e :H:ONDA

CB250·360·CL360·CJ250T •CJ360T
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• This SERVICE MANUAL has been prepared as a "SERV·
IC!l GUIDANCE" for the mechanic responsible for the
I. GENERAL SERVICE PRECAUTIONS ..... ... .
II. CONSTRUCTION
I. Cam shaft and valve mechanism . . . . . . . . . . . . 2

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upkeep of the HONDA CB2SO, CB360. CL360 and
CJ2SOT/CJ360T .
It Is compiled into seven ,.ctions and summarW:s the
prO«dures for disassembling. mspecting, and reassembling
the components of the mach1ne.
2. Cam chain tensioner mechanism . . . • . . . . . . . 3
3. Lubricating system . . . . . . . . . . . . . . . • . . . . . 4
4 . Power transmittlng system. . . . . . . . . . . . . . . . S
5. Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Frame .............................. II
7. Elect ri~ system . . . . . . . . . . . . . . . . . . . . . . 16

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Ill. INSPECTION AND ADJUSTMENT
Strict adherence to the instructions given herein will result I. Tappets . . .. . .. .. . . . .. .. .. . .. . .. . . . .. . 17
in better, $lifer service work. 2. Breaker poilll gap and ignition timing . . . . . . . 18
3. Carburetor .............. ... ........... 20
4. Throttle cable ........... ... ............2 1
S. Clutch .................•.•........... 22
HONDA MOTOR CO., L TO. 6. Cam chain ..........•.•............•.. 23
7. Engine oil ............................ 23
Service Publications Off.ee 8. Oil filter screen and rotor ........... ..... 24
9. Front brake . . . . . . . . . . . . . . . . . . . . . . . . 2S
10. Rear brak• . . . . . . .. .. .. .. . .. . .. .. . .. .. 28
II. Drive chain . .. .. . . .. .. .. .. .. .. .. . .. .. 28
12. Front fork ................ ·.......•.... 29
13. Rear shock absorber .................... 29
14. Air cleaner ........................... , 30
IS. Compression pressure . . . . . . . . . . • . . . . . . . . 30

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IV. ENGINE
ALL INFORMATION, ILLUSTRATIONS, DIREC· 1. On·frarnc servicing .......... ........... . 31
TIONS AND SPECIFICATIONS INCLUDED IN 111IS 2. Engine removal and installation ............ 31
PUBLICATION ARE BASED ON niE LATEST 3. Cylinder head, camshaft, cylinder and pistons . 37
4. A.C. generator and starting motor .......... 4S
PRODUCT INFORMATION AVAILABLE AT niB 5. Right crankc.ue cover and clutch ........... 47
TIME OF APPROVAL FOR PRJNTING. HONDA 6. Oil pump and oil filtor rotor .............. SO
MOTOR CO., LTD. RESERVES niE RJGHT TO 7. Kick starter and lower crankcase ........... 53
MAKE CHANGES AT ANY TIME WlniOUT NOTICE 8. Gearshift mechanism .................... 51
AND WITHOUT INCURRJNG ANY OBLIGATION 9. Crankshaft and upper cTankcase ........... 61
I 0. Carburetor ............. ........ ....... 63
WHATEVER.
V. FRAME
NO PART OF THIS PUBLICATION MAY BE REPRO· I. Front wheel and front brake .............. 68
2. Front disc brake ....................... 73
DUCED WITHOUT WRJTTEN PERMISSION . 3. Rear wheel and rear brake ................ 78
4. Steering handlebar ..................... 81

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S. Front suspension . . . . . . . . . . . . . . . . . . . 85
6. Steering srem . . . .. .. .. • .. . .. . . . .. ..... S7
7. Rear shock absorb<rs and rear fork ......... 90
8. Frame body and other r<lated parts .....•... 93
VI. ELECTRICAL SYSTE.M
I. Charging system ........................ 97
2. Ignition system ....................... 100

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3. Starting system ...... ............ ...... 103
4. Other electrical parts .................... lOS
VTI. SERVICE DATA
I. Special tools ............. . ............ 108
Z. Maintenance schedule . . . . . . . . . . . . . . ... II 0
3. Tightening torque standard ............... Ill

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4. Maintenance standard . . . . . . . . . . . . ..•.. 112
S. Trouble shnoung . . . . . . . . . . . . . . . . . . . . 114
6. Specoticaunns . .. . .. .. . .. .. . .. ..... 118
7. Wirinp, di3,11ram ........................ 120
VIII. CB360T, CL360KI SUPPLEMENT .... ....... 1 ~7
IX. CB360T, CL360KI SUPPLEMENT ......... ... 13 I
(LATE MODEL)
X. CJZSOT/CJ360T SUPPLEMENT ....... ....•.. I.17
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 -----1. GENERAL SERVICE PRECAUTIONS - - - - -
• I. Always replace gaskets, 0-ranp, Coller pins, etc with new ones when reassembling .
2. When tightening bolts, nuts or screws, begin on larger-diameter or inner one first and tighten them to specified torque ln a
criss--cross pattern.
3. Use genuine Honda or Honda-recommended parts and lubricants when servicing.
4. Se sure to use a special tool or tools where so specified.
S. A joint work of more than two persons must be carried out with mutual safety attention paid.

• 6. Wash clean engine pans upon disassembly. Coat their .tiding surfaces with high-quality lubricant when reassembling .
7. Coat or pack grease where so specified.
8. After reassembUng, check to be sure each part is tightened properly. Also check for proper operation.
9. ~sure to retain fuel and oil pipes with clips.

Electrical System

• I. When tracing electrical system problems, refer to the wiring diagram at the end of this manual.
2. Check cables and wires for disconnection, open circuit, binding o r breakage of coverings, and grommets and covers for
removal or breakage. Repair or replace them if necessary.
3. Check if fuse failures are due to blow-out or to mechanical open circuit. If a fuse Is blown,locate the cause before installing
a new fuse. Always use a specifically rated fuse.
4. Route the battery breather tube as shown on the label.

NOTE :
It is advisable to cbeclc tile electrical plllU at a tempen~ture of about 20.C/68•F (room temperature) .

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2
----------------II. CONSTRUC~T~I~O~N~============~~
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I. CA\ISHAFT AND VALVE MECHANISM

Cylinder head
The cylinder head is so designed that the rocker arm shaft< and
rocker arms arc Incorporated into the cyllnder head cover.
It can be removed or installed with the engine mounted on the

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frame to enable the cylinder and pistons to be replaced easily.

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Pia. 2-l

Vah·e cuides
Each valve guide is securely supported by the spring seats u
shown It nght. It is also provided With the stem seals to prevent
oil from Inking uno the combustion chamber.
When dlsas~mbling the '"Jive guide , take care not to compress
the valve compressor (Tool No. 07957 3290000) more than
necessary; otheiWise the stem seals may be damaged.

Cylinder
~ ... 2 2 (I) Volve ~ide
m Spn1111 ....
(3) Stem,.••
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The cylinder Is an aluminum die casting which is light·welght
and has great cooling efficiency. Two special cast iron sleeves
are pressed into the cylinder.
Eight stud bolt holes are provided in the cylinder and the two
holes at the rear outside act as oil paiSages to the cylinder head.
In the two holes O·rings are inserted to prevent oil leakage.

l'ij. 2-3 Ill Cylinder

(2) Cylinder uml bolt MU~ket
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 II. CONSTRUCTION 3
Pistons

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The p1stons are made of aluminum alloy. They are three-st-se
tapered as shown to provtde for unequal expansion that occurs
at operating temperature .

• Fil- 2-4 Seclional view or p111011

(I) Piston head

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(2) Piston skirt

Piston plns
Each piston pin is full floating In both the connecting rod and
piston with snap rings in both piston bosses. It is I mm offset
(0.039 in.) to the intake side with respect to the center of the
piston. The reason for this l$ that since the pressure on the
p1ston on the explosion stroke rises to the maximum aner the
top dead center position, the side thrust on the piston is moved
before the top dead center posit•on to avoid rapid movement of Crankshaft
the side thrust on the explosion stroke, preventing the piston angle
from slapping the cylinder sleeve. The head of each piston is
marked to make it easier to instnll it correctly.

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Fig. 2-5 Pi <ton pln offoct

2. CAM CHAIN TENSIONER MECHANISM

The cam chain tensioner is made of spring steel on whiCh
heat-resistant rubber is lined by paking and then heatreslstant
teflon having less frictional resutance is coated, minimizing
chain noise and improving dur•bUlty.
2. The chain tension can he easily adjusted by looS<:ning the
adjusting bolt and then retightening it.

• Cam chain slipper

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I . The cam chain slipper installed to the cylinder block prevenls
chain vibrations often developed due to temporalily
disturbed engine speed during deceleration.
2. The cam chain slipper Is so constructed that the synthetic
rubber is attached to the steel plate and it has great
durability .

• Fig. 2 - 6 ( l) Cam cham \IIpper

(2) C""' ehuiJI 1en$.ioner
(.\) Adju\Un_g holt
C4) TerhtUIIt'l JHI'h bar
(S) Tcnsiontr a.rm
4 II. CONSTRUCTION

3. W BRICATING SYSTEM

The models CB250, CB360 and CL360 are continuously

pressure·lubncalcd with a trochoid oil pump.
Lubrlcaclng oil is fed 10 lhe engine parts through the
cenuifugal oil ftlter coupled direclly to the crankshaft and
the oil filter screen located at the sucUon port of the oil
pump. •
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(I) OU filler to tor (2) Troc:hoid od J'ump (3) Oil filter t>Crten
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 II. CONSTRUCTION

Trochoid oil pump

The trochoid oil pump is dri~n by the crankshaft through the

• pump idle gear and drive gear .

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• Ffl. 2-8 (I) Oil pump body

(l) Ouu~r ro1or
()J Inner rotor

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(4'): Drive aeat
Centrifugal oil filler
As the oil from the pump enters the filter rotor through the
guide metal and is picked up by the spinning vanes of the niter
cap, foreign materials such as metallic dust and carbon particles
4re stparatcd from the oil by centrifugal force and are attached
to the Inner waU of the rotor. The oil cleaned in this manner is
fed to the engine parts through the outlet port in the ~nter
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se<:toon of the fUter cap.

Fig. 2- 9 Oil flow In oil filter

• 4. POWER TRANSMITTING SYSTEM

Clutch
The clutch is prmided to transnut engine power to the
tran&mission mainshaft or disconnect it from the shaft through
frict•on between the clutch friction di!Jes (3) and clutch plates
(4).
When the clutch is engaged, the friction discs and plates ore
"$1!ndwichcd" between the clutch pressure plate (7) and clutch
center (S) by means of the clutch >pring (6), thereby causi.lg the
clutch outer (2) and clutch center to be pressed together. IJnder
Chi~ condition. engine power is tran~itted from the crankshaft
<13) (11)

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fncllon discs. plates and clutch center.
As the clutch lever is <qute7e<l, the clutch liOer earn (II)
connected to the clutch cable is rotated and then is pushed out
by rneans of the ~ 10 steel ball (12) located between the hfter
c:un and clutch adjusting cam. Then ll•e force is transmitted to

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the steel ball (IO),Iifter rod, lifter joint piece and pressure plate
to cause the clutch spring,<; to be compressed. Now the friction
di'<Cs are separated from the plotes, resulting in disengagement.

• Fig. 2-10
6 II. CONSTRUC'TION

Tnrumi.osion
The transmission is of a constant~esh type and provides a The enawe power' transmiued from !he crankshaft to !he
selection of six speeds, fulffiling !he characteristics inherent
to a four-stroke engine ranging from low speed to high speed.
Especially the transmission plays Its most Important role in
riding at the overtop (sixth} speed. Return shifting type is
used .
mainshaft through the clutch, is changed in speed and torque
by gearing. h is !hen transmined from the drive sproelcet to
the rear wheel through the drive chain.
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Gear Ratios
i1 Primary
3 714 ( 7o/z l )

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a ear
~econdary
c ha1n z. 125 (34; ls)

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_}'r-
Gea r Rat1os
1St

2nd
2. 500 ( 4-o/1'6)

1. 750 (3Y2o )
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IIIII
3rd

4th

5th
I. 375 (3y24)
1.11 1(3o/27l
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o. 965 ( 28/zg)
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l n._; 6th 0. 86 . (2o/30l
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 II. C'ONSTR UCTION 7
Ceanltift mechanism

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The seanhlft mechanism is a linka&e between the gear change
pedal and the shift forks and includes a shift arm, a shift drum,
a neutral stop, a drum stop, etc.
When the pedal is depressed for shifting, the shift spindle
rotates, causing the arm to pu•h the drum pins to rotate the
drum. As the drum is so rotated, the fork is moved by the cam
action of a groove cut in the drum to shift a gear. After sltiftlng,

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the am1 is returned to its original position by means of the
return spring. The drum stop b pro,ided to prevent uninten·
llonal gear engagement, shifting the gears smoothly. The drum is
pressed by theiiO steel ball to make it possible to shift Into the
neutral position properly .

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Fig. lo-12 (l) Gearshift drum (4) Drum stop Cllm plate
(2)Neutral stop (5) Gcvshift spindle arm
(3). I 0 11eet ball (6) Shifr drum stop

Crankshaft
The crankshaft seo·es to change the reciprocating motion of the
piston mto rotary motion In connection with the connecting
rod. It also stf\eS 8$ a nywheel limiting the tOrque nuctuatiOn.
The crankshaft is supported at four places by antifriction
bearings-two needle roller bearings on the inside and two ball
bearings on the outside, Increasing the load capacity and
improving the strength and durability at high speeds .

• The crankshaft bearing• arc lubrkoted by oil from the oU pump.

The oil enters from the upper crankcase. pa<ses through the oil
FiJ. 2- t3 C'rankohoft

• holes in the center hearing outer rings and lub ricates the
benrings. Then the oil collects Into the notches in the side< of
the crank weights and enter< the crankpins to lubricate the big
ends of the connecting rod< .

• fig. 2 - 14 L.ubfication to cr;tnkshafc

8 II. CONSTRUC'TIO'I

5. CARBURETORS
Two sets of carburetors, one for each cyhnder, are equipped.
They are of a single·barrel, CV (Constant Vacuum cype, the
venturi area Is automattcally changed by the negative pressure
created by air to be drawn into the cylinder) type. Following
are the remarkable features:
(I) Because ora variabJe.venture type, smooth power transition
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between low·speed and high·speed operations is provided.
(2) The construction is simple.
(3) Acceletltion is good and fuel consumption is less.

Pla.l-15 (I)Primaryairjec
(2) Vacuum piston sprln&
{3) Vacuum piAton
(4) Scconda.ry air jet
(5) Throttle vah·e
( 6 ) Main nozzle
( 7 ) Primary main jet
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( 8) Secondary main je1 (13)
( 9) llecdlejel hold<r I ZJ
(10) Needle jet (11)
(II )lei needle (S) (ID)
( 12) Aoat valve
(l)) Valve $Cat
( L4) (."hoke valve

I. Star ling circui I

When the eosine is started while 11 Is cold, a richer fuel·air
mixture IS required.
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When the choke lever is raised, the choke valve is closed to
cause the amount of incoming air to be reduced, resulting in ~ -r~
an lncrea<ed negative pressure within the main bore. Now
fuel Is fed to the bore from the low.spccd and main circuits.

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The choke valve is controlled by the rcllcf valve depending
on va<uum created by air to be drawn into the main bore.
2. Low-speed circuit
The low·speed circuit is provided to supply the proper
amount of mixture to the engine at idle and low speed<.

Fuel P"'''" through the primary main jet and slow jet and "
mixed with the air bled by rhe ~lnw ""jet here. Then the
moxturc is squirted from the bypass and pilot outlet. The
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mixture to be squirted from the pilot outlet is regulated by
the polot screw.

(4)

tJ•s· 2- 16 (I) Pilul ou tie(

('2) H>'Pil""
(3) Slow air jet
tSl Sto" jcl
(6) l'runu.t)' mai1l jet
(1) ~bin noalc
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(4) Pdot sCtl:'w
 H. CONSTRUCTION 9
3. Main circuits

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Primary circuit
The primary main circuit is provided chiefly for the low
speed engine operation. fuel flows into the main nozz.le
through the primary main jet and is mixed with the air bled
by tltc primary air jet in the main nozzle. Then the mixture
Is squirted from the lip of the main nozzle.

• Secondary circuit
The secondary main circutt is provided chiefly for the
normal and high speed engine operations.
Fuel flows into the needle jet through the secondary matn
jet and is mixed with the au bled by the secondary air jet in
the needle jet. Then the mixture passes between the jet

• needle and needle jet and is spwted from the tip of the
needle jet.

Operation of vacuum piston

The vacuwn piston Is operated by the vacuum within the
venturi. When the negative pressure is low, the piston is
Fig. 1 - 17 (I) Primary air jet ( 6} Primary main jet
pushed down by the spring pressure. As the vacuum rises,
(2) Vacuum plqon ( 7 ) Needle jet holdor
the piston overcomes the spring presswe and moves up. The (3) S.Condary "",.. ( 8) Seconduy maln J<t
jet needle built in the piston is used to supply a char~ of (4) Tluottk vah·e I 9) let ne<dle
optimum fuel-air mixture to the engine. (S) Mt1n nouae (10) Needle jtl

• 4. fl oat circuit
Fuel flows into the float chamber from the fuel ttnk
through the pipe adapter and the clearance between the
float valve and seat. When the fuel level exceeds the
specified height, the float moves up on the fuel to cau~<e the
float valve to be closed, •hulling off tlte supply of fuel. As
the level drops below the specified helght, the float valve is
upened to permit fuel to flow into the float chamber. By
repeating this process. the level of the fuel in the float

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<hiUllber is always maintained lithe same level.

Fie- 2-18 (ll Float t5) """' .....,...

(2) Vah-e ltlt
(3) float nlve
14) Spedat ellp

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10 II. CONSTRUCTION

The float valve is provided with a spring at the area where

the valve come• m contact with the arm. The spring
prevents the float valve from vibrating when the float moves
abnormally due to riding and road conditions, mamtainin&
the fuel level constant. The float valve is also provided with
a special clip at the Up, which is hooked over the arm, to
cause the float valve to be opented together with the float.
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PIJ. l-19 (I) Float valve
(2) Special clip
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s. Llnkase
The openlng and closing of the throttle valves are
controlled by the two cables, one for opening the valves
and the other for elo•lng them.
The linkage mechanism, which operates the opening and
Bach pilot screw is provided with the idle limiter to
obtain the oonstant CO content (~) In exhaust gases at
engine idle speed.
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closing of the two carburetor throttles at the same time, Idle limiters
which a til respectively coupled to the link arm, by means The CO content in exhaust gases varies excesslvely with
of the odjusting holder. the adjustment by the pilot screw. This is why each pilot
The throttle stop screw is of a flexible type and the right screw is equipped with the idle limiter to limit the
and left carburetors can be adjusted at the same time. adjustment range.

(2) -
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fig. 2 lO (l) Throtuc levt'r (2) Idle lim her • 3) Throttle stop screw
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 11. CONSTRUCTION II

6. FRAME

• Front di.c: brake 3. The brake fluid so forced throughout the chamber A
passes through the brake hose (6) to cause the stop
The front disc brake con~istS mainly of a brake lever on the
switch (8) to operate at the joint (7). Then the brake
right side of the handlebar. a master cylinder, calipers
fluid passes through the brake hose (9) and enters the
Installed to the lef\ front fork and a brake disc installed to
chamber B of the caliper A ( 12).
the wheel hub, increasing safely in the operation of the
4. The brake fluid moves the piston (I 0) within the
motorcycle. The brake disc Is provided with the cover not to
chamber B to force the pad A against the disc.

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allow mud and dust to come in contact with the disc,
S. Since the calipers A and B are "free-joined" with the
resulting in a longer life of the pads.
holder, the reaction of the pad A is exerted on the pad 8
(13) through the calipers A and B to cause the disc to be
Qperallon "sandwiched" between the pads A and B.
1 As the brake lever (I) Is squee1ed, the cam (2) at the
bottom of the lever moves the piston (3) wtthin the

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master cylinder.
2. The piston so moved cau~s the primary cup (4) to cover
up the oil pa,;sage to force the brake fluid in tlte chamber
A.

• (1) Il l
(I)

(9)

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• (Chamber A)
12 II. CONSTRUCTION
Roar brake

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The rear brake is of a drum type (drum di.ll.: 160 mm or 630
in.) and uses the leading and trailing type shoes. The brake
linings are speciOcally molded and, therefore, the coefficient of
friction hardly varies With lugh temperature and pressure.
The rear brake is equipped with the brake indicator to make It
possible Ond wear of the brake shoes and drum earlier.

Fi1. 2-22
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Brake Indicator
The brake panel Is provided with the Index mark, and the brake
arm is installed on the brake cam shaft with the brake indicator
plate in between.
If the index marks on the panel and on the indicator are not
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aligned when the brake pedal is depressed, it indicates that the
brake shoes and drum are in good condition. As the brake shoes
wear, the brake cam moves as shown and, therefore, the index
marks reach allanment. Check the brake shoes and drum for
wear and replace if the service limit is exceeded. Brake shoes and
drum not worn

(5) •
Brak e shoes and
drum worn

f i$. 2-23 (l) Blake cam

(2) Index mark
(3) A tTQW mark
(4) Brake indicator plate
(5) Wear limits
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14 II . CONSTRUCTION
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Rear shock absorber ~mbUes
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The rear shock absorber assemblies fe<~ture the telescopic type
oil dampers with bouom vah·e to give an optimum dampifla
perfonnanc:e under all bumpifla and rebounding conditions. The
damping perfonn3nce on the extension side is well matched
with that on the compression side, providing maximum damp-
ing.

Stroke of rear shock absorber: 77.6 mm (3.06 in.)

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Piston valve Bottom valve
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(1) (2)
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\3)

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Fig. 2 - 26 (1) Rear shock absorber !lprlng
(2) Damper rod
(3) Damper pisoon
(4) Damper cyllnder
Operation
Each oil damper is equipped with the piston valves A and 8 and
bouom valve. On the extension side. the damping action is
provided by means of the piston valves. While. on the
compression <ide, the damping action is provided by means of
the botlom valve. m
On extenston stde: m
The oil in the chamber [a] flows into the chamber [b] through
the orifice (I) in the valve A (sheet metal). By the resisting force (3)
of this oil. the d3mping action is provided. The valve A Is

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overlapped with the valve 8 (leaf spring) which cove" the huff (4)
of the orifice. The dam ping action is regulated by the deflection
of the valve 8 . Under sud> a condition, the bottom valve Is I

opened and lhe oil in the chamber [c] flows into the chamber (6)
[b] smoothly to prevent air bubbles from being produced.
(Piston valve side)
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On compression side:

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()) (ll
The nil in the chamber [b] flows by amount of oil equi•alent to
the volume of damper rod into the chamber [c] through the (6) l&l
orifice on the bottom ''olve. By the resisting force of this oil, the
damping acuon is provoded. At this time the piston valves are
•l.~. !
't- II
(I)

opened and the oil flows from the chamber [b] into the I
' ' L:§ y; F
chamber [al smoothly. '·F-..,......

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(Bottom valve sode)
Ool flow on extension
• --- Oil flow on compression
2- 21 (I) Orifi<e (I)
(2) VaJvc .. A"
0) Valve "B"
(4 ) l'i<Oon
(5) Chumbtr "a"
(6) ('h;unber "b"
{7) Chamber "c"
18) Oottom valve
(9)0rificc (II)
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 Jl CONSTRUCTION 15
Air cleanen

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Air that os taken mto the carburetor (cylinder) and miXed
wuh fuel must be IS free from dust IS possible. If th~> is not
done, the dust acts as an abnlSi~ and undu extreme
condouons, the resulting wear will reach such proportioo.s
that it soon becomes necessary to recondition the engine. To
reduce the amount of dust entering the carburetor, two air
cleaners, one for each carburetor, are installed at the air
Each air cleaner uses a replaceable, bellows type paper
elemeoL Both air cleane11 are connected with each other by
a central air passage to assure constant supply of clean air to
the engine even if any one of the elements is clogged,
resulting in a high efficiency. A cloaged element reduces the
amount of air to be taken into the carburetor, resulting in
excessive fuel consumption and poor acceleration. The

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entrance so ali air is screened and filtered. In addition to elements should, therefore, be cleaned periodically.
r.Jtering the air, the aJr cleaner is also designed to act as a
•ilencer to reduce air sucUon noise .

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{ . . - - -- - ll

,, ~;;;======-====~~

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Caburetor Ceburetor

Fig, 2-lA Au cl..,;.lllt'rll \'Ommunk:ltcd by ccntr:tl air ph.~..,

16 II. CONSTRUCTION
7. ELECTRICAL 'SYSTEM

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t u!d
Three fuses are plo~d rn the fuse box and they are easily
checlccd b) ojltninsthe seat. The main fuse is I SA fuse and the
sub-fuses aze 1A fuses, one for the headlight and the other for
the p<>SJtion IArnp, taillight and meter lamp, to make it easier to
lind circuit failure. Even if the 7A fuses are burnt down, as long

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as the ISA fuse Is normal, the horn, tum signals, ignition switch
and stop switches are operated properly. However, lt ls
recommended that the cause be located before the damaged
fuses is replaced.
Fla. 2- 29 (I) Fuse box

•
•
•
 17
- -·---III. INSPECTION AND ADJUSTMENT-----

•
This stet ion cove~ the inspection and adjustment of Important
one' of the Items mvolved in the MAINTNANCE S('KEOULE
on page 110. For other items, see the paragraph for "lnspec·
tion" of each group.

I. TAPPETS

•
The tappet cleatancc must be adjusted when the engine Is cold.
For ease of ser\llce, open the seat and pull the rear fuel tank
rubber mounting away from the rear tank mount. Raise the
back of the fuel tank slightly.
I. Remove the tappet adjusting hole caps.
2. Remove the generator cover.
3. While slowly rotating the generator rotor counterclockwise

• watch the left (L) cylinder inlet valve tappet. When this
tappet goes down all the way and then starts to lift, then
watch for alignment of the index mark and "LT" mark. lo
this poSition, the piston in lefl cylinder will be at T.D.C.
(top dead center) of the compression stroke, and the inlet
and exhaust valves in that cylinder should be fully closed.

4. Check the clearance of both valves by inserting the feeler

aauge between the tappet adjusting screw and the valve
stem. If clearance is correct there will be slight drag or
resistance as the gauge is inserted. If clearance is too close
or loose, adjustment is necessary.
The standard tappet clearance is
l n. 0.05 mm (0'. 002 in.)

•
Fig. 3 - 1 Place pinon 111 T.O.C. lX.))Iition on compression stroke
llx. 0.011 mm (0.003 in.) ( 1) "LT .. mark (2) lndc:!C ma..rk on stator

5. Adjustment Is made by loosening the adjusting screw lock

nut and turning the adjusting screw until there is sllj!ht drag
on the feeler gauge. Hold the tappet adjusting screw in this
position and tij!hten the lock nut.
Recheck the clearance with the gauge .

• h . Turn the generator rotor 180° counterclockwise to position

the right piston at top dead center. In this position the "T"
l'ig. 3-2 (I) Lock nut
(2) Adju .,ti~ .\t..TOW
(3) Feeler gat~gc:

•
mark w111 be aligned with the index mark .
7. Che.:k righl cylinder vah•e tappet clearance. The adjustment
procedure IS the same as described in step 5.
II. Reins13ll the fuel tank .

• Fig. 3-J (I) ••r• mark

(2) Index mnrk OJ) $10.h.>J
 18 Ill. INSPECTION AND ADJUSTMENT

2. CONTACT BREAKER POINT GAP AND

IGNITION TIAIING
Contac:t Breaktr Point Gap Adjustment
I. Rtrno~ the contact breaker point co~r and generator.
covtr.
2. Clean and Inspect the contact breaker poiniS. Replace af
worn or badly pitted. Light pitting may be rtrnoved with an

•
ignition point file.
3. Thrn the generator rotor counterclockwise until one set of
contact breaker points opens to maximum clearance.

4. Check contact breaker point gap with a feeler gauge.

The correct gap is 0.3.0.4 mm (0.012-0.016 in.). If the gap
is not within these limits, loosen the breaker plate locking
screwt and move the breaker plate to obtain the correct
gap.
•
Tighten the loci in& screws and recheck the gap.
5. Tum the generator rotor counterclockwise until the other
set of contact breaker points opens to maximum clearance.
Checlc gap and adjust if necessary.
6. Lubricate the breaker point cam with a thin ftlm of grease.
NOTE:
Contact breaker point gap adjustment will affect ignition
tUning. Ignition timlna must. be checlced after contact breaker PIJ. 3-5 (I) PoinHam (5) Cont>ct brMk<r plalolocl<ing

•
point &•P adjustment. (2) L/11 oontact brenker point 'H."rcw
(3) R/H conlacl b=ker puinl
(4) Contact breaker plates
Ignition Timlnc
Oleck ignition liming upon completion of the contact breaker
point gap adjustment.
I. Tum the generator rotor counterelockwise until the "LF"
timing mark on the rotor aligns with the index marl< on the
generator stator.
If lefl cylinder l&nltlon timing is correct, the left breaker
points will JU.\1 begin to open as these marks align.

St~rt of adv•nce (at crankshaft) 1,800rpm

1-
3,400rpm
--
• Full advance (at cr•rlkshaft)

•
t-
Advance ongle 0 12.5 (1) ,.LF" mark
(2) Index mark on 81"or
(3) Index marks at full advance

NOTE:
Static ignition limlna may be checked with a 12V-3W con-
tinuity light. When connected a.• illustrated in Fig. 3-7, with the
main switch in the ON position, the light wiD come on u the
brealcer points open.
Sbtie timing it relati>-ely accunte, but for best results a
stroboscopk timin& light should be used to check ignition
timing in both retarded and full advanced position•.
•
•
 Ill. INSPECTION AND ADJUSTMENT 19
2. If left cylinder ignition timing is inconect, loosen the base -~-;~r~;;;~(:i!ij;:i:j~~;;iiiiii
plate locking screwt and rotate the base plate to obtam
correct liming. Rotate the base plate clockwise to advance
t1mmg, or counterclockwise to retard timing. Tishten the
base plate locking screws and recheck left breaker point
gap.
3. Tum the generator rotor counterclockwise 11ntil the "F"
tlming mark on the rotor aligns with tile index mark on the

•
generator stator. If right cylinder ignition tlming is correct,
the right breaker points will JUSt begin to open as these
marks align.
4 . If right cylinder timing Is incorrect, loosen the nght breaker
plate locking screws and increase or decrease point gap to
Plf. J-8 {l) B... plotelodtlni ICRWS
obtain correct timing. Do not loosen the base plate locking ( 2) Base plate
screws. Increasing the point gap advances Ignition timing. (31 L/H contact breaker platelocti,. .ocre"'

• Decreasing the point gap retards ignition timing. (4) R(ll conc.et bruker platetocki,. JCrew•

NOTE:
l&nition point gap must remain within limits of 0.3·0.4 mm
(O.OI :Z.O.OI6 in.) after Ignition timing has been set. If eorrect
timin& results in a point pp which Is outside these limits,
increase or decreue botb point g1p1 equally to bring pps within
limits, then retime by rota tin& base plate.
e.,. If left point gap is set at O.JS mm (0.014 in.) and risht
point pp produces correct timin& at 0.42 mm (0.017 in.), and
rotate base plate to time ignition.
If both point gaps cannot be adjusted within limits, replace
point a,.;emblies.

.. Pia- J - 9 (t) "F" mork

(2) Index mark on stator
(3) lndex m1rk tltlulladvance

•
•
20 Ill. INSPECTIO:-\ AND ADJUSTMf..'\T

3. CARBURETOR

Carburetor adjustment $hould only be made when the engine is

at operating temperature.

Chtcking idle speed

I. Set the idle speed to 1.200 rpm with the throttle stop
screw.
••
Turning the screw cloc:kw..e will increase engine speed.

•
2. Starting witll either the nght or left carburetor, turn each
pilot screw to fmd the point of highest rpm; the same
should be done with the opposite carburetor. Turning the
pilot screw in produces a lean fuel air mixture, turning the
screw out produces n rich mixture.
•
3. Readjust the throttle stop screw if it is necessary to rest the
idle speed.
After performing the odjustment above if the proper idling
speed cannot be obtained or if the exhaust back pressures
from the cylinders are not uniform, the carburetors require
individual adjustment and synchronization.

