Slllll' MANUAl C . HON DA , 125 '175 35321132 FOREWORD This Shop Manual is a servicing guide for the C8125, 0.125, C5175 and CL175. The Manual has been prepared using the C3175 and CL175 as the basic models, however, the information contained will apply equally well to all models. There are minor dit‘lerences among the models, primarily in the engines; these difierences have been specificially noted for the CB125 and C1125. This Shop Manual is applicable to all model serial numbers shown below and subsequent CBiZSKi Engine Frame c5125i<2 (General Export Typel Engine Frame C5125K3 lGeneral Export Type) CL125K1 Engine Frame Engine Frame CL125K3 [General Export Type] C3175 CB 1 75K3 CB175K4 CL175 CL 1 751(3 CL175K4 Engine Frame Engine Frame Engine Frame Engine Frame Engine Frame Engine Frame Engine Frame No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No. No, 200001 1 ~ 2000000~ 3000001 N 3000001 ~ 4000001 ~ 4000001 ~ 2000001 ~ 2000001 ~ 4000001 ~ 4000001 ~ 1000001 ~ 1000001 ~ 4000001 ~ 4000001 ~ 5000001 ~ 5000001 ~ 1000001 ~ 1000001 ~ 400000] ~ 4000001 ~ 5000001 ~ 5000001 ~ To ensure proper servicing, the special tools must be used and all repairs made to the specified tolerances. The information peculiar to CB/C1125, 175 revised models is compiled at the back of this publication as a supplement, June 25, 1974 HONDA MOTOR CO., LTD. Service Publication Office FEATURES ENGINE 1. Chain driven overhead camshaft Assures quieter operation, clue to the silent chain drive, and a more efficient higher speed engine resulting from lhe elimination at power loss 1 Dual oil filtering system Provides only highly cleaned oil to lubricate the moving parts oi the engine to greatly extend the trouble tree engine life. a. Constant-meshed tramminion gears Make possible smooth and eiiortless gear change. 4. Variable venturi carburetor Provides economical operation and greater power output at all speeds. FRAME L The irame main unit is made of welded high strength steel tubing of backbone design lor lightness and rugged service. 2. Front wheel is mounted on an oil dampened telescoping fork which provides superb handling and good stability. Rear wheel is on a swing arm pivoted about plain hearings {or increase rigidity and suspended on cushions provided with three stage load odiusrments, 3. The CL models have a wide raised handle mounted on rubber for comfort. Semi- raised handle is mounted on the CB models. 4i Block tread pattern tire ix installed on the rear wheel oi the CL models to! good read holding on bad roads. 5, All lights are used throughout ldr greater solely, and their operating switches are all mounted on the handle bar where they are accessible without moving the hands, 6, Front wheel brake is oi the two leadings type lot greatest broking emciency. 7i All protruding ports are designed with generous radius and sharp corners have been eliminated to prevent iniuries to the riderc CONTENTS SPECIFICATIONS SPECIAL TOOLS C3175, CLI75 . . . C5125, CL125 .. ENGINE (C3175, CLI75) ............. 3.] Engine Removal and lnsmllalion . A. Engine conslruclion .. B. Removal .......... c. Rsassembly . 3.2 Cylinder Head and Cylinder 1. Cylinder head. , . A. Conslruclion . . B. Disossembly ,,,,,,, C. lnspeclion ,,,,,,, D. Reossembly 2. Cylinder head cover and brealher . . A. DescripIion B. Disassembly .. 3. Camshaft ........ A. ConsIruclion .. B. Disossembly .. C. Inspeclion D. Reassembly A. Rocker arm... A. ConslrucIion . B. Disassembly . C. Inspeclion. D. Reossembly 5. Valve A. Description . a. Disassembly . C. lnspeclion D. Reussembly 6. Valve sea! ..... A. Descriplion B. Inspeclion 7. Cylinder .. A. Conslruchon . B. Disossembly . C. Inspection .. D. Reassembly 33 Left Crunkcase Cover 1. Left crankcase cover . . . A. Construclion a. Disassembly C. Reassembly 2. A.C generalor . A. Conslrucvion . B. Disassembly . C. Reassembly l 3 l 3 l 5 I7 l8 I8 l8 1 9 20 20 20 20 2] 22 23 23 23 24 24 25 25 25 26 26 26 26 26 27 27 27 27 28 28 28 28 29 29 29 29 30 30 30 30 3l 31 3] 3| 32 32 3.4 3,5 3.6 3.7 3.8 3. Slarlzng sprocket and cluich ........................... A, Conslruciion ............... B. Disassembly and reassembly lsmnlng clutch) .. ca alsassembly and reassembly [Siarring sprocket) 4. Clutch adiuslar and neulral swilan ralor . A. operallan, a a a. Disassembl'y ana reassembly (Clutch udlus'eri‘ c, Disassembiy and reassembly lNeulral switch rolarl Righl Crankcase cam Assembly 1, ngm crankcase cover A. Construction 5‘ Reassembly 2. Clutch ,,,,,,,,,,,,,,,,,,,,, A. Descripiion and operalian B. Disassembly . c. Inspection . D. Reassembly . on Pump, Filter and Separator l. on pump A, Descripilon H E. Disossembly ,, C. lnspscfion .... D. Reassembly 2. on nllar ,,,,,,, A. Descripfion B, Disassembly , c. Reassembly 3. on separatora A. Operalion Crankeuse . A. Descriphon . . B. Disassembly C. inspection . ..... D, Reassembly , . Crankshaft, Connecting Rods and Pistons A. Construction . B. Disassembly C. lnspec'ion ., 2. Connecting rods“ A. Descrpilion B. Inspection 3, Pision ...... A Description B. Disossembly C. Inspeclian a D. Reassembiy a 4, Plslon rings ....... A, Cons'ruciion . a . B. lnspeciion ,,,,, Cr Replacing the plslon rlngs Cam Chain Tensioner and Cam Chain Guide Roller” A. Operalion.. B. Disassembly 32 32 32 33 33 33 33 33 C. Inspection . . . . . D. Reasssmbly . E, Cum chain tension adiustment , ,, 3.9 Transmission ..... . . , . A. Descripiion B. Disassembly . . . . C. Inspection . . D. Reassembly 3.10 Gear Shift A. Operation B, Disassembly . , C. Inspection ...... D, Reassembly 3.11 Kick Starter .......... A, Construction, B. Disossembly . C, Inspection . .. D. Reassembly 3J2 Carburetor Construction . .. ... Function of the main components Adiustment .................... Engine (C3125, CLIZS) ............... 3.1 Engine Removal and Installation ........ A, Engine description B. RemovoI ........ . c. Recssembly ............... , 3,2 Cylinder Head and Cylinder ......... 1. Cylinder head. cover and breather . A. Construction ................. B. Disassembly , C. Inspection .. D. Reassembly 2. Camshaft ....... A. Construction . B. Disassembly . C, inspection .. o. Recssembly 3. Rocker arm.... A. Construction. B, Disassembly . C. Inspection . D. Reassembly 4. Valve A. Construction . B. Disossembly . C. Inspection . . . D. Reassambly 5. Valve seat A. Description 6. Cylinder ...... A. Construction . B. Disassembly ........ 3.3 3.4 3.5 3.6 C. inspection ........................... . .................. D, Reassembly Lefl Crankcase Cover . . . . . 1. Left crankcase cover . 2. A. C. Generator.. A. Consirucrion . H B. Disassembly c, Reassembly 3. Clutch liner ihread A. Descripiion B. Disassembly C. Reassembly 4. Cam chain isnsioner A. Construcnon ......... B. Disassembly . c. Inspection . D. Reassembly Rzgm crankcase cover assembly ...... 1. Righi crankcase cover . A. Construction .. B. Disassembiy .. C. Reassembly .. 2. Clu'ch . . . . . A. Descripiion and Operation . B. Disassembly ..... . . . . . . . . . C. Inspection . . . D. Reossembly 3. Oil pump B. Disassembiy C, Inspection , D. Reassembly 4. OH filter . A. Operailon B. Disossembly C. Reusxembly Crankcase 1. Upper and under crankcase . A. Description B. Disossembly c. inspection .. D. Reussembly 2. Oil separator . . A. Description B. Discssembly C, Reassembly Crank‘hafl . ..... A, Construction B. Disuxsembly C. Inspection . . .. D. Reassembly .. 2. Connecfing Rods. . A. Disassembly 3. Piston ......... A. Description 81 B. Disassembly 81 C. Inspection .. 81 D. Reassembly 32 4. Pision Rings... 82 E. inspeciion . 82 C. Replacing the piston rings 82 3.7 Transmission., . 83 A. Description 83 B. Operation . 83 C. Inspection . 84 3.8 Gear shift 84 A. Description 84 a. Discssembly 85 C. Inspection 85 D. Reassembly . 85 3.9 Kick Starter ‘‘‘‘‘‘‘ 86 A. Description 86 a. Disassembly . 86 C. Inspection . 86 D. Reossembly 86 3.10 Carbureior ..... 37 Construction . , 87 Function of the main components . 87 Adiuslment ........................ . , , , . a7 4. FRAME .......................................................... 85 4,] Steering Handle . . . 88 A. Description 88 B. Disassembly , 88 C. Inspection . 89 D. Reussembly 89 4.2 Front Cushion ,. . 90 A. Description 90 B. Disassembly . .. . 93 C. Inspection ....... . 94 D. Reussembly 95 4.3 Steering Stein and Steering Handle Lock A. Construction .. B. Disassembly .. C. Inspection . . D. Reussembly .. . 4.4 Fuel Tank ............. A. Construction . . . . B. Disassembly C. Inspection ....... D. Reassembly 4.5 Frame Body ....... A. Construction .. B. Disassembly . c. Inspection . D. Reossembly .. .. 4.6 Air Cleaner Case and Seat A. Construction ........ B. Disassembly C. Inspedion . . . . . . D. Reassembly 4.7 Stand . ........ i . A. Construction . B. Disossemb‘y C. Inspection . D. Reassembly . 4.8 Muffler and Exhaust Pipe . . . . A. Conslruciion . E. Disassembly . C. Inspection .. . D. Reassembly . .. 4.9 Air Cleaner and Yool Case . B. Disassembly .. C. Inspection ...... D. Reassembly 4.10 Rear Fork and Rear Fender . A. Construciion ......... B. Disassemny C. Inspection . . . D. Reussembiy 4.” Rear Cushion ..... A. Construcilon . B. Disassembly C, Inspection D. Reussembly 4.12 From Wheel . A. Construction .. B. Disassembiy .. c. Inspection .. D. Reassembly 4.13 Rear Wheel. . A. Description B. Disassembly C. lnspeciion . . D. Reassembly 5. ELECTRIC SYSTEM .. . . . i. ignition Cir: t A. lgnition coil 8. Spark udvancer. C. Contact breaker . D. Condenser ....... E. Spark plug 2. Electrical power supply A. AC. genevmor. 3. Selenium rectifier . . 4. Battery A. Cons'ruciion 8. Rating . C. instruction on use and servicing D. Buttery charging procedure. . . . . . . E. Trouble shooting and corrective action ...................... 129 5. Various lauds .. ............ . . 130 A. Headlight ...... . 130 B. Tail, stoplight 130 C. Neutral and speadomeier lamp . 130 a. Siariina maror .. 131 A. Description 131 B. Disassembly 132 C. Inspecfion .... 132 D. Reassemly ,,,,,,,,,,, 132 7. Service Iasier insirudion . 133 6. PERIODIC ADJUSTMENT 138 6.1 Maintenance Inspection 138 A. Engine Adiusimeni ..... 138 1. Measuring compression. 138 2. Tappe' adiusimeni ...... I38 3. Igniiian Iiming udiusimeni... 139 4. Coniaci poinis ........... 140 5. Spark plug cdiusimeni ..... 140 6. Fuel supply sysiern 141 7. Fuel strainer clecnmg 142 8. Oil filier screen cleaning 142 9. Air cleaner servicing 142 10 Corbureior cleaning and qdiusimeni 143 B. Lubricating ...................................... 143 I. Paris nor requiring periodic oil change or lubrication I43 F. G. 6.2 Periodic Inspection and Servicing 7. TROUBLE SHOOI’ING W?".“?f-".‘.WN— 8. WIRING . Drive chain adiusimeni . , Brake odiusimeni 2. Engine oil change... I. From brake aaiusimeni. 2. Rear brake adiusimeni . Spoke Iorquing Baiiery inspeciion .. Security inspecrion of parts Main engine trouble Carbureior irouble. . . Engine noise Sieering system . Clinch sysiem Gear change sysIem . Suspensions ......... Brake system Drive chain. . .. DIAGRAM C3125 wiring diagram CL125 wiring diagram . C8175 wiring diagram ...... . CL175 wiring diagram (General exporl type) .. . CL175 wiring diagram (U, $.A. Export type! . 3: mm— om; 0o. 03 a? mm— 3: v? «m— mm: mm: 09 NR— mm— «K— N: NE at at cm— na— mo— «w— «w: m3 m3 No— mo. «3 1.: 5235 9%.; L233 20:29 Etna ,m 6.0:. 9:55 .N I. 2...‘ EmEmSmuoE £2.50 9:995 ._ 33:35 3;; BE. é 2 . i 39E :5; .m conconma 52 .N :33” :5; .F .1: 25¢ 8.93:5 ,C,.i1;mtu.mv_u_v_ Gnu—.38 :::::.:::::.§mseou, m ‘ Etofixui .e . ..... ..... i councaco: m. I.21:11:21.222,:cfixpnzo .w m N _ . 52.5.th Efi Emmy .. 3091.90 33:3 25 By. 3226 €2.53“: 51:2qu 235 2:113? 3.562 .m 3:639 $385. 9:95 95,5955 ._ 0595 95.522 .23 2:56.55 .5 3.8.3. .2335. .0 ‘gl I. SPECIFICATIONS 'I. SPECIFICATIONS C3175 (U.S.A. ‘l'yp mm (inl I'om K 0 K a K I DIMENSION OveroII lenglh 1,975 (77.8l L990 Imus) 1,975 07.5) OveIoII widm 745 (29.31 Same as Ielr Same as Iell Overall Imam Lols ream 1,040 440.?“ Lois mom Wheel base 1,275 (50.2) 1,780 150.3% 1,275 (50.2) Seal heigm — 770 (30.32) Same as {ch Ground decmnco 145 I 5.7) “:7 I 6.57] Same as lelr Dry weigh! 129 kg (784ml Cmb werghr 127 kg (271 lbxl Curb Weight 136kg mwlbsl FRAME Type Backbone Semi double male lubler Wpe Some :1: Ien L suspension, lvuveI Ielescoprc Iork Same as leIl Same as ler Same es la“ Same as leI: R. suspension. naval 5mg arm rype r. lire size, rype 2.5048 M m 2.75484 Same a: lelr 2. we size. rype 2.75—16 I4 PR) 3.00-l8—4 Same as lell r. brake lnrernal expandrrrg slrae Same as IelI Same as leIl R. broke Imemal expanding shoe Same as IeII Same as leIl Fuel capacily I061" 12.8 us gal. 2,3 Imp. gal.) Same a: IeII IDA) m. 12.6 Us gal. 2.2 Imp. gal.) Fuel Issarvs capaciW 2.5 III. (5.23 US pv, 4:45 Imp, pl} Same as lelr Casler angle 64° Same as In“ Same as Is" Trail Ianglh 86 (3.138) Same as Io“ Same as Ioll ENGINE Typa Air coo’ed A slroke cycle Same as lelr Same as leh Cylinder unangemem Twin, so“ inclined Irom verlical Tw'lrr parallel a“ Inchned lrorrr vervical Same as My Bore and shake 52x41 (7.04m L515) Same as IeIl Same as ieIr Disp‘ncemenl I74 cc (10.65 curinl Sama us IeII Same as leIl Compression ruvro 9.0:] Same as IeIr Same as Ieh Valve Main Chain driven overhead camshail Same as leIl Same as Ieir Maximum horsepowev 20.0 PS Iomo rprrr Same a: IeIl Same as lelr Maximum Iorarre L5 kw. no.5 II. lbs! Same as Ielr Same as Iel' Oil capaciry 1,5 lil. 13.2 US mg. 2.7 ImDr plsl Same as IeII Same as Ier Iubricalion xyslem Forced pre;sure a we! sump Same as lei: Same a: leIr 3 I. SPECIFICATIONS mm “M nun K a x 3 x 4 Open; 10“ 10“ Same as 1.1. Wak. valve cases 40" 30“ Same as 1.41 Opens 405 40° Same as leIl Exhaust valve Closes 10° 10° Same as leII Valve maps. clearance 0.05 10.0021 5am as Ian Sumo a: 1m Idle speed 1,200 rpm Some US leh Same a: 1:11 DRIVE TRAIN Gulch Mvhlple we! place: Same as 1.11 Same as leIl Transmission eonsmm meshed asaa Same as law Same as Is“ Pvimary reducnon 3.700 Same a: 1.11 Sam: as lelv Gear who 1 7.769 5am as Is“ Same as Volt Gear sane 11 1052 Same as leIl Same as 1911 Gear mm: 111 1.450 Same u: Isn Same as 1m Gear sana 1v 1.173 Same as Ieh Same as leII Gear ratio v 1.000 Same as 141 Same as my Final rsaucnon 2.500 2.470 Same as Ielr Gear shifl pans”. my food apasaysd "1mm type Same a: 1m sams as Is" ELECTRICAL Ignition Bane-1y and mum coil Same as 1a" Same as leII sqaning syxlem Molar and kick Same as In“ sama as 1:11 Alverna'or A.C. generulov valor Wye Sums as raw Same as 1511 Bansry aaaaany 12V79AH 5am. as 1911 Same as 1911 Spark awa Dams, Hzrs D—BHS Same as IeII CL! 7 5 (U.S.A. Type) I. SPECIFICATIONS Labrleollon syslem mm fill] non- I K 0 K a x 4 DIMENSION Overall IenglIl 1,975 (77.8) L990 (78.3) Same as lell Overall widm 745 l29.3) 820 (32.3I Same as loll Overall ha‘lgh) lms mom Loan H15) Same as leII Wheel base I275 (50.2] 1,290 £5118? Same as loll Seol nelgm —— 790 l:ll.ll Same as lell Ground demance us I 5.7» mu l 7.8] Same as loll Dry weigh! 12‘7kg l2salbsl Cwb weigh! 124 kg mu lbsl Curb weleln lsalg (300 lbs) FRAME 1w. Backbone Semi-double cradle Iublel type Same as lel. F. suspension, naval Teleseopie fork Same as lelx Same as leh R. suspsnsion, Iravsl Swing arm Same as lell Same as lell F. me sue, type 2.5045 l4 m 3.00494 Same as lell RV me size, lype 17sz :4 FR) 100434 same os lell re brake lnlomol expanding shoe Same us Is" Same os lell R. bmke lmemol expanding shoe Same as leIl Same as lell m” “"“CW III-2'36 gal.. 2.l Imp. golJ $33.05 gale, L9BlmpegalJ 5““ “S '9" reel veserve capacily E?“ at, 16‘ hm ml Same as lell Canal angle .54“ Song os lell Same os loll Trail Ianglh so (3.38) 90 l3.5l Same as lea ENGINE Type All cooled A strata cycle 5am. os It" Some as lell Cylinder arrangement 1313‘)” ‘"‘”"°“ "°'“ m: 5:52: 5“ "mm" Some os loll Bore and make 52x41 Izonx L615) Some os lell Same as lell Disp|acemem 174:: noses curlnl Same es la" Some os IeIl Compression raliD 9.0 Same as low Same as lell Valve noln 2:30?” °"°"‘°°‘ Same as lell Same as loll Maximum horsepower 20 P5 [0,000 rpm Same as loll Same as I.» Maximum torque 1.5kg-m IICLB II. lbsl 5,5oovpm Some as lell Same as lell all capoe‘w L5 lil. (3.2 us pls, 2.7 |mp.plsl Same as lell Some es lo” Forced pvessme a we! sump Same as lell Same as loll 5 I. SPECIFICATIONS mm lin) If. In K D K 3 K 4 Opens l0“ 10° Some 0: Ien Intake vawe Cloxes 40° 30° Same as Ia" Opens 40° 40° Same as Ien Exhausv valve Cloxes 10° 10° Same as 1.1. Valve Vanna! c1earanee 0.05 10.0021 same as ten Same as In“ Idle speed 1,200 mm Same as Ien Same as law DRIVE TRAIN Cluvch Mumple wal plums Same as 1.0 Same as In" Tvansmmian Conxlam mashed gear! Same us let: Same as Is" Primary reduclian 3,700 3.700 Same as 1e11 Gear mic x 2.769 Same as left Same as len Gear valio 11 1.502 Same as 1er Some 0: 1.11 Gear ratio 111 ”50 Same as Ien same e; 1e“ Gear rulic 1v 1.173 Same as 1.11 Same as Ien Gem who v 1.000 Same as leIl Same as my final (educiion 2.375 Same as 1.11 5am5135 Ieu My, Gun shm panem Len Iaorapemea return «ype Same as IeI! Same as len ELECIIIICAL |gniiion Bowery and lgnmon coll Same as In“ Same as Ien swung sysvam Motor and kick Same as Ien Sumo a: Is“ Almrnuto: A.<:. genoralor voter type Same as My Same as Ien Banery aapaainy I2V79AH Same as 1es. Same as Ien Spark plug D—aHs, Hm D~8HS Same as [ch 1. SPECIFICATIONS C31 25 mm (In) In In K 0 K 2 x 3 DIMENSION Overall mm 1,975 (77,8! Same as lefl 1,950 (77.95: Ovamll widm 745 (29,3) Same as leh Same as Is“ OveraII high) 990 (39.01 Same as lefl Low (40,94! WheeI baxe I275 (502) Same as My I350 (50.39) San height — 750 (30,7I 79D I3I.I0I Ground clearanca I45 I 57! Same as left no I 5,5“ Curb waighv II9 kg (262.4 beI Dry welghI I15 kg I253 a my Cuvb walghl 115 kg [260.2 Ibsr FRAME Yypo Eaclhone pIpe lIame Same as left Semi double cradle mm: Iype F. Suspension, IvaveI Telescopic Iork Same as lell Same as Ier . suspension, naval Swing arm Iypa Same as (ch Same as Iah r. we size, Iype 2.5071874 5am as Is“ Same as Iafl R. lire s-za, type 27571874 Some 0: IaII Same as leII F. bmka Inmnal expondmg shoe Same as law Same as leII R. braks Internal expandIng shoe Same as Ian Same as Iere 10,5 In. loam, “9' “WW (2.5 us ga1,, 1.5 Imp. gum (2.6 Us gaL, 2.2 Imam.) 5““ °‘ "" Fuel mew. :apucily — 2.5m. (5.3 us at, 4.4 Imp, an Some 0: IeII cm.” angle .54" Same as lgII Same as lelI mu Iangvh as (3.39: Same as leIl Same as leII ENGINE Type Aiv cooIed 4 man cm. Same as left 5am. as Iell Cylindev uvmngemem Twin. 30“ inclmed Irom vemcnl Same a: 15" Swin pamIIeI, 8° inchned Iram venical Compression racia Bore and make 44x“ H.732XL615) Same as 1:“ Same as leII Displacemem I“ CC I7.59curmI Same as leII Same as Inc 9.44 Same a: la“ Some :1: [eh Chum dvlvan ovavhaad Same as loll Same a: My Maximum torque (7.59 {I lbsI 9,000 Ipm Valve Ilain comm" Maximum horsepower l5 Ps/l 1.000 m... Same as la“ 15 PS/I0,000 rpm 1.05kg-m Same as M 10.5kg-m (momma 3,500 rpm Oil capaciw I 2 m. (2,5 us pix, 2,1 Imp. am Same as IaI: Same an Ier Lubiicunon syslem Forced pvesxuve a. we? sump Same as IeII Same as Ien 7 I. SPECIFICATIONS mm Vin) lur— K o x z x 3 Opus 5" Same as my Same as my Intake valve Closes 30° Same as Ian Same as In“ Open: 35° Same as Ian Same as Is" Exhaust valve Closas 5° Same as Me Same as ‘90 VaIve Vappsv claamnco 0.05 “1.00m Same as lell Sauna as Is" Idle spud 1,200 rpm Same as leh Same as \er DRIVE "IAIN 6mm MuIliDIa we! place: Same as My Same as Ieh Transmission Conslanl meshed years Same as leII Same as Ian Primary reaacnaa 3,675 Same as Ian Same as Ielv Gear rana 1 2615 Same as Is" Same as In“ Gear rana 11 1.611 L667 Same as leh Gear rana m 1.1?0 1256 Same as IeIt Gear rana 1v 0.917 L043 Same as Iern Gem rana v * 0.5m) Same as [ch Final Marlena" 2.867 1133 Same as Is“ Gear smn panem Le“ (00' operated remm :yp. Same as Isl! Same as Is“ ELEGRICAL Ignzvion Bullery and ignivion coil Same as left Same as Ian sraning sysrem Marar and kick Same as ssh Same as Is“ Ahernamr A.C. ganaramr rarar syae Same as Ian Same as IeIt sauery capacity 6V—6AH ‘ av—nAH Same as ten D—SHS,_)(—24FS DraHS Same as In“ Spuvk plug I. SPECIFICATIONS CL! 25 mm 11n1 nun K 0 K 2 K : 0111121131011 01:11:11 lengm 1,930 1711.01 Sumo as 1:11 Same as 1.11 01:11:11 M1111. 830 132.71 Same as Jan 810 131.1391 OvamH 1.:1g111 1,0411 111.01 1,035 140.61 1,030 1411.551 wn:.1 has: 1,270 150.01 5am: 115 1:11 1.230 1511.391 Sea1 11:11am — — — Ground Cleuiunce 150 1 5.91 5am: as 1:11 155 1 6.11 Dry M19111 1171a 12531161 Cnvb mam 11511; (153.6 lbs) 5am: as 1:11 ram: Type Backbone pip: [rams Same as 1:11 Semi aaam: cradle 1.11:1:1 1m F. suspens1an. navel Te1ascapic 1011: Same as 1:11 Same as 1:11 R. suspsnsian, Iruvel Swing aml 1w: 5am: as 1:11 5am: as 1:11 1. 111: size, 11a: 17548-4 5am: as 1:11 Sun»: as 1:11 11. 111: sixe, 1w: 3.00—15—4 Same as 1:11 5am: as 1:11 1. brake 11.1:rna1 expanding shoe 5am: as 1:11 Same as 1.11 R. bloke 1n1sma1 :xaana1ng shoe 5am: as 1:11 Same. as 1:11 W" “’me 112135111291: 2311111.. ga1.) kilns gal., 11 11119. 961.1 5°" ”5 '3" 11:1 reserve capacuy —— #— i Cns1er angle 64" 5am: as 1:11 5am: as Is" nan lenglh as 13,381 Sum: as 1:11 5am: as 1:11 ENGINE Typc A11 cooled 4 max: cy<|e 5am: as 1:11 5am: as 1:11 Tw 11, 30° 111c1mea hem Twin pa1a11al, 8° 1n<11n:a van: 11a1n camshaft Cy11nder anangamem 1:111:111 Sam: as 1:11 mm mm“ 3a.: and sucks 44x41 11.732x 1.6151 Same as 1:11 Same as 1:11 Displacemem 121 cc 17.59:...1111 Same as 1.11 5am: as 1.11 Compression 10110 11.4. 1 Same as 1:11 Same as 1:11 Ch” d'M‘" °"”‘““ Sam: 1:: 1:11 Same 1:5 1:11 Max1mum horsepower l4 PS/I0,000 rpm Same as 1:11 Same as 1:11 Maximum 1orqu: 1.0611ng (7.67 11, 1bs1 1,500 rpm 5am: as 1:11 Same as 1:11 Oil capamy 1.2111.12.5 Us 91s, 2.11mp.p1s| 5am: as 1:11 Sumo as 1:11 lubrlculion syslem P1:ssu1: & w:1 sump 5am: as 1:11 Sumo as 1:11 9 I. SPECIFICATIONS mm (in! I! a In x a K 2 K 3 Opens 5° Same as Ian Same as Ian Imuke valve Clasas 30“ Same as I." Same as my Open: 35“ Same as rare 5am as law Exhaass valve Class; 5‘ Same as leII 5am as Ielr Valve mppev cleumnce 0.05 (0.002) 5am. as Ian Same as Ian Idle spaad 1,200 rpm 5am as Ian Same as late DRIVE RAIN clam. Malnpla war praras Same as Ion Sam: a: la“ 1rarrsrrrissrarr Cansram mashad gears Same as Is" Same as Ian Primary radacnon 31375 Sumo as In“ Same as Ian Gear rana I 2.515 Same as Ian Same as law Gear rana 11 L61! Same as Is" 5am as Is“ Gear raria m 1.190 Same as In” Same 0: Ian Gear rano IV of)” 0.330 Soma as Ian Gaar rulio V fl — i Final reducmn 3.000 arm Same as Ian Geqy shih panarrr [er Iaar operand ram". type Same as leII 5am as Ialr ELECYRICAL Ignmon Bunery and igniriarr coil Same as lelt Same as Ian sranmg sysmm Marar and kick Same as Ian Same as Is" Allemulcv Ac. aanararar rmov ryaa Same as IoIt Same as In“ Hungry zapaazry bVAéAH Same as my Same as Is" DrSHS, x7205 Same as Ian Same as Ian Spark plug C3125 DIMENSIONAL DRAWING ("IT“) 002 1N ("HT”) 088 SPECIFICATION & PERFORMANCES (“n '67.) on (WOW) 9% (WIS) 9H 1.275(501in) 1.975(77. m) 745 (29.3w) 10 C3175 DIMENSIONAL DRAWING II 7‘5 (29.3in) < SPECIFICATION & PERFORMANCES (nursz) nu (Mom) 999 (Mrs) 57 121s (50.2w) 1915 (7min) "'I'ZE) 918 ml!) 9161 CL'I75 DIMENSIONAL DRAWING (WITH) (0%” . SPECIFICATION 8: PERFORMANCES ‘A g- 1277 (50‘3in)#—-—l 1930 (75.05») 12 13 2. SPECIAL TO 0L5 2. SPECIAL TOOLS C3125 - I75 ENGINE @@®@®® g 69 ®®®®©®©®@®®@®®@ Tool No. 0740143010000 07 702*2000000 07902,2400000 0790272500000 07908700] 0000 0791672400000 0792242000000 07922—2350000 07933-2000000 07933.2] 60000 0794‘2‘21 60100 0794273290100 0794241290200 07945*2160000 079454400000 07946—2860100 07946—2860200 07947-230010!) 0794743550000 07949—2860000 07954—200000!) 07954—2350000 07957-3290000 Tool Description Gauge, float level Spanner, pin 43 mm Spanner, pin 46 mm Spanner, pin switch Wrench, tappet odiusting Wrench, lock nul 16mm Holder, drive sprocket Holder, drive sprocket Pviler, rotor Puller, rotor Driver, valve guide Remover, valve guide Driver, valve guide Driver, bearing Driver, bearing Driver, bearing Driver, bearing Guide, lork seal Guide, fork seal Handle, beating driver Compressor, piston ring Compressor, piston ring Compressor, valve spring Q'W CB/CL I 25 O 0000 O 0 00000 00 CB/CL 175 O 0 Remarks Main switch Dynamo Dynamo Fran! wheel Rem wheel Front fork Front fork 2. SPECIAL TOOLS l4 b % ® ® C5125 - 175 FRAME 15 2. SPECIAL TOOLS No. Tool Na. Tool Deseripiion my (3%? “3/7? Remarks ® 0795072500000 Ease, piston I O 0 @ 07959—3290000 Compressor, shock absorber I o o @ 07973-2300000 Slider, spring I O @ 07980—2400I00 Caner, 90° um I 0 ® D7980~2400200 Omar, 90" (EX) 1 O @ 07960—2400300 Cutter, “a? I 0 ® o7930,2400400 Omar, flat I 0 ® 07950—2I60500 Cuner, inieripr IINI I 0 ® 0798(k2160600 Cuflel, interior (EX) l O 8 07980—2350100 Cuuer, 90" I 0 ® 07980*2350300 Culver, Fla! [IN] I O S 07900—2350400 Cniier, IIqI lEXl I 0 ® 07980—2350500 Culer, interior (IN) I 0 ® 07980—235060!) Curler, inferior Ex) I O Q 07981A2160000 Holdev, sea! cuner l O Q 07981—2350000 Holder, seal cuner I O @ 07904-2000000 Reamet, valve guide I o o @ 07797—05I0100 Case, seal curler l O O @ 077974920300 Case, special iool I o 0 ® 07999—2460000 Coven liming Inspeeiien I O @ 07999—2350000 Cover, liming inspeciion I O 2. SPECIAL TOOLS ®® 17 3.1 ENGINE 3. ENGINE CB/Cl'l75 Engina assemb|y diagram 3.1 ENGINE REMOVAL AND INSTALLATION I8 3.1 ENGINE REMOVAL AND INSTALLATION A. Engine Construction All DI the models incolporale the O.H.C. design, driven lrorn the center at the engine by a lightweight chain. This provides the engine wi high speed and high power output due to the elimination of the reci- pracating movements mechanical losses, and reduclion in weight. Further the chain is always maintained in a constant tension by the spring operated automatic tensioner to assure quiet operation and precise valve timing at all speeds. (2 8mm bolts and nuts. Removing tho step bar (9 Step bar Fig, 3-1. The lubrication system utilizes a plunger type oil pump, driven through the transmission main shah to provide lubrication under pressure to all of the primary moving ports at the engine and in coniunction, a screen and u centriIugal filter are incorporated in the system to assure that only highly purified oil is circulated within the engine to minimize the parts wear and attributing to the extended engine lite. ® 6Xl2 hex. bolt Removing the air cleaner ® Air cleaner @ 5X16 crass screw Figs 3—2. B. Engine removal (CB 175 and CL I75) 1, Shut oh the Iuel cock at the luel tank. 2. Remove the step bar © by unscrewing the two 8mm nuts and 5X25 bolts ® (8 mm bolts for CL175l. (Fig. 3—1) Remove the 6 mm nuts from the cylinder head and 8X36 bolt, and then the muffler can be separated. (CL I75 : Remove the 6mm nuts (rain the cylinder head and 8mm nut and 6 mm boltJ 3. Remove the air cleaner cover. 4, Remove the air cleaner (0 by unscrewing the two » - 6x12 halts ® and the 5x la cross screw @4 (9 Clutch zuble ® Clutch llIter thread (Fig. 34) 5, Remove the leit crankcase rear cover and dis- connect the clutch cable © lower end from the clutch litter thread @. (Fig. 373) 6. Rotate the rear wheel to position the chain ioint adiacent to the drive sprocket and disconnect the drive chain @. (Fig. 374) 34. Disconnecting the clutch cable (D John clip (2) Drive chain Fig. 3—4. Disconnecling the drive chain 19 3. ENGINE ® Carburetors ® 6mm hex. bolls fig. 376‘ Removing the carburetor: © T>hund|e cross screw driver rig. 3—1 installing the engine DIRECTION OF ROTATION — ® Joint (lip rig. 3-5. Joint (iip insialialion 7. Disconnect the high tension terminals 'rorrl the spark plug. Remove the starting motor cable, and then disconnect all leads. (Fig. 345) 8. Remove the carburetor ®. (Fig. 34) (Note) Separate the Iuel rank to lacilitare the removal of fire 6mm boil; 9. Remove the engine mounting bolts and the engine can be freed from the frame. c. Reassembly l. Perlarrn the engine installation in the reverse order at removal described in Section a.l Ba 2. The engine installation can be made easier w temporarily hanging the engine on the lrarne by the use of the T-hundle cross screw driver G) loliowad by the installation 0! the engine mounting bolts. (Figs 3—7) (Note) When reconnecting the drive chain the ioint clip should be installed with the opening lacing opposite to the direction of ihe normal drive chain. (Fig. 3—8) 3. Adlusl the chain tension so lhat there will be I to 2cm l0.40~0.80in| slack ul midpoint between the sprockets. 3.2 CYLINDER HEAD AND CYLINDER 2O Pies-9. Velve mechanism 3.2 CYLINDER HEAD AND CYLINDER ‘Il CVLINDER HEAD A. Construction The cylinder head is a cost aluminium rwiri cons- irvciien er a semi-spherical cambusiien chamber with a squish area for better combusiien emeiency. The slngle piece overhead camshalt rocker arm and valve mechanism are all incorporated in ihe velve chemiser above ihe cembusiien chamber. (Fig. 3—9, 340) Contact breaker assembly is mounted on the left end al ihe camshali. Cylinder head cover inedrporeies e breaihei pas- sage to prevem the pressure build up. a. Disassembly L Drain ail lrom ihe engine. 2. Remove ihe kick siarier pedal, righi crankcase cover and cylinder head side cover. 3. llemeve ihe gear change pedal, leli crankcase cover, pain: cover end breaker assembly. 4. Remove the eight 8mm blind nuts (D and 6X45 hex. boll ® and then remove the Cylinder head cover (:5). (Fig. 3—li) 5. Rotuie ihe crunkshah so ihai the cam chain iaini clip ® is reward the top of ihe com sprockei and ihen discarmeci ihe com chain a). (Fig. 3—12) . 9 _ . . ANOCh 0 wire '0 both ends of the chain before (D 8mm bind nut ® 6X45 hex bolt disconneeiing, ihis will simplily the assembly iesk ® Cylinder head cover Iaier. Fig. 3—l1. Removing ihe cylinder head cover 6. Separate ihe cylinder head CD Cam chain at taint clip Fig. :Hz. Drsconnectrnp the cam chain 3. ENGINE @ Cylinder head (2) Bluing or red lead rig. 3713, chucking the cylinder head lar walpage C. lnxpection 1, The cylinder head is exposed to the high ptessure and terrrparamre tesulting tram the combustion of the fuel mixture, further, when the head is unevenly torqued, it mw develop cracks or warpage and will cause defective xealing between the head and lhe cylinder resulting in gas leak, air sucking with consequent drop in compression. The warpage of the cylinder head does not develop suddenly and it may be ovellooked, therefore, caution should be exercised during reassembly since the uneven tarquing at the cylinder head is a very common lault. To inspect lor warpaga at the cylinder head, apply a thin caat at bluing or red lead on a surlace plate and work the mating surtace oi the cylinder head an the surtace plate; the warpage can be determined by the transler al the blame on to the cylinder head. ( 343) To correct the warpage, lap the cylinder head on the surlace plate with a #200 sandpaper, finally finish by u ing a £400 sandpaper, and then inspect again with the bluing. 