Honda CB125 CB160 (1972) [51/139] Refer to fig 3 25

Содержание

• Preface 3
• Contents 5
• Engine 5
• I features 5
• Ii specifications 5
• Iv frame 5
• V electric equipment 6
• Vi inspection and adjustment 6
• A engine 7
• B frame 7
• Features of cb 125 and 160 7
• I features 7
• Il specifications 8
• Cb 1 60 11
• Engine r p m running speed km h 11
• Special tools for cb 125 160 14
• Ill engine 15
• A disassembling engine 16
• Disassembling and assembling engine 16
• Refer to fig 3 3 16
• Refer to fig 3 and 3 16
• To fig 3 16
• A disassembly 18
• B assembling engine 18
• Caution 18
• Cylinder head and cylinder 18
• Refer to fig 3 1 18
• Refer to fig 3 10 18
• Refer to fig 3 2 18
• Refer to fig 3 9 18
• Assembly 19
• Caution 19
• Caution required during disassembly and 19
• I disassembly 19
• Refer to fig 19
• Refer to fig 3 4 19
• Refer to fig 3 6 19
• B description of cylinder head cover and 20
• Breather 20
• Li assembly 20
• Refer to 20
• Refer to fig 3 0 20
• Refer to fig 3 19 20
• Refer to fig 3 7 20
• I disassembly and assembly 21
• Refer to fig 3 0 and fig 3 1 21
• Refer to fig 3 22 21
• Refer to fig 3 24 21
• Refer to fig 3 3 21
• C description of camshaft 22
• I disassembly 22
• Refer to fig 22
• Refer to fig 3 2 a 22
• Refer to fig 3 7 22
• To fig 25 22
• Caution 23
• D description of rocker arm 23
• Dead center refer to fig 3 32 23
• Dissassembly 23
• Ii assembly 23
• Refer to fig 3 0 23
• Refer to fig 3 1 23
• E description of valve 24
• Fig 3 6 24
• I disassembly 24
• Ii installation 24
• Iii valve seating 24
• Refer to 24
• Refer to fig 3 33 24
• Refer to fig 3 4 24
• Refer to fig 3 5 24
• Caution 25
• Disassembly 25
• F description of cylinder 25
• Fig 3 38 25
• Fig 3 7 25
• Ii assembly 25
• Refer to 25
• Refer to fig 25
• A construction of left crankcase cover 26
• B ac generator 26
• I disassembly 26
• Ii installation 26
• Left crankcase cover 26
• Refer to fig 3 0 26
• Refer to fig 3 2 26
• Refer to fig 3 3 26
• C starter sprocket and clutch 27
• Caution 27
• I disassembly 27
• I operation of starter clutch 27
• Ii installation 27
• Refer to fig 27
• Refer to fig 3 4 27
• Refer to fig 3 6 27
• To fig 3 7 27
• Caution 28
• D clutch adjuster and neutral switch rotor 28
• I operation of clutch adjuster 28
• Ii disassembly and installation of clutch 28
• Iii disassembly and installation of starter 28
• Refer to fig 3 0 28
• Refer to fig 3 1 28
• Refer to fig 3 9 28
• Sprocket 28
• A description of the right crankcase cover 29
• Caution 29
• Crankcase cover assembly right 29
• I disassembly 29
• Ii disassembly and assembly of clutch adjuster 29
• Iii disassembly and installation of neutral 29
• Refer to fig 3 4 29
• Refer to fig 3 53 29
• Refer to fig 3 55 29
• Switch rotor 29
• To fig 3 54 29
• Clutch 30
• Ii installation 30
• Refer to fig 30
• A description and operation of clutch 31
• Refer to fig 3 7 31
• Refer to fig 3 8 31
• To fig 3 8 and 59 31
• Caution 32
• I disassembly 32
• Ii inspection 32
• Refer to fig 3 1 32
• A description of oil pump 33
• Caution 33
• Fig 3 5 33
• Iii assembly 33
• Oil pump filter and separator 33
• Refer to 33
• Refer to fig 3 7 33
• I lubrication circuit 34
• Caution 35
• Fig 3 0 35
• Ii disassembly 35
• Iii assembly 35
• Refer to 35
• Refer to fig 35
• Refer to fig 3 51 35
• Refer to fig 3 72 35
• To fig 3 71 35
• B operation of oil filter 36
• I disassembly 36
• Refer to fig 3 5 36
• Refer to fig 3 73 36
• A description 37
• C operation of oil separator 37
• Crankcase 37
• Igsamfctshftusmmmnmmgijs 37
