PREFACE This manual has been complied as a guide ior disessernbly and. assembly of Honda Models CB 125 and 160 The manual is divided inlo six secliens, each of which gives delaiis of canslruclien, disassembly, and assembly. Required inspeclleh and mainlenance procedures are oIso included. To further clarify the details conIcIined herein, as many ilIusIraIicns as possible were used. This manual, If read carefuIIy, will supply lhe lechniaues of curred mainlenance and lie iundamenlal lechnical knowledge required of both mechanics and sales siar‘rz SERVICE DEPARTMENT FOEEIGN SALES DIVISION HONDA MOTOR (30., LTD. <9 <9 fP?FPP??PP.““ CONTENTS FEATURES SPECIFICATIONS ENGINE 1 Disassembling and Assembling Engine 2 Cylninder Head and Cylinder ..... 3 Le“ Crankcase Cover ......................... 4 Crankcase Cover Assembly, Right 5 Clutch 6 Oil Pump, Filler, and Separanr .......................... 7 Crankcase .................................. 8 Crcnkshall, Connecfing Rods, and Pistons 9 Cam Chain Tidllener and Cam Chain Guide RoIIer 10 Transmission .............................................................................. II Gear Shili ................................... 12 Kick Sialer . 13 CarbureIor . FRAME Handlebar Conslrucfion of Fronl Cushion. Sleering Stern and Handlebar lock ................................................................. 59 Fuel Trunk .......................................................................... Frame Body ................... Air Cleaner Case and Seal SIand .. Exhaust Pipe and MUMer .......................................................................... Air Cleaner and Tool Case Rear Fork and Rear Fender Rear Cushion . Fronl WheeI Rear Wheel ............................................................................... CONTENTS V ELECTRIC EQUIPMENT 1 2 3 4 5 6 7 8 9????99“ General of ElecMcal Pans .................................... EIecIrical System .................................................... lgnivion Circuit... Power Source Circuiv Self-Sinner ........ Safery Paris ................................................................. Swilch ““““ Wire Harness VI INSPECTION AND ADJUSTMENT 6.1 6,2 .1” Maimenance ................ 126 Periodic lnspecvicm and Repair . 1 FEATURES Features of CB 125 and 160 A. Engine 1. This engine is a paallel two cylinder engine, and each cylinder has special carburetors The intake pipe is quite smooth, with low resistance, for high intake efficiency, and has Cln overhead cam tor high rotation and high output. 2. The camshaft drive is by chain, aid is between the right and lelt cylinders; and steady performance and durability maintain low cylinder temperature. 3. Lubricating oil is filtering by both filtering mesh and a centrifugal fitter, plunger pump to the orankshnlt, camshalt, and transmission shaft, Care has been given to wear and It is torceted by a seizure resistance of each unit. 4. For power trmsniission from the crankshaft to the transmission strait, double spur gems and shock absorbers reduce gecx noise and increase durability by increasing the practical efiective ergagemeni ratio, B. Frame 1. The frame has two subrtubes which are horizontally extended from the head pipe and have high twist rigidity, in addition to strength required tor a sports vehicle. 2. The front wheel suspension is telescopic and the rear wheel is of swinging arm type. with hydraulic shock absorbers Superb riding comfort, steering, and stability is obtained 3. The brake Unit is a " front two leading " type and rear leading, md trailing type. Due to the seminletallic lining Used for brake lining, brd:< The point base serves as ihe bearing of ihe cam- shafi wilboul u bushing. Wiih oil grooves cm in lhe sliding porfion, lhi's Uni! is residuufly lubricated by oil from cam iubricalian. (of) Assembly is ihe reverse order of disassembly. [9] During assembly, anemian should be direcled lo ihe cut on ihe conlacl breaker base plaie showing upward. mm CRANKCASE Fig. 3.2! Principle ai breaihar Fig. 1.21 Remnval ai breaker aaini base plara Fig 3.23 Disassembly al spark advance l6 3. ENGINE g. a. 25 Camshaft BASE CIRCLE ’ CAM HE! BUFFER CURVE ‘ GHT . 3.2.5 Names 01 can purl: rig. 3t 23 Removing camsholt c. Descriptian or camshaft The camshaft of this engine has a cam sprocket 0' the center and polished cam sections al the right and left sides. The bearing sections are a logical type which,ae supported by the side cover and point base. The com sprocket is driven by the cam chain from the gear shift at l/2 transmission gear ratio. (Refer to Fig. 25) The com provides a dumping curve over a fairly large range between the base circle and the cam Unit, and clamps the shock generated when the rocker hits the lift curve; this prevents noise (Refer to Fig. 3.26) I. Disassembly I. Remove the cylinder head. (Refer to Fig. 3. 2A) 2. Atter the poim base and the right side cover as- rsmoved, remove the tappet cdiustlng hole cap. Remove the rocker arm to the right and left on the base circle and the camshaft can be separated from the cylinder head. (Refer ta Fig. 3. 27 and 3. 2E) \ \ / 3,2 CYLINDER HEAD AND CYLINDER ll. Assembly 1. When the adjusting screw of the rocker arm ls turned back fully, set it to the rocker arm pin and assemble it in reverse order of disasserrhly. 2‘ The stanard tcppet ctearmce is 003 to 0.05 mm (0.012 to 0.0201n] when the engine is cold (CAUTION) Correct or replace the unit when the cam is scored or worn unevenly. D. Description of rocker arm The rocker am is an important unit which changes the rotating motion of the camshaft to reciprocating motion tor the valve. The rocker arm contact surface is finish treated after hardening. The tappet Odftlsting screw is coupled at the other end and pushes up the valve at the tip of the screw. 1. Dissassembly L Refer to section c above. When the right and left covers are removed, removal can be made. (Refer to Fig. 3.30) It. Assembly 1. Inspect the rocker arm contact surface and replace the unit it there is scoring, .2. When the rocker arm shaft is being assembled, the rocker arm should be matched to the oil pool groove. (Refer to Fig. 3.3” 3, When the rocker arm has been disassembled and reasselrbled the tappet clearance (valve clearance) should be measured and aditlsted, Adiustment should be pertormed at the position where the T mark of the ArC. generator rotor md the arrow mark of the stator are matched. (Compression top dead center). [Refer to Fig. 3. 32) ROCKER ARH sum Fig. 3‘ 29' Valve mcker arm Fig 3.32 Adiusrment ct tappet clearance mew v‘allvn we?“ “fin Fig. :l. :3 Valve Fig. 3.34 Eemaving valve fig. 3.36 Dvesxlng valve seal a. ENGINE E. Deszripfien of valve The valve performs the importanl role of air tightness in the cylinder, of intake and exhausi for compression and combustion, and extensively influences lhe engine culpur. At flue exhaust valve, the camber is small, {or ob- taining better heat radiulion and fhe clearance between the slem and cylinder is made large. At the inlel valve, it is large for increasing the inlake efficiency and the clearance befween the stern and ihe cylinder is made small for satisfying various conditions con- cerning valve. A double sprirg system is employed for the valve. (Refer to Fig. 3.33) l. Disassembly 1. Remove the cylinder head according lo Section 3‘ 2, l. 2. Depress the valve lliler spring and remove the two valve coller pins wifh long nose pliers or lweezers, lhe retainer valve spring from lhe head cover, and the valve from the combustion chamber. (Refer to Fig. 3.34) ll. Installation 1. Belore fhe valve is assembled, the valve contact surluce should be inspected (or wear, pining, or carbon. Affer cleaning, oil the valve stem, and the valve should be inserfed from the combufiorv chamber side. (Refer to Fig. 3.35) 2, The Valve spring outer and inner retainers should be filled ironl lhe cap hole of the lappel adjusling hole and be compressed by using llre valve llrler. Secure wilh the valve caller pin. lll. Valve sealing l. Dressing of a valve seal is made by Using three cuilers [such as a 9D" plane cufier, INTAKE and EXHAUST plane cutter, and INTAKE and EXHAUST interior surface cutter, 2. The position of a seal is determined by the INTAKE and EXHAUST plane culter and the width of a contact surface is delermined by Using an lNTAKE and EXHAUST inferior surface cutter. When a seal surface is excessively burned, &esse sing should be performed by using a 90° cutierso that the seal surlace becomes even. (Refer to Fig. 3. 36) 5" . 3.2 CYLINDER HEAD AND CYLINDER 19 (CAUHON) (at When the valve Stem is greatly worn, me valve guide is usually also worn. Hence, when a valve is replaced, it also is desirable to replace the valve guide. As the guide was press» inseried. ii is better lo replace the guide aller healing the head '0 300°C in a furnace lbl When the valve is assembled, the compound which was used during lapping should be com- pletely removed, F. Description of cylinder A cylinder sleeve of special alloy is pressrinselted in a cylinder of lightweight cost aluminium alloy. At lhe cenler of lhe cylinder, a clearance for the operaA iionol range at the cam chain tightener and corn chain is esimlished The lubrication oil led from ihe oil pump passes ihrough the slud holes at lire rear righl and leil of lhe cylinder head or the gaskel surface. Filling of cylinder is determined by two guide keys, (Refer to Fig. 3.37) l. Disassembly l, Remove the cylinder as in Section 3. 2. I and the 6x22 boll relclining lhe cylinder; the cylinder can be removed lrom the stud bolt. (Refer to Fig. 3.38) ll. Assembly l. inspeci the cylinder and allEI' confirmation at no Willy such as gwnd wear or scars, remounl ii. 2, Place packing al lhe conlacl surlcice with lire crankcase and inserl the cylinder, 3. when a pislon is inseried inio a cylinder, use a piston “ slider ". Applying a base between the piston md case, insert the cylinder, (Refer io Fig. 3. 39) 4, Assenble ihe cylinder head and head cover unii. (CAUTION) Inspect to determine if lire crankcase packing has slipped irorn the cylinder lapping surface. (For air ligiiienessl Valve Timing medals CB l25/160 1N opens (at Ll mm liltl 5" (B, T. D. C! In closes l 'I l 30° (A. B. D. C] EX opens l II l 30“ (B, B, D, C] EX closes l 0 l 5“ (A. T. D, C.l E. ‘ meme“— fig. :1. :7 Cylinder Fig, 3.39 Coupang pislon in cylinder 20 3." Starter and cable fitted in case cover Fig. 143 AC generator and stator 3i ENGINE 3.3 Left crankcase cover A. Construction of left crankcase cover The left crankcase cover, as well as the crankcase, performs the role of formation and protection and is of lightweight alloy for protectlng the AC. generator against water, sand, etc. For the purpose of making inspection and odiust- ment easy, the A.C, generator cover is fitted at the center ot the case cover and the stator assembly at the AC, generator at the back side, The clutch cable is connected at the reara (Refer to Fig. 140 cud 3i 4]) I. Disassembly 1. Drain the engine oil tor lay the engine on its side). 2‘ Remove the gear shlt’t and the neutral cord from the switch. 3. When the cross-point screws that retain the case cover are removed, the left crankcase cover can be separated front the crankcase. ll. Installation l. Assembly should be performed with attention directed to the following points, - Breakage of letl crankcase covet gasket. - Action of clutch cable, ' 2, Alter complete vehicle assembly and inspection, adjustment of the clutch should be made with the clutch cable (Refer to Fig. 3.42) B. AC generator A description at the AC generator. is given in Electrical Parts [5L In CB l25 and 160, in order to have the per- formance displayed by narrowing the width oi the crankcase to the minimum, ct logical design is employed with the AC generator located near the crankshaft cmd the stator coupled In the left crankcase cover. (Refer to Fig. $43) 5. 5 LEFT CRANKCA'SE COVER 2| 1. Disassembly I. Disassembly of AC generalor (a) The AC generator at the left crankcase can be removed or mounted without dismounilng ihe engine In this section, operation is explained when the engine is dismounted and ihe cylinder head and cylinder cre disassembled. lb] The piston is safely secured by the piston base (cl By removing the generator rotor bolt, dismount ihe rotor from the crmkshaft by use of a genera- lor rotor puller. (Refer to Fig. 3.44) 2. Removal of AC generator retort (a) Remove the left crankcase covere [Refer to Fig. 3.30) lb] AC generator sialor coupled in ihe left crankcase cover can be separated by removing the three 6X28 boltst [Refer to Fig. 3.46) >’( At the back of the AC generalar rotor, the starting clutch is coupled (by the ihree 6X20 pan screws). ll. Installation L Installation of the AC generator rotor can be made by matching the groove at the ihe rotor side to me key set at the crankshaft side. Secure by rotor Selling bolt. (CAUTION) When the key is dislocated from the crankshaft, ii should be fined by light lapping on the side of the key and slightly pressing to the 591 groove. 