f Replace ii under o.l97 0209 mi? 5.3) 0M (2 a) 4. For oiher inspeciihg iiems. reler lo seciioh 4.12 C. page ll2. c. Reassembly Periorm lhe reassembly in lhe reverse order oi disossembiy. Periorm ihe brake adiuslmem in ace cordahce wilh seclion a inspeciion oboye. rip. 9-79. 4. REAR WHEEL Rear wheel componems. Refer lo Fig. 4—6072 page 115. A. Disassembly i. Remove lhe drive chain. 2. Remove lhe bque adivsier nul irom ihe rear brake leyer ond ihe lorque orm boll irom lhe brake paneL 3. Loosen lhe rear axle nul and remove ihe rearaxle. ihe rear wheel will drop away irom ihe reor fork. 4. Remove lhe driven sprockei by vniasienihg lhe 8mm special iohgued washer and circlip. (Fig. 9’79) (D circlip amrn Special longved washer rig. v-7v. 189 9.3 FRAME 5. The brake shoes are removed lrarn the brake panel by spreading them upon by hand. B. Inspection ,l. Adiust the stroke or the rear brake pedal. (Dlsr assembly is not necessaryl. a. Lower the main stand or place the block under the engine to raise the rear wir’eel oil the ground. b. Spin the wheel and apply the rear brake pedal until the brake star! to take hold; measure the amount of the bloke pedal navel. The normal pedal travel when measured at the forward tip shauld be 3/¢~t-l/4 in (2~3unl. (Fig. 9730) c. Perlorm the adiustment with the rear brake adjuster nut. (Fig. Hat) 6) Rear brake pedal (2 Free play 2. Rear brake drum wear Check the wear al the brake drurn by measuring the inside diameter ol the dwm with a Vernier caliper. ll the wear is beyond the serviceable limit shown belaw. the brake drum should be replaced. I Made] / Slanduvd Value Sewlceahle Limit _ . c3125 5.11 ~5.l26 Leplace it utter a) iiear brale adlvsrev run am in 130 2i 520 l|32l pig, 9.” cans 5512~5 su Replace ll ovev c1175 [140~140.3) 5.60 ”42) 3. Rear bmke shoe weal Measure the thickness of the bloke shoe with a vernler caliper and if it is worn the beyond the selvlceable limit shown below, the shoe should be replaced. Standard Value Serviceable llmil iieplaee il under 0.lb7~0.l69 I4 o~4 3l 0.08 mm A. For the inspection oi the other items, reler to section 4. l3 (2, page lla. 9.4 ELECTRICAL 9.4 ELECTRICAL I. CHARGING CURRENT MEASUREMENT I90 Connect an. ammeter between the battery i+l terminal and the selenium rectiiier, and check to see ii the values obtained are in accordance with the standard specifications listed in the chart below. When the battery charge is low. the cause may be in the A. c. aeneraror. selenium detective wiring. rectifier or the Charging Charging Charging Model Item Charging start current current current /3,000 rpm /5,000 rpm /ID.000 rprri Day Itrrie Max. 2,400 rpm Mirl. 0.5A Max. 3.0A CB I75 Night time Max. 7.800 rprri — Min. 0.5A Max. 3.0A Battery voltage 12.3 v 13 v 16.5 v Day time Max. 7,400 rpm Min. 0.5A Max. 3.0 A CL I75 Night time Max. 2.800 rpm ; Mirl. 0.5A Max. 3.0A Battery voltage 13.2 V I4 V I6.5 V Day time Max. 1.300 rpm Mirt. IDA Min. 2.7A Max. 4.5A CB 125 Night time Max. I300 rpm Min. LZA ‘ Min. 2.0A Max. 4.0A Battery yoltage 6.3 v 6.7 v 7 v 8.3 v Day time Max. 1,300 rpm Min. 1.7A Max. 3.0A CL 175 Night time Max. 2.000rpm 1 Min. 1.7A Max. 3.5A Battery voltage 6.3 V 7 V 5.3 V 2. STARTING MOTOR (CBI75/125] Starting motor is mounted at the iront of the crankcase. The power to drive the crankshaft is reduced in speed by a planetary gear incorporated within the starting motor and iurther reduced at the sprocket and Starting motor specification and characteristics (Fig. 9752). chain connecting the motor to the crankshait. 2. ii the solenoid switch has been used tor a long period, the contacts will become pitted or burned, :rea'» ing a high resistance which will prevent flow of current to properly operate the starting motor. When such condition develops, dress the contact points with a file or sandpaper. 