Honda CB250 CL250 [181/219] Trouble shooting

Содержание

• C 0 forward 1
• Shop manual 1
• Foreword 3
• Honda motor co ltd 3
• Features 4
• Contents 6
• Carburetor 55 7
• C 1 tech data 12
• Technical data 12
• 1 technical data 13
• Bawd sjnvwhojujd 2 vivo 1vdinhd31 l 14
• Cb250 engine performance curve cb250 driving performance curve 14
• Performance curve 15
• Cb350 engine performance curve cb350 driving performance curve 16
• Performance curve 16
• Cl350 driving performance curve 17
• Technical data perfarmance curve 17
• Cb25o 35o dimensional drawing 18
• Perfarmances 18
• Cl250 350 dimensional drawing 19
• Technieal date perfarmance 19
• C 2 spec tools 20
• Special tools 20
• 2 special tools 21
• C 3 engine 22
• Engine 24
• Engine 13 24
• Engine 14 25
• Engine 15 26
• Engine 16 27
• Cam case and cylinder head 28
• Engine 3 18 29
• Cam case and cylinder head 30
• Engine 20 31
• Cam case and cylinder head 32
• Assembly paragraph 1 3 33
• Camshaft 33
• Dimensional measurement fig 3 31 33
• F rocker arm and rocker arm pin 33
• G rocker arm and rocker arm pin disassembly 33
• H inspection 33
• I rocker arm and rocker arm pin reassembly 33
• Install a 0 mm 0 08 in shim which are available fig 3 30 33
• Large noise will develop between 5000 6000 rpm when such condition develop 33
• Perform the assembly in accordance with the 33
• Refer to the section on cylinder head dis 33
• Rocker arm 33
• Rocker arm pin 33
• The camshaft and perform the opening and closing operation of the valves the rocker arm which is supported by the rocker arm pin is made of chrome molybdenum steel with the cam shaft and valve contact surfaces having a welded face of special hard surfacing to provide wear resistant fig 3 29 33
• The end clearance of the camshaft is 0 mm 0 12 in if the clearance is excessively 33
• The functions of the rocker arm is to rotate 33
• Cam case and cylinder head 34
• 3 engine 35
• Assemble so that they will not be damaged or lost 35
• L inspection 35
• M properly store all parts which have been dis 35
• Valve fig 3 37 35
• Valve guide 35
• Valve is to be replaced due to excess the 35
• Valve spring fig 3 38 35
• Wear of the valve stem it is recommended that the valve guide also be replaced as the valve guide will also be worn 35
• When replacing a valve guide use a special valve guide tool tool no 07046 28601 to drive in the valve guide being careful not to cause damages and then use a reamer to ream the hole to the specified diameter when 35
• Cam case and cylinder head 36
• After reboring the cylinder finish honing must 37
• Alloy and is press fitted into the cast aluminum body a compartment is provided between the cylinder barrels to accomodate the cam chain and tensioner there are two cylinder studs which are hollow and serves as an oil passageway an o ring is installed on the sleeve skirt to prevent gas leaks fig 3 42 37
• Be performed to provide 1 s 1 s surface finish the permissable stock removal during the honing operation is approximately 0 1 mm 0 004 in the cylinder sleeves are available in oversize up to 1mm 0 40in in 0 5 mm 0 10in oversizes increments cylinders re quiring reboring beyond 1 mm 0 40 in should be replaced with a new cylinder sleeve 37
• Engine 26 37
• Measure the cylinder bore taper and out of 37
• Measurements at the top middle and bottom in both diametrical axes fig 3 43 37
• N cylinder construction 37
• O cylinder disassembly 37
• P cylinder inspection 37
• Remove the cylinder 37
• Remove the cylinder head in accordance with 37
• Removed with a ridge reamer fig 3 44 37
• Round with a precision cylinder gauge take 37
• Section 3 b 37
• The cylinder sleeve is made of special steel 37
• The cylinder the cylinder ridge should be 37
• When only the piston is to be relaced without 37
• Cam case and cylinder head 38
• Engine 28 39
• Cam case and cylinder head 40
• 3 engine 41
• Oversize piston are available in four difference sizes at an increment of 0 5mm 0 090in 41
• Piston diameter fig 3 53 54 41
• Ring groove clearance 41
• When a new piston ring is fitted fig 3 55 41
• Cam case and cylinder head 31 42
• Measure the ring gap by inserting the piston ring into the cylinder so that the ring is at right angle to the cylinder axis the gap should be measured with a thickness gauge fig 3 56 42