2. Following the reverse order of disassembly, as- sembly should be made followed by coupling of the left crankcase cover; c. Sinner sprocket and clutch I. Operation of slarter clinch During transmission of rotation of the Slariing motor to the crankshaft, rotation from the motor can be iransrnilted lo the crankshaft; conversely, rotation of the crankshaft cannot be lrmsmiiied io ihe moior. [For detail, refer to Electrical Paris (Chapter 5] [Refer to Fig} 3.47) Fig, 3. 47 Starts! clutch 22 3. Fig 1.4:; Setting operation at starter ettrtctr roller Xpring .3 gene made: Fig. 3. st cum ndwxiev ENGINE ll. Disassembly and installation of clutch l. Following Section 2.3 B, the AC generator rotor is separated trom the left crankcase cover. 2. As the starter clutch is installed at the back of the AC generator rotor by using three 6X20 pan screws, it can be separated by removing the screws. 34 When installation is being performed, attention should be directed to the following points. . Smooth roller operation. A Starter clutch side plate and guide. - Weak clutch roller spring (replace). Ill. Disassembly and installation of starter sprocket i. Atter separation at the AC generator and the left crankcase following the previous section, the starting chain is disconnected at the ioint section. 2, By removing the starting sprocket set plate (ex l2 screws) coupled in the lower crankcase, the sprodret can be separated from the crankshaft. (Refer to Fig. 3‘49) 3. The starting motor sprocket is coupled only by serration and can be extracted quite easily. (Rerer to Fig. 3.50) (CAUTION) The joint clip slot of the starting chain should face opposite the direction of rotation. D. Clutch adiuster and neutral switch rotor l. Operation of clutch adjuster For transmitting operation of the clutch cable to the clutch through the clutch red, the clutch adjuster pushes the clutch rod and indicates relationship in direct start, transmission gear shitting, and stop. That is, adiustment oi the clutch is generally made at the clutch odiustet odiustrttent ; affects the vehicle perfor- mance. (Refer to Fig. 3.51) 3.4 CRANKCASE COVER ASSEMBLY, RIGHT 2: l5 ll. Disnssembly and assembly or cllllch aaiusrer l. Following Secllorl a. 3 5, remove llle lefl cranle case cover, 2 By removing the 6X35 bolls holding «lie adiiisler fixing pleie and clulch lever spring, lhe clulch ad— iusler can be separated (Rerer re Fig. 3.53) 3. When assembly is performed, grease should be applied '0 llle cluldl odiusler [Grease Type HD Muilipurpose NLGl No. 2) III. Disassembly and installalion of neulrul swilch rotor 1‘ Remove the lell crankcase cover. 2‘ By pulling oul llie 6x12 screw holding lhe neulrcll swllch slalor, remove lhe slulor. 3. By removing lhe 6X205crew, llle neutral swilcli rolor is separaled lrorn llie gear slim drum. (Rerer ro Flge 3‘54) 4. Afler lhe goove of lhe neutral switch rolor is mulched lo lhe key of llle gear shill dmnl, assembly should be performed in reverse order of dlsassembly. 3.4 Crunkcase cover assembly, righl A. Descriplion of the righl crankcase cover The righl crankcase cover, as well as lhe [ell crankcase cover, performs lhe role prolecllorl, The oil filler cover is filled lo lhe case cover and pro- vides for passage of lubricmlng oil in bolh direclions. (Refer lo Fig. 3.54) I. Disassembly 1. Remove lhe kick slarler arm from lhe klck pinion shall. 2. By pulling oul me ten cross-poinl screws securing the case cover, lhe righl crankcase cover is re moved. (Refer lo Fig. $55) 4‘ Aller pulling our lhe ihree 6X40 crossepoinr screwsr lhe filter cover is removed, (CAUTION) hiring operaliori, allenllon should be direcled lo lhe lwo 74.5)(3 " 0" rings filled to the oil l‘ll- ler cover. Flue 3,55 lighr crankcase cover screw: 24 3t ENGINE ll. Installation L Before installation, inspection and confirmation should be conducted to determine that the right crankcase cover is not broken, since a break causes oil leak 2‘ After sufi‘tctently washed, the oil filter cover should be installed with attention directed so that the 74.5X3 " O " ring is not broken (Refer to Fig. 3.56) 3‘ While installation is performed, all tightening Fig, 15.5 "o" ring on oil mm cover screws should be tightened repeatedly and evenly. 3. 5 Clutch Clutch plate retaining plate Clutch 1mm om. clutch complete Clutch Irlcliovl fix: ®©®@® @®®@@ Outch plale Clutch rod Clutch center 20 mm :9! ring Clutch pmsure plate exist”; hall 3,5 CLUTCH 25 ion and operation of clutch As sham in the previous ligure, the clutch is a wet multisplale type and consists of the outer clutch. pressure plate, friction disc, clutch plate, and clutch center etc. For transmitting rotation from the crankshaft to the transmission, the clutch has the role to engage or disengage power. It also provides for starts and stops which do not unreasonably load the engine. (Refer to Fig. 3.57) When the right crmkcase cover is removed, the outer clutch complete, is exposed, To the outer clutch complete, the clutch spring driving the clutch pressure plate is installed The clutch plate is installed with the clutch friction disc between the clutch center with {our 6X15 hex bolts. The clutch plate has teeth cut on the insides These teeth are engaged with teeth cut on the outside‘of the clutch center. The clutch center is coupledlto the transmission main shalt by spline. Hence, it and the transmission main shaft are essentially a single unit The clutch piate, clutch center, and clutch pressure plate rotate. On the other hand, to the groove cut on the eXr terior circumference of the outer clutch, the clutch friction disc is coupled by the collar entering the goove; freewheeling rotation with the transmission main shaft is obtained. Hence, while the clutch is connected, the outer clutch center, five clutch plates, five clutch friction discs, and clutch pressure plate are esSentially a single unit through triclion exerted by the clutch springr rotation of the crankshaft is trms< mitted to transmi on system Inside the router clutch, the primwy driven gem. (Refer to Fig. 3.58) When the clutch lever is gripped, the clutch 0d iuster rotates clockwise, the adjustment thread is pushed out by the sqta'e-hedded thread in the clutch adjuster fitted to the left crankcase cover ; this is pushed out by the clutch ioint through the clutch rod The clutch spring is compressed and the five clutch friction discs and live clutch plates become disengaged. Hence, the rotary motion of five outer clutches and live clutch discs is not trmsmitted to the clutch center. (Refer to Fig. 3.55 and 59) Figs 3.57 Clutch installed Icomplete vehicle] CLUTCH OUTER CLU'ICH mu: m CLUCH CENTER rnzssunz rm: L—‘ crurcn smNG CLUTCH LIFTER , j .rolm PIECE s e , 1‘ . l FllC'iloN DISC fig. 158 Sectional view of clutch CLU'ICH Autumn Fig, 3.59 Sectional View of clutch adiustmnnl thread 26 3. ENGINE Fig. 3..“ Removing ovrer clutch and pump body Hg. 3. oz Inspecting dittortton ot clutch plate rig. 3.63 Measuring thickness of clutch trtction disc I. Disassembly 1. Remove the right crankcase cover. 2. By removing the foot 6> , Fig. 3. I30 chk starter kick srnrsx SFINDLE BUSHING , p— t. _# KICK sukrrk SPRING ’ «z KICK srAnrsk PINNION SETTING smNa KICK srAann PINNION Fig. 3.1:” Kick starter assembly figs 1132 Assembling kick starter spring 8. Assemble the crankshaft with transmission gears in the upper case and tighten the lower crankcase. 9. Hence, assembly can be made according to the assembly order of the crankshaft (CHECK THE FOILOWING) - Bent gear shift - Uneven wear shift guide pin - Wear and play of shift guide roller - Fatigue of gear shift spindle return spring - Tightness of return spring pin 3.12 Kick starter As Operation of kick starter As shovm in Fig. 3. ISO and 3, 13], the starter uses a pinion ratchet system which engages the pinion with the gear and drives through the kick starter ratchet. (Refer to Fig. 3.130 and 3.131) When the foot is released from the kick starter, the kick stater ratchet returns by the force of the kick starter pinion set spring and is stopped by the kick starter spindle bushing; the pinion rotates regardless of the kick starter spindle. I. Disassembly and assembly It When the upper and the lower crankcase are sepaated by following the disassembly order of the transmission, the kick starter spindle is exposed. 2‘ At assenhling, especially of the kick starter spring. operation ls easily performed if reference is made to the figure (Refer to Fig. 3.132) 3V is CARBURETOR A7 Fist 3.”: Sectional view ol carburetor A. Description of carburetor I. Main sysreni Air from the air cleaner is led irom the intake through the throttle valve and main bore, and is sucked into me engine. By this air flow, a negative pressure is produced at the needle iel and the fuel of the float chamber passes through the main iet and enters the needle iet holder. It then passes through the air iet and is mixed with the air entering through the hole around the needle let holder, passing through the clearance between the needle jet and the needle, and under the throttle valve, Here it is mixed with the air and turned into vapor for engine intake. (Refer in Fig. 3.134) 2. Slow speed system (Pilot system) The air irom the intake passes outside the air screw; it is aaiusied by the air 5:!er Ir eniers the slow speed iet rrorri the hole of me slow speed iet and is mixed with fuel coming from the luel hole at the lower part of the slow speed [ell becoming a densely mixed gas. The mixture passes to the bottom ol the throttle valve and is mixed with the main air from the intake for engine intake, Adiustment oi the the mixture ratio of the slow speed sysiern is generally obtained by odiusting irre air screw ia heavy mixture by turning clockwise and a thin mixture by turning counter- clockwiseti when a wide range odiustrnenl is required, the slow speed iel should be changed, obtaining a heavy mixture by a larger number and a thin mixture by a smaller number. (Refer to Fig. 3.135) wwrrLE VALVE NEEDLE cur PLATE NEEDLE cup iEr NEEDLE r _ iROATCNANIEI WASHER FLOAT vvas NEEDLE JET NEEDLE iEr HOLDER no" HAlN rET Fig. 3.1“ Main xyxtem Fig 3. Us Slow mead sysiem 4! ELoAr VALVE VALVE sEAr FKOAT Am PIN ELoAr Fin. 3.136 Float chamber . :t. ”7 Choke L . Fig. 1m Main [ei ll ll 1E1 NEEDLE NEEDLE lEr NEEDLE in HoLoEA FLOAr VALVE VALVE SEAT FLOAT Am PIN FLOAT Fig. 3.13? Needle iet ENGINE 3. Float chamber As previously stated the carburetor produces mixed gas mitable by opening aid closing the throttle for all speeds of the engine. Hence, it is necessary to keep the Tuel level constalt; the float chamber plays this role. Fuel fed from the tank passes through the passage between valve and enters the float chalrber. The float becomes buoyant as fuel enters and pushes up the Valve through the float arm; when the Valve contacts the valve seat. the flow of fuel stops. When the level decreases die to consumption of fuel. the float drops corresponding to the change and the valve opens for allowing fuel to enter the float chamber. By repeating this operation, the fuel level is held constant. (Refer to Fig. 3.136) A. Choke As shown in the figure, the choke Valve closes at the position where the choke lever is pushed up and opens at the position where the choke lever is lowered. (Refer to Fig. 3. l37) B. Operation of component parts I. Main iet The main purpose of this unit allows adiustmentof the mixture ratio by controlling the flow of fuel with the throttle fully opened. However, the iet influences the mixture ratio] not only at full throttle, but also at other points. (Refer to Fig. 3. I38) 2. Air iet For insuring that the mixed gas does not become excessively heavy at fully throttle and high speed, and that it does not become excessively thin at redu- ced throttle and low speed, bleeding air is fed into the needle iet holder. The air jet controls this amount of air. At a oertain throttlle openiru, a larger air iet produces a smaller difference of fuel flow between high and low speed; the flow decreases. 3. Needle iet This unit reodillsts the adiusted fuel by the main iet at full throttle and medium speed. Adiuslment is simultaneously performed with that of the needle iet. The hole diameter is highly precise (Refer to Fig. 3.139) 3. 