• Ii assembly 37
• Refer to fig 37
• Refer to fig 3 76 37
• Refer to fig 3 77 37
• Refer to fig 3 9 37
• Disassembly and installation of starting 38
• Fig 3 1 38
• I disassembly 38
• Ii assembly 38
• Refer to 38
• Refer to fig 3 83 38
• A description of crankshaft 39
• Crankshaft connecting rods and pistons 39
• I disassembly 39
• Refer to fig 39
• Refer to fig 3 84 39
• And left 40
• B description of connecting rods 40
• Bearing clearance 40
• Bearing should be measured at the value obtained 40
• Clearance of the crankshaft 6305 special ball 40
• Crankcase should be set on the assembly is the 40
• Crankshaft complete should be placed on it guide 40
• Have an h shaped section bushings are not at both 40
• Holes of bearings should be matched and the lower 40
• Ii inspection 40
• Iii installation 40
• Measurement of crank outer ring and left main 40
• Polished after case hardening and mounts the roller 40
• Refer to fig 40
• Refer to fig 3 90 40
• Retainer made of special aluminum alloy staggered 40
• Reverse order of disassembly 40
• Rollers are used in order to increase the load capacity 40
• The bearing is moved up and down and to the right 40
• The connecting rods are of molybdenum steel and 40
• The crank shaft and piston ends the crankshaft is 40
• The upper crankcase should be inverted and the 40
• When the crankshaft is set on v shaped blocks and 40
• Without race the roller 4x13 is held by the roller 40
• C description of pistons 41
• Inspection 41
• Refer to fig 41
• Refer to fig 3 1 41
• Refer to fig 3 2 41
• A new piston ring is fitted 42
• Be directed so that the ring is not twisted em 42
• Before cleaning carbon adhering to the piston 42
• Caution 42
• Cb 125 160 42
• Crankshaft and remove the piston pin 42
• Head or sing groove should be removed with out 42
• I disassembly 42
• Icb 125 160 42
• Ii inspection 42
• Measurement of outside diameter of the piston 42
• Measurement of the ring groove clearance when 42
• Ployment of the piston ring tool is recommended 42
• Refer to 42
• Refer to fig 3 7 42
• Refer to fig 3 98 42
• Refer to tig 3 96 42
• Remove the piston pin retainer from the removed 42
• Sandpaper should not be used for removing 42
• The piston being scarred 42
• When the piston pin is removed attention should 42
• Caution 43
• D description of piston rings 43
• Iii assembly 43
• Refer to fig 43
• To fig 3 100 43
• 11 if the gaps are somewhat less they 44
• A when a gap is dressed with a file adjust 44
• B if the piston ring gap is too small seizure 44
• Be fitted with the gap approximately 15 mm 44
• Between the ring and cylinder occurs due to 44
• Caution 44
• Center line measurement of the gap should be 44
• Fig 3 05 44
• Fitted to the cylinder inspection should be made 44
• From skirt of the cylinder at a right angle to the 44
• I inspection 44
• Ii replacing piston rings 44
• Made with a thickness gauge 44
• Ment should be made at a right angle due to 44
• Penetration or gas leakage occurs 44
• Refer to 44
• Refer to fig 44
• Refer to fig 3 04 44
• Right angle fitting 44
• Rings are between 0 and 0 0 mm 11 and of 44
• Should be dressed with a file 44
• Sion measuring instrument as shown in the figure 44
• Tension of the piston ring is measured with a ten 44
• The oil ring between 0 0 039 to 0 0 mm 44
• Thermal expansion if the gap is too large oil 44
• To determine if the gaps p the top and second 44
• When a piston ring is reassembled it should be 44
• When the piston ring has been removed it should 44