2. Inspect the :ombuslion chamber. inlet and exhaust ports for cracks. 3, Inspect the valve guide and valve stem. Check the valve guide diameter at the top. center and bottom in bath the X and Y axis. using a precision cylinder gauge. Check the valve stem with micro. meter. If the valve guide inside diameter is beyond serviceable limit, it may be repaired by using a reamer (Teal ND. 07008—0010” and replacing the valve with one of an oversize. ltarrl Standard Value Servreeable Limlt Outstde diameter 5.48~5.49 mm Replace rl under l0.2]58~0.2|62 int 5.46 mm (0.215 int inlet valve , . Canlact lace runaut M'h '"Ig‘ggog’im I d d . 5.5~5.5l5mm Replace ii aver "" ” “"‘e'e’ (0.2]65~0.2|71ihl 5.555 mm (0.2l9in) lnlet valve guide Outside d2ameter ~ :gé’fé‘flggfam om ~o.oes mrn lnrerlerence m l0 00M~0 0026 III I I I I o.ot~o.035 mm Replace - over "° W “3 "WW" lo.ooo4~u.oomrnt 0.08 mm (0.028 int 5.4e~5.e7 mm Replace il under Exhaust valve OUISlde d amerer Contact lace runout lo 2l50~01l54 irrl 5.44 mm l0.‘2|4 lnl with in 0.02 mm (0.0008 in) Exhaust valve guide inside dlumetev ~ Outxlde diameter - rnrerlerence lil ~ 5.5~5.5l5 mm Replace ll over- '0.2|65~0.2|7‘l int 5.555 mm ln.2l9rnl lo.055~ l0.065 mm lo.3959~0.3953 int 0.04~0.065 mm to.oolb~0.0026 inl Exhaust valve clearance 0.03~0.055 mm Replace it over lo.uol2~c 0022 int u.l mm “1.0039 in) 3.2 CYLINDER HEAD 4. When veplacement ot lhe valve guide becomes necessary, rarrtave and replace with an oversize guide, use the valve guide remover (Tool No. 07047—04001) and the valve guide driver iToaI No. 07046—2160“ tor veplccement operation. Alter installing the valve guide, use a rearner to obtain the proper valve clearance, AND CYLINDER 22 o. Reassembly I. Clean and Inspect the cylinder head interior and exterior '0! cracks, damage and warpage, also inspect the head gasket, valves, vulva guide and spring for salistactory canaitian. Perform the head assembly in the revelse order 07 disassembly. . When installing the cylinder head to the cylinder, the cum chain should be assembled as shown in Fig. 3—14 and attention should be given to the proper valve tlming. Align the “T" liming mark on the generaiol tn the liming index mark (the piston is at toprdeadrcenlell, position the camshaft sprocket so that the "0" mark on the lace ol the sprocket is at the top, and then assemble the cum chain, The ] nt clip must be lnslalled with lhe opening facing in lhe opposite direction to the novmal chain movement. ll the cam chain lensioner pushbar is not completely pushed in, the can. chain cannot be connected. (Fig. 3-15) . The cylinder head should be lightened unllarrnly with the torque wrench in the sequence shown in Fig. 3—”. [Torque: 160~210 Kg. crn lll.6~ 152 ll. lbl] (i) Center cmnksholl (2 Cum chain guide raller @ Tensiencr push rubbev Q) Can. chain tanslaner spring (5) Tensianer :al halt ® Tensianer push bar a) Cum chain tensionel ® Cant shalt Fa. H4, Asternlrlan the earn chain (2) Tentloner push bar Fla. 3715, Pushing ln lhe tension push bar (D 'lensianer set bolt of the cylinder head, th. 5-15. Tightening sequence 23 3. ENGINE (D rram crankcase ® Exhaust gas Fig 3-”. Ptlnciple 0' breather (D Contact breaker rover ® cenraer breaker assembly rig. new. Remo ‘hg the aantaet breaker assembly (D Wood" Mock stepper ® Spark odvuncer rig. 3720. Removing the spark advoncer 2. CYLINDER HEAD COVER AND BREATHER A. Description A bteathei chamber is incorporated in the heaa cover which provide censtant pressure within the crankcase. Funher, the oil is separated trorrr the gas which is exhaust. As the oil laden oil vapor passes thraugh the breather passage, the on is separated from the gas by centrifugal force and flows down the oil passage where it is adhered. (Figa 3—]7, 3—18) B. Disassembly at lhe spark advancer 1. Remove the Contact breaker cover G), contact breaker assembly (2) and then remove rhe spark udvoncer from the camshaft. (Figs 349) (Note) A wooden stoppev block © should be used to key the camshalt ® from turning. (Figs 3710) 3.2 CYLINDER HEAD AND CYLINDER 24 2. The correct breaker point base can be removed by loosening the four mounting screw; (Fig 3—21) 3. The spalk udvancer center piece serves as a bushing tor the camshaft. It is oiled by the oil vapor and does not require special lubrication 4, Periorm the assembly is the reverse order DI disoxsembly. 5, The cure“ on ihe Contact bleaker point base should be aligned so that it is at the 10p, / ® Coniucl breaker per... base Fae 3-2L Removing the canine! breaker point base 3. CAMSHAFT A. Construction A single piece camshafl contains both inlet and exhausl cams together with lhe sprockei which is mounted in lhe center of the camshaft. The cam sprocket is driven by the clunkshoh 0! IA the Speed oi lhe crankshuli. (Fig, 3-22) Fig. 3—22A, Camshaft rt "W‘tn ® a 5w (D Camshaft (2) Tuppel udwsll‘ng nut @ tzoeker drrn ® Rocker amt strut. Fiq. 3—223. The cam is pwvided with d long gradual rise to prevent abrupt rise and drop of the valve, thus assur. ing a quieter vetve operation. (Fig 3—23) © Best circle ® Max cam Ill! ® Bufier curve a) Cam heighl Fig. 3-23. Cam contour 26 3. ENGINE B. Disassembly 1. Remove the cylinder head in accordance with Section 3.2.1. B. 2. Remove the left and right cylinder head side covers, contact breaks! assembly] spatk udvuncar and tappet adiusting hole cap, Rotate the cam- shaft so that both rocker arms are resting on the heel ol the cam, in this position, disassemble that rocker arms from the head by removing the rocker arm shuns. (Fig. 344) G) Valve vockei arm a) Rocker arm shalt Fig. 372‘. Removing me volt. meter arm 3. Remove the camshaft from the cylinder head. (Fig. 3‘25) (D Camshuh Fig. 3—25. Removing Yne camshah 3 TE '3 cow -- as 03” (D m - ‘9 0;: :3 220.5(8,6811in) 333 To age: 2.5 13$ “Us 11. :3 mm ‘D at: «22 83 Peas w 2:; (96 * - m 3‘25. Camshalt Ct Inspection Item Standavd Value Serviceabte Limit , , l9.9é7~1?.98 mm Repiace it under ‘- 50mm" [F'B- 3’25) ”‘9" 9“ d‘°’""°’ © [0.786i~0.7flébini I930 mm tonsaini , 19367-4938 mm Replace if under [9" “d‘ ““W" ®___ (fl.786i~0.7866in\ H.747 mm (0.7853inl Cam bass circle 21.0 mm 10.52“") , IN 25.057 mm [0.9865 int 5"“ ”‘9'" EX 24.57] mm to,9792ini D. Reassembly i. Screw out the tappet adiusting screw and assemble the rocker arm into the cylinder head in the reverse order or disassembly 2. Adiust the tappet clearance to 005 mm [OtOOZDin] with a cold engine. (Note) Repair or replace the camshaft it the cam is scored ur worn exessivety. 4. A D. 3.2 CYLINDER HEAD AND CYLINDER 26 ROCKER ARM Construction The function of the rocker arm is to transpose the rotary motion ol the camshalt to a reciprocating moliorl lar actuating the valve. The rocker arm is made rigid to prevent deflection and the end which contacts the cam is finished smooth alter surlace hardened ta rrtinlmixe wear. The end which operales the valve is provided wilh a tappet adiusting screw that canlacls lhe valve. (Fig. 3727) Disossembly lc Dlsassemble the rocker arm in accordance with Seclion 3.2.3. B. Inspection 1. Rocker arm slipper sur~ replace .l aver race wear 0.3mm iu.ol2inl shalt bore l0.0~l0.0l5rrlrrl Replace it ever aia lo.3937~u,3943 tni to.l mm two in} 2. Rocker arm shalt ltetn Standara Valve Serviceabte Lnnt Outside 9.972~9,9B7 mm Replace ll under dia lu.392a~0.393:l inl 9.92 mm (0.3934 inl o.ol3~o.043 mm Replace il aver Clearance [0 00 0017 int 0.05 mm (0.003“ lrll 3. Check tar praaer tappet clearance, (both inlet and exhaustl should be 0.05 mm «3.00sz too srnall a clearance will allect the engine caustng com- pression leak and results in hard starting. 4. Check lar proper valve timing (Fla. 3—28—1) (Refer to page ml 5. Check to see that the cam chain is nol stretched. Reassernhly 1. Inspect the rocker arrn cantact svrlace and repair or replace if there ls scaring ar excessive wear. 2. I! lhe rocker arm had been disassembled, the tappet clearance should be readiusled. Make the udluslmenl by pasitranlng the piston on loprdeadr center ol the compression stroke, this will free all of the valves. Align the "T" liming mark on the generator rotar la the timing index arrow mark on lhe stator. 3. Check the valve loppel clearance with the thickness gauge. (rag. 372842) five © Valve rocker arnt (2) Rocker urrrl shalt Flax 347. Rocker arm and rocker arm shalt. a \Gllmml\ (D inlet valve opens 10° @ lrrlel valve close: to? (3 Exhaust valve open: 40° @ Exhaust valve clases l0“ Fig. sen-r. Valve tinting araararn. \. e/ "I“ " e . rash yllnder head cap (2) Adllming xcvew Lack nul q) Thickness gauge rig. avzn. Checking the valve tappet clearance 27 3. ENGINE a) lnlel valve (2) Exhaust valve @ Valve spring seal @ innar valve spring @ Outer valve spring @ Valv. wring retainer (3 Valve collar :49. Valves am. (1) Valve lifter Fig. 3-30, Removing the valve ® ®—— EXHAUST VALVE (D (9——~ INLET VALVE Fig. 3—3l. Inlet ana exhast Valves 5. VALVE A. Deszription The valves control the volume of inlel gas and also me exhausl gas entering and leaving the cylinder, The diameter of lhe exhaust valve tread is made smaller [or better heat radiation. Inlet valve ls made large for greater volumetric efficiency. Double spring leature prevents the valves from llaallng during high speed aperanen, (Fig. 349) B. Disassembly l, Remove the cylinder head in accordance with Section 3.2 l B. 2. Disassemble the rocker arm From lhe cylinder head by pulling out the locker arm shaft. 3. Compress the valve spring with the valve lifter 6) ”col No. D7957A3290000l and after removing the valve cotter, valve spring and the retainer, ma valve can be removed. ( 3*30) C. inspection Exhaust Ive (F 3—31) Item Standard Value 72.l5~7z.45 mm Replaee iI under ”"9"“ (D l2.stos~2.052«inl 7le mm (2.8248inl 5.4a~5.47 mm Replace it under 5"“ d'“ ® l0a2l50~0.2154tn) 5.44 mm (0.1142 inl Head 0.55~o.as mm Replace ll under thickness @ l0.0217~0.0335 in) 0.3 mm l0.0llB in! $373373; Wirhln 0.03mm ° «mm 2 inl 2. lnlet valve Item Slandara Value Serviceable Lim 73.35 1 7165 mm Replace [I under ”"9" (D (2.5878~2.8996inl 72.95 mm l2.5720lnl . 5.40%.»? mm Replace it under 5'” d‘“ ® l0.2i58~02l62 ml 5.46 mm l0.l25lnl Head 0.a5~o.es mm Replace ll undgr thickness (3) l0.0l3&~0.0256 int 0.2 mm l0.00§3int Concantricity . \Mmln 0.03 mm or valve lace “mum,” 3. Valve spring measurement Outer valve spring Item Standard Value Sevvlpeaple lelt Replace it under Free langth 31.5mm ll.2520lnl 30.6".” ”mm", 29.5 nun/7.5~B.3kg 1.l6|4in/l6.533~ i swing "3.302 gal pressure 23.3mm/29.4~32.6kg (0.9173 ln/M.az7~ ’ 7| .883 lbs] Inner valve 5p 'rlg Item Standard Value sew ecbla Free lenpllr 30.2 mm ll.lB90inl :‘un " 1213'", 26.2mm/4.05~4.52ka ll .03l5 in/E.9%~ ‘ spring ”.57 lbs] presiure 20.3mm/l0.9~l2.lka «1.7992 m/24.035#~ — 26.68! ibsl 3.2 CYLINDER HEAD AND CYLINDER 28 a. lleassenrbly 1. Before lhe valve is assembled, lhe valve conlacl surluce should be inspecled lor wear, pining, or carbon. Afler cleaning, all lhe valve slern, and lhe valve should be inserled lrom lhe combuslion chamber side, 2. The valve auier and inner valve springs and relainers should be filled from lhe cap hole of lhe lappeladiusling hole and compressed by using lhe valve llfler lTool No. 0795743290000l. Secure willi lhe valve callers. 6. VALVE SEAT ‘ ‘ ‘ 6) Valve seal culler ® Cylinder head A. Descripllon Fig. 3-32. Rewovlihg lne valve seal The valve seal is repaired wilh lhree lypes ol curler. The relative localion and lhe widih of lhe valve seal conlacl area is accomplished wilh lhe seal lap culler and seal belloni cullers while lhe lelacing ol the valve canlacl area is perlormed by lhe 90° culler. (Fig. 3—32) Valve seal callers Descrrpnon W Valve seal cuiier 90" 07930--2350l00 Flal surlace xeal culler lINl 079604350300 Hal surlace sear culler lExl 079604360400 lnierior seal cuiier llNl 079504350500 lnlerior seal culler lEXl 0795072350600 Valve lapping operation is performed lasl, l rs is lo oblain a leak prool seal belween the valve and the valve seal. Place a liberal amounl oi lapping compound cln lire valve lace and lap lhe valves. applying a slighl pressure while rolallrlg lhe valve back and iarlh wilh a sucllon cup lapping lool. Wash ofl lhe compound lhoroughly and inspecl lhe valve seal willl laluing. ( 343) (Nola) lal When lhe valve slern is greallv worn, lhe valve guide is Usually also worn. Hence, when a valve is replaced, il also is desirable lo replace lhe valve guide. since lhe guide is press ruled, ii is recommended lhal ihey be replaced wllh an over. size guide. lbl When lhe valve is assembled. lhe campound which was used during lapping should be complelely removed. Fig. 3-33. Valve seal delail la. lnspeclian l. A valve seal in good can an should have a lull surlace conlacl wilh the valve lace. Slandard value 1.0 mm l0.04inl Serviceablel it in excess ol 2mm “108 in) 2. Assemble lhe valve lnlo lhe cylinder head so lhal lhe valves are well sealed, and fill lhe cylinder head combuslion chamber wilh oil, iniecl a blasl ol air in lrarn lhe lnlel and exhausl pans and if any bubbles should appearl ills an indicallon lllal lhe valve seals are nol compleielv sealed. ha. :l-al. Cylinder 29 3. E N G I N E 7. CYLINDER A. Construction The cylinder sleeve ls made oi special havd steel alloy and is press fitted into the lightweight cast alumi- num body. A compartment i provided between the cylinder hares to accomodale the cam chain and tensioner. (Fig. 3—34) a. Dimnembly 1. Remove lhe cylinder head in accovdanco wilh Seclion 3.2.1. B. 2. Remove the 6 mm hex. pair a) and then remove ihe cylinder (3 from crankcase @. (Fla. 3—35) ® 6mm hex bolt ® Cylinder rig. 3-35, Removlng the cylinder (3) Upper crankcase c. inspection 1. Measure lhe cylinder bore, taper, out.ol.round with: precision cylinder gauge, Take the measurement at the top, die and bottom in both the x and Y axis. (Fig. 3—36) Serviceablo limit Repair it over rnm l2.05l Repair it over 0.05 mm lo.0020 inl Repair it over 0.05 mm (0.0020 inl item Slandurd Value cylinder 52.on~52.m mm bore 59~ .59 - q" d" 0.005 mm l0.DUDZlnl taper Cylinder out 0! round 0.005 mm l0.0002 inl The clearance between the piston and cylinder will greaily afiecl the engine performance. Because the pislon is ellipllcal, lhe clearance is controlled very closelyr The clearance are nol lha some. however, it any area is greater than 01 min lQOlMln), the cylinder should be rebcred and fitted wllh an oversize piston. Oversize pistons are available in 0.25, 0.50, 0.75 and 1,00 mm (0.01. 0.024 0.03 and 0.04m] size, G) cylinder gauge ® Cylinder 2. Fig. 373.5. Measuring the cylinder bore 51 55~Sl SD zuzeijzlmsin) 3. When removing carbon deposils tram the piston top and ring gioaves, care should be exercised so as to not cause any sclulches or damages to the piston. 51.96—41.98 20157~Zl1465lnl 4. Measure the piston perpendicular lo the piston pin hole. (Fig, 3—37) item Standard Value Top 51.55~5|.60ri\m Outside lzoau~zeal .nl dlu SW 5|.96~5L96 mrn l2.046~2.o47 inl Fig. 347. Piston Servieeable limit 5. Measure ihe piston ring side clearance with a lhickness gauge, (Fig. 3-38) ltern Standard Value Sewlceuble Limit 1 c.025~o.055 rnrn Realaee ii oval em" W «1001 ~0.0022 .nl 0.l mrn (OsDN lnl ,in We D.ol$~0.045 mm Replace il over clegah “cm“ l0.0006~0.0018inl 0.1mm lmmmt ance m o.m~o.ois mm Replace il over ' lo.ooni~0.00l3inl o:l mm l0.004lnl ® Piston (it) Piston ling Rip, 3-33. Mauxuving the piston ring side clearance ® Thickness gauge 3.2 CYLINDER HEAD AND CYLINDER 30 6. Piston rlng groove trern Standard Vutlre serviceable Limit . 45.9~46.0 mm B°"°’“ 5‘“ lt.7o7~l.alt int Top 1.205~l.220mm Replace it aver Groove second l0.047~0.04fi int 1.3 mm inoslzini width 0“ 2,5o~2,52 mm Replace it over [0 098~0.099 W 2.6 mm I0.1024inl 7. Pistan rings Measure the ring end gap by inserting the piston rtna into the cylinder so that the ring is at right angle to the cylinder axis. (Fig. 3739) liem Standard Value Serviceable limit G) “Mm; gm. ® piste" mg @ cyltnde, Top :61:st 161,835 Iain", fapgcnemvlmtruzrm’ he. 37:7, Measunna the prstan ring end gap Ring Sum l.l75~l.'l9D mm Replace It unaer thickness lo.oca~u.o47 int Ll35mm lommnt 0“ 2.4754490 mm Replace it under «0.097 ~o.095 in) 2.43 mm (0.095 7int mg rep 0.52~0.7a kg Replace rt under “wing Second 3.7125~ll0,7028I:sl :Jfkg (3.922%! . . ~ . e ace. an .r W" 0" (l,59~2.21|b?l naps kg (11.59 last he and gap 0.is~0.40 mm Replace rt ayer_ m.no.s~o.ole in) on mm lo.03i5 rnt 0, Check the gaskets tor damage. Replace it any damage exists. (Nate) , I. Oversize piston rings are available in tour sizes; 6 Cylinder ® Piston blue (3) Piston ring compressor 0.25, 0,50. 0.75 and 1.00 mm (0.01, 0.02, 0.03 "I 3—40, Installing the cylinder and 0.04mi, 2‘ When ma rig piston ring and gap measurement. insert the ring carefully into the cyfinder to prevent scratches or gauges to the cylinder Wall. o. Renssembly 1, Atter assuring that lhele are no damages or exces» sive wear to the cylinder, assemble the cylinder in the reverse order of disassembly. 2. Make sure that the cylinder gasket and the two dowel pins are installed. 3, During the installation at the cylinder ®, use piston bases ® to prevent piston movement, also use a ring campressar @ to prevent ring damages (Fig. 3—40) 4, Assemble the cylinder head and cover unit. (Nate) Check to make sure that the gaskets are properly in place. 3.3 LEFT CRANKCASE COVER 1. LEFT CRANKCASE COVER A Construction Ttte purpose ol the crankcase is to protect the vital components of the engine. The left crankcase houses the AC generator stator. (Fig. 3—41, 3—42) F. 3—“, lalt crankcase cover ENGINE u 3] a. Disnnembly 1. Drain vhe oil from the crankcase, 2, Remove the gear change pedal, 3. After removmg me mounfing screws, me la“ crunk‘ Case cover can be separared from lhe <2 0 ring @ Curler valve guide @2 Pump lock washer @@ 6 mm hex nur, Fig. 3-66. Pump compcnem polls 7. Component porls ol oil pump. (Fig. 3—66) c. lnspeencn I. The normal copoczry ol rhe oil pump is 3600cc/minule or 10,000r‘pm: ii lhe capocily rolls below 3400a; lhere is a danger 0! developing engine seizure. rherelore rhe pump should be repaired or replaced. 2. Clearance of componanr puns llem srondord Value Serwceaole Linur Plunger lp 0.025~0.063 mm Replace If over housing |0l001~0.0025in1 0.17 mm (0.0057 in) o. Reussembly l. Assemble rhe pump in rhe reverse order at disuse sembly, (Note) a. Proper operoricn or rhe oil pump can be checked by loosening rhe len reor cylinder head cop nur. ll oil seeps our, rhe lubricorion is normol. b. If lhere is absence of oil, check rho lollowino poims: lol Proper assembly el rhe pump. (bl Condirion el geskers. lcl Excessive clearance ol punger. ldl Molluncrien ol rhe sleel ball valve. le) Clogged screw. lli Clogged tiller or oil passages. 3.6 CRANKCASE 40 2. OIL FILTER A. Description The engine oil is 1100ny filtered through the cenlrtlugal mter arid the rnesh screen filter to assure clean supply at all to the engine, (Fig. 3—67) The screen nlter ls on the pump inlet side and the centrilugal filter is on the outlet side. Disassembly Remove the rrght crankcase caver ln aceardenee with Seetlan 3.4. B. For cleaning at the centrilugot oil filter, anly the lemovul at the all nlter cover ls required. l. Grasp the rib of the oil filter cop (D with a plier and draw stralghl out. (nee 3—68) 2. use a screwdriver and unlock the lock washer. 3, Remove the mounting nut with a speclal tool. 4‘ Pull oil the all filter rotor. c. Reassernbly l. Alter cleaning at all the parts, perlarrn the reas- sembly In the reverse arder al disasseblys 2V Malre sure that the 16 mm mauntlng nut ls praaerlv torqued and filter cap well sealed. 3. OIL SEPARATOR Au Operation The all separator (D is located ln the larward sectlen el Ihe lower crankcase, directly below the crankshaft Its prlrnary tunetlan is ta eantral the all splashed by eranlshalt counter welghts, prevents all penetration and controls the all temperature. (Flg.3— 69) 3.6 CRANKCASE A. Description The upper and lower crankcase: are constructed at lightweight aluminum alloy and can be separated at the center llnes of the crankshaft, transmission shaft, and the kick starter splndle. In uddltlon, the starting motor ls mounted at the from section of the C3175 crankcase In the Upper sartaee at the upper crankcase, the cylinder stud bolts are lnserted. The lower crankcase is equipped with the oil separator, lower crankcase cover, and two drain plugs. (Flge 3—70) Cl) 0}! filter rotor ® 46x2 Oring © Oll filler cap rip. H7. on (‘lltor (D Oll filler cap Fig. 3-63, Ramoving the all nlter cap Q on separater nae 3—e9. Lewer clonkcuse @ Dram plug Fig‘ 3—70. Drain plugs 41 ENG (D 8mm bolt (2 6mm ball Fla. 377M. Crankcase bolt 3—7“. Bolts and nuts on the lower crankcase D. G) 6X20 hex bolt ® 6X28 hcx bolt (3 Start © 4X36 hex halt Fig. 342. ksmoymg the Starling matar A. Figs 3-7”. Cronkshalt. INE Disassembly 1. Drain oil in the crankcase. Remove the cylinder head and cylinder. left and AC Separate the crankcase cover generoton Separate the right crankcase cover, oil filter. clutch and oil pump. Remove 8 mm nut and 6 mm nut from the stud bolts at the upper part of the upper crankcase. (rig. 3—7l—A) Remove 8 mm nut, 6 mm bolts and 5 mm bolts lram the lower crankcase. (Fig. :Hlvs) Remove the two 5X12 cross screws and starting motor side cover, and then remove the 6X20 and 6X26 bolts on the right hand side at the crank- case which mount the starting motor. (Fiql 3—72) By removing the 6X35 bolt on the lelt hand side at the starting motor which is supported by the crankcase, the starting motor can be removed. . While the key on the gear shift arm is released trom the shirt drum, dismount the motor. c. Inspection l. Check for damages especially around the machined mating surtuces since eVerl a small defect will cause oil leaks. The mating suriacas should be that to within 0.05 mm lo.oozinl. Measure with a thickness gauge on surtace plate. Reassembly 1. Assembly should be parlarmed with attention paid to the following points . Clean the crankcase and inspect the mating sure laces or the crankcase tor sign ol leaks, scratches and other damages. - Apply liquid gasket to the mating surlaces alrhe casai assemble alter drying. 3.7 CRANKSHAFT, CONNECTING RODS, AND PISTONS Construdion The crankshaft iournals are made 0! high carbon steel and the counterweights are of nlckelechrome- molybdenum steel, assembled by press ntting. Crank. shalt is supported by three roller bearings and one ball hearing which takes the thrust laad and are fixed in place by dowel pins. Sprocket to drive the cam chain is machined on the cenler shalt. (Fla. 3'73A, B) 3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 42 (D Lcii crankshcll ® 35 mm circlia @ 35mm side washer G) L rnain bearing Omar ring @ 4x10 roller (9 |.. main bearing roller reiaincr CD 5mm scaling Washer (3) Le» cemov cmnk Weighl 4x13 roller «9 Cemor hearing raver raiaincr ® Ccniar crank inan @ ii cenler crank Duler ring @ Eight ccnrcrcrank wei‘gM @ Connecting raa @ zsxio roller @ Connaciing rel: raner rcrainer (1) 6305 SHS ball bearing @ Righ) :mnkshnh Fig. 3—735. Crankshali camplcrc secrionai diagmm The an curler passage in ma upper crankcaxe is aligned to the oil annular groove in the crank counreb weight Oil is Iorced imo me crankpin by cenvriiugal force to Iubricaie ihe conneciing rod hearing. There is also a sepumre oil route to Iubricaie rhe main bearings. (Fig. 3774) a. Disassembly 1‘ Drain oil from me clankcase. 2. Separate the cylindev head and cylindeL 3. Sepaiace me Ian and righi crankcase cover. 4‘ Separate me AC generuior and clutch o‘il pump. (D Oil ® Cenrer crank onrcr ring (5) Crank weigh! 5, Disassembie me crankcase in accordance wiih $.C5’392f'”§,finnr. iabricaiing passage section 363. , c. Inspection I Suppori ihe crankshah on V block: at how bear- ings and measure me amount 0! runom. (Fig, 3775) Item Standard VG‘US Sarwceable limil Len bearing chiace or repair web side at gggg‘w .i over iorai 30 mm mm ' ocoa mm «1.0032 ini runovi iiignr bearing Replace or repair web side or magi", it over 30 mm[1.3in1 ' 0.08 mm [0.0032 inl (D Dial gouge Q) Crankshaft compiete Fig. 3775. Measuring me man runoul 43 3. ENGINE ® Mum hearrna outer ring (2) v block @ Crunkxhuh g) Dial gauge Fig. 3—76 Checkin iha crankshalt for verllcal cleavanco (D Main bearing aular ring (2) Dial gauge ® v block (9 Cranksnalt r' r 3~77r Checking the crankshalt far side clearance (D Connecting rod ® Roller ® Retainer rig, a—7a. a) Max deneciion Figs 3-79. Checking deflection a! the piston end 0' "to connecting rod 2. The clearance in the bearing is measured by fixing the crankshaft on centers and moving the bearing in the axial and vertical direction (Figu 3*76. 2—77) item Standard Value Serviceable ii Axial wn .n 0‘05 mrn R-ploce it over clearance (0.0020in) 0.1 mm I0s0040inl Clearance D.0l2~0.02 mm Ronlace i over normal to axis l0.0005~0s00083n) 0.05 mm moment When the clearance in the axial direction becomes excessive, the crankshuh will move from side when engine is running and produce undesireable noises as well as causing uneven wear to the cylinder, piston and ihe timing gear. CONNECTING RODS Description The connecting rods are oi molybdenum steel ana have on Heshaped section; the roller bearings oi the crankshaft end. The crankshan is polished alter case hardening and mounts the roller without race. The roller l2.5>< 10) is held by the roller retainer made oi special aluminum alloy. Staggered rollers are used in order to increase the load capacity. (Fig, :48) Inspection L Measurement of deflection at the piston end at the connecting rod. (Fig. 3779) item Standard Value Servicaobie Limit u Replace 1! oval D°“°°"°" 313mm IoJlal inl 3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS 44 2, Measurement to determine it the connecting rod ends are correctly aligned and parallel is obtained by measuring the difference ot inclination oi points 50mm limit) away from the center when a IClOnlrrr (4.0m) bar with the same thickness as the piston pin diameter is inserted into the bore of the piston end and twisted to the right and left, and when the bar is rotated 90" and again twisted to the right and left, (Fig. 3—80 3. PISTON A. Description The piston is made trorn select material, an aluminum casting. This material is light and suitable tor high speed, in addition to having good heat conducting property to dissipate the heat rapidly. Furthermore, the coetiici nl oi heat expansion is small thus minimiz- ing the worpage at elevated temperature and permitt- ing a small piston to cylinder clearance design. The shape oi the piston is an elliptical lapel. The head of the piston, compared to the skirt, is exposed to her temperature and since the expansion is greater. it is taperingly smaller toward the top. The tapering of the piston also tends to lessen the piston slop when the throttle is lightly strapped without the engine being loaded. (Fig, :Hal) The piston employs a tour step taper. The piston pin boss area is made thicker thereby resulting in greater expansion at high temperature. For this reasonr the diameter of the piston skirt is made smaller in the direction ol the piston pin so that at the high oprating temperature, the piston will expand into a true circular shape. The skirt is constantly provided with flexibility to assure that no deformation will result even rront extended continuous driving. The piston pin is other irnm lo.04inl trorn the piston centerline in the direction at the inlet side so that when the piston approaches the top dead center of the compression stroke, the side load iron. the cylinder moves from the right side to the left. With a “O” onset. the point will move to align with the top-dead- center at the compression stroke. B. Disassembly I. Remove the piston pin clip and push out the piston 3783) \ A—B =DEGREE 0F PARALLEL lSM (D Max deflection degree or Parallelism rig. 34m. Checking level or parallel at the piston and or the connecting rod ® Valve escape ® Piston ling grooves @ Fislan pin hole rig, 345i. Piston LULUXMiII) rig. 342. Piston onset (D Piston pin elip ® Plston iia. 3—83. Removing the piston pin 45 3. ENGINE 2' Remove the piston rings tram the piston by using a piston ring tool tspeciol tooli. If the tool is not aVoilable, the rings may be removed by hand, spreading the rings at the ring opening with both hands During the process, the ring should not be twisted or expanded more than necessary as it will cause the ring to break. (Fla 3434) (D Pistan ring (2; Piston Pig. 3-“. Removing the piston ring c. inspection l, aelare inspection, carbon adhering to the piston head or ring groove should be removed, using care not to scratch the piston. (Note) Sandpaper should not be used lor removing carbon. use a carbon scraper. 51554150 zsnzvsjzaslsm) 2. Piston outside diumaiar (Fig. 3—85) l in Standard Value - Head 5| r55~5l .50 mm 5'36 51‘” diarneter l 0295-4 3n V0t57~2 MGSin Maior 51. 6~5 . 5mm diameter (2.0457~2.0¢55 inl Fig. 3-55. Measuring the piston outside diameter 3. Ring grooVe elearanee when a new piston ring is titted. (Fig. 3—86) item Slandmd Value Serviceuble Limit I V 0.025~o.ossmm Replace it over °P ""9 l0.00l~0e00in) 0.1mm lomunl V 0.ol5~0s045 rnrn Peplaee it over 53““ ""9 m,ouoo~o.oolaini o.l mm 10.0041"? 0‘ . OVOID~U.045 mm Papiaee il over ‘ ""9 lo.auu4~o.uola inl ml min imminl CD ThHmess gauge ® Piston 1mg (5) Piston Pia. 3AM Measuling the ring groove clearance A. Piston pin hole (Fig. 3—57) ltem Standard Value Serviceable Lirnlt Bo 14,002~u.ooe rntn Replace it ever '° I0.55| ~o.552 in! ”.05 mm to.5532 inl 5. For oversixe pistons, there are three at intervals 0' 025 mm i0.0l inlo q) Cylinder gauge a; Piston Pia. H7. Measuring pmon pin hate D 3.7 CRANKSHAFT, CONNECTING ROD, AND PISTONS Reassernbly l. Assemble the piston on the connecting rod, anty a slight pressure should be required to install the piston pin. Install the piston pin retaining clip at both ends, (Fig. 3*88) (Nate) lal The top at the plston is marked with "IN” to one side. Piston must be installed with this mark toward the inlet side. (bl Use the new piston in clips. PlSTON RINGS Constructlan The piston Tings pertarrn a vital function at tanning a seal between the piston and cylinder. controlling the lubrication at the cylinder wall and dissipating the heat from the piston. This serves to develop greater power output. The rings are made of special cast iron for strength, wear resistance, heat resistance and good heat conducting qualities. Rings are given parkerlzing treatment for added strength. Tap two rings are compression rings to prevent gas leak, these two rings ant made with a slight tapered surface where it contacts the cylinder wall to expedite wearingein, top ring outer surtace is hard chrome plated for extra wear. The oil ring is grooved tor oil scraping Inspection I. When the piston ting has been removed, it should be fitted with the gap approxi ately l5 ntnt lo.6 in) lronl skirt of the cylinder at a right angle to the eenier line. Measurement oi the gap should be made w h a thickness gauge. (Fig. 3*89) item Standard Value Sow eahle Ll Top mg o.l5~o.