13 CARBURHOR 4. Jet needle ‘ ' H , , w The tet needle, with the needle tel, adlusts the mixture ratio at mid-throttle. The [at needle with c 1 long taper section is float fitted at the Center hole of the throttle valve and the taper at the tip enters the needle jet. According to the position at the throttle valve. the flow amount fuel is increased or decreased through the taper and a suitable flow amount [a suitable mixture] is obtained, The jet needle has live grooves for positionirga Lowering the posi- tion from the first step to the filth, density at the ., mixture becomes heavier. (Refer to Fig. 3.140) 5. Throttle valve The throttle valve adiusts the air fed to the engine tar setting speed and output. in addition, it also odiusts the mixture. There is a cutaway at the air intake side of the throttle valve and by changing the size of the cutaway [number] the negative pressure is dwnged the fuel flow and mixture ratio is changed However, the cutaway range covers mainly tron. idling to around 1/4 throttle, with little influence above l/2 throttlet (Refer to Fig. 3.1“) Fin. 1M0 Jet needle fiat :t. in Throttle valve 6. Slow speed iet The slow speed iet controls the fuel flow at idling and low throttle, and prochtces cl mixture with the air coming from the air breedirg hole ; it vaporizes the fuel. (Refer to Fig. 3.142) Figa 3.142 slow speed iet 7. Air screw The air screw controls the air flow entering the slow speed system By adjusting air mixed in fuel coming from the slow speed iet, it prowees a proper mixture and eiects the mixture from the tip of the slow speed iet. (Refer to Fig. 3.143) Fig. 3.14:! Atr s=rew so a, ENGINE cl Adiustment t. Adiustment at high speed In the range from full throttle to 1/2 throttle, ad iustrrlent ot the mixture ratio is made by the main iet. (Reter to Fig. 3.144) Determinatio‘r at mixture density is obtained by the tollowing methods. a. At luel throttle, it the speed is redlced by slightly closing the choke, the mixed gas is too thin. In such case, the main iet should be replaced with cl larger one and 0 condition check made. b. It speed is redlced by closing the choke, the main jet is suitable or is too large. Determination is made by the tallowing methods. Hi When the main iet is suitable: When 0 smaller main iet is employed and speed decreases. and when the choke is slightly closed and speed in- creases, the new main iet [smaller one) is too small. Hence, the original one is suitable. [2i When the main iet is too large: Gradually r u mull" “W“ ‘ ' smaller main iets should be employed in replace- ment until the status described in section (it results. 2. Adiustrnent at mid-throttle Adiustment of the mixture in a range from 1/5 to 1/2 throttle is mainly obtained by the iet needle steps md the cutaway ot the throttle valve. However, as the cutway ol the throttle valve influences the range below l/B throttle misadiustment is apt to occur. For medium speed adiustment, as long as ocoelero— tion characteristics are maintained, employment ot a smaller jet needle is more practical. (Refer to Fig. @YKROTTLE STOP scrisw 3' ”5) ‘3’““9‘5‘” a. Jet needle @CHOKEVALVE (it if donorrrral black smoke is elected drring operation at medium speed, the mixture is too heavy: the fat needle should be pulled up one step. (2| During engine braking after accelerating or cruising when the engine sounds rough the fer needle clip should be lowered by one step. b. Cutaway of throttle valve When the throttle cutaway with a larger number is employed, the mixture becomes thinner and vice versa. The throttle vavle covers not only medium speed, but also low speed in the range or udiusl~ merit: taken while adiusting. lit Except ror special cases such as racing, rep‘ lacement ot the cutaway is not required 3.13 CARBURETDR 3. Adiustment at law speed The mixture covers the range from 1/8 throttle to idling. Adiustment is made by the air screw cutaway and the throttle valve. (Refer tn Fig. 3. I46] a. Air screw Adiustment of the mixture at idling is made by the air screw. it the screw is turned clockwise. the mixture becomes heavier; it the screw is turned counter-clockwise, the mixture becomes thinnert However, the adiustment or the air screw should be made with attention directed not only to idling but also to starting and acceleration Also observe running performance in relation to density at the mixture at the point where ltle throttly open b. Throttle valve cutaway Near l/a throttle the density of the mixture sometimes cannot be compensated by only the air screws In such case, it the mixture is too heavy, a valve with a large cutaway number should be employed (or vice versali Thus adiustment ot the air screw is obtained . in CB 125 and 160, replacement of the screw valve is not required since the cutaway is com pletely adjusted, A. Adjustment of standard fuel level As shown in Fig 3. I45. the fuel level is esta- blished at height (ll) from the main bore bottom; it is diflerent for every engine. It is rather difficult to measure the actual fuel level. Hence, this is delerrtllned by the float heighli Ad- iustment ol float. (Refer to Fig. 3.147) a. The carburetor should be turned upside down md slid horilontally. b. By pushing the float vertically md lightly with the tip of a finger, find the position where the tip of the float valve and the float arrn Contact slightly. c. The difierence between the height of the tip of the float and that of the carburetor body is equal to h, it this height is not ucceptdfle, adjustment should be obtained by carefully bending the float armt h of N22 i9.5 mm (78'! 5t rig. 3i I47 Measuring standard luel level 52 3. rig. 1m ENGINE (CAUTION) The spring se’ or she Hp of he float valve is depressed easily imo the valve by pushing. This obscuves the position where )he valve essentially closes. Hence, careful anemion should be paid when observing the content! poim of )he float arm and rhe flea! valve. 5. Adiuslment of the throflle opening of flue righ! and Is" carburelors Two carburlors are employed. The adiusments of bolh mus? be me same, Adiusvmen' should be made a. a poim somewhul above full close [fippvoximmely 1mm). Hence, we openmgs of both he vighr and left carburetor bemme 'he some. Adiustmenl‘ should be obioined, after Ohe ourburelor is removed from me engine, Wm. me slow speed fie! screws on Me righv and left sides. (Refer to Fig. 4. MB) IV FRAME 4. I Handlebar A. Construction of handlebar The complete handlebar is made of pipe and is insl‘ulled on the from fork 10p bridge by (he plpe holder, The lork lop bridge is mounled on ihe from cushion by lwo from fork bolts. ln adilion, every wire unir is exposed for making handlebar replacement easy. (Refer Io Fig. 4.1) s. Disassembly 1. Tools recwlred for cflsussembly and assembly of l‘he handlebar. (Refer m Fig. 4.2) 3" For disassembling the from brake cable, lurn me front brake arm coumerclockwise lwhere l‘he brake is efiecl‘ive), and remove l‘he end or the cable. (Refer fo Fig. 4.3) 3. For disassembling (he clutch cable. loosen the lhree small cross pain! screws of the drive chain cover and remove the end of the cable lrom (he clulch udiuslmen' thread. 9 For disassembling (he Ihroll‘le cable. loosen and remove the carburelor cap: lhe lhronle valve can be pulled oul. Remove lhe cable end from the rhrorrle valve. (Refer la Fig. 4.4) smoon TER ASSEMBLY - . HANDLE BAR HANDLE BAR HOLDER V Fig. 1.; Removing ochre end Iron: Ihe lhroMll valve g. 4.3 Adiuslmenl or broke cable play A. FRAME 5. For disassembling lead wires of the horn and dimmer, remove the head lamp asselrbly and dis connect the connector, with the wire homes; in the lamp case. 6. Remove the clip under the steering stem and the steering damper knab, When tour 8X32 hex bolts are loosened and the handlebar holder is removed. the complete handlebar (:01 be removed from the fork top bridge. Then remove the wires togeer with It. (Refer to Fig. 4.5) N 57“ For disassembling the clutch cable and broke cable lrom the handlebar, loosen the clutch cable adiuster and remove it lrom the handlebar lever. Also remove the cable lrom the handle lever. (Refer to Fig. 4. a) 9. For disassembling the throttle cable. loosen the 5x l4 and 5x22 small cross-point screws and remove the flasher switch case; remove the wire from the handlebar grip. C. Inspection I. inspect condition and operation of the throttle cable, clutch cable, and inner and outer cable ot the front brake. 2. Inspect the operation of the throttle grip. 3, Inspect the operation of the hmdlebar lever. 4. Inspect the handlebar tor straightness, D. Assembly l. Install the throttle cable, clutch cable, and front brake cdnle on the throttle 'grip and hand levers. 2. Pass every cable and lead wire through the handlebar holder by 8X32 hex bolt. 3. Install the steering damper knob. 4, Connect all cable ends to the front brake Clrlflt throttle valve, and clutch odiustment thread. 5. Alter installation, adiust the plw of each cable. (Refer to Fig. 4.7 and 4.9) Throttle cable [twist grip angle] 9 to lo degrees Front broke cable (lever end) 30 to 10mm ”.17” to .39'] Clutch cable [lever end) 20 to 30mm (78' to l. l7'l 4.2 CONSYRUCYKON or PRONT cusHlON 6. Clamp coupling of all lead wires (Refer to Fig. 4. 10) (CAUYION) When all wires are placed in the designed posilions, ihe handlebar should be free '0 mm 10 he right or left. When lhs handlebar is inslclled. rhe wire should nor be clamped by ii. 4.2 Construclion of front cushion A. Dexrip'ion The from cushion and rear cushion should nol be separated, The slums of this suspension and damping device gives direcr influence lo the sleering perfor- mance and stability of lhe vehicle. The lronl fork, in addirion lo damping veriiozil vflnrolion ol the from wheel, should mainlain Slrenglh during opernlion, sup- poning lhe from wheel and enabling Sieeringi The horn cushion spring employs ihe spring with Uneven piich, The oil shock absorber contains 170 cc L04 US 90L, .037Imp.gal.l of No. 3 operation oil lldemiisu Kosanl and iis maximum stroke is 94 mm (3.76”). (Refer to Fig. 4.“) rig, 4.1a Lead wire clamp 55 FORK DlAlN COCK PACKING FRONI roux son now roux ll! non roux on 3m RElAINER f0“ my; FIONI mm mm mm roux wrrom com Huron on :m swim mm ' ‘ - non roux Do i 3w comm: FR r rank 7 “ON PW um com 1 EM Bulimia; Roux PlSiON SNAP RING ' FORK PIPE “Lu FIONl roar mu nouns WW“ ”mm 51“" \ now runs filom'flg’m 0-HNG "ch SHOCK “$073“ SPllNG HWY FORK m GUM NONI FORK PleON IONT fCflK 1°? FUDGE JIX3OJ1NG FRONT DAMPER VAlVE Fig. A." Disassembling ol lreni cusnion B. Disassembly ls Tools required for disassembly and assembly of the from cushion. (Refer 00 Fig. 4.12) 2‘ Remove lhe handlebar according to Seclion 4.] B. Fig. 4, I2 reels med of dixmsemblv and assembly oi Irenr :ushian 56 mo 4.” Removing front wheel Fin. 4. l5 Removing speadomerer 4. FRAME P 5. 6‘ 7. 3. Loosen lhe speedometer cable cap and remove n from the gear box. (cwrrou) A: disassembly of ]he speedomeler, insure moi, when yhe cap is loosened and removed, yhe inner porlion is nor dropped. When only yhe wheel is removed, lhe gear box can be removed as lined I‘o 'he speedome'er cable. When a proper bench is placed Under I‘he engine, l‘he from brake l‘orque boll is removed, I‘he 3X28 spring colrer pin is srroiglened and removed, lhe from wheel axle nul‘ is loosened, and the from Wheel axle is pulled on]; lhe ironl wheel can be removed. (Refer Io Fig. 4. l3) Loosen four 8X10 hex bolls and remove the from fender. (Refer to Fig. 4.14) Remove yhe head lamp rim] rhe head lamp sealed beam unit. and two 5 mm hex nuts; remove the speedometer ossenbly‘ (Refer to Fig. 4.15) Loosen l‘wo 8X20 hex bolls and remove the head lump bodyl 4.1 CONSTRUCTION OF FRONT CUSHiON 57 8. Loosen the steering head stem nut. (Refer to Fig. 4. ‘6) 9. Loosen two front fork bolts and remove the top bridge and the front fork upper cover. 10. Loosen two 8X32 hex bolts and remove the» front cushion in a downward direction. (Refer to Fig. 4. ‘7) ll. Loosen the front fork seal housing and remove the front bottom case. Remove the front cushion spring as well as the oil in the bottom case. I2. Disassemble the front pipe limit ring, front fork piston, and front djsorber valve from the front fork pipe (completel. (Refer to Fig‘ 3. l3) C. Inspection 1. Measurement of the front cushion spring. simmc DAMPER was SYfENNG srsn NUT g Hm mew W m @mnvu run: A E yFRlCYlON DISC Vow?“ runs a Vomm smut: mcnoN mare. e/Nin 2. Measurement of the outside diameter and bend of the front fork pipe. Standard value Correction limit 31.5 to 32.0 mm 11.25' ta 1.28’t Outside diameter Oval Maw 11.: Taper Below 0.2 neneetian Below 0.2 3. Measurement of the front fodr piston Stmdfird value Correction limit 31.450 ta 35A75mm Outside diameter ll.4'I 11.41’l Oval Below 0.02 Taper Below 0.02 standard value Cl?'