•
Pig. l - ll (I) Pilot screw

Chtcking synchroniution
I. Remove the fuel tank and connect it to the right and left
carburetors by the longer fuel tubes provided for this
purpose. Hold the fuel tank nigher than the carburetors.
2. Remove the plugs from the right and left carburetors and
attach vacuum gauges. (Tool No. 07504 3000100).

3. Start the engine and check if tile pointers of the two

Fit!. l - ll (I) Phog

•
•
vacuum gauges remain between 16 and 24 cmHg. If
necessary. loosen the lo.:k nul and mrn rhe adjusting screw.
The difference in the negative pressure between the two
carburetors should be within 2.0 cmHg.

NOTE:
If each pointer tlucruate excessively, adjust it witll the

•
•acuum gauge adjuster.

l 3 (l) Lock nut

(2) Adju.sring screw
 Ill. INSPECTION AND ADJUSTMENT

4. Upon noting that the pointers of two vacuum puges remain

•
between 16 and 24 anHg, snap the engine two or three
times.
If the poonters come outside the specification. repeat the
step 3 above.
• If the pomten are below IS cmHg, check the following
Items.
(I) Ignition timing(see page 18)

•
(2) Tappet clearance (sec page 17)
(3) Spark plug gap (sec page 102)
(4) Compression pressure (see page 30)

Fig. 3-14 (1) Vacuum gauge adjuster

• S. Upon noting that the vacuum of the two carburetors reach

the specified value, turn the thrortle stop screw to obtain
the standard idle speed.
6. Adjust each carburetor with the pilot screw.
7. Trun the throttle slop screw to again adjust the idle speed
to 1,200 rpm

FJs. 3- I S (I) High spe<d (lhrotllc 100 open)

•
(2) Slandord
(3) Low speed (lhrollle 100 closed)

4. TH ROTTLE CABLE

Two control cables connect the throttle grip to a linkage on the

carburetor operating bar. One cable opens the throttle valves.
while the other cable ensures positive closure.
Standard tluottlc grip play is approximately 10-15• of grip
rotataon. Thts play can be adjusted ot the grip play adjUJter and
also w1th the cable adjuster at the lower end of the openmg
cable at the throttle crank. To adjust, loosen the lock nut and
turn the adjuster. Tighten the lock nut upon completion of
adjustment and check for smooth operation of throttle grip

•
through the engine range from full open to full close with lhc
ltandlebar :.ct to the extreme right and left steering rositions . Fii· 3-16 (t) l.nck nul
(2) C.rip play adju.aer
(3) Cable adjustor

•
•
22 Ill. INSPECTION AND ADJUSTMENT
---------------------
5. CLUTCH
The no rmal clutch lever free play is I 0.20 mm (0.4-0.8 in.) at
the lever tip.
To adju$1 Ute clutch, perform the following steps.
I. l.oosen the lock nut and tum the clutch cable upper
adjuster located at the clutch lever, all the way into the
clutch lever bracket.
m •
Pil. 3- t 7 (I) Lock nut
(2) Outclt cable upp<r ;KIJU>Itr
•
2 Turn the clutch cable lower adjuster located at the clutch
housing, in direction (A) all the woy down to loosen the
clutch cable . •
Pig. J - 18 (I) Clutch cable lower adju"cr

•
(2) Luck nu l

3. Looten the dutch adjuster lock nut until nut is flu.<h with
screw adjuster. turn the clutch adjuster in direction (8)
until a slight resistance is felt.
from thiS position, tum the adjuster m direction (A) ~.
turn.
CAUTION:
Durina this adjustment . allow the adjuster nut to rotate
freely. If the nut is held in position during this adjtL•tment,
the nut may tighten against the oover. llfoviding with the
re,btance which may throw away the adjustment.
Tiidlten the lock nut.

•
4. Turn the clutch cable lower adjuster tn dorection (B) so that
there " 10.20 mm (0.4-0.8 in.) of the play at the clutch ..... l-19 (I) C1utch adjtuler kxk n~o~t
lever. then tighten the lock nut. (2) Outch adJU<~tt"r
Perform any subsequent nunor adjustment with the clutch
cable upper adjuster.
5. After the adjustment has been made. ensure that the clutd t
is not slip ping and that the clmch is pro perly disengagiitg.
Aflcr the engine starts>pull in the clutch lever and shift into
gear. Jll<.l ensure that the engine Uocs not stan. nor Ihe
motorcycle start to creep. Gmdually release the clu tch lever
and open the throttle. The moturc) de should star t smooth·
I)' and •ccelerate gradually.
•
•
 6. CAMCHAIN

• A loose cam chain will cause the valve liming to cftanae,

resulting in poor perfonnance. II will also cause excessive engine
noise.
I. Adjustment must be made when the four valves arc closed
completely and the toppers are free. This position occurs
at 90• A.T.D.C. on tho compression stroke of the left $Ide

•
cylinder. Rotate the generator roter counterclockwise until
Index mark on the stator is 90• A.T.D.C. (after 90' "LT"
mark). lf the valves arc still lifted. rotate the rotor 360' and
repeat realignment above.
2. Loosen the tensioner lock nut and the tensioner boiL
When these are loosened. the cam chain tensioner wiD f'~ J-20 (I) Lock nut
(2) TtruH)ncr bolt
automatically position Itself to provide the correct cam

• chain tension .
3. Retighten the tensloner bolt and lock nut.
7. ENGINE OIL
Checlting oil level and refilling
I. Remove the oil filler cap and check the oil level using the
oil level gauge with the motorcycle in the up-right position.
2. The oil level should be between the upper and lower level
marks. Do not screw the level gauge m.
3. If necessary, refill the crankcase Wlth the recommended oil
through the oil filler hole.
4. Again check the oil level.
• Excessive oil may cause abnormal noise and inoperative
clutch.

•
Fig. 3- 2 1 (I) Oil level J01'8C
(2) Upt>cr lovet mlllk
(3) Lower l.,.et mark

011 Recommendation
Use only high detergent, premtum quality engine oil.
The regular use of special oil addttlvcs is unnecessary and will
only increase operating expense\,
NOTE:
Non-detergent and low quality oils are specifically not recom.
mended.

Vi<cosity
Vo<eostly selection r.hould be based on the average atmospheric

•
temperature in riding area. Change to the proper viscosity oil
whenever the changes in 3\'erage atmospheric temperature
require it .
Recommended oU viS<'osity:
Gcm:ral. all temperatures
SAE IOW·30 or SAE IOW-40

• Altemate·
\lxw e 59"' F •J S"C •
.1~' 10•1 to 59T ( I5°C)
SAE 30
SAE 20 or 20\\'

•
~-Jm, 3:!,.F ~occ 1 SA£ JO\\
24 Ill INSPECflON AND ADJUSTMENT

Cha.nalna on

•
1. Remove the oil filler cap from the ri&ht crankcase cover.
2. Remove the oil drain plug with a 17 mm wrench.
3. After the oil stops draining from the crankcase, operate the
Ieick starter several times to drain any oil which may be left
in the recesses of the engine.
4. When the oil has been completely drained, reinstall tl1e
drain plug making sure that the O·rlng used on the drain
plug Is In good condition.
S. Fill the crankcase through the oil filler opening with
recommended grade oil. Check the oil level with the fiUcr
cap dops11ck, however, when malclng thos check, do not
screw in the cap. Oil level ahould be between the upper and
lower level m:11ks on the dipstick. When checking the oil
Pfl. 3-22 (I) Dmn pJu&
•
•
make cenain that the motorcycle Is In upright and level
position.

.. qt)
Unit· liter (US
I.S (1.6),
Amount of oil When changing oil
- approx.
to be fiUed When separating 2.0 (2.1),
crankcase IJ!prox.

8. OIL FI LTER SCREEN AND ROTOR

A dual system of metal screening and centrifugal oil filtering is

utohzed to provide engine components with highly purified oil
•
to mlnlml7e wear and Improve engine cooling. The oil filters are
serviced in the following manner.
I . Drain t.heengine oil.
2. Remove the foot rest, the mufficr and tlte kick starter
pedal.
3. Loosen the right crankcase cover mounting screws and
remove the crankcase cover and cover gasket.
4. Remove the snap ring and di•assemble tlte oil filter cap
from the od fdter rotor.

S, Clean any sludge from the center of the oil filter rotor.
r~a. J-23 (I) Oil fihu cap
(2) Snap ril1&
(3) .00 niter rotor
•
•
Pl1. 3-24 (I) Oil filler rotor
•
 6. Remove the screen filter for cleaning. Wash the screen mter---;;:;;;;;;;;::;:;;;;;;;;;;;,~::;;;;;;;;;;i

•
'" clean solvent and then mstall.
7. Reassemble all parts removed in the proper order. If the
crankcase cover gasket I~ damaged, replace it with a new
gasket.

• Pi8- 3-25 (I) Saeen niter

(2) Sn"Mn filter anactu.nc bolts

• NOTE:
• When assembling the uil filter cap and the oil filter rotor
ensure that either of the cop ribs is aligned with the rotor
index marks.

•
Pig. 3- 26 (1) lnde> mork
(2) Rib

9. FRONT BRAKE
(Disc Type)
Replenishing brake fluid
Remove the reservoir cap, washer and diaphragm, and whenever
the level is lower than the level mark engraved inside the
rc..:rvoir. fill the reservoir with DOT 3 BRAKE FLUID up to
the level mark. Reinstall the di3phragm and washer, and tighten
the reservoir cap securely .

• Adjusting brake caliper

FC. J-27 (I) Levd muk

•
Whenever the brake pads arc replaced, the brake caliper must be
adju>tcd. This adjustment h made in the following manner, so
that there is a small clearance between the fixed frict iun pad
and the hrakc disc.
I. Ra1<e the front wheel off the IUOUnd uslllg a suitable prop.
2 Loo<en the catiper stopper bolt lock nut.

•
3. Using a suitable <erew dnvcr. turn the stopper b<>h m
dorecuun (A) until the frictton pad cunlacls the brake di~ .
When the wheel is rotated, sloghl drag should he nollccd.
4 . While rotating the front wheel. turn the <topper bolt in
direction (B) until the ftont wheel rotares freely.
5. Turn the stopper holt !h turn in direction (ll) further ond Fig. l - 28 (I) Stopper bolt lock nut
tighten the lock nul. (2) S topptlr boll
 26 Ill. INSPECTION AND ADJUSTMENT
Bleed ina the brake .,.stem

•
The brakes must be bled witll great care sub>equent to work
perfonned on the brake I)'Stem, when the lever becomes soft or
spongy, ur when lever travel is excessive. The procedure is best
performed by two mechanics.
I. Remove the dust cap from the bleeder valve and auach
bleeder hose.
2. Place the free end of the bleeder hosc Into a glass container

•
which has some hydraulic brake fluid in It so that the end of
the hose can be submerged.
3. Fill the reservoir using only the recommended brake fluid .
Screw the cap partially on the reservoir to prevent entry of
dust. Fil- J - 29 (I) Bleeder ho,.
4. As t.hown at 11ght (Fig. 3 308), a!lach a rubber of about

•
IS mm thick to the end of the handle grip to decrease the
stroke as measured at the tip of the handle lever.
S. Pump the brake lever several times until pressure can be felt,
holding the lever tight, open the bleeder valve by about
one-half tum and squeeze the lever all the way down.
Do not release the lever until the bleeder valve has been
closed"ll"'"· Repeat this procedure until bubbles cease to
appear in the fluid at the end of the hose.
6. Remove the bleeder hose, tighten the bleeder valve and
onstall the bleeder valve dust cap.
7. Do not allow the fluid reservoir to be.-ome empty during the
bleeding operation as this will allow air to enter the system
again. RepleniSh the fluid as ofien as necessary while
bleeding.
8. Check for proper effect of b leeding and absence of leaks in

•
the front brake lines while holding pre~~ure against the brake FJa. 3 ·JOA (I) Diaphra(ll11
(2) Level maJk
lever Repleni•h fluid in tho reservoir when bleeding is (3) Reservoir
completed. Reinstall the diaphragm, washer and reservoir cap
and toghten.
When the hydruUc brake l)'stem has been dramed, it should be
fust foiled as outllned below.
1. Fill the fluid reservoit.
2. Open the bleeder valve by one-half turn, squeeze the brake
lever, close the valve and release the brake lever. This 15mm
procedure must be repeated in this sequence until hydraulic (0.59in.)
fluid begins to flow through the bleeder hose. Having filled
the hydraulic system with fluid, proceed with the actual
bleeding operation.
NOTES:

•
• Brake fluid ..-hicb has been pum1~ed out of the system must
not be uwd opin.
• ca~ mu~t be taken, as brake fluid will damage the paint
f ... J-JOB (I) Rubber
fmi>h and instrument lenses.

•
•
Revised August 5, 1975
 Ill. INSPECTION AND ADJUS'fM£1\T 27
(~~) ------------------------------~~~==~~~

•
I. Raise the front wheel off the ground by placing a support
block under the engine. spin the front wheel by h311d and
measure the travel the front brake lever must be moved
before the brake starts to take hold. The lever free play
should be 20-30 mm (0.8-1.2 in) at the end of the brake
lever .

• Fi$. 3-31 (I) Front brake

(2) l.evet ,,.. play
-r
• 2. Normally the adjustment can be made at the front brake
arm on the front brake panel.
First loosen the lock nut and then tum the front brake
adjusting nul. Turning the nut in the clockwise direction
(A) will decrease the brake lever play and turning in the
counterclockwise direction (B) will increase the play.

Fig. 3 - 32 (I) Front broke•rm

•
(2) Lock •lui
(3) Ad]uttins nut

3. Minor adjustment can also be made with front brake cable

adjuster on the front brake lever by turning in the same
direction as above .

• Brake wear indicator

F''l- 3-33 (I) Front bral<e<.,.ble odJusta
(2) lo<k nut

•
The wenr indicator is provided in the front brake.
When the brake is applied, u red arrow, adjacent to the brake
aom, moves toward a red reference mark on the brake panel.
The distance between the arrow and the reference mark, on full
application of the hrake, indicates brake Uning thickness.
If the arrow aJi&ns with the reference mark on fuU application
of the brake, the brake shoes should be removed 311d in<pected

•
for wear. Replace the brake shoes. if the thickness of the lining
os 2.0 mm (0.08 in) or less.

Fig. 3-34 (I) Front broke panel

(2) Re(crcnt..;l.' nlMk
(3) ;\rrow mnt~
(4) Front tmake a1m
28 Ill . INSPECTION AND ADJUSTMENT

10. REAR BRAKE

Adjusting pedal height
1. Raise the rear wheel off the ground by placing the
motorcycle on its center stand.
2. The stopper bolt Is provided to allow adjustment of the
pedal height. To adjust tlte rear brake, loosen the Joel< nut,
111d tum the stopper bolt.
•
Fie- 3-35 (f) Lock nul
(2) Publ s10pper boll
(3) Rear brake pedal
•
•
(4 ) Free play
Adjusting rear brake pedal f..,. play
The real brake pedal free play should be 20- 30 mm (0.8- 1.2
in) as measured at the tip of the pedal.
I. To adjust, turn the rear brake adjusllng nut. Tum clockwise
for less free travel, counterclockwise for greater free travel.
NOTE:
After adjusting, check the lighting rime of the rear brake
stop lamp. (See page lOS.)

Fig. 3- 36 (I) Rear brake adj usting nul

Brake wear indicator

The wear Indicator ts provided in the rear brake.
When the brake is applied, a red arrow, adjacent to the brake
arm, moves toward a red reference mnk on the brake panel.
•
The distance between 1he arrow and the reference murk, on full
application of the brake, indicates brake lining thickness.
If the arrow aligns with the reference mark on full applicalion
of the brake, the brake shoes should be removed and inspec1ed
for wear. Replace the brake shoes, 1f the lhickne;s of lhe lining
is 2.0 mm (0.08 in) or less.

II. DRIVE CHAIN

Checking drive chain tension
FW. 3 - 37 (I) Rear brake panel
( l) Rdc:renoe mart
(3) Anow mark
(4) Rear bnke arm •
I. Place the motorcycle on its cen1er s1and 10 raiS<: the rear
wheel off the ground. Shift the transmiSSIOn into neutral.
2. Check vertical movement of the lower length of the drive
chain at a point midway between the sprockets. Move the
chain up and down with your lingers and observe 1he
amount of slack. Orive chain ten<iun >hould be adjusted to
•
allow approximately 20 mm ('l'") vertical movement at this
point.

f ig. 3 - 38 (I) Drive chain

•
 Ill. INSPECTION AND ADJ USTMllNT

3. Remove the rear axle nut colter pin and loosen the rear axle

•
nut.
4 . Loosen the lock nut and tum the adjusting bolts on both
the right and left chain adjusters to increase or decrease
chain tension.
Align the chain adjuster index marks to corresponding scale
graduations on both sides of the rear fork.
5. Tighten the rear axle nul and secure the nut wilh a new

•
cotter pin .
Tighten the lock nuts.
6. Recheck drive chain tension.
7. Rear brake pedal free travel is affected when repositioning
the rear wheel to adjust drive chain tension. Check rur
Fill. 3-39 (I) Cotter pin (S) Lock nut
brake pedal free travel and adjust as necessary. (l) Rear Ide nut (6) AdjuSii"' bolt

•
(3) tndtX M3Jk
(4) Corro'l>ondlnaoclle
12. FRONT FORK
Changing fork oil
I. Unscrew the front fork drain plug at the bottom of fork
leg. Drain the oil by pumping the fork while plug is out.
Replace the plug securely aner draining.
2. Set the motorcycle on the center stand.
3. Place a jack under the crankcase to control lowefirl& of the
front cod.
4. Remove the handlebar by removing the four handlebar
bolts.
S. Unscrew the fork filler plugs until free.
6. Lower 01e jack under the engine to extend the fork springs

•
with the attached filler plugs. Pig. 3-40 (I) rmnt rork drain plug
7. Move the fork springs to one side and pour 13S- 140cc
(4.6- 4 .7 ozs.) of premium quality ATF (automatic trans·
mission fluid) into each fork leg.
8. Raise the jack under the engine to aUow the fork springs
and mter plugs to return into the fork legs.
9. Securely tighten the fork filler plugs.
10. Reinstall handlebar, tightening the two front bolts first,
then securely tightening the two rear bolts.
II. Remove the jack from under the engine .

• 13. REAR SHOCK ABSORBER

Fi&- 341 {I) Fork llll<r plup

• Each rear shock absorber has five adjustment positions for

different types of road or riding conditions.
Position I is for light load• ami smooth road conditions.
Positions II to V progressively increase spring tension for stiffer
rear suspension, and are u<ed when the motorcycle is heavily
laden or operated on rough roads.

• Pig. 3-42 (I) Rear shock absorber

(2) Pin \l)unner
30 Ill. INSPECTION AND ADJ USTMENT
14. AIR CLEANER
I. Open the seat.
2. Remove the IJr cleaner cover.
3. Remove the air cleaner ~se by unscrewing the case fix1ng
nut.
4. Remove the air cleaner element by unscrewing the element
flxlng bolt and connechng tube fixing screw.
•
Pi@. 3--43 (I) Air cleaner case
(2) C.ase flxln& nu I
•
•
(3) Element fixing bolt
(4) Fixing screw
5. Clean the air cleaner element by tapping it tightly to loosen
dust. The remaining dust can be brushed from the outer
element surface or blown away by applying compressed air
from the inside of the element.

•
Fig. 3-44 ( 1) Air deancrclcrncnt

15. CYLINDER COMPRESSION PRESSURE

I. Remove the spark plug.
2. Put a compression gauge attachment into the plug hole and
hold the gauge securely to prevent leaks of compressed
gases.
3. Fully open the throttle and choke valves and continuously
operate the k.lck starter vigorously and quickly.
The specified compression pressure is 12kg/sq.cm
( 1711b/sq.ln.)
If the actual compression pressure is above 12kg/sq.cm, it

•
indicates that carbon is accwttulated in the combustion
c hamber~ or on the piston heads. Disassemble the cylinder
Fig. 3- 45 (1) ('om [>res~iOJl8<lUge altachnH'Int
head and cylinder and decarbonize. If the actual pressure Is { 2) ('omprc~~io n t!<IUge
below 10.5ksfsq.crn ( 149 1b/sq.in.), compre!l<ecl gases leak
from the valves, piston rings, cylinder head o.r cylinder
gasket. ReadJUSt the tappet clearance or di.assemblc the
cylinder head , cyhnder and pistons to check the piston rings
and gaskets for cond1trun.

•
•
 31
- - - - - - - - - - N. E N G I N E - - - - - - - - - - -

•
I. ON-FRA.\1E SERVICING (Engine Disas.<;embly)

No. Item Ref. poae No. Item Ref.peae

Cylinder head, cylinder and pistons 37 4 Oil pump and oil fllter so
l
Left crankcase cover,
- -s Gearshift <pindle 57
2 45

•
A.C. generator and •tarting motor
6 Carburetor 63
3 Right crankcase cover and clutch 47

2. ENGINE REMOVAl AND lNSTALLATION

•
Removal
Dismount the engine for di.assembly after the engine oil hu been drained out.

(I) Open the seat and remove the battery. (2) Disconnect the starting motor cable at the
• Remove the battery cable Orst . starter magnetie switch.

• (t) Battery (3) Posoti>e terminal (I) Starting motor cable (2) Starter magnetic nritch
(l) ~eaative terminal

(3) Remove the fuel tank {4) Remove the right nnd left mufflers
• With the fuel valve in "OFF" position, remove the • Remove the two nuts (2) and bolt {3) and remove
tank taking care not to break the fuel tubes. the left muffler.

•
Repeat the above for the nght muffier.

•
• (l)l'uet tube (I) ten mufllcr (lndk:atc-,(8 ty~
32 IV. ENGINF

(S) Remove the change pedal aod left crankcue rear (6) Remove the drive chain with the drive sprocket.

•
cover. • Remove the drive sprocket futing bolts.

•
(I) C'll&n~e ped&l (2) Lert crankcase..., cover (I) Drive sprookct fixing bolu
(2) Fi•IMJ plate
(3) Drive sprocket
(4) Dri•·• cbain (endless) •
(7) Drain the carburetor and loosen the coMectlng (8) Remove the carburetor.
rube band. • Disconnect the carburetor at the insulator side and
• Remove the drain screw and drain gasoline. push it toward the air cleaner.
Keep out of rue. Then remove the urburetor toward left by lower·
ing h.

•
(1) Drain screw (3) Carburetor insulator hand
(2) Connectin& tube band

•
(9) Remove the A.C. generator connector. ( I 0) Remo>e the brake pedal.
• Pull out the starting motor cable. • Remove the boll and brake pedal pivot shaft and
remove the pedal.

•
(I) A.C"'. aenerator conne-ctor (2) Stanjng motor cable (l) Drake pcd.al pivot shaft (l ) 8rakc pedsl
•
 IV. F.NGNE 33
(I I) Disconnect the tachometer cable 81ICI primary lead. (12) Remove the UBS nuts (2) and nut (3) and remove
Remo•-e tbe spark plug caps. tbe engine upper han,er.

•
•
• (I) Prlmary lead (I) EnPne upperhanp:r

(13) Remove the UBS nuts (2). (3) and (4). (14) Remove the bolt (3), pull out the bolt (4) 81ICI
• Remove the nut (2) and remove the foot peg. remove the engine hanger plate.
• Remove the nut (4) and pull out the bolt. Remove the bolt (S) with nut and right foot peg
together.

•
u, u.r. foot .,., (I) Ri@ht foot pq: (2) flljOont ha"l<< plait

(IS) Remove the bolts (2) and (3). (16) Lower L~e engine toward right as .hown.

• • Be careful of your feet. h is advisable to lower the

engine by two persons .

•
• (l) Fnp::inc l'lottom hunt:tr
34 IV . FNGINE

lD!tallation

•
To instaU the engme, reve11e the removal procedures.
I. Install the engine on the frame from right side so that it Is
slightly inchned forward.
• \lake sure that the starting motor cable is not binding.
• Position the engtnc bottom hanger correctly before ugh ten·
ing the bolu.
2. lnstaU the engine hanger bolts os shown in the figure below.

•
•

Fl,g. 4 - 2 (I) o_.ucry groum.l ~able

(2) Engine hanger plate
(3) 8 x 14 UBS bolt
(4) 10 x 110 UBS boll
(5) 10 mm UDS nut
( 6) l~nafno 11id~ culloar
( 7 ) Ke1u e,.lnc lower ha.nger l>olt
( 8) 8 x 45 UijS bolt
( 9) 10 '45 UDS bnll
(I 0) 8 mm UBS bolt
(I I) Sx 8; O•n&ed bolt
(L2) F.nglne UJlJl-C' hnngc'
(13) Snun UBS nut
(14) 8 mm nu1 •
•
3, The threaded part of each en~,ine rear hanger boll witlt
which the foot rest •• tightened, must be identical in length.

Fig. 4 - 3 (I) Engine"'" hanger bolt• (l'hrt•dcd parh

are identical in length.)
(2) Foot test
•
 4. Route the startinA motor cable as shown in Fig. 4-4 and
connect it to the Starter ma&netic SWitch.

•
• Fi&- 4-1 (I) Swtinc motor cable
(2) Starter m.,nettc \Witch

• S. Push the carburetor towonl the insulator completely and

secure it with the connecting tube band.
NOT£:
Install the A.C. generator connector before installina rhe
e.vburetor.

•
Fig. 4-5

6. Loosen the rear axle nur, chlllll adjuster lock nut and chain
adjuster, and push the rear wheel forward all the way.
7. ln•tall the drh·en sprocket to the drive chain and rhen the
assembly to the counrershaft ~cure the sprocket with the
fiXing plate and fixing bolts .

• 8 Adjust the chain tension.

• The chain slack shou ld be 20 mm <*in} at the position

•
shown at right.
• Align the index marks on Ihe right and lert adjusters with
the reference marks on rhe side scales .

• Fig. 4-7 (11 Chain ; lack (2) Index and reference marks
36 IV. ENGINL
9. Maklna sure that the $ 10 steel ball ii aruide the clutch lever
as shown. install the left c1'11Jlkcase rear cover.
CAlTilON :
Missing of the steel ball may eauM: the clutch to be
dlseng~ improperly.
•
(I) f 10 steel ball
mauacb~ ..
•
10. Making sure that wire• and leads ore not binding, install the
fuel tonk. Connect the fuel rube from rhe righr carburetor
to the rear side of the fuel valve and the fuel tube from rhe
left carburetor to the front side of the fuel valve and secure
with the cUps.
•
1'1&. 4- ? (I) Fuel valve

•
(2) Tube from right c~rburetor
(3) Tube from left .,:arburetor

II. Route the battery overflow tube as shown on the label,

takina care not to bend it.

12. When the engine has been rea•sembled after overhauling,

fill with uil and •tart the engine. Remuve rhc tappet hole
•
•
caps and check if the oil comes up in about 10 seconds.

,.:is. 4 - 1I Chcd. ml dr~ulatton

•
 IV. ENGINE 37
3. CYLINDER HEAD. CAMSHAFT, CYLINDER AND PISTONS

• Cll

•
•

• (1) Cyhnder head COYCJ

(2) Saling washer
(3) Ril\ht rocker arm IIIJO

•
RfftnUII to rocker ann teo n un pcge J31

Fig. 4-12 ( l ) Rocker arm
( 2 ) Rocke r arnt shafl (L)
( 3 ) ·racho meter seiU
( 4 ) t.)'linder head cov..:r
( 5 ) Breather covtr
( 11) Point oovtr
(12) Vatvc cottcn
(13) Vatve ,-.ring retainer
(14 ) Vatve outtr spring
(IS) Vah·e Inner 'Prirtg
(16) Valve srcm ocll
(21) Cylinder bud aaskel
(22) Cylinder
(23) Cylinder &asket
(24) C'am cl\11ln tcmdoncr holder
(25) Ttns.ioner sJipper
(26) 22 x 35 x 6 oil...t

•
(6 ) Breather tube
(7) Spark advsncer (11) Vat-.-e spurc ~at (27) C•m<hafl
( 8) Contae1 breale.r aut:mbly (18) Valve JUode (28) Cam q>rof.:kct
(9) Contact break.tr (19) Clm Chain &UICIC (29) {'am ehaon
( 10) Point cover J~'ket (20) Cylinder head (30) Valve
38 TV. ENGIN E

Disassembly

•
• Completely remo~ mud, du•t or dirt from around the
engine before dis:ossembling.
• Take care not to allow dun and dirt 10 get instde or to
come in contact with the cyUnder, crankcase, carburetor
and air cleaner.
I. Open the sut and remove the fuel tank.
2. Remove the nuts (I) and remove the engine upper hanger.
3. Remove the bolts (2) and remove the breather cover.
4. Remove the po111t cover and remove the contact breaker.
5. Remove the spark advancer.

1"'1- 4 - 13 (I) Nuu (2) BollS (3) PoUlt ..,..r

•
6. Remove the spark plug caps and remove the spark plugs.
7. Disconnect the tachometer cable and remove the tappet
hole caps.
• Leave the tappet adjustlna screws loosened.
•

•
Fig. 4- 14 (I) Sp011< plug cap
(2) Tappet hole cap
(3) Tachometer cable

8. Remove the six 6 mrn bolts (two bolts are inside the
breatlter cover) and ci~ht 8 mm bolts and remove the
cylinder head cover.
• Remove the cylinder head cover toward l~ft whUe inclining
it forward.
• Completely remove used scaling agent from the cover.

9. To remove each right rocker ann V!aft , firs1 remove the

scaling bolt. Then tum the 6 mm screw or bolt in and puU It
FW. 4 15 (I) Cylinder head ro,.r

•
to remove the shaft.
To remove each left rocker arm shaft. remove the rubber
plug and remo,·e the shaft by pulllns it with pliers
10. Remove the snap nng and !<move the tachometer gear .

..
•
l'ig. 4-16 (I) R1ght rocker ann <haft
(2) Left rocker arm shilft
(3) Tachometer gear
•
 IV. ENGINE 39
II. Remove the cam chain.
Remove the generator cover and tum the rotor to allow one

• flxina bolt to be removed. Then turn the rotor li turn more

and remove the other rlXlng bolt.
12. Remove the cam chain tensloner holder.
13. Remove the cam chain guide and tensioner slipper .

• 17 (l)fixi"'tl>olt
(2~ C.un 'Prudtt'l

•
(3) C4m thain tcm1oncr h.oldcr
(4) ltn~1oncr sJjpper
14. Remove the cam sprocket from the camshaft, remove the
cam chain and pull out the camshaft.
NOTES:
I. Until the cylinder head Is removed, hold the cam chain
with a screwdriver to prevent it from dropping into the
crankcase.
2. Tlke care not to drop the thrust washers into the
eJJ8ine room.

IS. Remove the right and lert mufflers.

16. Remove the carburetor. (See page 32.)

• 17. Remove the eight 8 mm nuts and two 6 rnm bolts and
remove the cylinder head.
CAIJJ10N:
Do no (,(core or scratch the cylinder attaclling surface of the
qlinder bead.

'

• 18. Remove the cylinder.

• Attempt to position both the pistons on the same level and

• to prevent damage of the pistons .

• FiJ. 4-20 (t) Cylinder

 IV. ENGINE
19. Remove the piston pin clips and piston pin and remove uch
piston.
NOTE:
When ~moving the piston pin clips, place a rag over the
cnnkc:ase to prevent the clips from dropping into tht
crankcase.
20. Remove the piston rings taking care not to damage the
•
•
piston.

.,.. 4 - ll (I) Piston pin clip

(2) PiJton
(3) Rot!

21. Remove the valves.

Compress the valve springs using the valve spring compres.
sor (Tool No. 07957- 3290000) and remove the valve
cottert, springs and valve in this order.
CAIJTION:
Compress the valve springJ with care ottention plid not to
•
domoge the valve stem seal.

Pia. 4 - 22 ( I) Valve 'Pring compres<or

•
(2) Va1ve cotten

22. Rtmove the stem seal and puU out the valvt guide using the
valve guide driver (Tool No. 07942-611 0000)
CAIJTION:
Do not remove the valve guidt exctpt when ~placing it, ••
a rule.

Inspection
FiJ. 4-23 (I) VaM ~;~~Ide remom

GOOD
(2) Va!>t ~;~~ldt

NO GOOD
•
•
Refer to servict data on page 11 2.
I. Check the rocker arm·ln·shaft clcaroncc.
2. Check the CIUllsllaft journals for wear or damage.
3. Check the cam height for wear.

•
 IV. ENGINE 41
4 Check the valve seat contact :wl:;;;;d~th:-;a:n~d~if;:-:n:ece::m::ry::--r=============-.:...--===~
rewodition.