¢ mm Replace rt ever_ lo.ooe~o.ula lnt 0.8 rnrr. lu.oal5rnl Second mg 0.ls~u.4 mm V Replace it over l0s006~0.0l6 int 0.8 mm (0.0315 int 0" mm o.ls~o.4 mm Replace il aver (0.006~0.0!6inl 0.5 mm lo.0315 in) measuted with a 2. Tension of the plslon ting tension measuring instrument. lterh Standard Value Sewlceuble Limit Top, o.52~u.75ka Replace it under Second ting lo.nzo~o.03plal onka “1926 lb) Oil " o.72~lo.oakg Replace it under "9 l0.¢25~0,397lbt 0.53 kg ll.lé9lbl 46 (D Plstott pin (2) P ten Fla. Has Assembling the pislon © Thielrnass gauge (3 Pislan ring Fla. a-av. Measuring the pistan ring gap 47 a: ENGINE ® Hg, 3—90A. Pislon ring (Top! Fig. 34900. Figs-00c Piston ring 10:" P151011 1ng isecondi 3. ision ring dimensions, (Fig. 3~90A. B, 0 No. Hem Standard Value Serviceable 1-1.... Mm (D Outside die lStanduvdl 51.00 12.047 1m None Outside the 0.25 10.7.1515) 51.25 120570.: 25 0 Outside dia 0.50 [Oversixul 5250 12.057 in) 50 ; Outside din 0.75 [Ovalsizol 52.75 12.07701 75 : coma: did 100 lOverSIza) 53.00 12.057 in) 100 9 ® Widlh 2.3~2.5 10.091~o.095im @ Thickness 1.155~1.1a10,045~0.0¢5¢1n1 1.125 10.04431") @ Aug1e zo'~50' CD 00 ' di’a (Svandord) omide am 0.25 (Oversize! g Outside din 0.50 10mm» Sam as lap vino ; Oulsida dia 0.75 (Oversixal E Ouvsids an: 1.00 [Oversize] E @ Widlh 2.a~z.5 10.091~0.o95m ” a) Thieknos: 1.175~1.1910.045~0.047im 1.135 10.044700 @ Angla I°~l°30’ @ Outside din mandam) Outside din 0.25 (ovenizei o omide diu 0.50 lOverxixe) Same as mp ring g omside die 0.75 (Ovsrsize) : omide din 1.00 ioveuszel 0 ® Widm 2.34.5 10.091~0.095in| 6; Thickness 2.475~2.4910.097~0.0901n1 243100957110 a) Angle None 3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER 48 c. Replacing the piston rings l. When a piston ting is reassembled, it should he fillednlo the cylinder. inspection should be made to deleimine it the gap ol each ring is between o.i5inni [0.006lnl and 0.4 mm iomaint. it the gaps are sonewhet less, they should be dressed with a file. (Caulion) (ul When a gap is dressed with a file, adiuslmenl should be made perpendicular lo the rings. lbl It the piston ring gap is too small, seizure between the ring and cylinde! occurs due to thermal expansion; if the gap is loo large, oil penetration or gas leakage occurs. 2. When piston ring is assembled on the piston, any interference between the ring and the groove may prevenl smooth operation. lt is necessary to inspect lot clearance, when new ring is filled to the groove, by rotating the ring around the eiiciiniierenee. (Fig. 34m 3. Install the rings on the piston with the piston ring tool, the rings mw also be installed manually. Install the bottom rlng first, (Caution) (a) Core shauld be exeisized no! to install the rings upside down. The top side of the ring is marked near lhe ring opening with the manutectuiers initials. (Fig. 342) lb} Warn or rlrlgs which has lost its tension should be replaced. 4. Space the piston ring gaps 120" apart. at the gaps will result in pressure Ieok. Aligning a) Pislon ling ® Fla. 1H7], Inspection at the piston ring by rotating around the ring groove 0 Fig. 3-92. Piston ling 3.8 CAM CHAIN TENSIONER AND CAM CHAIN GUIDE ROLLER rig. m. Com chain Ienslonei 49 3. ENGINE l. CAM CHAIN TENSIONER A. Operation The can. chain iighiener is used to tighten the cam chain from the outer side with the cam chain guide vo|ler in between As shown In the Figure, the tensioner push bar is automatically Under compression by the cum chain tensioner spring and supports one end of the tlghiener. On the other hand, the tensionet roller is uppiying pressure against the cam chain, when the tensioner set bolt is loosened, the iensioner push bar cute» matically takes Up the slack at the cam chain by applying lorce item the spring. (Fig. 3—93) Bi Disassembly L Separate the cylinder head and cylinder. 2. Tie a wite across the ends ol the cam chain. 3. Remove the two 6X20 bolts mounting the cum chain guide roller and separate the cam chain tensionei from the crankcase. 4. The cum chain guide roller is coupled to the cum chain tensioner and remove the cam chain guide lolier pin and then separate the cum chain tensianer. (Fig, 3794) 5. When the 5mm thin nut is taasened and the J A ~ . tensioner set ball is removed, the tensioner push 3) CW" “mi" 9““‘3’°“" .‘2’ C“ "‘°"‘ bur coupled to the cylinder head is separated “' 5‘“- C°"' mm ”mm” tageiher with the tensiener spring. (Fig. 3—95) c. Inspecrien 1. Check the can chain tensioner tar any damage or wear. Item Standard Vatue Servicwble linnr Tensionet , spring tree as mm (3.21“; int Qgflfifia'ux?" length ' '" . tl inn/u 55~oe5kg T°""°" ”.6“ in/ 43 lbs] D, Reassernialy l. Perlovm the assembly in the revetse ovder of (D Tehsloner set halt (g) ienstaner push but disassemhlyt @ “WOW WW a. Replace any warn or damaged guide or ten- Fig. 3795. Assembling the ienstonev push bar . stone! voiler. b. Assemble the tensioner push bar and spring into the cylinder head and lock with the set bolt. The push bar should be in the vetvacted position to iacilitate connecting the cam chain. (F t 3*95) E. Cum chain tension adiustment 'lt Loosen the tensioner Set bolt and the chain will lighten automaticaily. 2. Reset the iensionei set bolt and lock with the lock nut. (Fig. 3476) 0 tacit nut ® Tensiener set bah Fig. 3-95. Adiustlng the can chain 39 TRANSMISSION 50 3.9 TRANSMISSION A. Description The transmission receives the rotary power trarrr the crankshutt and through a series oi gears, eharrges it to the desired speed and then transmits it to the dliVe sprocket to drive the rear wheel. All the gears are fully canstunt meshed, assuring srrraath gear eharrge. (Fig. 3e97) ® .5304 HS ball bearing (2 Transmission main shah © Man. shot) top gear (4) 20 mm thrust waxher A S) no mm cirrclin @ aati eearirrg set ring A ® 3x152 stud ® IOXH knock pin (9 Mair. shah shining gear 63 Main shalt second gear @ i5mm becrittg bush A @ Knock pin @ 8x25><8 0“ seal ® 16mm bearing bush B a; Knock am 6; Counter shetr low gear @ Counter shah second gear @ 20 mm err~eirp @ 20 mm thrust washer A Q Counter shair tourrh gear @ Counter shan third gear @ Counter shatt top gear @ 20x52x9 TCrtype an seat @ Drive sprocket nert @ Drive spreeiret fixing atare ® exm hex. bolt @ 10XN kneel pin @ Transmission counter shah Figs 3477, Transmissiarr is OPERATION When rhe clutch is engaged, the power tram the . l I _ , crunkshatt is transmitted through the clutch assembly to drive the transmission main shafts During the shitting Oi the transmission gears, the clutch is disen- gaged to stop the ratation ot the main shait. FF The position oi the gears will be described in reterence to the neutral gear. Neutral: (Figr 3*75) When the transmission is in neutral. the gears in % the transmission are arranged so that there is no power transmitted train the rransmission main sitait to the counter shaft. The fixed main shalt law Fla- 3473. New“ gear 6) is meshed with the tree ratating counter shalt low gear @. tree rotating main shait rt t—rtt 3. ENGINE gt it fig. 349‘ Low gear Fig. ZHOL Third gear Fig. 3402. fourth aeot top gear 6) is meshed with the stiding counter shah top gear (7), sliding main shah thirdJounh gears ® are meshed with the [res rotating counter shatt- thirdtourth gears @ 6) and the tree rotating main shalt second gear ® is meshed with the splined counter shah second gear ®. Low: (Fig. 3—99) When the gear is shilted to low, the sliding counter shah top gear 6) is moved by the shih tori to engage with the tree rotating counter shatt low gear @. The power tram tha transmission main short (D is transmitted through the fixed main shatr low gear to the counter shah low gear, across to the counter shah top gear and then to the drive sprockt @ mounted on the and at the counter shah. Second: (Fig. 3400) When the gear is shittea to second, the sliding main shah third»Fourth gear (2 is moved by the shih tark to engage with the tree rotating main shah second gear CD. The power from the transmission rnairt shah (D is transmitted through the main shah third.tourth gear to the main shah second gear which drives the counter shaft second gear (A) and hence the drive sprocket ® mounted on the end or the counter shah. Third: (Fig 3—10” When the gear is shifted to third, the counter strait top gear © is moved by the shirt fork to engage with the counter shah third gear @. The power lrom the transmission main shaft is transmitted throught the main shah thiraefourth gear to the counter shah third gear, across to the counter shah top gear a) and ta drive the drive sprocket @ mounted on the end of the counter shaft. Fourth: (Pia, 3-102) When the gear is shihed to tourih gear, the sliding counter shah second gear © is moved to become engaged with the tree rotating counter shah fourth gear ®. The power tram the transmission main shah is transmitted through the main shah thirde tourth gear (2) to the counter shah tourth gear 6). across to the counter shah second gear @ and then to the drive sprocket @ at the end at the counter shaft. Top: (Fig. 37103) When the gear is shitted to top gear, the sliding main shah third-fourth gear G) is moved by the shih fork to become engaged with the tree rorating main shah top gear @. The power tram the transmission main short is transmitted to the main shaft third-fourth gear (2), over to the main shah top gear @, across to the counter shah top gear G) and than to the drive sprocket (Q at the and ot the counter shah. 3‘9 TRANSMISSION 52 B. Disassemhly C. 'l. 'l. Disassemble the cylinder head and cylinder, 2. Separate the crankcase Inspection Main shalt re main shaft gear clearance. Item l sranaara Value Servicaablu limi! Second o.0ls~0.045 mm Replace it over gearllsgSl l0.0005~0.00lain) 0.1mm «mount Top gear 0.0H~0.0A5 mm Replace it over l202l I0.0004~0.00I a in) 0.1 mm [0.004 in] 2. Caunler shaft to counter shalt gear clearance. Item Slundord Value Servlaaaala lelt Third. o.009~0.025 mm Replace it over 0.1 mm [0.004 in] Replace il cm 0.1 mm [0.004 W Fourth gear m.oum~o.unloin> l o.oxa~a.045 mm °"’ 9°“ (D.ODOé~0.DDIBinl a. Hearing clearance. (Fig. Hon Item Standard Value Serviceubla limit Axial lem 0.05 mm Replace it over clearance (0.002 in) 0.1 mm (0.004 in) Raalal 0.ol~0.025 mm Replace .I over clearance (0.000‘~D.0010 ml 0.05 mm i0.002inl A. Shllt drum groove. (Fig. 3—405) Standard Value: 6.1 ~62 mm (D.240~0.24A lnl Serviceable llmll‘: 6.4 mm (0.256 in) D. Realsembly l. Assemble the transmission gears in lhe reverse order of removal. N After assembly, all components should be checked to assure that the operation is smooth wllhaut any binding, .9 Inspect the mating surlaces of the crankcase lor any scratches or damage which will be a source 0! oil Isak. ’ fl fig. a—wa. Top gear (D Dial gauge @ Bearing @ v block Fig. a-m. Measuring clEu'unze ol the hearing 7E~Ilsslrlll (u.lfl§~t\t722ll) as-aasizm :s—i 3m) fig. 3-105, Measuring the shill am.“ groove 53 3. ENGINE (D strut drum stopper ® Gear sniit drum © Gear shilt arm spring ® Geausbiit return spring © Gear shirt spindie comp. r r 3406. Gear shit) arm ® Shitr iarir gt) e pin clips (2 Gaar shirt torlrs Fig. 3—107. Rumovmg the shiit inrk guide pins (D axzo hex boit drum stopper ® Stopper arm plate - . 3.10 Removing the shii drum stopper 6) Gear shiir spindle ® 12mm sei ring fig. 340% Removing the gear shift spindle 3.10 GEAR SHIFT A. Operation The gear shift fork is moved linearly by the rotary movement of the gear shift drum. When the gear shilt pedai is depressed, the gear snittspinaie, through the gear shin arm, causes the shili drum to move either in the clockwise or counter Clockwise direction, depending upon whether the torward or rear oi the pedal is depressed. The shilt lorks are fitted over the shift drum and guided in its linear movement by the cam groove on the surface of the shift drum into which the fork guide pins are insertedr Rotation of the drum shilts the forks to the right or left which in turn performs the gear shifting. A gear shift return its normal position utter each gear change stroke (Fig. 3—106) Disassembly i. Disassemble the transmission in accordance with section 3.9, B. 2. Pull out the gear shin guide pin clips and guide pins. (Fig, 34107) 3’. Remove the neulral switch ro‘iot and stator lrom the left end of the shift drum. 4. Unscrew 6X20 hex. bait (D and remove the shift drum stopper ® and stopper arm plata ® (Fig, 3408) Draw out the gear shift drum The gear shift spindie and return spring can be removed by removing the set ring iron the ow posite and oi the gear Shit! spindier (Figa 3409) C. l. 3. D. R 'I. 3.11 3.10 GEAR SHIFT Inspection Inspect the gear shiit spindle] gear shitt arm and gear shut tarlrs tar twist or bend. inspect the gear shiit drum and guide pin lar excesslve wear. Check the springs lar bveukaga and proper tension. eaxsembly Insert the gear shift drum at the right side of the upper ciankcose and assemble the gear shift fork in the crankcase. (Flu. 3—1"), 3—H” Assemble the shift fork with the gear shift fork guide pins and guide pin clips. Assemble the neutral switch rotor and the stator. . Assemble the shift drum stopper; this completes upper case assembly. , Assemble the gear shiit return spring in the lower crankcase. The gear shill spindle should be inserted together with the return spring tram the right side of the lower crankcase. The gear shilt spindle side stoppe‘r and oil seal should be inserted at the lett end at the shilt spindle and then install the set ring. Assemble the crankshalt with transmission gears in the upper case and tighten the lower crankcase. . Complete the assembly in accordance with section 3.8. KICK STARTER 3.11 KICK STARTER 54 (D Gear shill lork guide pm (1) Gear shilt lork guide pin clip @ Lett gear shill Iork @ Center gem shitt lavk @ Right gear shllt lart © Gem shill drum. ® Gear shill lorlr ® Gear sttitx drum Fig. :Hll. Assembling the gear shilt tart 4 G) 25 mm {in spring ® 4xl5 knock pin F p Q) Ftiztion spring @ Kick starter pinion 3-l12A. G) Kick starter washer Kick starter aswmbly G) chk starter spindle (3 Kick starter (D 25 nun ctrrclip ® Friction spring (:9 Kick starter pinion © Kick starter washer (3 Kick starter spindle ® Kick starter spring ria. :leu, Disassembling the kick statier A. D. 3. ENGINE Conflrucfion The kick starter pinion engages with the transmis- sian low gear and by utilizing the transmission gears kicking is made easy and does not require much tarce. When the kick starter shaft is rotated by the kicking action the serrated kick starter ratchet flange is rotated simultaneously and the pawl of the kick starter ratchet flange slides down tram the kick starter guide and is pushed against the kick starter pinion graoye by the pawl spring. Power is translerrea from the kick starter pinion to the countershatt law gear. When the kick starter is not depressed or the kick starter pedal is released alter kicking, the kick starter ratchet hange ls pushed back by the kick starter spring, The pawl rests on the kick starter ratchet guide and the kick starter pinion is (reed. (Fig, 3—iiiA, a) 'sassernbty l. Separate upper and lower crankcase in accordance with section 3J0. B. 2. Take out the kick starter shalt. 3. Remove the main shaft, countershatt and gear shilt drum. Inspection Check the ratchet and the kick starter pinion ratchet for excessive wear and teplace ii excessive weal exists. Reaxsembly Reassemble the kick starter in the reverse order of disassembly. Setting specificatian [CBI75, (1175) Moael ca 175 CL I75 Calbwelov type PW 2o PW 22 Setting mark 03-5 5 Main bore 20 mm “1.757 int 22 mm (0.5.57 int Main iet s 95 5 95 Air iat ttlno $100 All bleed AB] o.a¢x4 Asl o.9¢x4 AB 2 o.s¢x2 AB 2 o.a¢><2 Alia o.s¢><2 AB A 0.6¢X2 A53 n.s¢x4 AB 5 aegixz Needle iet 2se¢xu¢ 2.a¢><3.6¢ let needle 3°, 25:5ng stage 4“, wastes stage Cutaway iihrattie yalyet no $3.0 lWIdlh L2 aepth 0.5t All screw wit/g %:% Slow iet #35 to.7x2x3i 538440 (0.696X2X2l Valve seat up 2.09s mat outlet D.8¢ t=a.o nnn Lots P=s.5 mm) Fuel level 19.5 mm (0.768inl 23.0 mm in int 3.12 CARBURETOR 56 3.1 2 CARBURETOR (C3175, CH 75) Ar CONSTRUCYION The C8175 ar CLI75 is equipped with a twin variable venturi carburetors operated synchronously by a single cable lrarn the ihrairle grip branching ia the two ihroiile valves. The choke valves are cannecied by a linkage. Each cylinder is equipped with an individual carburetor to provide maximum parlannance. The operation at the engine creates a vacuum within the cylinder and this draws the outside air into the cylinder after having been passed through ihe air cleaner where the air is cleaned, ihraugh ihe carburetor where ihe plcper arnaunt of fuel has been mixed to torn. a combustible mixture and finally enters the cylinder where it is ignited to praduce the power necessary ic pcriarni work. FUEL SYSTEM As the air enters the covbuletor, it passes under the throttle valve where vacuum pressule is produced due to the restriction caused by the lhroltle valve extending into the main air passageway. The luel discharge outlet is located in this so-colled venturi area so that the vacuum pressure can draw out the tual. This carburetor incorporates both the main and a slow system. Fig, :Hla. Sectional view at carburetor lCBl75l 57 3. ENGINE fig. 34”. Sectional view at carburetor (cum A. Main system (Figr 3413. J-I'H) The luel passes through the main [et ® and enters the needle iet holder ® where it mixes with the bleed alr entering from the bleed hale located around the needle iet holder Q). The fuel air mixture passes by the opening between the needle jet (3) and iet needle Q) and is discharged from below the throttle valve (5). it is here that the mixture is combined with the main air and alter being atomized, is taken into the engine. Fig. :l-llse G) Slaw iet B. Slow synem [Flor 5H”) The air which enters from the inlet passes through the outside of the air sctew where it is metered and enters the slow iet bleed hale. it mixes with the fuel which enters the slow set G) to produce a full spray lhul is discharged from lite pilol Dullel al a point lmdel the lh'ollle valve. This mixes with lhe air from the air inlet '0 form a combustible mixture before being lake“ into lhe engine. 2. FLOAT CHAMBER (Fig. 34'6) The carburetor must provide a proper mixture of tuei at aiilerent throttle openings and engine speeds: in order to accomplish this, the trial level in the carburetor must be maintained constant. The heat chamber functions to serve this purpose. The fuel from the tank enters the float chamber through the fuel inlet passage, between the lloat valve seat (3 and neat valve (2) and lills the chamber to the level where the float ® rises to shut all the flow at the fuel by seating the float valve against the valve seat through the action of the float amt (D. As the fuel is comumed, the fuel leve| in the float chamber, drops the final will lettaw the level, and the luel will start to enter the chamber between the opening at the neat valve and valve seat to mainlain a conslant fuel levelr Sr 13 CARBURETOR 58 A spring is incorporated in the head at the float valve which comes ln contact with the float arm The purpose at this spring is to prevent the float valve lrom oscillating so that a constant luel level can be maintained even when riding over rough or bad roads. it iurther serves to prevent any shock between the Immrl iioat valve and scan thereby reducing the amount oi ,,,,, W 7 7 _.. wear to these parts. ‘ Overnew pipe When riding on a steep grade or when any toreigrt substance becomes lodge in the float valve, it causes the fuel to overiiow irom the needle iet or m no“, mm, mm, ® Hm W," the slow jet. and enters the engine causing the engine ® “W. m.“ m. (D H“, m ® no“, oil to become diluted. In order to prevent such a rage gene 5mm“, view or "W. cy,,,.g,,_ condition, an overflow pipe has been incorporated . in the float chamber. Al normal condition, the pipe opening is above the luel level and it serves no puvpose, out when the overiiow con on exists and the luel level rises, the luel will drain out oi the overflow pipe to the outside rather than into the engine. 3. CHOKE (Fig. 3417) ror starting in cold weather, a rich tuei mixture is momentarily requiredt to serve this purpose, a choke valve G) is used in the carburetor, A relief valve ® is included in the choke valve and is held closed by a spring. By raising the choke lever lully, 60",“ NM ® Me, W." the choke valve closes and the air entering iron. the m. 37ml Chm WM air inlet becomes restricted. When the starting motor is engaged with the throttle lever opened approximately Us, the iuel will be drawn out oi the pilot outlet and the needle iet by the voc‘uum pressure. At the same time, the vacuum pressure will cause‘Ihe reliel valve to open by the piopet amount lo provide an ideal luel mixture to efiect and engine start. As the engine starts, the vacuum pressure becomes greater and the reliel valve is opened further to provide the proper tuei mixture to warmup the engine. In this manner, the throttle valve movement causes the reliel valve to operate and. thereiore, the operation oi the choke valve is not required to warm up the engine. The choke valve is opened after the engine warms up. FUNCTION OF THE MAIN COMPONENTS The main componenIs of Ihe calbule'or IuncIions in the iouowing manner. I. MAIN JET (F . 3—1”) The Iunclion of the maln iel‘ is to control the Iuel discharge and to provide the proper luel air ure at the higher range oi throttle opening idriving at maximum speed]. However. the main iet will also have a varying degree of efiect in the vicinity of 1/2 throttle opening. The mom iets are numbered, so that _ e , the larger the number. bigger the opening and Com m. H”. Mom 1,, seguentty a richer ItteI-al’r mixture. 59 3. ENGINE 2. AIR JET Al tull throttle opening, the tueLair mixture has a tendency to become rich, and in order to prevent this conditlon, a bleed air is added to the fuel through the needle iet holder. The purpose ot the air iel is to meter the amount ol this air,- the larger the air iet, more air will be added to the luel mixture and a leaner tuel mixture is provided. Also. by mixing the air with the luel, better atomizalitm will be assured. 3. NEEDLE JET (Fig. 3—]19) At lull or intermediate throttle opening, the needle iet will regulate the fuel which had been metered by the main iet. This control is accomplished together with the jet needle which will be described in the following paiagruph, The hole of needle iet ls made very accurately tor precise control. Fig. 3-4". Needle kt 4s JET NEEDLE (Fig. 3—120) The iet needle together with the needle iet des- cribed in the previous paragraph, meters the discharge at theJuel mixture in the l/4 to 3/4 throttle range. The long Tapered needle is suspended within the needle iet opening. The iet needle moves up and down with the throttle to control the fuel mixture proportionally to the throttle opening, There are three grooves on the head at the iet needle by reselting the set clip toward the lower groove, a richer tuel mixture will he provided. rial a~r2or Jet needle 5. THROTTLE VALVE (Fig. 3411) The throttle valve regulates the amount of luel air mixture taken into the engine to control the output and speed at the engine. In addition, it serves a very important lunction in that it controls the fuel mixture. There is a cutaway on the throttle Valve at the air inlet side which atlects the vacuum pressure that controls the function, of the needle iet. The use of the throttle valve with ditlerent size cutaway will control the discharge rate ol the luel, which oflects the t‘uel»air ratio. The larger lhioltle valve cutaway number provides leaner mixture, however, this is only effective wit inthe lower range at the throttle opening and has no efiect above l/2 throttle opening. There is also a throttle stop screw which sets the idling speed, Turning this screw IN will raise the idling speed, and lowers the speed when the screw is turned OUT. Fla, 3—:er Throttle valve 6. SLOW JET (Fig. 3422) The slow iet controls the luel at slow speed and at idling by regulating the air entering lrom the air bleed to produce a fuel-air mixture which assists in the atomization of lhe fuel. The slow jet, like the main iel, provides a richer luel mixture when a lot or larger numbev is used. @ Slow let tie. 3422. Slow let 7. 3.13 CARBURETOR AIR SCREW (Fig. 342:!) The air screw regulates the air entering the slow system by controlling the pilot hole. Turning the screw IN will richen the mixture and turning the screw OUT will lean the mixture. . FUNCTIONAL RANGE OF THE RESPECTIVE COMPONENTS In summarizing the description stated above, the lunctional range a! the respective components are as follows: from full close to 1/8 throttle opening Air screw 2 Throttle valve cutaway: 1/8 to 1/4 throttle opening let needle: 1/4 to 3/4 throttle opening Main |elz 3/4 to full throttle opening ADJUSTMENT 1. HIGH SPEED ADJUSTMENT During driving, it the speed increases when the choke valve is closed slightly, it is an indicationthot the iuel mixture is lean. In which case, replace the main iet progressively with the next larger size until properly adiusled. The main iet sizes above #100 are #105, #HO and #115 and (or sizes below #100 are #98, $95 and 4m. in the opposite case. ii the speed should fall OK when the choke valve is closed, the main iet size is proper, or else, it may be too large. in which case, lollew the procedure below to make the determination. A. Properly set When, alter replacing the main iet with one of a smaller size and if lt is lound to cause a drop in speed, and an increase in speed when the choke is slightly closed, it is an indication that the main let is too small. The replaced iet can be con sidered to be of the proper size. a. Main iet too large When the iet is too large, progressively replace the iet with one at a smaller size until the con. dition in paragraph A above occurs, and make the odiustmenl accordingly. INTERMEDIATE SPEED ADJUSTMENT (Fig. 3—125) The adiustment within 1/8 to 3/4 throttle opening is made by the changing the position oi the clip on the iet needle groove and the replacement at the throttle valve cutaway. However, the throttle valve cutaway will ufiect the tuel mixture between idling and l/A throttle opening. In the intermediate speed range, it is vecommended that the iet needle be ediusted within the range ot good acceleration as this will prove to give better fuel economy. Fig, 3423, Air screw ® Throttle stop screw (2) Air screw Fig. 3424. Adtushng carburetor © tloat valve (2) Float arm @ Float gauge a) Heat Fiv. :H 25 61 3. ENGINE A. Jet needle ill When excessive black smoke Is emitted lrorn the exhaust during intermediate speed, it is an indication or rich iuel mixture, thereiore, lower the iet needle by one groove. (2) During driving, it the engine misses or bucks, raise the let needle one groove. B. Cutaway of the throttle valve The throttle valve with a larger number stamped on the cutaway will give a leaner mixture. Throttle valve will chart the periormance oi the slow speed as well as the intermediate speed, therelore. the range directed should be considered when making the adiustment. 3. SLOW SPEED ADJUSTMENT The ruel mixture adiustment between idling and 1/5 throttle opening is accomplished with the air screw and the cutaway at the throttle valve. A. Air screw The mixture adiustmem at idle is made by the air screw. Turning the screw clockwise will give a rich mixture and turning in the opposite direction will lean the mixturel Not only is the idling screw used to make the idling adjustment but it also should take into consideration the mixture condition at the point where the throttle starts to open so that there is a smooth trartsition from the idling speed to the start of throttle opening speed, 8. Adivsting with the throttle cutaway As a point l/a throttle opening, the air screw may no longer be etlective ln udiustirlg the fuel mixture in such a case, replace the cutaway. ii the mixture is too rich, replace the cutaway with one or a larger number and it the mixture is too lean replace with one of a smaller cutaway number. C. Idle adiustment (Fig. a—m) idle adiustment is made by the use al’ both the throttle stop screw and the air screw by the tollowing procedure. ill Use the throttle stop screw to set the engine to the proper speed. (2) Manipulate the air screw back and forth slowly to obtain the point at maximum speed. [3) Reset the throttle stop screw to bring the speed back to the normal. [4] In this position, recheck the air screw to assure that the setting is correct. isl After completing the idle odiustment, check the engine response by snapping and accelerating the throttle. Perlorm this check between 1/6 to 1/4 throttle opening. 4. FUEL LEVEL ADJUSTMENT (Fig. 3—125) rhe noat level is specified by the height or the horn "h" shown in figure 3—l25. The iloot adiusting procedure is described below in coniurlction with figure 3—IZ5t CBI75:h=i9.5 mml0.768irl| CLl75:h=28.0 mml'l.iinl a. Invert the carburetor, in this condition, the weight at the float has caused the lloat arm to bear against the Iloat valve and the spring is compressed into the valve. This is not the normal fuel lovol position, b. Next, set the carburetor as shown in the figure with the float arm pin toward the top, tilt the carburetor so that the float is on the bottom with the lloat arm in the position so that it is last about to separate Irom the end at the float valve and set in this position. (the arm will separate lront the end oi the valve when the carburetor is raised approximately 70°, theretote, about 10° trom this point is sufficient, i.e., where the arm is not compressing the valve andl. c. in this position, measure the distance the bottom oi the float is from the body flange area with the gauge, this is the height 'h” The tolerance is 1 trim, the float may be depressed l mm or there may be a clearance at imm between the gauge and the float. This much to lerance will not adver sely airect the operati n. lithe ilaat is positioned in excess oi this amount, make the adiustmenr by bending the lip or the ilaat arm. There is a spring incorporated in the end of the float valve which will permit the end of the float valve to submerge and will give and erroneous reading, therefore, exercise care when determining the point at contact. Improper measurement and adiustment will not give the proper Fuel level. . 