!e<"°" rmrt Permanent Installer. delermatian ttan gangrene”: NS! period Loud gifij Fig. 4.16 Sectional View at stealing 311.5 Height 21): 1.2 kg 29m mm 3:132?ng (Nib: 61M 111.s't - 40: ”9 tea nit“ 1171 70:4.2 ig ll54lhi91lhl rree mu ta 4119.3 length 11.5.29' ta 16,37'1 Depres- , sian Below 0.5 [.017 ) Fig. 4.17 Removing front cushion downward Fig. A. is Removing pislon 58 A, FRAME Slarldavd valuo Conection lintit filial ‘v'tQULW‘ ‘ 35 5 35 539 t . . to . nnn l ggg‘rfiau“ W Outer diameter [l_l') w ”12”) v t {V Ml! . l IA 1mm ‘ Oval Below 0.2 Tapev Below 0.2 D. Assembly 1. Couple the front absorber valve and front fork piston and install it on the front fork pipe loome plate) by the front pipe limit ring. (Refer to Fig. A. 20) 2. Apply 170 cc of No. 3 operation oil lldemitsu lawn with WM thwmhr Kosanl in the from fork bottom case. 1‘- w: writs NT 3* “WW? M sW‘FV Mfi’t'll ‘ 3. Put the front cushion spring with the shorter pitch in the bottom case and insert the front fork pipe (complete). Tighten the front fork seal housing. (Refer to Fig. 4.2l) 4. Alter the coupling ol the lront cushion is finished, insert it in the designated position of the steering stern together with the lront fork lower cover. Tighten by the 8x32 hex bolt. (Refer to Fig. 4.21) 5. Secure the front fo'l'ktlop‘ bridge. “9"" ““9““? °‘ "°""“""‘°" 6. Following Section MD, install the complete handlebqv on the front fork. 7. install the head lump body and install the sealed beam unit on the body. 3. install the iront fender. 9. install the front wheel on the tront cushion and odiust the brake. io. Adtust the throttle md the clutch cubies. airways: Mil! smesg mm 4‘“ 44.22 0.3 STEERING STEM AND 4.3 Steering stem and hand|ebar lock A. Construction of the steering stem The steering stem is supported by 8X32 hex bolts on the front Cushion. The stem, with the cone race inside, is an important unit for steeing since it is a rotation axis with the frame head pipe as the centers To the steering stem, the steering absorber is installed allowing for adiustrnent according to the status of road operation, and load. When the steering absorber knob is turned clock~ wise, the steering absorber spring nut goes up and the steering absorber plate A and B tighten the steering absorber friction disc: handlebar operation becomes stifi. It the steering absorber knob is turned counter- clockwise, the steering darrper spring nut comes down, producing gaps between the steering plate A, steering absorber plate B, and the friction disc; handlebar operation becomes tree. The handlebar lock consists of the support unit which is a single unit consisting of the steering arm and the steering stem. 3. Disouentbty 1. Tools required tor disassetnbly and osserrtsly oi the steering stern and handlebar lock (lteter to Fig. 4.24) 2, Following Section 4.1 B, separate the handlebar. 3. Following Section 4.2 B, separate the front cushion. Loosen the steering head top thread (complete) by spanner arid remove the steering stein in a downward direction. (Refer to Fig. 4. 25) 5. When the 3X8 small cross-point screw is re- moved, the cap of the handlebar lock can be P separated. when the engine key is inserted and turned counterclockwise, the lock piston is separated from the steering stem (CAUUON) When the steering stem is removed, care should be taken so that the 1/4 steel balls are not dropped or leslt HANDLEEAR [DU 57 STEERlNG nmm KNOB SYEEIKNG STEM Nu’r SYEEKING HEAD 10? mum) rorcoNE RACE y F Qumran rm: A vFRICYION Disc Vnmm you: a Vomm smut. FnlcrIoNnmrEtl 3/wr Fig. 4.2: Sectional View or steering Fig. 4.21 roots qull'led lor disassembiy and assembly of steering rtern and handlebar lock tg. L25 Initiating steering sternrn downward direct it 60 t. NAME C. Inspection l. Inspect the 36 l/4 steel balls for damage and wear. 1. Inspect the contact surface of the steering top cone or race and steering bottom cone race for soars, wear, and scratches. 3. Inspect the steering head dust seal for wear aid breakage. 4. Measurement ot bendlng and twisting ot the steering stem. (Refer to Fig. 4.26) Standard value Correction limit Below 0.05 “5"” mm W] Twist 5. Measurement of steering absorber friction disc. 6r Inspection of other threaded sections for damage, breakage, and deformation. 7. Inspection ol handlebar lock return spring. D. Assembly . 1. Mount the handlebar lock on the steering stem. f 4 27 Fuel tank . 2. Insert the l/4 steel balls into the ball race by Using grease and insert the steering stem from the bottom. Insert the top cone race and tighten the head top thread [complete]. (CAUTION) a. When the steering stem is being inserted by using new grease, insure that the steel balls are not dropped. b. Special experienee‘and skill is required tor tightening the head top thread (complete). ». ' » * When the steerirg stem is slightly tightened Fig. 4.29 Tools requlred lor drsasserrrhly and assembly and the "on, wsim' fend”, and wheel are °‘ ’“e' '““k installed, the tort tap bridge is tightened by the front fork bolt and head stem nut. The top thread is fully returned md the stem should be tightened to the extent that there is no play, but is not stilt. The weight of the steering stem should be such that, when the front wheel is suspended in air, the wheel falls by its Own weight when a slight force is exerted When the front wheel is moved forward, backward. laterally, and vertically, there should be no play . at the race section. Fig. 4.29 hosition cack letter at 510? and renters 3- 1'15”” the “0'" 015““ and mm wheel. tubes, A and B hunt the carburetm 4. Install the handlebar. 4.4 FUELTANK 4. 4 Fuel tank A. Construction bf fuel tank The fuel tank is placed on the frame body lrrr mea'lately above the engine and is installed on the frame body through the fuel tank cusion. The knee grip rubber. as well as the tank mark, fitted with the tank side cover, are installed on the fuel tank. The knee grip rubber can be gripped by the knees during operation. (Refer to Fig. 4.27) a. Discssembly 1. Tools required for disoembly and assembly or the fuel tank, (Refer to Fig. 4.23) 2. Loosen the seat setting bolt and remove it. 3. Place the lever of the fuel cock STOP and remove fuel lines A and B from the oarhtretor. (Refer to Fig‘ 4.29) 4. Loosen the 6mm hex nut and remove the fuel tank rear brace: then the tank may be removed. 5. Set the hose clip at one end of the reserve line and extract it backward with care. (Refer to Fig. 4. 30) 6. When the tank side cover is removed, the hex bolt is loosened, and the side cover is moved backward, the side cover can be removed. Fig. 4.30 Remeve the «out ky using me Lose clip '7 5| b2 4. FRAME 7. By loosening the joint nut, the cock assembly is separated lrom the tank. (Refer to Fig. 4.3l) . B. When the fuel strainer cop packing and the tuel strainer screen are removed, along with two 6X 24 small cross point screws, the fuel cock body is separated from the fuel tank (complete). (Refer to Fig. 4‘32) figs 4. 3t Removing ol lual cock C. Inspection 1. Inspection of gas leakage at fuel tank. (CAUTION) Generally, a water pressure test is made. How- . ever, high pressure may damage the lighl Contact section. 2. Inspection of blocking ol the fuel fillew cup hole. 3. Inspection of futique and breakage of the front and rear cushion rubbers Al Inspection of fatigue and breakage of the cock valve packing A, and strainer cop packing, and filler cap packing. 5. inspection of aging and breakage of fuel lines A and B and the reserve line. D. Assembly 1. Install the cock assembly. . 2. Install the side cover, (Refer to Fig. 4.33) (CAUTION) Ar 33 Installmg side cove! As the side cover is hooked to the tank body at Its rear section and is secured by the inner side of the emblem, the designated 6X ID 6mm bolt ”’ElTANK sh ldbe d Rf F' 334 SIDE COVER 6X8 HEX son 0“ "59 ~ l 9 9" '° '9~ - l , FUEL I‘ANK Fly. 4.94 Sectional view or side covet relaining screw ‘ ’ l. 5 FRAME flour 3. Fit the front aid rear cushions to the frame body. The front cushion should be inserted by pushing the fuel tank from the rears The nut of the rear brace should be tightened for securing the cushion. (Refer to Fig. 4. 35) 4. Fit the fuel line: A and B and the reserve line and secure them by the dips. 5. Fit the seat and tighten it with the seat mounting butt. 4. 5 Frame body A. Construction of frame body As the frame supports the engine and contacts the grand through the tront and rear wheeis, it is all- impartant. In addition, it is an important element in determining the design. The main function of the frame is maintaining strength of the body for sup- porting the engine, passengers, and carrier load. Another function allows for absorbing shocks through the wheels. Sufficient rigidity is required for steering performance and lightness weight is desired for run— ning perfannmce. Fig. 4.35 Pushing fuel tank tram the rear side mm IDHOM Pm: IEF! aorrom Furs menus mm my: Fig. 4. 39 Driving n ha IerCe 4 FRAME B. Disassembly 1. Tools required (or disassembly and assembly of the trame. (Refer to Fig. 4.36) 2. Following Section 3.1 B. separate the engine from the frame. 3. Following Section 4.1 B, separate the handlebar. 4. Following Section 4.2 B. separate the front cushion. 5. Following Section 4.3 B, separate the steering stem. 6. Following Section 4.4 B, separate the seat and the fuel tank. 7. Following Section 4.135, separate the rear wheel. 8. Following Section 4.1 1 B. separate the rear cushion. 9. Following Section 4.12 B, separate the rear fork and rear fender. 10. Following Section 4.9 B. separate the air cleaner, and tool box. 11. Remove the electrical parts from the frame body. 12. Following Section 4.7 B, (when the stand is re- moved] disassembly of the trame is completed. (Refer to Fig. 4. 37) C. Inspection l. Measurement of the stern head bushing bore. Standard valuo Correction limit 13.95 to 14.010 Eu" L56" to 55.0w 2. Inspection of t'ldxing at welded section and pipe breakage and damage. 3. Inspection at angles and deformation of stem head 4. Inspection of the top ball race and bottom 'ball race for scars, wear. and scratches. (CAUTION) The interference of the ball race with the stem head is approximately 0.01 to 0.05 mm (.00039' to .0019”), and can be removed by lightly driving from the inner side with a wooden patch applied. When the ball race is driven in, it should be done so that the ball race is not atllt. Drive to the bottom evenly. (Refer to Fig. 4.33 and 4.39) 5. Inspection at trame coating. «6 AIR CLEANER CASE AND SEAT 65 D. Assembly Assembly is ihe reverse order oi disassembly 4.6 Air cleaner case and seal A Construction of air cleaner case and seal The air cleaner case is a slamped melal plcle arid prolecls lhe air cleaner, an imporlanl in conslruclion of ihe vehicle. (Refer Io Fig. 4.40) A double seal is employed, lhe ironi seclion hooked lo lhe frame aid the rear section bolled lo lhe frame. The cushion consisls of coil springs verlically placed sponge placed on lhe springs, Old lealher wrapping. Ai ihe cenier, lhe hand grip is filled wilh lealher. (Refer to Figs 4.4l) B. Disassembly 1. Tools required lor disassembly and assembly of lhe air cleaner case and seat. (Refer to Fig. 4. 42) 2. By removing lhe 6mm hex boll, lhe case is removed from lhe frame body. (CAUTION) When lhe air cleaner case is disassembled, as mere is a long hole cm on lhe Upper side of lhe case used lor hooking 10 lhe frame, il should be pushed up a llllle after the ml is removed. 3. Loosen 1he two 3X16 seal mounling bolls then separale lhe seal from ihe frame by pulling it backward. (Refer to Fig. 4.43) c. Inspeclian l. Inspecl lhe air cleaner case for defornlalion and cooling, 2. Inspecl lhe seat leather for wear. i Mews“ , , Air cleaner case Fig. 4‘ 4| Seal 10x14 OPEN . _ mpg) WRENCH m % FTYPE aox, WRENCH“ , Fig. L42 Tools requlred (or a sse or air cleaner case seal Fig. 4‘43 Seal monnllng boll ms 4‘ nnnmm - ‘ nAlerANu SYOP RUBBER Fla. 4. 45 Stand 5,; 1.47 Removlng stand FRAME D. Assembly 1. When the seat is fitted, alter confirmation of secure hooking at the ftont section, the Seatmountlng bolt should be tightened. (Refer to Fig. 4.44) 4. 7 STAND A. Construction of stand For teduclrlg weight, a bent pipe is employed tor the sttnd. The section which contacts the ground when lhe stand is erected has an oval plate fitted by welding for increasing the Contact area. At lhe left side of the stand, a but is fitted for making election easy. (Refer to Fig. 4.45) The step is mounted under lhe crankcase with tour at 8x25 hex bolts. B. Disassembly I. Tools required for disassembly and assembly ot the slancL (Refer to Fig. 4.46) 2. Following Section 3.] B when the single unit of the exhaust pipe and the mufl'ler is removed from the frame, the step which is secured to the mufiler can be removed 3, Remove the nut and loosen the adjuster. Sepatclte the bialie cable and the stop switch ling iron. the tear bide pedal. 