• Piston pin diameter 42
• Piston ring and gap 42
• Ring tension 42
• Ring width and thickness 42
• The piston ring tension is measured with a tension measuring instrument 42
• Engine 3 32 43
• Engine 34 45
• Cam case and cylinder head 35 46
• Crankcase cover right 46
• 3 engine 47
• Crankcase 48
• 3 engine 49
• Crankcase cover right 50
• 3 engine 51
• Clutch center fig 3 77 52
• Clutch plate distortion fig 3 79 52
• Clutch spring 52
• Crankcase cover right 52
• Disassembly 52
• Exercise care when installing the pump rod 52
• Friction disc 52
• Installing pump rod in reverse will render the pump inoperative 52
• J clutch inspection 52
• K clutch reassembly 52
• Of a special dimension 25 x 1 mm therefore exercise care that the standard circlip 25 mm therefore the standard 25mm circlip is not to be used 52
• Outer fig 3 78 52
• Reassemble the clutch in the reverse order of 52
• Remove the 25 mm circlip and disassemble the 52
• Remove the bolt 52
• Remove the oil pump together with the clutch 52
• The circlip use to a set the clutch center is 52
• The oil pump lock washer should be replaced 52
• Unlock the oil pump bolt locking washer and 52
• With a new item 52
• Crankcase cover left 53
• Crankcase cover left 42 53
• Upper and lower crankcase 54
• Engine 3 44 55
• Upper and lower crankcase 45 56
• Engine 46 57
• Connecting rod small end internal diameter 58
• Crankshaft runout fig 96 58
• I crankshaft inspection 58
• Main bearing diametrical clearance fig 3 97 58
• Upper and lower crankcase 47 58
• At this time the dowel pin on the bearing 59
• Cedure 59
• Cm 11 6 1 5 ft lb torque fig 3 101 59
• Connecting rod side clearance fig 3 99 59
• Diametrical clearance of the connecting rod 59
• Engine 3 48 59
• From hereafter follow the reassembly pro 59
• J crankshaft reassembly 59
• Large end fig 3 98 59
• Outer case is firmly installed into the crankcase fig 3 100 59
• Uniformly tighten the four center bearing cap bolts in a diagonal sequence to 160 210 kg 59
• Upper and lower crankcase 60
• 3 engine 61
• Upper and lower crankcase 62
• 3 engine 63
• 3 upper and lower crankcase 64
• Assemble the gear shift drum into the upper 65
• Assemble the lower crankcase to the upper 65
• Assemble the shift drum stopper neutral switch 65
• Case at this time make sure that the location of the shift fork are in their respective 65
• Check to make sure that the action of the gear shift fork is smooth 65
• Crankcase 65
• Engine 54 65
• Fork and lock with a clip 65
• Gear shift fork fig 3 116 65
• Gear shift fork guide groove fig 3 117 65
• Install the shift fork guide pin into the shift 65
• Position 65
• Reassemble the remaining components 65
• Reinstall the gear shift spindle 65
• Reinstall the transmission gear assembly 65
• The two outside and the center gear shift forks are different 65
• U gear shift inspection 65
• V gear shift reassembly 65
• When assemblying the gear shift drum exercise care not to damage the oil seal press fitted into the crankcase 65
• Carburetor 66
• Carburetor 55 66
• 3 engine 67
• Carburetor 57 68
• 3 engine 69
• Carburetor 59 70
• Carburetor setting table 70
• C 4 frame 72
• Handlebar 72
• Frame 4 62 73
• Fork top bridge 74
• Frame 64 75
• Front cushion 76
• Front cushion 65 76
• Frame 66 77
• Front cushion 78
• 4 frame 79
• After completing the assembly of the front 79
• Assemble the individual components into the 79
• C inspection 79
• Clean all the part thoroughly before as 79
• D reassembly 79
• Damper valve and the upper surface of the piston for any scratches 79
• Damper valve into the front fork pipe make sure that the damper valve is operating smoothly 79
• Front cushion spring 79
• Front fork bottom case 79
• Front fork pipe assembly fig 4 22 79
• Front fork piston 79
• Particularly inspect the bottom surface of the 79
• Sembling 79
• Front cushion 80
• Steering stem 81
• Steering stem 70 81
• Fuel tank 82
• Â frame 72 83
• Frame body 84
• Frame body 73 84
• Frame 74 85
• A seat 86
• Stand brake pedal and step bar 87
• Stand brake pedal and step bar 76 87
• Stand brake pedal and step bar 88
• 4 exhaust pipe and muffler 89
• Air cleaner 89
• Muffler 89
• Air cleaner 90
• 4 1 rear fork and rear fender 91
• A construction 91
• Chain tension fig 4 55 56 91