3. ENGINE y ENGINE-CB/CL'I25 Engine ammbly diagvam (Fin. 3—]26) 63 3. ENGINE Enginn assembiy diogvam (rig, 3427) 3.1 ENGINE REMOVAL AND INSTALLATION 64 3.! ENGINE REMOVAL AND INSTALLATION A. Engine Description The motorcyde periormance characteristics are determined by the engine which is used. Primary requirements ol on engine are high power output, light weight, compactness, ability to withstand rough handling and low maintenance cost. Furthet, the engine must be designed so that it harmonize: wrth the styling oi the lrome to give it a well balanced appearance. All Honda motorcycles ore engineered to provide these features. The extensive use or aluminum alloy gives a good weight to power ratio which attributes to high per. tormonce. it also plovides good engine cooling. OHC driven by a lightweight chain makes possible higher engine speed, greoter power output and quiet operation. Long lite oi the engine component and trouble free maintenance is assured by the emplayment of dual oil filtering in the pressure lubrication system, , v e G} Mutiler (2 Exhaust plpe setting bolt (5) axzo hex. bolt Fig. a—rza. vina the mulller (Cl mi 3. Engine removal (CB I25 and CL125l l. Shut oil the Iuel cock at the luel lank. ,m 2. Remove the miller by unscrewing the tour 6mm . ® 5X16 clan scrow © All clean-r nuts at the cylinder head and the two 8 mm bolts. G) 6X10 hex. halts To remove the muHIer © lct 125), unscrew the Fig, 342?. Removing the air cleaner four 6mm nuts at the cylinder head, exhaust pipe setting bolt (2 and 8x20 bolt 6) at the rear at the seat. (Fig. 3—]28) (Note) Remove the exhaust pipe protector to facilitate the removal of the exhaust pipe setting bolt. 3. Remove the air filter covers. Unscrew the two 6X12 baits (Dana 5x15 cross screw ® at the air cleaner connecting tube and remove the air filter (:3, (Fig. 3419) 4. Disconnect the high tension terminal lrom the spark plug and all electri:al leads. (Fig. 3430) t9...& (2 clutch a) clutch cable _ter thread ria. :HJI. Dtsconnecting the clutch cable 65 3. ENGINE _ __4. _ _ . (1) Jom) clip ® Drive chain rig. 37132. Removing the drive chain . ,,-,. A .e . (D Carburetors Q) 6mm hex. nuts 34:3. Remcvlng the carburetors ® T’handie cross screw driver Fig. 3434‘ lnxluii‘lng the engine DIRECTION OF ROYATION _ 0) Joint elio Figu 3435. Joint clip installation 5. Remove the drive chain cover and disconnect the chuck cable and Q from the clutch lifter thread (2. (Fig. 343]) 6. Disconnect the chain ioint clip (D and remove the drive chain (2, (Fig, 343:) 7. Remove the 6mm nuts (2 mountind the carburetors G) to the cylinder head. (Fig. 343:) 5. Remove the four 8X25 baits at the underside of lhe crankcase and remove the step bar. 9. Unscrew the tour engine mounting nuts. Place a support block under the engine to prevent drop- ping, push out the mounting bohs and then the engine will be lreed from the frame. c. Reassembly 1. Perform ihe engine installation in the reverse order of removal described in Section 3.1 B. 2. The engine installation can be made easier by temporarily hanging the engine on the frame by the use of a T-hcndle cross screw driver (D followed by the installation of the engine mounting laolts. (Fig. 37134) (Note) when reconnecting the drive chain, the ioint clip should be installed with the opening iacing opposite to the direction oi the normal chain movement. (Fig. 3-135) 3. Adiust the chain tension so that there will be l is 2cm l0,40~0.50inl slack in the chain. 3.2 CYLINDER HEAD AND CYLINDER 66 3.2 CYLINDER HEAD AND CYLINDER l. CYLINDER HEAD. COVER AND BREA‘lHER A. Construction The cylinder head is a cast aluminum twin head construction at a semi-spherical combustion chamber with a squish area for better combustion efliciencys (Fig. 3436) The single piece overhead comshait, rocker arms and valve mechanisms are all incorporated In the valve chamber above the combustion chamber. Cylinder head cover incorporates a breather pain Fig. 3-136. Cylinder head sage tor dissipating the pressure build Up. a. Disassembly L Drain oil from the engine. 2. Remove the 8mm blind nut and five 8mm hex. nuts. and then remove the cylinder head covert (Fig, 3437) 3. Remove the tett and right cylinder head side covers by unscrewing thct long bolt irorn the lelt side it, Rotate the crankshaft so that the com chain ioint is toward the top of the cam sprocket and then remove the cam sprocket mouutlng bolts. 5. Attach a wlra G) to both ends of the chain (2) Q 5mm hex nutx ® amm blind nut and then disconnect the corn chain, this will simplity rte. 3—l37. Removing the cylinder head cover. the reassembly task later. (Fig. 3—133) _\ 6. Separate the cylinder head from the cylinder. Ci Inspection l. Disassemble and clean all the parts before inspec. tion. Carbon should be removed with core, using a carbon scraper to prevent damaging the head. (Figs 3439) Refer to section 3.2 C on page 2i. Inspect the combustion chamber, inlet and exhaust ports tor cracks. 4. inspect the valve guide and valve stem. Check the valve gulde diameter at the top, center and bottom in both the X and Y axes, using a precision cylinder gauge. Check the valve stem with micro. meter. ® WII‘Q ® Cam c ul Fig. aelaa. Attachirg the wire to the com chain Fig. 3-139, Scraping carbon Item combustion chamber 67 3. ENGINE ltern Standard Vulve Serviceable Liruit Outside diameter Inlet valve Contact lace runaut- Replace if under 5.4:: mm (0.2]5inl 5.ta~5.49 mm l0.2l58~0.2l62 irrl vmhin 0.02 mm (0.0005 inl Inside diameter inlet valve guide Outside diameter . lnterterence m 5.5~5.515 rrun l0.2la$~u.2l7l int l0.055~i0,065 rrun i0.3959~0.3963 inl 0.04~o.665 mm l0.ocle~o.0026 inl Replace il Dvar 5.555 mm (0.219 in] Inlet valve clearance 0.01 ~om5 rnrn i0.0004~n.ool4 inl Replace it aver 0.05 mm (0.0mm Outside diameter Exhaust valve Cantuct lace ruuaut 5.¢e~5.47 rnru to.2i5u~o.2l54 inl ‘ 0.02 mm (0.0008 inl Replace it under 5.44 mm (0.2]4 ‘lrtl inside diameter Exhaust valve guide Outside diameter ~ Interference nt 5.5~5.515 rrun lo.2165~o.2171 int “1055-1104165 rrun Io.3959~o.3s63 inl 0.04~0.065 mm l0.DO|6~D.0026 int Replace il aver 5.555 mm team in) Exhaust valve clearance Replace ll over 0.1 mm “1003? inl c.03~o.055 rnrn to.ooi2~ .0022 in) II the valve guide is beyond serviceable limit, it may be repaired by using a reamer lTool No. 0700841010“ and replacing the valve with one or an oversize. Alter installing the valve a) "0" mark Hi, 37140. Installing the cam sprocket ® Cylind-r head cover gasket Fig. Hu. When replacement or the valve guide became: necessary, remove and replace with an oversize guide; use the valve guide remover lTaol No. 079424290100 replacement operulion. l and the Valve guide driver lTool No. 0794245290200] lor guide, use a reamer to obtain the proper valve clearance. D. Reussembly i. Reassemble the cylinder head in the reverse order of disassemhly. (Nate) la] Before installing the cam chain, the valve must be timed in reference to the position of the crankshaft. To do this, first, position the crankshaft so that the knock pin at the tapered shaft end is on the cylinder centerline and toward the cylinder head. Then align the 0" mark stumped on the cam sprocket to the index mark on the cylinder head (both inlet and exhuust valve should be closed, it not, rotate the cam 180°.) In this position, connect the cam drive chain. . 3440) Check the condition of the gaskets. It is recorn. mended that a new gaskets be used throughout, especially the head gasket. (Fig. 3-141) II the cam chain lensioner push rod is not screwed in completely. the cam chain cannot be connected. lb lc 3.2 CYLINDER HEAD AND CYLINDER 68 2. Tighten lhe cylinder head cover nuts unilormly in the sequence shown: (Fig. 3—H!) Tovque: 180~230 kg. cm [13.0~16.7 fl. lbs] 3' Insert the bolt in through the center bolt hole on the left side cover, assemble and tighten the right side covel. 2. CAMSHAFT A. Construction A single piece camshaft convalns both inlet and exhaust cums together with the sprocket which is mounted at the Is" and (Figs 3443, IAA) The com sptocke) is driven by the cvankshah u? 54 the speed. The cam is designed with a long gradual slope to pleven) ebwpt rise and drop of the valve, thus assuring a quieter valve operafione Fig 3—143. Camsholt , —----— 1 —,———¢———‘-___-_____ r H! (D Cumshutt ® Cylinder head (1) Cylinder heed r:ght side cover © Cylinder heed Iett side cover Fiys 3-144. Oil passage diagram 69 3. ENGINE a lGNlilON‘ a) Inlet valve opens: 5°ETDC @ Inlet valve closes: GODABDC © Exhaust valve opeas- 5°BBDC 8) Exhaust valve closes: 35°MDC Fig. 3445. Valve timing diagiam e “v (D Dial gang. @ Camshatt Fig. 3446. Measuring the (amxhalt Fig. 340. Camrhait dimension: B. Disassembly 1. Remove the Cylinder head in accordance with Section 3.2.1 B. 2. Remove the lappet adiusting hole cops and loosen the rapper odiusting screws. 3. Remove the 5 mm hex. bolt holding the rocker arm shalt stopper and pull out the rocker arm shafts, and the rocker arm: can be removed lrom the cylinder head. 4. Remove the camshatt tram the cylinder head by sliding out the iett side. c. Inspection 1. Valve timing (Fig. 3-145) 2. Check the cam tar excessive wear or scoring. 3. Camstwit (Fla. 3446, 3447) sranaara Value 59w eaare . . l9.953~l9.964 mtealacer under R‘9”""““"“""""@i 7557 7545!: l9.93nimi 734ml . 323274234 mm Replace it under Le" "d "“"‘°’°‘ ‘2 ll .2963~l.2968 inl32.9o7mmu.2955inl Item Cam base tcle Cam height 4. Cam sprocket root diameter Standard value Q 59.87~59.99 mm l2.355~2.364 inl Reassembly 1. Screw o'ut the rapper adinsting screw and assemble the camshaft into the cylinder head in the reverse order of disassembly. 2. Adiust the tappet clearance to 0.04 to 0.06 mm l0.015 to 0.023inl wilh a cold engine. ROCKER ARM Construction The function of the rocker arm is to tmnsposa the rotary motion at the camshaft to a recprocaling motion (or actuating the valve. The rocker arm is made rigid to prevent deflection and the end which contacts the cam is finished smooth after suriuce hardening to minimixe wear. The end which operates the valve is provided with a tappet adjusting screw that contacts the valve. Disassembly l, Disassemble the cylinder head in accotdance with Section 3.2.] E. 2. Remove the tappet adiusting screws. 3. Rotate the camshafl so that the locker arms are resting on the base circle at the cam lthis can be set by aligning the “0" mark Stamped on the cam sprocket to the index mark on the cylinder head leit cover flange). . 3,2 CYLINDER HEAD AND CYLINDER 7O 4. Remove the bolt holding the l‘Dcke( amt shalt Stopper ® and pull out the rocker arm shaft (:04 the rocker arm can then be removed. (Fig. 3-148) To lacililate the removal use the Snap ring pll'er. (Fig. 3—H?) . c. rem... l. Clean all parts, especially make Sure that the all holes are clean. 2. Inspect the rocker aim Cam contact surlace and repair or replace it there is,scnring or excessive we“ (D Rocker arrrr shall stopper (3 5> Caneenrrlettv 0! mm 0.02 nnn valve lace (D to 008m) :®——® 2. Valve spring measulemenl (Fla. 3453) INLET VALVE Outer valve spring 7% 33%;; Item Standard Value Serviceuble lelt me lenglh 32.1 mm ".2638 in| 5753:; Q'L‘é'g‘s'w 20.3 mm/19~2|kg Fiel 3452, Valve dlmenslon: Tonsion I0.799ih/4l.595~ — 46e305lbsl ® Valve lllrer (2 Cylinder head Fiv- 3~l5l. Removmg the valves EXHAUST VALVE Innev valve spring Item Standard Value Servicenble Lirntr Repluca il under 15.6 mm allow in) Fre- lengrh 26.! mm (1,0276ln) 15.6 rum/1015'“ V ”.55 ka Vern-0" (0.6l421n/13.D42~ 25.4w lbsl De Reassembly I. install the outer and inner valve springs trom the tappet adiusting hole and compress the springs ® Valve We, @ Valve with a valve litter and reassemble the valves wilh fig. 3—153. Measuring valve tension valve callers. VALVE SEAT A. Description The valve seat is lepalred with three types ol cutters The relative location and the width ol the valve seat contact area is accentplished with the valve seat top :utter and valve seat bottom cutter while the relccing at the valve Contact area is aerternrea by the 90" cutter. (Figl $154) Fig. 345‘. Valve seat delall 3.2 CYLINDER HEAD AND CYLINDER Valve lapping operation is perlormed last. This is to obtain a leak-proof seal between the valve and the valve Seal. Place a liberal amount at lapping compound on the valve lace and lap the Valves, applying a slight pressure while rotating the valve back and lorih with a suction cup lapping tool. Wash ail lha compound thoroughly and inspect the valve seal with bluing. (Note) la] When the valve stem is greatly worn, the valve guide is usually also warn. Hence, when a yalye is replaced, it also is desirable to replace the vulva guide. Since the guide is prexs hired. ii is recommended that they be replaced with an over- size gu‘de. lb! When the valve is assembled, the compound which was used during lapping should be completely removed 6a CYLlNDER A. Construction For improved cooling eflect and weight, reduction, the cylinder is made at aluminum allay wrth a press fitted special cost steel cylinder sleeves. trips—155) The cam chain guide roller is incorporated at the left hand side of the cylinder. 3. Dimssembly l. Remove the cylinder head. Reler to Section 3.2 B. 2. Remove the two 6mm hex. nuts and the cylinder from the crankcase. (nu. 3456) c. Inspeclian 1, Measure the cylinder bore, iaper. out-oleround with a precision cylinder gauge, (Fig. 3457) Take the measurement at the top, middle and bottom in both the X and Y axes. Serviceaale Ll Item Standard Value t a u.o~u.0l mm Repair if over °" n.7323~l.7327 int 44.1 mm n.7aa2inl Taper, . Repair it over aut-at-raund 0'0“ "‘"‘ ““7007 "" 0.05 mm (0.0020 in) 2. The clearance between the piston and cylinder will greatly aliecl the engine performance. Be- cause the piston is elliptical, the clearance is controlled very closely. The clearances are not the Same, however, it any area is greater than 0.] mm (0.004inl, the cylinder should be rebored and fitted with an oversize piston D. Reassembly I. Install the gasket between the cylinder and crank- case and insert the o/linder over the stud halts. 2. Make sure that the cylinder gasket and the two dowel pins are installed. 3. During the installation of the cylinder, use a hard- wood pislan base to prevent piston movement, Also use a ring compressor to prevent ring damages. (Fig. 3—]58) rig, :Hss. Cylinder @ 6mm nuts fig. 3456. Renauing the cvllndar ® Cylinder C 'rra r an e (D y“ a g g the cylinder bore ria. 3-157. Measuring ® Piston ring compussar <3) Piston e) Pinon base. fig. 3-lss. lnsialiing the cylinder :- 5) 6mm hex. aotr ® Stator 3459. Eamovtna the dynamo stator. (D Spark advancur ® Dynama rotar setting bolt (3) Washer Fig. 3460. Sport advancer ® Generator rotor putter ® Generator rotor r; 37m. Removing the AC. generator rotor (1) Clutch litter rev. 3462. Clutch litter thread installatlen 3. ENGINE 3.3 LEFT CRANKCASE COVER 1. LEFT CRANKCASE COVER The purpose or the crankcase cover is to protect the vital component parts at the engine, The contact point is mounted on the leit and of the crankshaft. 2. A.C. GENERATOR Construction The detailed description at the A.C. generator ts given in the electrical section, Disassembly A.c. generator can be disassembled or reassembled without separating the engine tram the tram. How. ever, this section describes disaSSembly ol the A. . generator (mm the engine which had been separated from the frame, and the cylinder and cylinder head disassembled. l. Remove three screws and lake at? the contact breaker cover. 2. ozseannect the primary lead tram the breaker assembly terminal and remove the two Contact breaker plate screws to remove the breaker assembly. 3. Remove the left eronkcase cover. 4. Remove the three bolts holding the A.C. dynamo stator and AL. dynamo stator can be separated. (Era. 3459) 5. Remove the bolts holding the A.C. generator rotor and the spark advoncer assembly can be removed. (Fla. 3—160) 6. Remove the rotor lrom the crankshaft using the A. C. generator rotor puller. (Tool No. 07933— 2000000! (Fig. 3—161) c. Reassembly l. Align the dowel pin on the flywheel when recs- sembllrtg the AC. generator rotor. set in the crank- shaft with the groove on the rotor and insert the rotor. Install the spark advancer over the rotor and tighten the rotor setting bolt. 2. Reossemble the crankcase cover, etc. In the revelse order at disassembly. 3.3 [EFT CRANKCASE COVER 74 3. CLUTCH LIFTER THREAD A. Description The clutch litter thvead is located between the clutch level and the clutch litter red It tvunsmits the action at the clutch lever to the clutch rod during starting and changing at the gears. In other words, the clutch lifter thread regulates the iunction oi the clutch mechanism, and theretore, [t indirectly attects the periortnance at the motorcycle. (Fig. 3462) 5. Disassembly it Remove the left ctonkcase cover. 2. Remove the bolt trout the udiuster fixing piece and the clutch lever spring. The clutch litter thread can then be disassembled. (Fig. 3—163) c. Reassembly 1. Apply grease to the clutch litter thread belore assemblying. Use HD type multi-pulpose NLGI, Na. 2. 4. CAM CHAIN TENSIONER A. Costruction An automatic cam chain tensioner has been employed to simetity the maintenance and eliminate the adiustment oi the cam chain. This is done by automatically applying pressure against the tensiahet push red by means or the cam chain tensioner spring. The force is applied by the push rod to one side of the "seesaw" typei tensioner to maintain proper tension to the cam chain at high speed; further, the iocatlon at the guide roller has been engineered to minimize the chain noise. In addition, a manual udiuxting lecture is also provided to correct any stretch in the chain as the result at the centritngatt ctce tram extended ri (Fig. (Hui s. Disassembly l. Remove the bracket point cover, point tetminul Iett cover. AC Generator total, and then dis. assemble the AC Generator stator base. 2. Remove the cylinder head and disassemble the cylinder. a) Clutch udluster locking bolt ® 12mm washer (it) Adiuster fixing piece ©‘Clutch adjuster (5) Clutch litter thread @ Clutch level spring Fig. 3463. Component parts at elutcn adjuster O Tension" rolter i2) Tensioner arm © Timing sprockot © Clankcase (5) Adjust screw lock nllt © Tonsioner aaiust halt ® Tenstaner pushrod head (9 Tensioner pushrad ® Tensioner spring G Di! damper chamber Pia. 3-!64. Construction at the com chain tensioner a) Yettsioner aaiust bolt (3 Tenstaner pushroa (3 Cam chain tensiatter spring 6) cam chain tensioner @ Tensionev set plate B (5) Tenxianer set plat. A q) Cam chain lensioner mite: rig, 3-165. Component parts at the cam chain tension" @ rensianer set plae A (2) rensraner set plate a @ 6><2 A82 0 7 "MIX 2 ABC! 0,7 mm x 2 Valve seat 1,7 mm / Prior curler 0.9 mm, Piicn 7.0 mm Fuel level 2] mm (0.827 in) 4.1 STEERING HANDLE as 4. FRAME 4.1 STEERING HANDLE A Description The s'eeving handle (D I: made ol high strength steel pipe, and is mounted on the iron! fork top bridge wilh the handle pipe holder (3). The lerk lop bridge is onached to the front cushions by two Hon! fork halts. All central cables are exposed to simplify steering handle replacement (Fig. 44>], 2) ® Steering handle pipe (2 Steering damper knob (3 Handle‘ pipe holder rial 4~ ca type steering hondle a. Disassembly i. To disassemble the iranl brake cable (D, push the brake arm toward the bulking position to prDVIds slack to the cable and then disconnect lha brake cable hen the brake erm. Remove the 5mm crass screw and pull out the speedometer cable (2) lram the hen bmke panel. (Fig. 4—2) m S'eevmg handle pipe rig. 4-H. CL lype steering handle 2. Disassemble the clutch cable lower end by loosening the three 6mm screws on the drive chain cover A and disconnect the clutch cable iron the clulch lilter. 3, Disconnect the lower end of the lhrotlle cable (D by removing the carburetor cap Q), pulling 9m the throttle valve © and then disconnecting the throtlle cable irom the valve, (Fig. 473) A a) From brake cable (2 Speedcmuler cable r l 442. Removing the speedamercr and brake cables ® Thtollle cabla ® Corbwalor cap © Throttle valve Fig 471 Disconnecting the throttle cable hum the throttle valve 89 4. FRAME ‘ I (D Steering handle plpe (3 Wire at cables Fig, A". Removing the steering handle pipe © Throttle cable ® L‘lght swi h assembly Fig. 4-5. Removing the throttle cable (17 Lock nut ® Throttle cable udi‘uster Fig. 476. Adiustlnenl ol the throttle cable (D Lock nut Fig. 477. Adluxlment al the Iron! brake cable 4. Access to the wlre harness connectors for dime sembly of the electrical equipment is made by removing the headlight unit to expose the com hector: housed in the headlight case. 5. Remove the 6 mm snap pin under the steering stem and the steering damper knob. 6. Loosen the lour 8X36 handle mounting bolts to remove the steering handle (D from the (ark top bridge. The steering handle can be removed together with the cable and wires (2 as a complete unil. (Fig, 474) 7. Unscrew the brake and clutch cable cdiusting bolts ,and disconnect the inner cable from the levers. B. Disassemble the throttle cable by unscrewlng the two 5x25 cross screws lo separate the light swltch assembly, Disconnect the throttle cable trorrt the handle grip pipe. (rig. 4—5) Inspection 1. Check the throttle, clutch and treat brake cable tor wear, damage. kinks and nnsrnoothness or operation. 2, Check the handle levers tor unsmoothness at operation. 3. Check the handle pipe for bend and twist. 4. Check all the switches lor improper operation and also check the electrical leads tor damage Reunembly I. Connect the upper ends at the cables to thelr respective levels. 2. Positlon the cables and electrical leads in their proper location and then clamp the steering handle in place between the upper and lower handle pipe holders with the lour mounting bolts. 3. Route the cables though the supports and the elactrlcul leads into lhe headlight case. 4. Connect the clutch cable and to the clutch lllter thread, the brake cable end to the brake arm and the throttle cable end to the throttle valve. 5. Adiust the respective cables to the proper speci- fication with the adjust bolt at bath ends ol the cable assemblies. Tighten the lock huts after completing the odiustmem. (Fig. 476, 4‘7, 1H1, 479) 6. Free travel: Throttle cable grip twist angle 9 to 10 degrees front brake cable (at end at leverl IO to 30 mm (0.4 to 1.2“ Clutch cable lat end at lever! 20 to 30 mm l0.8 to 1.2”! 4.2 FRONT CUSHION 90 ® Clutch adlustzl tasking bolt (2) Clutch adluster m Cluten eaiustmg bolt (2 Locking nut F HA Adiustmattt o! the eluteh play rial H7. Adinstment at the eluteh play. 7. Connect all electrical leads within the headlight case. Join the leads of the identical color. 5. Atter the reassembly has been completed, move the steering handle through the tull travel to make sure that the cables electrical leads are not binding ar restricting the movement oi the hem lorks (D Headlight ease (2) Electrical leads Fig, Ha. training the leads. 4.2 FRONT CUSHION A. Description The iront and rear cushions should not be con- sidered to be tunctioning independently. The suspem sian and dampening components directly influence the steering characteristic and stability of the motorcycles The front fork must not only withstand the load from the vertical cushioning but also the horizontal force resulting tram the steering function. The trant cushion spring is designed with two different pitchest this is to pro e a broader range at eflecttue cushioning. The oil damper contains t35~145 cc (B.27~8.85 cu. int hydraulic fluids 91 4. FRAME "m n... mm- vs: mm _ .- xquunll uu—xuu-l F... .. «- mix-mwuummm nus-imam hot-moulil It. a... no... 12 374.5m( iuuin) _ 2.9m- 8‘776in 12,4nn(u.llm) lagi‘um ‘mzlnn I 25 (D From lork boll ® From lork washer © 8.4x“ o ring ® Fork lop bvidge (9 From cushion spring (3) From lork uppev com (2: From lork rib ® From lork rib packing ® sneerino srem @ From lurk undev cover ® From lolk pip. compleio @ Rebound slroke (Wrnm: c.745im ® Almrrr infernal circlip @ From lork oil seal @ Bonom case cover @ From lork pipe guide @ Fork pipe sroppor Flag 331 Fork valv. slopoer ring (13 From damper vulva @ Pislon smpper ring ® From (ark pisron ® Fork pixion snap rlno @ From lork honom case comp. ® Fork drain cock pa (0.0000 ml 004 mm moms in) 4, Front fork bottom case item Standard Value Sewiceahle Limit inner 35.53~35 57 mm Replace it ova! diameter i139BS~ 4004 int 35.72 mm [1.4063inl Om at mud Within 002 mm Replace pm _ moons in) 0.04 mm mums .nl “W wiltnn 002 mm Replace it over (0.0003 int 0.04 mm (Otflolétnt ® From lork pipe @ From cushion spring @ rront tori bottom caie Fia. Ha. Reassembling ma trant cushion 95 4. FRAME D. Raossembly l. Assemble the lrant dampel valve and lrcnt lork piston on the tram lork pipe. and lock with the front pipe tings. (Fig. 447) 2. Fill the ham lork with SAE \0W30 hydraulic fluid. ”35 cc~ N5 cc 2 8.26~B.B7 cu in) 3. Inselt the liont lork pipe assembly into the iork bottom case and push the front fork oil seal into place, being careiul not to damage and then set the internal cilclip. (Fig. 4—15) 4. After completing the assembly, install the front lolk into the steeling stem. (Fifi. 4-19) 5. Assemble the hem lovk to the top bridge. rtg. H9. Installing the trant lovk 6. Assemble the steering handle to the top bridge in accordance with section 4.10, 7. Install the headlight case, connect the electrical leads within the case and then assemble the light unit. 8. install the front lender on the lront lcrk, 9. Assemble the lrcnt wheel to the trant lurk. in. Connect the speedometer cable to the gear box and connect the tront brake cable and complete the udiustment. 1]. Connect and adjusl the throttle cable. 4.3 STEERING STEM AND STEERING HANDLE LOCK A. Constructian The steering stern is mounted by the bolt: to the lrant Iork through the top bridge plate and supported by upper and lower sets oi ball bearings in the stealing head on which it pivots. ll $9 i 30 (1) Steering head stern nut ® Steellng stern wushev @ Steering head tap thread © Steering top (one race @ Steering bottom cone race (9 Steering head dnst seal ® Steering head dust seal washer ® Steering stern 9) 5x32 hex. bolt @ Handle lock spring ® Handle lock @ Handle lock case cover ® 3mm llat washer @ axe crass sclew Fly. A—ZO—‘I, Steering stern and steering handle lock lCB/Cllzél 4.3 STEERING STEM AND STEERING HANDLE LOCK 96 @ Dnmpev lock spring safllnq hall (2 Steering damper locking saring ® Slaenna head xlem nul © Sluring slam washer 6) Slurina hood lap lhread © Slasrina lap cone race 6) Sleering bollorn cane race ® Slaaring head dim soul (2) Slearlng head dusl seal washer ® snoring Slam 33 3x32 hex. hall «9 Handle lock spring (3 Handle loci ® Handle lock casa novel 03 3mm nal waxhev ® 3X8 class straw @ Sharing damper knob @ Slurina damper plale A 33 Slearing damper lrlclian disk @ Fliclian disk anchor hall 6) Slaeling damper plal. a @ Slearina dumps! spring @ Sleering damaar nul @ 6mm snap pin Fig. 4—20—1 srwing min and nearing nandl. lock lea/cum B. Disassemble l, Separale lhe fleering handle pipe in accordance wilh seclian MB. 2. Remove the from cushion in accordance wilh seclian MB. 3. Remove lhe steering slenr lap thread and draw lhe sleering slam @ aul ai lhe head pipe G) being careiul nal la drop lhe sleel bolls ®r (Fig. L21) q) Head pipe (2 Sleel ball @ Slearing slem bollarn cane race 6) Siealing mm Fig. 4—2l. Ramoving lhe sleering stem 97 4. FRAME C, Inspection 1. Inspect steel bulls ter cracks, wear and ather damages. 2, inspect the cone and bull races at both the top and bottom tor any wear or damages 3. Inspect the steering head dust seal for wear and damage. 4. inspect the steering stem tor twist and bend, (Fig. 4—22) Ilem 5t ndard Value serviceable |. © Steering Stem @ Small dial gauge at Height gauge aend iii/.332" ",95'“ —— G) Magnetic v black Fig. 4-22. Meuxurament or the steering stern bend 5. Inspect the thread and oi the steering stern tor damaged threads. 6. Inspect the spring on the steering handle lock tar breakage. D. Reassernlsly l. Mount the steering handle lack an the steering stem. 2. Mix the its steel balls 136 total in grease and lay into the lower and upper ball races and earetully insert the stem to prevent dropping the balls, Tighten the steering head top thread. (Note) Special care is required to tightening the top thread. I! must be tightened in coniunction with the steering stern nut and the front iork bolt. When the stem nut is properly tightened, the (rent wheel should move to either lock under its own weight when a slight lorce is applied. Further there should not be any looseness in the vertical or the horizontal directions. 3. Assemble the front cushion and from wheel. 4. Install the steering handle. (D ca type tuel tank Fig. 4-234. ruel tank 4.4 FUEL TANK A. Construction The iuel tank is placed on the frame body directly above the engine and is installed an the frame body through the fuel tank cushion. The knee grip rubber, as well as the tank mark, titted wilh the tank side cover, is installed on the luel tunku (Fig. 4*23) G) CL type iuel tank rig. 4-23—2. Fuel tank 4.4 FUEL TANK 98 a. Disassembly I. Loosen lhe two seal mounting bolts. 2. Posilicn the iuel cock lever to STOP and remove the luel tube ® lrom the iuel cock. (Fig. 4724) (D Fuel cock ® Fuel reed lube Fig. 44A. Removing m2 luel feed tube 3‘ Yo remove the ruel tonk (D. pull it upward toward the rear and exercise care so as not to damage the fuel cock (Fig. 445) (D Fuel tonk 4. After the emblem is removed, the 6X8 bolt ls Fig, 4—25. Removing the luel tank loosened, the side cover pushed lorword and the slde cover can be removed. 5, To remove the fuel cock 6), unscrew the tuel cock eup, remove the o ring and tuel strainer screen and unscrew lhe mounting screws, (Fig. 4—26, 27) c. Inspection 1. Inspect the ruel tank lor leaks. (Caution) (D Fuel cork ® Fuel (mil: Normally a water lest is performed at a speclfied fige 172.5. Removing the luel eoek pressure. Howevsru exercise precaution since excessive pressure will cause rupture at tire tank seam, 2. Check tor clogging or the filler cap vent hole. 3. Check the from and rear fuel tank cushion rubbers tor wear and damage, 4. Check ttte tuel cock fixing packing, strainer cup packing and ruel filler cap packing for wear and damagee 5. Check the iuel tube for wear and breakager a) 5x25 cross serew ® ruel cock body (3 Fuel tank Fig. 4727, Removing ttte luel :ock body 99 4. FRAME D. Reassembly L Install the fuel cock, 2. Install the side coveri (Fig, 4728) (Caution) The side COVEV ® is hooked to the clip at the rear oi the fuel tank © and the lorward end is attached to the tank by 6X8 hex. boll. Make sure that the bolt is of the proper length to prevent puncturing the tank. (Fig. 4—29) 6) Clip ® Fuel tank side cover Fig. 4—29. Installing tank side cover 3. Fit the lront and rear rubber cushions to the home body. The front rubber cushion should he insarlad by pushing the luel tank from the rear. Install the Fuel tank rear end by placing it under the rear Q frame, (Fig. 4*30) 4, Fit the fuel line to the carburetor and secure it UL” 1111 by the clips. ® Fuel tank side cover ® 6X5 mm hex, bolt ® Fuel tank ‘ \ ® fuel tank Fig. +211 lnstalling the luel tank 4.5 FRAME BODY A, Construction The lrame body is the main structural member around which the motorcycle is assembled. lt mounts the engine and is supported on the front and rear wheels. The frame is made strong to support the weight of the engine, rider and carrier load and in addition, it must be substantial to receive the dynamic reaction imposed by the road and riding conditions under the load. The lrante must be rigid to provide good steering characteristic and at the same time lightness is de» sllable tar lose in handling and lor gaad riding “5- ML Frame body pertarnance. (rig, 4731) 4.5 FRAME BODY 100 s. Dimssambly I. Remove the engine from the trarne in accordance with section MB. 2. Remove the steering handle in accordance with section 4.15. 