•
Apply a thm coat of red lead to the vah-e seat surface. Press
the valve against the seat and rotate it to check if the
contact width is uniform. If not, lap the valve, seat and
again check the contact width. If necessary, recondition the
valve seat using a valve seat grinder.
CAUTION:

•
Use the valve seal &rinder in occord3tlce with the instruc·
tion manual.

Fig. 4-25

• S. Measure the valvc·tO·gulde clearance.

6. Measure the valve spring free length. Also check the
Installed load.
7. Check t11e matching surface of the cylinder head for
rougltness.
II. Measure tile cylinder bore.
Using a cylinder gauge, measure the cylinder bore in the
dnections X and Y at the upper, middle and lower potnts.
If wear is too veat so that the service limits are exceeded,
the cylinder should be rebored, and oversize piston 3tld
piston rings installed. The following four oversize piston
and piston rings are avail•ble as service parts:

•
Fis. 4- 26 Mca11ure 1he cylinder hore
Unit: mtn (in.)
O,venize ____.Siu lo .,.,hkh cylinder is to be rebored
Iand ring
JJI\Iun
2S0cc I 360 cc
0.2.5 ,___
56.26·56.21 (2.2149-2.2153)67.26-67.27 (1.6481).2 6484)
0.50 56.51·56.52 (2.2248-2.2252) 67.51-67.52 (2.6579-2 6583)
0.15 S6.1(rS6.11 (2.235·2.2951 67.76.07.77 (2.6677-2 6681)
1.00 57.0t·57.02 (2.2445·2.2449) 68.01-68.02 (2.6776-2.6780) I
9. Mea.wre the piston skirt 00 (outside diameter).
10. Measure the piston pin hole di•meter.
II . Measure the piston pin 00.
12. Check the side clearance of the piston ring in the grnnve.
13. !'heck the pi&ton ring gap.
Install the ring squarely In the skin of the cylinder to check

• the ring gap .

A"""mbly
F'll. 4-27 Ol l'l<ton nn11•P

•
To assemble, reverse the di<assembly procedures paying attcn·
lion to the following:
I. When the valve guide must he repl•ccd, install it using the
valve guide driver (Tool No. 07942 6110000) and finish
the in&ide surface u•ing the valve guide re•mer (Toni No.
07984-5900000) .

• Fig. 4-28 fl) Vuh~ auii.Je remove1

(2) Volvo ••l~c
42 IV. ENCINE

2. Assemble the valve so that the smaller pitch ~Ide of the

valve springs is toward the cylinder head, using the valve
spring compressor (Tool No. 07957-32<>0000).
CAUTION:
Compress the sprinp with c.mful attention paid not to
break the valve stem seal. •
Fie- 4-29 (I) Inner nhe 'Priog
(2) O.ncr nlvc "'""'
•
•
(3) Valve stem ~•

3. Use the piston rings of the ume brand •n a set. Face the
madtinp on the rinp upward when Installing them in the
grooves In the piston.
CAUTION:
Do not install the top and second ring.< conve,...ly.
• When using new piston rings. install them In the grooves in
the piston and check for proper fil.
4. Each ring gap must be staggered 120• and must not be at
right angles to the piston pin.
S. Install the piston with the arrow, If murkcd, on the head
facing front (exhaust side).
• Apply a coat of oil to the piston rings lirst.

6. While holding the piston rings with the piston ring

r;g. 4-JO (I) Piuon nng gaps
(l) ~lut
() l Pitton pin
(4) Piston pin clips
(SI Top "IIC
(6)S...vnd ""'
(7)0~ ""' •
compressor (Tool No. 07954 3670000 for 250 model,
Tool No. 07954-3690000 for .160 model). carefully install
the cylinder.
7. Upon nohng that pistons arc p1opc•ly positioned in the
cylinder. route the cam chain Into the cylinder an~ install
the cylinder 11ecurely.
•
Pig. 4-31 (!)Cylinder
(2) Pillton
(3) Piston ting comprc:~"ur
•
 IV. h NGINL 43
8. Tiglllen the cylinder head m the numerical order shown at

•
rlgll1.
S~ified tightening torque:
10 mm bolt: 3.0-3.4 k&·m (21.7-24.611>9-ft)
6 mm bolt: 0.7- 1.1 kg·m ( 5.1 - 8.0 lb!l-ft)
NOTE:
1. Apply a coat of oil to the tbrellds.

•
2. Take care not to score or scratch the cylinder attaching
surface of the hud with the cylinder sruds.

9. Install the C3J11 ch11n guide and tensiooer slipper securely.

Ffs-4- 32

• 10. Before installing the camshaft, set it to the cylinder head

and check the •ide clearance. If necessary adjust the
clearance so that it becomes 0.07 to 0.3 mm (0.003 to
0.012 in.), by using the thrust washer below.
NOTE:
lmert the wuben into the clearance (3) shown in Fia.
4-33. Do not insoert them into the clearance on the ltCC
side.
Description Parts No. Thickness -

Tiuust washer A 90483·369.000 1.0 mm

Thrust wa,her ll <;1041\4·369.()00

•
I .I mm Pig. 4 - JJ (l) Camshaft
(2) Tluuu \oltll t~her
(3) Cauu~hllft Wde dem-unce

II. Install the earn chain and cam sprocket and install the
camshaft.

• 12. Rotate the generator rotor in the direction of arrow to ahgn

Ffs. 4-:14 (I) Cam!hall
(2) Cam ch»n
(3) Cam 'q)hl~,;..cl

•
the " LT" mark with the inclox mark on the stator.

• Fig. 4- JS "lT.. mark and Index mark on stator

 44 IV. l!NCINE

13. Under the condition mentioned above, pull the cam chain
to align the top of the cyUnder head with the matching hnes
on the CIITI sproxket. At this time, set the cam sprocket to
the camshaft.
14. Rotate the camshaft untO the thread holes in the camshaft
and cam sprocket are ahgned and tighten one fiXing bolt.
Rotate the crankshaft and tighten the other fiXing bolt.
•
~

Pia. 4 36 (1) ~fatching linell on cum ~prockcc

•
IS. Install the cam chain tensioner holder.
NOTE:
Attach the cam chain tensioner holder damper with the
nanow side to...-.rd the cam "!'rocket.
•
16. Fill the cylinder head oil baths with oil. Also apply a coat
of oil to the camshaft journals.
17. Apply a coat of oil to the tachometer gear, rocker arm
shafts and rocker arms.
18. When lnstalllna the cylinder head cover, position the
camshaft by slowly rotating so that all cam lobes nrc
towards the bottom to avoid the rocker arms from
contacting the cover.

•
I'IJ. 4-37 (I) Cam chain tenlioner holder
(2) Damper
(3) Oitbatb
(4) Camshaft joum•t
19. Apply a coat of sealing agent to the cylinder head .,cover. ,......,....,....,............,...
While rotalong the camshaft. install the head cover. Slowly
tighten the head cover bolts in the numerical order shown
at right .
NOTES:
I. Take tare not to drip excess sealing agent on the other
parts.

, 2. Use the foUowing bolts:

(1)-(6): 6 x 45 mm, (3) and (5) need a washer.
(7), (8), (10), (II), (12): 8 x 45 mm, ( 12) needs a
cable clamper.

' •
(13)-(14): 8 x 60 mm, (13) needs a cable clam per.
Pig. 4 - 38 C)• Under head OO'<t:r llghtcnlr~g ~l'4lU.lntc

20. Install the ~park 3dvanccr and contact breaker by fitting the
holes onto the camshaft dowel pin.

•
21. Adjust the cam chain tension.
22. Adjust the tappet clurance.
23. Adjust the igniuo n timing and point gap.

Fig. 4 39 (!) Dowel pin

f2) .Spark advancer
•
 IV. F.NGINE 45
4. A.C. GENERATOR AND STARTING MOTOR

• Fla. 4-40
(I) Startlng spn.x:ket .seulng plate
(2) Startioa chwn
(3) Stortma sprocket
(1)

• <•> I eft crankea...~ cover gasket

(S) L<rt aankca,. cov.:r
(6) '\culnl switch
(7) Clutdll<v<r
(8) Dutl teal
( 9) Clutch baD re:tain.er
(tO) Clut<b 1<'-.. "'"'"I
•

•
(II) Clutch odj.,ling cam
(12) Clut•h lifter odjuSiing screw
(13) Left crankcase rear cover
( 14) Sturllf11! motor cable
(IS) Starling motor assy.
(16) Starting <-proclcel
(17) Stalor
( 18) Starting clutdl outer
(19) Stutirw clutdl side plate
(20) A.C. 'c.ncrator rotor
(21) A C leoerator *"'Y· Ull
(22) Rotor xtllng boll I <21)
(23) Ccncntot COYer p1fcet
(24) Genetltorcovet
(15)
(ZJ)

•
Disassembly
I. Remove the gear change pedal.
2. Remove the lefl crankcMe rear cover .

• Pia. 4-41 (1) Clutch lever (2) Clutch cable end

•
3. Remove the A.C. generator connector and disconnccl the
lead from the neutral switch.
• It is advisable to remove the carburetor before removing the
connector.
4. Remove the left crankcase cover.
S Remove the three bolts (S) and remove the A.C. generator

•
~tator from the left crankca<e cover.

Pig. 4-42 ( 1) Ldt crunkc11'c CU\'Cr (3) Neutral llwitch lc.ad

(2) St.ator (4) Generator cablt'
46 IV J::NCINE

6. Remove the A.C. generator rotor by removing tlle rotor

•
setting bolt and screwing ill tlle rotor puller (Tool No.
07933 2160000)

Fitt. 4-43 (I) Rotor seniog bolt

(2) Rotor puller
•
7. Remo,·e tlle starting sprocket setting plate and remove the
starting sprocket. starting motor sprocket and starting chain
togetller. •
'

•
.Pig. 4-44 (1) Starting rnolor llpf01.1k1.1l
(2) Starting chain
(3) Starting ~procket

8. Disconnect the ~tarting motor cable from the starting

motor. Remove the tightening screws and give a tap to the
starting motor to remove it from the crankcase.

Inspection
r~a. 4 - 45 (1) S<arting motor

•
•
I. Check the roller. roller cap and clutch outer of the starting
clutch (over·runnlng clutch) for damage or abnormal wear.
2. Check the roller and spring for proper movement.
3. For the startmg motor. refer to the chapter "llLECTRICAL
SYSTEM" on page 103.

Fig. 4 - 46 (I) St:uting dukh outer

(2) Roller
(3) Roller cap
(4) Spliog
•
 IV. ENGINE 47
Assembly

•
To llSSmlble. reverse the dtsuxmbly procedures paying auen·
lion to the rollowing:
I. Apply a thin coat or oil to the starting motor 0-ring and
install the motor to the crankcase.
2. Connect the cable to the starling motor .

• t'lf. 4-17 (I) O.rirc

(2) Scartina motor

• 3. Install the A.C. generator rotor.

Make sure that the starting clutch roller and spring move
properly and that the crankshaft woodruff key is not
missing. Fit the woodrurr key into the keyway in the ro tor
and push the rotor into position while rotating it.
• With the rotor held, tighten it to the specified torque.
Specified tightening torque.
3.0-3.5 kg-m (2 1.7-25.3 lbs-rt)

• S. RIGHT CRANKCASE COVER AND CLUTCH

(1)

I
Flf.4-19 1
I
• C1) Riehl cnnk.case co"er
(2) Rcht cnnkcatc ~c• pdttl
t)) Oollenl 1!"113•
t4) Clutclt Sj)ring
(5) (.1ucch pres:sure plate
( 6 ) Uuh.:h frlction disc
( 7) (Jutch plate B

•
( 8 ) Stopper ring
( 9) Clut..:h plate A
( 10) Clutch lil'tcr joint piece
(II) 25 mm snap ring
(J 2) Clutch center
C131 Clutch outer
( 14) Out,·h hfler rod

• <I> (U) (13) !14)

48 IV. ENGINt:

OisaSMmbly

•
I. Drain the engme.
2. Remove the right exhaust mufner. (On CB type only)
3. Remove the right fool peg.
4. Remove the kick starter pedal.
5. Remove the 6 mm screws and remove the right crankca•e
cover.
Place an oll pan in position to collect oil.

Ffl. 4 -SO (I) Ri&llt foot reJ

(2) l<ic:-k starttt pedal
(3) Right crankcaw tOYer
•
6. Remove the bolts (2) and remove the clutch springs and
clutch pressure plate. Then the clu tch friction discs and
clutch plates B can be removed. •
1'1&. 4- Sl (I) Clutch pressure ploto

7. Remove the clutch lifter joint piece and 25 mm external

•n•p ring. Then the clutch center C3n be removed.
•

8. Remove the clutch outer after removing the oil lilter rotor.
(Sec page 50)
f'l- 4 -52 ( 1) 25 mm t\.ttmal t.nap ,.,.
(2) t-lutch ttnler
•
•
rta. 4 53 (I) Clutch outer
•
 IV. ENC I'IE

9. Remove the stop ring and clutch plate A from the clutch
center .

• lrupection
Refer to service data on page 112.
l. Measure the friction disc thickness.
2. Check the clutch plates for face runout.
3. Measure the clutch spring free length. Also check the spring

•
installed load .

FiB- 4-54 (I) Outcb plate A

(2) Clutch center
(3) Stop riJ11

• A.sembly
To assemble, reverse the dlllllsscmbly procedures paying atten-
tion to the following:
1. Install the clutch plate A to the clutch center and secure
with the stop ring.
• Face the chamfered side of the clutch plate outside.

•
Pi$.4-SS (1) Clut<'il plato A
(2) Clutch center
(3) Stop rl"'l

2. Install the clutch center to the clutch outer and install the
eliJtt friction discs and seven plates 8 alternatively.
3. Install the clutch a3Sembly to the main slulft and secure
with the 25 mm external snap ring.

• 4. Make sure that the clutch lifter joint piece is not missing.
Install the clutch pressure plate and clutch springs and
Fig. 4- 56 (I) Out•h plot< B
(2) Fncnon dox

• lighten with the 6 mm bolts .

5. To install the oil filter rotor, sec page 5 J.
6. Adjust the clutch. {See page 22.)

• Fi$. 4-57 (I) Clutch llftct joint piece

(2) Chtlch pre$$Ure pt.te
so IV. ENGINE

6. OIL PUMP AND OIL FILTER ROTOR

(1)(2)

I •
I'll- 4 58 (I) 4~ mm 1ntemal<n3p riJ1&
(2) 011 rdt•• cap
(3) 41 '2 O·nnc
(4) 16 mm lock nut
($) 16 mm lock 'O'aJhn
"'>Jhe'
( 6) 011 ftllct lock
( 7 ) OU niter rolor
•
•
18) l'rlnWY clriYe~u
( 9 l Otllille< ocr«n
(10) Oil pump IU)I.
(II) 011 pump lOt line plate
(Ill 011 pump drh'O&Cir
(13) Oil pump dde eover
(14) 01l pump ~·er psket
(IS) Oil pump inner rotor
(16) Oil pump oul<r rotor
(17) on pump body
(18) on pump idle,••,
(19) Oil pump ldleahaft

Disassembly
l. Remove the right crankcase cover.
2. Remove the oU pump idle gear by lifting the idle shaft.
•

3. Remove the bolt> (2) and (.l) and remove the oil filter
FC. 4-59 (I) Oil pump >dle ohaft
(2) Oil pump idle ~·

•
•
screen

Fig. 4 - 60 (I) Oil filter screen

(2) Doll
(3) Roll
•
 IV. I::NGINE

•
• Pic-4-61 (t)Odpump......,bly
(2) Boll

• S. Remove the screws (2) and disassemble the oil pump

assembly.
CAUTION:
Do not disassemble the oil pump assembly unless necessary.

fia. 4~2 (I) Oil pump body

• 6. Remove the 45 mm snap ring and remove the oil filter cap.
To remove the mter c•p, screw a 6 mm screw or bolt In as
shown at right and pull it

• 7. Straighten the lock~ng lugs of the 16 mm lock washer and

remove the 16 mm lock nut '"ing the 16 mm lock nut
Fig. 4- 63 (I ) 45 mm <nap,.,.
fil•••
( 2)0.1 cap

•
wrench (Tool No. 07916 2830000). Then the oU niter
rotor and primary drive gear can be removed .

• Fig. 4-64 (I) IIi mm lock nul wrench

52 IV. ENGINE

Inspection

•
Refer to service data on page 112.
1. Check the filter screen for contamination or brcaktge.
2. Check the inside surface of the oil Oller rotor for
contamlnation.
3. Measure the oU pump inner-to-outer mtor clearance and the
side clearance.

Pil- 4-65 (t) Prinwy drtveaeu

•
Assembly
To assemble, reverse the dt.assembly procedures paymg atten·
tion to the following:
I. Install the primary dnve gear 110 that the larger chamfered
side faces toward the crankshaft.
(I)

•
2. Install the lock washer with the >ide marked "OUTSIDE"
facing front.
3. Install the lock nut so that the larger cha111fcred side toward
the oil mter.

(3) ( )

Pig. 4-66 (I) Oil filt<-rrotor (3) 16 mm lock washer

•
(2} Lock washer (4) wok nut

4. Tighten lhe lock nut using the lock nut wrench and bend
the locking lugs of the lock washer securely.
Specified Ughtening torque :
4.5-S.S kg·m (32.6- 39.7 lbs-ft)
S. Install the O·ring when installing the oil filter cap. Secure
the cap with lhe snap ring.

6. Install the two O·nngs when mstalling lhc oil pump.

1"'1- 4~7 (I) L<>ck nut
(2) t6mmtoc:twiUber
()) Od mter a.p
(4)(klll&

•
•
Pig. 4-68 (I) ()-ring
•
 IV. ENG INE 53
7 Install the filter tcreen to the oil filter screen and install tbe
assembly to the crnnkcajC!

• CAl1TJON:
Do not forget to install the O·ring .

• <3>
Fi&- 4~9 (I) Oil mrer scrun
(2) O.riJw
(3) Fllltr JCr•en

• 7. KICK STARTER AND LOWER CRANKCASE

Fw. 4- 7o
( J ) OJJ $Cpatator setting har
r--------------------------------------------------------,
( 2 ) Oll<eparator
( 3) 18mm wmer
( 4) 18mm snap rina
I S ) 1( ide <torttt sprint:
16 ) t(,.;t ........ tpindle
( 7 ) K ict starter p mion
( 8 ) lOmm 1hrus1 washer
( 9 ) S.uing spring
( 10) Kkk starter ratchet
( 11) lS mm thrust wuher
( 12) Rotcher spring
( 13) Raiche< guide plate

•
( 14) nuust washer '
(IS) 12mm >11ap ring
(16) Gur shift spindle
0 7) Ge-ar shift return sprif\1
(18) Tcn,;ioMt 9!ltill!, bolt
119) 011 - boll
(20) Ttn:wouer ouler ~ri,_ (11)
(21) Tcnsaoncr inner sprln&
(22) Tenstoncr pu'lh b;u
(23) LoW<r crankcasc
(24) 14' 2h 7 oil seal
(2S) Orain bolt

•
• DISil&~bly

I. Remove the engine. (Sec pages 31-33)

2. Remove the left crankcase rear cover and left crankca<e
CO\'Cr,
3. Remove tbe right erankc:a<e <'<lvcr.

•
4 Remove the upper crankca.e tightening bolt .

Pta. 4-71 (l) Upper crankcoS< ri&htcning boll

54 IV. F.NGINE

S. Remove the crankcase tightening bolts.

•
- •
I'IJ. 4-72

6. Remove the lower crankcase by lifting it.

The crankcase can be removed without any Jdgn of binding
by moving the change arm of the gearshift spindle as shown
at right.
Completely remove sealmg 83<Dt from the crankcase.
7. Remove the gearshift spindle.
•
Pia. 4-73 (1) Lower crankc1sc

•
(2) Otange arm

8. Remo'-e the 18 mm washer and snap ring and remove the

kick <tarter <pring.
Perfonn this job after r<moving the right crankcase.

9. Remove the 12 mm external snap ring using the snap ring

pliers and the ratchet guide plate, kick starter ratchet and
l'ig. 4 - 74 (I) 18mm >nap ring
(2) K1ck dattcr spring

•
•
kick starter pinion will be remoYed in this order. Remove
the kick ~tarter spmdlc from the lower crankc~se

Fig. 4- 7S (I) Snap ring plim

12) 12 men external ~n:'lp ring
(3) Rat..·hct guide plate
•
{4) Kick starter ~md l c
 JV. ENGINE 55
10. Remove lhe oil separator setting bar and the oD separaton .

•
• Fw. 4-76 (I) on oeponton
(2) Ool oepantor tettlnc bot

• II. Loosen the tensioner selling bolt and remove the cam chain
tensloner push bar and springs.
12. Remove the oil filter and oll pump. (See page 50.)

ln.<pection
I. Check the mating surface of the crankcase for scores or
scratches.
2. Check the kick staner spindle to kick staner pinion clear·
ance.

•
Fig. 4-77 (I) Tendone,.ettlng bolt
(2) Lock nuc
(3) 011 check boil

AIIOfmbly
To a""mble, reverse the disassembly procedures paying allen·
liOn to the following:
I. first tighten the cam chain tensioner selling bolt With the
tenJioner push bar pushed and the mark fac[Jig a• mown '"
Fig. 4-78.
After assembling the engine, adjust the cam chain. (Sec page
23)

• 2. Assemble the kick starter in the numerical order in the l'ig.

4-79 .
Fil:. 4-78 (I) Cam dutn tenQcmer pu.~ bu
(l) Mark
(3) Ten~t)ntr ~tllfll bolt
(4) ln<k ""'

•
•
56 IV. eNGINE
3. Install the kick starter ratchet so that the kick starter

•
spindle Is poslUonod as shown in Fig. 4-80.

Pig. 4-80 (1) Kick starter ratchet

(2) Kick !ltarttr s.plndle
•
4 . Check the kick starter for proper operation.

•
Pia. 4- 81

S Apply a coat of new ~aling agent to the lower crankca~.

Install the crankcase in such a manner that the gearshift ann
comes to the shift drum stopper installation position.
CAU110N:
•
When applylna new su1ing agent, take care not to allow
excm ll&'<nt to drip on the crankshaft, mainshaft and
countershaft bnfin&s or inside the ctallkease.

6. Install the two starting motor cable dampers as »>lOwn.

using the bolt< of the following length.
Fi&. 4 -8 2 (I) Geauhift am1

•
•
(1)8x ISOlJBSbolt (2)Rx liS CBS bolt
( .l ) R x 971.JBS bolt (4) 6 x 55 bolt
(5) 6 x 100 UBS bolt (6) 8 x 50 UBS bolt
(7) 6 X 35 boll (8) 6 X 145 boll

•
.......
 IV. HNGINE 51
8. GEARSHIFT MECIIANIS~t

• f .. 4- 34
( l ) Shift drum stopper
( 2 ) Shift drum $topper
IPrina
( 3 ) Shift fork guide shaft

~ ~/"
( 4 ) Gear shift fork A
( S) Shift drum guide screw

•
( 6 ) 12 nun lock washer 0
( 1) Drum stopper cam plate
®-._(I)
•
( 8 ) Ceanhift drum
( 9) Ceanhlft fork 8
(I OJ Ceanhlft spiDdle
(II) Ceudul\ return spfirw
o (I )

• ~~(OJ
0

(II)

• O~bly
I. Remove the engine.
2. Straighten the locking lug of the 12 mm lock wasller and
remove the shift drum guide 5erew. Then remove the
neutral stop spring and 110 steel ball.

• J. Remove the lower crankcase.

Before performing this job, remove the oil filter rotor (page
FC. 4- 85 (I) 12 mm lock w""'er
(2) Shift drum pide JCrtw

•
SO) and clutch assembly (page 47) .
4. Remove the transmi«lon mulnshaft and countershaft .

• Flg. 4 -86 (I) Mainshaft

(2) Countel1\l>afl
58 IV. F.NGINE
S. Remove the shift drum stopper and shift drum stopper
spnng and remove the shift fork guide shaft and two
gearshift forks A.

•
Fig. 4-87
(2) Shlft drum •tOpper sprlo>&
•
•
(3) Shift fork guide ihaft
(4) Georshirt forlc A
6. Remove the guide pin clip and pull out the guide pin. Then
remove the ,carshlft drum from the upper crankcase and
gmshlft fork.
Inspection
Refer to service data on page 112.
1. Meawre the gearshift fork fmger thiclcness.
2. Measure the shift fork guide shaft OD (outside diameter).
3. Measure the gearshift fork 1D (inside diameter).
4. Measure the gearshift drum 00.
5. Check the clearance between the lug of the gearshift fork
and the groove In the gearshift drum.

•
Pig. 4-88 (I) Guide pin clip
(2) Guide pin

A<Sembly
To assemble, revene the disassembly procedure paying auentlon
to the following:
1. Set the drum to the gearshift fork Bas shown in Fig. 4 89.

2. With the gearshift drum in the neutral position, install

the# 10 steel ball and neutral stopper spring. Tighten the
Pig. 4 - 89 (I) C.ear<hift drum
(2) Gear51tirt fork B
•
guide screw and bend the locking lug of the lock wuher.

•
l'ig. 4-90 (1) #10 steel ball
(2) Neutral stopper \'Pring
(3) Shift drum guide llcrcw
•
(4) 12 mm lock wa~cr
 IV. ENGINE 59
3. With the gearshift d rum in the neu!tal position, iluert the
suide pin into position and install the suide pin clip as

• shown in Fig. 4 9 1.
• The gearshift drum in the neutral po sition can be judged by
the state or
the points of the neutral !witch.

• PI&. 4 - 91 (I) lnot•Hatlon dlteclion of guide pin cUp

(2) N~ulnl po$ilion

• 4. Install the geam.ift forks A (the some parts) as shown a t

right and install the shift fork suide llhaft.

•
Fig. 4 - 92 (I) Oc., .hlft fork A
(2) C.auhift fork gu ide shaft

S. Assemble the malnshaft and oountershaft as shown in Fig.

4-93.
Replace any deformed snap ring wtth a new one.
Apply a coot of oil to the rotating and sliding surfaces .

•
• m?r (22)(23)

• Fe. •-93 ( I ) 20 mm noodle beanng ( 9) 2$ mm Joli wa11.heJ (11) Transroj,(k\n mam~.tfl

( 2 ) 20 mm thnu& washer ti012S nun thruSt""""'' U (18) ~1-Stla J<al
(19) M-Jnl and 4th cw
tl
c• ,c .sm.
)C l<t . ..,
1eu
{ 5) 2S mm 'nap ring
(II)(' -4th g<u
(Ill c 6th'""'
( 1J) 1 ranlJniss.ion countchhaft
(20) M-6th. I""'
(21) ~I 2nd 1•••
( 6) 2S mn' thru(t washer (14) 52 mm b~arin~ set Hill (22) 20 mm needle bcaung
( 7) (' )r~. gear ( IS) 34x52, l 3.Sxl5.5 nil scul (23) Rx34xR oll scot
( 8) 2tl mm ~plinOO bushing Cl(>) ~205 liS batt bearing
60 tV. ENGINE
6. Install the malnmafl.
Make wre that the bearing set ling and dowel pin are not
missiJ1&. Securely llt the dowel pin into the hole in the 20
mm needle bearing while rotating.

•
Fla. 4 - 94 (1) Dowel pin
(2) Set ring
•
7. Install the countershafl.
Similarly u In the mainsb.aft, make SUie that the bearina set
ring and dowel ptn are not mlssin8 and install them Into
pOSitions. Pl'operly llt the lug of the oil seal into the hole in
the upper crankcase.
•

•
FiB. 4 - 95 (I) Dowel pin
(2) Set riJ1i
(3) Lug of oil t<:&l

8. After inSialting the mairuhaft and countershaft, check the

gear backlash and the dogs of the gears for proper contact
with the transmission in the neutial position.
Apply a coat of oil to the tnmsmission and crulcmaft.
9. Apply a coat of new ocaling agent to tho lower crankcase
and install the crankcase. (See page 56.)
CAtTTION:
Do not allow excess agent to drip on oth<r parts.

tO. Install the shift drum stopper.

After inmlllng. check the stopper for proper movement .
•
•
Fig. 4- 97 (I) Shift drum "opper
•
 IV. ENGINE 61
9. CRANKSHAFT AND UPPER CRANKCASE

• Fii. 4-98
(I) Cylmder stud boll 8
(2) CyLinder stud boll A
(1) 6 x 80 Oange boll
(4) Uppet aankca..c
(S) Cord PIOlector
o(iL.r" (2)1_
•
(6) Crankshaft assembly / (2)

~ U' ~3)
e
• El

• Oi'"''""mbly

•
I. Remove the engine.
2. Remove the cylinder nnd pistons. (See page 37.)
1. Remove lllc left crankcase and remove the starlin~ rnolor
and related parts. (See page 45.)
4 Remove the righl crankcase and remove the oil filter rotor
and primary drive gear. (See page SO.)

•
S. Remove the lower crankcase. (See page 53.)
1> Remove the cam chain ltnsiOner ann .

Fig. 4-99 ( 1) Cam ~.:haln tensioncr arm

62 IV. ENG INE

7. Remove the cranl<shafl and cam chain together.

8. Remove the transmission and gea.Wft forks.
Remove the maimhaft with the clutch assembly.

•
PW. 4- 100 (l)Cn,.kshaft
(2) Cam chain
•
Inspection
Refer to service data on page I 13.
I. Check the crankshaft runout. Measurements should be
taken at several pomu and by rotating the shaft in V blocka
at E and F as shown.
•
Standard value
C, 0, G and H . . . . . . . . . . . . . . . . . . . 0. I mm (0.004 ln.)
A and J ............... ......... O.OS mm (0.002 ln.)
Crankthrow (on machined face) ...... 0.02 mm (0.008 ln.)
2. Check the nial and radial clearances of the connecting rod
big end.
3. Measure the piston pin hole diameter.

•
4. Check tho crankshaft bearings for excessive looseness or Fig. 4- 101
abnormal wear.

As9tmbly
To assemble, reverse the disassembly procedures paying otten·
lion to the following·
CAUTION :
Carefully handle the cnnkshatt.

1. Properly fit the dowels of the crankshaft bearings into the

holes in the crankcase.
First set the cam chain in position.
2. Apply a coot of oil to the rotating •urface< of the
crankshaft.

H&- 4- 102 (I) Dowel pin

•
•
•
 IV. ENGINE 63
10. CARBURETOR

• Fi~-4-103
( 1 ) CQiburctor a~y.
( 2 ) Link set
( 3 ) Jet needle ""t
( 4 ) Vacuum piston set
(5) Scn:w!letA
( 6) Slow jet

•
( 7 ) Needle jet holdet
( 8 ) Main JOt
( 9 ) l'loat valve set
110) Mam nottle
(IJ) Primary main,tet
(12) Connector joinl tel
(13) Float"''
(t4) float cbambcr act

•
(IS) Screw,., 8

• Removal

•
To remove the carburetor, rcrer to the ''Engine removal" item
(page 32.)
1. Disconnect the throltle cnhles rrom the carburetor stay .

• Fig. 4-104 (t) Carbur.tor stay

64 IV. FNCINE
2. St111ighten the locking lugs of the lock washer and loosen
the bolt (2).
Then remove the connector joint from the left carburetor.
3. Remo~ the four ierews and remove the carburetor U·
sembly from the stay plate.
•
PW. 4-105 (J) Connector joint
(2) Bolt
•
lnstallarion
To install, reverse !he removal procedutes.
I . Connect the right and left carburelors by the connector
joint. Tlahten the lock nut and bend !he loc:ldng lugs of the
~-,··.\.
~- 1· .,.
... ~ . ~.. . -.
··.
,
-~
'
/ '/
- .•
)t'
~--
.
·.. . •
~- ·.· _:~ -.· '· :' ~-:..._ ~:.;: ~ ·~
lock wuher securely. .:;t":.;o-/ ' / \ . :·.· ' .
·-·,.~--··
...... -_ . -, ,'tf/1: .. ' . "..-_, "' ..

-A~
. . -~-:-.t__-:· 0;'/-~ ;~
..·· •.

/
·:·.··:~:~:-
/
·. \. ' <· •.....,.. "· ,• '
' ..

.:.. . / /-' ~
•'·-~--"'"""-"":--~--··
/!., . ,.'
... .• · '·
:(> -:
~
.f' - .: :ao.'-':-:~ .• .... .·.· '-·" ·! .

•
Fia. 4- 106 (I) Connector joinr

2. Set the throttle lever to the stop screw (I) as shown.

3. lnslall the coil spring in the position shown and inslall Che
carburetor assembly to the stay plate.