4‘ Remove the 20X25 split cotter pins and washers on the rec brake spindle (complete). and sepaiale simultaneously the brdte cdale from the reclr brake cable mount and the rear bide pedal from the rear brake spindle 5. Place cl bench under the engine and loosen the 10mm hex nut; remove the stmd mounting bolt (ml the stand (Refer to Fig. 4.47) c. Inspection 1. Inspection of the stand spring Standard value At In nun/h 59,6]:9 (7” @ IJLI lbl At I58 mm/h SlJiflkg l6.3' @69.Dlht6.6lbl Qoiiaeiion limit Tanxion 4. B EXHAUSI PIPE AND MUFFLER a7 2 Measuremenl oi lhe oulside dameler of lhe stand mounling boll, Slandavd value Cnvraclinn limit Outside log} m5 2nd class diumeler by Jls 3s Meoswemenl‘ of the slmd mounling hole. Slmduvd value Correclion limll a 14.4 to 14.5mm ”9 L57’ «a .5a'l D. Assembly l. Tighien lhe main slmd wil‘h ihe 10mm boil and null 2. The rea brake cable assembly is lhe reverse of disassernbly. 3a Evenly righlen the muffler wilh four 8X25 hex bolis io lhe underside of the crankcase. (Refer to Fig. 4.43) 4.8 Exhaust pipe and mufller R PIPE GUIDEB END PlECE SE? '0'! l PIPE E are A INNER PI GuDEA Fig. 4. 49 Secliond view at mumer A. Consirudion of the exhaust pipe and muffler The exhausl pipe posses live exthJsl gas from the cylinder head lo the muffler; if benl, lhe horsepower is reduced. For exhousl gcs lbs passage is lhrollled in lhe rmfiler md noise is reduced. in addilion, noise is diffused by the diffuser pipe which also reduces noise. B. Disnssembly 1. Tools required for disassembly md assembly of lhe exlrmsl pipe and muffler. (Refer Io Fig. 4. 50) Fly. 4.50 Too: qulllred lar d xsembiy and unambiy ol me “my pipe and nwlllur so A. fRAME 2. Loosen the two exhaust pipe ioint nuts and remove them. 3. Loosen (our 3X25 hex bolts and remove the iootrest bur complete. 4. The muffler is secured together with the footrest. By loosening the 2 X58 hex bolts, the exhaust pipe and miner are separated as a unit from the trainee (Refer to Fig. 4.51) 5. The exhaust pipe and the mufiler are removed by twisting in the reverse direction. 6. By loosening the 6 X8 hex bolt, the diffuser pipe is removed from the muffler. (Refer to Fig. 4. 52) rte, 4.5l Muffler mew-ling halt C. Inspection I. Wash the difiuser pipe otter carbon is removed by brushing. (Refer to Fig. 4.54) 2. Inspection of cranks and damage of the muffler packing 3. Inspection of the exhaust pipe and muffler for scars and scratches. D. Assembly t. insert the exhaust pipe into the muffler. (Refer to Fig. 4. 55) 2, Lightly tighten the exhaust pipe icint nut and tighten the 8X25 and 12x53 hex bolts, (CAUTION) (a) If the exhwst pipe iaints nut is sufficiently tightene ed first. it cannot enter the mufi'ler hale. Hence, it should first be tightened lightly ; after the muffler is securely tightened, the joint nut should be tightened nrntty. (bl The dtlruser pipe can be installed either prior to or after the muFfler is installed. (ct Do not forget that the 12x58 footrest and 8X25 hex bolt are tightened together with the footrest bar (complete). rte, 4.52 Removing amuse. pipe rig 4.53 Remavina carbon with wire brush fig. 4.54 Cflflpllny exhaust e and mltfiler 4.9 All! CLEANER AND TOOL CASE 4.9 Air cleaner and foul case A. Construction of "I: air cleaner Flll‘er paper is employed in lhe air cleaner lar in- creasing the filler perlormance by enlarging lhe surlace area. As lwo ccrburelors are employed, air cleaners are employed on bolh lhe rlghl and lell sides. (Refer '0 Fig. 4.55) a. Disossembly 1. Tools required for disassembly and air cleaner and lool case. (Refer lo Fig. 4.56) 2. By removing lhe 6mm hex nul al llre bollom, lhe righl and Iell air cleaners are removed from lhe frame. 3. Remove lhe air cleaner comecling lube lrom lhe carburelor. 4. When lhe 6mm lool box mounllng boll, nul. and 6X12 hex boll are removed, lhe air cleaner can be removed from lhe frame. 5. Remove lhe air venl tube from air cleaner. 6. By removing the 6 mm hex nul and 6X70 hex boll. lhe lool box complele is separaled from the frame. (Refer lo Fig. 4,57) C. lnspeclion l. [Nsl‘ on lhe air cleaner can be elimincled by wiping. When lhe nller pcper is blocked, com» pressed air or gasoline should be employed. 2. lnspecllon of lorn or sloined filler paper. D. Assembly 1. Mounl lhe lool box (complete) on file frame and secure by 6 mm hex nul. 2. Mount the air clemer and secure by rhe 6 mm lool box mounting bolt, nul, md 6X l2 hex bolt. 3. lnserl lhe air venl lube inlo lhe air cleaner. 4, Inserl lhe air clemer connecling lube inlo llr; carburel‘or. 5. lnslcll the air cleaner case. l I fly. 4.55 All cleaner rlflz‘fl arm ENDED Minor w ”m my mew.” fig. 4. 55 Tools required of air cleaner laol case fig. 4. 57 Kamovmg laal box lrarn lar dlsussembly an frame 69 e where”. _.l d assembly 70 4. FRAME l7 mm 1 rm BOX WRENCH 25 ml LSPANNER H mm 1 we BOX WRENCH '9 X ’7 5mm” HXIUSPANNEE I0 mm 1 7er Box WRENCH‘ ,i...‘ ., 57 Tools required for disassembl at rear fork and rear fender g; rig. A. 61 Removing rear fork pivot bushing 4.10 Rear fork and rear fender A. Construction of the rear fork One end of the tear fork is fitted to a section of the frame and the other end is fitted to the frame through the rear cushion. When the rear wheel bounces, the section which is titted to the frame becomes the rotation axis ortd the rear wheel bounces in an arc. Influence on the chain is quite small. (Refer to Fig. 4.58) B. Disossembty I. Tools required for disossembly aid assembly of the rear fork and fender. (Refer to Fig. 4.59) 2. Following Section 4. I 3 B, separate the rear wheel. 3,‘ When two 6Xl0 hex bolts and one 6X12 hex bolt are removed, the chain case is removed from the frane, 4. Following Section 4.ll B, cushion. 5. When the IA mm self locking nut is removed and the rear fork pivot bolt is removed, the rear fork can be separated irom the frame. (Refer to Fig. 4. 60) 6. Remove the rear fork center collar and the rec! fork pivot bushing by light topping. (Refer to Fig. 4. 6|) 7. By loosening two 6X12 aid 12X18 hexbolts, the rear fender can be removed from the frame. (Refer to Fig. 4.62) 8. By removing the 8X20 hex bolt and rear fork pivot bolt, the footrest bracket can be removed. Disossetrbly of the rear fork is easily mode if the footrest bracket is removed. separate the rear C. Inspection 1. Measurement of the rear fork center oollor. Standard value Correction limit 19.972 to 19.99: mm (199' to .7w7'l am V1950 to 14.010 mm l,559’ to .560'I 47.3 to 47,4 ntnl 41.57' to 1.39m Outside diameter Overall length 2. Measurement of rear pivot bushing bore, Standard value Correction limit 20.05 to most mm 3°” (.502' to .503't 4.10 REAR FORK AND REAR FENDER 7! 3‘ Measurement of rear fork pivot bolt Standard value Correction limit Outside 11925 Io 13.958 mm dlameler L557” to .558'l Bend Below 0101 4. Measurement of twist of the rear lorkr (Refer to Fig. A. 63) standard value . Below 1 0.] ’W'“ Lolm'i l (CAUTION) Measurement should be made when the rear fork pivot bushing and the center collar are inserted into the rear forks 5. Inspect the rear lender and the drive chain case for stains and dents. 6. inspection of elongation of the drive chain should be made by the same method as {or same method as tor cam chain inspection I Correction limit D. Assembly 1. Install the reclr tenderr 2‘ Dere in the pivot bushing and the center collar, Insert the rear lorlr seal cap. 3. By inserting the pivot bolt through the side bracket, couple the rear fork and the lrarne. Tighten by the Hm lock nut, 4. Install the rear cuslon. 5, Install the reclr wheelr 6. Install the drive chain, 7. When the assembly is finished, adjust the rear brake pedal and tension of the chain, 8. Install the drive chain case, (Refer to Fig. A. 64) 9. Insert grease in the grease fitting. (Refer to Fig. 4‘65) Fly, 1462 Disassembly oi rear lender 'MCHET’KC '1' LFK' l rig. 4r.“ installetlon or chain can lg, £65 inserting gleam 72 I. ERAME 4.1] Rear cushion BUSHING REAR suocx ABSORBERRESPRP EHOCK ABOREERREAR SHOCK AssoRBsR MOP ”RING sEAt REAR SHOCK ABSOREER ' UB {figs Rwr REAR SHOCK ABSORBER REBOUND srowER SPRING QEREEEC‘WV‘ COMPlHE REAR smaL ABSORBER RCASE REAR SHOCK ABSCjRBER BoiroM JoiNr LL: SHOCK ABSORBER , neg... . AR SHOCK ABSORBER REAR HOCK 0°HEARKv SHOCK A UPPER CASE ABS LEV REAR SHOCK ABsoRBER tNNER tuBE BsoRB ER REAR SHOCK ABSORBER ”RING ADJUSTER sgggEgHOgS‘ R AR SHOCK ABSORBER PISION Nur REAR sHocR ABSORBER SPRING ABSORBER on sEAL ABSORBER PIST REAR SHOCK ABSORBER BorroM use fig. 4. 66 Rear cushion . its: mag} We. Warm-m i, r g. 4.6} ”Tools mm... for drsassemhly and assetrlbly or rear cushion A. Construction of the rear cushion The rear cushion consists of spring and double cylinder system oil shock dasor’aers. The compressirg load is absorbed by the spring and elongation is absorbed by shock absorber. The oil shock absorber contains 52 cc (.013 US ga|., .Ull lrnp gal.l of #60 white spindle oil is included. If this anounl is not suitable, reduced Olshion stroke, oil leakage, or noise occurs. Adiust- ment can be made in three sieps according to road md running conditions (Refer to Fig. 4.65) B. Disassembly 1. By loosening the 10mm remap mt (using 14x 17 doub|e~ended wrench] and the 3X23 rear cush- ion lower bolt, remove the rear cusion assembly. 2. Compress the rear cushion upper case, remove lhe rear cushion spring seat lim, pull out the upper case in m upward direction, and remove the rear wshion spring. C. Inspection I. Measurement of the rear cushion spring. I Standard value Correction limit rm length 194 mm (7 76'] 157.9 nun/h r5.12'/tn 50 k +3.6 [‘32 lb+8 ibl Tension 123. 9 tum/h I H) kg: 5.6 [242 lbi “,5 lb) 107.7mm/h l50kg:9.0 1:130 lh;l: l 9.3 lb) . Helaw 1.0 mm Right mgr. “339,1 Z lnspeclion of all leakage at the cushion absorber. 3. lnspeclion of breakage deformation of lhe rear cushion limit. 4. 12 fKONT WHEEL 7, D. Assembly 1. Couple the rear cushion spring and Upper case, push up the upper case, and install with the spring seat limit. (Refer to Fig. 4.68) (CAUTION) (cll When the sprlng seat limit is mounted, the upper ioint should be up‘ If it is not, mounting becomes very difficuIL (bl The rear cuslon spring has Uneven pitch and lnsrallation should be made with the small pitch facing down. fig. [.63 Cuupling rear cushion 3, Install the rear cushion assembly to the rear fork and frame by the 3X28 rear cushion bolt and 10 mm hex-cap nut. 4.12 Front wheel SPEEDOMETER CABLE FRONT BRAKE STOPPER \RM FRONT BRAKE SHOE Fig. 4.6? From wheel 74 4. Fig. 4.70 Tools required lor disassembly and assembly 0! the tront wheel Fig. 4.71 Fig. 4. 72 Measurement or deflection al rirn Measuring lrant axle bend FRAME A. Description of the front wheel The 6392K ball bearings and the aluminium cast fullwidth hub inside the brake drum, the brake panel. and the speedometer gear box are coupled by the front wheel axle and the front wheel axle nut. Return rotation force generated at the damping period is absorbed by the left hand axle through the limit arm of the brake panel. (Refer to Fig. 4.69) a. Disassembly 1. Place a suitable bench under the engine. 2. Remove the front brake wire. 3. Remove the speedometer ccble from the gear box assembly. 4. Loosen the front brake torque bolt and remove the front brake limit arm. 5. Straighten the 3X28 cotter pin and remove it from the front wheel axle. 6. Loosen the front wheel axle nut. When the front wheel axle is pulled out. the front wheel can be removed. (CAUTION) lnsure that. when the front wheel axle is re moved, the gear box is not dropped. 7. Remove the panel from the front wheel and loosen the 9x16 small crossApoint screws. Remove the bearing retainer, two 6302 R ball bearings, and the front axle spacing collar. 8. By removing two 2x25 cotter pins and the anchor pin mounting washer, remove the brake shoe from the panel. (Refer to Fig. 4.7!) 9. By separating the' tire and tube from the rim with the tire iron. pull out the tube. C. Inspection 1. Measurement of deflation and eccentricity of the rim. (Refer to Fig. 4.72) Standard valve Correction limit Within 0.5 mm (0.! ts’l sidewurd deflectian Eccentricity 2. Measuring outside diameter bend of the front axle. (Refer to Fig. 4.73) 4. l2 FRONT WHEEL 75 Standard value Correction limit Outside 14,957 to 14.954 mull diameter [.598’ to 599': Below um 53“ l.UDD4’t l 3 Measurement of the clearance in the axial and radial directions of the 6302K ball bearings. Standard value Correction limit Axial clearance Radial clearance 4. Measurement of brake shoe spring. Standard value Correction limit . an; at 54 mm mm” [17.6lh @ 2.56': 55 mm rm length ‘21,, 5. Measurement of the outside diameter and thick- ness of the front brake shoe. Standard value Curraciinn limit Outside r diam," 170 mm (5.6 l Thickness 6. Measurement of thickness of the front brake can. Standard value Correction limit Thickness 7. inspect and tighten my loose spoke; 8. Air leaks of the tube shwld be checked by sub merging the tube in water. 