3. Remove the tram cushion in accordance with section 4.23. 4. Disassemble the steering stem in accordance with section 4.35 5. Remove the seat and luel tank in accordance with section 4.43. 6. Disassemble the rear wheel in accordance’with section M33. 7. Remove the rear cushion in accordance with section 4.115, 8, Disassemble the rear fork and rear lender in accordance with section 4.103. 9. Remove the air cleaner and tool box in accorv dance with sectian 4.53 and 4.93. lo. Detach all electrical components ltom the tram. ll. Remove the stand in accordance with section 4.73. c. Inspection 1. Inspect the weld i nt tar any breaks and cracks. 7. Inspect the steering head pipe (or twist, bends and misalignment. (Note) The ball races should be Fitted lo the steering head pipe with light driving (interlerence lit- 0.0I mm~0.05 mm/0.0004~'0.002 in] and must he bottomed so that it is not cocked, ( | 4—32, 33) 4. inspect the irame paint coating tar any chips and rust spots. a. Disassembly Perlarm the assembly in the tel/else order at disassembly. 4.6 AIR CLEANER CASE AND SEAT A. Construction The air cleaner case is a stamped metal plate and protects the air cleaner. The motorcycle is equipped with a tandem seat iar double riding; the trout section hooked to the trame and the rear section bolted to the home. The seat consists oi sponge padding and vinyl leather covering. A hand-hold strap is installed across the seat tor the rear rider. (Fig. 4—34) ® Plastic hammer (2 Wood © Head pipe Ramoving ball race Fig. «:2. © Hammer (23 insertion tool © Steering head pipe Fig. 473:. Driving ball raca Fig. 4—34. Seat 101 4. FRAME a. Disassembly l. Remove are air cleaner case by pulling il lrom me rrume body. 2. To remove me sear (D Iron. me Home body (03175:, loosen lheiwo 8Xl6 ® sear mourning bolls lCLl75: axle and 6X20 balls] and pull me sear m the rear. (Fig. 445—!) rig, 473571. Remumg me my 3. Remove the air cleaner (D by unscrew the rwo 5x12 bolts (3 and the 5x16 cross screw @134 (Fig 473572) (r) Arr cleaner f2) 5x12 hex. boll @ 5><125 hex, bolt ® Main stand sprinw (a; Main stand distance collar @ Main Stand (9 10mm spring washer @ 10mm hex. n t Fig. 47334, Main stand (CB/(1175) 4.8 EXHAUST PIPE AND MUFFLER A. Construction The muffler and the exhaust pipe have been made into an integral welded unit to greatly improve the silencing efiectiveness of the mufiler. The length and bend in the exhaust pipe and the Volume el lhe muffler will have a great efiecl an the engine output. The exhaust gases noise is reduced as it is routed through me nanow passages in the mufller. The remaining noise is diflused by the dlfiuser pipe to ossute gleater silencing efiectiveness oi the mufllev. Bs Disassembly '|. Remove the two 6mm nuts at the cylinder head. 2. Loosen the four 8X25 bolts and remove the behest bar. 3s The muffler is bolted to the (name together with the step; rherelore, loosening the 2X58 step mounting nolts will also separate the muffle! lram the Frame. (CBI75) \/ i e l 6) Inner pipe (3 Mufllar hall (3) Seawater A G) Sapatutor a (S) Sepalctor c Pics 4739. Seclional view at nluRIor 4.8 EXHAUST PIPE AND MUFFLER 104 c. Inspection 1, Inspect the muffler gasket la. damage. 2. Inspect the mufller lor cracks, dents and other defects. D. Reassembly Perform the assembly in the reverse order at disassembly. (Mate) First install the exhaust pipe ioint but do not tighten as It will make the installation of the other muffler mounting bolts diflicult. The tightening ot the exhaust pipe [olnt hm should be made last. (D Exhaust plpe law (2 Exhaust pipe {0th collar ® Exhaust plpe gasket @ 6mm hex. mu (5) 8x7! hex. bolt (0 8mm rprina walker a) 6mm spring washer {3) 5mm hex. nut ® Right exhaust mufllev @ Lelt exhaust multler GD sxsa hex. bolt ® 8mm sprlng washev (3 5mm flat washev @ 5mm spring washer 83 5x8 hex. bolt 0 Exhuuxt difiuser pipe Hg. 4-404. CB|25 Mufilel 105 4. FRAME ® Lett exhaust pipe ® Exhaust pipe iaint collar ® Exhaust pipe gasket (3) Exhaust pipe iaint @ 6mm hex. nul Exhaust pipe brackel A ® Exhaust pipe bracket 5 (23) 6mm iiat washer (9) 6X32 hex. halt «3) Right exhaust pipe (5) 5mm hex. nut ® 5mm flat washer (Q Mumer hanger stay 6) 8mm spring washer ® 8mm flat washer ® 8mm sprzrtg washer (3 Exhaust pipe setting boll @ 6X20 hex. bait ® Mumer band @ Mufiler packing ® Exhaust pipe protector @ 6mm iiat washer @ axlz crass screw ® .5on cross screw fig. 1440—2. C1125 Mumer a) Exhaust pipe joint (2 Exhaust pipe ioim collar © Exhaust pipe gasket 6) Right exhaust mumer (S) Lalt exhaust muHIer 3) Right pruiart step arm at Pinion step pin ® Pillion step rubber ® Pinion step washer ® Pillion step bar 63 Leit pinion step arm @ axle hex, butt 6) 5X36 hex. bait @ 6mm hex. run (a) 6mm «at washer @ 3mm spring washer 63 L6th cotter pin Fig. 4-40-3. 133175 Mufiler 4.9 AIR CLEANER AND TOOL CASE 106 ® leh exhaust pipe (3 Exhaust pipe |olm ® Exhausi pipe .oini collar @ Exhcuxl pipe proleclor @ Exhaust pipe bracket A Exhausl pipe brackec B CD Exhausl pipe gasket Right exhaust pipe (9) Muffler hanger stay 69 Mumer band @ Mahler packing @ Lelt prilian step arm ® Fllllon step pin @ Pillion xlop rubber @ Pillion flop washer ® Piliian step bar ® Exhausl pipe setting boll @ 5x20 hex. bolt @ 6X32 hex. bolt @ axle hex. boll ® 6302 cross scvew @ 5XID cross screw ® 6mm hex. nut @ atrtni Sprlng washer @ 5 mm flat washer ® 8 mm liar washer ® 6mm spring washer @ 8mm spring washer Q3 Lexis cotter pin Fig. 4404. c1175 Muhler 4.9 AIR CLEANER AND TOOL CASE Filter paper is employed in the air cleaner for increasing the filter performance by enlarging the suriace area. As the molorcycle is equipped with rwin carburetors, air cleaners are mounted on both the right and Ielt sides. B. Disasxembly l. Loosen the two 6X l2 nuts and remove the right and ieit air cleaners. (Fig. 441) 2, Remove the air cleaner canneciing lube from the carburetor by loosening the 5mm cross screw. 3. The air cleaner can be Separated from the frame. 4. Separate the tool box G) by removing the two 6mm bolls. (Fig. 4—42] ® Air :leunev (2 6mm hex: bolt Fig. 441. Removing the air cleaner © Tool not Removing the tool box from the Frame Fig. ten, (D Rear cushion under tubber hurtling ‘ a) Rear iarl pivot earning @ tear brake steppe! errn Fig. 4—43, Rear tori Cl) itear tork 4741. Removing the rear lovk C. Inspection 1, The all cleaner which is clogged with dust should be cleaned with dry compressed air or by brushing lightly. 2. Inspect the lilter element for tear or stains. D. Reassembly is Mount the tool box on the lrame and secure by the 6mm bolts. 2. Insert the air cleaner connecting tube into the carburetor, and tighten the air cleaner tube with the air cleaner connecting band. 3. Install the air cleaner case. 4.l0 REAR FORK AND REAR FENDER A. Construction One end oi the rear lork is filled to a section of the heme and the other enci is fitted to the tram through the rear cushion When the rear wheel bounces, the section which is fitted to the llama becomes the pivot axis and the rear wheel moves in an arc. The close pro sprocket p035: negl (Fig. 4743) ity of the pivot axis lo lite drive gible change to the chain tension, a. Disessemblv l. Remove the rear wheel in accordance with section 4.]33. 2. Remove the 6Xl2 bolts and 6X20 bolt to separate the chain case trom the lrome. 3. Remove the rear cushions in accordance with section 4.llB. 4. Remove the axle nut and pull out the rear fork pivot bolt. (Fig. 444) 5. Drive out the rear lork center collar and the rear folk pivot bushing. (Fig. 4—45) 6. Loosen the two 5x12 G) and rear lender setting bolts ® to separate the rear fender from the lrume. (Figs 4—46) C. D. 4.10 REAR Inspection 1. Rear Iork center collar Standard Value lwl~l4m mm I5.5|6~5.5l9 in) Item Sewlceable Limit Replace it over 3°” 14.2 mm (0.559 in! 2. Rear Iork pivot bolt Item Standard Value Servlceoele Limlt Outside 13.925 ~13.768 mm diameter K1545 ~ 0.550 in! Replace it over 0.02Mux (0.008211) 0.05.” mom-m Bend 3. Rear lork (Fig. H7) Standard Value Item Servicoqble Limlt Twist 0.1 Max (0.004 In) (Note) Measurement should be made with the rear tort: pivot bushing and the center collar assembled in the rear fork. :‘ Inspect the rear lender and drive chain case to: dents and other detects. 5. Check the drive chain lor stretch, Reassembly I. Install the rear tender. 2. Drive in the pivot bushing, and the center collar. insert the rear fork seal cup. 3. Insert the pivot bolt through the side bracket and assemble the tear fork to the home. 4, Install the rear cushion 5. lnslall the rear wheel. 6. Install the drive chain. 7. When the assembly is completed, udiust the rear brake pedal and the chain temion. (Fig. 4—43) 9-7 Install the drive chaln case. 108 CUSHION (D Plastic hummer ® Driver @ Rear lurk reg. 1—45. Removing the rear (01k pivot bu ® 6XI2mm hex. bolt @ Rear lender settlng bolt rig. 44.5. Disassambly ol the rear lender o Magnetic v blo A.C. generator (3) Battery ® Switch Fla. s—I. C9 Ignlilon ria. 5—2. Ignition syxiem coil Ignition coil @E& r rnnfié ._I Q) Ignition coil (2) Law tension lead 4mm inner cord connector ©© High tension cord Fig. 5-3. Ignition coil assy. 121 5. ELECTRIC SYSTEM rig. $4. Spark advancer “i rotation (D 5" advanced angle (2 40" advanced angle G) Contacr breaker arm (2) Breaker points Fig. so. Breaker points rig. 5~7. Contact breaker assembly The spark advancer, mounted on the let! end at the camshait tor the CB/CLI75 model and mounted against the AC. dynamo rotor tor the CB/C|.125.is held in a fixed position, at 5° advance, by a spring. As the engine speed increases, the revolving weights on the advancer moves outward by centritugal tame. overriding the farce at the spring to move the cam in the direction to cause an early ignition. The spark advancer starts to become active at the engine speed of 900 RPM (CB/Cll25: I800 RPM) and advances 40‘ at 3,?00 RPM lCB/CLIQS: 3200 RPM). (Fig. 5—5) Contact Breaker Contact breaker is a device which pertarms a very important function at interrupting the primary circuit at the ignition coil to enable the build-up ot the high secondary voltage. It is composed or the breaker arm, stationary and movable paints, primary terminal. breaker arm spring and all felt, all at which are assembled on the base plate and mounted together with the spark advancer. The breaker arm is a termed sheet metal piece with a bakelita cam (allower attached to one end. It must operate very lightly and, turther, in order to tn 2 the inertia, the arm must be light and strong. (Fig. sea, 5—7) The movable point requires a strong sprlng tention to prevent chattering during the collapse oi the primary circuit, however, on the other hand, the tension must not he excessively strong so as to cause wear of the triction areas, which would result in change ta the ignition liming. The proper breaker paint tension is 7oo~900g (1,54~2.0 lbs}. To prevent wear to the trictian areas. a small amount of grease is applied to the telt lubricating wick and also to the pivot shalt. Necessary requirements at breaker points. 6) Must be wear resistance ® Good electrical conductor @ High melting temperature @ High resistance to oxidation @ Not enected by ail or water 6) Possess suitable hardness inspection it Make sure that the points are tree of oil. a. Points became black and result in excessive wear, it dirty, a. It lett uncleaned tor a long time, a hardened oil insulation film will result and causes faulty ignition. 2. Breaker arm with excessively warn pivot hole shouid be replaced. 3. Make sure that the insulation at the contact breaker terminal is tree of oil, water and dirt. 4. Fitted or dirty points should be cleaned with a point me or sandpaper. Points with excessively pitted surfaces should be removed and both suriaces dressed so that the paints are making parallel contact. 5.1 IGNITION CIRCUIT 722 D. Condenser The purpose oi the condenser is to prevent unwanted sparking across the paints, however, it the condenser capacity is too large, the ignition spark will deteriorate, normal value is 0.: pl, :lo%. At the instance of point opening, the condenser will have several hundred valts applied momentarily, therelore, it muxt have sufficient capacity to withstand this surge. (Figs 5—8) Aiter perterming a leak test on the megger, a simple capacity test of the condenser can be made by removing the terminals Iran! the megger while still in operation and use a wire to short across the terminals. ii there is a good strong spark, the cm!- denser can be assumed to he in good condition. Actually, the capacity at the condenser will not change. A use of a service tester will provide an accurate measurement ol the capacity and resistance values. E. spark Plug Spark plug performs one at the most imporlant lunctions in the engine ignition system. The high voltage produced by the ignition coil Is received by the spark plug and produces the high tension spark as it iump across hour the center electrode oi the spark plug to the side electrode. The spark ignites the compressed Iuel mixture in the combustion chamber and causes an explosion which aperates the engine. Even under various ads verse conditions, durability and rsliabil' is iequired. (rig, H) l. Spark Plug Condition The operation or the engine can be determined by the condition of the plug, The filing area at the insulator colored white. gray or light gray indicates good condition and is performing satis— factory. 2 Heat Range The firing area oi the spark plug insulator is exposed to Carbon and oil while the engine is operating, and to prevent its build-up. plugs are designed to burn ofl any deposits by the heat at combustion. In order to function as above, the surIoce of the insulator firing area must be maintained at appra- ximaiely 500~a7o°c i932~l,600°Fl range. This temperature is reierred to as the sell.cleanirrg temper- ature, end will Vary to a considerable degree with the type engine and design, riding cond n and type IueI Used. in order tor the plug to Iunction properly under the diflerent conditions it is necessaiy Io! it to dissipate the heat caused by the combustion. Fla. sea, Condenser Fig. 579. Spark plug 123 5. ELECTRIC SYSTEM The rare ol hear dissipalion ol lhe plug in deler. ® mined by rhe heat range ol lhe plug. A plug which CD readily dissipaies rhe hear and which is diflicuh to overheat is relerred lo as a "Cold Type", A plug which velalns lhe heal and which will burn (andin is reierred '0 as a "Hol Type't 0n engine operaiing al high remperarure, a plug which is dilliculi In (were hem, in olher words, lhe cold lype plug is used and lo! engine operaling al low lemperalure u hol rype { plug is used, (Figs sew) 3. Spark Plug Ranch The reach ol «he spark plug refers lo lenglh ol lhe lhreoded seclion. Diherenr model moiarcycles have cylinder head designed wirh dlherenr deprh © Ho. mac (2 Medium rype (3 Cold lype o, s k I h I . ‘ _ _ par pug oe. iherelare, lhe spark plug Willi Flue 5-l°« Swim“ “9W °' '"° 5W“ “”9 ihe proper reach should be used. (Figs 5—ili Reach: 12.7 rrlm. The lollowing unsarislaciory candirians will occur ir plug or improper reach is used. ill Reach loo long a. Carbon will be deposired on he exposed lhlead and cause damages to the lhreads in ihe spark plug hole during plug removal. b. The plug up will become averheoled, causing pre-ignillcn. 12 Reach loo sholl a. Carbon will be deposiled an lhe lhreads al the bollcm cl lhe plug hole and when the spark plug of lhe proper reach is lnslclled, rhe (D Reach 'hleads will be damaged 0! snipped. PM 5*” 5P” 9'"? "M b. Due to the cavlly leli by ihe shori reach, exhausi gas will accumulule causing a decrease in power ouipui. overhearing and engine mollunclion. 4. Spark Plug Gap The esark plug nring, regardless ol wheiher lhe primary power supply is lrom an AC. generaior or a D.C. source, is produced by rhe high vohage, secondary coil. The volluge generaled will vary wilh the engine speed, however. wilh rhe proper spark gap, ihere is always sullicienl voliage lo produce a spark reauired lor ihe igniiion ol ihe compressed luei mixlure. ll lhe spark gap is loo wide, a very high volrage is necessary lo produce ihe necessary spark and, in which case, a mishre will resulr or low speed. 0n lhe omer hand, il lhe gap is '00 narrow a spark will be produced or a very low voirage and being pi a low energy, on inconiplere explosion will lake place, resulling in engine mailunciion. . Main Spark Plug Trouble and Covrecfive Action. a. Poor slarling, occasional mishre, knocks during accelerations b, Mollunelians when climbing, backhres, preignilion. 5. MAIN SPARK PLUG TROUBLE AND CORRECTIVE ACTlON A. Poor slarling, occasional misrire, knocks during acceleralion, Symplom Probable cause Correcllve oclion L Dlrry plug eleclrodes Misfire caused by lhe insulallon of l, Adiust lhe spark gap, adlusr lsaoryl lhe eieclrodes due lo carbon deposiis carburelor. 2. Plug wel wilh fuel or louling wilh oil. 2. Dry lhe plugs, change lhe pro- 3. Flushed over 1. Too rich o luel mixlure. cedure on lhe use ol choke. 2. Excessive inlake of fuel during 3‘ Cleanand properly udiusllhe gap, slnnlng. srondord 90p: 0.6le nun 3. Heavy carbon deposil on the elec- l0.024r0.028 in) lrode resulling in bridging or narrowed gap. 5.2 ELECTRICAL POWER SUPPLY 124 B. Maltunctions when climbing, backfires, tyre-ignition. Symptom Probable cause Corrective action 1. Electrodes not notice. Spark plug 1. Replace plug gasket or relaraue able ditty. l. lnsutncienttv torqued causing the plug. 2. Electrodes excessively exhaust gas lead. 2. Adiust the carburetor. eroded. 2. Too lean a tuel mixture. 3. Adlust ignition ti ing. 3. Small deposits on the 3. Ignition lirning too tor advanced. 4. Replace with plug at higher heat insulator. 4. Improper plug, head range too range. lhigher numbered plug: 4. Indication of burning. low. F. Noise Suppressor A. The oscillating current which contains the high lteauency radio wave produced by the high tension ignition circuit is radiated from the high tension circuit and the vehicle chassis to cause interference to the reception ol the radio and television sets. To prevent this undesirable condition, the spark plug is fitted with a suppressor. The suppressor consists al a resistor incorporated within the plug cap and housed in the shield cover. The resistor lunctions as a diminishing resistor. the shield cover increases the high treauency suppressing characteristics as a combined part at the suppressor. (Caution) t. The suppressor should be handled in the some manner as the plug cap, however, provide adequate care lo the iunction ol the high tension card and make sure that the cord is fully screwed in. 2. It the resistance value should accidentally change or if the value should become intinate, it should not reflect the perlormance; (discoloration oi the outer insulated coating) it is recommended, however, that it be changed with a new item. ELECTRICAL POWER SUPPLY A.C. Generator (Fig. 5-12) A generator produces electricity because an iron core cuts across a magnetic field. This basic principle holds true both in the flywheel magneto, D.C. Generator or an A.C. generator. ln the A.C. generatarr the output voltage changes direction, hencetonh the name AC. tatternaling currenil generator. The advantage at an AC. generator is that the mattunction as rcompared to the other type is less lreauent due to its simpler construction and lower parts which are subiect to wear. Another tnaiar advantage is that the kick starter can be employed as an auxiliary starting method even with the battery com- pletely discharged, This is because the AC. generator induces a large voltage which when ted through the rectifier to the ignition coil will produce a spark at suflicient strength to produce ignition. ® Stale! ® Rotor ® Washer © Sat bolt rig. 5—m. AC, generator construction 125 B. Characteristics 5. ELECTRIC SYSTEM ltenrs RPM CB/CLi75 30041000 RPM ca/cuzs 300—10500 RPM Normal voltage Electrical loud lZV Alter lull wave rectification. Day: 6V—12AH battery+ ignition coil isingle lobe cam with spark every revolution, contact breaker closed we" at each revolution) Night: in addition to the day load, the lamp loads are added lH.L. 35w, T.L. aw, ML. 3WX3, B_L 6V After full wave vectiflcation. Day: 6V—6AH+igniiion coil ID.C. ignition, spark every revolution. contact breaker closed 180“ of each revolution] Night: In addition to the day load. the lamp loads are added [H.L. 25W, TrL. 5W, ML 3W! 2.5W) Charging -lniiial charging speed -Charging at 5000 RPM Day 2 2400 RPM max Night: 2800 RPM max Day = 10:0.“ Night: I. i0.5A Day : 1300 RPM max Night: 2000 RPM max Day 1 2.0 :33: Night: 2.0 :33: AC i 2_ l 31W l DC (D Recliner fig. 543. Selenium rectifier construction diagram Her 544. Selenium rectifier 3. SELENIUM RECTIFIER A rectifier is an equipment which converts the A.C. (alternatingl current to a D.C. reztl current and is necessary lar use with an A.C. generator or an AC. generating coil. Battery requires DC. voltage for charging and il the electrical voltage produced by the generator is an A.C., this must be converted to DC. so that the battery can receive the charge. Rectification is a process at causing the cyclic reversing current to ilow in only one direction. As shown in the figural it permits the current to ilow in one direction but blocks the current from flowing in the opposite direction, thus is known as a hall wave rectification @, There is another type which changes the reverse flow of current so that if also flows in the same direction; this is known as lull wave rectification ©, (Flax 5—13) Rectifiers are at many types in construcllouy material and shape, however, principally the theory al opera. tion is the same, i.e the current is readily permitted to now in one direction but restricted lrom flowing in the opposite direction. The selenium rectifiel is made with the plate of either aluminum ov nickle plated steel sheet coated ol vacuum alated with a highly purified selenium and a rare element, This plate is heat treated under a controlled pressure followed by spray coating an area which will be used as a terminal. In which case, a special electrolytic action is set up at the lays! between the selenium water and the sprayed allay terminal, As shown in the figure, the current will readily how in the normal direction and only a negligible amount flaws in the opposite direction. When this unit is placed in the primary A.c. circuit, the current will fiaw in only the specified direction term the output side. (Flg. 5—14) 5.3 SELENIUM RECTIFIER 5.4 BATTERY 126 A. Selenium Rectifier installation and Handling I. Do not bend, cut or scratch the ulcnium waters. '2. The rectifiar locking not should not be Iaosend or the waters roluted. .cation runctian turther, it will destroy Any movement will cause the electrode alloy to peel, affecting the re the moisture proofing and thereby, shortens the lite ol selenium rectifier. 3. Take adequate precaution not to permit ruin] sail wutar. Water or battery electrolyte to gel on the selenium er, as it will cause the amount 0' current flowing in the reverse direction to increase. Further, if the selenium water it exposed to moisture for any length or time. oxide will be produce on the surtaee, resulting in a shorted condition and the following trouble will occur. a. Battury will be discharge. b. Mallunctian oi the charging system. 4. Do not operate engine without the battery or electrical load connected to the circuit, lexamplesl a. Loose or disconnected lead at the battery tsrlninaL b. Loose or disconnected terminals on the lead between the battery and the ® side of the selenium rectifier. c. Running without a battery. ll the engine should be started under the above condition or it such condition should develop while the engine is being operated. a high voltage will be produced due to the absence at any load on the coil, and this high voltage will cause a large omout ot current to now through the rectifier in the reverse direction. resulting in the eventual damage to the selenium rectiner. Therefore : at Always maintain all electrical connections in the circuit in a good condition. b, Under no circumstances should the engine be started without the battery connected. A. BATTERY A, Construction The battery stores the electricity produced by the generator for use as a source of power tor the salety items such as the lights and horn. At present, all batteries used tor small type vehicles are of a lead storage type Enclosed in a plastic case. The construc. tion end the name or the component ports are shown (0/ in (Fig. 5—15). (D Pole Q) 9 terminal @ Negative plate @ Separator &_glass net @ Container (B terminal ® Positive plate rig. 5-ls. Battery construction a. RATING Item CB/CL175 CB/CLl25 Type Mewsslzc B3676 Voltage l2 v o v Capacity 9 AH 6AH soecinc grayity oi electrolyte l.260vl.280 at 20°C (65°Fl Same as left 127 5. ELECTRIC SYSTEM C, Instruction on use and Servicing 13W 1. Check specific gravity $23 Before using the battery, check the oapacity and 1:240 it the specific gravity ol the electrolyte is below 330 me at 20°C [68°F) lless than 75% capacity), G) titan the battery should be recharged, lzlil (Note) Hi“ The relation between the battery capacity and the ' It 20 3° W 50 6“ 7“ 3° 9“ 10“ specific gravity (residual capacity! is shown in (D (Fig. 545). When the specific gravity is L189 at 20°C [68°F] [less than 50% capaciryl the residual capacity is small and il continued to be G) Specific gravity 90°C) (2 Residual capacity |%l used in such a condition, it will eventually lead “Hr 5*” Specific swvi'v 0"“ “WW capacity cm to trouble as well as shortening the battery lilel therefore, the battery should, under such a condi- tion, be recharged us soon as possible. (Fig. $16) * ' 2t inspecting the electrolyte level. As shown in Figu 547, it the electrolyte level tails below the LOWER LEVEL remove the filler cap with a screw driver or an appropriate tool and fill the battery to the UPPER LEVEL with distilled water or battery water. Do not fill beyond the UPPER LEVEL. (Fig. 547) 3. Whenever the vent pipe is removed during recharg. lng, It must be reconnected when the battery is installed. Care should be exerslzed not to restrict the opening. ® Upper level mark (2) Lower level mark fiqt (H7. D. BATTERY CHARGING PROCEDURE 1. Connection to Charger (Fig. 548) Connect the positive i+l terminal at the battery lcolored redl la the positive terminal at the charger, and the negative l-l battery terminal to the negative terminal or the charger. lFig. 5—13» When more than one battery is to be charged at once, they should be charged in series, as shown in (Fig. 5—183). Series connection tor Multiple Charging 44-53 Fig. 5—1“. G) Charger 6) Battery rig. 5-133. (Note) When series charging more than one battery, the charger voltage must be the sum oi the battery voltages. For example, to charge three six volt batteries, the charger must have an output voltage In excess of 6+6+6 or 18 volts. 5.4 BATTERY 128 2. Charging Charge the battery at the current specined in following table. Electrolyte Capacity Charging S .r Volume oi Specific gravity of 1 Voltage ctiO-hr mm, ”9"“ electrolyte electrolyte when We lVl rate 93"]! required iully charged at tAHt W "‘63,,” tar nlling 20°C team ¥_ llitersl MEWS—12C . 0.7 I, [Used on CB/CLI75] ‘2 7 0'9 1 26° 25° l 7, _. 336*6 (Used on CB/CL1251 s 5 0.6 L260 0.26 1.280 The charging time (or a new battery is determined by the length at time in storage since the date of manufacture. (Date oi manutacture is printed an the buck oi the specification booklet, enclosed with motore cycle batteriesl. The table shows the approximates charging times. D . ( Less than 6 to l2 Over l2 ”’“"°" ° “”9" a months. months. months. Duration oi charge iota 20hrs. 20 to 30 hrs. Over so hrs. (Note) I. During the charging operation, it the battery temperature exceeds 45%: mam, discontinue charging or decrease charging current to 1/2 or the specified value until the temperature tails to a sate level. In this case, charging time must be increased. 2. Be sure to charge the battery at the specified current. 3. It the electrolyte level {ails during charging, refill with distilled water to the upper level line [to the level indicator in hard rubber»cu§e batteriesl. Near the and at the charging period, adlust the specific gravity to between 1.270 and 1.290 (between 1.250 and 1.270 in tropical areasl, and continue charging for two to three additional hours. 4. Explosive hydrogen gas is discharged tram the cells, theretore, do not charge batteries near any open tire. Always turn charger OH before connecting or disconnecting batteries. 5. After chargingy add distilled or battery water to the cells to bring the electrolyte to the upper level line lto the level indicator in hard rubber case batteries). Tighten cell caps firmly and wash OH with clean water any acid spilled. 6. The battery is now ready to install. When installing a motorcycle battery, be sure not pinch the battery vent tube. Explosion may result it the exhaust tube is blocked. 3. Preventative Maintenance The battery is being recharged all the while the engine is running, Further, while running, the load such as the use or the winker, horn are placed on the battery idischargedl, as the result, the battery is being dis- charged at the same time it is being recharged. In the long run, the discharge and the recharge is in balance. The system has been designed in this manner. Under certain condition when the balance is upset, than trouble develops. To obtain maximum life from the battery, it is necessary to locate this trouble and take the appropriate action early. rhe trouble to the battery are mainly external such as cracked case, broken terminal, disconnected iead wire. The battery condition, trouble. corrective action are shown in the tollowing table. 