4. Connect the throttle cables with the tluottle fully closed.

Screw the "closed" side cable in the lower pan of the
F ig. 4-107 (I) Stop <Crew
(2) Spring
•
throttle lever. Insert !he "open" side cable into the upper
part of the lever, adjust the length and lock with the lock
nut.
•
fig. 4-108 (1) "CioM:d" <ido cdhlo
(2) "Open" side c:\hlo
(3) Throttle lelf~r
(4) Lo"k nul
(S) AdjlJ~ting nut
•
 IV. ENGINE 6S
Disasttmbly
I. Remove the four screws (I) and remove the top. Then

• r<move the coil spring and vacuum piston .

• Fig. 4- 109 (I) Screw• (2) Top

• 2. Remove the needle jet screw and then the jet needle from
the vacuum piston.
''(})
' I ...
I -·

T
~
I
(J)
(2)
(J)

•
Fi$. 4-t10 (I) Needle jetScrew
(2) Jet newlo
(3) Vacuum plslon

3. Remove the screws (4) and remove the noot ehomber body.
4. Pull out the arm pin and remove the Ooat.
• The noat valve is removed together with the noat. Take
care not to drop it .

• S. Remove the primary main jet and main nozzle. Remove the
secondary main jet,
Pig. 4- Ill ( I) Float arm pin
(2) Float
(3) F'lotU chamber bvdy
(4) Screws

•
Remove the needle jet holder and jet needle .

• l'ig. 4 - 112 (I) Needle Jet holde•

(2) Primar)' main jc1
(3} Secondary m~ln jcr
66 IV. ENG!NF.

6. Remove the screw (I) and remove the valve seat plate and

•
vaJve seat.

f'll- 4-113 (l)S«<w

(2) Valve ,..t plate
•
•
(J)Valveseat

7. Remove the clips (I) and (2). Straighten me locking lug1 of

tlle lock washer and remove the holdtng boll. Remove tlle
Uuottle lever together with the adjusting holder.

•
FiJI. 4-114 ( l), (2) CUps
(3) Holding bolt
(4)Throtlle lever
(5) Adjusting holder
Inspection
I. Blow the jets to check for clogging.
2. Check the float valve for proper operation.
3. Che.:k Ute sliding surface of the vacuum piston for scores or
scratches.

'
4. Check the J<t needle for wear, scores, or scratches.
(1)
I
- (5)
Carburetor Setting Tobie

Setting mark

Primary
I-
CB250

7448
CB360

7458

168
I CL360

7478

-
Fie- 4-1 IS (I) Primary nulnjet
(2)Siow jet
(3) Needle jet bolder
(4) Hoat nM:
(S) Valve ,..t

•
•
Main jet
Secondary • 95
L 1 68

Primary 1150
Air jet --
Secondary # 50

3S

•
Slow jet ~

Slow air jet • 85

--
Float height 18.5 mm (0.75 in.)
 IV. ENGINE 67
Assembly
To assemble. reverse the disassembly procedures paying atten·

• tion to the following:

I. Install the float valve after anaching the special ring in
position.
2. Take care not to install the valve seat set plate upside down .

• Fig. 4- 116 (I) Special rln&

• 3. Use a longer screw for the left carburetor float chamber

body tightening screw (2).

F ig. 4- 117 (I) Float chamber body

•
(2) Screw (lnn&cr)

4. C'orrectly set the vacuum piston into poslllon and then

install the top.

• float level adjustme~

Fig. 4-118 (I) ~!.!chin; point

•
Hold the carburetor with its main bore in a vertical position, so
the float ann tang will just close the float valve, without
comprUS~ng the spring loaded plunger in the end of the valve.
Measure float height with a float level gauge.
Float he1ght (distance between the carburetor body and the
opposite edge of the float) should be IS.S mm (0.73 in.) when
the float valve JUst closes.

•
If adJUSUnent is needed, carefully bend the float am1 tang
toward or away from the float valve until the specified float
he1ght 1S obtained. Replace any damaged or leaking float.

fig. 4-tt9 (l)Floatlevelgauae

(2) 1-loat
68
-------------------V. FRAME---------------------
1. FRONT WH EEL AND FRONT BRAKE
(DISC BRAKE)
Fi1.5- 1
( I l tronr .,heelule
( 2) 8 '90 boll
( 3 ) Speedomerer &011 bo•
( 4 ) Cear bo'4 retainer cover
( S ) Gear bo~ reulncr
•
•
<6 l Relainer 0-tlnc
( 7 )Tire llap
( 8) Wheel rube
( 9 ) I'ronI wheel lire
( 10) r.ront wheel rim
(II) 6302U rodlol ball b.,.rlna
(12) Front 11:xle dlstonce collar
(13) f'ront wheel hub

•
(14) Front wheel be.arlna retainer
(15) Dull ...1
(16) Fronr •heel olde collar
(17) Front .,;1\etl a'<le nut
(18) fronl broke due,

0 •

Oisassem bly
I. Place a stand under the engine to raise the front wheel off
the ground.
•
2. Dlsconnecr the speedometer cable.
3. Remove rhe nuts (3) and remove the front wheel from the
front forks.
CAUTION:
Do not operate the front brake lever with the front wheel
removed; otherwise, the pads may rome out.

4. With the axle nul held in a vice, turn the front wheel axle
and remove the axle nut.
FiiJ. 5-2 (I) Speedomeler cable
(2) Axle holder

•
•
S. Pull ou l the front wheel axle and the speedometer gear box
can be removed.

Fig. 5 - 3 (I) Fronl wheel axle

{2) Spect!ometer ge!U hu:<
•
 V. FRAME 69
6. Remove the 8 mm UBS nuts and remove the brake~disc~·:_---~~jijp;:~iiiiiifiit~iiiig_,
7. Pull out tile bolts (3) and the gear box retainer and cover

•
can be removed .

• Fie- S-4 (I) Brau disc

(2) 8 mm UBS nuts

•
(3) Bolts

8. Remove the dust seal and remove the bearing retainer using
the bearing retainer wrench (Tool No. 07910 3230100).
9. Remove the ball bearings.
CAIJTION:
Do not perform the jobs In the steps R and 9 above unless
necessary.

s-s (I) DeariJl& retainer wr•nch

•
Pig.

lnspec:tion
Refer 10 service data on page 113.
I. Check the front wheel axle for bend.
2. Check the ball bearings for looseness.
3. Check the wheel rim for runout or damage . i
4. Check the spokes for looseness or bend.
5. Cheek to see if metal pieces or stones are borten in the tire
tread pattern or wall. Also check the tile for scores,
scratches or wear.
6. Check the tire inflation pressure.
Also check for air leakage from the valve.

•
Specification: 1.8 kg/em2 (26 psi)
Fig. S-6 C"hedr:ir« wheel rim for runoul

Assembly

•
To asstmble. reverse the dl<assembly procedures paying atten-
tion 10 the following:
I. ln<1311 the ball bearings.
Fill the cavory tn ea<:h ball bearing and ilntde the wheel hub
with grea>C.
Install the bearings uslnj!. the bearing driver alwchment
(l'ool No. 07945-3330100) ond driver hnndle (Tool No.

•
07949- 611 0000), taking <are not to allow the spacer collar
to inclme

Fig. S-7 (I) Be11rlng dtt..·er attachment

t2) OJlver hundle
70 V. FRAME
-2. After
- -tightemng
--- - ---- - - -
the bearing retainer, stake it at two points
--=--==-----------
usin& a punch.

•
Fi3. S-8 (I) Dearing retainer
(2) St.3lce these points with a punch
•
3. Make sure that the O·ring is attached to the wheel hub.
lns~ll the gear box retainer and cover to the wheel hub
using the 8 mm bolts and install the brake disc to l.h e
opposite side
NOTI! :
•
The brake disc tiahtenlna nuts are 8 mm UBS nuts. & sure
to use the aenuine Honda parts. Tighten them to the
specified torque.

Fig. S-9 (I) O·ring

•
(2) Gear box retainer

4. Install the 1peedometer gear box to the front wheel. ln~ert

the axle nut.
NOTE:
Apply a coat of grease to the speedometer gear box.

5. Tighten the front axle holder nuts, beginning with tltc front
one on the disc side. as shown in Fig. 5- 11.
Specified liglucning torque:
2.7- 3.3kg·m (19.5-23.8 lbs-fl)
Fi3. 5 - 10 (1) Gear box retain~r
(2) Speedometer gear bo .~C

•
NOTES :
l. Secure the axle holden to the front forks tightly at the
front.
2. U~~t R mm UBS uuts. Tighten them to the specified
torqut.
Gap
L . . . Front
•
•
6. Adjust the frunt brake caliper. (See page 25)

l'iiJ. S-11 (I) Axle holden

 V. FRAME 71
FOJ.S-12
OJ (2) <3l (6) (J) (16)
( I ) rront .,h..l Side <Oilu

•
( 2) 26. 4h 7 ·~'"'
( 3) 6302 radiAl boll beanDs
( 4 ) front axle diJtance coUat
( 5 ) Front •heeloxle
( 6 ) f-ront .. heel tube <W cm em
( 1 ) .. ront wheel bre
( 8 ) l'ronttue O..p

•
( 9 ) Front wh«l rim
(10) rront wheel hub
( II ) 6302 rod lal ball beating
!12) 54667 oll<e•l
( 13) Speo<lometer gear
( 14) Spt«<ometer aear washer
(15) Wheel balancer
!51•· 1Oar. 15v, 20gr)
(16) Prone brwke CIJTI A and 8

•
(17) Front brake llloe<
(18) Front brokelhoe springs
(19) 2.0' 15 colter pln
(20) front andlor pin wa5her
(21) hont bnlte pancl
(22) front .. bed axle-..
(23) Brake cam duJt ...J
(24) 14 mm plain wa•l><r
(25) BrakelndiClltor platc
(26) 8 • 28 boll (U.B.S.)
(27) front brake: stopper ann
(28) rront brake ar-m reaurn (19) (22)
tpnna
(29) 6 X 36 boll
(30) I ront bnakc 11.nn A (34) Front br.tkt arm A
(3 1) 6 mm wuhcr (35) 6 mm wa<thcr
(32) 6 mm mll (36) 6 X 36 bolt
(33) l.O x 18 cotter pin

• Disn<sembly
I. Place a suitable blo'ck under the engine to raise the front
wheel off the ground.
2. Remo••e the 8 mm bolt (U.B-~) securing the front brake
stopper arm m pl.« .

• 3. Back off the 5 mm screw: pull off the tachometer cable.

Otscnnnect the front brake cable from between the br:tke
Fill' 5-13 (I) 8 mm bolt (U.B.S.)
(2) Front brak~ uoppe.r llNtl

•
am1 and br:tke panel.

• Fis- S-14 (0 $ mm ~rew

(2) TadtOil\eter cable
(3) rrunt hrakc: cubic:
72 V. FRAME
----------------
4. Remo,·e the two 8 mm nuts from the right and left front -~~~~~~~---
forks. Remove the axle holders. T~ front wheel can now
be taken out from the motorcycle.

•
Fig. S- IS ( l) 8 mm nuts
(2) Axle holder
•
S. Remove the front axle sleeve and withdraw the front wheel
axle. Remove the front brake panel from the front wheel.
Inspection
Refer to the semce data on page I 13.
•
1. InspectiOn items on page 69.
2. Measure the in•lde diameter of the front brake drum.
3. Measure the thickness of the front brake shoe.

Pig. 5-16 (1) Front axle l.leeve

•
(2) Pront wheel axle

Assembly
I. Install the front brake ilhoes to the brake cams. ln<tall the
front anchor pm washers. Secure them with cotter pins.

2. Install the front brake arms "A" and '·B", being careful that
the marks ah~11.
Fig. 5-17 (1) Anchor pin washef'
(2) Couer pins

•
•
Fi,s. 5 - 18 (I) Front brake arm A
t2 • Fronl l>rake a1 m R
(3) Mark~
•
 V. FRAME
3. lnmll the axle holders, lightening the front nul firs1. Refer
IO Fig. 5 19.

•
Specified tighlening torque: 2.7-3.3 kg-m (19.5-23.8
lbs-ft)

• F"IJ. S-19 (I) Front oxlo holder

(2) 8 mm nut

• 2. FRONT DISC BRAKE

Pia. 5 - 20
(I ) Muter cylinder assy.
(l)Bool
( 3) 18 mm mlcrnal snap riOI
( 4 ) PiJion xt
( S ) Primary cup
( 6 ) Oil cup cap
( 7 ) Dlaclu:un
( 8 ) Ma,ter cylinder hokler
( 9 l Oil bolt
(10) Prout broke hose B
(II) Front stop switch
(12) Thr..,.w•y joint

•
(13) l'ront brake hoae
(14) Jlronc brake. pipe
(IS) Caliper holder joint
061 C.ltp<r holder
(I 7) Caliper assy.
(18) Caliper 8
(19) Pad 8
(20) Pad A
(21) Pulon
(22) Pi•ton '~~Cal
(23) Caliper A
(24) Uleeder valve
(25) Brake di.sc
(26) Coliper holder pin
(27) Di~ cover

•
•
•
74 V. FRAME

RemOVlll ( 1)

•
I. !fuoonnect lhc front brake pipe from lhe capllper A.
Operate the brake lever and remove brake fluid.

FIJ. 5 - 21 (I) Master cylinder

•
2. Remove the oil bolt and bolts (3) and remove lhe master
cylinder assembly.
•

•
Pig. S-22 (I) Oil boll
(2) Master cylinder assembly
(3) Bolts

3. Remove the bolts (I), bolts (2) and adjusting bolt and
remove the cali!X'r assembly.

4. Remove the front emblem. Remove the bolt (I) and

di~connect the front stop switch lead. Remove lhe three·
Pw. 5-23 (!). (2) Bolts
(3) Adjusting bolt
•
way joint and disconnect the oil pipe.

•
Fi@. S-24 (1) Bolt
(2) r:'ront 'itop !>WhCh
(3)Thr<»way joint
(4) OJJ pipe
•
 V. fRAME 75
lnstaUotion
--------------- -----------------------~
To inStall, reverse the removal proceduns paying auenlion to 2. After inslalling the front disc brake, fill the master

• the following:
I. Connect the pipes as shown In Fig. S-25.

"II- 5- 25
cylinder with DOT 3 brake fluid and bleed it completely.
(See page 26.)

•
(I) Front brake bose R
(2) Od bolt
(3) Thr~''lY joint
(4) Stop ,.itch
(S) front blake hose A
(6)0dboU w&Jhu
(7) 'ThJeo.way joint holder

•
(8) Oil tube

• Oisawmbly
Coli per
I. Remove the caliper awmbly.
2. Remove the caliper Jetting bolts and the caliper 31$(!mbly
can be separated into the calipers A and B.
(When separating the assembly with it installed to the front
wheel, disconnect the oil pipe.)

• 3. PuU out the cottcr pin and detach the pad B from the
caliper B.
Pia. S-26 (I) Oil prpe
( 2) Cahpc:r tct llfll bolls
(3) Cahper A
(4) Cahper 0

• 4. Give a tap to the head of Ihe caliper A to detach the pad A.

• Fig. 5 27 (I) C31ip•r R

t2)Padll
(3} CoLter phl
76 V. PRAME
S. Remove the piston using compressed air.

•
Fla. 5- 28 (t) C.aliper A
(2) Pi<ton
•
Master ")'Iinder
I. Remove the master cylinder.
2. Remove the brake lever.
3. Remove the boot and remove the 18 mm internal snap ring
using the snap ring pliers (Tool No. 07914-3230000).
•
CAIJTION :
Take c - not to cbmqe the boot.

•
FiJ. 5-29 (IJ Snap ring pliers
(2) Snap ring

4. Remove the piston, check valve and primary cup.

Remove the primary cup by applying 2 to 3 kafcm' (28 to
43 pst') air pressure from the brake hose joint. The cup may
also be removed with a tool by which the check valve is not
scored or scratched.

'
I

)
I
'