• A operation of cam chain tightener 45
• Cam chain tightener and cam chain guide 45
• I disassembly 45
• Refer to fig 45
• Refer to fig 3 107 45
• Refer to fig 3 108 45
• Refer to section 3 8 cl 45
• Roller 45
• To fig 3 106 45
• Ii installation 46
• Iii cam chain adjustment 46
• Refer to fig 110 46
• Refer to fig 3 11 46
• Refer to fig 3 12 46
• A description of transmission 47
• Condition 47
• Portant as it transmits power from the aankshaft 47
• Required torque and speed corresponding to the load 47
• Speed forward employs the limit type reciprocating 47
• System 47
• The performance of the transmission is very im 47
• The transmission of the constant mesh type four 47
• Through the clutch with the relationship between the 47
• Transmission 47
• B transmission system 48
• Refer to 48
• Refer to fig 3 114 48
• Refer to fig 3 15 48
• Countershaft bearing 49
• Countershaft c4 gear omitted 49
• Directions for the transmission main shaft and 49
• Following the same order as for the crankshaft 49
• For the fourth speed 49
• Gear on the main shaft is by operation 49
• I disassembly 49
• Ii inspection 49
• Main shaft through m 3 and m 4 gears to the coupled 49
• Measurement of clearance in the axial and radial 49
• Measuring play on the gear teeth surface of the 49
• Of the shift fork in shifting dowel connected with 49
• Refer to fig 49
• Refer to fig 118 49
• Refer to fig 3 20 49
• Refer to section 3 11 separate the upper and 49
• The free m 4 gear and drive is transmitted from the 49
• The lower crankcase and remove the transmission 49
• Transmission unit 49
• A operation of gear shift 50
• Gear shift 50
• I disassembly 50
• Iii assembly 50
• Refer to fig 50
• Refer to fig 3 122 50
• Refer to fig 3 23 50
• Refer to fig 3 24 50
• Ii assembly 51
• Refer to fig 3 25 51
• Refer to fig 3 26 51
• Refer to fig 3 27 51
• Refer to fig 3 28 51
• A operation of kick starter 52
• Check the following 52
• I disassembly and assembly 52
• Kick starter 52
• Refer to fig 3 132 52
• Refer to fig 3 30 and 3 31 52
• A description of carburetor 53
• Main system 53
• Refer to fig 3 134 53
• Slow speed system pilot system 53
• Air jet 54
• B operation of component parts 54
• Float chamber 54
• Main jet 54
• Needle jet 54
• Refer to fig 3 137 54
• Refer to fig 3 139 54
• Refer to fig 3 36 54
• Refer to fig 3 38 54
• Air screw 55
• Jet needle 55
• Refer to fig 3 40 55
• Refer to fig 3 41 55
• Refer to fig 3 42 55
• Slow speed jet 55
• Throttle valve 55
• To fig 55
• Adjustment at high speed 56
• Adjustment at mid throttle 56
• C adjustment 56
• Refer to fig 56
• Refer to fig 3 144 56
• Adjustment at low speed 57
• Adjustment of standard fuel level 57
• Refer to fig 3 46 57
• Refer to fig 3 47 57
• Adjustment of the throttle opening of the 58
• Caution 58
• Refer to fig 58
• Right and left carburetors 58
• A construction of handlebar 59
• B disassembly 59
• Easy refer to fig 4 59
• Handlebar 59
• Iv frame 59
• Refer to fig 59
• And 4 9 60
• C inspection 60
• D assembly 60
• Refer to 60
• Refer to fig 4 60
• To fig 4 6 60
• 3 6 refer to fig 4 11 61
• 4 us gal 37 imp gal l of no 3 operation oil 61
• A description 61
• B disassembly 61
• Caution 61
• Clamp coupling of all lead wires 61
• Construction of front cushion 61
• Device gives direct influence to the steering perfor 61
• Idemitsu kosan and its maximum stroke is 94 mm 61
• In addition to damping vertical vibration of the front 61
• Mance and stability of the vehicle the front fork 61
• Porting the front wheel and enabling steering 61