129 5. ELECTRIC SYSTEM E. TROUBLE SHOOTING AND CORRECTIVE ACTION Trouble Probable cause Correct action A, Sullation The electrode plates are covered with white layer or in spots . Motorcycle . Charging rule is too small or else excessively large. The specific gravity or the mixture oi lhe electrolyte is improper. Baltery Ielt in a discharged cone dition lor 0 long period. llett with the switch turned on). Exposed to excessive vibration due to improper insulation. stared during cold season with battery connected. 5" . When mararcycle is in starage. the battery should be recharged once a month even though the motorcycle is not used. . Check the electrolyte periodically and always maintain the proper level, In a lightly discharged condition, pertarming recharging and dis- charging several times by starting the engine may be sufficient. B. Self discharge Battery discharges in cddfi tion to that caused by the connected load. Dirty contact areas and case u Contaminated electrolyte or elec» trolyte excessively concentrated. . Always maintain the exterior clean. . Handle the replenishing electrolyte with core c. Large dilchurqa raie Specific graviry, gradually lowers and around 1.100, the winker and horn no longer luncrian. D. High charging rate The electrolyte level drops rapidly but the charge is always maintained at l00% and the condition appears satislacrary. A condition which is overlooked. lSpecific graVily over new . The ruse and the wiring is saris. factory, lauds such as winker and horn does not Iunction. In this condition the motorcycle will operate but with prolong user bolh (-9 and 6) plates will react with the sulfuric acid and farm land sulfide deposits, (sultationl making it impossible to recharge. . The deposit will heavily accumulate at the bottom and will cause internal shorting and damage the butlery. . When the speclfic gravity tells below 1,200 l20°Cz68°FL the battery should be recharged im- madiately. , When the battery trequenlly be- comes discharged while operating ar normal speed, check the gener. ator Ior proper output. If the battery discharges under normal charge output, it is an indication of overloading, remove some of the excess load. . Check to assure proper charging rateu , when overcharge condition exist with the proper charging rater place on appropriate resistor in the charging circuit. E. Specific gravity drops Electrolyte evaparates snarled i lnsurncient chorging Distilled water overiilled . Contaminated electrolyte Perform specific gravity measure» mant. It the addition at dis'led water causes a drop in specific gravity, add sulfuric acid and adiusl to proper value. 5.5 VARIOUS LOADS 5. VARIOUS LOADS A. Headlight The headlight is to provide sale riding at night and, therelore, it should always be maintained at proper udiustment. On tile cs/cms, a sealed beam type lamp unit is used, 'whereas, a semi sealed type is used on the CB/Ctlzsl On these types, deietiorcttion rate pt brightness is velatively low. (Fig. 5719472) at Mallvnctions 1. Broken bulb filament Primary causes are; Excessive voltage applied Excessive vibration due to bad roads or high speed rlding. Detective materialr 2. Detective Contact. Contact points making poor contact B. Taillight, Stop light A combination light bulb is used lot the taillight and the stoplight. The bulb rating is éV—lB/fiw, lCB/Cll75: 6V-25/8Wt the stop lamp is lBW (CB/CLl75 : 25Wl and the tail lamp 5W lCB/CL175: BWL The glass enclosure is a pear shaped bulb [CB/CL IZSJ (Fig. 5—20) is, Inspection 1. Broken filament The main cause at broken moment can be altrlbpted to excessive Vibration resulting tram riding over had roads or excessive voltage, ltoweve, in a rate case it can also be caused by dlectlve material used in the manulacture oi llle bulb. Remedy: Replace the bulb. 2. Detective contact Bulb contacts making poor Contact l iln the socket. 3. Broken cord Cause: Bleak at the terminal due to Vihtation tram riding over rough road Remedy: Peel buck the insulation oi the cord and tesolder the wire to the paper terminal on the socket or connector. c. Neutral temp and Speedometer temp This lamp is to indicate ihe gear change to be in the neutral position and is located within the spe- edometer. Lamp rating is evx3.ow. lieter to section L2 ter remedy in case at detective operation (Fig, 5—21) 130 © Head light rim (2) Head light unit Fig. 5—19—i. Component parts at head light (CB/CL 175: (2) Head light bulb @ Head light rim @ Head item Socket @ Socket supporter (5) Boat Figu “9-2. Camponent parts et head lien. (CB/CL l25l (D Tail light has: ® Tail llght bulb @ Tail light lens (9 4x45 cross serew Compc parts at tail light ® Neutral lamp bulb (2) Socket rial 5*2l. Component: parts at neutral lamp 131 6r STARTING MOTOR A. Description 5. ELECTRICAL SYSTEM CB Us is equipped with a starting motor mounted on the forward section of the crankcase. a kick starter can be used as an auxiliary starting method. When the starter switch is depressed, the powerlul series wound electric motor incorporating a planetary reduction gear drives the crankshaft by means oi a chain and sprockaix. the crankshaft exceeds the starting motor, however, the starting motor is presented from being motorized by the overrunning clutch mounted The starter magnetic switch is installed in the starting circuit to permit a large current to now to the starter on the driven Sprocket. when the starter switch is depressed. Starter Specification As the engine starts the speed or Rated voltage 12v Rated output 0.35 KW Rated loading time 30 sec. Reduction ratio 5.45 Directlon of rotation leh hand, viewing the sprocket Battery l2V - 9AH Weight 2.5kg max. Starter Performance at sprocket shalt withaut load with load at been locked Voltage 1 1.5V 9.4V 6.7V Current 28A max. 100A 240A Torque —— 1.5kg. m min. RPM 2000 rpm min, 500 rpm mlri. Power output —— 0.33 KW min. A 550 i 55 gri Brush spring tension Carbon brush 5.85 ~555th X112 ~12.4mm X H ~115mm Brush holder 6.]5~6.3><12.6~12.8 mm Clearance, in rotary direction O.2~0.45mm in axial directlon 0i2~0.6mm 5.6 STARTING MOTOR 132 0(00 (D a) o ring (2) Sprocket mutt a) Gear cover @ Ring gear (5) Planetary gear (3) Rubber gaskat Ci) Oilleer metal D ® End bracket A (9 Drive sprocket ® Otlless metal c a; on zeal @ Rotor shalt (:3 Cities: metal A (37 Gilles: metal a Fig. 5-22. Construction or starting motor s. Disassembly a. Removal of staffing molar 1. Disconnect the electrical power cable lrom the starting motor terminal. 1 Remove the two 5Xl2 cross screws and starting motor side cover. 3, Remove lelt crankcase cover. 4 Remove the starting motor sprocket by removing the starting chaint 5 Remove the three starting motor mounting bolts and separate the motor from the engine. ct Inspection Check the commutator ier wear and it necessary, repain Check wear at the brush, it worn excessively, replace. check tension of brush spring, ii there is loss of tension, replacet Check the reduction gears for wear and damages, replace 1'! necessary. Check the driven sprocket, overrunning clutch spring and roller tor wear and damage. Replace any delee. tive parts. 6. Check all ball bearings and bushings lor wear and damage, replace it necessaryt 7. check the operation oi the starter magnetic switch by applying battery power to the primary terminal while grounding the solenoid body, A click will be heard tor a solenoid which is in good condition It the starting motor does not operate properly. the solenoid contact points may be in poor cond ton. Disassemble the solenoid and clean the points with a fine file. FPFNT' D, Reassembly Reassemble the starting motor and overrunning clutch lit the reverse order of removal, (Note) Apply a thin coating oi silicone grease to the overrunning clutch rollers during assembly I33 5. ELECTRIC SYSTEM 7. SERVICE TESTER INSTRUCTION Item Power Direction for Use Connect the IesI leads to Ihe "X Ievminals and attach the ends or the test leads to the part to be Iesled. N Were is coniimi'y, Ihe red "Cominuiiy" lamp will be lit, No lighting indicates that there a m is no continuity. 2 % Examples: ; g l. Light bulbs, shorted or open electrical circuit. g ': 2. Many other electrical continuity tests can be (3 @ g 3 Pe'lmmed' (D Continuity lamp (2) Power lev or 1th ® Continuity @ 8;: turn the switch oil ® Test lead Short out the ends or the test leads connected to , £9 the "X" terminals and adiust the indicator needle a 999 at the resistance meter to "O" by the adiusting knob. Attach the ends ol the test leads to the (L W points across which the resistance is to be measured | ‘3 L6“ and read "12 meter indicufion. ; > Examples: 2 E l. secondary ignition coil, 5,000—10,000 ahrn Q a ___—_> G) g a 2. selenium rectifier normal direction, 5—40 ohm @ '71 ° 3. selenium recliner reverse direction, 600 ohm (D Black “0‘8 °‘ ‘° mm (2) Adiusfing knob 4r in addition, measurement at resistance across ® PW” “V 0' 12"? the points and many other uses. © ““90"“ @ Turn the switch of! Test lead (7) short lAdiust the needle to "0") short out the ends oi the test leads connected to Hi: ' " terminals and udiusI Ihe indicmor needie ol the insulation meter to "O" by the odiusting knob. Anach the ends at the test leads across the points to be measured, the insulation value is Indicaied on me meIeI’e Examples: l. Condenser insulation value: g L: Under lM ohm . . . . defective Z > Over 5M ohmuusalislamoly g 5: 2. Various insulation tests may be performed, 5 . (D Black scale E o (2) Adiusting knob _ 0 ® Power (6V or i2Vl @ insaIation (5) Turn the switch ofi, discharge after the measurement © Condenser, Short out the terminals to discharge @ Over 5M chm ...... satisfactory ® Under iMohm ...... detective ® Condenser 5.7 SERVICE TESTER INSTRUCTION 134 Item Power Direction for Use With the initial resistance adiust the indicator needle ®_ @ ot the meter to "0" by the adjusting knob and ©% _ posltlon the switch to "Conderser‘: Attach the E ends oi the test leads to the test condemer ®_‘“0 K m terminate and read the capacity on the meter. 0" a ‘9 Range at measuring value: ocs~03pr 3 N c '— 8 (5 § 5 © 6) :9 “’ (D Red scale .3 ® Adiusting knob (29 Power (W ar l2Vt Q) Condenser @ Turn the switch Attach the red test lead tram the terminal to _ Q the 9 side and the black test lead truth the "X" (D (90 E terminal to the 6 side at the test part and read E the measurement on the melerc We § X, Examples: 3 g I. Battery terminal voltage I J E if 2. Measuring the output at the D.C. dynamo 3* = it = a 9 e ‘s’ Z @ q (D Blue scale 0 (2 Battery G) DC, voltage @ Turn the switch at! Connect the DC. current measuring leads to the DC. current terminals. When the current flows tram the red terminal to the black terminal, the indicator needle on the meter swings to the normal direction It the indicator needle swings in the reverse direction, the connection at the D. c. connection must be reversed. (D (Camlen) -e It the connections are reversed, tuse tlsAl will be 5.9 g blown. When the lndtcater needle at the meter g 5 does not swing, inspect tor fuse, g : Example: ‘f 2 I. The charge or discharge cenaittan at the ® Yellow scale 3 bullevyu (9 DD. ament 2. Measuring the current consumption of the ® Charge flasher, horn, light, etc. © Discharge G) lurn mr switch OH (3) Swtte' (i) selenium rectttier (9 Battery Q) Mounted on chest: @ at > § n 135 5. ELECTRIC SYSTEM Itern Power Direction for Use Attach the ® test lead train the "X" terminal to E the 69 side at the dynamo tAtCJ either day or 2 night operation and the 6) test lead to the e g v side or to the chassis and measure the volluge é a; with the engine running, 5 c} (Caution) 8t : Do not run the engine at high speed. Measure at L; 2 a speed below 2,000 rpm. f c) Blue scale <2) A.C. volloge U. (3) Turn the switch ott < ® Day @ Night Chassis ® Dynamo tA.C.I Plug in the timing light attachment into the timing receptacle. Next, attach the timing light high tension cord to the hex bar installed on the head ol the spark plug. Position the switch to " iming", start the engine and the timing light will start flashing. Paint the , £- tight to the flywheel adiacent to the case 'iming E 3 index matk. The ignition timing and spark ad. ? 5: vancing can be inspected. E _ F: ° @ Earth (9 Power av orlzv ‘° (3) Timing ® The switch may be turned either ON or OFF @ Hex bat HS) Engine @ Plug cap Timing light 9 Ignilion timing alignment mark ll) Rotor Plug the crow taot plug into lhe crow loot (p G) receptacle to connect the primary coil, and connect ® the red test lead to the ® side at the primary @ ’! coil and the white test lead to the 6 side. Then, 5%? connect the high tension cord train the upper RH H (9 corner at the pockel in the tester bady to the high tension secondary coil. 6 Position the switch to "Coil Test" and the spark 9M8 will iIIrrlp across the three needle test gap. ® g) g. Measure the sport gap by turning the adiustinent ; T; knob. 6) Block E g (caution) ® G'W'd _ f3 .0. Ground the black cord in the upper LH pocket ot © PM“ (W 5" C°"=r g, the tester body to avoid possible electric shocks "‘9 6" PM" “"d . mm ",8 mt use 11v power tor 12v cotlsl ior 6V coils use 6 volts power and 12 volts power @ “WY W" © 0’" ‘°" ,0, 12v was. The switch may be turned either ON or OFF ® High tension secondary lFor slinut. taneous ignition) Coil ® Primary coil For common use (13 tied ® White ® Normal ® Reverse 5.7 SERVICE TESTER INSTRUCTION 136 ltem Power Direction tor Use Use the transistor tachometer unit attachment in the _ timing test started above tar measuring the revalu. ;: - tion of the engi e, the revolution Ior the charge E g 13; starting and the revolution tor the governor advanc. ° 5 .e , 5.: z, mg, ere. o~e,ooo rpm. ® 2 E 2' c 5 ~ g E 3 g 2 Z __a ,: ® Tachometer ® Turn the switch on The shunt um. attachment IS Used tar measurlng the 3’» ® starter current, the current under no load and for Q testing the sellstarting motor eertormance @ e z O~60A ? @ 7J7 2 0x6 3 e .: 1: u a: a .e : 2 a g —a is j g (D 5m... é ® Wiring diagram for starter current in measurement ® Starter cord @ Turn the switch ofl 6) Battery 1. The service tester shall be operated with care and the switches turned eh when not in use. 2. When the power indicator lamp is not lit wlth the battery connected, c the probable cause: at the trouble are either blown iuse or detective 5.3 vibrator. Inspect the parts. 5 3. When using the timing light, it the service tester is operating but the ti ing light is not hr, the bulb (xenon meet is prabablv detective and should be replaced. Q) Power indicator lamp MEMO 6.1 MAINTENANCE INSPECTION 138 6. PERIODIC ADJUSTMENT 6. I MAINTENANCE INSPECTION Periodic inspections should be oerlormed at regular schedule and designated mileaaes in order to obtain salisl‘aclory service as well as to extend the useful lite or the motorcycle. A. ENGINE ADJUSTMENT 1. MEASURING COMPRESSION A low compression pressure will result in a core . . , l Com rers responding dropinthe engine power output. Pressure 2“ H" Mfgsfixgzommmm “We leak lrom any cause may ellect the engine speed adiuslmenl at low speed and creale engine stall co nditio n, a. Remove the spark plug, b. Insert the end of the compression gauge into lhe spark plug hole and hold fiIme to prevent pressure lrom leaking. (Fig. 64) c. operate the kick starter repeatedly several times with both the choke and throllle in the lull open position, (Note) I, Make sure that [he lhrottle and choke are fully open, or else, a lower pressure indication will be registered on the compression gauge. 2‘ The cylinder compression pressure indication will gradually increase with each kick, Iherelore, continue kicking until the pressure stabilizes at the highesl point. 1 To obtain a true cylinder pressure indication, lhe measurement should be made alter the engine attains operaling temperature. Check lor the praper operation or the valves, Make sure that the compression gauge is firmly fitted in the spark plug hole to prevent pressure leak. The normal cylinder compression pressure is lord/cm2 (142.3lb/inzl. In case the compression pressure exceeds 12 kg/cm2 (I721b/ln21, it is an indication oi heavy carbon deposil accumulation on the cylinder head or the piston. The deposils should be removed by discssembly. ing the cylinder head trom the cylinder. i, when the compression pressure registers less than Ella/cm2 lll4Ib/in91, it is an idicetion ol pressure leak, First check the tappel odluslment and see ii the condition can be corrected, disassemble the engine and inspect the Condlllon of the valves, the head gasket and piston rings, 1 TAPPET ADJUSTMENT The tapoet clearance will have a great deal ol el’lect on lhe valve ing. ll the clearance is '00 small it may prevenl lhe valve lrom iully closing and result in pressure leak al the valve On the o'her hand, an excessive tappet clearance will produce Iappet noise and result in noisy engine operalion. The topper clearance will also have a varying degree of efiect on the engine power output, engine opera tion at slow speed and engine noise. repose l, Valve clearance a, Remove the lelt crankcase cover and align the (D 1mg index wk r mm "T" timing mark on the A.C. generator rotor with #2. Aligning m “Ti. "ml the timing index mark on the stator. (Fig. 672) . Unscrew the tapoet adiusllng cap on the cylinder head and check the clearance between the adiust. ina screw and the valve with a thickness gauge. (Fig. 6—3) a- 139 6. PERIODIC ADJUSTMENT . I , (D Thickness gauge: 0.05 mm lo.007lnl @ Adius ng screw Fig, .5» . Adiosting tappel clearance ® Timlng indek mark ® ‘ ‘ mark rig, e—t. AIIgning the ir mert ® Breaker point ud‘usting screws ® Contact breaker Fla. e—s. Adrusting the ignition timing ® Contact base plate Screw: G7 Conluct base plalc aggfib (D Sen/K: resrar ® aaitery <21) lrming tight rig. ed. 6) Card It the valve is being actuated by the rocker arrrlr rotate the AC. generqur rotor one complete turn lo set the pis'on aI lop-dead»cenler of the calm pression stroke, and then perlorm the check, 2. Adiustrrtertt Loosen the adiusling screw locking nut and make the odiustment with the adiusting screw to obtain lhe standard clearance of 0.05 mm (0,002 in.) (or both the inlet and exhaust valves Turn screw clockwise for chaser clearance. (F . 649) (Note) I. The adiustment must be made with a cold engine and the clearance measured wllh a thickness gauge. 2. When locking the adiusting screw locking nut hold the screw to prevent its turning. 3. Inspection u. Check '0 make sure lhal Ihe Iappef clearance is within standard tolerance. Too small a clearance will cause the valve to stay open with a conse. guent pressure leakage which will result in hard starting or no starting at all. b. Check tar improper valve .rnmg c. Check tor stretch in the cam ch IGNITION TIMING ADJUSTMENT Art improper ignition timing, regardless oi the accuracy of the valve timing or the proper compres- sion pressure, will not realize cl salisfaclary engIna performance. ignition timing out ot adiustment will seriously afiect engine power oulpui as well as the fuel consumption. l, Alignment at the "r" mark a. Remove the lett crankcase cover and align the "F" marking on the generator rolor to the timing index mark on the stator, Check to make sure that the spark is produced across the spark plug gap at this point. (Fig. 6—4) rertorm this test by removing and placing the spark plug on top of the cylinder head with the high tension case connected. 2. Adiustment Make the adiustment it required, by loosening the contact breaker adiusting screws. 0 When the ignition timing is retarded, move contact breaker toward the right. 0 When the ignition timing is advanced, move the contact breaker toward the left. 3. Breaker point gap, 0.3 to 0.4 mm loom—0.0mm.) max, Improper ignition timing will result in combustion to take place at the incorrect point aI compres- sion, making it impossible to obtain smooth engine operation the throttle grip will require greater opening, consequeunlly, the fuel consumption is increased. 6.1 MAINTENANCE INSPECTION 140 Results of retarded ignition timing: l. Drop in power output. 2. Drastic increase in iuel consumption. 3. Engine overheats with a possibility oi piston seizure. Results of advanced ignition timing: l. Produces knocking and drop in power output. In severe cases, damage to piston, connecting rod, crankshatt may result, therelare, peri dic inspection should be performed. 2, Upon completion oi the paint gap and ignition timing adjustment, check for proper operation oi the spark advancer by the use at a timing light. Checking the operation at the spark advancer with a tachometer. Reter to section service tester on page 123. 4, CONTACT POINTS Inspect the surfaces of the contact points; it they are burnt or pitted, dress the surface with an oilstone or a point dressing file so that the points are making parallel contact. (Fig. 6—7) Alter the points have been dressed, wash in gasoline or trichloroethylene to remove all trace oI oil. Insuii ient breaker point gap. a. 6‘) ® .9 it) Narmai ® Worn contact point (3 Side contact point ® Dirty contact point rig. 1H. Breaker paint contacting condition The spark tends to linger, that is the interruption of the primary circuit is not completed at the points, thereiare, the secondary high voltage build up is reduced. a. The closed duration at the points is longer, producing heat and resulting in damage. tinting; this will cause a drop in power output. Excessive breaker point gap a. The duration that the points are closed is loo short to allow for suliicient current flow in the primary circuit with a consequent low voltage buildup in the secondary high voltage circuit. This condi on will cause poor engine starting. ignition missing at high speed and resulting in loss of power. Engine over—heats readily. c. The ignition timing is advanced. SPARK PLUG ADJUSTMENT A dirty or damaged spark plug or plug electrode which are eroded will not product a good strong spark, thereiore, the spark plug should be inspected perio catty and cleaning and adiustmeni made. Spark plug with sooty wet electrodes, or electrodes covered with deposit: will permit the high lension voltage to bypass the gap without sparking, l. Cleaning a. The use oi the spark plug cleaner is the wealth mended method oI cleaning the plugs, howeverr a satistactorv cleaning can be perlorrned by using a needle or a shit wire to remove the deposits and then wash in gasoline lollowed by drying with a rag or Compressed air. (Fig. oral In coniunction with ® above, the points will be late in opening with a consequent delay in the ignition (D Spark plug ® Spark plug cleaner rig, a—s. Cleaning the spark plug 141 6. PERIODIC ADJUSTMENT “ b. Adiust the spark gap otter cleaning. Set the gap to 0.6—0.7 mm (0.024—0.028ln.) by bending the electrode an the ground side. (Fig. $9) spark Plug Inspection a. Check the spark intensity produced between the gap of the ground and the center electrodes by observing the color. Good condition Poor condition Blue spark Red spark Cause due to l. Low supply voltage Defective ignition coil Detective spark plug . Absence at sparking rnay also be due to compression a) Thtcknexs gauge (2 spark plug 2 Fig. acv. Aarusting rhe spark plug gap 3- 4 (Nola) t_ Do not remove the deposits by burning. 2. When installing the spark plugs, clean the seating area free of oil or toreign matter and install finger tight before tarquing with a plug wrench. 3. The spark plugs can be tested atter aaiustrnent with the plug tester. With the high lemion voltage maintained torment, vary the fest chamber pressure and inspect the condition of the spark. 6. FUEL SUPPLY SYSTEM Restriction in the fuel supply system will prevent sufficient fuel flow to the carburetor and cause engine to sputter during acceleration or the engine may stall at high speed. 0. Check for sufficient supply of fuel in the tank. scanned the fuel feed tube from the carburetor and check the fuel flow with the fuel cock in the ON or the RES position. (Fig. #10) c. lf the fuel flow is insufliclenl, remove the iuel tank from the body and clean internally. When the flow is still inadequate. remove the fuel cock, disassemble and clean. ’ A . ,, (Note) (D Fuel cock 5: STOP RESERVE l. The imufficienl fuel flow may be caused by the Fig. sew. plugged venl hole in the filler cap as well as the restriction in the tuel line. (Fig. 671!) 2. The fuel cock is switched to RES lreservel from the ON position when the fuel rank becomes empty. The reserve tuel supply contains approxi- mately. ca/cL175: 1.8! (3.8 us. pts., 32 lrnp. pix.) CE/CLI25: L52 (3.2 u. 5. pts., 2.6 inrp. pfs.) a. Fuel strainer cleaning The accumulation at ant and wafer in the tuel cock strainer cup will cause a restriction in last now, resulting in strap in engine speed and mallunc» lion 0? the carburelor. Clean the cock, xlrainel and the filter screen at periodic interval. rig. bill. Sectional vlew at the luel lank cup 6. 1 MAINTENANCE INSPECTION 7. FUEL STRAINER CLEANING The foreign substances contained in the fuel passes through the fuel line from the Iuel tank and enters the strainer cup, The foreign substances and water, if not arrest lI'I the strainer cup will enter the cylinder and causes engine mallunction. 1, Cleaning a. Set the fuel cock lever to the STOP position. a. Remove the strainer cup, c, Clean inside the strainer cup and filter screen. (Fig. 642) 8. OIL FILTER SCREEN CLEANING The engine oil is filtered through a system at double filters, the centrifugal rotor oil filter and the pump filter screen betore being supplied to the various parts at the engine. When the impurities have ac- cumulated in the filters to prevent its proper tunctian, the oil supply to the various parts are starved and eventually result in seizure and damage to the engine. It is therefore, important that the filters be cleaned periodically. 1. Cleaning Remove the right crankcase oil filter cover to gel access to the rotor all filter and tar access to the pump l‘tlter screen, remove the right crankcase cover. Clean the units in gasoline. 9t AIR CLEANAR SERVICING An air cleaner clogged with dust restricts the tree passage at inlet air-and result in powerless or drop in acceleration theretere, to assure proper perr formancey periodic cleaning or the air cleaner should be mode. I. Removal Remove the seat to get access to the air cleaner. Reler to section 49 B on page 118. 2. Cleaning Tap the air cleaner lightly to loosen the dust and then blow dry Compressed air Irom the inside or use a brush. (Figteial (Caution) l. The air cleaner is made of paper and il torn or damaged, will cause dust to enter the engine cylinder, resulting in Increased cylinder vvear,lllere- lorey replace with a new element. 2. Oil or water on the cleaner element will render it ineflective by restricting the New GI air and causing a drop in power, (9 o ring ® Screen ® Fuel stratner cup Fig, 6—11. Cleaning the iuel slm‘lnar Wes/we.“ @ Air cleaner element ®Atr gun Fig. 6-”. Cleanlng the air cleaner element 142 143 6. PERIODIC ADJUSTMENT o. CARBURETOR CLEANING AND ADJUSI’MENT A dirty coiburetor or carburetor out oi adiustmenl will couse peor engine periorrnonce. As on example. a carburetor sell to a lean fuel oil mixture will cause the origin: lo overheat while a rich mixture wlll cause engine to run sluggish. Further, overnwing oi iuel from lire cerburetcr is o possible me more iinereiore. periodic cleaning ond ediustrneni should be perlormedr 1. Cleaning as Disassemble the catburelot and wash the parts In gasoline, bu Blow out the nolees with complsssed air and after cleaning and reassembly, make Ihe adiuslment. 2. idle odiusimeni The idle odiusiment is periorined with both the throttle stoe screw end the pir screw by the Iollowiilg procedure. (Fig. 6—14) at. Beth carburetors must be odiusted simultaneously. b. Set ihe throttle stop screw to the specified idling speed (lioo~laoorpm), c. Next, udiusl the air screw by turning slowly in both directions to obluin the highest engine speed. Turning the screw in will produce d rich iuel mixtures Turning the screw out will produce o leon iuel mixture, d. Reduce the engine speed which hes gone up in to the specified RPM by regulating the throttle stop screw. (P Th'°"'° “W {"9" ‘3 A" 5"“ er At this throttle stop screw selling, recheck the "" ‘5‘” MW"? "‘° ‘°'b“""°’ carburetor ddiustrnent by monipulotingihe airsct‘ews . After the idling ediustment has been completed, check the carburetoi by snapping throttle and elso check the throttle resporee, (Note) I. All adiuslmenl should be made after the englne has attained operating temperature. 2. Adiust both carburetors alternately through aacli oI operations. I. LUBRICATING The purpose 0' lubrication is to prevent direct suricce to surtoce contact oi lite moving ports by providing a film of oil between ihe surioces and thereby, reducing friction and pvevanllng wear. It also serves to cool the parts from lhe heat produced by friction. Further, the lubrlcunl penetrates between the piston and cylinder to term on oil mm which act as e seol to maintain the cylinder pressure, 1 I. PARTS NOT REQUIRING PERIODIC OIL CHANGE 0R LUBRICATION There are some pails which only requlie lubrica- tion whenever the ports file disassembled ior repair 0! replacement. Steering stem steel bolls and cone race Throttle grip Grease Moin stand @ Dmln plug Fig. 6—I5r Removing the drein plug 6.1 MAINTENANCE INSPECTION 144 2. ENGINE OIL CHANGE Change oil at initial 3wkll| (Issmi) and at every IOOOkm (620 mi) «herearter. l. Oil Change a. Remove the oil cap and drain the engine conic pletely ot oil by unscrewing the plug at the bottom or the engine. (Fig. 6—l5) (Note) The oil should be drained while the engine is still warm. This will save me and assure .praper draining. m on level gauge ® Upper level mark (3) Lower leyel mark Fig. we. on level gauge a- . The proper all level is indicaled by llla oil level markers on the gauge when checked wllhoul screwing the cap dawn. (Fig. e-le) on capo CB/cms. 1.53 L12 U.s.pt, 2.7.lrnp pn cB/cmsr 1.2; (2.5 us. gt. 2.1 lrrrp. ptt Oil Brand and Grade The grade or oil tor the season is shown on the upper crankcase. use the oil corresponding to MS. D6 in the A. P. I. service classification. (Fig. 6—17) Under 0°C l32°Fl.. SAE 10W O°~l5°C l32°~60 Fl. SAE 20W Over 15°C I60°Fl SAE 30 (Nate) 1, Oil plays a prominent role in the Iiie and the trouble tree pertarrnance at an engine, therelore, it is very important that.the oil change be per- lormed periodically and relrain lrom using dirty oil over a long period. The more lrequent the oil change. «he betrer i« is lot the engine. 