Inspection
Pig. 5- JO (I) Primary cup

•
•
Refer to service data on page 113.
I. Check the pads for wear.
Each pad is marked with the red groove. If the pad wean
down to the groove, replace it.
2. Meuurc the caliper cylinder bore and piston OD. Check
them for wear or damage.

~~~. 5-Jl (I) Pad A

(2) P•d 1l
(J) Red groove
•
 V. FRAME 77
A~b·~~-----------------------------===========~~======~

•
Cahper
I. When auaching the p~ds, apply a coat of grease to the rear
sides. Use silicon sealing grease.
CAtlflONS:
I. Do not aUow grease to come in contact with the ditc
attaching surfaces of the pods.

•
2. Take care to prevent foreign materials, dust or dirt
from getting inside the calipers.

FIB- S-Jl (I) Callpct 8

(2) Pod B

•
(3) Apply.,.,,. to pari marked (X)

~hster cylinder

I. Apply a coat of brake fluid to the inside surfac:e of Ute

cylinder.
2. InstaU the check valve to the return spring and install them
In the cylinder.
CAUTION:
When installing the eheck valve and return "'ring in the
cylinder, make mre thot the valve is facing come~ and
that the spring is in comet position.
'
'-....i-..,

•
Fig. S-JJ (1) <-lleck valve

3. Apply a thin coat of brake fluid to the outside surface of

the primary cup.
lnstaU the primary cup takmg care not to allow du.u to
auaeh to it or not to damage it. Make sure that the cup is
not inclined or not reversed in the cylinder.
NOTE:
Wben the primary cup has heen disassembled, replace it
with a new one.

4. Install the 18 mm internal snap ring.

Turn the snap ring to check for proper fit.

• FIB- S-34 (I) Pnmary rup

•
•
78 V. FRAME
3. REAR WHEEL AND REAR BRAKE

II
(I) \~)
~fi~(4)
(2) (I) (I)
•
o•~
111(11) (21) •
(11)

~
•
(23)

Fie. 5 - 35 ( 1 ) Rear brake arm ( 9) Rear br~~oke ldloe :q>ring (17) Rear axle distance collar A (25) Rear wheel :tide collar
( 2) Brake indicBtor pl~te (10) Rear brake cam (18) Rear axle distance oolhu D (26) Rear wheel hub plua
( 3) 14 mm plain washer (II) Rea.r wheel tube (19) 6304U rndial baU bearing (27) Rear wheel damper
( 4 ) Brake cam duM .,r.al ( 12) Tiro nap (20) Du<l seal bushing

( S ) Rear wheel ulc
{ 6 ) Re01t broko !Hanel sklc collAr
( 7 ) Rear brake )Janel
( 8 ) Rear btake Ahoe
( 13) Rcarwhcol lirc
(14) Rew- wheel rim
(15) 6303U rodlal ball bearing
( 16) Re•r wheel hub
(21) Hc~ ring retainer
(22) Final driven sprocket
(23) 70 mm washer
(24) 69 mm snap ring
•
(28) Drh·c chain
(29) Drive ch•ln odju"cr
(30) Chain adjuMcr stopper

Disassembly
I. Remove the mufners. (CB type oruy)
2. Remove the rear brake rod and rear brake Slop am1 from
the brake panel.
3. Loosen the right and left chain 1djuster lock nuts 1111d chain
adjuster bolts. Pull oul the coner pin a.nd remove the axle
nut.

4. Pull out the re3I wheel axle. R<move the drive chain from
FiJ. S-36 (I) awn odjuste< boll
(2) Lock nut
(3) awn adjuster
(4) Axle nut
(S) Cot!« pon

•
•
the final driven sprockel. Remove the rtar wheel with the
brake panel.

Fig. 5 - 37
•
 V. FRAME
S. Remove the 69 mm snap ring and remove the final driven
<procket as ~town in Fig. 5-38.

•
NOTE:
The final clrkat sprocket and f'vcing bolt are mllde in one
piece•

• Pig. 5 -38(1) Wood block

(2) Final driven oprocket

• 6. When the btU bearings must be removed for replacement,

remove the bearing retainer using the bearing retainer
w~nch (Tool No.
bearings.
CAlTfiON:
07910-3290000) and ~move the

Do not remove the ball bearings unless neecss~~~y.

Pig. S-39 (1) Bearlng Jeta.lner wrt~nch

• Rear brake panel

I. Remove the brake shoes.
PuU the colter pin out of the anchor pin of the brake panel .
WhUe expanding the brake shoes by your hands, remove
them together with the shoe springs.
2. Remove the 6 mm bolt and remove the brake arm and
brake cam.

• Inspection
Refer to service data on page I 13.
Fig. 5- 40 (I) Cotter pin
(2) Rra~e shoe
(3) Bra~• shoe sprlna
(4) Bra~e com

• I Check the rear wheel axle for bend .

2. Check the baU bearings for Joo,.,ness.
3 Check the rear whecl rim for runout or damage.
4 Check the spokd for looseness. bend or breakage.
5. Check the fmal dnven sprocket for wear or damage.
6. Check the drive chain for wear, damage, elongation or
0 X

•
jarnnung.
7. ('heck the tire for scores, scratches or wear.
8. Check the tire inflation pressure.
AI!() check fur air leakage from the valve.
Specification: 2.0 kg/em (28 psi) f-'ig. S-41 Checking final t.Jriven ~ru~.:kc.l for wear
80 V. FRAME
9. Cited< the brake panel for scores, scratches or cracks.
10. Check the wheel hub, brake shoes and brake cam for wear.

•
II. Check the serrations of the brake ann and brake cam for
wear.
12. Check the rear wheel damper bushings for damage.

•
ASIImlbly
To usemble, reverse the disassembly procedures paying special
attentio n to the following:
CAUTION:
Pay special attention not to allow oil, grease, du•1 or djrt to get
•
inside the brake shoes end wheel hub.

I. Install the ball bearings.

FUI the cavity in each ball bearing and instde the wheel hub
with grease. Install the bearings using the race driver
attachment (Tool No. 07945 3330 100) and driver handle
(Tool No. 07949 6 110000), taking care not to allow the
space collars to incline. FIJI. 5- 42 (I) Dri""r handlo

•
(2) Race ddver atttt·hmcnt

2. Install and tighten the bearing retainer with the bearing

retainer wrench used at the time of removal. After
tightening, stake at four points as shown in Fig. S-43 using
a punch.

3. Install the fmal driven sprocket to the wheel hub squarely

at shown in Fig. 5-44.
P is. 5 ·4 3 ( I) Stake these poinu with a punch
(2) Rearing retaJnur

•
•
After installing. secure wtth a 70 mm washer and 69 nun
snop r~ng.
NOTE:
Usc UBS nuts for the I 0 nun nuts. Tighten them to the
specified torque.
Specified tightening torque:

•
6.0- 7.0 kg-m (43.4- SO.?Ib!i-ft.)

Pia. 5 44 (I) 69 mm m>p ring

(2) 10 mm lJHS nul
 V. FRAME 81
4. Install the brake cam with the punch mark inside. Apply a
coat of grease to the brake shoe attaching surfaces of the

•
anchor pin and cam, brake panel-i<H:am contact surface and
dust seal.
CAlm ON:
Do not allow &Rase to o.ttach to the bntl<e shoes llld the
in~ surface of the wheel hub .

• Fig. 5-45 (1) Face tho punch m11k: on brake cam tQward the
inside
(2) Cam-to·brake shoe cont•ct 'iurraccs

•
(3) Anchor pln•lO·brlk.e Ahoe contact surfaces
5. Set the brake panel to the wheel hub properly and Install
the drive chain on the final driven sprocket. Then Install the
rear wh~l to the rear fork with the wheel axle.
6. After assembling, adjust the drive chain and rear brake.

Fig. S-46 (1) Drive chain

• 4. STEERING HANDLEBAR

Fw. 5-47
( I ) Rlaht Jilt> rubbtr
( 2 ) Throttle Jrrp pope
( J ) llcodJraht/llrutaon switch
( 4 ) ltondk:b11 pope
( 5 ) ~ble holder
( 6) Upper holder
( 7 ) llorn/dimmcr <~witch
( 8 ) Ltrt arrp rubber
( 9) Muter <yllnder ""'Y.
(10) Throttle cable i\
( II) Throttle cable B

•
( 12) Or10kc ho,. B
(13)011bolt
( 14) Clutch <able

•
•
82 V. FRAME
Oisnotmbly
I Remove the bolts (2) and remove the master cylinder.
CAUTION:
Take care not to spill brake nuid.

2. Disconnect the clutch cable.

•
Pta. $--48 (!) Master cylinder
•
3. Separate the starter{ignilion switch into two parts. Dis·
connect the ends of the throttle cubic wires from the
throttle grip pipe and the throttle cables A and B from the
starter{ignilion switch.
•
Fia. S- 49 (1) Throttleg!lp pipe

•
(2) Headligha/lgnlllon swllelt
(3) Tluoa!le c•bae A
(4) Throttle cable B
4 . Remove the fuel tanlc. Disconnect the hom/turn signal
dunmor swatch, headlight/ignition swatch and clutch lever
switeh leads on the frame from the wire harness.
S. Remove the handlebar upper holders and remove the
handlebar pipe .
6. Pull the horn{ turn signal dimmer switch ond headlight{igni-
tlon switch out of the handlebar pipe.
Attach a w~re to the end of ench wire and remain tht wire
in the pipe to facilitate installation.

ln~ction
Pta. S-SO CIJ W'ue lum.,s

\
(2) Hom/dunmt"r t"A-Jh.-h leach
(3) HeadlJ&ht/iJnnoon ""'''h leod>
•
I. Check the steering hand leba• foa worpilgC or breakage.
',', f-
•
2. (.;heck the wires for breakage or open circuit. '' ''
3. Check the cables for breakage. ' ' ,,.....,
.....
(,
'\..
\ (---.. ..

'

Pia. 5-St Pulling switch lead

•
 V. FRAME 83
Assembly
To assemble, reverse the di$8SSembly procedures paying atten-

• tion to the following'

I . Install the handlebar switches.
Allach a wire to the end or the wire and ro ute it lluoush
lhe handlebar p1pe.
Sunilarly install the clutch lever switch .

• Fig. S- 52 Routin& ,...,,ell lead

• 2. lnstalllhe hondlcbar pipe.

Alisn !he punch marks on the pipe wilh lhe top of the
lower holde11.
Route !he front brake pipe, clutch cable and clutch lever
switch lead inside the cable holder.
Specified flshtening torque:
1.8- 2-5 k&·m ( 13.1- 18. 1 lbs-ft)
NOTES:
I. Face the punch marl<.s o n the upper holders toward the
front.
2. Tishten the upper holde11 beginnina with the front
side. Do not tighten d1e fron t side loosely.
Fig. S-S3 (1) Punch mark on handlebar pi{H' and rop of1owet

•
holder
(2) Punch rnu.rk. on upper holder

•
•
•
M V.FRAME
~------------------

(1)
•
•
•
CB type
"""- C B type

CL type CL type

•
( )

em
•
-e
m

•
(

\' - - I

Fis. S- 54 ( 1 } Clutc.;h c.abl"'

( 2} lluotlle(.;uble
l 3 ) l;,u;hom<'Crr c:•hlc
f 4 ) Spel.'t.lometcr calli\.'
( 5 ) Wire h arm:~!\
( 6) O<.~ltery band
( 7 ) High 1CR'\iOn l'llble
( 8) 11ll~ clam per hold'\ wire harnes~.
poilu lead Md high tension cable.
f ~ ) Th1s chunpcr holds wire harness.
JlOIIlf IC'ad Md clutch cable.
(10) Pumt lead
(II) Pomllcall is located between
sixth llnd seventh fins.
( 12) Tachometer cable clip
•
 V. FRAME 85

S. FRONT
SUSPENSION

•
(2)1----i~~ 3l
Fil-5-55
( t ) Front fork US\'.
( 2) Front fork bolt
( J ) O.rq
( 4 ) f'ront suspension S!pri.na
( 5 ) Piston rtna

•
( 6 ) BoliDm pipe
( 7 ) Front rebound <pnna
t 8) Front f01k pope
( 9 )Od lock piece
(10) Front for k dust ..,.J
(11)0dJOal >toppn ....
(12)33 x 46 • IO.S od ocal
(13) Front fork bottom cuo

•
(14)0il duln bolt
(15) 8 mm ...Ut boll
(16) hon1 axle holdtf

• Disa.....,mbly
I. Loosen the front fork bolls before removing the forks.
2. Remove the front wheel.
3. Remove the caliper assembly and front fender.
4. Remove the front emblem. Loos.cn the bolls (4) and pull
the front forks downward .

• 5. Remove the front fork bolls and drain front shock absorber
Fig. S-56 (I) Front fork bolu
t 2) Front <mbkm
tJ) honr fork!
t4) Bolls

• oil .
6. With each front fork bottom pipe held in a vice, remove the
socket bolt usinr the Allen head wrench (Tool No.
07917 3230000) and separate the pipe from the bottom
case.

• Fig. S-51 (1) Allen head wrench

(2) Pront fork bottom COI'IC
86 V. FRAME

7. Remove the front fork dust senl, 48 mm Internal snap ring

•
and oil seal.

fll. S-S8 {I) 48 mm mll:mal mop nnc

•
Inspection
Refer to service data on page 113.
I . Measure the front shock absorber spring free lenath. Cheek
the spring tension.
(I)
•
2. Check the front fork piston rings for wear.
3. Check the front fork pipe·to·bottom ease clearance.
4. Check the oll seals for scores, scratches or breakage.
S. Check the sliding surfaces of the front fork pipes for scores
or scratches.
•
•
Pig. S-59 (!)Front shock absorber sprtn&
(2) ~ront fork pipe
(3) Piston ring
(4) Bottom c..,.
ASliembly
To assemble. reverse the disassembly procedures. paying atten·
tion to Ute following:
I. Position each fork pipe in the bottom case. Apply a coat of
locking sealant to the socket boh and ti&hten it with the
Allen head wrench used at the tome of disassembly.

2. Apply a coat of !ugh quality AT~ to the mside and outside

circumference> of the oil seal and lnstalltt tL~ing the fork
Fll. S-60 (I) ADen bead ""'ncb
(2) Front fort bottom cue
•
seal driver {Tool No. 07947 -3330000).

NOTtl:
Use a new oil seal.

3. !'ill the fork pipes with high quallty ATF up to the

•
specified level.
Capacity (each fork pipe).
160-t6Scc (5.4-5.6 ozs.) at the time of fork disassembly.

Fig. S-6t (1) OH "'Ill

(2) J-+'ork se~l drlver
•
 V. FRAME 87
4. Install the front forks so that they are identical in height.

• CAUTION:
Remo.., oil, if any, from around the fo rk pipes.
S. After assembling, check:
The forks for smooth movement.
OU leakajle from the oil ...Is .

• FfB. S-62 Front forks sbo..ld be ldentraol'" beill>t

• 6. STEERING STEM

Pic. S-63
( I ) Steering stem nul
( 2 ) St=ing he>d top thrud
( 3 ) SteeriAg lop cone race
( 4) # 8 llcel baD
( S ) Stecrill& top Nil race
( 6) Stocring bottom ball race
( 7 ) Sleetln& bot tom cone nee
( 8) Ou•l >cal
( 9) Oust s<al .,.,her
(10) fork top bridge
( I I) Steerina !lem

• (11) - -

(9)

• D~bly

•
I. Optn the headlight case and disconnect the wires inside the
case.
2. Disconnect the sptedometer and tachometer cables from
the meters.
3. Remove the front emblem 3nd remove the three bolts (1).
Then the headlight ca.. with the stay and tum signals and
the meters wilh the meter set plate can be removed .

• Pig. 5-64 (I) Bolts

88 V. FRAME

4. Remove the handlebar pipe. (See page 81.}

•
5. Remove the front wheel and remove the front forlc.s. {See
page 85.)
6. Remove the oil pipe and related parts u an assembly.
7. Remove the steering stem nut and remove the fork top
bridge.

FW. 5-f>S (I) Steeriqgstcm nut

(2) Fort top brid&e
•
8. Using the 46 mm pin spanner (Tool No. 07902 2400000)
remove the steering head top thread and pull the steering
stem downward

CAUTION:
( )
•
Take cue not to lose the #8 steel baUs.
9. Remove the handlebat lcxk.

•
Pig. S-66 (I) 46 mm pin spanner
(2) Steering he.ad top thread

10. When removing the top and bottom ball races for replace·
ment, remove them from the steering head using the ball
race remover (Tool No. 07953 - 3330000}.

Inspection
FW. 5~7 (I) BaD race r•mo=
!218aU race
•
•
I. Check the 18 steel balls for wear or damage. If any one ball
is worn or damaged, replace all balls wilh new ones.
2. Check the contact surfaces of the top and botlom cone
races for wear or damage.
3. Check the steering head dust seal for wear.
4. Check the steenng stem for bend and the threaded part for

•
wear.
5. Check the stop for deformation or cracks.

Fig. s-68 (I) Stop

 V. I'RMfE 89

Assembly

•
To assemble, reverse the disassembly procedures, paying atten·
tion to the following:
I. When the ball races h\ve been removed, instaU them
squarely using the race driver anaclunent (Tool No.
07946-3290000).

• FC. 5~9 (I) Roce clrlftt atw:hment

(2) on~r handle

• 2. Apply a coat of grease to the ball races and put the steel
baUs mto them (18 balls into upper raoe and 19 balls into
lower race). InstaU the steering stem IntO the head pipe and
install the top cone race. WhUc rotating the steering stem,
hand tighten the head top thread until it turns freely right
and left. Any slightest amount of play in axial direction
cannot be tolerated here, until It is tumed with reasonable
ease.
NOTE:
Wash the cone rnces, bnU races und steel balls and apply a
coat of new grease to them.

Fi;g. 5- 70 (ll Top cone race

•
(2) # 8 steel baU
(3) Steering head top thread
(4) 46 mm pin spanner

3. Temporarily install the front forks. Install the fork top

bridge and tighten the steering stem nut. After tightening,
check if the stem moves smoothly by its own weight from
the position S to 10 • from the center. If it wiU not move,
the following causes may be suspected and checked.
• Maladjusted top thread
• Bent stem
• Wrong number of balls
• Abnormally wom race~

• FC. 5 -7 1 (I) Fork top briciAO

(2) St..rinJ st<m
(3) Front f<Kl

•
•
90 V. FRAME

7. REAR SHOCK ABSORBERS AND REAR FORK

Fi&- 5-72
( l ) Dn..,e d\ain ca.'IC
( 2 ) (.111Jn <a<e piUJ
( 3) Rear shoc.k. absorber*-'-~·
( 4) Jolnll\lbbcr
•
•
( 5 ) Upper jolnc
( 6 ) Sprinc ,., stopper
(7)9mmlodtnut
( 8 ) Rear lho<t aMorbcr
stopper rubber
( 9 ) Rur sltoct aboorbcr
!J'rinl upper teal
(I 0) R...- sl!o<k obtorbu 'I'M&

•
(ll)lipnnu••
( 12) Rur <hod< ob.orbu ''""'"
(13) SprJn& ldjuster
(14) Rear dornper
(15) Dud ..,.1 cup
(16) Reor fork P"Ol bushina
(17) Rear fort
(18) Rear fort cente-r colb.r
(19) Rear brake uoppe.r arm
(20) Rear rork pivot boU

Disassembly
1. Remove the exhaust mu men.
2. Remove the nut (4), side glip (left side only) and boll (3).
•
Then remove each rear •hock absorber.

3. Remove the bolts (2) and remove the dtov< chain ease.
F11. 5-13 (I) Reor shock abOO<bu
(2) Side ~np Cleflme only)
(3) Bolt
(4) Nuc
•
•
Pig. S 74 ( 1) Ori\'C chain cue
•
 V. FRAME 91

4. Remove the rear fork pivot nut and pull ou~t~t~h~e~p~iv~o~t~b~o~lt~.--[il:;;iiiiiiiiiiiiiiiiiiii£.:::Z~Z:~:7:--,

Then remove the rear fork.

•
5. Remove the rear brake $tOpper arm from the rear fork .

• FIJ. S-7S (I) Reu fort pivot bolt

(2) Rear fort
()) Rear bnl<e $10i>pcr um

• 6. Compress each rear shock ab!Orber using the rear shock

absorber comprenor (Tool No. 07959 3290000) and
remove the spring ~at stoppers and rear shock abosorber
spring.

Fig. S- 76 (1) Rear shock absorber compressor

•
(2) Sprlog..,.t st<>ppcrs

7. LoQsen the 9 mm lock nut and reml)ve the 11pper joint.

TI1en di"'"emble each rear shock absorber.

(4)

• Inspection
Refer to service data on pa~e 113.
Fi3- S-77 (I) Upper joint
(2) 9 mm lock nut
(3) Stopper rubber
(41 Reu damper

• I. Mea•ure the rear shock absorber spring free length. Check

the spring tension.
2. (heck the rear dampers for deformation or oil leakage and
the rods for bend.
J. Check the stop rubbers for breakage.
4. Check the rear fork center coiJnr·tO·bushlng clearance.

•
5. Check the holes for the rear axle provided in the rear end of
the rear fork for proper· alignrnent.

Fig. 5-18 (I) Rear shock abwrb~r spring

{2) Stopper rubber
(3) Spring au ide
(4) Rear dampet
92 V. FRAME
Assembly

•
To 35Semble. reverse the disassembly procedures, paying atten·
tion to the following:
I. When the upper joints have been removed, apply o coat of
thtead locking agent to the tapped ponlon for the rear
dampers.

Pic-S-79 (l)t:pperjoint
(2) 9 mm lock nut
•
•
(3) Stopper rubber
(4) Rear damper
2. Compress each rear shock absorber spring, pull the upper
joint upward and secure with the spring seat stops.

(1)

Fla. S-80 ( t) Spring seat Slops

3. Apply a coat of grease to the inside and outside of the rear

fork center collar and to the inside of the rear fork bushing.
Install the right and left dust seal cops and Install the rear
fork to the frame UJing the rear fork pivot bolt.
(2) Rear shock absorber comprCli."'r

•
Apply a coat of grease to the rear fork pivot bolt.

4. lnstaU the nght and left rur shock absorbers !10 that the
adjusters (I) are in the same position. The Slandard
Fil- s-81 (I) Rear fork
(2) Duu .W caps
(3) Rear fort ceo1er collat
(4) Pivot bolt •
installation position 1s the I st groove mark.

•
Fig. 5-82 (1) AdjuSier
(2) Pin !>-panm:r
•
 V. FRAME 93

8. FRAME BODY AND OTHER RELATED PARTS

•
•
•

•
--
•
~J::t;!:; l . r
• r}k
~
{~;. ~ ~
'11 ~"
.. .•.. ~\ ~\ •
t
~
~

• ""· 5- 83
94 V. FRAME
Fuel valve and fuel tank cap~-------------;::=================:,

•
I. Drain the fuel tank and remove it.
2. Remove the fuel strainer cup, 0-rlng and strainer screen in
this order. Remove the 6 mm screw and remove the fuel
valve from the fuel tank.

m--f_/:·--~-
3. Remove the 3 nun screws end remove the fuel valve lever
set plate and valve lever.
4. Remove the fuel valve gnsket.

•
5. To install, rever~ the removal procedure$.
6. Connect the fuel tu~s and hold them securely with the 1 <3>
clip$.
I ~~~
l
7. Check the following ttems.
• Contamination of fuel strainer screen
• Weakness of fuel valve lever spring
j "' (J) Il l

•
• Clogiog of vent in fuel tonk cap

C /
fig. S- 84 (1) ~ue l valve aslly. (6) Valve ga.<k<l

•
(2) Valve jojnt nut (7) Valve lever
(3) Joint ring (8) Vnlvc lever 11prlns
(4) Scrc•n (9) Valve lever set plate
(S) fuel $trainer cup
Air cleaner ---,
J. Open the seat and remove the right and left side covers.
2. Remove the nut (2), bolt (3) and screw (4) and remove each
air cleaner case.
3. Separate each air cleaner element from the air cleaner case.

4. Clean the aar c:lcantr element~.

Fie- S-85 (I) Au cleaner cue

(1)
•
•
Gi"e a light tap to the air cleaner element to remove dtrt
and dust. If necessary. direct a blast of compressed ~ir ••
the inner ~urfaceto blow off din and dust completely.
CAUTION:
If the air cleaner elements berome oily or if they are
broken, replace.

5. To install, reverse the removal procedures.

Fig. 5-86 (1) Air clc~n~r clement

•
 V. FRAME 95
Battery box and tool box

•
I. Remove the air cleaner assembly.
2. Remove lite battery.
3. Disconnect the starting motor cable.
4. Disconnect the electrical part wires at the battery box.
S. Remove the three bolts (2) and the battery box can be
removed.
6. Remove the electrical parts.

• FiJ. S-87 (I) Battery box (2) Bolts

• 1. Remove the four bolts (2) and remove the tool box.
8. To install, rcvcriiC the removal procedures.
Install the electrical panaand connect the wires as shown in
Fig. 5-89 below.

Fig. S-88 (I) Tool box (2) Uolh

• PiJ. S- 89
( l) Fuse box
(2) Fu!tt box lead~
(3) Flasher r<lay
(4) Wlrc hameu
(S) Starlin&mac-netic ~witch
(6) Swtinc molor cable
(7) B•ttery ..,.
(8) Silicon rechner

•
•
•
96 V. FRAME

Wire harness

•
I. Connect the wire harness u shown below.
Hold the wire harness wilh one wire band at the position
20-30 mm (0.8 1.2 in.) from the rear side of the fuel tank
rear stay and with the other band at the po$ition
t o-20 mm (0.4-0.8 in.) from the front side of the upper
tube cr= plate.

•
•

•
Fla. 5- 90 (t) Wire harn.., t J) Wire h3rnell clip B
(2) Wile harncu clip A (4) Wire band

•
•
•
 97
--------VI. ELECTRICAL S Y S T E M - - - - - - - -
1. CHARGING SYSTEM

• The charg~ng system con!lsts essentially of a Oywheel type AC

generator, a silicon rectifier and a current limiter. Alternating
current from the flywheel type rotor Installed to crankshaft is
converted tOto daroct curront (DC) by bndgo·type silicon rocti·
fier and then is fed to the bauery. Upon bauery voltago reaches

•
15.0±0.5¥. the regulator begins to actuate in ordor to bypass
a surplus current, reducing the amount of chargmg current, to
prevent the battery from bemg overcharged.

F._ 6 1 (I) A.C. senentor

•
(2) Silicon roctar..,
(3) Resulator
(4) Batlery

I . Charging tost
1. Check charging current and voltage by means of
voltmeter and ammeter.
2. Use a full-charged (12V-12AH) battery
If the specific gravity Is lower than 1.26 (at 20" C or
68• f), recharge battery so that the specific gravity is
up to 1.27±0.01 (at 2o•c or 68• f).
3. Disconnect the battery cable from the+ terrnltllll of the
battery. and connect ll to the + side of ammeter. Then,
connect the side of the om meter to the+ tenninal or
battery. Next, connect the - side of voltmeter to the+

•
terminal or battery and consequently + side to the -
terminal as shown in Fig. 6- 2. .
Fig. 6-2 Hattery charging lest
4. Check o roadlng of ammeter and voltmeter during riding
ut night and In the dny time In accordance with the
specifict-tlions gJven below:
NOTE:
Wbeo cbeckinJ, di-t111ect reaulator cable.
5. Start the engine. Simulate the nighttime riding and
daytime riding conditions and take the ammeter and
voltmeter readings at each speed.
Compate the readings with those in the table below.
If the actual readings are very dtfferent from those in
the table, check the generot1>r for condition. The
genenllor output may slightly vary wtth temperature .

• Charging dlan~cteri>tic>

Load
(without reaulator)

Beginning of
charging (rpm)
Fig. 6-3 ~

5,000 rpm
ch.a:rat:terutM.-s
( t) lputton coli
(2) ConL>Ct breaker

10.000 rpm

• Daytime
riding

Nighllirnc
Battery (12VI2
All)+ ignition
coil x 2
l.oad In dayllme
riding 1 50W1
1,550 max. at
battery voltage
12.6V
2.100. max. at
battery voltage
J.2A, mlJl. at
battery
voltage 14.8V
1.2A, min. at
battery
4A, max. at
battery
voltage IS .5V
4A, max. at
battery

•
tidillg 7Wt3Wx3 12.6V voltage 14.8V voltage 15.SV
98 VI. ELECTRICAL SYSTEM

2. A.(; generator stator continuity test

•
Using a tester, check for the continuity between:
• White lead and stator
• Yellow lead and stator
• Pink lead and stator
If there is no continuity in any one of the cases above,
replace the stator.

Pil- 6-4 Sl2tor continui1y le$1

•
Sillcon diode tedifiU
Check each diode fot continuity with a radio tester in high·
teading range. If current flows In forward direction (from
cathode to anode) only, the diode Is normal. Current now in
both directions or no current is a U&n of the malfunction of the
•
diode.
To determine that the rectifer is In good condition, follow the
instructions given below. Connect the negative probe of the
tester to the terminal (1) (green), and positive probe to the
terminal (2) (red/white), (3) (yellow) or (4) (pink). If the
needle swings, il Is an indication that the diode Is normal.
In like manner as above, connect the positive probe to the
terminal (2) (red/white), and negative probe to the terminal (I),

•
Fig. 6-5 Silicon rectifier
(2) or (3). The diode is correct if continuity exists. Continuity
should not exist between any terminals or comblnntions other
than those described above.
NOTE:
I. Do not use a megger for this test as the megget will generate
high voltage to damage the diode.
2. Make sure of proper baltel)' polarity when connecting.
Connection In "'verse polarity will shorten the battery
lll'rvice life or cause a blgh current now throupout the
ele<trical system, "'suiting in domaae to the diodes or
burning up the hamesa.

13)

4. Battety
I. Specifications
Fig. 6-6 (I) Green lead
(2) Red/wllitt lead
( 3) Ydlow l...S
(4)Pllllr.lead
•
Type
Voltage
Capacity
12N12A-4A {Yuasa)
12V
12AH
•
Pig. 6-7 (I) 12Nt2A-4A battery
•
 VI. ELECTRICAL SYSTEM 99

2. Rate of charge

•
Use a suction type hydrometer. Place the glass tube vertical m
and slowly suck the elecuolyte until it rises. Take the
readina at the uppermost heiaht of the electrolyte. If the
specific gravity is below 1.200 (at 20 C or 68 F). recharge
·-.,...
'
~· ..:.
I

L
;:-

the battery. (l) \.

3. Inspection and servicll\& ..
•
tOI'JlOfO~I.o'O~·
a. Check the eleclrolyte level in each ceU. If it is below (l)
the lower level mark, add the distilled water up to the
upper level mark.
b. Periodically measure the ~flc gravity of the elec-
PiJ. 6-ll (I) Spedlkr;ra¥1ty or dc:ctn>lyte
uolyte. (2) Relation betwe<:n Slate or cb01Je lllld
When the distilled water hu been added, thoroughly tpedli< lf>'riiY or el«UolYt•

•
sUr the eleclrolyte before measurl1111 the specific gravi· (3) State or cll.qe (l'l
ty.
c. Thoroughly check for poor contact due to the corroded
connector and terminals, falling-ofT of the ceU plateS
and sulphation which may be the major causes of the
battery troubles.

4. Charging
Precautions for charging:
I. Try to avoid boost-charging the battery; otherwise, the
service life of the battery may be s.hortened excessively. If
the battery must be boost-charged, the charging current
should not exceed 2.0A.
Standard charging current l .2A
Fig. 6-9 (I) Sediment (S) Lower level mnJk
When recharging tho battery with It mounted on the frame,

•
{2) Pl•te
remove the rectifier connector first . (3) Battery ca1;c
2. While charging the battery, keep out of fire since hydrogen {4) Upper level mark
gas is cmlucd.
3. After charging, thoroughly wash out spilled electrolyte.
Apply a coat of grease to the batlery terminals. (1)

• 1 30 1 294
1 29
1 2905
-
-
12870
- 1.2835 1.280
FC-6-10 (I) OWJ<r

•
1.28
1.27 1 274
1 26
1.2705 --
-------

1.2670--
1.2765
- -- - - -

1.2635 ~;;;--._.,
---- 1.273

1.25 1.2565 1.2530

SG

•
1.24

c o· 5' 1 o· 15' 20' 25' 30'

F (32' ) (41') (50') (59') (68') (77') (86')

Rclath>tUJllp between atmospheric temperature and spct..ific granty

100 VI. ELECTRICAL SYSTEM

2. IGNITION SYSTEM

•
I. Ignition coil
Continuity test
(i) Primary winding
Check for the continully between the attaclting stay
and primary windin& (black/white lead) using a tester
with the knob in the 0 range.

•
(2) Secondary windlll&
Check for the continuity between the attaching stay
and hi&h·tcnSion cable using a tester with the knob in
the olun range.
U there is no continuity in the above tests, open circuit Is in
the ignition coil. Replace the coU. Pi&- 6-11 Ignition coil continuity tell
Perfonnance tesl

•
Even if there i$ a continuity in thel&nitlon coil, the long use
of the coil may re'uh In the poor perfonnance. If the
en81Jle fails t<> start, check the spark plup, points, con·
denser, etc. for condition.
(I) Use a fully charged battery and service temr, and
connect them.
(2) Turn the service tester selector knob to COIL TI:.ST.

•
Pig. 6-12 Performance t<::~t

(3) Observing tl1e spark jun1ping across a 3-point spark gap.

tum the knob and measure the maximum jumping
distance.
Spedflcation: 7 mm (0.27 in.). min. If the spnrk appears in
the fonn 8 in Fig. 6- 13, connect the high-tension cable to
the tester in the reverse direction and measure the jumping
distance with the spark an the fonn A.
~
===::::,Jr:==:::J'\'<:==== (II
n
2. Cond..-r
fie- 6-13 M~ diUa.n<::e or $park
3-point spark pp
Jwnpuy ,crm.,

•
•
Using a service tester, measure the condenser capacity. Also
check for short circuit. If the capacity oa the insulation
resistance is too small, replace the condenser.
Capacity: 0.2St•F
Insulation: IOMO(by I,OOOV megger)

Pig. 6-14 Condcno;cr checking

•
 VI. ELECTRICALSYSTEM 101

3. ContBCt breaker
Check the poin ts for wear or burning . 0 ®(I)
• ~~'m
x+,~· 'm
• (I) Normal
(2) We.s
L-~
FiB- 6-IS O.ed.~ the ron lad brealttr po<nU
(3) PortW ,....,
(4) l"ouJln&
(4)

• 4. Spark advancer
I. Remove dust and foreign materials from the sliding surface
and check for smooth operation.
2. Check the advance pin for wear.

I)

Fig. 6 - 16 (I) Spark advanoer

• 3. Check the advance anglo.

Using a stroboscopic timing Ught. measure the speeds (in
rpm) at the beginning and end of advance. (See page i8) .

• Pis- 6-17 (I) Tunmcll!P>t

1- 1-

•
0 14"• 1o6!i0r{llll_
15
/
VI II
10 0

/ l1'•1.800•pM
/ /
v t.ooo
0
5
/

• 0
650
.__ ___ __
soo
_ _ _ ___::(a:.:t~camshaft)
950

Ji'i:g. 6- 18 Timing <Klvancc chart

t.soo 2-000•pm
102 VI. Fl.ECTRICAL SYSTEM

s. Sporl< plugs
Check the spark plug electrodes for wear, improper gap and
fouling. Also check the insulator of each plug for breakage.
I. Clean lhe plugs, If foul, with a plug cleaner or a wire brush.
•
•

Fls- 6- 19 (I) I'll>& <leaner

•
2. Measure lhe plug gap wilh a feeler gauge. If it is out of
speciOcalion, adjust it by bending the side ele<:trode.
Specification: 0.7-0.8 mm
(0.028 0.032 io.)
•
3. If lhe insulators or gaskets are broken or deformed, replace.
Specified plug: 88ES (NGK)
W24ES(ND)

Fig. 6-20 (I) Plug ll"P

•
•
•
 VI. ELECTRICALSYSTEM 103

3. STARTING SYSTEM

·- When the statler switch on the right side of the handlebar is

pressed, lhe starter maanetic switch Is actuated to permit
current of about 120A to now from the battery into lhe
• starting motor .

• I. Starting motor
Sp«ilications and character!Jtlcs
Rated wltaae 12V
0.45 KW

•
Rated output
Rated hours 30 seconds

Under no load Under load When locked

~age 9V IIV sv
Current 35A 120A 280A
0.7 kg·rn 1.8 lcg-m