9. For tire wear or puncture._not only the outside but also the inside should be checked. 1). Assembly 1. The tune can be easily inserted by putting it inside the tire and applying a small amount of air. insert into the head unit in the rim. (Refer to Fig. 4.74) (CAUIION) (at when the tire is on the rim, apply air to 1/3 the designated pressure anal lightly strike around the tire with a woaden wallet in order to pre- vent the tube from being pinched (Refer to Fig. 4. 75) lb) The valve stem of the “be shouldbe placed pointing toward the axle. It not, air leakage occurs. (Refer to Fig. 4.76) Hut no Anglo or van. xlom 76 4‘ Fig. 4‘77 Insertion ol bearing am; {3315; Fig. 4.79 Angle 0! gear box inslullall’un Fig. 4.80 Play 0! hour brake lever ”(AME 2. Grease the 6302 R bclll bearing and the inside of the front wheel hub and insert ihe spacing collar. Drive in the 6302K ball bearing. (Refer to Fig, 4.77] (CAUTION) As the 6302R boll beurlng provides the dust seal, insure that correct use of the outside and inside exists. Tighten the front wheel bearing retalnen Hook the spring to the from brake shoe and install the two anchor plus and brake cams. Fit the unit to the front brake panel and tighten with me anchor pin mounting washer and 2x25 cotter pin. 5‘ Couple the pmel to the front wheel and the gear box to the bearing retainer side Secure them by the front wheel axle to the from fork (CAUTION) The gear box ioinl section should be in line with the axles of the front and rear wheels. If no), due to excessive bend, the speedometer cable may break, [Refer to Fig. 4. 78) :59” 6‘ Install the from brake limit arm on the front brake panel. 7. Connect the speedomeler cable to me gear box. 8. Connect the front brake cable to the brake arm and adiusr the play‘ For adiustment, loosen the nut in); if the udiusrer (bl is turned clockwise, the play increases clnd vice versa. The deslgluted play rmge§ from 30 (1.17”) to 40 mm (156”. (Refer to Fig. 4.7? and 4.80) 4.13 REAR WHEEL 77 REAR AXLE Fig. 4.31 Disassembling rear wheel 4.13 Rear wheel A. Descriplion of rear wheel The rear wheel consisls of lhe 6302 R ball bearing, aluminum casl‘ rear Wheel hub wilh brake drum, and Ihe bvuke panel. ll is equipped win. lhe single can rear brd£e panel Ihvough I‘he pavel side collar on lhe right side. Al lhe lefl side of lhe wheel hub, lhe hub and lhe final driven sprockel aye held with lhe sprockel mounting nut. This unit is mounted on lhe reclr fork lhrougll lhe rear side coller all 'he rear axle. [Refer ‘0 Fig. 4.81) a. Din-assembly 1. Tools required for disossembly and assembly of lhe rear Wheel. (Refer eo Fig. 4.92) 2. Followirg Seclion 4. 7 B, yemove llle rear brake cable. 3. By removirg lhe drive chain ioinl, separale lhe chain. (Refer 00 Fig. 4.83) 4. Loosen lhe rear brake panel limit ball. and yemove the rear brake limil arm from file panel. 5. Sivalghlen the 30x34 colrer pin and remove il from me axle. 6. Loosen lhe rear wheel axle nu! and extracl lhe rear Wheel axle. Fig. (.32 Tools required In: dimssemhly and assembly of veal wheel rig, 4.33 Removing drive chain 7B A. Fig. 4.87 Meaxuremem at rear wheel axle bend FRAME 7. Tilt and extract the rear wheel. (Refer to Fig. 4. 84] 8. Straighten the 8mm look washer and remove the 55 mm retainer. Loosen the thin 8mm nut aid remove the final driven sprocket. 9. Remove the oil seal internal retainer, two 6303 R ball bearings. and the rear axle spacing collers. 10. For disassembling the rear brake shoe, remove the brake arm complete from the panel. two 2,0X 25 cotter pin, the anchor pin mounting washer, and the brake shoe complete. (Refer to Fig. 4.85) it. By using the tire iron. remove the tire and tube. C. Inspection 1. Measurement of deflection and eccentricity of the rim. (Refer to Fig. 4. B7) Standard value Correction limit Sideward Within 0 5 mm deflection (.02’1 . Within 0.5 mm Eccentricity l.02"t 2. Measurement of the outside a'iameter bend of the rear wheel axle. (Refer to Fig. 4.87) Standard value Correction liniit Outside 16.957 to l6.984mm diameter (.57 to 63’] Band Eelaw 0,01 mum'l 3. Measurement of the tooth bottom diameter of the final driven sprocket. Standard value Corruttan limit “mm". 161.15 to 161.33mm a' [5.45' lo usa'fl tametev 4. Measurement of the axial and radal clearance of the 6303 R ball bearing. standard value Correction linrlt Axial clearance Radial clearance 5. Measurement of rear brake shoe spring. Standard value Correction iinit . lblrg at 154mm T'"“°" 13.521a @ 2,5’l Free length 5.5.4 mm l2.26'i 4. )3 REAR WHEEL 6. Measurement of can unit thickeness of rear brake cum. Slandard value Correction limit . 9.35 to 10.15 Thickness (39. ,0 “iv, 7. Outside diameter and thickness measurement of the rear brake shoe. (Refer to Fig. 4.88) Sianddrd vdive Corveclion limit Outer diameter 170 mm l6.6’l 4,5 to 4.8 mm rhrekness Us to w”) B. lnspect and tighten all loose spokes. 9. Inspect for air leakage by qaplying air to the tube and placing it in waler. 10. Inspect the inner and outer portion of tires for any abnomality. (Refer to Fig, 4.39) D. Assembly l. Place the inner tUbe belween the rim and the tire, and apply a small amount of air and l‘tx the bead section to lhe rim. (CAUTION) [at when the tire is coupled, apply 1/3 the amount of air designated, and lightly hit the tire with a wooden mallet to prevent inner tube protrusion. (bl The valve of lhe tube should point toward the axle. 2. Apply grease to ball bearing 6303 R, and the rear wheel hub. Insert the spacer and hit 6303 R ball bearing into position (Refer to Fig. 4.90) (CAU‘I’ION) As ball bearing 6303K employs ball bearing with dJst seat. check the difierence ot the external and inlemul sides. [Refer to Fig. 4.90) a. Atter the oil seal is installed, the sprocket retaining bolt should be inserted into the drive flange and the final driven sprocket tightened by lhe Bmm tongJed washer and arm thin nut. (Refer to Fig. 4.9” m. 4.39 rne inspsetion Fig. 4.90 Ball bearing poritioning Fig. 4.91 Tightening the final driven Sproclal 77 80 t. FRAME 4. Fix the spring to the rear brake shoe. and fit the anchor pin, and can to the shoe; install these parts to the brake pedal. Fit the 20x25 cotter pin. mchot pin setting washer and brake arm, and fix them with the 6X22 hex bolt. (Refer to Fig. 4. 92) iii t iii 5. The panel should be coupled to the rear wheel. and it should be contained In the trane and be tightened by the rear axle. However, the chain should be fitted, prior to this and set by the clip; tension of the chain should be odiusted by the dive chain odiusler. (NOTE) When chain tension is adjusted by the chain od- iuster, left chain odiuster and that of the rear fork should be set at the same position. in addition, slack of the dialn ranges from 10 to 20 mm. (.39 to ,73’) (Refer to Fig. 4.93) F .4.92 Rear brake coupling 6. Install the rear brake limit arm to the rear brake panel. 7. Install the rear brake wire to the brake clrrn. set the rear brake pmel on its side and adiust rear brake play. (Refer to Fig. 4.94) (NOTE) Rear brake pedd play ranges from 20 to 30 mm. [.73 to l.l7') rig. u: Rear brake pedal play /. 81 V ELECTRIC EQUIPMENT 5.l General of electrical parts The electrical system of a vehicle is of vital im— oprtancer If the ignition system, lamps, or alarm do not function properly. vehicle operation is Impaired. Hm 5.1 Mum Elem“, purl: w Hence. these parts require periodical maintenance and repair. The parts are mmuloclured and conform to JIS the Jcpanese land transportation vehicle law, safely and other standards designated by mmufacturerst Electrical parts of Model CB 125, atd CB 160 are divided as follows: l. Generator (AC Generated 2. Ignition (lG coil. contact bred cunmr '= r 2 WWW CURRENHA) i W lIV SYANDARD E 0 I: mm 2M) mflfl 4m) 5mm m» hm Lain LOVE ENGlNE msnlmm.) Fig‘ 5,9 Smirk yeriormance graph spsancmms Chunk/(Inflows- :anerrmown lm-inwn gun/mm limflrpml . Reunion and wold 2, warn... mm. m can.” a. Normal land Emery [Cop-rm m4 mm lunman zml {Om manner In on ”ark, o... (land angl- rm 5. Nighl rm In oddwnn m n. m... :wwxl muw x: m 5. Chgmy new, we... of dwylim- chum-w [below umrpmr ro mum, 7:05mnaru Begum-lg point a, "hm hm: charm Maw mourn n: mum, 2:0.Samperu. Day (ml: m“. Nugh (ml; m, Carmen: Brown mun. um grew in». "a and 7. Inning... r...“ nun "r" an: IV: ilmvld 0n: .4 in. mm lint of r». mm new. .ne clack Mxlerhlk A. Color (udl re. ulewlcnl Wing Fig, 5. ID Ignrrson :ail spazllicalion V... E: Fig 5. I2 Terminal uni) cuVering 34 5e ELECTRICAL PARTS C. Capacitor INSUIATING " The capacitor wroids generation of harmful sparks WE“ “ 3 between points. That is, when high voltage is gene- rated at the secondary coil of the ignition coil by I switching the points, additional voltage is generated l‘ O at the primary coil, (Self induction voltage). When l the primary current is disconnected, sel nduction ~voltages tends to continue current transmission (nd “35 cause sparks between points This results in burnt . paints. a reduction of secondary coil, week voltage Fig, 5.13 Capacitor consttuction ignition sparks, or causes tire. The capacitor absorbs stelfSOUND PRESSURE -—> QIRRENT Fig. 5. 92 Eelallun between voltage and current ELECTRICAL PARTS d. In case of improper contact (described in section El. confirmation of U-ring damage should be made. It is advisable to employ liquid sealer together with the Oarlng after cleaning the interior. 5.6 Safety parts A. Circuit For the circuit. refer to the section on electric distribution. (Fig. 5.39) E. Horn There are three types of electrical diaphragm horns, flat. spiral. and long pipe types, The principle is the some in each horn. In Model CB l25 and CB 160. the spiral type horn is employed, (Refer to Fig. 5. 91) Constmction and principle ol horn As shown in the Figure. ii the horn button switch- (5] is closed. current is led from terminal A to con- tact point B which excites electromagnel‘ C and D and comes out at terminal E. ThUS, it draws armature G and depresses insulator H by tripping contact point B and disconnecting at current C and D. Then. axis rod F to which G is installed is pushed up by plate spring P. and S closes again: current is fed ...... the operation mentioned above is then re- peated. As the result, diaphran P and resonator Q. which support F vibrate and generate sound Screw l adjusts volume. By turning the screw llhe position of J supporting the contact points is vertically changed: and the distance in which G moves is charged prior to the opening of contact point B. The amplitude of P aid Q is chmged and the sound volume is cont- rolled [Refer to Fig. 5.91) The spark suppressor at contact point B is not ettr ployed In the small type horns oi twowheel vehicles. The volmne of sound (sound pressure] does not change corresponding to current. shown in the figure on the left. Hence, even if the adiustment is per- formed in the direction in which the current ls irr creased. at a certain point. only current is increased' and sound quality is lessened, However. the volume of sound does not increase. Hence. It is desirdule to limit the volume and maintain a small current. When sufficient sound is generaled. proper adjustment has been performed when horn volume is natural, the current will match the stmdard value. (Refer to Fig. 5. 92) 5. 6 SAFETY PARTS 107 If the cover screw is loose, the sound quality of the horn is lessened. If the packing between the diaphragm end the cover is not replaced upon as- sembly, and if a section or the fitting leg is loose, sound quality is lessened. Hence, Upon disossembly and assembly, these loetors should be noted. (Refer to Fig. 5.93) o Tire sound ol the horn should meet us require ments, At a distance of two meters from the front oi the vehicle, the volume is from 85 to 115 phons and the current is less than that required ror on types or horns. Stendord frequency should be iron. 100 to 600 cycles ~c. rorl lump and stop lamp The tail and stop lamp are not designed as single bulbs but as cl composite bulbe Ratings of these are 12 V, 25/8 W. The tail lump rating is BW and the stop lump rating is 25 W. lnsure that the profile of the gloss section is convex and different from that of types (oval type) generally sold at service centers. The ovol type bulb can also be employed: however, deformation of the lamp cover occurs due to lens temperature or a short dis- tance from the covers If possible, these type lumps should not be employed (Refer to Figs 5. ?4 and 5. ?5) Tail lamp operation is performed by the lighting switch interlocked with the head Iam'p. The stop lanp is operated by the Stop Imlp switch. Operation of the stop lamp switch is described in molhel’ section. . D. Neutral pilot lamp The neutral pilot lamp indicates that the change position is neutral Hence when gear engagement is disconnected by mean of transmission, neutral is obtained and opetdtion of the lamp is not performed [Refer to Fig 5,96) Filament tor Stop Lump file»... «or run Lon. IO! 5. l‘ NEUTRAL um? SOCKET BULB mLo1 auu SOCKEI’ Fig. 5‘97 Componenls at me nevlml lump re-w. e—ehweem we .w, a.” ,, , l NEUTRAL swrrcn coma Mei” L i I NEUTRAL SWITCH STAYOR Fig. 5. 