• Drive sprocket posses negligible effect on the 91
• On the frame and the other end is fitted to the frame through the rear cushion when the rear wheel moves in the vertical direction the section which is fitted to the frame becomes the pivot point and the rear wheel moves in an arc 91
• One end of the rear fork is fitted to a section 91
• Rear fork and rear fender 91
• The close proximity of the pivot point to the 91
• Rear fork and rear fender 92
• 4 frame 4 2 93
• Rear cushion 93
• Rear for 93
• Rear cushion 94
• And lock the assembly 95
• Assemble the under 95
• B disassembly 95
• C inspection 95
• Case to the damper using a special tool with the spring seat 95
• Compress the assembly 95
• Compress the rear cushion upper case by 95
• D reassembly 95
• Disassembly of the rear cushion damper is 95
• Frame 84 95
• Inspect the cushion damper to insure that 95
• Inspect the damper case and rod to insure 95
• Inspect the rear cushion stopper to insure that 95
• It is not damaged or deformed 95
• Not necessary fig 4 66 95
• Of the side hand hold loosen the 10 mm cap nut 10 mm bolt and remove the rear cushion assembly fig 4 641 95
• Rear cushion spring 95
• Remove the 6 mm bolt from the forward end 95
• Seat spring and upper 95
• Stopper fig 4 67 95
• That they are not damaged or deformed 95
• There is no fluid leakage 95
• Using a special tool and remove the rear cushion seat lift off the upper case and then remove the cushion spring fig 4 65 95
• Rear cushion 96
• 4 3 front wheel 97
• Front wheel 97
• Front wheel 87 98
• 4 frame 99
• Axle bend and wear fig 4 76 99
• C inspection 99
• Check for air leak by submerging the tube in 99
• Check the tire for damage to casing both 99
• D reassembly 99
• Front brake cam thickness 99
• Front brake shoe diameter and lining thickness 99
• Inside and outside 99
• Inspect anchor pin for bend 99
• Inspect and tighten any loose spokes 99
• Palance wheel assembly 99
• R bal bearings axial and radial clearance 99
• Rim runout fig 4 751 99
• The tube can be easily mounted by inflating 99
• Tightening torque 20 25kg cm 1 1 ft lb 99
• With small amount of air to make the tube firm fig 4 77 99
• Front wheel 89 100
• Rear wheel 101
• Rear wheel 90 101
• Rear wheel 102
• 4 frame 103
• Axle bend and wear fig 4 91 103
• C inspection 103
• Fig 4 89 and remove tube fig 4 89 103
• Remove 2x15 mm cotter pin and anchor pin 103
• Rim runout fig 4 90 103
• Using tire irons remove tire as illustrated in 103
• Washer separate the brake arm from the pane in order to extract the rear brake shoe fig 4 88 103
• 1 1 ft lb 104
• Check the anchor pin for bend 104
• Clearance 104
• Final driven sprocket root diameter 104
• Immersing it in water 104
• Inspect and tighten all loose spokes 104
• Inspect the casing for any damage on the inside and outside fig 4 93 104
• Inspect tube for air leak by inflating and 104
• Rear brake cam thickness fig 4 92 104
• Rear brake shoe diameter and lining thickness 104
• Rear wheel 93 104
• Tightening torque 20 25 kg cm 104
• Z and 6304z ball bearing axial and radial 104
• Z ball bearing 104
• 4 frame 105
• Rear wheel 106
• C 5 electrical 108
• Electrical equipment 108
• Electrical parts 108
• Electrical parts 97 108
• Ignition circuit 108
• Power supply system 108
• Electrical parts 98 109
• Ignition circuit 110
• Electrical parts 100 111
• Ignition circuit 101 112
• 5 electrical parts 113
• Ignition circuit 103 114
• Electrical parts 104 115
• Ignition circuit 105 116
• Electrical parts 106 117
• Ignition circuit 118
• Electrical parts j 08 119
• Power circuit 119
• Power circuit 120
• Electrical parts 121
• Power circuit 122
• Electrical parts 112 123
• Power circuit 124
• Electrical parts 114 125
• Power circuit 126
• 5 electrical parts 127
• A recently developed new type battery vacuum 128
• A the batteries when initially filled with 128
• Are that though the filler caps and other areas are sealed after a period of extended storage moisture will enter the dry charged battery and produce sulfation of the lead sponge deteriorating the dry charge effectiveness in contrast the 128
• B comparison of affect to the charge ca 128
• Charge when the electrolyte is added however it will not be a 100 charge normally it requires charging for a approximately 10 hours at a charging current of 10 15 hour rate to obtain full charge 128