Torque - (s .o6 t tb-ft) ii3.0 lb·ft)
Speed 1,700 rpm 5,000 rpm -

F;,. 6 - 21 (I) SlaTting motor (6) Startu'i mognetlc <Witch

•
(2) Brushes (7) Slluter button
(3) Atmature (8) Plunger
(4) Poles (9) Main switch
(5) Field coil
Inspection
I. Carbon brushes
Check the brushes for wear, roughness of the contact surfaces or
spring tension and replace if necessary.

Standard Service limit

f-
Brush 11 .0 11 .5 mm Below
length (0.43 0.45 in.) 5.0 rnm (0.20 in).
Brush
spring O.S- 0.6 ka Below
(1. 10- 1.32 lb) 0.4 kg (0 .88 lb)

•
tension
PiJ. 6-ll (I) Carbon brwll
( 2) Brush spnnc
(3) Commutat01

2. Commut.ttor

•
Check the commutator surface for contamination. If necessary,
recondition it with a line emery paper and then clean .

• Fig. 6-23 Checking stator cull

104 VI. ELECTRICAL SYSTEM

3. Starter magnetic switch

•
The starting motor, because of its characteristics, draws a large
current (above IOOA) that exceeds the capacity of the starter
switch. This needs thick wires to reduce the resistance in the
starter circuit and the contact surface of the switch controlling
such a large current mu.\1 also be increased in area. If a large
current is suddenly cut off, spark wiU be given out and some
amount of resisW>ce may also be applied to the circuit due to
the pressure of the contact surface of the switch. This Is the
reason why an electromagnetic switch is provided In the circuit
and thus the stater circuit is remote-controlled wirh 1 smaU
current.
(I)

(2)
(3)
(4 )
(13)
(14)
•
•
(5)
(15)
(5)-

(})
- (16)
(8)

FitJ. 6 24 (I) Stopper ( 10) Contact boll (lJ)

(II) case (9)
(2) Stopper holder
(3) Wa!her ( 12) Contact pbtc
(4) Roller A (t3) Yoke
(S) Con tact sprina (14) Coil bobbin
(6) rl•t washer (IS) Coil
(7) Plulll!cr holder (16) Re1urn spring
(8) Plunger Khort (17) ijody
(9) Ptuni<r

Inspection
I. Check the primary coil for continuity.
If there b no continuity, the primary coO bas an open
•
circuit.
If the coil clicks when 12 volts are applied across both
tenninals, it Is in good condition.

2. When the magnetic switch is u~d for a long time of penod,

Fig. 6-25 (I) Starter mapehc: switch

•
•
the contact surfaces may be burnt to mcrease the resistance,
prc,.entmg current from flowing.
With 12 \'Olts applied across the tenntnals of the primary
coil. turn on the switch and check the tenninals for
continuity. If there is no continuity, the magnetic switch is
defective.

Fig. 6 26 ll) Slatter magnetic: switch

•
 Vl. ELECTRICAL SYSTEM lOS
4. OTHER ELECTRlCAL PARTS

•
I. Main switch
Check the switch for continuity at the key positions (ON and
OFF). If there is a continuity between o-o in the table below,
the switch 1S in good condition.
If there is no continully or 1f there IS a continuity between the
other parts thano-o , the swllch iJ defecuve.

• IC _ B TLi TL2
·~
OFF
- .....
I ,J c
u (
- - Pig. &-27 (I) Main switch
Leads color Blick Red Brown/white Brown

• 2. Front stop switcb

Attach the probes of a tester to the switch and check for
continuity with the brake lever operated. The l<lop light should
come on when the lever moves S to 10 mm (0.20 to 0.4 in.) as
measured at the tip of the lever.

•
Fig. 6-28 (1) Front Mop $Witch

3. Rear stop switch

Pull the rear stop switch spring to the end of lhe rear stop
switch and check for continuity between the black and
green/yellow leads. if there is no continuity, replace the switch.
After checking. adjust the rear stop switch by turning the
adjusting nut so that the stop light comes on when the brake
pedal is depressed and moves about 20 to 30 mm (0.8 to 1.2 in.)
as measwed at the tip of the pedal .

• 4. Hom
Fig. 6-29 (I) Reat stop"'"""
(2) AdJU.ShnJ nul

•
Ouconnect the leads 111sodc the headlight case. Connect a I2V
battery to the leads on the horn S1dc and check for proper
sound. If no abnonnal condihons arc found, check the horn
button switch for condihon

• Fig. 6 30 (I) Horn

(2) Hom ledd\
106 VI. ELECTRJCALSYSTEM

S. Hom button switch

•
Disconnect the hom/turn signal dimmer switch leads (yellowish
green and green) from the frame and check for continuity using
a tester. If there is a continuity only when the horn button is
pushed, the switch is in good condition. If the switch has an
open circuit or is broken, replace it.

Pis- 6-31 (I) Horn buuon

•
6. Tum signal switch
DiscoMect the horn/tum signal dimmer switch leads (gray,
orange and sky~lue) from the fr11me and check for continuity
at each knob position using a tester. If there is a continuity as
shown below, the switch is in good condition.
•
w 8 l R
~

l2 J"\

ll
0
( .r. -
N
Rl 0
-= 5

•
R2
Leads color
\.
Gray
- · Orange Sky-blue
Pig. 6-32 Tum slgn».lswltch

7. Dimmer switclt
Disconnect the hom/tum signal switch leads (blue/while, blue
and white) from the frame and check for continuity ot each
knob position using a tester. If there is a continuity as shown
below, the switch is in good condllion.
p IlL Hi lo
,...
Hi ~

(N) \. ""' ~ 0
Lo
f-

•
leads Black/ Blue White
color Yellow Pic- 6-33 (I) Dimmet swit<h

•
•
 VT. ELECTRICAL SYSTEM 107

8. Isnltion swikh

•
Disconnect the ignition switch leads and check the leads on the
switch side for continuity using a tester .
If there b a continuity u shown below, the switch is In good
condition.

IG KIL
1--.-.· . ........ ! - --1

• Black
- --- .... - · ---o
Black/white

Fie- 6 - 34 (I) llnilion swnch

• 9. lleodlight ....;tch
Disconnect the lighting switch leads from the frame and check
the leads on the switch side for continuity at each knob position
using a tester. If there 11 a continuity as shown below, the
switch is in good condition.

IG Tl..l IL DY SE

,-;:--
0 -v
Leads Brown/ 81 ock/ Yellow/ Yellow
color lllack blue red white 1 Fig. 6-35 (t) lleadtlghl switch

• 10. Neutral switch

With the transmi~•ion In the neutral position, remove the left
crankcase cover and check for continuity between the switch
and crankcase using a tester. If there I~ a continuity In the
neutral position only. the switch is in good condition .

•
•
•
108

VII. SERVICE D A T A - - - - - - - - - - - - - - - -
1. SPECIAL TOOLS

~ ' (l)
•
•
Il l
(J)

I
---
001 0 (1 ) •
(15)
(II)

··-
··~ ..... ...
~

(II)

(11)
•

\\ Ltl
!II)

uu
f ( !l)
•
(0 PI

•
1261 r •
 VII . SERVICE DATA 109

• ~f.

(j)

®
No. Tool Part No.

07902 2400000
07908-32:10000
Tool Name

Plo S5)8nner, 46 mm
Tappet adjust wrench
Remarkt

• @

®
®
0791()-3.."90000
0791()-3230100
07914-3230000
Wrf'nch. ret•iner (rear)

Wrcoch. n:taiucr ((ront)

P1iers, soap nng To disoosemble and assemble master

cylinder piston

•
(AI 07916-28JOOOO Wronch, lock nut, 16 mm Oil filter rotor

0> 07917 3230000 Wrench, set. hollow, 6 mm To di.....-mbk ood assemble lroot lork

® 079'..!2 3000000 llolder. drive sprocket

® 07933-2160000 Pullrr. rotor

@ 07942..Ul10000 Drivtr. valve g\lide To install and remove valve guide

® 079~5 3330100 Attachment, driver Whcd beariog (6302, 6303)

® 07945-:J:J:IO'lOO Anachment, driver T ransmission lwaring inner

@ 07946-3290000 Oriv(•r. httll rttce

® 079~7 ~330000 Driver. fork seal

•
® 0794~Gll ()()()() Driver handle For@,@ and@

@ 07953-3300000 l~emover, ball race

® (Y/95~ 3670000 Comprc-.$Or. piston ring For 250cc

@ 07954-~690000 Comprenor, piston ring For :!60cc

@ 07957-3290000 Valve spring compressor

® 07958-;lS()OOOO Pi~uon base

® 07959-3290000 Disassembler, rear shock

absorber

@ 07974-32:10'~ Gutde, pisroo cup

~ 07964 ·5900000 Valve guide reamer

• '8
OPTIONAL

3
I
07797-:!9'-!IXIOO

Oi50-l- :l000100
t
Tool case

Vacuum gauge $4."C For carburt"tor adjustm~ol

•
~ 07908 3690000 \Vr••nch, carburetor \\'ith ~

@ 07975 ;lO(l()()() I Tool. drh.e chain Dri ... e cha1n

@· 07510·<16!l0l00 Attachment, vacuum gauge Witb@

I

•
11~0--------------------------~V~li~.~S=ER~~
~C=E~D~A~T~A~---------------------------
2. MAINTENANCE SCHEDULE

MAINTENANCE SCHE DI:LE

ThiJ Maintenance Schedule is baaed upon 11vcr uge riding condiuont.
Machlnee aubjected to .severe uRe, or ridden in unusually dusty areas.
I'C"(luire more frequent servic.:ing.
INITIAL
SERVICE
PERIOD

500
milu
RECUl,AR SF.RVICF. PERIOD
Perform It every mdicatcd month or
milcaRe intt'rval, whiche"er 0<.-c:ur& finu .
I
month
500
a
month•
1 .~00
6
momhs
3.000
12
month II
6,000
•
•
miles mile~ mil~ miles
ENGINE OIL Change.
CENTIUI'l.iCAL OIL FILTER Cl..n.
• 0
- 1- 0
-
f - -- 1 - -
OIL I'ILTE.R SCREEK Cltan. 0
SPARK PLUG- Clean and adjust gap or replace if ne«nary.
- f-.

•
0
•coNTACT POINTS AND lGNITIO!'I TIMING CJean, check,
and adju.sl or replace lf n~uary. • 0 :
•VALVE TAPPET CLEARANCE Check, and •djus1 if ncceHsory,
• 1-
0
I
•CAM CHAIN TENSION-Adjust.
PAI'I>R AIR Fli.TE.R ELI::MJ::NT-cl..n.
• 0
0 I
Se:rvict' more frequently'
-R<ploc<. if opc.ratrd in dusty aru.J
0
•CARBURETOR- Check. and odJUII of n«<UUy.
• 0
TH'KyLTLii OPERATT0:-1- llllpttt cable.
Check. and adjwt Cree play.
FU£L r.n.TER SCREEN- Cieon.
• 0
0
I'UEL LINES Cheek. 0

. .• •
1- k
•CLUTCH Check opeTation, and adju111 i£ necessMy. 0
DRIVe t;HAlN-Check, lubricatt, and ad)Uft if necessary. 0
BRA~.!!"'2JU LEVEL (only do,.. ryp<J Cht<"k and idd fluld af
nee: .
•BRAKE SHOES PADS-lns pecc, "'rl "'place if worn.
• 0
0
BRAKF. COI\I ROL LI:-IKAGE Check hnb~c. and adjusr lr""
play 1f necessary. • 0
•WHF.F.I. 'RlMS AND SPOKES Ch«k. IIRhtcn spoke:s and
trufl wheels, i£ necessary. • 0
TIRI::S Inspect and check uir prtuurt>.
FRON'I FORK OIL Drain anc.l re(IIJ. . ..• 0
I
-- 1- 0
f'ROJ\1 Al\0 REAR SUSPF.NSION-Chr:<k operation.
• 0

•
RE.\R FORK BUSHING-C"'•"· rh<'<k lor r:xcessh·e loosen<'». 0
•Sl t;t;RJNG HEAO BF.ARI:-IGS Ad]\lat. ' v '
8.\TTERY Check el«crolyt~ 1~\el, •ncl add warer tf necessary. I
• 0
LIGH'riNG EQUIP~fE~ -Check and adJust if nccc:~ary.

T.> BOLTS, A!W OHTiiT< I'AS1'ENF.RS-Chcck :st.-curuy • 0

-
AL'I.I\'G
•
•
" nd 1\ lnen i£ nt:ce:s:sur)'.
0 0
llcm• morlu:d * ~hould be servict-d by lin 3\lthorized Honda de11ler, unlt:!!.l the owner has propt•r cn(}hl 1tnd u1 mechanically
pro hclt'lll. Orhcr mainttnan(e ilf'lllfi> •rt- ~ i m 1)le 10 perform and mlly be &crvi~.:t:<J hy lJ1e owner.
.. lniti•l &crvic;e period 20U miles,
• •' Imual ..,.rviN" period 1,500 milt'~ ,

•
 VII. SERVICE DATA Ill

3. TIGHTENING TORQUE STANDARD

• Engine

Item Size ( mm)

kg·m
To rque

lt.fl
-
-

•
RL. crankca.se cover holt 6 0.7- 1.1 5.1 8.0

Cybnder bead hold-down bolt 10 3.~3.4 21.7-24.6

Cylinder htad •n•ulator bolt 6 0.7-U 5.1-8.0

Camshaft •procket fixioa bolt 7 1.3-2.2 13.1-15.2

•
A.C. gcocrotor mountina bolt 8 3.~3.5 21.7 25.3

Oil lilter lock nut 16 4.~5.5 32.6-39.7

Crankcaoe mounting bolt 6 O.!H.2 6.5-8.7
8 2.~2.3 14.!H6.6
I

Frame
Torque
I tom Si7.e ( mm)
kg·m lbft.(t

Steering stem nuL 24 7.(}-9.0 50.7 65.1

•
Fork holt 27 2.~3.0 111.1-~ l.7

Hau.Jiebar holder ottorh\ng bolt 8 1.8-2.5 13.1-18.1

Fronl fork bottom bridge 8 1.8 2.5 13.1- 18.1

Spokr 0.1~.21) I 1· 1.5

Rear fork pivot bolt 14 5.5-7.0 :197-507

Front fork axle nut 1~ 5.~6.5 :1\1.7-17 n

Front lurk uud<r hold<r SUBS 2.7-3.3 19.!;-23.S

Engme hanger bolt SUBS 27 3.3 19.5 238

Engme hanger bolt IOUBS H)-55 ~ o-:1'17

• Rear axle 16 8.~10.0 57 9-72.3

Final dnveo 'prockt.:l 10 UBS 6~70 13 ·1-50.7

Brake erm 8 18-2.5 13 1-18 I

Rear brake tiloppe:r nm 8 1.8·2.5 131 Ull

• R~ar 3l1ock ah~rht·r 10 :1.0-4.0 ~~ 7-~o

Foot rn1 10 UBS 4.0-5.5 29 0-39 7

Cbongc l'<'dal 6 0.8-1.2 5.8-8.7

S...•t bond 6 O.!Hl.95 5.8- 6.9

• Kick 8 2.5-;1.0 1!1.1 ~l.7

BUll
I
11 2 VII. SERVICE DATA
4. MAUMENANCESTANDARDS

•
Engine Unit: mm (in.) ( ) : 360cc ouly
It.enu to be iMpeded Standard Service Limit
Rocker arm-to-rocker arm ohaft d . .rance 0.011Hl.061 (0.0006 0.00'.!4) 0.1 (0.0039)

Cam lift IN. 40.314 (1.5872) 40.1 (1.5787)

•
I--
EX. 40.339 (1.5882) 40.1 (1.5787)
I--
0-07~.3 (0.0028-0.0118) i\bove and below
Camshaft s ide clearance standards
Valve oeat width I.Q-1.3 (0.0394-0.0512) 2.0 (0.0787)
1-- -

•
IN. 6.975-li.990 (0.274~.275'.!) 6.93 (0.2728)
0.0. of valve stem
EX. 6.955-6.970 (0.27~.2744) 6.93 (0.27'.!8)
I--
IN. o.ot-o.035 co.0004~.00I4J 6.93 (0.27'.!8)
Ve1ve·to.valve guide cl~t~rance
EX. 0.03-0.05 (0.0012-D.0020) 0.09 (0.0035)

INNER 30.5- 35.1 k g/31 (67.24 77.38 lbs/1.2205) - -

VaJve apring tension/
u compre.ud length OUTER 62.6-72.0 kg/31 (J:i8.oJ-158.731bt/1.2205) -
INNER 39.8 (1.5669) 39.3 (1.5709)
Free length of valve spring
OUTER 49.0 (1.9291) 47.8 (1.8819)

Trtnsverot warpage on cylinder head mating fac.- 0.3 (0.0118)

f-- -
•
56.01- 56.0'l (2.2051-2.2055) 56.1 (2.2087)
1.0. of cylinder (67.01-67.02 (2.6382-2.6386)) [67.1 (2.6-117))
55.97-55.99 (2.2006-2.2043) 55.85 (2.1988)
0.0 of piston at skirt (66.97-66.99 (2.6366-2.6374)) (66.85 (2.6.119);
15.002- 15.008 (0.5906-0.5909) 15.05 (0.5925)
Pt11on pio bole 1.0. (16.002-16.008 (0.6:)()()-0.6302)) (16.05 (0.6319)J
14.994-15.00 (0.59<l:J-o.5906) 14.9 (0.5866)
o.n. of piston pin (15.994-16.00 (0.6297 0.6299)) ( 15.9 (0.6260))
I TOP O.O'l-Q.06 (0.0008 O.OO'l4) 0.15 (0.0059)
-
1---
Pisloo ring-to-ring J(roG\'C 0.015-o.045 (00006-0.0018) 0.15 (0.0059'
SECOND (0.02-Q.04 (0.0008 0.0016i) (0.15 (0.00591)
dc:araoce
-·
OIL O.Q\0-G.045 (0.0004 0.0018> 0.15 (0.0059)
-
-
•
0.75 (0.0295)
-
0.15-D.35 (O.OOS!Hl.OJ:JK)
TOP (0.2-0.~ (0.0079 0.0157)] (0.8 (0.0315))
Pi!tOD ring t:nd )C&.p 0.15-o.35 (0.0059-Q.OI38) 0.75 (0.0295)
SECONf>
- -
OIL 0.2-Q.4 (0.0079-o.0157' 0.8 (0.0315~
-
i- -

•
Oil pump outer rotor.tO·pump body dear&tlce 0.15-Q.21 (0.0059-0 00831 0.35 (0.ot38;

Radit~l clearo.oce of oil r•ump outer rotor o.o~-o.os (0.0008 o00.121 n.1 co.oo:w,
Thit·kuess of cluu;h rrictioo disc 2.62-2.711 (0.W:lHl.1095) 2.3 (0.9055)
--
Transverse warpttgt oo clutch plate 0.1 (0.0009) 0.2 (0.0079)
-

•
Clutch spriog tension 25/21.1!-:!.'1.2 kg :0.984(48.06 51 1511.<)
..
~··•• leugth of dutch •prin~ :u .25 <).23051 29.7 ( 11693)

G<•r shift fork width, A a.od 6 5.93-6.00 (0.2.1:~<;-0.:r.l62) 5.5 t0.2165)

I
0.0. of gear • hilL guiJe 8haft l2.957-12.9!Y1 (0.5101 0.5112) 12.9 (0.5079)
 VII . SERVICE DATA 113

• l tema to be huopected
l.D. of gear onift fork A
O.D. of gu r shift drum
Standard
13.()00-13.018 (0.5118-0.5125)
39.950-39.975 (1.5374-1.5384)
I Service Limit
12.95 (0.!i098)
39.9 (1.5709)

• I.D. of gear shift fork B

Kick starter panioo-to-shalc clearance
Gear shift fork-to-drum clearance (A and B)
Thic\c.ne:u of cam chilD tenaioaer slipper (at ceoter)
40.()00-40.025 (1.5748-1.5758)
0.0Hl.082 (0.0018-0.0032)
0.()6-().22 (0.()()2j}-0.0087)

4.0 (0.1575)
40.075 (1.5796)
0.1 (0,0039)
0.3 (0.0118)
3.0 (0.1181)

• Tbickne11 of cam chain guode ( II center)

Crankshaft ruoout (See Fig. 4-101 on page 62)
1.0. of conoocting rod omall end
6.1~.3

-
(0.2402-0.2480)

15.016-15.034 (0.5912-0.5919)
(16.016-16.034 (0.6306-0.6313))

0.07 0.33 (0.0028-0.013())

5.0 (0.1969)
Below 0.1 (0.0039)

15.07 ~0.5933l
( 16.07 0.6327 )
0.60 (0.0236)
Coouec:ting rod biR end tide clearance on pin
Coo occting rod big eod radial clearance on pin 0.004-0.012 (0.0002-0.0005) 0.05 (0.0020)

Frame
Jtemo to be lnopected Standard Service Limit

•
'Wheel rim su rface ruoout 0.5 (0.0197) mRX. 2.0 (0.787)

W hcd bearing axial play · 0.07 (0.0276) max. 0.1 (0.0039)

Wheel beoriug rodial pl•y 0.03 (0.0012) max. 0.05 (O.OO'lO)

Front axle bend 0.01 (0.0004) 0.2 (0.0079)

TransverSe warpage oo front brake disc 0.05 (0.0020) 0.3 (0.0118)

Thicknu• of (root brak< disc 6.9-7 .1 (0.2717-0.2795) 6.0 (0.2362)

I D. of cahpcr cyhodu 38.18-38.20 (1.5032-1.5039) 38.215 (1.5045)

0 0 of calipo:r vlstou 38.115-38.18 ( 1.5006-1.50:12) 38 .I 05 ( J.'iOO'l)

l.D. of muter cyboder 14.Q00-14.043 (0.5512-0.5529) 14.055 (0.5534)

•
0.0. of muter cyliod.r piston 13.957-13.984 (0.5495-0.5506 13.940 (0.54811)

Rear axle beod 0.01 (0.0004) 0.2 (00079)

ThickocSI of broke Ionon~ 4.9 5.0 (0.1929-0.1969) 2.5 (0.098)

I. D of rnr brake drum 160.()-160.1 (6299'l~.3110) 161 (6.331!6)

•
Free length of front su~pensioo spring 478.6 (18.843) 468.0 (18.4251

of Cront fork hutiOm cur 33.025-33.064 ( 1.300'l-1.3017) 33.139 (1.3047)

• 1.0
0 D. ul front fork pipe 32.97-32.\185 () .2.980-1.2986) :12.25 (12697}

Free )(;nglh of rear susprostoo spring 207.6 (8.1732)

•
0.0. of rc:ur fork center collar 21.427-21.460 (0.&136-0.1:1449) 21.46 (0.1:1449)

I I l of rear fork buthiog 21.5-21.552 (0.8465-0.8485) 21.70 10.&~4:!)

114 VII . SERVICE DATA

5.
-----
TROUBLE SHOOTING
Engine
Troublo
Ea,rlne doe uot at.art
Probable eaaee

I. Intufficlent comprc.ion preuure

I) TM:orrcct tappet adJuttment
2) \Vorn valve «Ui~ or improper valve seating
Adjus1
Remedy

Replace or repair
•
3) lnc:otft'C'C valve: ciminK
4) Wom pt~-~on rin,p
5) Wom cyfindu
2. !"rro ~~ 11 tpark plu.g and con1aa point
I) Dirty opork pi\IC
Adjust
Reploce
Replace

Clean
Clean
•
•
2) w., opork plu«
3) Dirty coniiCt bmok f1' poin1 Clean
4) lmproJ><'r p<l4n1 IIIP Adjus1

5) Incorrect Jgnu1on um1ng Adjust

6) {)("(t.etivc iamtion coil Replace
7) Di.Jconnt<"tinn or abort circuu of ignition cord Rt-place
8) S hort circuil in cnnden•er Replace
3. f'ut.l does not Row 14> C'flthu~or
I) CloM.ced ve.nt hnle in te.nk rap Clean
Clean
2) Cloggod fuel valve
vt~ lvC" R eplace
3) Dd'cctive cArhu,emr Jloat
4) C logg•d fu el feed t>ip• Clean

Engine stall• 11oon I. Dirty ll)llrk plug Clean

Clean

•
2. Oir1y conl ft<'l b rcokcr w in t
:J, Incorrect iRnition timing AJ.ju$1
4. Clog"ed !uel !••d 1>ipc C lean

5 Clogged cerbur~:tor jet C lean

Adjus t
6. In..:orrect teppet Hdju\ltment
Noiey enrtne l N~itytappet
l) Largt tapp~t clearenct Adjust
2) TAl• Q( v11lvt- 11prin,g tenJtOn Replace

2. P•tton knodnn.R'
I\ Wnm pLtton nntt or cylinder ReplaCf'
2) Carhon accumut1tf'd in combU<StiQn ch~n,hf>r CJ.-.m
:-i) Worn P~t()l"' ptn or conntctina rod small ~nd Repl•tt
~. C.•m cMm
I) Screeched Cllm ~hatn Replace or adJU~t cam cham tcmnont:r

•
2) \\'orn c-am tprocket or rimang sprodcft Rq>la~

4 1'\oU~f clutch
l) l.ootr dutch centf'r ~ptln~ Replace
2) Excf'PIYf" t'IMnant'f' W.w....-n dutch friction di~ Replace
•nd rmh u( chuth outrr hOU!!oin"-
3) w.,""'. frk·lton difc; ur dutch plat~ Replace or repair
s.

•
(.;.rankthaft
1) \\'om crank11halt ltf'JI.ring
:.!) Wom connect•nsr rod hig pnrl
Nvi•y Rt"llr
I ) \'lorn tr"11ntuniJ.~tion f:e8r
g611r!l
()f 11\lc."rfcrcnce bt-twtt-n
Replace
R..-plal·f"

Repti\ce
•
•
2) \\'()na lroJilinf" Replace
3) \Vnrn primary gear or Interference b(1WN""I\ gear'$ Repla~e
 ------------------------ VII. SERVICE DATA
-----------------------~
liS

• Troublt:
Clal<h olipo
I P robable t a.._
I. Imptoptr clutch adJu••mt1U (no pla7 in dutch kver)
2. Wuk clutch preMure plale 1pri.ng
3. \Vorn or warped prt.ure plate
(. Warped durch plare
1
Adjust
Rtpla«
Rtpl""e
Replace
Reaoodr

•
5. \Vom or warped friction di'(" Replace
Ciut<h will not be I. Imp roper clutch adjullmtnt (e xc::et~ive play of clutch Adju!n clur..·h lenr
dl..nJ•K•d lever)
z. \Veak or non-uniform tcJUiun o( clutch spl'ings Kt:plncc w('ak IIJ>rin,y
3. \Varped. clutch JliAt., Replace

•
DtnkuiL .rear ahiftin1 I. Dclormed shlfc drum I'!Of>pt'r Rc~ir or rc"placc
2. Broken gear ~~ohift drum Replaee
3. J)eformcd ,:rear ahif1 fork R~ir or rcplart
"""""Cii"U,e rear ~~.u ~
out ~h lon I I. Wom shifting J:UN on main tthaft and countershah
2. Wora or btnl ~ter thift fork
3. W~1c shift drum stopptr tpn"Jl'
I
R.-pla<e
Repair or
Rep!..,.
~plac;~

t;n.. •• ldli-.. . . not I. lmpro~r rappct adJustment AdjU§"I

11tablt 2. Improper 'letltin~t ft(
cylind.-r head valve Replace: or ffptar
3. Dt£ective valve: guide Rep)ac~
4. Incorrect ignition timinsr Adjwu
~- Faulty ¢()ruact breaker puint Repnir
6. Excessive &pArk plug Jl'-'P Repair
7. We~ k il(nition tpu,rk(clefeccive cQn deus~r o r ignilion coil Replace:

•
8. Tmtlropcr carburetor flM~t le..·cl Adju~l

9. Incorrect tarhuretor a.ir tcrew sdju&l ment AdjuNt

Enr!n• hlah opeod I. Wc::.ak \'Aive !'.prinK Repla.e~
r .. nnlntr i• not &U.ble 2. IncotTt:<'t va1v.- timinA A.djust
3. Jru.ufficif'nt spark plut: C•JI Adjua-t
4. Re.ard«< ignition timin,~r AdJU'II
5. \\'nk point arm •pnng R.Pae•
6. Deff:Ctlve ignation coil R~lct-
7. Improper carbumor Rout le..·d adJu•trnt'nl (k»..- IE'\·fl) Ad1utl
8 Cloftged air cl~ner t!f'mf'nt Clean
9. lnsufficitom (u.-1 in urbumvr C1on or "upply (uel
ExhanJ!I ~&mo k e from I. Excr~:sive fi\)(11\C oil t\dju!n oil l("'lf'l
mu ffler Check wirh l~vd j,(iluj,(e

•
~ . Worn cylinder llnd 1>i:Hon ring~ Rt>llli'II"P

:l. \Vorn vAlve guide Kcplace

4. Defective!': l'y'lindc>t RrplncC"'
--
Lmcli or po..-er l. Incorrect IAJlJ'H"t adju•Hn4."nt AdjuM
2. toss of \•olve ~1•rinK c<>n,.inn Replac•

•
:I. lncotre<'t \•alvt tim1n.: AtiJU"'1
•5. v.•orn cylind~r arw.l Jn"ton
Jmpn:>pPr nlvr Ra.un~
Rep!"''
R~pla.:e
!i. lnrorr«t ignition tinunK Adju•t
1. [)e(ettiYf' contact brukC'r ....,.nt Rrpair or tf'plac.·t'
0 lncortt"Ct ~park plu.r gap Rlt'p~~ir
Clogg.=od c.-:artu,~r..rnr mam or du\., JC'l ...~~le'

•
9. Clc.-an
10. £mpropcr Aoat l~\f'l adJu•tment Adju~t

11. Clog~N'I a1r cleaner Clean

116 VII. SERVICE DATA

Trouble Probable cauH Remedy

f---- ·

•
EJ'lgin.e ovtrheatil\1' I I. H Nvy a rbon dtpo.it on cyhnde-r hu d O.:carbonit~

t. lntufticit:nt en.aint oil S upply co normal lcvcJ

3. Oe:fec1ive 01l pump. or doued oil )»3tage C lean
4. Too le~n gat mixture Adjuot
5. Adwanc;ed 1&nlltnn timinsc (knocking) Adjust

Frame
Troable
Hard otoorins
Probebl• ......

I. O.cr·tiahtt'ne-:1 a.eerina tlcm

2. Oarnaa-M t.Cetrina: 11tm •tHI btUt
Adjust
Rep!a.,.
Rtp~
Re•eciJ
•
•
3. Bent au:erintc •ltm
4 Low lire 1n8ation pm~~~un" Adjust
5 0\-tr·tiRhtmed 1t«rin1 con~ race Adjust

Motol'Q'd~ pulll to I. Unequal ttnlion of ldt and right iutpension springs Ktplac.
oae side 2. Bent fron1 fork Repair or replt~~«

3. Bent front ulf', or incorr«:t alignment of wheel R eplace or repair

front wheel wobbltlll l. Ddormf'rl rill\ R eplace

2. Worn front whed be11rinas Repla«'
3. Loo,. apok• Recighlen
4. Dtf('("livc tire Rtplace
5. !AJ.wc fronl u le Reiighten
6. Improper balance Rebalanc~

Soft. front euapenAion I. l..0111 o f apring u:nsion Replace

•
2. lntuflicienl d•m ptr oil Add oil
.
HaN front •uapen81on I. l li~eh villco•ity (')( dam per oil Ch a ,~ge

t. Exceuive dampt•r oil Adjust

Noi&)' front sugpen11ion I. lntttrff"rt!nct b~:twctn .hock ab~Mhcr cuse an d ~pring Re place
2. OamR~~:t<l llhnck •hllorber atop..,.er rubber Replace
3. rruuO,cicnt damper oil Adjust

Rear wheel wobb1ett I. 011tOrled rlm Replace

2. \"lorn rear whN'I hnnnJro Repla<e
3. !..oooe <p<>ke Retighten
4 , Def«uv~: ure Replace
Sotl rnr eus ~n!! io n I. Lou of 11prina t~ntion Replace
2 lmpn>pt-r rear •hock abtorbtt adJu~ttr adjll!itmenl Adju!!.l

•
Ra.rd rur aus pniloiOil lmpropcr rear ,hock ab&orbc-r adJUSter adJu!Ument Adju!>t
-iSoily rur aUJptn.8ion I lntttferenct hetwttn thoclr: alburber ca-.e and s pring Repla..-
2. l.NuM" in•tall~.tion Retightm

Poor brak il'l ~ I. Poor contact of brake thM R~ac:e or ~pe1r

2 BrakC' IminA i• oontaminattd with l)j( or gr'f;ti(! Rt>placc

•
3. Lootc bn.lc.c:- uble or worn bnke pnW :-;haft Rtpair or adju!l.t

1-
• lmproptr brakt adJU•tmcnl Adju.sl
Repla~
-
No edjuwting I . Wum brakC' shoe
allo-wance 2. Wort\ brM.lcc 1h(.)f; c-.ar'l\ Rt>pl:~c~

:I lmpru~rly 4"1l,:(ll!lC'd ht3ke ann &err$hOn Replace

4. Worn brake caun Repla('e

Bnke
applied
squeal~! when I. Worn brbkt.• 'iht~t
2. Fortign mttl h.'f ¥tickin" to l.rakC' shoe surface
3. I 11\rdc.•nc.••tl brake ~h(')c.• Jurfnce
I 4 . Bt.•nc or IW,Mf'd brRkt ahoe
Rel>la('e
Clean or repll'lc:e
R~placc:
Kepi<.let'
•
 VII. SERVICE DATA 117

• Electrical
Trouble
No or poor aparkln.g
Probable
I. Defective ignition ooil
~. Defective $park plug
e&U&e

Replace
Replace
Rerne<ly

•
Bllrtted eontac.t Defective condenser Replace
bNaker point
Spark plug elect rode I. Too rich gas mixture Adjust ~.:buretot
routed with carbon 2. Poor quality of gasoline Change
3. C1ogged air cleaner Clean
4. Use of cold "park plug Use proper heat range plufl:

• Spark plug tlt etrode

fouled with oil

Spark plug electrode

overheated or burnt
l. Worn pi8ton ring$
2. 'W orn piston or cylitlder
3. Excessive cl~.arl\nce between valve guide and valve
I. Use o( hot Rt>ark plug
2. Engine overheating
Replace rings
Repl~ce
Replace-
pi.slon or cylinder

Usc proper heat range plug

Adjust
3. Incorrect ignition timing
4. Loose spark plug Retighten
5. "foo lean gas mixlure Adjust carbun•tor

No chargin~e I. Broken wire or l'lhonerl or I()OSe connection Repair or replace

2. Defective generator coil du~ tO short circuit. 01' Replace
grounding
3. Defective silicon diode Replace

•
4 • Shorted or brokc.n lead wire of regulator Repair or replace

tna:u.fticient eharJrinJr l. Wiring

• Broken or $hoMed wirt, or loose connection Hepair or retighten
:!. Generator
· Shorting acr~s layers in stator coil Replace
• Op(.'ll circuit in slalor coil Replace
. Defective sihcon diode Replace
a. Regulator
. Voltage below ~pedfied value at no Joad Replace
• Coil or resis10r inten\ally ~honeci Replace
4 . Battery
• L<1w electrolylt level Add di•tilloo water to t~Ormal levd
. Defecti\•e bauery ph~.te$

•
ExeeMive charging I. Baucry intern('llly $hOI'led Repair
2. Heguhuo r
. Excessive voltage 8l no load Revl::~ce
• (mpropt>l' Jo(rounding Ground properly
• Broken coil le:td wire Repair Qr replace

•
tJnst..able charginJr I. W'ire ~hurting icnerrniucndy under vibration Repair or replace
voUaJ'e 2. Generator layer shorting Repair or replace
:t Regulator
· lnl~rmiHent open circuit in coil Repair or rcplttl't'
. Improperly ;,\djusterl vohage N.epl(\ce
. l>efecti•:e key switch Replace

•
• Dirry point~ Clc:.an
I
118 VII SERVICE DATA
6. SPECIFICATIONS -------------------
DUIF.l'iSION
Ov<nll lenRth
Overoll width
rJl"•"'ll height
Item CB200 (G•n•r•l typo)

2J).tO mm (80.3 in.2

77(> mm (30.5 in.)
l,l25 mm (44.3 in.)
• 800 mm (:U ..1\ 1n.)
'1.070mm (42.1 m.)
..
• '1..085 ntn\ ( 82-1 in.)
~X)mm (31..5in.)
HL,070mm (42.1 in.)
•
•
Wheel base 1,345 mm (53.0 in.)
SeAt hrlght 810 m m (31.9in.)
Ground clearanc~ II;() mm ( 6.3 in.)
llrrw..,.!u 162 kl! (3o"7 U..) ' 165 kg (364 II><) ••155 kl! cJn41bsl
-
F RAME
~Tyve ____ Seu·u·doubl~ t:r.tdle

•
..... : · ~u!lpeusion, I ravel Tdt:I5CCJj)iC fork, ll4.5 mrn (4.~ 1n.)

l<. autpenslon, tr1wel Swin~t arm, 77.11 mm (:1.1 in.)

F hrr ~.. (!rMIA:UI"e 3.00 IK ·41'R. 1.8 kg )({ em (~i P'-'>
-
R b~ tize. prbtioul'f' :l.'i0-18 41'R. 2.0 kR "l· em (28 .,.i)
F br•ke lntemaJ upanchng !!hoeoo. Ott&C' brake
-
R. br•ke Internal txpending sh04!11
Fuel c~pacity 11.0 ht. 1~.7 U.S. gol .. 2.21 mp ~ol.)
-
Furl reserve CAj)llCily 2.51it. .(IJ.7 U.S. gal .. 0.61mp. ~•1.)
Cuter angle 62.S'
T""l ltngth 92 mm (3.~i in.)
I!!>GINE
~ -- Air cool~. 4-slroke. 0 H C f'n6(lne
\yhndtr arrangement Venieal, 1win parallel
Sure and stroke 56.0 X fi0.6 m1n (2.204 X Ul92 in.)
-

•
Displacement 249 CC' ( 15.2 cu. ln.)
~pression rauo 9.S: I
Valve U'81n ChJiin dnvcn over ht-ad cam,haft
~0.1 CI~Citl 2.0 lit. (2.1 U$. qt., 1.8lmp. qt :
l.uhnc:t.llOn syM ..m f'Mced and wet .su.mp
-
l nlekc val,•e ~--~l)t'll'l At 5.. ( hdorr: lop dead centerl
-
C' lo~t:s At 40,. (u.her lwttorn rt~.arl C't•ller)
()~"' At 40• (hfoforco bottom dead t:t't\ter)
1-:'lthau.s.~ ''ah·e
Cl~ao AI $" 6hc-r top deed ct-ntf'rJ_
-
Valve tappec clntt'lln4.:c l:-1: 005mm (O.ocrlin.), EX: 0.08mm (OJXl~n.j
-
Idle •ececl 1.1tXJ rpm
- DRIVE T RAIN
--
(;lulch Wet, multi._plate tY~_

•
han•mls..o;.ion 6·it>N"-<t. C'onsumt mesh
Pnmar-1 reduenon 3.714
-
~:tr ratto I 2.500
(~t>ar rauo II 1.750
---
lical' ra~ 1.375
Ccor rntio JV 1.111
-

•
c: ....r raho v 0_965
G~ rwo \~I 0..1166
Final r«<ualon 2.375
~t r ..,h,ft pattern Ldt fooc <JptrJted return "l•tcm
ELECTRICAl.
l~tlliiiOO Battt'ry Anti tgmlion coil
--

•
St•ning ~YS-tt.·m Starung motvr :md kick -llrter
j\ltc:roator -~ c Kt'ncra.IUr. 0.1311;\\. !"),(Jll rpm
_ Ratrrry capacity l:!V 12AH
Spork plug !'C. K ll ~t::S. NL> \\ 2-IE:>
• ln<.lic-:atf!!i. l'tl"lt'cihcll.lion of O.K. rypl.:.
-• Indicates SIX:Ot:ilk~tli(ln of Eurot)ean l)'I"X'.
 VII. SERVICE DATA 119

• DIMENSION
Overall len~~th
0\'eraJI width
0l'erall height
Item CB300 (U.S.A. and general ty~)

2,040 mfn (S0.3 in.)

775 mm {30.5 in.) * 800 nun (31.5 in.)
•"2,085mm (82. 1iu.)_
••
SOO mm (31.5in.)
ll25mm (44.3in.) •1P70mm (-12.1 in.) Ul.(Y70mm (4:t.l in.)
CL3GO

2,040 mm (80.3 in.)

820 mm (32.3 in.)
1,115 mm {43.9 in.)
-
·-

•
Whee) ba!'.e 1,345 mm (53.0 in.) 1,345 mm {53.0 in.)
Seat l1eight 810 mm (31.9 in.) 810mm ( 13.0 in .)
Ground clearance 100 mm ( 6.3 in.) 160 l'l\m { 6.3 in.)
Dry weight 182 k• (357 Lbs) *165 kg'(364lbs) ..165 kg (364 Lbs) 162 kg (357 1bs)
FRAME
T y_ee Semi·doubJe er.,dle _!YJ)e Semi·double cradle: type

•
F, tulit)flnliiion, t ravct Telc5copic: fork, 114.5 mm (4.5 in.) Telescopic fork, 114.5 m m {4.5 in.)
R. $U~pt: n;ion, travel Swinll( arm~ 77.6 mm (3.1 in.) Swi11112 ar m, 71.6 mm (3.1 in.)
F. lire size, pressure 3.00 18-4PR, l.8kgfsq.cm (26psi) 3.00-18-4 PR, 1.8 kg/ sq. em (26 Jl6i)
R. tire si,e. pressure 3.50-ls-4 PR, 2.0 kg/sq. em (28 psi) 3.50-1s-4 PR, 2.0 kg/sq. em (28 psi)
F. brake Disc brake Internal expanding shoe!!
R. brake Internal expanding $hoe! Internal expanding shoes
-
Fuel capacity 11.0 lit. (2.7 U.S. gal., 2.21mp. gal.) 9.0 Lie. {2.4 U.S. gal.. 2.0 Imp. gal.)
Fuel reaerve capaci1y 2.5 lie (0.7 U.S. g•l .. 0.61mp. gal.) 1.8 Lit. (0.5 U.S. gal .. 0.4 lmp. gal.)
Caster angle 62.5" 82.5"
Trail length 92 mm (3.6 in.) 92 rnm (3.6 in.)
I-ENGINE
-
'Type Air cooled, 4·stroke, O .H.C. engine
-
Cylinder arrangement Venical, twin parallel
Bore and stroke 67.0x50.6 nun (2.638x l.992 in.)

•
Oisplaccm ~::n t 3..!)6 CC (21.7 CU·in.)
Compression ratio 9.3: I
Valve train Chain driven overhead camshaft
Oil capacity 2.01it. (2.1 U.S.qt., !.8lmp.qt.)
L\lbti<:Rtion sy:s1cm Fvrcetl aud wet Sul'op
OQ!::n~ At 5° (bc!ore top de-.ad center)
Jmake \'lllve
CIU;:o;ei At 40° {after bottom de-ad center)
0 >ens At 40° (bt.-forc bottom d(:ad center)
ExhauM valve
Cl~es At 5" {after top dead center)
Valve tappet cle3rance lN: 0.05 mm (0.002 in.). EX: 0.08 mm (0.003 in.)
Idle speed I,lOU rpm
-
DRIV& TRAIN
Clutch \Vet, multi plate type

•
Tratumi!l.sinn t)..speed, constant mcl'>h
~rimary reduction 3.714
Gear ratio I 2.SOO
Gear ratio TI 1.?50
Gear ratio 111 1.375
Gear rat1o IV !.Ill

•
Gear ratio V 0 ~J5
Gtoar ratio VI 0.86t\
fin.tll rerluction 2.125
Gear shift J):)tlern Left foot or>erated rewrn $}'~teen

ELECTRICAL
l~nition O:ttte-ry and iKnition coil

•
Starting system Starting mutor ami kick :starter
Ahernator A.C. generator, 0. 13 kW/ 5,000 rpm
Bauery <'. apacity tt.V-12AH
Spark plug :-IGK B8ES, ND W24J::S

:t I ntlic:.'lh"~ sp.eeiiication:; of U.K. type.

u lndicat<.-s specific:<.ltiO()S ,)f European type.
120 Vll. SERVICE DATA
~--------------------
7. WIRING DIAGRAM
It ~
~!~ ~
,..., 1
•
•
•
-
w
0...
>-
....
<
(/)

:::>
0
CD
M
CXl
u
•

•
·g·.
•
1:
J~· •. -
•
•
 VII. SERVICE DATA 121

•
•
• ~ -- ---------
--

llE
-. .'
.. ..

~·
• 0
It)
N
IXl
(.)

•
• ! x~

• i
IJ. · ..........
.. ..:.t
122 VII. SERVICE DATA

•
•
•
w
0..
>-
1-
...J
<(
a:
w
z
w
(!)
~

0
(JJ
(")
~ .:1
~~"
.,!I - lc
lc;•Ic;
•
0 ·~ Il l
10
N
IJ)
u
·~ IS- -
"~
ciN,e.
"H
"..
..
.
;?

..
;
f-
I :

~
•
•
110
7

" '!!~!:

'i! -6'!>-+
-
•
•
'.,61
l.o & X ::.j_
 VII . SERVICE DATA 123

• ~~I !mo
i
"- riI

• r
3 ~'1
I,
i~==========~~ffir~========~ !
,
·· ! ~ ·1
~~~ - =
3