797 9.4 ELECTRICAL RPM kgm KW mm 3.0 l.8 0.5 25 15 0.5 2.0 1.2 0.0 1.5 0.5 0.] LB 0.6 0.2 0.5 0.0 0.1 CB IOU 200 175 ( ) OURPENT (A) Wkgm KW V X”? ' 3.0 2.4 0.3 s ) ‘ g 0‘” ‘ 2.5 2.0 s [\\ 0/— K / \ u 5‘ V 7 04 20 LG 0.2 A \\ / 74K \ AP # L5 L? 3 / ‘ __. I - 00 00 0| 2 X _,\6§§K \ # / \\ g 0.5 0.4 I > L ‘ N HPM U/ WN (013125) IOU 200 300 CURRENT (A) (Fig. 02) 9.4 ELECTRICAL I92 lCBl75) Items Specification Rated voltage 12 v Rated output 0.35 kW Intermittent operation 30 sec. Reduction ratio 6.44 Without load With load Lock Voltage 11.5 v 9.4 v 6.7 v Current Max. 25A 100A Max. 240A Torque —— Min. 0.55 kgem Min. 1.5kgem RPM. Min. 2000 rpm Min. 500 rpm — Output —— Min. 0.33Irw 7 (C3125) Items Specification Rated voltage 6 v Rated output 0.25 kW Intermittent operation 30sec. Reduction ratio 6.44 Without load With load Lock Voltage 5.5 V 4.2 V 2.5 V Current Max. 40A 120A Max. 300A Torque 7 Min. 0.55 kg-m Min. 1.5kgem RPM Min. I900~27001pm Min. 400 rpm — Output — Min. 0.22 kW — A. Disassembly 1. 2. Remove the L. crankcase cover. Remove the generator rator by using the rotor puller. Remove the starting sprochet set plate. Remove the starting chain together with sprockets. Remove the starting motor cable (rom the starting motor. . Remove the two starting motor setting screws and then remove the starting motor. Remove the starting motor side cover and remove the carbon brush (Fig. 9733). ® Carbon brush setting Screw rig. 9733. ® Carbon brush 1 93 9.4 (D Carbon brush fig. 9-54. G) Sleeper ® Slapper holder @ insulalian washer ® Insvlullcrl collar A ® Conlaer Spring @ riar washer ® Plunger haider ® Plunger shair ® Plunger @ Carrracl ooh @ Case @ Conlacl aiare @ Vake ® Caii bobbin @ Coll camaleie (13 Relurri spring @ Body 9-55. c. Reassembly ELECTRICAL a. inspeelion I. Measure Vile amount of brush wear will! a Vernier caliper. (rig. 9734) Siandard Value Serviceable Lirrm Replace ii under o.433~o.¢92 lll~l2r5) 0,197 '50] Also check lo make sure lhal lhe brush is rim binding in rhe holder causing lhe brush lhe lo noal away lrom lhe commulalor. 2. Measure lhe slarling curreril Use a service lesler and an exlernal slum! ’0 measure lhe slarring currenr. (Reler lo page 136I c. Reassembly Reassembly is periarmed in lhe reverse order oI lhe disassembly procedure. 3. SYARIER SOLENOID SWIYCH A large currenl is required lo operale lhe slarler and il lhe slarler circuil was corinecled direclly lo lhe push bimori swilch on lhe handle. the swiI_ch will burn oul. A slarler solenoid ol a large capacity is ihslalled belween lhe ballery and lhe slarlihg molor. when lhe push bulron swilch is pressed. lhe solenoid coil is energized, crealing an eieclramagnel which draws is lhe iron core. A heavy duly eieclrical cohlacls are mounled lo lhis iron core which closes lhe circuirs belween lhe banery and lhe slarling molor. A. Disassembly l. Discorrriecl lhe slarling molor cable from lhe solenoid swilch. 2. Unscrew file lwo mourning bolls and remove lhe slarler solenoid swilch. a. inspeelien l. Press lhe slarler swilch lisleri lor lhe click in lhe solenoid swilch, ii is an indicalian lhal rhe plunger wilhin lhe solenoid swilch is lunclionirig. Reassembly is perlormed in lhe reverse order of lhe disassembly procedure. 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HORN EU TTO N TURN SIGNAL SWlTGH Wme/YeHow an Green/YeHow n/ - Red/Wm: wmxe/mww Ane Rea uh: mm L “L’Jawm STARTING MOTOR CAB E IGNmON SWWCH ARRANGEMENT EAL \0 IL- TL: -O To-Fo c I 0 NEUTRAL PILOT LAMP Izv-aw 2H TACHONIETER LAM TURN SIGNAL PILOT LAMP Izvrzw SPEEDCMETER‘IiVAMg RFMNY TURN SIGNAL LIGHT 12V~3 CL] 75 WIRING DIAGRAM (General Export Type) STARTER BUTTON/LIGHIING DIMMER SWITCH ,, v nslz P I2V~3w *‘ IGNITION SWITCH IL IL WINKER RELAY WITCHING ARRANGEME LIGHTING DIMMER SWITCH T [GINIVL L uvIsz oIo 0....1 Hz :5 9 9 M :3» %I33 7&3) R REAR TURN SIGNAL LIGHT W é,» -— |___| m r Izv-IoN HIGH BEAM PILDT LAMP w" “2—3:"? I Imow “:91“ ”.43..an 1 W; m “77‘ E E! cps—I 6‘} "43.4 :on I 2“" l E‘— Ebfi-II I r—szIrr . 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