• Positions the handlebar should be free to turn to 61
• Refer to fig 61
• Refer to fig 4 12 61
• Remove the handlebar according to section 4 61
• Separated the status of this suspension and damping 61
• The front cushion 61
• The front cushion and rear cushion should not be 61
• The front cushion spring employs the spring with 61
• The right or left when the handlebar is installed 61
• The wire should not be clamped by it 61
• Tools required for disassembly and assembly of 61
• Uneven pitch the oil shock absorber contains 170 cc 61
• Wheel should maintain strength during operation sup 61
• When all wires are placed in the designated 61
• Caution 62
• Refer to fig 4 13 62
• Refer to fig 4 14 62
• To fig 4 15 62
• C inspection 63
• Disassemble the front pipe limit ring front fork 63
• Fig 4 16 63
• Fig 4 7 63
• Front cushion in a downward direction 63
• Loosen the front fork seal housing and remove 63
• Loosen the steering head stem nut 63
• Loosen two 8 x 32 hex bolts and remove the 63
• Loosen two front fork bolts and remove the 63
• Measurement of the front cushion spring 63
• Measurement of the front fork piston 63
• Measurement of the outside diameter and bend 63
• Of the front fork pipe 63
• Pipe complete 63
• Piston and front absorber valve from the front fork 63
• Refer to 63
• Refer to fig 3 18 63
• Spring as well as the oil in the bottom case 63
• The front bottom case remove the front cushion 63
• Top bridge and the front fork upper cover 63
• D assembly 64
• Refer to fig 64
• Refer to fig 4 1 64
• A construction of the steering stem 65
• B disassembly 65
• Caution 65
• Fig 4 24 65
• Refer to 65
• Refer to fig 4 25 65
• Steering stem and handlebar lock 65
• C inspection 66
• Caution 66
• D assembly 66
• Refer to fig 4 26 66
• A construction of fuel tank 67
• B disassembly 67
• Fuel tank 67
• Refer to fig 67
• Refer to fig 4 27 67
• Refer to fig 4 8 67
• To fig 4 9 67
• C inspection 68
• Caution 68
• D assembly 68
• Refer to fig 3 34 68
• Refer to fig 4 1 68
• Refer to fig 4 33 68
• To fig 4 32 68
• A construction of frame body 69
• Frame body 69
• To fig 4 35 69
• B disassembly 70
• C inspection 70
• Caution 70
• Refer to fig 4 36 70
• Refer to fig 4 37 70
• Refer to fig 4 38 and 4 39 70
• A construction of air cleaner case and seat 71
• Air cleaner case and seat 71
• B disassembly 71
• C inspection 71
• Caution 71
• D assembly 71
• Refer to fig 71
• Refer to fig 4 1 71
• Refer to fig 4 3 71
• To fig 4 0 71
• A construction of stand 72
• B disassembly 72
• C inspection 72
• D assembly 72
• Refer to fig 4 44 72
• Refer to fig 4 5 72
• Refer to fig 4 6 72
• Refer to fig 4 7 72
• A construction of the exhaust pipe and muffler 73
• Bolts to the underside of the crankcase 73
• Cylinder head to the muffler if bent the horsepower 73
• D assembly 73
• Disassembly 73
• Evenly tighten the muffler with four 8x25 hex 73
• In the muffler and noise is reduced in addition 73
• Is reduced for exhaust gas the passage is throttled 73
• Measurement of the outside diameter of the stand 73
• Measurement of the stand mounting hole 73
• Mounting bolt 73
• Noise is diffused by the diffuser pipe which also 73
• Reduces noise 73
• Refer to fig 4 73
• The exhaust pipe and muffler 73
• The exhaust pipe passes the exhaust gas from the 73
• The rear brake cable assembly is the reverse of 73
• Tighten the main stand with the 10 mm bolt and 73
• To fig 4 8 73
• Tools required for disassembly and assembly of 73
• C inspection 74
• Caution 74
• D assembly 74