• ~-
"'"' ~~-~
·· · ~ -·

~ ij I~!
w ~ -~ ~ 2
c.. 'if' ,,
>- f -"' ,

• -u...0
co
C")

0
It)
.
N
co
u

•
•
•
124 VII . SERVICE DATA

•
tuiu
•
•
0 • • ~

~-~~.;J.

0
(0
(")
•
0
It)
N
co
u

•
•
•
 VII. SERViCE DATA 125

•
•
• ~I
w
a..
>-
1-
z l;i
~
w
a..
0 i
• a:
:::>
w
0
co
M
\1§:~ ~
,._

0
't:::=::::o>~ J
It)
N
fJJ
u

•
•
•
126 VII . SERVTCE DATA

•
-~•••• •
•

0
co
M
...J
u
•

•
tg
f
· .,
·.. - '

J '"' ...
•
•
 127

VITT. SUPPLEMENT '1'0 CH3601' · CL360Kl

• I. FUEL COCK
The indication rna rlu and their posittons on the fuel cock was

•
changed to a new type.

• 2. SlOE STAND
Fia- T -I (I) Fuel cock
(2) Lever

The side uand was changed to a new type with a shock

absorbing rubber pad.
The stand must be inspected periodically to determine that it is
in good condition.

lnl§pectiun

• I. Check the entire stond assembly (side stand bar, bracket and
rubber p•d) for installation. deformation or otherwise
excessive damage.
2. Check the spring for freedom from damage or other defects.
fll. T-2 (I) Side stand bar
(2) Spring
(3) Rubber pad
(4) 6 mm boll
(5) Sklc: stand pi.,ot bolt

3. Check the side stand for proper return operation:

a. Wtlh the SJde stand applied, raise the side stand ofT the
ground by using the main stand .
b. Attach a spnng scale to the lower end of the stand and
measure the force with which the st•nd is returned to its
ongtnal poSthon.
c. The stand condition is correct If the measurement falls

• within 2 3 kg (4.4- 6.611».).

If the stand requues force exceeding the above limit, this
might be due to neglected lubrication, overtightened side
stand ptvul bolt, wuut \land bar or bracket , or otherwise
excesstve tension. Repatr as neeeSS3ry.

•
F'~&o T-3 (I) Side stand bar
t2) Spring Scale

•
128 Vlll. SUPLI!MENT TO CB360T • CL360KI

4. Check the rubber pad ror deterioration or wear.

When the rubber pad wear Is excessive so that il is worn
down ro the wear line. replace 11 with a new one.

•
P"os. T -4 (I) Wear Une
•
Rubber pad rtpltoement
I. Remo•e the 6 mm bolt; separate the rubber pad from the
bracket at the side stand.
2. Aller making sure the collar is installed, put a new rubber
pad in place in the bracket with the arrow mark pointing
•
toward out.
NOTE:
Use rubber pad havi.n& the mark "OVER 260 lbs ONLY".
3. Secure the rubber pad with the 6 mm bolt.

Fig. T - 5 (I) Rubber pad

•
(2) Collar

3. MAINTENANCE SCHEDULE
Some additions ocourcd in the MAINTENANCE SCHEDULE,
of which details are as shown immediately below:

MAINTENANCE SCHEDULE INITIAL REGULAR SERVICE PERIOD

SERVICE P~do.rm at t!...,:ry indicated month

.. .....,_.
Th\• mamtenance achcdul~ a.t bt'-td upon avera.ge or milu.ge intern], whichf'ver
PERIOD OCCUCC:$ fine.

..... .=
.".l-
ttdmg cond.itiona. Machines 1ubjected to severe
uw, or nddtn in unu:~ually du.cy are1:1, ~uire 500 .
'
....... I
I
•••t•• •••till.•
mort: frtqutnt ttn•acina mlltt
.u••
a.-
• SIDE ST'\NO Check •natallation, o~ration,

•
deformation. d•m.a:e and v.ear. 0

lttms marked • lhould ~- ltr'\"l«d by •n •uthorued Honda dealtr. u.oleu the owner has proper 1ools
and IS mt<-h&n1cally profia tnl Other maintenance item& are simple to perform a.od may be senicrtd by
the OWOC'r.

•
•
 VIII . SUPLEMENT TO CB360T • CL360Kl 129
4. WI RING DIAGRAM
(CB360T)

• I

•
I
~

•
i

~ ;~-·

• '~ ;01 "

l vj--<'

;r.•

•
•
130 VIJ I. SUPIF.MENT TO CB360T • CL360Kl
CL360KI

lc;?
!;p.
8
~
<~t i
a §
~
a I
l rf I ~ ;
~
-~D
.~
•
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~! ~ ~:,i ~

~~~
~!'l
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.•
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= '"

~~~.J
•
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~
~ J= . :~
,_ ... ~ -/~ Ia
i -~~. ~~ .
J; I~ j-l·
~·~~ ',- .JdJ
••e~ ~·~ r: /'~ J ·~-:
--·-):~~
r· •',,/ ~~~ ~~

tc~~l: ....
.. ~[~;
I I~
a~~~
f•
~,:,
~ a
•
L."~ ' ';
r= I;; ~

l lL
~~='·
·~-~
~

~ :~
~~
!n
't
;:
' •
~

·=: ; · l~ ~~~ -~
~t •

~
•
--
_:;_
- ;:-1! :--==!-d ~

•
•

s~ r~ 1
~~ I
'~ l
~ I~ , § ., ~
. ~.-~~ isg~ "" 1 ~ ·~ ;l
~ ii: ~ -
::: !,'-
~
~ ~
;r 1~~ ~ "
~
~
~
~
'
i
•
'~" r
~A
0<

~
~ •
 131

• I. AJR CLEANER

The following Slll.lW> changU Of the shape and doussembJy

procedure only.

• Disa~mbly
I. Open the seal and remove the nghl and kf1 side cover1.
2. Rem<m: the nuts (2), and remove the air cle•ner case cover.
3. Remove the au ckaner bolt and loooen S mm screw and
remove the air cleaner element •

• 4. Separate each aor cleaner element from the air cleaner case.
Fig. I (I) 6 mm nut> (2) Air cteaner cue covt:r

S. Loosen the inlet tube band and remove inlet tube .

• Fig. 2 (I) Inlet tube band

(2) lnlcl tube
(3) S mm sere"'
(4) A1r cleaner el~:rne.nt
(5) Air clcan.:r bolt

6. Loosen the Inlet lube band and remove inlet tube.

7. Remove the 6 nom bollS and air cleaner case .

•
•
Fig. 3 (I) 6 mm bolu

•
:.:IJ:.:2_ _ __ _ __ _ _ _rx
_. _SU?_PLEMENT TO CB360T (LATE MODEL)
8. Clean the air cleaner elements.
Give a light tap to the air cleaner element to remove dirt and
dust.
If necessary. dorect a blast of compressed oir at the inner
surface to blow orr dirt and du~t completely.
CAI!TION :
If the air cleaner elemenlll become oUy or if they are broken,
rep~.
•
v-. 4 U) Au dn.ocr element (2) Au run
•
Assembly
I. To mstall reverse the removal procedures.
NOTE:
For easier installation of inlet tube, remove screen and install
•
band from inside by fing<'rs.

Fla. 5 (I) tnlettube

•
(2) Inlet tube band
(3) Screon

WIRING DIAGRAM

•
•
~- ..,. ..J,,jiLO!

'
••
..•
"
••
>
·''
,. ) •

--.•.·-... . -...
-·
•..
•
 IX. SUPPLEMENT TO CB360T (LATE MODEL) 133
---
CHANGE TO THE CENTER CRANKSHAfT Select fit table of the center bearins
JOURNAL FIT MARKINGS (radial clearance 12 20p)

• Applicable production Modell and Engine Serial Nos.:

CB2SOC5 CB2SOE 6011678 and sub~quent
K5
('BJtJO cBJSOE 1055298 and sub~quent
Center crankshaft
markmg
1 or A
o orB
Center bearing assy.
markmg
A
8

•
CB360G
,,or C ('
CL360 CL360E-1012J86and sub~quent
D
The fir markmss of the center crankshoft journal have been
c~ed as shown In the table below.
.::.or D
;t-orE E
-
'1\>lten replacrng center crankshaft and center beanng assy. select
the crankshaft and burrng wuh the same marking1 according to

•
the right side table .

•
•
• (I) (.;enter crank
(2) Center hearing
(3) Marking po'lition
134 IX. SUPPLEMENT TO CB360T (LATE MODEL)
ROCKER ARM SHAFT
Tite foUowing shows rocker arm shafl dis.1Ssembly and a<sembly procedures.

A
(OLD) (NEW)
•
L Qt:;
(OLD)

(NEW)
i
l
•
Standard torque
4 0 4 5kg m
(29- 33 1 bs-ft)

1 ~)
Standard torque
0 7- 1 1kg-m
(5 . 1 - 8 0 1bs It)
•
I
1 . a: , LI

I ·
(NEW)

FH
5 2+0

- 03
~o!-
j
Applicalicon of Modificotion•
Thts changes have been applied on the pmducti<>n models
starltng with 1he following engine <enal numbe.-.
(O LD) 4 5 0 5

•
TYPE lNt.INI! \o
CB250 K5/G b01110l
CB3bOG IOH8381
CUbOKI 2008449
l HJbOT 10311(>4

Disas<embly
•
•
Referring to disa~mbly procedurt< un page JH.
Ex~ept thJI Rtght rocket aun shafl "renm,·ed only loosening
bolt.

fig. l ( I) CylindeJ head <'OVei

(2) Scaling w<.~ sher
(3) Rt~t rocker ;,tnn shali
•
(4) Lefl rocker aun sh"fc
 IX. SUPPLEMENT TO CB360T (LATE MODEL)

Alllltmbly
Referring to a"""mbly procedure un page 44. Taking care of the

• foUowing .
I. lnstaU new r<X:ker arm shafls tnto the bores with sealing
washers.
NOTE:
Tbe 10alina wuher cannot be re-<ned after once being
tiglt~ned to tbe abo•e specif~ed torque, beeause of possible

• deformina or warpa,e
2. Ret.gbten the $haft(bolt to a torque of 4.0 to 4.5 kg-m (29
to 33 lbs-fl) using a TORQUE WRF.NCH'.

Cylinder head t.gbtening torque is 07 - 1.1 kg-m (5.1-8.0

lbs-ft) for 6 mm.
Elg. 2 (I) Rubbef pl"' (2) Spuk advanct•

• SPECJFICA TIONS
Caster angle
- Trail
Gear ratio I
63°
9Smm
2,438
I
Gear ratio II 1,667

Fig. 3 (l) R.ighl rocker arm \hlll'll'

•
•
•
136 IX. SUPPLEMENT TO CB360T (LATE MODEL)

•
•
•

•
•
•
 X. SUPPLEMENT TO CJ250T/CJ360T .137

• SUPPLEMENT TO CJ250T / CJ360T

•
• This addendum is a maintenance manual for the Honda CJ2SOT/CJ360T
motorcycle. For information th<tt is common to the CB2SOT, CB360T and
CL360, refer to the preceeding pages.

I. CONSTRUCTION .. . .See page 2

• I. Front Shock Absorber

The front shock absorbers are of a long-stroke, direct-acting
type using a free valve. The boltom case is made of alminum
alloy. The absorbers dampen out spring oscillation after siding
PtKg)
t 92.5

'7
over holes or bumps.
Stroke: Compression: lOS mm; Expansion: 34.5 nun
(Total: 139.5 mm)

29.5

0
/ 49 2 154.2 tmm•

•
-+8
F1g. 1 Pcrtormance curves

2. Rear Shock Absorber PtKg)

The two rear shock absorbers are direct-acting shock absorbers +

•
204.9
that are equipped with a bottom valve. An oil damper is utilized
10 pre\1ent cxt:cssive wheel movement and tlarnpcn out spring
oscillation.
Stroke: 77.3 nun
135
18y
7
37
31.3
7;

•
I

0
/ I
16.9 20
'
I

73 101.7(mm)
-+8
Fig. 2 Performance curves
138 X. SUPPLEMENT TO CJ 250T/CJ360T

3. Gransmission
The gtansmission is~ 5-speeu ~onstant·mesh type.
Gear ratios: Primary gear: 3.714; Secondary chain: 2.063 •
Gear ratios:
l•t . . .... .. ... ... .... ... ... .... .. 2.438
2nd . . . . . •. . . . ••. . . . . •. . . . . . . . . . . 1.667
3rd . ... ... .... ... ... ... ... ..... . 1.375
4th ............................ 1.111
Sth ............................. 0.965

4. Air Cleaner •
The air cleaner uses a pleated paper element to Jl(event dust and
grit m the llr from entenng the engme through the carburetor.
It abo muffies the noise resuhut& from the intake of air through
the carburetor and valve ports. 11 ts very Important that the
element be semced carefully as gnt and dust could, ause •
serious damage to the enS"'•·
,,..-
r
I
Air Cleaner Air C leaner

~~ •
Caboreter

•
Coburoter
.... 3
II. INSPECfl ON ANO AOJUST\IENT . . . . . . . . . . See page 17

I. FRONT FORK
Changing fork oil

•
1. Unscrew the front fork drain plug at the bottom of the fork
leg. Drain the oil by pumpin~ the fnrk while plug i> out.
Replace the plug securely after drammg.
~. Set the motorcycle on the center stand.
3. Place a jack unde• the <Jallkc@SC to cont iOllowerillg of the
front end.

•
4. Remove the handlebar hy removing the four handlebar
bolts.
5. Unscrew the fo1k filler plug' unhl free.
6. Lower the jack under the engine 10 extend the fork springs Fig. 4 (I) front fork d!llin plug
with the attached filler plugs.
 X. SUPPLEMENT TO CJ2SOT/CJ360T 139

1. Move
----
the fork springs to one side and pour 120 ee of
premium quality ATF (automatic transmission fluid) Into

•
each fork leg .
8. Raise the jack under the clljline to allow the fork springs
and filler plugs to return Into the fork tess.
9. Securely lighten the fork filler plugs.
10. Remstall the hllnulebar, tightening the two front bolts first,
then lightening the two rear bolts to the same torque.
II . Remo•.. the Jack from under the eng;ne.

• 12. Pour 140 ISO cc of premaum quahty ATF into each fork
tea if the fork hu been disusemblcd.
F'IJ. 5 (I) Front fork filltr pluJ<>

• 2. Air Cleaner
t. Open the seat and loo<:<n the screws (1).
2. Remove the three nuu (2) and remo111l the air cleaner case
cover.

Fig. 6 (I) Screw

•
(2) Ntll
(3) Alr cleaoeJ case cover

3. Unscrew the bolts (I) and remove the air cleaner case from
the carburetor and frame body.
4. Remove tho bolts ( 3) and screws (4) unu take out the air
cleaner element.

•
Fig. 7 (I) Bolu (4 ) Sc•n~
(2) Au deantr cast (Sl AU cleaner ~lcment
(3) Bolt•

5. Shake any dust orr the cleaner element Apply a blast uf air
from mside the element.

•
CAUTION:
Replace the element if it i> found to be wet with oily or
greasy substances.
6. fo install , reverse 1he foregoang, removal procedure.
7. ~lake sure tllJI 1he tnlct tube and connecting tube are
secured in place and 110 1 leaking air.

• Fig. 8 fl) Air cleaner element

140 X. SUPPLEMENT TO CJ2SOT/CJ360T

ill. ENG INE

•
I. ON-FRAME SERVICING (Engine Di~a....,cmbly)

No. Item Ref. page

I Cylinder he•d . cyhndcr and pt>IOn> 17
,- Left .:r:~nkcase cm·er. A.C:. ~cncra1or 143
3
4
s
6
Right crank use co,·er and dutch
Oil pump and otl Iiiier
Gearsltift spindle
Carburetor
47
50
51
63
•
2. ENGINE RD10VAL AND INSTALLATION
Removal
Renl<"'e, the engine for disassembly after the engine oil has been dramed.
(J) Open the seat and remove the b3uery. To remo••e the
~--------------------~
® Close the fuel cock and remove the fuel tube. Remove
•
battery. disconnect the negative terminal nrst. the fuel tank. Avoid damaging D1e fuel tube.

•
(I) &uery (I) Fuel tube
(2) Battery neptjvc terminal
(3) &ttery positive terminal

® Remove Ure gear shift pedal and l,c;rankcllSt cover. ® Remove the drive chain together with the drtve sprocket .
Remove the drive sprocket fixing bolts.

•
•
(I) Gearsruft
(2) l.-cronkca~e cover
(I) Drive sprocket ft.:dng bolts (3) Drh-e sprocket
(2) Lock pl.atc {4) Ori..-e ch11in (endless)
•
 X. SUPPLEMENT TO CJ250T/CJ360T 141

ell Remove the mufner by removing the nut (2) and bolt Remove the bolt ( 1).
(3).

•
•
• (I) Muffler A"Y

@ Disconnect the A .C. generator wires at the coupler as

(I) Doli

CD Drain the remammg fuel from the carburetor by

shown. loosening the drain screw. Loosen the clamp at the
connecting tube. Use standard gasoline warnina .

•
(1) A.C'. ,enerator couplet ( 1) Drain .screw
(2)0amp
(3) calbWetor insulatOf band

Ql) Remove the carbureto~ toward the left while pushing ® Remove the tachometer cable. spuk plug cJps and
them down toward the atr cleaner. breaker point wires.

•
•
• (1) Qu-buJe1on (1) Tachometer cable
(2) Spa1k plug cap
(3) Breakts poilll curd
142 X. SUPPLEMENT TO CJ250T/CJ360T

® Remove the UBS nut> .nd nuls ( 3) illld toke out the ® Remove the UBS nuts (2), (3) and (4). The left foot peg
engine upper hanger. will be removed when the nut (3) is removed . Draw out
the bolt by removing the nut (4).

•
•
@ Remove the bolt (3) and pull oil tlte boll (4). fake out 6.l Remove the bolt (2) to take out the brake pedal.
•
the engme hanger pla te. Remove the nu t (5) and remove
the plate complete with the right foot peg (with the boll
(6) and nut). Remove the kick >tarter pedal.

•
(I) R1ght rout P<t (I) Brake
(2) EnJ~ ne ha.n,er pl.ale
(3) Kic::k starter pedal

~ Remove the bolts (2) and (3) Ul With the aid of an assi>tant remove the engine from the
nghr side. Before removing, install the luck >tarter pedal

•
to facilitate the operation.

•
To install the engine. refer to t>uge .l4
(I ) lUck p«<> 1

•
 X. SUPPLEMENT TO CJ2SOT/CJ360T 143
-------------------
3. CYLINDER ttEAD . CAMStlAFT, CYLINDER AND PISTONS . . . Refer to page 37
4. A.C. GENERATOR

•
• ( I ) Left <r.mkcue co-tr p>ktt
( 2 ) Lcfl crankcase <O'<r
( 3 ) Neutral \'4ntch

•
( .() Oulth ~t:r
( s ) Dull t<al
( 6 ) Oul<h ball r<tun<r
( 7 ) Oulch lenr 'J)MJ
( 8) Oulch ld)unin& cam
( 9) Outch lifler adjuuma \Crtv.'
(I 0) Left crankcase rear tO\'er
(II) Stator
(12) A.C. ecncntor rotor
(13) A.C. p:n<rator Assy.
(14) Rotor settlna bolt
(1 S) Generator CO\'tr @iUlcel
(16) c~ner.ator cover
Fla. 9
®
The construction of tho generator is ns showu in Fig. 9

•
immediately above. The startiug mechanism is eliminated .

Disassembly
1. Remove the change pedal.
2. Remove the LA:rankcasc rear cover.
3. Remove the clutch cable end off the clutch lever.

• 4. l>is<:ounect the A.C. generator coupler and renlO,.. the cord

from the neutral switch.
Fir. 10 (I) Out<h levu
(2) Outcb able tr>d

•
5. Remove the J.A:rankcase CO\'Cr.
6. Remm·e the A.C. generator stator from the L-crankcase
cover by backing off the l>olts (5).

• Fig. 1 I (1) I.-crankcase cover

(2) Stator
(3) Neu hal switch cottl
(4) Cenerutm curd
144 X. SUPPLEMENT TO CJ250T/CJ360T

7. To remove the A.C. generator. remove lhe rotor set boh

and screw in the "Rotor Puller" (Tool No. 07933-

•
2160000) as shown.

A~mbly
Assembly is lhe reverse procedure of removal. However, observe
the followina assembly notes·
J. Before installing the generator rotor, n>:~ke ~ure that the

•
woodruff key is properly seated . Ttshten to specified
torque while holding the rotor by hand or with a suitable
tool.

FiJ. 12 (I) Rotor,., bolt (2) Rotor I'IIUer

•
S. RIGHT CRANKCASE COVER AND ClUTCH . . . . . . Refer to page 4 7
6. Oil Pm fP AND 01 L FILTER ROTOR . . . . . . . . . . . Refer to page 50
7. KICK STARTER AND LOWER CRANKCASE

( I ) Oil separator senlna bar

( 2) Oil separutor
{3) t8 mm washer
( 4) 18 mm snap 1in,g
( S) Kick starter l!pring
( 6) Kick llla.rter &pindlc
( 7 ) Ktck starter pinion

•
( 8) 20 mm chrusl wat~hcr
( 9 ) Setting spring
(10) Kick starter ratchet
(II) IS mm thrUit W~lh<<
(12) Raccllcl 'lpring
(13) Ratchet f,Uide plate
(14) lllrust washer
(IS) 12 mm snop ring
(16) G<arshlft spindle
(17) Tensioner settina bolt
(18) 0.1 ch<ck bull
(19) Tensioner outer spnna
(20) Tensionct inner sprina
(21) TelUloner puh har
(22) Lo"'"'
ctanl<.ca,.
(23) 14 X 28 X 1 Od S<al
(24) Drun bolt
@

•
Fis- 13

Refer to page 53 for disassembly, tnspectron and assembly

I. Assemble the parts'" the order named.

•
2. Install the k•ck starter rat~:het with the kick ;tarler spindle
placed in the position shown tn hg. l4.

Fig. 14 (1) Kick starter ratchet

(2) Kick starter spindle
•
 X. SUPPLEMENT TO CJ250T/CJ360T 145

8. GEARSHJFT MECHANISM AND TRANSMISSION

•
•
• (
(
(
1 ) Shift drum rtoppt"r
2) Shifl drum stopper 'PTIIIJ
3 ) Shift fork ll'ide shaft

r
( 4 ) Gconhoft fork A
( S ) Shlfl drum pi do sere~· 0 '
16) tl mm lock wuher
I
( 7 ) Drum •topper t.a~m plltc
( 8) Gearshift ~rum
( 9) c...
uhlft fork D
,
(J
(I 0) Gconhitt <pindle
(II) Ceanhift return sprina
Fig. IS

I. Refer to page 57 for disassembly, Inspection ond assembly.

•
For assembling, refer also to the sketch lonmedlntely below .

• 14 ((@
~ 17

• ( 1 ) 20 mm needle roUer bc:arin&

( 2 ) 20 mm th.mst 'W8\her
( 3) C·l$1 i""
( 4 l C-5th go:;u
( S ) 25 mm ~nap rinJ!;
( 9 ) 25 mm lock wuher
(10) 25 mm thrullt v.'J~e.r B
(II) C-4th ~ear
(12) Countershaft shifter
(I 3) 'franunitlsion countershaft
(17) Tran~Jmi~'lon mam \lufl
(18) M·Sth g..r
(19) M ·3r~ ,...,
(20) Collar
(21) M-2nd J<lr

•
( 6 ) 25 mm thru\1 wa,hcr (14) 52 mm beoringset rin~ (22) 20 mm needle toUer bc:uing
( 7 )C-3rdgm (15) 34 X 52 X 13.5 X I S.S Oil seal (23) ij x 34 x ij oil sui
( 8 ) 28 mm ~tpllned bushiJli (16) 520S HS b>ll be:uing

Pis- 16
146 X. SUPPLEMENT TO CJ2SOT/CJ360T

9. CRANKSHAFT AND UPPER CRANKCASE .......... See page 55

10. CARBURETOR
Refer to page 63 for disassembly, Inspection, adjustment and
assembly. For carburetor adJUStments, refer also to the instrue-
tioiU gtven in the table on the right. Main jet
Item
Setting No.
Primary
Secondary
Slow jet
7S9A
#68
#110
# 3S
•
•
-
Jet needle setting 2nd
Pilot screw opening 2 (Standard)
Float level 18.5 mm

•
[V. FRAME
I. FRONT WHEEL AND FRONT BRAKE .............. See page 68
2. REAR WHEEL AND REAR BRAKE ......•......... See page 78

I. REAR BRAKE PEDAL @

®r}
~~

®- •
( 6 ) Brake rod JOUU pin (11) AdJusun~ nut
( 1 ) StOI> swjtch A»Y
( 7 ) Cotter P'" (12) Cllan# ped>l
( 2) St01> ••itch JprUIJ

•
( 8 ) lteu bnke rod (I J) Clwlto pcd.l Nbl>er
( 3 ) Brah pedal
( 4 ) Bralte podol 'l'rinA ( 9 ) Bnke rod •t>rin&
( 5 ) Ktu brake p!Yot •haft (10) !tear bnk. . rmjoint
Fij. 17

Disassembly

•
1. Remove the stopper switdt spru1e.
2. Remove the kick starter pedal.
3. Remove the right foot peg.

Fill- t8 (I) Stopper switch spring

(2) Kick starter pedal
(3) Ri81lt foot peg
•
 X. SUPPLEMENT TO CJ2SOT/CJ360T 147
4. Remove the bolt ( I) and remove the kick starter pedal.
5. Remove the brake pedal spring.

•
• rt~- 19 m Bolt
(2) Kid: starter pedal
(3) Brake pedal spriJt&

• 6. Remove the brake adJusting nut, then remo\oe the rear

brake arm joint and brake rod spring.
7. Remove the rear brake pivot shaft from the frame.

Fig. 20 (I) Brake acljustin& nut

•
(2) Rear brake arm joint
(3) Brake rod $(-lring
(4) Brake rod

Assembly
Assembly is the reverse of the removal. However, observe the
following assembly notes:
I. Install the brake pedal spring with the end hooked on the
pedal bracket as shown .

• 2. Align the pundt mark on the pivot shaft with that on the
brake pedal; then, tighten the pedal securely .
r,._ 2 I (I) Brake pedal sprift.l
(2) Bake pecbl
(3) Pivot shaft

•
3. Adjust the rear brake pedal play and height.
4. To adjust, follow the Instructions given on p•ge 28 .

• Fig. 22 (I) Pivot 'haft

(2) Punch nuuk
(3) R.,r brake pedal
148 X. SUPPLEMENT TO CJ250T/CJ360T
3. HANDLEBAR ............................... See page 81
4. FRONT SUSPENSION .... .. .................... Sec page 85
S. STEERING STEM .......... .. ......... .. ... ... See page 87
6. REAR SHOCK ABSORBERS AND REAR SWING AR!vt ... See page 90
•
( 1 ) Orive chain guard
( 2 ) Chain guard plug
( 3) ~tear shock absorber
( 4) Shock ab50rber bushing
( 5 ) Upper join 1
•
•
( 6 ) Spring se1 stopper
( 7) 9 mm Jo(k nuc
( 8) Rear shock absorber stopper n1bber
( 9) Rear shock ab:«>rber $pring upper seal ,.- /-"" ~
(l 0) Rear shO<:k ab~orber ~pring _,../ ~
(I t) Re.ar shock absorber ~pacer /
(12)St>ringadiustcr ~""
(Ill Rear damper
(14) Dust seal cup '
(IS) Rear fQrk pivot bush ~ .&'
(16) Rear sw1ng arm
(17) Rear fork center coUa.r
~
(18) R..r brake stopper ann
(19) s~i ng arm ph·ot bolt ®
Fig.23 19 ~

•
14

Removal
I. Raise the rear of lhe motorcycle by placing a block under
the engine.
2. Open the seat and remove the seat cowl by removing the
three bolts (1).

3. Remove the tiLreC bolts (I) and lake out the rear fender
stay.
Fig. 24 (I) Bolts
(2) s.,, t cowl •
•
Fig. 25 (I) Bolt
(2) Rel.r fender stay
•
 X. SUPPLEMENT TO CJ250T/CJ360T 149

4. Remove the nuu (3) and bolts (4) to remove the rear
bumper and rear sbock absorbers .

•
• FiJI. 26 (l ) Rear bumpor
(2) Rear shock llbr.orber
(3) Nut

•
(4) Boll
S. Remove the chain guard.
6. Pry off the couer pin and remove the axle nut.
7. Loosen the right and left drive chain adJU>ter lock nuts and
loosen the adjusting bolts.

l'ig. 27 (I) Lock nut

•
(2) Adjusting bolt
(3) Axle nut
(4) Cotter pin
8. Remove the rear brake stopper arm from the brake panel.
9. Remove the rcor brake adjusting nut and disconnect the
brake rod from the brake arm.
10. While pushing the rear wheel forward. remove the drive
chain from the driven sprocket.
II Withdraw the rear wheel axle and remove the rear wheel.

• 12. B:ock nff the 14 mm self-locking nut; and. remove the swing
ann pivot bolt and rear fork in the swing arm.
Fig. 28 (I) Hrakc p•ncl
(2) Rear brake stoppc1 arm
(3) Re-ar bro~.ke adjulllln~
(4) Drake rod
nut

•
13. RemoYC the rear brake stopper arm from the swing arm .
14. For inspection, refer to page 91.
I 5. To as,.emble, re..:rse the disas.'lembly procedure .
16. Replace the rear axle cotter pin with a new one .

• Fig. 29 (1) Swing arm pivot bull

(2) Swing arm
(3) Rc:u hi".Jkc ~topper nrm
ISO X. SUPPLEMENT TO CJ2SOT/CJ360T
- - - - - - --
7. FRAME BODY AND OTHER RELATED PARTS ....... . See page 93

I. Fuel Filter Cleaning

I. Turn the fuel cock lever to the OFF position, disconnect
the fuel hne, and remove the fuel tank.
2. Drain fuel from the fuel tank thoroughly.
3. Loosen the nut (2) and remove the fuel cock from the fuel
•
•
tank.
4. Remon the fuel ftlter from the fuel tank.
5. Check the gasket and, replace tf nece,.,..ry.

•
FiJ. 30 (I) Fud occk lever
(2) Fuel cock
(3) Fuel tube

6. Oean the fuel filter with sol,·ent and blow dry with a
compressed air. Discard the old filter element and install a
new one if found to be clogged, broken or damaged.
7. Install the fuel filler in the fuel tank.
8. Install the fuel cock in t11e fuel tonk.
9. Install the fuel tank. Connect the fuel line to the fuel cock.
10. Fill the tank with fuel. With the fuel cock lever in 0'1
position, eheck for leaks past the mating surfaces of the
fuel tube and fuel cock.

2. Battery Case
I. Open the seal and remove the fuel tank.
2. Remove the right and left air cleaners.
Fig. ) I (I) Fuel cock
(2) C.<kct
(3) Fuel 1Uter element
•
3. Remove the battery.
4. Disconnect the flasher relay and slltcon rectifler wir~ at the
battery case.
5. Remove the battery case by removmg the three bolts (2).
7. To install the banery. reverse the foregoing removal
proCI!dure.
8. Apply grease to the banery tcrminol> to prevent corrosion.

•
9. For inspectton, refer to po~ge 98.
I 0. Route the battery overflow tube as per the mstructions
given in the caution label. beutg sure that it is not bent or F'OJ. )2 (I) Battery case
twisted.