98 Neural swilch he. 5. loo Speedomaler scee ELECTRICAL MRI: The neuiral pilot lump employs a 12v, 3w bulb in addilian lo we speedomerer lamp. The switch socket Is connecled lhrough the cone necling poini of ihe sockel lo the IG lerminai of me combination swiich. In general lamp uniis, the socket body 9‘ ihe bulb is grounded. However, the pilot lamp sockel is insulaled by lhe rubber cap combined as a body and couplers The wire connecled lo the sockei is lead to lhe neulral swilch unii coupled at «he righi side of ihe upper crankcase and forms a ground cichii according ’0 switch selection. Therefore, insure ihal, if ”is sockel coniacis the frame, ihe bulb will Ilghi even if no! al‘ neulrul, (Refer In Fig. 5.97) The neulrul swilch is comecled io ihe Ierminal secl‘ion of ihe shifi drum al ihe righi side of me crankcase and performs inienuplion of ihe conl‘ocl poini in accordance lo ihe roralalion angle of rhe shill drum. (Refer lo Fig. 5.99) E speedomeier The speedomeler employs a magnelic needle sysrem speed gauge and whales corresponding lo lhe nUIrr ber of roialions of lhe wheel which are nonsmiiied ihrough the speedomeler cable 10 He speedomelevr (Refer Io Fig. 5‘99) - Maximum indicalion. ,160 km/h (99 mph.) - The speed indication [Driving axisl..,60km/h (36 mph.) or 1400 rpm The speedomelev poiniel employed in Model CB 125 and ca 160 indicates km/h and mph. (Refer to Fig. 5.100) 5. .5 Wm PARTS m9 Constmction oi the speedometer is shown in Fig. 5. 101. Mogtet rotation corresponds to the number of rotations of the imer cable The induction plate (constructed of aluminum or copper] moves together with the pointer; the magnetic shield plate is em- ployed for generating the lnog'tetic field which causes the rotating magnet to produce eddy currents at the induction plate It is moved by the rotation ioroe corresponding to the magnet by the eddy currents, atd the indication on the point ol the seal at which it balances the reaction force of the correctly ad» iusted hair Spring is root. when the vehicle stops (at the rotation gouge, operation stops], the pointer and the induction plate are returned to zero by force of the hair sprira (Refer to Fig. 5.10l) Gear box The gear box iscl sirgle unit with the front wheel hub cover and is installed at the right side of the item wheel hub. It drives the speedometer through the inner portion oi the speedometer cable. The gear ratio is designated so that, when the vehicle runs 1 km, the inner portion ol the Speedometer cable performs 1,400 relations The ratio should change according to tire size. (Refer to Fig. 5.102) - Speedometer for Model CB 125 and CB I60 Counter integration ...... at 1,400 rotation per 1 km In order to remove the speedometer assembly trom the body, after retrieving the head lamp, remove the ioinl of-the meter cable aid then remove the meter filling spring trom the speedometer bulb socket or coupling section - Inspection and asserrbly at When gloss is‘broken, the interior stained, or the pointet damaged, the meter should be replaced (Standard (or Operaling safety) - Speedometer error should be less than 15% posi- tive and 10% negative . Speedometer deflection should be below 3km. (L86 mi.) both in positive and negative directions. (CAUTION) a. instrument lump 12V, 3W. Z-eoch b. Do not strike or drop the speedometer when handling. tNoucrloN NiEDlE AXLE INSULATlON PLATE fig, 5‘ ID! Principle oi speedometer Fig. 5.102 Seat box icomplelei Speedometer Service Value: Dlolirm/tt In 4d 60 real loo lzu (Hut Tolerance +25 +3fl +35 +A5 +50 +55 +50 —0 70 —0 —0 —D —D —0 Fig. 5. m Replacement values tor xpeedometerrepuit Ho 5. ELECTRICAL PARTS fig, 5. I04 Head lam will” w A Dust SEAL REFLECTOR |ENS [st \\ U —Exrr£sszs MGR mm new mix ---'EXPIESS£S low FEAM IICH' FIUX fig 5. we Principle 0! the head lamp (light beaml VEtlttcAl sEcrIoN 0F LENS HotllzoNTAl sECTION of LENS nemcnou os VERIICAl BEAM Fig. 5.107 Principle or hand lamp (lensl F. Head lamp The head lullp is one oi the most impartalt items of equipment for safe night driving The following conditions should be considered carefully, [Refer to Figc 5. 104) l. The beam should be ol sufficient intensity and should distribute the light over a sufficiently wide area 2‘ The head lamp should be able to resist vibration arld shock, 3. it should be of dust and waterproof construction. 4. When passing oncoming traffic, it should not blind the other driver. Head larlp construction is classified by the tol- lowing types: I. Type in which disassernbly is possible. [Refer to Fig. 74 A) 2. Semi-sealed, [Refer to Fig. 5. 74 B) 3‘ Sealed. Reflector lens, and bulb determine the pertormatlce of the head lamp. All are equally importmli The reflector positions the bulb filament at the focus on the rotating parcbolic surface and the reflected beam is level. If the position of the filament does not match the locus when the bulb is fitted to the reflec tor, the intensity of the beam is greatly decreased The shape and size of the filament affects the light distribution. Specified bulbs should be used [or the head lamp. [Refer to Figs 5.l06) As shown in Figs 5.107. the cross-section of the headlamp is woveshaped and the lower part is thicker. The light is spread horizontally, and retract- ed downward to illuminate the road surface When the bulb is installed, the extensions in the base of the bulb should be inserted in the depression of the reflector rib. If this is not done, the center of the tillmlent does not match the focus of the reflector and ln a bulb with a double filment the diflerettce between high aid low beams is losti [Disassenbly and semi-sealed typel [Refer to Figs 5.107) \ 9 51 6 SAFE" PARTS Ill High beam Low beam Measured point Intensity ILX) Measured point Intensity ler H—V More than 100 207v More than 40 1/2 D—v ,, 200 1/2 U—Q R less than 25 1/211—3 L at? w 40 1/2 U—AR v 20 1/2 D—6 l 61? o 10 3 0—4 12 More than 20 1 Div «« 150 3 D—é R v 10 2 D—v u 50 1/2 v—z L Less than 25 3 Div ,, 25 1/2 V—4 L V 20 3 [17.5 L s R II 5 3 DAA L More than 20 rovv Less than 50 3 D~5 L N 10 Maximum value // 450 [Test Valtaga, 1&5 Vl To avoid blindin cnoncomi driver, a li ht reduc- urea BEAM '11; 111x. . . 9 r9 , g m ”Sig—fl“ “NE “1614mm Al 1mm rorwnn u1’E’rc‘rloN 11cm and directloncll change system ls used. In one HEADlchIarleNEss IAMP‘DIIAGE 115V NOIIIONIM 1114: . , _ Am m—-1»—11 AllA 11115111 type of |1ght reductlorl systems mother less powerful $33101 "ngpr bulb is Used and in the other, a smaller filament in ‘5 70 Is 1'00er . . - WN the same 11111: 1: used. war a double filament, the ”f :rggw . . ,. , - A u - 11 upper 15 usually swrtched 110111 the local posmon oi 1' “Fl ‘ “" raw’e‘é‘EM' ‘ “‘6 ‘ lumrluxl V . . Brllcumsss Al 1 ... IN mnwnn um en the reflector. Drflerent Irghr reduction can be mode 7 1a 1.; 1 1- 1 ryomer my by charging the size of the lilcment, HORIZON!“ 1le Ar . , l . . . . um 1mm To delermme Imenslty clnd 1Ilun11r1atron, a screen ls ‘5 w 30 2‘11ch . . m w r placed 10 meters 111 {real or the lighted head lamp H H my Tm, “p.11 11mm mm 1~11 >41 and the 119111 measured at every point on the screen, (Refer to rig. 5.1031 The headlamp capacity or Models CB lZs/CB 160 is 12v 30/3ow and the center intensity a1 illumination (High beam] is more than 230 luces 10 m. away. 1111; is sumaenr to comply with the law. Fig. 5‘ 108 inspection ol lamps distilhulion Automotive vehicle bulbs For automotive vehicle bulbs, c1 large wattage, tungsten filament is enclosed in a small glass tube. Although the bulb's life is shortened somewhat. better lumen-watt efficiency is sought for in design. JlS shows the life to be 100 hours. The varicnce in 119111 intensity and life at the lungs— ten bulb as caused by the charge of applied voltage, is quite wide, The light intenSily is increased or decreased by 35% with a charge of 10%, more or 1e55, in the voltage. The life is decreased to one‘ third with a voltage change at more 111m 10% and “515111” Commie" oi 1111;411:111. increased by 3. 5 times with a voltage of less thm 10%. To keep the voltage constant to maintain perfect comedians at all head lanp circuit and switch 1 I2 5. ELECTRICAL PARTS HAN 2 Lock an to it it at ss tin arr cm. s. ems I 00 z.. t. ....,..i I 0000 00 c... t. wet it o 0 an... t. fig. 5. III Operation and connection at combination switch rig. 5.1I2 Stop switch WMHER aliusti c ACTION AxlE {“1“ ‘7 //‘/7\/\\/\/\/// [m]; /////// / ”ca/Y DORB|E NUT lNSUlATOR BRUSH D rig. 5. ll: Construction al slap switch Comedians. This will prevent the light intensity from dropping. Connections between lamp socket and gound are often faulty. It is advisable to attach a ground wire to the lamp socket and fix the wire to the head lamp housing or to the vehicle. (Reier to Fig. 5. 102) 5. 7 Switch A. Combination switches This switch is operated by a special cylinder key. It performs general functions required by vehicle operation. In Model 0240 a conbination switch is used with the day and night driving switch circuits the generator charging circuit and the starting circuit. When the key is turned, the inner contact points slide to connect Oi disconnect the selected citatit. (Refer to Fig. 5.110) The key is Used for both the cortbination switch and hand lock. It is operated in three steps, as shown in Fig, 5.111. Position 0 The key my be inserted and removed. Engine is at? and no electrical units can operate. Position | The key cannot be removed. Daytime operating circuit. Certain electrical units can operate. Position ll The key cannot be removed. Nighttime operating circuit. All electrical units may be operated. (Reter to Fig. 5. ill) 8‘ Stop switch This switch is interlocked md operates with the brake pedal. There are two types, reciprocating motion and rotational. (Refer to Fig. 5.112] Models CB l25 and 160 use the reciprocating mtion type stop switch. As seen in the sectional view on the left, when axis A periornls reciprocating motion interlocked with the brake pedal, the metal contact point B (coupled to axis A] also perlornls reciprocating motion by flashing on and on as the contactors C and D are closed. Disassembly and Assembly A double nut is used tar adiustmeni. To position. loosen the upper and lower nuts When disassembling, dismount by loosening the two nuts. The interior cmnot be disassembled because the housing is sealed. (Refer to Fig. 5. H3) 5. a SWlTCHES “3 C. Horn button and dimmer switch The dimmer switch is installed on the lett handlebar grip. It is u doublesrep change switch and sums or changes the head latp bean direction during night operation at the vehicle. It is joined to the horn pusttsunon switch (lieter to Figs 5.114) 5.3 Wire Harness The wire harness 0t automotive Vehicles is the artery which serves the electrical parts and is a very important unit. Troubles in the system cause not only operating dimculties, but sometimes fire as well. it is wise to refrain from patching the Wiring system The wire system consists ot harness] supplementary leads, terminals, terminal sleeves. wire nipples, instru~ "lent connection and instruments using small units as connectors. (Rater to Fig. 5. “5) The wires which make up the wiring system are gathered together to facilitate wiringr They are con~ tained in the wire hamess, and branches we provided wherever required. For protection and insulation, cotton knitting, lacquered or waxed cotton net or vinyl sleeves are used. When an untamilier wiring system must be inspected and faulty wiring traced, the merits of the wire harness become clear. In the doove example, the one faulty branch can not be replaced, but repair must made‘ by using new wiring. The wires of the wire harness and other supple mentary wires are marked in a color code or tags of identification are attached to the ends ot the wires. (Refer to Fig. 5. Ha) A (use is installed on the top of the negative terminal or the battery, This tuse prevents aver-dis- charge at the battery or tire resulting from faulty electrical parts and gound shortsr However, when an AC generating coil and selenium rectiner ere coup led tor power sovrce, the selenium rectifying plate is sometimes broken by high reverse current it the engine is operated without a fuse, or it the tuse is burned out. Breckage at the selenium rectifier can be prevented by connecting its output terminal directly to 'the batv tery. (Reter to Fig. 5.117) fig. 5. n5 Wire harness Ditiitzll‘ SWITCH . In fuse box Maintenance strap Checking Compression VI INSPECTION AND ADJUSTMENT 6.] Maintenance Thus tar, maintenance artd adiustment have been defined as related to an individe system or unit. However, inspection, repair and adiustment are some» times periorrned to many systems and parts, collectively aid periodically. This is for the sake of convenience and is also reierrea to as preventive maintenance. Main- tenance is periornied on each group in sequence ior the purpose oi keeping the vehicle in good operatirg condition at all times (Refer m Fig. 6.l and 6. 