• Refer to fig 4 1 74
• Refer to fig 4 52 74
• Refer to fig 4 54 74
• To fig 4 55 74
• A construction of the air cleaner 75
• Air cleaner and tool case 75
• B disassembly 75
• C inspection 75
• D assembly 75
• Refer to fig 75
• Refer to fig 4 57 75
• A construction of the rear fork 76
• B disassembly 76
• C inspection 76
• Rear fork and rear fender 76
• Refer to fig 76
• Caution 77
• D assembly 77
• Refer to 77
• Refer to fig 77
• To fig 77
• 132 lb 8 lb 78
• 242 lb 14 lb 78
• 330 lb 19 ibl 78
• 4 frame 78
• A construction of the rear cushion 78
• Absorbed by shock absorber 78
• And running conditions 78
• B disassembly 78
• By loosening the 10 mm hex cap nut using 14 x 78
• C inspection 78
• Compress the rear cushion upper case remove 78
• Cushion limit 78
• Cushion stroke oil leakage or noise occurs adjust 78
• Cylinder system oil shock absorbers the compressing 78
• Double ended wrench and the 8 x 28 rear cush 78
• Fig 4 66 rear cushion 78
• Fig 4 67 tools required for disassembly and assembly 78
• Free length 194 mm 7 78
• Gal 11 imp gal of 60 white spindle oil is 78
• Ibliilillitssim 78
• Included if this amount is not suitable reduced 78
• Inspection of breakage deformation of the rear 78
• Inspection of oil leakage at the cushion absorber 78
• Ion lower bolt remove the rear cusion assembly 78
• Load is absorbed by the spring and elongation is 78
• Measurement of the rear cushion spring 78
• Ment can be made in three steps according to road 78
• Mm h 110kg 6 78
• Mm h 150 kg 9 78
• Mm h 6 78
• Of rear cushion 78
• Rear cushion 78
• Refer to fig 78
• Right angle below 1 mm 78
• Standard value correction limit 78
• Tension 78
• The oil shock absorber contains 52 cc 13 us 78
• The rear cushion consists of spring and double 78
• The rear cushion spring 78
• The rear cushion spring seat limit pull out the 78
• Upper case in an upward direction and remove 78
• Caution 79
• D assembly 79
• Front wheel 79
• Refer to fig 4 8 79
• A description of the front wheel 80
• Axle refer to fig 4 3 80
• B disassembly 80
• C inspection 80
• Caution 80
• Refer to fig 4 1 80
• Refer to fig 4 2 80
• Refer to fig 4 69 80
• A when the tire is on the rim apply air to 1 3 81
• Air leaks of the tube should be checked by sub 81
• B the valve stem of the tube should be placed 81
• But also the inside should be checked 81
• Caution 81
• D assembly 81
• Fig 4 5 81
• For tire wear or puncture not only the outside 81
• Insert into the bead unit in the rim 81
• Inside the tire and applying a small amount of air 81
• Inspect and tighten any loose spokes 81
• Measurement of brake shoe spring 81
• Measurement of the clearance in the axial and 81
• Measurement of the outside diameter and thick 81
• Measurement of thickness of the front brake cam 81
• Merging the tube in water 81
• Ness of the front brake shoe 81
• Occurs 81
• Pointing toward the axle if not air leakage 81
• Radial directions of the 6302 r ball bearings 81
• Refer to 81
• Refer to fig 81
• The designated pressure and lightly strike around 81
• The tire with a wooden wallet in order to pre 81
• The tube can be easily inserted by putting it 81
• Vent the tube from being pinched 81
• Caution 82
• Refer to fig 4 78 82
• Refer to fig 4 9 and 4 0 82
• To fig 4 7 82
• A description of rear wheel 83
• B disassembly 83
• Rear wheel 83
• Refer to fig 4 1 83
• Refer to fig 4 3 83
• Refer to fig 4 82 83
• Ball bearings and the rear axle spacing collers 84
• By using the tire iron remove the tire and tube 84
• C inspection 84