•
AIR C
OI<Ait<
l'\J& J

fig. 33 (1) Batter)' es.ution label

•
 X. SUPPLEMENT TO CJ250T{CJ360T 151

3.Muffiu

•
•
• ( I ) E><hou.•t pipe )Clint collat
( 2) Exhau>t poJ*lomt
(3 ) uhauil pope
( 4 ) Ex.hauJ1 pipe c1unp
( 5 ) E><haUJI pipe pootector
( 6 ) A11:h•u~1 &ulina~J.!ket
( 7 ) Exhaust chomb<o
( 8) E.\har.ust ('hambtr dumper
( 9) Fx.hau11t chamber dtmpcr bu\hlna
(I 0) J:.xhaust chamb<r damper joint
(11) Mufner protec::cor
(12) Murner clamp
(13) Mufner seallng paket
(14) Muft1er
(15) Mufner bracket

• Disassembly
1. Remove the two bolts (I) and lake out the mufner.

• 2. Remove lhe exhaust chamber damper by removing the bolt

(I).
'-• 35 (I) Muffiet
( 2) Bolt

•
• Fig. 36 (I) Boll
(2) Exhaust cluunber damper
152 X. SUPPLEMENT TO CJ2SOT/CJ360T
~--------------~
3. Remove the exhaust pipe Joints, collars and mufflers by
removing the four joint nuts.

•
~i&, 37 (I)Joint DUI
(2) E\haust pipe joint
•
4. Remove the exhau•t pope and muffler protector .
S. Unscrew the two exhaust clamp bolts and remove the
exhaust pipe and seahng gasket from the exhaust pipe
chamber.
6. Remove the muffler clamp bolt; then, free the exhaust
•
chamber from the muffler together wllh tho sealing gasket.
7. Remove the mufncr stay by backing off the two bolts.

Pig. 38 ( 1) [xhaust pipe j ulnl

•
(2) Mufner band

~. Free the damper JOint and damper from the exhaust

chamber by backing off the two bolls.
Inspection
I. Check the exltautt pipe gasket and, it necessory, replace.
2. Check the exhaust pipe and murner sealing gasket for
dllll\3ge or other defects: if necessary. replace with a new
one.
3. Check the damper rubber bu>hlng and repl•ce if dama!ll'd
or detcrio111ted.

Assembly
F"13- 39 (I) Boll
(2) ~mpe.
(3) tbmper
joint
•
•
Assembly is the reverse order of the removal. Hn\\oever, observe
the folloWlng assembly notes
1. Put the sealing gaskets "''tr the exhaust rit>e and exhaust
pipe chamber before a<sembling.
2. Tighten the mufner clamp• on the location as t>er the
instructions given in Fig. 40.
3. Place the protector over tho mufOer clamp• pm1cdor stay,
then tighten the prn1cctor and stoy.
4. Install the exhnust pipe to the cylinder with the point.
collar and nuts.
5. Install the damper to the murner and rromc.
6. If the cylinder gasket os renewed, retighten the band bolt~
after 500 km 111 riding.
1-'ig. 40 n) Muffler clamp
(2) Exhaust chamber
t3) Exhausl pi)>(' damp
(4) Exhaust pipe
(5) Exh:wst dmmhcr d:1mpcr
•
 X. SUPPLEMENT TO CJ25aT/ CJ360T 153

WIRING DIAGRAM

•
•
•

• 1/ I
I

•
•
•
( 1 } Ttuou1e cable C6 ) V.'irc htrnelll
( 2) Front brak( C11blt ( 7) 01eathet •ube
( 3) nut<:h cable ( 8 ) Stop I witch cord
( 4 ) Speedometer cahlo ( 9) Ot~uery breather tube
( S) TachumeleJ cable ( 10) Oreather tu be
154 _ X. SUPPLEMENT TO CJ250T/CJ360T

V. ELECTRICAL SYSTEM ......................... See page 97

I. INSPECTION
I. Main switch
Check for continuity between terminals. The switch is normal if
continuity exiasts between terminals as shown (0- 0). If there
is no continuity, or if there is continuity in the circuits other
•
•
than marked, discard the old switch and install new one.

B IG ru TL2
orr 0 0 0 0

•
2 Fig. 41 (I) Main switch

Cord color Red Black Brown/ white Brown

2. Front stop switch

Check for continuity between the black and green/yellow wires
with an Ohm meter The switch is normal if the stop lamp lights
when the brake lever is pulled in 10-20 mm as measured at. the
lever tip.

3. Tum signal switch

Disconnect the switch wires in the headlight case and check for
continuity between terminals. The switch is correct if there is
continuity between Ute terminals as shown in the table below.
•
w L R PI' lP RP
L2
Ll
(N) '

Rt '

•
R2
Fig. 43 (I) Turn signal switch (5) Black/yellow
ford Black/ Orange/ Blue/ (6) Orange/white
Gray Orange Blue white
(2) Gray
color }'elJow white (3} Orange (7) Blue/white
(4) Blue

4. Dimmer switch

•
Disconnect the dimmer switch wires and check for continuity
between tcrmii1als in each knob position.

PF llK I Hi Lo _
Hi I
(N) 0

Lo
Cord
color
Black/
yellow
Black/
yellow
Blue White

Fig. 44 ( t) Dimmerswitch
(2) Black/yellow
(3) Blue
(4) White
•
 5. Ignition switch
Disconnect the ignition switch wires and check for continuity

•
between circuits The switch is normal If continuity exists
between the circuits as lndtcated by the mark "0-0" in the
table shown immediately below·

IG KILL
OFF

• RUN
OFF
Cord color Black Black/white FJa. 45 (I) Klllswitch
(2) Bladtl"ilit•

• 6. Hom switch
Disconnect the light green and green wires in the tum
signal/dimmer switch and check for continuity between these
two wtres. The switch is correct If continuily exists when the
switch button is depressed. Discard the old switch and install a
new one if there is no continuity.

Fij. 46 (I) Horn "'itch

•
•
•
156 X. SUPPLEMENT TO CJ2SOT/CJ360T

VI. SERVICE DATA

•
1. SPECIAL TOOLS

Ref. No. Tool No. Tool Name Q'ty

I 07902-2400000 Spanner. pin 46 mm I
2 07908- 3230000 Wrench, tappet adjusting I
3
4
s
6
079 10- 3290000
0791 S- 639000 I
07917- 3230000
07922- 3000000
Wrench, R. retainer
Wrench, lock nut 16 mm
Wrench, hollow set 6 mm
llolder driver sprocket
l
I
I
I
•
•
7 07933- 2160000 Puller, rotor I
8 07942- 6110000 Driver, valve guide I
9 07945 - 3330100 Driver, ATT hearing 1
10 07945- 3330200 Driver, ATT bear1Jl8 I
II 07945- 3330300 Driver, baU race I
12 07947-3330000 Driver, fork seal I
13 07949-61 10000 Handle, driver I
14 07953- 3330000 Remover, ball race I
IS 07954- 3690000 Compressor, piston ring I
16 07957- 3290001 Compressor. valve spring I

•
17 07958- 2500000 Base piston I
1-- Compressor, shock absover
18 07959 3290000 I
f--- 19 07984-5900000 Reamer valve guide 7 mm I
20 07797- 2920300 Case tool set l

OPRIONAL SPECIAL TOOL

Ref. No. Tool No. Tool Name Q'ty

1 07504- 3000100 Gauge set, vacuum I
1·1 07504-3000200 Gauge vacuum (I}

•
2 07510-3690100 Attachment A, gauge 2
3 07908- 3690000 Wrench, carburetor adjusting I
Tool set, chain joint I
-
4 07975- 300000 I
- 4·1 07975-3000600 Bolt B. pressure (I}
07975- 3000700 Wedge ser, joint (I}

•
4-2

•
 X. SUPPLEMENT TO CJ250T/CJ360T 157

2. MAINTENANCE STANDARDS

• Items to bt inspected
Rocker arm-to-rocker arm shaft clearance
'c;m lift IN.
-
Unit: mm (in.)
Standard
0.016-0.061 (0.0006 0.0024)
40.314 (1.5872)
) . 360ccooly
Service Limit
0. 1 (0.0039
40.1 ( 1.5787)

•
EX. 40.339 ( 1.5882) 40.1 (1.5787)
C'amshoft side clearance om o.3 co.oo28 0.0 118) Above and below
standards
Valve scat width 1.0 I .3 (0.0394 0.05 12) 2.0 (0.0787)
0.0. or valve stem IN. 6.975 6.990 (0.2746- 0.2752) 6.93 (0.2728)
-
•
EX. 6.955 6.970 (0.2738 0.2744) 6.93 (0.2728)
1-:-:-.
Val"e-to valve guide clearance IN.
-- 0.01-0.035 (0.0004-0.00 14) 6.93 (0.2728)
EX. 0.03-0.05 (0.0012-0.0020) 0.09 (0.0035)
V1lve \pnng tenSIOn/as 1 I!'.NER 30.5 35.1 ksf31 (67.24-77.381bs/ 1.2205) -
comp!<»td length
I OUTI!II.
1
62.6 72.0ksf31 (138.01-158.731bs/1.2205) -
I r« length of valve spring I:SNER 39.8 ( 1.5669) 39.3 (1.5709)
OUTER 49.0 ( 1.9291) 47.8 (1.8819)
Tran>Ver>e warpage on cylinder head mating face 0.3 (0.0118)
1.0. of cylinder 56.01-56.02 (2.205 1-2.2055) 56.1 (2.2087)
[67.01 67.02 (2.6381-2.6386) 1 [67.1 (2.6417))
t-o:o:""or pisto11ut ;k irt 55.'17-55.99 (2.2036-2.2043) 55.85 (2.1988)

•
[66.97 66.99 (2.6366-2.6374)] )66.85 (2.6319)]
Pl<tnn pin hole 1.0. I 5.002-15.008 (0.5906-0.5909) 15.05 (0.5925) ·-
)16.002- 16.008 (0.6300 0.6302)) [16.05 (0.6319))
O.D. of piston pin 14.994 15.00 (0.5903-0.5906) 14.9 (0.5866)
[I 5.994-16.00 (0.6297-0.6299)) [15.9 (0.6260)]
f--
Piston nng·lo·nng groove TOP 0.02 0.06 (0.0008-0.0024) - 0.15 (0.0059)
clearance -SECOND O.QJ5 0.045 (0.0006-0.0018) 0.15 (0.0059)
[0.02-0.04 (0.0008-0.0016)) [0.15 (0.0059)1
OIL 0.010-0.045 (0.0004-0.0018) 0.15 (0.0059)
Piston ring end gap 0.15-0.35 (0.0059-0.0138) 0.75 (0.0295)
TOP [0.2-0.4 (0.0079-0.0 157J) {0.8 (0.0315})
S£CO~D O.l 5- 0.35 (0.0059- 0.0138) 0. 75 (0.0295)

• OIL
0 11 pump outer rotor-to-pump body clCllrance
!{;dial clearanc-e of oil pump outer rotor
·n,lcknes• nf clutch friction disc
0.2 0.4 (0.0079-0.0 157)
0.15 0.2 1 (0.0059-0.0083)
0.02 0.08 (0.0008-0.0032)
2.62 2.78 (0.1031-0.1095)
0.8 (O.O.l!S)
0.35 (0.0138)

--0.12.3 (0.0039)
(0.9055)
-

•
Transverse warpage on clutch place 0.1 (0.0039) 0.2 (0.0079)
Outch sprmg tens10n ~5/21.8 n2 kg (0.984i48.06-SI.I 5 lbs)
+
I
rrte lensch of clutch spring 31.25 (1.2305} ?!-1.7 {1.1693)
(.;ear <h1ft fork width. A and B 5.'13-6.00 (0.~335 0.236~) .~.5 (0.2165)
0 n. of ~<ar >l1ift gUide shaft 12.957-12.984 (0.5101-0.S 112)
--
I ~.9 (0.5079)

•
158 X. SUPPLEMENT TO CJ250T/CJ360T

Items to be inspected Stancbrd Serice limit

-
•
1.0. of gear shift fork A 13.000-13.0 L8 (0.51 LR-0.5125) 12.95 (0.5098)
0.0. of gear shift drum 39.95{}-39.975 ( 1.5374-1 .5384) 39.9 {1.5709)
J.D. of gear shtft fork B 40.000-40.025 ( 1.5748 1.5758) 40.075 (1.5798)
Kick starter pmton·to-shaft clearance 0.04- 0.082 (0.0016 0.0032) 0.1 (0.0039)
Gear •htft fork-to-drum clearance (A and B) 0.05-0.22 (0.0020-0.0087) 0.3 (0.0 118)
Thickness of cam cham tensioner sltpper (at center) 4.0 (0.1 575)
Thickness of cam chain gutde (at center)
Crank>haft runout (See I'Lg.4-101 on page 62)
J.D. of connecting rod smaU end
6.1 - 6.3 (0.1402 0.2480)
-
15.016-15.034 (0.5912-0.5919)
3.0 (0.1181)
5.9 (0.1969)
Below 0.1 (0.0039)
I 5.07 (0.5933)
•
•
Connecting rod big end side clearance on ptn 0.07-0.33 (0.0028-0.0130) 0.60 (0.0236)
Connecting rod big end radial clearance on pin 0.004-0.012 (0.0002-0.0005) 0.05 (0.0020)

frame
Items to be in>pected Standard Service Limit
Wheel rim surface runout
- 0.5 (0.0197) max. 2.0 (0.787)
Wheel bearing axial play 0.07 (0.0276) max. 0.1 (0.0039)
\\>1Jee1 bearing radial play 0.03 (0.00 L2) max. 0.05 (0.0020)
front axle bend O.oi (0.0004) 0.2 (0.0079)

•
Rear axle bend O.QJ (0.0004) 0.2 (0.0079)
TI1ickness of brake lining 4.9- 5.0 (0. L<h9- 0.1969) 2.5 (0.098)
1.0. of rear brake drum 160.0 160.3 ( 6.2992- 6.31 I0) 161 (6.3386)
Free length of front suspension spring 478.6 (18.843) 468.0 (18.425)
1.0. of front fork bottom ca;e 33.025-33.064 ( 1.3002-1.3017) 33.139 (1.3047)
0.0. of front fork pipe 32.97-32.985 (1.2980-1.2986) 32.25 ( L.2697)
Free length of rear suspension ;pring 207.6 (8.1 732)
0.0. of rear fork center collar 2 L.427- 21.460 (0.8436-0.8449) 21.46 (0.8449)
J.D. of rear fork buJhlng 2 L.S-21.552 (0.8465-0.8485) 21.70 (0.8543)

•
•
•
 X. SUPPLEMENT TO CJ250T/CJ360T 159
3. T IGHTENING TORQUE STANDARD

• Enaine

Item

R. L. crankc:~se cover boh

Siu (mm)

6
10
kg-m
0.7-1.1
3.0 3.6
Torque
lbs·ft
5.1 8.0
21.7-26.0
-

•
Cylindtr head holtl-dov.n boh
Cylonder head insulator boll 6 0.7-1.1 S.l 8.0
Canrshart sprocket lixang bolt 7 1.7-2.3 12.3 16.6
A.C. r:ener~tor mounung boh
Orl filter l...:k nut
II
16 I 3.5 4.5
4.5- 5.5
25J 32.5
32.6- 39.7
6 0.9-1.4 6.5-10.1
Crankcase mounting boll
8 I 2.2-2.6 15.9 18.8

• Frame

- Steering Mem nul

·-
Item Siu (mm)
kg·m
Torque
lbs-ft
-
24 7.0-9.0 50.7-65.1
Fork bolt 27 2.5- 3.0 18.1 21.7
Handlebar holder au aching boll 8 1.8-2.5 U.l- 18.1
Front fork bouom bridge 8 1.8-2.5 13.1 18.1
Spoke 0 15-0.20 1.1- 1.5
!{car fork pivot bolt 14 5.5-7.0 39.7 50.7
Front fork axle nu t 12 5.5- 6.5 39.7-47.0

•
Front fork under holder 8 2.7-J.J 19.5 23.8
Engine hanger b"ll 8 UllS 2.7- 3.3 19.5 2.1.8
bnglne hanger holt IOUBS 4.5-6.0 32.5-43.4
Rear ox.le 16 R.0-10.0 57.9 72.3
Final driven sprocket IOUBS 6.0- 7.0 43.4- 50.7
llrake arm 8 1.8-2.5 13. 1 18.1
Rear brake •tupper arm 8 1.8- 2.5 13.1- 18.1
Rear shock absorber 10 3.~4.0 21.7-2'1.0
Foot rest 10 UBS 4.5-6.0 32.5 43.4
Change pedal 6 0.8-1.1 5.8 8.7
Kick arm 8 2.5 3.0 111.1 21.7

•
•
•
160 X. SUPPLEMENT TO CJ250T/CJ360T

4. SPECIFICATIONS CJ360T (A TYPe)

Overall length
O.erall width
Overall height
Item
- 2.075 mm
790mm
I,IJOmm
Metric Eng!L'h
81.7 ln.
31.1 in.
43.7 in.
•
Wlteel ba>e
- Seat height
Foot peg hctght
Ground clearance
1,37S mn1
805 mm
345 mm
140mm t
54.1 in.
3!.7 in.
13.6 m.
5.5 in. - •
•
Dry weight 159 kg 351 lbs.
Type ~m• double crable
F. suspension, travel Telescopic fork, travel 139.5 mm 5.5 in.
R. suspension, travel Swing arm. travel 77.3 mm 3.0 in.
F. tire size. pressure 3.00S 18 • 4PR Rib tire,tire air pressure 1.75/1.75 kg/em' ,15!25 pSI
- 3.50S 18 • 4PR Rib tire, tire air pressure 2.0/2.5 kg/em1 , 28/36 psi.
R. tire size. pres~ture
F. brake. linmg area Internal expanding shoe, lining swept area 104 em', 16.1 sq.in.
Internal expanding shoe, lining swept area 70 em', 10.9 sq.ln.
R. brake, lining area
- 3. 7 U.S. gal, 3.1 Imp. gal.
--
fuel capacity
- 14 lit.
0.7 U.S. gal , 0.6 Imp. gal.
-
fuel reserve capacity
- .. - 2.5 lit.
63•30'
-- -

•
Caster angle
Trail length R6mm I 3.4 in.
fpront fork oil <apacity 140cc
Type Air cooled 4 stroke OHC engine
2 cylinder in line
Cylmder arrangement
Bore and stroke
1-
67.0 x 50.6 mm 2.638 X 1.992 in.
-
Displacement 356 cc ~1.7 cu. m.
CompressiOn rauo 9.3: I
Chain driven over head camshaft
-
Valve train
Oil capactty
- 2.0 ht. ~.I U.S. qt .. 1.8 Imp. qt.
Lubrication system Forced pr~ur~ and \lt"et sump
-
Cylinder h«ad comptC»Jun prc)Sure
Intake valve

Exhaust valve
Open
C'lo.e
Open
I~ kg/em' ( 170.7 psi.)
At 5° (before top dead center)
At 400 (after bottom dead center)
At s• (before bottom dead center)
-
•
•
Close At 400 (after top dead centtr)
r---
Val\'e tappet elcarance IN: O.OS EX. 0.08 mm ] 1"1; 0.00~ EX 0.003 tn.
-
Jdle speed 1.200 rpm
Type CV Butterfly Tipe
1- 759A
Setting mark
Main jet
Slow jet
Air screw opening
Primary "'68, Secondary #110
#35
2
- •
 X. SUPPLEMENT TO CJ2SOT/CJ360T 161

Item Metric English

•
Float height 18.5 mm 0.728 in .
Wet multi plate type
c-:rClutch ..
ransnusston 5 speed constant mesh
ipnmary
. re d\ll:tiOil
. 3.714
2.438

•
Gear ratio I
Gear ratio II 1.667
Gear ratio Ill 1.3 75
Gear ratio IV 1.111
Gear ratio V 0.965

•
Fina1 reduction 2.063, drive sprocket 16T, dJiven sprocket 33T
Gear shift paltern Left foot opef3led return system
Ignition Battery and Ignition coil
Starling system Kick pedal
Alternator A.C. generator 12V O.l J kw 5,000 rpm
Battery capacity 12V 9AH
NGK D8ES ND W24EX
-
Spark plug
l·lcadlight low/High 12V 25/35 watt
Tail/stoplight Tail/stop 12V 8/27 watt 3/32 cp
1\ITit signal -light Front/rear 12V 23/23 watt 32/32 cp

•
Speedometer light 12V 3.4 watt 2 cp
Tachometer light 12V 3.4 watt 2 cp
I--
Neutrol indicator light 12V 3.4 walt 2 cp
1--
Turn signttl indicator light 12V 3.4 watt 2 cp
lligh beam indicator 12V 3.4 watt 2 cp

•
•
•
162 X. SUPPLEMENT TO CJ2SOT/CJ360T

CJ2SOT/ CJ360T (D. U. TYPE)

•
( ) · CJ2SOT
Item Metric Euglish
Overallleugth 2,075 mm 8l.7tn.
1--:-
Overall width 790mm 31.1 in.
O.erall height 1,125 mm 44.3 11\.
-

•
r.::-
Wheel base 1,375 mm 54.1 in.
Sw height 80S mm 31.7 in.
Foot peg height 345 mm 13.6 in.
Ground clearance 140mm s.s in.
Dry weight 162 kg 3571bs.
'JYpe
F. suspension, uavel
R. suspension, travel
t-_
F. tire size, pressure
Semi double crable
Telescopic fork, travel 139.5 mm 5.5 in.
Swing arm, travel 77.3 mm 3.0 in.
3.00S 18 • 4PR Rib tire, tire air pressure 1.75/1 .75 kg/em', 25{25 psi
•
R. tire stu, pressure 3.SOS 18 • 4PR Block tire, tire air pressure 2.0/2.5 kg/em>, 28/36 psi.
F. brake, lining area Disk brake,disk pad swept area 38 cm2 , 5.9 sq.in. -
R. brake,lining area Internal expanding shoe, lining swept area ISO em', 23.2 sq.in.
Fuel capacity 14 lit. 3.7 U.S. gal, 3.1 Imp. gal.
~el reserve capacity 2.5 Iii. 0.7 U.S. gal, 0.6 Imp. gal.
Caster angle 63°30"
Trail length
Front fork oil capacity
'JYpe
Cylinder arrangement
85 mm
140cc
3.4in.

Air cooled 4 stroke OHC engine

2 cylinder in line
•
Bore and stroke 67.0 x 50.6 mm (56 x 50.6 mm) 2.638 x 1.992 in. (2.205 x 1.992 ln.)
Displacement 356 cc (249 cc) 21.7 cu. in. (15.2 cu. in.)
Compression ratio 9.3: I (9.5: I) -
r-Valve train Chaln driven over head camshaft
Oil capactty 2.0 lit. 2.1 us. qt., 1.81mp. qt.
Lubrication system Forced pressure and wet sump -
r-Cyllndcr head comprenion pressure
Intake valve

F.x hautt valve

Open
Close
Open
12 kg/em' (170.7 psi.)
At 5° (before top dead cen ter)
At 40° (after bottom dud center)
At 5° (before bottom dead center)
- •
•
Close At 400 (after top dead center)
-
Valve tappet elearance
Idle speed
IN: 0.05 EX: 0.08 mm
1,200 rpm
I IN; 0.002 EX: 0.003 in.

'JYpe CV Butterfly Tipe

Setting mark 759A
Main Jet
Slow J<t
AJr screw opening
Primary #68, Secondary #110
#35
2 •
 X. SUPPLEMENT TO CJ250T/CJ360T 163

Item Mellie: English

•
Aoat height 18.5 mm 0.728 in .
Clutch Wet multi plate type
Transmission S speed constant mesh
Primary reduction 3.714
Gear ratio I 2.438 (2.500)

• Gear ratio II
Gear ratio Ill
Gear ratio IV
Gear ratio V
1.666(1 .170)
1.375
1.111
0.965

•
Final reduction 2.062 (2.312), drive sproclcet 16T, driven sproclcet 33T (37T)
Gear shift pattern Left foot operated return system
Ignition Battery and Ignition coil
Starting system Kick pedal
Alternator A.C.generator 12V0.13kw5,000rpm
Battery capacity 12V-9AH
Spark plug (NGK)B8ES(DENSO)W24ES
Headlight L.ow/IIJi)t 12V 25/35 watt
Tail/stoplight Tall/stop 12V 8/23 Walt 3/32 cp
Turn signal·light Front/rear 12V 23/23 watt 32/32 cp

•
Speedometer light 12V 3.4 wntt 2 cp
Tachometer light 12V 3.4 watt 2cp
Neutral indicator light 12V 3.4 watt 2cp
Turn signal indicator light 12V 3.4 watt 2cp
High beam indicator 12V 3.4 watt 2cp

•
•
•
164 X. SUPPLEMENT TO CJ250T/CJ360T

CJ250T/CJ360T (G TYPE)

•
( ) · CJ250T
Item Metric English
Overall length 2,145 mm 84.5 in.
Overall width 710mm 28.0in.
Overall height 1,070mm 42. 1 in.
Wheel base
Stat height
Foot peg height
Ground clearance
Dry weight
1,375 mm
805 mm
345mm
J40mm
162 kg
54.1 in.
31.7 in.
13.6in.
5.5 in.
•
•
357lbs.
Type Semi double crabie
F. suspension, tra\•el Telescopic fork, travel 139.5 mm 5.5 in.
R. suspension, travel Swing arm, travcl77.3 mm 3.0 in.
F. tire size, pressure 3.00S 18 · 4PR Rib tire, tire air pressure 1.75/1.75 kg/em', 25/25 psi
R. tire size, pressure 3.7SS 18 · 4PR Block, tire air pressure 2 .0/2.5 kg/em', 28{36 psi.
F. brake, Uning area Disk brake, di<k pad swept area 38 em>, 5.9 sq.in.
R. brake, lining area Internal expanding shoe, lining swept area I SO cm2 , 23.2 sq.in.
Fuel capacity 14 lit. 3.7 U.S. gal, 3.1 Imp. gal.
Fuel reserve capacity 2.5 lit. 0.7 U.S. gal, 0.6 Imp. gal.
Caster angle 63°30'
Trail le ngth
Front fork oil capacity
Type
Cylinder arrangement
8Smm
140 cc
3.4 in.

Air cooled 4 stroke OHC engine

2 cylinder in line
•
Bore and stroke 67.0 x 50.6 mm (56 x 50.6 mm) 2.638 x 1.992 in. (2.205 x 1.992 in.)
Displacement 356 cc (249 cc) 21.7 cu. in. (I 5.2 cu. in.)
Compression ratio 9.3: I (9.5 : I)
Valve train Chain driven over head camshaft
Oil capacity 2.0 lit. 2.1 U.S. qt., I .8 Imp. qt.
Lubrication system Forced pressure and wet sump
Cylinder head compression pressure
Intake valve

Exhaust valve
Open
Close
Open
12 kg/em' ( 170.7 psi.)
At s• (before top dead center)
At 40° (after bottom dead center)
At s• (before bottom dead center)
•
•
Close At 40• (after top dead center)
Valve tappe t clearance IN: 0.05 EX: 0.08 mm IN; 0.002 EX: 0 .003 in.
Idle speed I ,200 rpm
Type CV Butterfly Tipe
Setting mark 759A
Main jet
Slow jet
Air screw opening
Primary #68, Secondary #II 0
#3$
2 •
 X. SUPPLEMENT TO CJ250T/CJ360T 165

Item Metric English

•
Float height 18.5 mm 0.728 in .
Clutch Wet multi plate type
Transmission 5 speed constant mesh
Primary reduction 3.714
Gear ratio I 2.437 (2.500)

• Gear ratio U
Gear ratio Ill
Gear ratio IV
Gear ratio V
1.667 (1.750)
1.375
1.111
0.965

•
Final reduction 2.062(2.312), drive sprocket 16T, driven sprocket 33T (37T)
Gear shift pattern left foot operated return system
Ignition Battery and Ignition coil
Starting system Kick pedal
Alternator A.C. generator 12V 0.13 kw S,OOOrpm
Battery capacity 12V-9All
Spark plug (NCK) BR8ES (DENSO) W24ESR
Headlight Low/High 12V 40/45 watt
Tail/stoplight Tail/stop 12V 5/21 watt 3/32 cp
1\lrn signal-light Front/rear 12V 5/21 watt 32/32 cp

•
Speedometer light 12V 3.4 watt 2cp
Tachometer light 12V 3.4 watt 2 cp
Neutral indicator light 12V 3.4 watt 2 cp
Tum signal indicator light 12V 3.4 watt 2cp
High beam indicator 12V 3.4 watt 2 cp

•
•
•
166 X. SUPPLEMENT TO CJ250T/CJ360T

CJ250T/CJ360T (F.E.ED. TYPE)

( ) . CJ250T

Overall length
Overall width
Overall height
Item
2,145mm
710mm
1,070 mm
Metric English
84.5 in.
28.0 in.
42.1 in.
•
Wheel base
Seat height
Foot peg height
Ground clearance
Dry weight
1,375 mm
805mm
345 mm
140mm
54.1 in.
31.7 in.
13.6 in.
5.5 in.
•
•
162kg 357 lbs.
TYpe Semi double crable
F. suspension, travel Telescopic fork, travel!39.5 mm 5.5 in.
R. suspension, travel Swing arm, travel 77.3 mm 3.0 in.
F. tire size, pressure 3.00S 18- 4PR Rib tire, tire air pressure 1.75/1.75 kg{em>, 25/25 psi
R. tire size, pressure 3.50S 18 · 4PR Block lire, tire air pressure 2.0/2.5 kg{em>, 28/36 psi.
F. brake, lining area Disk brake, disk pad swept area 38 em•, 28/25 psi. 16.1 sq.in.
R. brake, lining area Internal expanding shoe, lining swept area 150 em2 , 23.2 sq.in.
Fuel capacity 14 lit. 3.7 U.S. gal, 3.1 Imp. gal.
Fuel reserve capacity 2.5 lit. 0.7 U.S. gal, 0.6 Imp. gal.
Caster angle 63°30'
Trail length
Front fork oil capacity
Type
Cylinder arrangement
8Smm
140 cc
3.4 in.

Air cooled 4 stroke OHC engine

2 cylinder in line
•
Bore and stroke 67.0 x 50.6 mm (56 x 50.6 mm) 2.638 x 1.992 in. (2.205 x 1.992 in.)
Displacement 356 cc (249 cc) 21.7 cu. in. (15.2 cu. in.)
('.ompression ratio 9.3 : I (9.5 : 1)
Valve train Chain driven over head camshaft
Oil capacity 2.0 lit. 2.1 U.S. qt., 1.8 Imp. qt.
Lubrication system Forced pressure and wet sump
Cylinder head compression pressure
Intake valve

Exhaust valve
Open
Close
Open
12kg{crn> ( J70.7psi.)
At 5° (before top dead center)
At40° (after bottom dead center)
At s• (before bottom dead center)
•
•
Close At 40° (after top dead center)
Valve tappet clearance IN: 0.05 EX: 0.08 mm IN; 0.002 EX: 0.003 in.
Idle speed 1,200 rpm
Type CV Butterfly Tipe
Setting mark 759A
Main jet
Slow jet
Air screw opening
Primary #68, Secondary #110
#35
2 •
 X. SUPPLEMENT TO CJ250T/CJ360T 167

Item Metric English

•
Float height 18.5 mm 0.728 in .
Clutch Wet multi plate type
Transmission 5 speed constant mesh
Primary reduction 3.714
Gear ratio I 2.438 (2.500)

• Gear ratio II
Gear ratio lll
Gear ratio IV
Gear ratio V
1.666 (1.750)
1.375
1.111
0.965

•
Final reduction 2.062, drive sprocket 16T, driven sprocket 33T
Gear shift pattern Left foot operated return system
Ignition Battery and Ignition coD
Starting system Kick pedal
Alternator A.C. gcneratQr 12V 0.13 kw 5,000 rpm
Battery capacity 12V-9AH
Spark plug (NGK) BR8ES (DENSO) W24ESR
Headlight Low/High 12V 40/45 watt
Tail/stoplight Tail/stop 12V 5/21 watt 3/32 Cp
Turn signal ·light From/ rear 12V 21/ 21 watt 32/ 32 cp

•
Speedometer light 12V 3.4 watt 2cp
Tachometer light l2V 3.4 watt 2 cp
Neutral indicator light 12Y 3.4 watt 2cp
Tum signal indicator light 12 V 3.4 watt 2cp
High beam indicator 12V 3.4 watt 2cp

•
•
168 X. SUPPLEMENT TO CJ250T/CJ360T
----
5. WIRING DIAGRAM CJ360T (A TYPE)

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 X. SUPPLEMENT TO CJ250T/CJ360T 169

CJ 250T/ CJ360T (GENERAL AND AUSTRALIAN TYPES)

• .
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170 X. SUPPLEMENT TO CJ2SOT/CJ360T
~----------------------
CJ2SOT/ CJ360T (U.K.· FRENCIJ · GERMANY· EUROPEAN TYPES)

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