2, When refilling or adding oil, it should not be filled above lhe spectl‘ted level. Overnlling will cause all pumping with consequenr louling or the spark plug. 3, Use only recommended oil of proper grade. dsl 7. on viscmlry C. DRIVE CHAIN ADJUSTMENT An excessively sluék drlve chuln wlll conse chain to whip, whereas an over.tension condition will produce resistance, resulting in lowering the power ® Dr”, chain output at the rear wheel. Always maintain the chain fig. 6.1g Mummy (We mm ”m" at the specified iension. l. Tension checking Procedure a. Check to see it the total vertical slack or the chain at the mid point is between l—zcnr (0.4H.ao in). (Fig. a—le) . Perlorm adjustment by loosening lhe axle nut and then adiust with the adiusting bolts. (Fig. 6‘19) Turn to the right to decrease chain slack. Turn to the lell to increase chain slack. (Note) The adlusters should be at the same alignment marks tor bolh the right and lelt sides. c, Periodically clean and lubricale the chain. Lack or oil will cause the chain links to bind and cause undesirable eireci on the sprocket. a- ® Alignment mark ® Adluslmg bull © Lock nut @ Adlusler r 649. Adlusling the drive chain 145 Hg. Ho. ® tack nut ® Adlustlng nut Fig. int. Adinsttng the trant brake levet ® Free play ol the pedal rig. 6*22. (D Ad.usnng nut rip. 6*23. Adluxllng the rear brake pedal 6 PERIODICA DJUSTMENT D. BRAKE ADJUSTMENT Brakes are the lite.line at the rider, therelare do not neglect to perform the periodic inspection, daily inspection and prerridlng inspection. FRONT BRAKE ADJUSTMENT i. Leuer tree play or The lree play of the brake lever, that is, the distance between the normal attitude and the point where the brake starts to take hold should be 2'3 cm (0.7341JZin), Adiustrnent can be made at the cable ediuster at the brake lever, by loosening circular lock nut and screwing the adjuster in to increase the lever play and screwing the adluster out to. decrease the tree play. . Adjustment is also made by the adiusting nut. (Fig. 6—21) Tum to the right to decrease the lree play. Turn to the lelt to increase the llee ploy. REAR BRAKE ADJUSTMENT l. Vadul tre. play a, The tree play at the brake pedal, that is the distance between the normal attitude and the point where the bloke starts to take hold should be 2—3 cm [0‘7Bvl.l2in) (Fig 6—22) , Adiustment is made by the adiusting nut. (Fig. e23) Turn to the right to decrease pedal play. Turn to the left to increase pedal play. C. When the braklng slroke is small, the following condition is apparent. l. Too small a clearance between brake panel and shoe, 2. Loss at tension in the brake spring. 3. Brake lining damaged due to overheating. SPOKE TORGUING Riding with loose spoke will place an ununiionn loading on the rim as well as on the remaining spokes, theretore, the spokes should be inspected treauently and relorqued when they become loose. Raise the wheel ott the gmund and check each spoke tor tightness, any spoke which are noticeably loose should be torqued to the same value as the remaining spokes so that the spokes are all of uniform torque. Use the spoke nipple tool and totalling wrench. BATTERY INSPECTION Loss of battery electrolyte occurs after long use and should be replenished perio ically. When the electrolyte level drops to the point where the plates are exposed, it will result in rapid discharge to the battery. The battery should always be maintained at the proper electrolyte level. 6.1 MAINTENANCE INSPECTION I46 l. Electrolyte Level .Remove the air cleaner cover disconnect the battery cable Item the battery, remove the battery setting bolt and then remove the battery. The standard butlery used is the MEWS—12C lCB/CL'IQS: 836-67 lMlg. by Yuasa Butlery COJ Always maintain the electrolyte level ubave the lower electrolyte level marking on the batlery. When replenishing add distilled water to raise the electrolyte level to the upper marking. (Fig. #24) a 9' n s Replenish by unscrewing the battery cap at the top and add the distilled water. All three battery cells should be filled to the some level. ® Upper level mark @ lower level mark rip. Ht. Buttery electrolyte level 2. Damaged and Dirty Battery Cable Connector inspect the connectors tor cleanliness and damage. Clean the dirty connectors or replace damaged connectors betore making connection and apply a coating cI grease or vasoline on the connectors to prevent corrosion. 3. Spaclflc Gravity Check the specific gravity of all three cells at 7 the battery with a hydrometer, it it measures below moo, the battery should be charged. A tully charged buttely should in icute a specific gravity oi mall at electrolyte temperature ol 20“C (68°Fll The specific gravity will vary somewhat with the temperature at the rate ot 0.00017 specific gravity variation tor each PC l1,8°Fl charge in temper. ature. A rise in temperature will Cause a decrease in specific gravity and vice versa. (Fig 6—25) © Hydrometer ® Battery Fig. 6725. Measuring specific gravity (Caution) 1. Do not add any sulfuric acid to the distilled water when replenishing. 2. When the drop in electrolyte level is excessive, check the discharge rate at the battery. 3. Exelcise care not to pinch the battery cable when making the battery i taltatlon. 4. Also, make sure that the vent tube is not pinched. 5. When the temperature drops, the capacity oI the battery will lower and cause hard starting. in such a case. store the motorcycle in a warm place. H7 6. PERIODIC ADJUSTMENT G. SECURITY INSPECTION OF PARTS 4'7“ pummgy y ghfj’, 4 \V "@252: ' Fig. 6776 G) Handle installalron nuv 150~250 kgrcm 110V1~18J ft lbs) ® Steerlng sVem nut 900~L200 kg‘cm ‘65.1~86V8li. lbs) CD From axle nut 700~900 kgrcm l50,6~723h.lbs) ® Rear axle nuv 900~L100 kg-(m t65.1~79.50.lbsl © \Nheel spokes |5~ZO kgrcm U.0~l.5 fl. lbs} Rear cushion upper and rear nuls 200~350 kg-cm H4.5~25,3fl.lbs) Cl) Rear lork pivol bolt 500~600 kgrcm (36rl~43,4 '0. lbs) Engine hanger bolts 8mm . 200~300 kgrcm (15~21.7H.1bs) 10 mm 300~400 kgrcm (2|.7~'28‘9 !L lbsl © Rear brake Iorque bol' nut. ‘50~250 kgrcm l10.8~18.1 IL \bsl (Fig. 6'26, 27) 6.2 PERIODIC INSPECTION AND SERVICING MB 6.2 PERIODIC INSPECTION AND SERVICING A. Daily inspeclion It is of utmost importance to pertorni periodical inspection and servicing so that lroubles can be prevented arid the motorcycle maintained in the best or operating condition. The inspection is classified irlIo two types, namely, the preeridirig inspection perlorrned by the rider daily and the periodical inspection which is periormed at a regular schedule either by the rider or the service shop. Fig. 6’28 The following items at inspection should be performed deity as a matter oI habit. (Fig. 6—28. 29) ® Check Ior excessive Iooseness or sway oI the handle. ® Check for proper free play ol the clutch lever. 6) Check the function a! the headlight, taillight, sIope light and turn signal lights. © Check Ior leoseness end all leaks in the (rent and rear Cushions. , 6) Check Iuel quantity. CBIZS/CBWS: l0.5 3 I18 U.s. 56L, 2.3 Imp. gal.) CL125/CL175; 9.52 I25 U.s. gnl., zl Imp. gal.) Fronl tire air pressure LB kg/cm" [25.6 lbs/in2| ‘(D Rear tire air pressure 20 kg/sz (28.5 lbs/in”) Check the horn tor sound and loudness. (9 Check tor proper play ot ironr brake lever. ® Correct level and condition of engine oil CB/CLI75; 1.54 (3.2 U.s.pt., 2.7 Irnp. pIJ CB/CLIQ5: L2! (2.5 U.s. ah, 2.I Irnp. pl.) @ Check tor proper play at the rear brake lever. 149 6. PERIODIC ADJUSTMENT (Nah) Alter inspecting the abave items, attention should be paid to the following points when riding. l. After starting, warm up the engine for two minutes at low speed. When the engine is cold, the viscosity at the oil is heavy and does not permit adequate lubric 2. Do not race the engine needlessly. a. lzelrain iron sudden acceleration oi braking, light cornering. 4. Check battery eleclrolyie level weekly without (all. Under the followlng conditions, checks should be made at a more lreauent intervals. a. Riding in mountainous area. b. More lrequent inspection is necessary when riding at high speed, ion to all parts Periodic Inspection 9 should be performed in accordance with the Following table, Perio inspeclion and sew ‘\\'"""“"”Y'1‘°‘[°"'"§' 300 mm 2,000 3,000 4,000 5,000 6,000 7,000 0,000 9.00010,0001i,000i2,000 , "‘ "‘ (150) (020) (1,240) (Law) (2,400} moo) (3,720) (£340) (use) l5;aoll6,2oo) (6.820] (7,440) items \ I O O O I O O O O O change engine oil Adiust lwnlllon timing Adiusi valve cl-urance . Adinsl cum chain 0 Aaiust clutch O Adimt carburetor Miust drive chain Q Adiust iront and war broke Clean spark plug Clean oil tiller 0 Clean air cleaner Cloan luel sliainer Cltun muttter cneck tightness at spokes . iletigliten nuts and bolts git'tina' eawrnents and Chad: butlary l. 0 O I O O 7.1 ENGINE 7 TROUBLE SHOOTING 150 It is most important that the cause at any trouble be located as soon as possible and the proper corrective action taken so that the serviceable life OI the engine will be exlended. Listed in the lollowing tables are the troubles, probable causes and the corrective actions. 1. MAIN ENGINE TROUBLE Traubles Probable causes Corrective action Engine will nat continue l. Clogged luel cock, Clean and inspecr. running. 2. Plugged vent hole in ruel rank cap. 3. Improper topper clearance. 4. The carburetor to intake manifold con- necting tube damaged or leaking air at the iaints. 5. lrnpraper oil level Engine mullunctlons alter l. Detective spark plug l, Overhenledspurk plug, replace warmeup. 2. Deicclive ignition coil with plugs oi correct heal range 3. Incorrect flout level Excessive smoke all high 1. Oil being pumped inlo the combustion By diagnosing the noise, rebare engine speed. lollpump- chamber due la excessively worn or and/or replace the parts as ing condition! damaged cylinder. piston, rings and required. burned during combustion. Noise produced near lhe l. Warn plston and cylinder 1. Inspect and rebare cylinder and tap at the engine The clearance between lhe piston and replace worn parts. cylinder is increased causing the piston 2. Replace connecti 9 rod, large skirt to slap against cylinder wall during and bearing and crank pin. combustion. 3. Adiusl to proper specificatian. 2, Worn Connecling rod large end produces knocking a. rapper noise Overhauling engine I. Carbon deposil accumulation l. Disassemble and clean 2. Dirty or louled spark plug: 2. Clean, drylouled plugs. Inspect 3. Improper type spark plugs or gap carburetor il plugs continues to 4. Insufficient lubrication to drive chain or loul. chain tension taa lighl. 4. Adlusl periodically, lubricate 5. Oil level too low, poor or improper 7. Adiust periodically grade oil a. Improper dislribular point gap clearance, dirty, burnt 7. Excessive carbon accumulation in come buslion chamber Engine does not start i. Foreign object caught between valve l. Disassemble and Clean lluclr of compression] and valve seat 2. Adlllst 2, Tappet stuck open 3. Adlust 3. Ignilian timing our of adiusimeni 4. Replace new ruse A. Blown (use 151 7. TROUBLE SHOOTING Engine suddenly stalls while running 1. Clogged lirei cock 2. ruel passage in the carburetor clogged 1. Disconnect the luel line and check the luel flow 5. It the toss is blown, the pilots 3, Dirty spark plugs lheavy carbon deposit or wet plugt lamps will not light up 4. ignition timing out oi adiustmont s. alpwn luse on becomes emulsified 1. Water mixed with oil 2, use Honda ultra Oil or equiva. (especially during winterl 2. Use ol improper type oil lent oils 3. Clogged breather pipa (Cauti n) The oil, even though clean in ap- pearance. may decomposed due to extended use and become thin, resulting in lass oi lubricat- ing properties Should be replaced. Increased luel consump- l. Clogged air cleaner Service air cleaner element tian. (Related symptomsl 2. Distributor paint gap outotadiustment, 2. Adiust gap clearance, rework . Low exhaust noise, dirty, burnt or replace burnt points low back pressure at 3. Excess accumulation of carbon in cylin- 4. If ignition timing is retarded, the mulfler der exhaust pen or inside muffler. distributor points will open after . Law compression 4. Ignition timing retarted the timing mark "F" has been noticeable when hick 5 Worn cylinder, piston, piston ring. passed. starting. Adiust to proper setting Insulncient engine rpm. l. Fuel passage clogged L When thatuel passage in cloge 2, Detective spark plug llouledl ges. the spark plugs will be dry. 3 Clogged rnumer 4. it the air cleaner is clogged, 4 Clogged air cleaner engine will not develop high 5. Ignition timing out of adiustrnent RPM and the exhaust smoke becomes dark. Clean the air filler element periodically. Poor throttle response it Clogged air cleaner. lcheck first to see that 2. Clogged exhaust port or exhaust pipe the throttle cable is pro- 3. ignition ti rig out oi adiustrnent perly adiustedl 4. Tappet clearance out at adiuslrnent Distributor points burnt 1. Points covered with oil The condenscrby method described 2. Improper ignition liming below. 3. Delective condenser ‘ 4. Condenser in poor condition (D Condenser Test Method After taking the resistance value with the manager, use a copper wire to short across the terminals, a @ good strong spark should be produced at the instance a the leads are contacted. CD (a service tester <2) spark @ Condenser rig. 7-1. Measuring candenser capacity Condenser Measurement With the distributor points open, measure the resistance between the primary terminal and the outer shell, 0 good condenser should measure at least 5 Mg resistance at standard temperature. The condenser is detective if it measures below l M!) Determine the condition of the condenser bythe above method. (caution) A loosely installed condenser or dirty terminal will cause ignition to mallunctlonl 7.2 CARBURETOR 2. CARBURETOR TROUBLE 152 Troubls Probable cause Corrective action L Fuel overflow (related wmplnmsl - Poor idling - Peer perlorrnence in all speed ' Excessive fuel consumption - Hard starting - Low power Dvlpu" - Poor acceleration l. Contaminated luel 1. Remove flout chumcet cover a. Remote locking clip and discs semble the tiger chamber b, Check for any dirt lodge in the valve seat, remove dirt by blow. ing with compressed git or by unscrewlng the valve seat, and clean c. Reossemble utter cleanlng in gasoline. 2. Domeged valve or valve seat 2. Replace bolh the valve and valve seat with new parts. 3. Punctured "col 3. Remove Ills float chamber cover, take out the float and check for fuel in "to float, lctteclring procedurel - Shake the float - Immerse the float in hot water 90—95 C ll94~763°Fl for approximately 60 sec» ends, bubbles can be observed if the float is punctured. 4. Float errn lip bent 4. Straighten the orrn lip if her" and use the luel level geuge to oblain the proper fuel level. Trouble Probable cause Corrective octlon 2‘ Poor idling lrelated symplomsl - Poor performance at s|ow speed . Paar speed transistiori 0 Poor response In throttle snapping ~ Poo! performance at medium speed 1. Air screw improperly adiusted l. Turn the air screw Iighlly to full close and check to see if the air screw was properly udiusled. Buck oil 1%:% turn from lull close. Slur! the engine and turn the air screw in both direction nol more than i turn and set at the point where the engine rpm is highest lsmoolhh 2e Throttle slop screw out of udiustment 2. Back oil the throttle slop screw all the wayand check lor proper operation of the throttle, turn the stop screw in until the proper rpm is obtained 3r Clogged slow is! lineluding pilot is!) a. Unscrew the plug, remove the pilot let, check for any dirt, blow out with compressed air if dirty. Remove the slow let and clean in the same manner. 153 7r TROUBLE SHOOTING (1’) Throflle stop sclew ® Ail Screw Fig. 7—2. Aeiusling idling ICE/CL l75l Trouble onbabl a cause Corvecfive action 3. Ppov perlormance at intermediate speed (related svmplemsl - Hal spol ~ Poor acceleration 0 Excessive fuel con- sumpfion - Poov speed lransillon l, Clogged slow lel linclud‘e.pllel iell 2, Jet needle a1 improper selling 3. Implopel luel level . Same correclive adion as for poor idling . Adiusl lo me ploper siege (3 stages) Replace worn iel needle with new pan. Use the fuel level gauge and adiust me level by bending lhe float arm lip. 4. Clogged air vem . Clean am the air vent Troub|e Probable cause Correclive acfion 4. Popr high speed pelr iormance lrek‘lfed symplomsl . Loss of power - Pom accelemlion - Black exhaust smoke - Poor engine perlormence Loose main iel OY clogged wiln din Clogged uir veul lube Choke closed Fuel cock impropevly pesiliened Lease iel heedle 9‘.‘5*'.'°.—‘ Remove main iel and clean, inelell and flghlen securely, . Clean out venl lube Open me enolre lo lull OPEN poflflon Posirieu lhe luel cock lever lo lull OPEN posinon. ll iel needle loeking clip Is bloken, replace with a new path 5. Hard sterling 1. Excessive use of choke 2. Fuel overflow 3. Fuel cock in closed pesilien snail engine will. :hcke valve fully open (clean spavk plug! . Same conecfive action as 1 above Open luel cock 7. E N G I N E 154 3. ENGINE NOTICE Trouble Probable cause Corrective action 1. Tappet noise i. Excusivs toppet clearance 1. Adiust to proper clearance 2, Worn rapper 2. Repair or replace 2. Piston slap l. Worn piston. cylinder 1, Repair or replace 2. Carbon deposit in combustion chamber 2. Remove carbon 3. Warn piston pin bore, connecling rod 3. Repair or replace small end 3. Cam chain noise 1. Tansioner out of adiusflnenl‘ 1. Raudiust 2. Stretched chain 2. Replace 3. Worn teeth on cam sprocket, timing 3. Replace sprocket 4, Clutcn knack I. Worn clutch triction disc outer tab area i. Repair or replace 2. Worn clutch center spline 2. Repair or replace 5, Crankshott noise 1. Crankshalt end play 1. Repair or replace 2. Worn crankshatt bearing 2. Repair or replace 6. Engine noise 1. Chafing between kick arm and oil seal 1, Repair lmogneto noise) 2. Breaker point noise, defeclivc slipper 2. Replace AC. generator sartace assembly 4. STEERING SYSTEM Trouble Probable cause Corrective action I. Handle operates 1. Overlorqued steering cone race 1. Readjust heavy 2. Damaged steering steel balls 2. Replace 3. Sent steering stem 3, Repair 2. Pram or rear wheel 1. Loose bearing in front or rear wheel i. Check for wear and replace as 2. Bent rim on iron? or rear wheel required 3. Loose spoke 2. Stroignten by loosening or light 4. Worn rear fork pivot bushing camp the spoke; 5_ Twisted frame 3. Replace ii uncorreciable 6. Drive chain adiuster out or adiustrnent 4. Replace 7. Detective tire 5. Repair or replace a. Aaiust to proper value 7. Replace 3. Pulls to one side 1. Right and lelt cushion not balanced. l. Replace from or rear. 2. Replace Z. Misalignrllem ol from and rear cushions 3. Repair 3, Bent (rant fork 4. Repair 4. Bent rear lork 5. Repair 5, Bent Iran! axle 6. Repair 6. Loose component in steering systerr 155 7. TROUBLE SHOOTING 5, CLUTCH SYSTEM Trouble Probable cause Corrective aaion L Clulch slips 1. Less ol lension in elureh springs l. Replace 2r Worn or warped clulch plate 2. Replace 3. Worn or warped clulch lricllon disc 3. Repair or replace 2. Clutch will rial i. Excesslvely worn clulch fliclion disc 1. Repair or replace disengage 2r Improper adiuslnienl 2. Adiusl to proper specificallen 3. Clulch our ol 1. Warped clutch plale or lricliorl disc 1. Repair adiusllncnl 2. Uneven lension ol ciulch spring 2. Measure lension and repair or lengine slallsl replace 6. GEAR CHANGE SYSTEM Trouble Probable cause Correcllve aclion i. Gears will nol i. Broken lug on shill drum 1. Replace engage 2. Broken lug on shill arrri broken 2. Replace :l. Unsrnaolrl rriovenlenl belween shill drum 3. Repair and shill lork 4. Replace 4. Broken shill lork 5. Replace 5, Broken lllg on counter shall second 6. Replace and lhird gear .5. Broken lug on main shall second and lhird gear 2, Gear change pedal 1. Broken shill relurn sprlng 1. Replace nol rerurning 2. Gear shill spindle rubbing againsl case 2. Repair or cover 3. Gear iurnp aul ol 1. Worn lug on counler shah second and L Repair or replace engagemeni "'in 9W 2. Repair or replace 2. Worn lug on main shall second and _ 3. Replace "Hid gear R 3, Worn or lsenl shill lork 4. “PM“ 4. Broken or loss of lension cl shill drum slopper spring 7r SUSPENSIONS Trouble Probable cause Correclive aclion l Sell suspension l. loss ol spring lension 1. Replace 2, Excessive land 2, Hard suspension 1. lnefiaclive fronl cushion damper 2. lllelleelive rear cushion damper 3. Suspension noise l. Cushion case rubbing l. lnspecl cushion spring and case 2. lnlerlerance belween cushion case and 2. Repair spring 3. Replace 3. Damaged cushion slopper rubber 4. Replace 4. insumcienl spring damper all lflonl and rear] 7, F R A M E 156 8. BRAKE SYSTEM Trouble Probable cause Correclive acvion I. No range of 1. Worn broke shoe 1. Replace earnsrmem 2. Worn brake cam slipper 2. Replace 3. Wow brake cum 3. Replace 2. Unusual noise when I. Worn broke shoe l. Replace applied 2. Foreign obiecf lodged in brake lining 2. Remove ioreign obiecr 3 Filled brake drum surlace 3. Repair 4. Worn brake panel bushing 4. Replace 3. Inenecrive braking 1. lnoperauve lronr brake cable 1. Remove loreign obiecl lrom 1. Loose brake rod cable and inspecl for bends 3. Improper shoe contact 2. Inspect and repair 4, Din or waler inside the brake 3. lnspecl and repair 5. Oil 0! grease on brake lining 4. Inspecl and repair 5. Inspecl and repair 9. DRlVE CHAIN Trouble Probable Cause Correclive adion 1, Drive chain slrelch l. Excessive load applied lo chain 1. Correct riding Vechnique rapid lduring riding or gear change] 2. Perform proper Iubricallan 2. Due lo oil leak, excessive Iubricarion periodically 2. Excessively worn 1, Driving wirh worn sprocket 1. Clean sprockel area sprocket 2. Sprocket malnrled to drive chain 2. Replace wilh proper sprocker ”not" Tum: SIGNAL LIGHT 6V 10w NEUTRAL INDICATED? LAMP 5v st I SPEEDUMETEI LAMP sv 2w CBI25 WIRING DIAGRAM LIGMIINE “IMMER SWITCH “macaw II: ”E II. 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Export type) LIGNTWG BEAM SWITCHING ARRANGEMENT we MB IL La m R. mom mm smnm ‘ 0 FN LAMPIZVIXW r ‘“' “ H 000 00 e ‘9 J 0“ M 0—0 0-0 5mm HEAR 1mm svmommx [AMP 12v 9AM ; >51 ' SPEEDDMEHR 12v3w>3 7 “*w ., 7 . ”AZ-1 3*) ‘1 mm Ianmon swncn Pkk MAIN-lGNleN swwcu a W K LREAR YUAN SIGNAL LAMP ‘ZVISW swncume Amuagnm New m m nfl OFF 1 000 s.‘ if ‘ 2 1 Q HORN sufion TURN SIGNAL SWWIH coumfimm INCLUDED ALGENEMTDR SYOP SWHCH . g\ NEUTRAL SWITCH +9 ‘LFRQNT TURN SIGNAL [AMP ”VIEW GIBEn and WIN I91 '8 WVHBVIU ONIHIM 9. CB/CL125,175K3 162 9. CB/CL'I25, 175K3 9.] DISMOUNTING AND MOUNTING ENGINE L DISMOUNTING ENGINE [CB/CUM] I. Remove the Step bat, kick stutter pedal and gear change pedal. 2. Remove lhe mumele 3, Remove the spark plug cups lvam lhe spark plugse 4. Remove ttte cylindel head 2. side cover and temave the tachometer cable by unscrewing the setting screwe 5. Remove the seat 6. Shul of! lhe fuel cock and remove the two Iuel tubes from the cavburelors. 7. Uncouple Ihe electric leads connecting (Fig. 94) 3. Loosen'the air cleaner tube bands and remove the remove "as tlttottle valve from the carburetor, 9, Remove lhe L. crankcase rear covet and remove drive chain at the will! clip. to, Remove the clutch cable ltam Ihe clutch lever. (Fig. v-2) H. Remove the slater magnelic switch. lctmsl 6) Clutch cable (2) Chuck lever Fiqt 9-2 Ramovin clutch cable l2, Pull out the engine hanger bolts [9 each) and ’ remove the engine to the right side. (Fig, 9—3) , a) 10mm halt ® 8mm bolt Fig. H. Remavlng engine hangar bolts 163 9.1 DISMOUNTING AND MOUNTING ENGINE (D Throttle valve . $5. Removing thronie vaive © Clutch cable ® Clutch lever re. Ht Removing etnteh cable O lem bolt Q) 8mm belt Fig. 947. Removing engine hanger borts [CB/(1125] . Remove the step bar, kick starter pedal and gear Change pedaI. . Remove the muffler. . Remove the spark piug caps from the spark plugsv . Remove the tachometer cabie tram the right Side or the eyttnaer heasi . Remove the seat, shut aft the tuel cock and remove the fuel tubes trout the carburetors. , Uncouple the electrical leads at the connectors. (rte 9—4) . Loosen the air cteoner connecting tube and throttle vaive Irom the carburetor. (Fig 9—5) . Remove the L. crankcase rear cover arid remove the drtve chain. Remove the dutch cabte from the clutch levere (Fig. 9%) . Remove the starting motor cabie Iran! the Starter magnetic switch, [03125) M out the engine hunger bolts t9 each) and remove the engine to the right state. (Fig. 977) 2. MOUNTING ENGINE Perrorm the mounting in the reverse order 0! remover, however, exercise cave on the tottowtng points. \. Remove the corrosion Irom the starting motor cabIe back to the specified location betore mounting with a bolt. The drive chain joint clip should be instaIled so that the open end will face opposite to the direction of rotation, 9.2 ENGINE MECHANISM (CB/CL175) 164 9.2 ENGINE MECHANISM [CB/CLI75] l. CYLINDER HEAD AND CYLINDER A. Disassembly I. Drain oil hunt the engine. 2. Remove the cylinder head tightening nuts (six nuts and two can nutsl, tightening bolt and cylinder head cover. 3. Rotate the dynamo rotor so that the cum chain joint is toward the top at the com sprocket and then disconnect the cam chain. . Attach the wire to both ends of the chain before disconnecting, 4. Remove the cylinder head. 5. Remove the cylinder setting bolt and remove ”1: cylinder. B. Inxpectian Retei to page 21. (it Cum chain tensmnet Fig, 9-9, Pushing down fenslonei c. Reassembly . , I 1, Push the cam chain tensionar, mounted on the cylinder head, all the way in and lock in place with the lock bolt, (Fig. 979) 2, Install the cytinder head on the qiinder. (Fig. 9710) (Note) Make sure that the four dowel pins are installed into the top at the cytinder, two 0 ring: and the gasket are properly installed. 3, To install the cam chain, turn the generator to align Vhe "T" mavk on the rotor 20 the index mark on the stator. The will position the piston to the iop-deud»cemer, Position the "0" mark on the cam Splocket to the top position, connect the chain with the laint clip, The position of the clip must be in the position shown in Fig. 978, (Note) When both sides of the cyitl’lde! head cover are removed, instuli the cylinder head side covers beiore connecting the com chain. G) Dowel Pin Fig. 9-10. Loosen the valve tappet udiustev betore installing the Side cover. 6) 0 mark q. 94!. Installing cam chain 165 9.2 ENGINE MECHANISM (CB/C1175) 4. Insmll ma cylindel head cover and fighlen me mouming nuts. my" cup nuts and one hex. hem (None) Perform ”le Iorquing in a diagonal paltern, mm. ing from me inside and working ourward. Torque to 160~1|0kg-¢m (ll46~l5.2fl-|bs) 5. loosen vhe cam chain tensioner icck be" and men Ie'ighien; followed by semng ma lock nut. [To Iighlen me cum chain! 6. Adiust Ihe valve happen clearance. Adlusl lo 0.05 mm (O‘ODZinJ cold sening‘ (D 6 mm bolt Fig. 942. Nut vi hvening ssquence 9 Camsnan When Iemoving me camshah hon me cylinder head, first lemove me pin or me right side of the camsnnh and men remove horn me cyhnder. (D Camshall ® Knock pm Fig. 943. Remawng knock pin Valve Cylinder 9.2 ENGINE MECHANISM (CB/CL175) 166 (9 Valve collev (2 Valve reialner @ omer valve spying @ lunar valve spring (5) lune! seal ® Valve siem seal cap (3 Valve slam seal ® Slenl seal rubbel cushion (5 Valve spring seav B ® Exhausi valve gu‘lde ® 0 ring ® Exhausl valve ® Valve spring seal @ Inlel valve guide @ Valve guide :Iip @ lnlei vulva ® Valve Iuppul adlust'lng loel nai @ Valve iaaael adnmer ® Rocker elm ® Xoekev arm :huh @ Knock p‘ln @ Carnelian @ Cum chain @ Dowel p‘la Fig. «HA. Assemble lhe inlel and exhaasl valve assembly componenls In accordance wilh Figa 944, exerslze cure nol lo mismalch, When assemblvlng lhe cylinder, lnsiall one each dowel pin on me Vighl and la“ side G) Dowel pln Fig. 9-ls. 1 67 9.2 (D 8mm bolt (2 6mm bolt (3; 8mm cap nut Fig, ?—I6. Removing lower crankcase (D Dowel pin H7. © Gear shirt arm @ Pmiection F3 945. ENGINE MECHANISM (CB/CL175) 2. CRANKCASE A. Disassembly 1. Remove the cylinder head and cylinder in accar. dance with 9.] on page MA. 2. Remove the L. crankcase cover, ArC. generator, and starting sprocket in accordance with section 3.3 on page 32~33, 3. Remove the R. crankcase cover, clutch, oil pump In accoldnnce with section 3.4 on page 34~36. 4. Remove the gear shift spindle and kick starter spring. 5. Loosen the crankcase setting nut and bolts and separate the lower crankcase. (Nate) Crankcose tightening bait is installed under the oil drain plug, therefore, do not target to remove the bolt. (Fig. 946) 3. Inspection keter to section sec on page 41, c. Reassembly Assemble the crankcase in the reverse order at drsassembly with attention paid to the lollawing point. Clean the crankcase and inspect the mating sure faces at the crankcase for sign of leaks. scratches and other damages. Apply liquid gasket to the mating surlaces at the crankcase, assemble alter drying. Make sure that the two dowel pins are installed an the upper crankcase. 3. GEAR SHIFT MECHANISM To prevent the gear shilt arm tram disengaging with gear shilt drum, a proiection is provided on the upper crankcase to limit iumping at gear shitt arm. Further to facilitate shifting into the neutral gear, the neutral stopper is made to m the drum directly. (Fig. 9—13) 9.2 ENGINE MECHANISM [CB/CL175) 168 A. Dismsembly l. Remove the cylinder head and cylinder 'tn accor- dance with 92.1 A on page 164. 2. Remove the R. Clankcase cover. 3. Remove the claret. and oil pump ‘ln accordance with 3.4.2.5 on page 35~36. 4. Remove the L_ crankcase cover, Aicv generalorr and sloning sprocket in accordance with section 3.3 on page 32~33. 5, Remove the upper crankcase in accordance with section 9.2A an page 167‘ 6. Separale the transmission gears from the upper ® Gear shilt dwm stopper (2) Neutral mapper crankcase, 7r Remove the gear shin drum stopper, neutral switch tram the gear shin drum. (Fig. 949) Remove the shift fork clip, shit! iork knock pins and pull out the shlfi drum. (Fig. 9-20) _ » e at Gear shih lurk @ Gear strict drum Fgg $20, Removing gear shilt drum ' a. lnspeetipn l. Measure the thickness at line gear shift fork 'lp. Use a vernier caliper, lrtg, 9—21) Serviceable Standard Value M and center 0.2H~u.2HZ Replace under shllt (ark l5rse~5rut 0.203 15.16) G) Gear shirt larlr @ Miarametar Fig. 9721. Meaxuring gear shih rark tip 2, Measure inside al the gear shitt lork. Use a cylinder gauge or inside micrometer. (Fig. 9—23) Serviceable L‘lml) 13394340 Replace 1! over l34.0~34.025l L342 {34375) Standard Value shrlt lork (D Gear shift lurk ® cylrnaer gang. rig. $22. Measuring inside diameter 169 9.2 ENGINE MECHANISM (CB/CL175) a. Measure outside diameter or the gear shitt drum. use a micrometer to make the measurement. (Fig, 9—23) c, Reussembly Reassembly is perlarmed in the reverse order at the disassembly procedure, however, special attention should be given to the lollowing itemsi A a) Gm xhl t drum (2 Mieremeter Figs 9-21 Measuring outside diameter i. When assemblyihg the gear shill iork into the upper crankcase the shilt lork shauld be assembled from the left side in the order at the stamped markings ’R”, "c" and ”L" so that the letters are facing la the lett. (Fig. 944) 2. Make sure that the shift tork guide pin is installed and then properly set the clip. 3. Check the shift fork to assure that it is operating smoothly. Q-G-ar shitt terk ® Clip . 