• Cotter pin the anchor pin mounting washer and 84
• Final driven sprocket 84
• For disassembling the rear brake shoe remove 84
• Measurement of deflection and eccentricity of the 84
• Measurement of rear brake shoe spring 84
• Measurement of the axial and radial clearance 84
• Measurement of the outside diameter bend of the 84
• Measurement of the tooth bottom diameter of the 84
• Mm retainer loosen the thin 8 mm nut and 84
• Of the 6303 r ball bearing 84
• Rear wheel axle 84
• Refer to fig 84
• Refer to fig 4 85 84
• Refer to fig 4 87 84
• Remove the final driven sprocket 84
• Remove the oil seal internal retainer two 6303 r 84
• Straighten the 8 mm look washer and remove the 84
• The brake arm complete from the panel two 2 x 84
• The brake shoe complete 84
• Tilt and extract the rear wheel 84
• Caution 85
• D assembly 85
• Refer to fig 85
• Refer to fig 4 92 86
• Refer to fig 4 94 86
• To fig 4 93 86
• A ignition system 87
• Electrical system 87
• General of electrical parts 87
• Ignition circuit 87
• Refer to fig 5 87
• Refer to fig 5 4 87
• V electric equipment 87
• B ignition coil 88
• Construction of the ignition coil 88
• E when 88
• Performance of ignition coil 88
• Refer to fig 5 88
• Refer to fig 5 5 88
• Refer to fig 5 6 88
• Allowing spark generation between needles 13 while 89
• As a resistance loss in the circuit 89
• As magnetic flux rapidly nears zero the voltage 89
• B the quantitative judgment of performance coil 89
• C the rubber cap attached to the connecting ter 89
• Cam circuit angle it again repeats the above 89
• Fig 5 2 89
• G the energy in the windings due to the smdll 89
• H then through the circuit period determined by the 89
• Ignition coil handling 89
• Level for spark discharge is not maintained and is 89
• Minal avoids insulator induction objects 89
• Process 89
• Refer to 89
• Refer to fig 5 1 89
• Residual flux generates an attenuation vibration in 89
• Service tester the test can be performed by 89
• Stopped 89
• Testing can be conducted by employment of the 89
• The interrupter is in operation 89
• The secondary and primary windings and diminishes 89
• The terminal ignition performance will not deterio 89
• Tion is affected by oily residue adhering around 89
• Unless the ignition coil is damaged or the insula 89
• C capacitor 90
• D breaker points 90
• Refer to fig 5 15 90
• Refer to fig 5 6 90
• To fig 5 3 and 5 4 90
• Employed refer to fig 5 0 91
• Fig 5 7 91
• Refer to 91
• Refer to fig 5 19 91
• E spark advancer 93
• Maintenance and replacement 93
• Refer to fig 5 25 93
• Refer to fig 5 26 93
• F spark plug 94
• Refer to fig 5 81 94
• Spark plug requirements 94
• Fig 5 1 95
• Fig 5 30 95
• Heat characteristics of spark plugs 95
• Spark plug construction 95
• To fig 5 28 thru 5 1 95
• Heat values 96
• Necessity of spark plugs with different 96
• Refer to fig 3 35 96
• Refer to fig 5 37 96
• Refer to fig 5 38 96
• To fig 5 36 96
• A ac generator 97
• Power source circuit 97
• Refer to fig 97
• Refer to fig 5 97
• B silicon rectifier 98
• Caution 98
• Performance of ac generator 98
• Refer to fig 98
• Refer to fig 5 44 98
• To fig 5 45 98
• Refer to fig 99
• Refer to fig 9 99
• I feature comparison of silicon and selenium 100
• Rectifiers 100
• Refer to fig 100
• Refer to fig 5 1 100
• Refer to fig 5 2 100
• Ii caution concerning wiring 101
• C battery 102
• Fig 5 4 102
• Fig 5 6 102
• Fig 5 8 102
• I battery construction 102
• Refer to 102
• Refer to fig 102
• V refer ta fig 5 55 102
• Battery charging discharging ratio and 103