2) A. Engine adiustrnenl Engine adiustrnent is to guarantee normal engine operation. It is a corrective operation aid different from mere inspection. Engine operation is dependent upon the function of the following systems. By inspecting aid odiusting in the below sequence, normal operation at the engine is guaranteed Compression system lgnition system intake system Combustion system Fuel system inspection should be periorrned on the above five systems. when Completed, normal engine aperotion should be regained. Corrective action will be ex- plained below. 1. Compression It the compression is ‘lrnulty, the engine output decreases lt‘ compression leaks exist. the engine trouble is generated in operation or the engine stalls at low speeds, o. Tools required tor checking engine compression. iiieier to Fig. 6.3) b. Disconnect the spark plug leads and remove the plugs with a socket wrench, c. Place the tip of the Compression gauge in the cylinder head opening and press firmly into place so that the seal is tight. d. Open the throttle and choke wide, and operate the kick starter several times. The pedal should be kicked vigorously. (Refer to Fig. 6. 4) 6. l MAINTENANCE (CAUTION) llt If the throttle and choke are not wide open, the amount of pressure registered on the gauge will be small and not representative. l2l The registered pressure will increase with every kick of the starter. The pedal should be kicked Until the compression gauge registers a maximum reading. lal Make sure that ”Is engine is warm when gmging the compression, otherwise the indicated pressure will mt be true compression. The compression pressure should be from (128 to I49 psi] 9.0 to 10,5 kg/sqcms (Refer to Fig. 6. 5] When the preSure is more than the (hove, carbon accumulates in the combustion chanber and on the piston lace. The cylinder head Shauld be removed, piston and cylinder assembled and the carbon removed. When the pressure is less than the above, either the piston rings are not making a good seal or the head gasket is defective. Piston rings and head gasket should be inspected, and the rappers should be adjusted or disassembled. o ‘F 2. rapper Adiustment rapper cleu'ance is artecied by the open and close period of the valve closure is insufficient the tappet will be raised when there is no Compression. If the clearance is excessive the rapper will knock. rapper clearance afiects engine power] performance at slow speeds and silence of engine operation. a, Remove the four cylinder head caps. b. Remove the generator cover. c. When the mark of the stator and the generator rotor are aligned, upper clearance should be adjusted or compression top dead center. :3. Rotate the crankshaft through 360 deg. and adiust the clearance of the opposite tappetr e. Standard tqapet cleu'ance should be lronl 0.03 to 0.05 mil. rial 6.8 Tightening the odiusllrrg nut Its iis a, lNSFECTlON AND MAINTENANCE (CAUTION) Adjust the toppeis when the engine is cold, A thickness gauge of 0.03 mm [.0012mm’) should pass, while that of 0.05 min [.00195”) comet. When the odiusting nut is ligitened. the clearance will change slightly. Hold the ocfiusting screw with the special clearance adiusting tool. while tightening the nut. 3. Ignition Timing Even though compression and valve liming are satis- factory, ii the spark timing is not correct the engine will not operate smoothly. II the timing is too bad. overheating or backfire may result. both of which are detrimental to the condition of the engine. Tools required for adiusiing the spark timing. (Refer to Fig. 6. l0) 0. Remove the distributor point cover. b. Remove the generator cover and check clearaice. c. Check the points for pitting, burning or protrue sions. Ii necessary, remove aid correct by honing with an oilstone. d. Rolote the crmkshcit and align the highest pan of the point corn with the breaker aim sleeve. (NOTE) There are two cams on the distributor point shaft. Either cam may be used. e. To adjust point clearance, loosen the two bred ‘ , lo. ls ihe fuel level we I WW II. From fire air pressire? Nomid operaiion 1.6 kg/squ. [25.5 psi) Loaded/high‘qJeed 2.] kg/sq.cm. (29.8 psi) 12. Rear tire pressure? Normal operation 1.9 kg/sq.cm. (27 psi] loaded/hid‘rSpeed 2.2 kg/sq.cm. (3|.2 psi) l3. ls ihe Color of exhousl smoke normal? (NOYE) 1. When operation is oonsianily over short disimces. The oil Should be changed mors ofien. Every 500 km. (3100!” in the winier. 2. Bowery fluid Should bechecked every week. but more oflen when : a. traveling more than 50 km. (3] mil daily b. using vehicle in mounioinous regions c. operciiing always cli high speeds Fig. 6.53 mm side or me vehicle B. Periadlcal Inspection and Repair Ilems and lime: or periodical inspecl=on and repail as shown in me iellowing Iable; Q Inspeclien lo be made by dealer, 0 lnspecllon which lhe uxer can make, mm“ 300 1,000 2.000 3,000 4,000 5,000 6,000 7,000 0,000 9,000 lo,000 H.000 l2,000 "00 (520) H.240 H.860) 0,4501 l3,I00l l3.720i H.350: M960: (5.500) imam maznl i7.440l <> 0 O 0 O O liems Change engme ell Q o 0 creasing Adiusl lgnilion liming Adilm vulva clearance Adlusl‘cnm chain Adi‘usl clinch Adi-is: carburawl 9 9 9 Adivsl drive mm 9 9 9 9 Adiusl heal brake Adivsl rear brake Clean spark plug Clean oil mm Clem oil cleane: Clean luei Sllalner Clean mum" Inspect lightness oi mus Q and bolls Inspecl suspension: lnspacl lighls, horn aid speedomelei 000 000 9 9 99999999999 99 9 99999999999 000 000 99 9999999999999999 000 000 00 000 99 9999999999999999 99 9 HONDA Models CB 125 12? 8; CB 160 Maintenance Specifications Parl Item Model ca 126 Model c0 IAU Cylinder nead Height inn ”9 new same 0islarlion llrnll nun . 8Xl.I5/rrl Head boll O.D.Xpllch rnnl l,al'x.o¢'/s.2s’l senre ngnlenlng lorque m-lg Gaskel Malerlal Slainlesr asbeslos some Thickness lnewl min 1 lo 1.1 [.39 lo .042') Sam Cylinder Vlmn ar wilhnul liner will. same Bore rnrn u sum 50 ims'l Error or verlleal bole mm Error helwaan cylinders mm Expansion llnill nun Wan! limll mm Pixlon Clearaiee mm 00 lo 0.l l0.0'la.004'l 0.1 lo 02 (.004 lo .ous'l Cenler ol pin lo nead mm 29.7 mm 25.5 L99'i Pin hole olfsel lnrn L5 mm mm. Cylinder eleararee lMinl mm 0.2, 0.50 (.009', .02’l 0.25, 0.50 LOI', .02'1 Oversize 0.75 l,029'l same Direelion oi inslallarion 0ireellan al arrow sane Pislon ring: Oulside nnlsn (Campresxlonl cnrarne plane sarne Oarside nnlsl. (compressianl Chrome plale sane Outside nnlsl. (Oil seall Oil enrorne plale sane Tension IComresslonl kg 0.30 lo 0.52 [.841b lo 1.: lb! 043 to 0,6701% lo LUhl Tension lOiI seall kg 0.5 lo 0.5 ll.l lb to 1.8 lbl mine . 0.0ls la 0.045 Grooveeleaaree[Compressionl mm [.0006" m .0018, sarne . . me lo 0,045 Groove clearance (OI‘ ring] rnnl 1.0004' ,0 .m a,] me 0.15 lo 0.35 sane ' Conlacl clearance (.0058’ m .0136'1 Angle oi eonlael surface '20. sanle (molding side pressurel Pislon Pin Installation syslem Healing sanie 0.0.xlengllr mm lexasxi L55'Xl.37'l loam L55'XL61') Weigh! lg 0.0m L039") 0022 (.0000’i lnslallalian ln pislon eald prex: seine Comscllng rad Clearanee wilh snrall end . pislon hoss mm 3 L” l W" Deneerion 0! small end nnn Dimension ol ail‘venl min 2.5 mm sane Large end ol eonneelina Construelion Single Imil sarne ”4 Play in axial direellen mm 0.l la 0.4 (.004' lo .Ulb'l sane Needle eollar.nmneer 3‘24 2ea. sane Needle collar diu.XIengIh nun 2.5xl0 LDS'XQM’I sanle Cwllkxhafl Conxllucllon Assenbly’ sane no Haiyhl a! nool mama valve cvlaway 26mm (Lol'l Pan llem Model ca l25 Model ca lw Crunksha'l nenecliandnleilennce al cvmkshuh 0,043 la 0.083 mm and aim mm [.002' lo .003') Pin lincnonnd [wilhin mml 0.003 (.naom some Limil of crankxhan play Timing Gears 7. Chain Piicli ol chain 7.774 mm. Nnmani of chain "Ii: 51 some Tenxlorl al chain kg 3.5 (7.7lhl ma Camshuh Cam Miyhl (inmhl mm Cam nelgm (exhuufll mm Beaxina cleavanca mm ”'03"? gym", same Valves Conslluclion liniakel Monohody same Conslracnan lethlxll Monabody same Cluovonce limakel an 0.03!!! 0.05l.lmii'm,auz'l me Clearance (ethll mm 0.03 In 0.05 [.00] l' lo .002’) mma Valve slam din. (make) mm 5.5 l.2l'l some Valve slem dia [exhausll mm 5.5 Lil’l same Undenixe limil (vulva slcml mm Valve seal racing llmil al depresslon 0qu 36.1 mm mm: Valve springs nee helglu mm Inner 25.6 (Ll'l sam- . o 9.5/29.5 no.9 lh/l.l5') same Inslalled [Dad/height lip/mm I ”/2“ ”0.3leva ms Limil ol lree height % al slandand same Plumb laleiance mm mm/iou mm l.037"/3.9') Same Valve guide Bole linlake a exhausll mm 5.5 (.2I'l same lenglh al insnnnd :etlinn n! cylindar ln. 0.040 lo 0.055 mm mm (.0016' la .0025'l Ex. 0.020 to cum Lima" lo .oow'l “m ln. n.0lo In .aoa5 (,lmm' la ,olm'l 5°“ Valve ilem clearance mm Ex. 0.035 la mm M. Loou’ la .0027'] Oil pump Kind Plunge: lype same . . , 3.78 “so Capacily mflng-ll'au/mm-lpm (3,5 Us gal, 53 Imp. 9°“ same Q‘I mm Centrifugal win nail. Canliilugal wira mash same lubvkullon SAE Slwlnlerl ID or 20 same SAE :lwmmeil so or 40 San: Gamma,” Type I. Mmulaclm rlnan valve [TKI same (Kelhinl Diameter IIIIII Diameler al Vanluvi mm in l.7’l 20 (JE') Main in S 78 S in Air iel $1.2 $150 ldl. in 0.35—0.6XV Gall l0J¢><2xal Needia in z59~l16xa £6X3.5 Jel needle T-llla 3/5 xlep I833|~3 slop Ai. icinw l/ll rahfln l-l/4:l/a 19.5 mm L76’l l3! Farl hem Model ca 125 Model cs I60 Clulch splTng limll or free hcighs rlwnh loleiancc loaded lenslon/limil of helghl Clulch plale Dislorh’on lnnn mm Clulch drive plale mac. same Thickness & number mm L6 5-ea. [.Uéinl same FvIclion d'lxcx Resin mold same whickncss 5. Milan Mm 3.5 5~sa. l.lunl same Tranmllxsion Gears Backlash lialio 1 2.767 Sam: lialio 2 1.779 L773 Euro 3 L313 sans Ma 4 Low same Main shall seasing 520m 5 some Counteuhafl Searing mm 5 same DlTva chain Manufacturer naldo mule No. of links (xecondary dvlve) no son. ‘ Front suspension Type Telucoplng xame Snake mm Brake cylinder caps cc no sans Fvee lsnglh ol spring mm Spring icnsian kg Spying Mfgr. Shawa Seimkusho same Steel hall diamelcr mm 5.35 as-ca l,2sinl same gear suspension 1ypc Pivoring saina Slvoke mm Blake cylinacn cap. cc as we us pl] sans rics lsnglh ol spying mm Spring lsnslon kg Spring Mlgr, Shown Sclsaknsho sans Flam wheel Akls diameler mm ls 1.5311“ same Bearings Ball (6302! same nun defleclion mm Blake dwm 1.0. mm leo l7inl same Blake shacs 0.0. mm Thickness ol brake can inn. Thickness ol hmks lining mm 4.5 UBinl some shes spsing lscs lenglh mm Play of brake levar mm ID lo 20 1.39 lo .7ainl same Real wheel Axle diumal‘ev mm l7 [.Mln) same swings Ball (6303) same le dallcclion mm Blake dnun LD. mm IBD l7ln) some Brake shoes O.D. mm 132 Pan hem Model ca 125 Model ca 160 ha: wheel Thickness ol hraka cam mm Thicknaxs or broke llnlng mm 4.5 ms in'l lame Shoe xpring he: Imam mm Play 0' brake level mm 20 Io 30 L75" lo mm mm: Eallely Type a number Mawa—lzc 1 ea. sam. Caaaally ”0.00m vale] 9AH male quna pal. Negalive Sam: level ol alaaualyle above alarm" w m ‘3 (0.39” ,0 0.50,, mm Ignilion call Type smoa (Kokvmn) lame 297007097 [Demo] xanle chz lHivuchi) Same Ruled vollage 12 mule Tesl spark clearance mm a l0.3l In! mm: lnsulallan vesilunce (Mm Advance angle deylce Slanlng lam leoo same Maxlmum vpm 404200 same Conllxl bunker Poim gap 0.: la 0.4 mm lo 0.02 ml xama Spring canslamm an. 700 lo 900 Sam: Capacilor Capaclvy 0F 0.: sum. lnxulalion lesixlanca wml 50 same Spark plugs Type D-BH some Poinl (leamrlce mm 0.5 co 0.7 [.023” lo .027”. same Haal range High temperalure same canaralar Type 5619 (Kokusanl some 37000—02; (Dense) mm. K107 lHImchi) mm. 00le valvuge v—w 14—70 same mung, Type smaan mule Poxi'iva lexlslanca 0 mm: Negativ! lexklance n same Type a M'gl, ccoa lxokusanl male I 5"" °' 25000—lll (Demol Same 5106 [Hllochil sum: Valley: and oulaul v, HP l2, 045 some Slavvlng alum" A Almmwe a pol. core clearance mm 045 [,DIB’) same Comlrllllalor dlame'er mm Insulalion rexlslanca Mn 0.05 some . . . 12X6Xll,5 0mm dlmenssons [wllhl mm l.40'x.2:’><.55’l same Bnuh if 9 Damien gm 500 (1.28 lbl mule Undemze limll al brush 1/; “and“ m, T Semi-sealed beam sealed beam lam lava: lam bulb capocil (WI 30/30 5““ P Y 25 same Slop lama bulb capaclly ml 5 m, Tail Ian's: bulb mwcny lWI (used lov license plan. lighllllg alxol _ lmnumem lamp lWl 3 7>aa some Clukh Type Wu mum-plane mine Camel xyslenl Manual cable same Clmch sun-‘9 rm heighl mm 34.9 same loaded lumen ka/mm [lbs/l0) 15/225 (33.1 lb/.9'I same CB l 25 AND l60 EXPLODED VIEW