• Comparison of the performances 128
• Electrical charge fig 5 44 128
• Electrolyte will produce the following 128
• Equipped with the new type battey 128
• Handling care should be exercised not to damage the packing so that the vacuum sealing is rendered 128
• Ineffective 128
• Pacity for storage fig 45 128
• Power circuit 117 128
• Sealed dry charged battery has simplified the servicing of the battery by eliminating the necessity for the initial charge the honda 250 350 is 128
• The difference between the two type batteries 128
• The present dry battery in use dry charged batteryl will produce a certain amount of 128
• Vacuum sealed dry charged battery 128
• Vacuum sealed dry charged battery is fully sealed so that it is not affected by the atmosphere or long period of storage further the plates are of different design which improves the preservation of the electrical charge each battery is sealed in vinyl package under vacuum and encased in a cardboard carton to prevent damage during 128
• 5 electrical parts 129
• Electric starter 130
• Electrical starter 130
• 5 electrical parts 131
• Electrical starter 727 132
• Electrical parts 122 133
• Electrical starter 134
• 5 electrical parts 135
• Safety devices 136
• Safety devices 125 136
• Electrical parts 126 137
• Safety devices 127 138
• 5 electrical parts 139
• Safety devices 129 140
• Electrical parts 130 141
• Safety devices 131 142
• Switches 143
• Switches j 32 143
• Switches 144
• And if not properly maintained it may cause fire for this reason make shift patching should be avoided the wiring system consists of the wire harness the backbone of the system the auxiliary cord which connects two places partially attached terminals terminal sleeves nipple cords connectors and other small parts 145
• Excessive battery discharge burning etc due to ground short circuit of wiring or electric parts damage however when the ac generator coil and selenium rectifier are combined for the power supply the selenium rectifier output terminal and battery should be directly connected to prevent selenium breaking since if the engine is operated under the condition in which the fuse is removed or broken the selenium rectifier plate may be broken due to high reverse voltarge therefore only the rectifier output is connected direct to the battery not through the fuse fig 5 82 145
• I e unfamiliar babel arranged in the harness makes it difficult to inspect or if one cable is broken the broken wire cannot be replaced only by itself but the whole harness must be replaced cannot be avoided thus if only one cable is broken an additional separate cable must be attached to the wire harness 145
• Not only for the cables which make up the wire harness but also for all other auxiliary cords 145
• On the positive battery terminal there is a fuse to prevent hazardous occurrences such as 145
• The core cables are colored for ease in identification 145
• The wire harness has the above described features however on the other hand inconveniences 145
• The wire harness is combined in one bundle and required unctions are provided on the harness 145
• The wire harness is the artery between electric parts it is important for electrical part functions 145
• To ease and confirm the network of wires and cables which make up the main electrical circuits in order to protect the main electrical circuits the surface has been covered with mesh wire waxed wire or vinyl tubing 145
• Wire harness 145
• Service tester 146
• Service tester 135 146
• Electrical parts 136 147
• Service tester 148
• Electrical parts 138 149
• Service tester 150
• Electrical parts 140 151
• Service tester 141 152
• 5 electrical parts 153
• Battery trouble shooting and corrective action 154
• Service tester 143 154
• C 6 insp adjust 156
• Inspection and adjustment 156
• Preventive maintenance 156
• Preventive maintenance 145 156
• And adjustment 157
• Inspection and adjustment 159
• Maintenance 160
• Preventive 160
• And adjustment 161
• Inspection 161
• Preventive 162
• 6 inspection and adjustment 163
• Maintenance 164
• Preventive 164
• Inspection and adjustment 154 165
• Preventive maintenance 155 166
• And adjustment 6 inspection 756 167