• Capacity charging ratio 103
• Electrical 103
• Refer to fig 103
• Refer to fig 5 1 103
• Caution required during starting 104
• Discharge rate charge rate 104
• Fig 5 2 104
• Initial charge 104
• Refer to 104
• Refer to fig 5 3 and 5 64 104
• Caution required during use 105
• Anode plate refer to fig 5 9 106
• Battery repair 106
• Iii battery trouble 106
• Negative plate refer to fig 5 0 106
• Refer to fig 106
• Separators refer to fig 5 1 106
• Thru 5 8 106
• A starting circuit 107
• I motor performance 107
• Refer to fig 107
• Refer to fig 5 3 and 5 74 107
• Self starter 107
• Ii starter reduction 108
• B starting clutch 109
• Commutator 109
• Iii removing starting motor 109
• Iv maintenance starting motor 109
• Refer to fig 109
• Refer to fig 5 109
• Removing the carbon brush 109
• Caution required during maintenance 110
• Lubrication 110
• Refer to figs 5 2 and 5 83 110
• When the engine starts 110
• When the starting motor rotates 110
• C starter solenoid 111
• Caution 111
• Principle of operation 111
• Refer to fig 111
• Refer to fig 5 85 111
• V 3 a refer to fig 5 7 and 5 8 111
• A circuit 112
• B horn 112
• Fig 5 89 112
• Fig 5 92 112
• Refer to 112
• Refer to fig 112
• Refer to fig 5 1 112
• Safety parts 112
• C tail lamp and stop lamp 113
• D neutral pilot lamp 113
• Refer to fig 5 6 113
• Refer to fig 5 94 and 113
• To fig 5 93 113
• E speedometer 114
• Refer to fig 114
• Refer to fig 5 98 114
• Refer to fig 5 99 114
• To fig 5 100 114
• Caution 115
• Gear box 115
• Refer to fig 5 01 115
• Refer to fig 5 102 115
• Standard for operating safety 115
• F head lamp 116
• Fig 74 a 116
• Refer to 116
• Refer to fig 5 06 116
• Refer to fig 5 07 116
• Semi sealed refer to fig 5 74 b 116
• A combination switches 118
• B stop switch 118
• Disassembly and assembly 118
• Fig 5 02 118
• Refer to 118
• Refer to fig 5 118
• Refer to fig 5 11 118
• Refer to fig 5 12 118
• Switch 118
• To fig 5 110 118
• C horn button and dimmer switch 119
• Refer to fig 5 14 119
• Refer to fig 5 15 119
• Refer to fig 5 16 119
• Refer to fig 5 17 119
• Wire harness 119
• A engine adjustment 120
• And adjustment 120
• Compression 120
• Maintenance 120
• Refer to fig 120
• Refer to fig 6 4 120
• Vi inspection 120
• Caution 121
• Refer to fig 6 5 121
• Tappet adjustment 121
• Caution 122
• Ignition timing 122
• Refer to fig 6 2 122
• To fig 122
• Adjusting the spark plugs 123
• Caution 123
• Refer to fig 123
• Refer to fig 6 13 123
• Refer to fig 6 15 123
• Refer to fig 6 6 123
• To fig 6 4 123
• Carburetor cleaning and adjustment 124
• Fuel supply 124
• Refer to fig 124
• Refer to fig 6 19 124
• Refer to fig 6 7 124
• Refer to fig 6 8 124
• Air cleaner 125
• Refer to fig 125
• Refer to fig 6 22 125
• Refer to fig 6 23 125
• Refer to fig 6 24 125
• A clutch adjustment 126
• Refer to fig 6 27 126
• Refer to fig 6 28 126
• Refer to fig 6 6 126
• To fig 6 25 126
• B drive chain adjustment 127
• C brake adjustment 127
• Fo fig 6 30 and 6 1 127
• Front brake adjustment 127
• Refer to fig 6 29 127
• Refer to fig 6 32 127
• Caution 129
• D battery inspection 129
• E lubrication 129
• Engine oil 129
• Refer to fig 129
• Refer to fig 6 39 129
• Refer to fig 6 40 129
• And 6 44 130
• Caution 130
• Grease 130
• Parts not requiring periodical lubrication 130
• Refer to fig 6 1 130
• Refer to fig 6 42 130
• Refer to figs 6 43 130
• Critical connections 131
• F tightening parts 131
• Fig 6 45 131
• Oiling the drive chain 131
• Refer 6 9 and 131
• Refer to 131
• Refer to fig 131