9—24t 4. Atter nssemblying the gear shift spindle move it as shown in Fig, 9*25 and check to make sure that it positively returns to normal position. G) Gear shtlt arm 9715i 5, Make sure that the gear shirt spindle is positively set with the washer and eirclip. (Fig. 9726) (D Circlip ® Washer Flu. 9e26, 9.2 ENGINE MECHANISM (CB/CL175) 170 4i CRANKSHAFT When ussemblylng the crankshaft into the crank Case, give proper attention to the following points, I. Install the dawel pins inta the Upper crankcase and positively gn ihe dowel pin holes in the crankseaft bearings lo the dowel pins. Work will be slmpiiged by aligning the scribe line on the bearing outer to the parting suriace of the crankcase. (Fiqi 9—27 and 9—23) 2. keier to page “~43, section 3.7. 5. TRANSMISSION 5.speed, constant mesh transmission is mounted. Refer to section 3.9 page 50~52 lo! details of the respective gears. A. Disossembly Refer to section 4. 3 Es B. Inspeciion 1. Measuring backlash Hold the mating gear so that it does not move and lightly rack the gear being measuredu Measure the amount ol backlash using a small dial gauge. (Fig 949) standard Value serviceable —_ ——__le__ 0.00l7~0.0052 Replace ll oval fl_w 0.008 n.2, Replace ll over 0.008 (0.2) 4th and 5m gear: 2. Gears when used lor u long periaa will develop wear to tire teen and dogs as well as resulting in side loading oi me gear teeth. This becomes the cause oi gear noise and in severe case, gear disengagement. Gear which are excessive worn should be replaced in sels. 3, Measuring gear.siiait clearance Measure the bore oi the gear with a cyllnder gauge or an internal micrometer, measure the shaft diameter with a micrometer and compute the clearance. (Fig, 9—30] Serviceable Slandara Value Um" M 4 0.0003~0.0024 ia02~o.oe2l Replace ii Over orooos~o.oola 000‘ I‘ll) "‘5' C1 l0fll6~0~045l 0.0016~0.003 Replace iI Ova! C 2' C 3 (0.04~0.062l 0.0047 «1.12) [70le pin (2 Upper crankcase , 947. ® Crankshaft ® Scribe F 9-23. ® Small dial gauge Fig. 9—21 cnecki (D Gear (2) Cylinder gauge (3 Shall @ Micrarneier Fig. 9-30. Measuring diameter 171 9.2 ENGINE MECHANISM (CB/CL775) ® 20 mm sex "rug ® Transmission comrm shall (3 6304 HS radial ball bearing © Bun bearing Se) ringA (5) zuxszx‘} oil seal © Drive sprocket ® Dyiva :procker fixin plain ® 6X10 hex bolr ® Guide pin 63 16mm bearing bush B @ 15mm lhrusl washu @ Counter shah low gear I35 1) ® Coumor shah cop gear (251» ® 20 mm mm washer B @ Cuumr shah four». gear 127 'n ® 20 mm Mum washer @ 20 mm rhrrm washer B @ Cuumev shah mud gee! 129 U Q} Comer shah second gear I321) ® Tranmrusrorr main shah ® Mainshnh top gear IN T) @ Mainshall shilving gem (231 & 20 n @ Mainshah second gear 8 Healing bush A Q 8x25><8 oil xeul Fig. 9731. 9.2 ENGINE MECHANISM (CB/CL175) 172 c. Reassembly Perform the reassembly in the reverse order of disussembly, however. Special attention should be given be to the iollowing items, 1, Do not use the circlips which have been removed, use only new parts. 2. Install all gears, washers, and circlips properly as shown in the Fig, 9-31. 6. KICK STARTER I. When installing the kick starter assembly into the upper crankcase, align the kick starter spindle pin groove to the dowel pin in the crankcase, and positively set the friction spring to the case groove ®. 7. CARBURETOR A piston valve type variable venturi carburetors are mounted one to each cylinder. A. Disassembly 1. Remove the carburetor maunling bolt, locsen the air cleaner connecting tube clump. 2. POSlllOH the fuel cock to OFF, and remove the luel tube. 3. The carburetor can be removed ulter removal of the throttle valve. B. Inspection 1. Idle adjustment The carburetors must be adjusted after the engine has warmed up to operating temperature. Further, both the right and lett carburetors must be adiustecl at the some tlme. (Fi 9—33) a, Adtust the engine idle speed to |.200 rpm with lhe throttle slop screw. h. Manipulule the air screw buck and forth and set it to the point at highest rpm (the air screw should be set to lkilé turn per from lull closed positionl. c. Reudiust the idling speed to the proper setting with the throttle stop screw. 2. Float level adiustment O Throttle stop screw Fl G) Fuel level gauge (2) Float @ Carburetor a. 9734. Remove the neat chamber cover and check the position or the floor with the lvel gauge, as shown in Fig, 9—34, at the point where the float arm inst comes in contact with neat valve, lCarburetor is tilled approximately lo°l. Adiustment is made by bending the neat arm with a small screwdriver. The fuel level gauge is Tool No. 0740l—0010000. (D Cap ntrt (I) "0" mark Fig. 9-37, 0 (Z) Hex m" Fig. 946. Nut tightening seqvencn <2) Knock boll 9.2 ENGINE MECHANISM (CB/C1125) 6) Contact breaker assembly © Spark advancer ® Contact breaker setting screw Fig. 945 (3) 6mm hex bolt it ENGINE MECHANISM [CB/CLI25] CYLINDER HEAD A. Disassembly C 1. Remove the R. side cover from the right side of the cylinder head and breaker point cover from the let: side. 2. Unscrew the two Contact breaker setting screws and remove the contact breaker assembly. (Fig. 9-35) 3. Unscrew the spark advancer mounting bolt and remove the spark advancer tram the camshott. (Fig. 9—35) 4. Unscrew the three cross screws and disassemble the point base. 5. Unscrew the two cam sprocket mounting bolts and remove the sprocket trem the end er the carnelian. a. Disconnect the chein being coretrtl not to drop the ioint clip into the cylinder, and then, with a piece ot wire the bath ends at the chain. 7. Loosen the six cylinder head attaching nuts to remove the head. Inspection Refer to section 3. 2. l C on page 66~67. Reassembly Tighten the cylinder head cover nuts uniformly in the sequence shown Fig, Ho. 2. The mounting of the cam chain can be simplified If the chain is reassembled prior to the installation at the corn sprocket lett and right bolts are of different sizes. therelore, exercise cove that they are not installed in reverse order. (Fig. 9*37) 9.2 ENGINE MECHANISM (CB/CL725) 774 3. Assemble the chain ioint clip so that the open slit is facing in the direction opposite to the chain movement. 9738) 4, Align the "T" timing mark on the AC. generator rotor to the timing index mark on the position, the piston is positioned to the top.deod-center. Position the “0" timing mark on the cam sprocket to the top and mount on the camshatt with the two bolts, (Fig 9—37) 5. When ossemblyihg the point base, make sure that the oil seal is properly installed on the eamsholt. (Fig 949) 6. Make sure that the dowel pln in the camshaft is properly fitted to the spark advoncer setting gvoove. (Figs 9-39) 2. CAMSHAFT At Disassembly l, keter to cylinder head disassemoly procedure on page 173. 2, Remove the tappet hole caps. 3. Loosen the Valve toppet adjusting screw. 4. Remove the yocker erni stopper and pull out the rocker arm shaft. (Fig 9—40) 5. Remove the camshaft from the cylinder head. at Inspection Measure the base circle and cum heights with a micrometer. (Fig. 9—4” Standard Value Cum base circle ‘gfigfltaggt 7 V l.030~l.03l Replace it under 5.1%?” 'N l2 57~26sl97t 1.024 (26.0} , ‘ l.013~t.0|4 nealace it under Ir I hm ‘ ”' Ex l25.72~25.76t 1.008 125.6! cs Reaxsembly Refer to cylinder head reassembly procedure, 6) Joint clip ® Cum ehain Fig. 948. a) on seal (2 P... @ Spatk advaneer graave g. 94% @ Rocker arrn shalt stopper ® Rocker arrrr shatt Fig. 940. ® Carr. xhult ® Mtuonreter Fig. 9—H. Measirr 9 Cum height 175 9.2 ENGINE MECHANISM (CB/CL125) 3. CAM CHAIN TENSION The design has been simplified, making ii perform wiih high degree ol reliabilny and also providing easy odiusimem. © (D Cam chain iensiener push vod ® Tension spring @ Tensions! spring A Q lock nm Fig, 942‘ © Cam vensioner adiusl A. Disassembly 1. Remove the generator [star by using the rover puller lTool No. 07933~200000). (Fig. 9*”) G) Generalor royor ® Rotor puller Fig. 9-43, 9.2 ENGINE MECHANISM (CB/CL125) 176 . 2. Remove the L. crankcase cover by removing the coin chain udiust bait and eight 6mm screws. (Fig. 944) 3. Remove the starting sprocket set plate and then remove the starting chain together with sprockets, (Fig. 945) 4. Remove the corn chain tensioner set plates and remove the cam chain tensioner. (Fig. 947) . x (D Starting sprocket set plate (3 Starting rnotar so @ Starting sprocket Fig. 945. B. Inspection . Carri cnain aaiustment can be made in accordance with lollowing procedure. a. Remove the dynamo cover. b. Rotate the dynamo rotor counterclockwise until the "T" mark on the rotor lines up with the timing index mark on the stator, This adiustment must be made when the pistons are on the top at the compression stroke. This condition can be determined by shifting the tape pets with fingers. It the tappets are free, it is an indication that (D Cm chain ,9,“ he, the pistons are on the tap ot the compression mg. 946. sHOke. ® Tensioner set plate c. Unscrews the cam chain tensioner adjust bolt and rotate the dynamo rotor counterclockwise one tum. d. Screw the corn chain tensioner adjust bolt and then tighten the lock nut. c. Reassembly Check '0 make Sure ”in! tensions! operates smoothly in the direction indicated by the arrow in Fig. 947, I77 9.2 ENGINE MECHANISM (CB/CL125) 4, TRANSMISSION The CB 'ype zs equipped wnh a 5-speed Vransmisxion while model cms is equipped with a 4-speed transmission. Fig. 9-49, Neuncl Fig‘ Mu. Is! 950 (c. shined! Fig‘ 948 a. Hg. 9—48 D. Am gear (sz shined) Fiq‘ 9—45 E‘ 5». gear (Mng shined) 9.2 ENGINE MECHANISM (CB/C1125) 178 A. Disassembly 1. Disassemble the cylinder head in accordance with section 4. LA or page I73. 2. Remove lhe cylindev. 3. Remove the L. crankcase cover generator rotor, starting sprocket and cam chain lensioner. 4. Remove the R. crankcase, ail filler. clutch, ell pump and gear shrll spindle. 5. Remove the 8mm and 6mm balls trom lhe upper crankcase. (Fig. 9—49) (D 8mm hall (2 6mm boll r a. 94v. 6, Remove the 8mm and 6mm balls from the lower crankcase and separale lhe upper crankcase. (Fig. 9—50) 7. Separate the transmission gears. ® 6mm ball ® amrn bolt Fig. Ho. 3. Inspection l. Measuring backlash Hold the mating gear so that it does not move and lightly rock the gear being measured. Mea- sure the amount ol backlash using a small dial gauge. (Fig. 945” Selviceable Standard Value Um.” o.ual7~o.oos2 Repluze it over "" 2” 3’4 96"" mma~ul33l 0.005 (zeal 0.00!6~D.005 Replace it ovev "" “"d 5"” 5“" inmz~ .l26) 0.003 mm 2. Gears when used lar a long period will develop wear to the lee». and dogs as well as resulting in side loading 0' lhe gear leelh. This becomes lhe cause at disengagement. Gear which are (D 5m” die. gm, excessive warn xhould be replaced in sels. Fig. vesl. Maasuring gear backlash 179 9.2 ENGINE MECHANISM (C3/CL125) 3. Measuring gear-shift clearance Measure the bore 0! the gear with o Lylinder gouge or an internal micrometer, measure the shot? diameter with a micrometer and compute the clearance. (Fig. 9—51) Standard Value 5'": 9“" mm M ‘ o.ooua~o.oozt io.oz~o.uezl } Replace it over —"i. oos~o. 013 0.004 io.lt ”‘5' C' io.oia~u.o¢5i n.oma~o.naa Replace it over C1 C3 lo.04~o,oa2t 0.0047 in.12l (1) Gear ® Cylinder gauge ® shalt ® Micrometer Fig, 9-52, Meuxwing diameter (D Knack pin, 6X98 ® 15min bearing bush E @ Counter shalt low gear 9) Counter stian lounh gear (5; 20 mm 59! ring (D 20 mm thrust washer A ® Counter Shaft third gear (3) Counter shalt top gear ® Counter xtialt lop gear @ Ball bearing Sat ring 3 ® .5204 HS aall bemlng ® 20 mm o ring @ Transmisxion counter shaft @ 25anx7 ail seal @ Drive sprocket @ Drive :procket fixing plate 0) 6X10 hex bolt @ Transmission main shaft 63 Main shaft iourih gear ® Main shalt second 5 thlral geor @ Main shun top gear @ 15mm bearing bush A @ axisxe oil seal Fig. 943, 9.2 ENGINE MECHANISM (CB/CUES) 780 . C. Reussembly Pertorm the reassembly 'tn the reverse order of disassembly, however, special altenllon should be given to the following items, l, Do not use the circlipswhrch have been removed. . use only new parts. 2. Install gears, washers, and circlips properly as shown in the following figures. (Fig. 9753) 3. Position all the gears in neulrul and rotate by hand to assure that the dogs are not hitting and that the gears are all rotating smoothly. 4. Alter assemblyl'ng the gear assemblies into the upper crankcase, make sure that the set rings arid dowel pins are properly installed. 5‘ GEAR SHIFTING MECHANISM To prevent the gear shitt arm from disengaging with gear shih drum, a projection is provided an the upper crankcase to limit iumping of gearshift arm. Further to tacill'ate shifting into the neutral gear, the neutral stopper is made ta fit the drum directly. (Fig. 9-54]' A. Disassembly I, Remove the cylinder head and cylinder. . 2, Remove the L. crankcase cover, generator rotar, starting sprocket and earn chain tensianer. 6) Gear shttt arm Neutral stopper bolt Fig. 9—54. 3. Remove the k. crankcase cover, clutch, all pump and gear shift spindle. Separate the lower crankcase from the uppercase. 5. Separate the tranvnission gear lrarn the upper crankcase. 6. Remove the shirt drum stopper, neutral stopper bolt and neutral switch, 7. Remove the shiit fork setting clips and guide pins. 8. Remove the gear shift drum from the crankcase. B. Inspection (D Gear shitt lork ® Micrcmeter 1. Measure the thickness at the gear shirt iark tip. "9» 9‘55- MWW'W 9W SM" “3* ”P Use a vernier caliper. (Fig. 9—55) Serviceuble Limit Right, Iothz cahlor o.2ll~o.2|5 Replace ii under shin Iork 45.35~5.45l 0.1955 (5.0!» Standard Valua 2. Measure inside diameter of the gear shift fork. Use a cylinder gauge or inside micrometer. (Fig. 9756) ® Gear slim lark (2) Cylinder gauge . Fig, 9—56. Meaxuling inside diameter 181 9.2 ENGINE MECHANISM (CB/CLIZS) Standard Valu- 5°’{i°3“b‘° rmrt . l.339~l.340 Replace it over Sh'" '°" l3t0~3L025l LaAz (34.075t c. Reaxsembly Reassembly is pevfovmed in the (averse order of the dlsnssembly procedure, however, special attention should be given to the taliawina items. I. When assemblying the gear shift iork of the CB type (5-speed transmission) inta the upper crank. case the shlft lork should be assembled tram the lelt side in the order of the stamped markings ”",S ”C" and L so that the letters are tacing to the lstt. (Fig. 9—57) 2. Make sure that the shift fork guide pin is installed and then properly set the clip. 3. Check the shitt talk to assure that it is operating smoothly. a) Guide pit. clip rial 9-51 4‘ Aher assembly the gear sh'tft spindle move it as shown in Figs 9~55 and check to make sure that it positively returns to normal position, 5. Make sure that the gear shiit spindl set with the washer and ci lip. (F (D Wash” ® Circlip Figs 9—51 9.2 ENGINE MECHANISM (CB/CL125) 182 6. KICK STARTER when the kick starter is operated, the kick starter pinion moves toward the right and engages with the counter shat) low gear to transmit the force to the piston through the main shaft. This causes the engine to start. the pinion to the normal position. (Fig. 9+0) As the starter pedal is released, the force at the kick stuter spring rotates the spindle and returns (D Law gear (2 Kick starter spindle ® Circlip (9 Friction spring (3 Kick starter pinion @ Kick starter spring Fig. Hm. A, Disassembly Refel ta page 79. B. lspection Check to make sure that the action or the kick starter spindle is smooth. c. Reassembly Reassembly is performed in the reverse order of disassembly procedure, however, special attention should be given to the following items. l. When installing the kick starter assembly into the upper crankcase, align the kick starter spindle pin groove lo the dowel pin in the crankcase, and positively set the triction spring to the case groove. 2‘ Assemble the kick starter spindle and check to assure that it is operating properly. (I) Dowel Pin (2) Groove Fin. 9—“. 183 9.2 ENGINE MECHANISM (CB/CL125) 7. CARBURETOR A. Disassembly Refer to page 56~61. B, lnxpection 1, Idle adjustment The carburetors must be ad|usted other the engine has warmed up to Operating temperature. Further, both the right and |eft carburetors must be cdiusted at the same time. (Fig. 9762) a. Adiust the engine idle speed to 1200 rpm with (i) Throttle stop screw ® the throttle stop screw. r . 9—62 , , b‘ Manipulate the air screw buck and forth and set it to the po'lnt ol highest rpm tthe air screw should be set to 1%t}§ turn open tram full closed posltionl. c. Reudiust the idling speed to the proper setting with the throttle stop screw. 2. Float level odiustment Remove the float chamber covet and check the position at the float with the tuel level gauge, as shown in Fig. 9-63, at the point where the float arm iust comes in contact with the float valve. ‘ (Carburetor is tilted approximately 10°]. Adiusl- ® Fuel level W99 ® ”on, Q) are»? ment is made by bending the neat arm with a small fig, 943. Screwdriverl The Net level gauge is Tool No. 0740143010000. 9.3 FRAME 184 9.3 FRAME l. FRONT SUSPENSION Refer la page 90~95 Of this Manual tor the inlormation on the front suspension at all other models. CL175: The front cushion compression stroke 4.53 in (llSmnl) while the extension strokeis L3flin (35 mm) for a total travel 0! 53' in (150mm)r 35mmilr38ill) 56mm(6. lsin lzs45 B 7 89 @4363 (D Front lork hair (2 24 mm washer is o ring G) From lork top bridge (5) from cushion spvlng 6) mm lork honour bridge ® From lurk pipe 6) From lork dusr seal ® Al mm internal circlip 33 From lork oil seal @ From lerk pip: guide @ Fronr pislon slopper ring 6; fork valve sloppar ring 03 Flam damper valve is rork piston slopper rlrlg ® rrom lork piston @ Fork piston snap ring ([0 from lork bottom case Fly. 9%. A. Disassembly l, Disconnecr the lronl brake cable and the speedr ometer cable from the hon! brake panel. 2, Remove the from wheel torque boltr 3. Place a block under the engine, remove the trout axle and separate the wheel tram the Fork. 4. Loosen the headlight mounting bracket bolls. 5. Loosen the lronl lork top bolt and the 5mm fork boll which mounts llre From lork and pull lhe front ierk out the bottom. (Fig. 97.55) 6. Remove the front fork dust seal and remove the inrernol circlip using the circlip pliers. (Figl 9—66) m From lor rep boll ® Headlight brackel selling be" r (3) 8mm bollors 9-65, 7. Draw lire from fork plpe assembly out oi the / V , e bottDm case, B. inspection 1. Check lront fork damper otl ldisussembly is not necessaryl. It the all is ditty or the level low, change or replenish lire oil. G) Circllp ® Pli: s Fig. 7—66: Find Hz a) From fork drain plug ®'From larlr lap ball 9.3 FRAM Cr (D rmnl iark pismn ® Micrameler rig. 9—68, Measuring diamelar cl (ark pislan I” a) rral lork ® From axle Fig. 949. G) Frarii lork ail seal d virlg weigh. (2 From fork ell seal driving guide rig. 94o. E Remave lne lrarii lork lop bolt and drain plug an die damper and allow all ia drain lollowed by stroking lire damper several limes lo gei complele remaval (Flg. 9+7) Replace lire drain plug and fill with l5s~lesca l9,5~io.i cu-in} oi gaad grade SAE ssioweao or equivaleml. 2. From fork pislan Measure Ihe diameter of me piston with a microm- eler la check lire amaunl oi wear. [Figr 9—68) Sewlceobla limll 1.39A5~1.3955 Replace if under 1.3937 [3.1“ Slandard Value Plslon diameler Reussembly Perlarrn iiie reassembly in the reverse order al lhe disossembly, however, aariicular ailenlion should be given lo lhe following poinls. l, Firsl insert lire axle lhrough lhe fork axle holes lo make Sure lhal lhe Iell and righl larks are level belore Iighl‘enlng llle 8 mm iron! fork mounle lng ball. (rig, 9+9) 2‘ When lnslalling lire from lork oil seal, apply a liberal amount of 'he grease between "is main seal lip and lire dasl seal lip lpeiraleum resisling grease) and exercise care rial la damage lire lips. Use lire dvsl seal driving weighl lo drive ia lhe seal. (Fig. 9-70) 3‘ ii is recommended Ihnl lhe fork pislan slapper rlng and the circlip be replaced wilh a new ilern. The old parl may have losl lls lensian or may have become dlslorled during lire removal. REAR SUSPENSION The rear suspension alilizes a De Carbon lype shock absorber, Compressed nitrogen gas and all is sealed wiihim lire cylinder and during camraclian and exierisian lire oil news back and iorlh rilrpugii lire arince incorparaled in lhe plslon; «lie lanciian ai llie valve which canlrols lhe now perlarm lire dampening. Damping iarce Model Exlension Conlrotlion SHOke 2,54 ln C3175 5D kg/DAE iii/sec l5kg/Us5 m/sec (67 mm} CB (1125 3.35 ' 03/75 as kg/0.5 iii/see l2 kg/0.5 m/sec [as m'n'; 9.3 FRAME 186 MAXJHEMNZIZ 5mm 57 man 1735 Zunsil IEBS 1mm l635 KHHDGEH an: 3 4 5 7 8 l 2 6 (1) Spring seal snapper ® Rear cushion spring (5) Rear damper assembly 6) Real cusian upper case @ Rear cushon spring guide © Rear cushion bonom case ® Spring adjusier (3) Under scai compleie Fig. 977:. CB/CUZS r————————iwx 30?,MIN NZ STROKE 6 IST SEY l73r5 NiTRUGEN GAS 2ND SET i515 3RD SET i515 6 | 4 ® Rubber iainr (2 Spring sear snapper (3) Rear cushion upper case (2) Rear damper assembly (57 Rear cushion xpring @ Rear cushion spring guide rip, 9472. c5175 -7MAX.331, MiNZOS STROKE 55!.— IST SET 200 ND SET ISS 3RD SET ISO NITROGEN GAS KM ' . “,lli _ ii i WWW-7W M ®® © m Spring sear sioppar ® Spring upper seai (3 Rear cushion Spring (5) Rear damper asssmbly 6) Rear cushion spling guide Fig. 7—73. CLl75 187 G) iiear eushien (2) Rear cushion disassembling & assembling tool Fig. 9—74. (D Rear cushion spring ® Vernier caliper Fig. V775. (D From blake lever ® Free play Fig. 9-71» 9.3 FRAME A. Disassembly I. Separate the rear cushion assembly from the frame, 2. Remove ihe rear cushion spring by using ihe rear cushion removol iaol. (Fig, 9—74) (Nola) The rear damper conlalns nitrogen gas under pressure, rherelore, ir should no! he diluuembly due lo the extreme hcxurd, B. lnspeciion 1. Rear cushion spring (Fly. 9—75) Measure rhe iree lengrh ol rhe rear cushion spring using a vernier caliper; replace ii is beyond the serviceable lirnii shown below. The spring compressive iorce is also shown as relererice. Spring free iengrh Model Siandald Serviceable Compressive iorce Value lei' CBI25 7.257 “5:31", " 6.8307ifi/31lbs cms ll84.31 M93 U70, ll73e5 him/“.5 kg) Replace ii 525;"; i333": wait ‘ use H74) ‘ "‘"‘ 9 Replace ii 5.3:“ 7.374 in/sz lbsl cms under mm 7.231 ”251 200mm/H.5kgl c. Reassernbly Renssembly is periarnied ihe reverse order of disassemblv. lnsiall ihe spring so ihai rhe end wiih the smaller coil pitch is Toward the lap. 3. FRONT WHEEL The Front broke uiilizes ihe rwo leading iype brake shoes lo provide superior braking performance. Refer lo section 4.12, page lll al ihis Manual ior ihe descriplion of ihe companeni pails. A. Disassembly Refer lo secrion 4. lzs, page ol ihis Manual ler rhe disussembly procedure. 3. Inspeclion i. From broke pedal adjustment ldlsnssembly is nor necessuyl. a. Place a black under lhe engine '0 raise me ironr wheel ofl ihe ground. b. Spin ihe wheel by hand slowly apply rhe brake lever uniil ihe brake stuns lo lake hold, measure the amoum of lever travel or the lip. The slandard lever iravel Maya/Ash (l~2ern). (Fig, 9—76) 9.3 FRAME 188 e. Perlerrrr the eaiusrmem by me loosening ihe lock rim ac lire horn brake arm and lamina the adiusler nul. For minor adiuslmem, lhe cable ecliusler on rlie front brake lever may be used. (Fig 9777) 2. Brake drum wear The wear oi rile brake drum is checked by rile measuring me inside eiemeier oi the brake drum will. a Vernier caliper (Fig, 9—73) sraraard Value Servicenble Limir ~ ~ Replace ii over 6.30 5.31 H60 150.31 6.381162i (2) Cable adluxier (D lock nm a. From brake shoe wear Fig. 9‘77. Measure the ibickness of "is broke shoe with a Vernier caliper and if ii is worn beyond me speci- fied selvlceable limit shown below, "19 Shoes should be replaced. Slandard Value Servreeable Limil ~ ~ Replace ii under men 0209 ISO 5.3} 0.08 [M] 4. For other inspecling ilerris, refer lo secliori 4.12C, page ll2, cl Reassembly Perlorm 'he reassembly in lhe reverse order of disassembly. Perform the brake udiusimem in ac. cordance wilir seclion B inspection above. ’45“: (D Vernier caliper Fig. 9779. 4r REAR WHEEL Rear wheel componenls. Reier in Fig. 4-6072 page lls. A. Disassembly 1. Remove ihe arive chain. 2. Remove the brake adjusier nu! from lhe rear brake lever and lhe torque mm boll from me brake panel 3. Loosen lire rear axle ml and remove the rear axle, The rear wheel will drop away fvom 'he rear fork. 4. Remove the driven sprockel by uniaslening me 8mm special longued washer and circlip. (Fig. 9—79) a; Circlip ® 8mm Special ronguea washer fig. 7-792 189 9.3 FRAME 5a The brake shoes are removed train the brake panel by spreading them apart by hand. B. Inspection ,1, Adiust the stroke at the rear brake pedal. (Dis. assembly is not necessatyl, aa LOWer the main stand or place the block under the engine to raise the rear wheel oh the ground. b. Spin the wheel and apply the rear brake pedal until the brake start to take hold; measure ' the amount or the brake pedal travel. The (1? “W brake WM ® “5° PkW normal pedal travel when measured at the F'“‘ ‘7'” torward tip should be 3/4~1°1/4in(2~3cm)s (Fig 9-30) c. Perform the adiustment with the rear brake udiuster nut. (Fig. 9—31) 2. Rear broke drum wear Check the wear or the brake drum by measuring the inside diameter of the drum with a Vernier caiipers it the wear is beyond the serviceable limit shown belcw, the brake drum should be replaced, Mode! Standard Vain: Serviceabie llmlt . ‘CBlié 5.l|0~5.|26 Lepiuee I! over G) Rear brake ud‘uster nut CUZS ”29.8~i3 i2) 520 (132) Fig. 9731. CB|75 5.5]2~5s5l4 Repiaca If ever CL|75 [140~140.3) 5‘60 [142) 3. Rear brake shoe weot Measure the thickness of the brake shoe with u yernier caliper and it it is warn the beyond the serviceable limit shown below, the shoe should be replaced. Standard Value Sewiceable innit f Replace it under oily 0.1.59 itso 4.3) ”5'10! 4. For the inspection at the other items, reter to section 4.13C, page not 9.4 ELECTRICAL 190 9.4 ELECTRICAL l. CHARGING CURRENT MEASUREMENT Connect amurrlmeter between the battery (+1 terminal and the seteriiurrl rectifier, and check to see it the values obtained are in accordance with the standard specifications listed in the chan‘ below. When the battery charge is low, the cause may be in the A. C. generator, selenium rectifier or the detective wiring. Charging Charging Charging Model Item Charging start current current current /3,000 rpm /5,000 rpm /io,ooa rpm Day time Max. 2,400 rpm Min. 0.5 A Max. 3.0A CB 175 Night time Max. 1800er — Min. 0.5A Max. 3.0A Battery voltage 113 V IS V 16,5 V Day time Max. 2,400 rpm Min, 0.5A Max. 3.0 A CL 175 Night time Max. 2,500 rpm —— Min. 0.5A Max. 3.0A Battery voltage l3.2 v 14 v 16.5 v Day time Max. i300 rpm Min, 2.0A Min. 2.7A Max, 4,5A CB ‘25 Night time Max. 1,900 rpm Min. LZA Min. 2.0A Max. 4.0A Battery voltage 6,3 v 6.7 v 7 v 8.3 v Day time Max. 1,300 rpm Min. I.7A Max. 3.0A CL 125 Night time Max. 2,000 rpm A Min. 1.7A Max. 3,5A Battery voltage 6.3 v 7 V 8.3 V 2. STARTING MOYOR (CBI75/125) Starting motor is mounted at the front of the crankcase. The power to drive the crankshaft is reduced in speed by a planetary gear incorporated within the starting motor and further reduced at the sprocket and chain connecting the motor to the crankshatt. Starting matar specification and characteristics (Fig. 942]. 2. it the solenoid switch has been used for a long period, the contacts will become pitted or burned, creat. ing a high resistance which will prevent now of current to properly operate the starting motor. when such condition develops, dresx the contact points with a me or sandpaper. 791 9.4 ELECTRICAL RPM kg—m KW V % > O LFRUNT TURN SIGNAL LIGHT § WIN LREAR TURN SIGNAL LIGRT @§_ FRUNT 5m: SWITCH WW” 2 STOP swnon HORN BUTTON TURN SIGNAL SWITCH Bkr g: STARTER MAGNETIC SWITcH Br- .2. LG- ‘LIEM Green/Red NITION SWITCH men/Whne . ARRANGEMENT_ th’IIe/VeHuw NEUTRAL SW‘TCH BATI IG TLIYL: Y H » ? SPARK PLUG A c QENERATOR LET/WEN LTARTING MOTOR fl, 1 hlte/YeHow Ube m-- ~:.~m 2 0--0 o—-o ed M STARTING MOTOR CABLE L C 9.5 WIRING DIAGRAM 32 E 32 Egg: I96 5:59 o... 3.: was; 5:5 .35! N . L3 é a e :a . , muémofizau Emzmaifia I I 5:5 29:29 I 3; o I I I I 5:3 .2ch E2 Em; A , E 28:5 2.3: «SE :53 W I : g .>N— 5:5 no: karma 7 V $9.. #55 2:3 533 a; o e o a a I , .. Emmi v.4 , , g : S .VIIIIIuJ w E, @ufl flfl ha: 52% 2!: Eu: 4 a Tm w 1 IIIIIIIII L {Enga— I I I IIu 33:35 Ea: .35 a .3» ALU J 22155: , Bl!“ LHUI : E IIIIII {Lu—$3 I :23 Si 24mm :9: 22.5 III III, am 5,5 :5: 335 2:3 Em: m :5: 42% 2:2 58:... 0:0 I6 4 / IW® 030 09.0.20 1 L SOERV m m Oomwnm . a I k 2 96 019.0 x :35 :23 SE 3% 25:. to 4 e 1 23a, :23 55:23 a 5 A a x g o a 22,93 :32 :23 543 .2532 Eufiazéfi azskim v o 4 5:5 5:25 5:5 5:225 3:5: azigdzotzm 5E5 5.4mm 5‘2; it; taste .2059 £5.05: 022:5 mhfiu CH 75 WIRING DIAGRAM (U.S.A. Typo) STARTER BUTTON/LIGHTING DIMM ER SWITCH " n v WINKER RELAY ‘3. NEUTRAL PILoT LAMP Izv- W ‘L I TURN SIGN‘fL #507“ LAWEVW -3w N IGNITI sw T H SPEEDUMETER LAMP ‘ . ‘ .I ARRgINGEMEIgT REF-AR TURN SIGNAL LIEHT 12va l ‘ [I] m K, 1‘ TL, WHEN I RFRDNT ! I u °FF TURN SIGNAL LIGHT , I I I o~-o o—-o Izv-25w I I 7 2 r HIGH REAM PILOT LAMP 'IZV-3W ;. ~o in 5.: _ I 33H K! g I __II I s HEADLIGHT I2v-35/25w TAIL L STOP LIGHT L 12V-23/7W Z O ____J » — 2 > LFRDNT TURN SIGNAL LIGHT L Q Izv-zaw ‘ I L REAR TURN SIGNAL LIGHT ”)3 @§_ FRGNT STOP SWITGH I I w g I :- I I : I GUNDENSER ToP SWITCH [OZ i? “LI RN BUT TON“ .Ll m Gram/Red TURN SIGNAL SWITCH LIGHTING DIMMER SWITCH 3 GGNTAGT BREAKER ‘ SWITCHING ARRANGEMENT Brawn/Wmte «WhIIe/Vellow In N TL L M SE Green/Yellow orr fled/WING H o--o--o 0-9 ~wnIIe/YeIIow Iubs NEUTRAL SWITCH N 000.0 (,0 -Red lube SPARK pLuc AG GENERATOR L 0-K: o--o C3125 WIRING DIAGRAM mm mm sum smvcutm «(mm In” spundmcunuum )(mm mm umm mm A mm slam mmwm my! my Ev??? mm m? cm communion swan * sum»: mum! n mm mm mm um mm mm mm 5mm um mm A um I 25w "E m 5 w m A smv um MEI/17w v mom rum SIGMI mm mm! 5"” “W" 1, um um IAHmV SIEIIAL LIENI WWII GVIZAN mmlmcmL mm mmlcswucn 1w 3mm comm LIIIUM nimu Sum mm mm (m 3mm M swimn 7 Ac mum: ' Mum snawwn s-nmn. Amman um Green mmmn mm m u k | n, s: 3‘ swncumnmmnmznl mum mm > u m m n on 2 slmmn mm mm W yum/m WVHSVICI ONIHIM 9 '6 86L 199 9.5 WIRING DIAGRAM CL'I 25 WIRING DIAGRAM ummu mum 5mm mm H o \ , \ \ Elo-n—I :Io—w mom um 5mm um mow ”II I 3w mum: ”W l. nun mm 3mm um! svmw fl vuv sum»: 63 m E s x u I I n mm mm mm um svm : [— n we 7 I u' ‘4 m‘cw—n-J I “ ‘ I A c ammo: momma can :1 sum nus comm [mm m [5/ Bl/W E u r17"— if ‘ ‘ I I 14* = I Mn slum um swncn (mi Icnmuu svmcn @: "mow ans/2M H. mm MN mm mm avm