• Preventive maintenance 157 168
• Inspection and adjustment 158 169
• Preventive maintenance 159 170
• Inspection and adjustment 160 171
• Preventive maintenance 172
• If the motorcycle is driven with loose wheel spokes the rims other spokes will be spoiled for this reason the spokes should be tightened after the first 1000 miles followed by re tightening at every 6000 miles thereafter with the front wheel lifted turn the wheel and retighten loose sope nipple properly so that all are tightened equally 173
• Inspection and adjustment 162 173
• Spokes 173
• Use the nipple rench fig 6 47 173
• Periodical inspection and maintenance 174
• Periodical inspection and maintenance 163 174
• Tightening torque standard 174
• 6 trouble shooting 175
• Trouble shooting 175
• Inspection and adjustment 165 176
• 6 trouble shooting 177
• C improper rpm particularly at low speed and idling 178
• Inspection and adjustment 167 178
• 6 trouble shooting 179
• D improper rpm high speed 179
• Inspection and adjustment 169 180
• E excessive oil consumption 181
• Exhaust blue or block smoke 181
• Trouble shooting 181
• F clutch operates faulty 182
• G shift operates faulty 182
• Inspection and adjustment 171 182
• 6 trouble shooting 183
• H engine runs with unusual noise 183
• I vehicle steers faulty 183
• Defective brake 184
• Front or rear suspension functions faulty 184
• Inspection and adjustment 173 184
• 6 trouble shooting 185
• L quick expansion of drive chain 185
• C 7 wiring diag 186
• R w a b 186
• Rectifier 186
• Wiring diagram 175 186
• Wiring diagram general type 186
• Copyright reserved 190
• Honda 250 350 190
• Models cb cl250 cb cl350 190
• Shop manual 190
• Honda motor co ltd 191
• Shop manual 192
• Sl350 supplement 192
• Foreword 194
• Contents 196
• Technical data 198
• Sl 350 operational performance curve sl 350 engine performance curve 200
• Unit in mm 201
• Special tools 202
• Dismounting the engine 204
• Engine 204
• General description of the sl 350 204
• Carburetor 205
• Case rear cover fig 205
• Installing the rear upper crankcase mounting bolt first will permit easy aligement of 205
• Model sl 350 205
• Of the link clip should point toward the direction of the normal chain rotation 205
• Of the removal procedure 205
• Primary secondary 205
• Remounting the engine 205
• Specifications 205
• The carburetor specifications are summarized below for further information and adjust ment refer to 250 350 shop manual 205
• The crankcase side 205
• The drive chain joint clip should be facing in the correct direction the closed end 205
• The engine can be easily remounted by sliding the rear of the engine in place from 205
• The installation details for the engine remounting are performed in the reverse order 205
• The remaining crankcase mounting bolts first the lower and then the cylinder head upper mounting bolts 205
• The steel ball must be in the clutch lever housing when installing the left crank 205
• Torque all engine hanger bolts to 25 32 ft lbs 250 350 kg cm 205
• Fork top bridge 206
• Front cushion 206
• Handlebar 206
• Steering stem 208
• Fuel tank 210
• Muffler 211
• Air cleaner 212
• Rear fork 212
• Rear cushion 214
• Bead spacer 215
• Front wheel 215
• Rear wheel 216
• Tire recommendation 216
• Electrical 217
• General description 217
• Starter lighting kill switch 217
• Wiring diagram 218

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6 3 TROUBLE SHOOTING E Excessive oil consumption Exhaust blue or block smoke Description of trouble Inspection Adjustment Probable Cause o Continue to crank of high j speed Exhaust unvisible D Cylinder and piston rings are worn 2 Excessive oil in crank case Piston rings are assembled reverse in piston upside down Flows on the piston or cylinder 5 Blowhole exist in compression section D Openings of all three piston rings are lined up at the same location Exhaust black or blue smoke Accelerate and try to close the throttle valve instantly Exhaust unvisible Inlet valve guide or valve stem are worn I 2 Fitting of inlet valve guide to cylinder head is loose Exhaust white smoke soon after the valve closed Continue to crank at low j speed I Exhaust unvisible Exhaust white smoke Exhaust valve stem and guide are worn I Fitting of exhaust valve guide is loose