• Refer to fig 6 48 131
• To fig 131
• 1 to 1 132
• 3100 mi by the method shown below if the spokes 132
• A daily inspection 132
• Are loose they are apt to damage other spokes or 132
• Best possible operating condition periodic inspection 132
• Check each spoke by hand using a nipple wrench 132
• Clutch disengagement 132
• Cm 1 8 to 1 132
• Do the head tail and stop lamps light 132
• Do the springs rattle and does oil leak 132
• Does the handlebar deflect abnormally or is it 132
• Does the horn sound 132
• Does the turn indicate work 132
• Following every day 132
• Inspection daily and that which is performed as 132
• Is the play of the front brake lever 3 to 4 cm 132
• Is the play of the rear brake pedal from 2 to 132
• Periodic inspection and repair 132
• Refer to fig 6 1 132
• Scheduled by owner or service agent 132
• Should be made there are two kinds of periodic 132
• The owner should form the habit of inspecting the 132
• The rim with the wheel suspended in air turn and 132
• Tighten all nippes equally 132
• To prevent accidents and keep the vehicle in the 132
• Very heavy 132
• Wheel spokes 132
• Wheel spokes should be checked every 5000 km 132
• A traveling more than 50 km 31 mi daily 133
• B periodical inspection and repair 133
• B using vehicle in mountainous regions 133
• Battery fluid should be checked every week but 133
• C operating always at high speeds 133
• Front tire air pressure 133
• Imp gal 133
• Is the color of exhaust 133
• Is the fuel level up 133
• Is the oil level correct 1 liter 6 gal 133
• Kg sq cm 25 psi 133
• Kg sq cm 27 psi 133
• Kg sq cm 29 psi 133
• Kg sq cm 31 psi 133
• Km 31 omi in the winter 133
• Loaded high speed 133
• More often when 133
• Normal operation 133
• Rear tire pressure 133
• Smoke normal 133
• The oil should be changed more often every 133
• When operation is constantly over short distances 133
• Honda models cb 125 cb 160 maintenance specifications 135

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3 11 GEAR SHIFT 5 Remove the 6X18 bolt of the shift drumltmi pressing the shift drum limit stop plate and remove the limit Refer to Fig 3 125 6 Remove the shift drum in the direction of the right crankcase cover side The gear shift drum limit plate is secured by 6X14 pan screws 7 At the lower crankcase the gear shift spindle together with the gear shift return spring and the gear shift spindle side limit are coupled Hence by removing the set ring with snap ring pliers it can be removed toward the right side of the case Refer to Fig 3 126 8 For removing the gear shift return spring a wrench or a deep box wrench should be employed Fig 3 126 Removing gear shift spindle II Assembly I Insert the gear shift drum at the right side of the upper crankcase and assemble the gear shift fork in the crankcase with attention directed to the division Refer to Fig 3 127 2 Mount the drum with the shift guide collar and screw 3 Assemble the shift fork with the gear shift fork guide pin and position the ear of the lock washer Refer to Fig 3 128 4 Assemble the neutral switch rotor and the starter 5 Assemble the shift drum limit this completes upper case assembly 6 Assemble the gear shift return spring in the lower crankcase 7 The gear shift spindle should be inserted toge ther with the return spring at the right side of the lower crankcase The gear shift spindle side limit should be inserted at the left side and the 12 mm set ring should be employed for securing Fig 3 128 Assembling of shift fork guide pin 45