Honda CB100 CL100 SL100 CB125S CD125S SL125 (1970) [5/101] I procedure of performing the work

Содержание

• Haa hah 1
• Shop manual 1
• Foreword 2
• Chassis 37 3
• Contents 3
• Engine 13 3
• Maintenance operations 5 3
• Procedure of performing the work 3
• V electrical 53 3
• Supplement 4
• All engine parts should be cleaned after disassembly metal surfaces which are subject to 5
• All packings gaskets and cotter pins which have been removed should be replaced with new 5
• Friction must be coated with oil 5
• I procedure of performing the work 5
• I when performing an overhaul all the parts which have been disassembled should be 5
• Inside to outside symmetrically 5
• Items when reassembling any snap rings which are deformed shoud also be replaced 5
• Refer to torque values shown in the following table 5
• Separated in their respective groups so that they will not become mixed 5
• The work should be performed with special tools for better results 5 all nuts and bolts are normally torqued starting from those of large diameter and from 5
• Special tools 6
• Il maintenance operations 9
• 120 and then install the cylinder 21
• Assemble the piston ring on the piston note the ring marking located adjacent to the ring gap should be toward the top fig 41 21
• C reassembly 21
• Insert the piston ring into the cylinder so that it is normal to the cylinder axis and then measure the ring gap using a thickness gauge fig 40 21
• Install the piston fig 42 note install the piston so that the in marking on the piston head is toward the rear replace all piston pin clips with new items 3 space the piston ring gaps equally apart 21
• Measure the piston at the skirt fig 39 21
• Measure the piston ring side clearance 21
• Note do not forget to install the two dowel pins in the mounting base 21
• Piston diameter inspection 21
• Piston ring gap 21
• Replace if beyond the serviceable limit 21
• Using a thickness gauge replace the piston ring or piston if beyond the serviceable limit 21
• When installing new piston rings roll the rings over their respective piston ring grooves to make sure that the ring side clearances are adequate rings should roll smoothly 21
• Ance with paragraph 3 c 25
• And perform the reassembly in the reverse order of diassembly 25
• C reassembly 25
• Clean all parts with solvent or kerosene 25
• Finally lap the valve into the seat using a fine valve grinding compound a uniform lap ring on the face of the valve indicates a good seating 25
• If there is uneven contact the valve seat should be cut by first using the valve seat interior cutter followed by the top cutter and then finished with the 90 seat cutter 25
• Reassemble the cylinder head in accord 25
• Valve lapping 25
• Valve spring 25
• Carburetor setting table 40
• Iv chassis 41
• 140cc 4 4 ozs 51
• Assemble piston stopper and piston on 51
• Attach the front fork upper and lower covers or fork boots and install the front fork as a unit tighten the front fork bolt 51
• C inspection 51
• Case for bend or crank if badly damaged replace with new one 51
• Cb100 cl100 cb125s cd125s 51
• Check the front fork oil seal for damage 51
• Check the front fork pipe and bottom 51
• D reassembly 51
• Fill front fork bottom case with sae 51
• Front fork spring fig 132 51
• If damaged replace with new one 51
• Insert the front fork pipe assembly into the bottom case install the oil seal and circlip and assemble the front fork spring into the fork pipe so that the end with the large pitch is at the bottom fig 134 sl100 sl125 place the large pitch end of the front fork spring into the bottom case insert the front fork pipe and assemble the oil seal and circlip 51
• Replace if beyond the serviceable limit 51
• Sl100 sl125 180 190cc 6 6 ozs 51
• The front fork pipe 51
• W 30 cb100 cl100 cb125s cd125s 51
• Wear of front fork piston 51
• A disassembly 52
• Cb100 cl100 cb125s cd125s 52
• Fig 136 cb100 cl100 cb125s cd125s sl100 sl125 52
• Fig 137 rear shock absorber disassembly 52
• Install the headlight case 52
• Metal and then separate the spring and upper case fig 137 52
• Mounting cap nuts and remove the shock absorber from the frame and r ar fork 52
• Rear suspension 52
• Remove the chain case 5 loosen the rear fork pivot nut extract 52
• Remove the cotter pin and nut and then 52
• Remove the rear brake stopper arm from the rear fork 52
• Remove the rear shock absorber bottom 52
• Remove the rear wheel in accordance with 52
• Section 2 a 52
• Shoo sl125 attach the headlight case stay between the fork top bridge and steering stem and install the front fork as a unit tighten the front fork mounting bolts 52
• Sl100 sl125 52
• The rear fork pivot bolt and then remove the rear fork 52
• Unscrew the two rear shock absorber 52
• Generating system 57
• The charging system is an a c generator magnetic single phase a c generator which consists of the stator and rotor the a c generator is rectified by the selenium rectifier and is used to charge the battery 57
• V electrical 57
• Charging system a charging test 58
• Current if they are less than values shown in the following table check or replace the stator selenium rectifier ignition coil and condenser with new one 58
• Disconnect the red white wire harness 58
• Measure the battery voltage and charging 58
• Olyte in battery if it is below 1 6 cor rected to 20 c recharge the battery its normal value is 1 8 corrected to 20 c perform the following test 58
• Start the engine and perform the following 58
• Terminal from the terminal of the battery and connect it to the terminal of the ammeter connect the terminal of battery to the terminal of ammeter connect the red white wire harness to the terminal of the voltmeter and ground the terminal of the voltmeter to earth 58
• Two tests in both the day and night opera tion mode fig 150 58
• Use the ammeter and voltmeter 2 measure the specific gravity of the electro 58
• A inspection 62
• Auxiliary electrical equip 62
• Check the front stop light switch for con tinuity by applying the tester lead probe to the black and green yellow green switch lead and depress the brake lever if there is no continuity the switch is de fective also check the action of switch manually 62
• Combination switch fig 164 62
• Front stoplight switch fig 165 62
• If continuty exists in any other leads than those shown below first make sure the wiring harness is connected correctly if the wiring is correct the switch is defective check by the testing conductivity of wires with the switch in each positions replace with new one if the conductivity is not correct 62
• Note check brake lever for excess play light should only operate by the brake 62
• O o o o o 64
• O o o o o o 64
• Trouble shooting 65
• Electrical system 68
• Maintenance schedule the milage intervals shown in the maintenance schedule are intended as a guide for establishing regular maintenance and lubrication periods by which the best and most safe rid ing conditions are assured the operating procedures for individual items are described in the section of mainte nance operation after 12 months or 10 000 km 6 000 miles perform repeatedly all items which are described in the column at every 6 months or 5 000 km 3 000 miles intervals sustained severe or high speed operation under adverse conditions may necessitate more frequent servicing 70
• O o o o 70
• Periodical maintenance 70
• Technical data 71
• G y bk 73
• Lb tube 73
• Lb ube 73
• Lg r lg 73
• O tube 73
• R tube _____fuse 15a 73
• Wiring diagram 73
• Y w y lb 73
• Вгч 73
• Contact 74
• Green with yellow spiral 74
• Lg r lg 74
• Light blue 74
• Light green 74
• Light green with red spiral 74
• Orange 74
• Red with white spiral 74
• Yellow 74
• Yellow with white spiral 74
• Or light 75
• Bk black 76
• Bl blue 76
• Br brown 76
• Cb125s 76
• Fuse 1oa 76
• G green 76
• Gr grey 76
• Lb light blue 76
• Lg light green 76
• Orange 76
• P pink 76
• W white 76
• Y yellow 76
• Bk black 77
• Bl blue 77
• Br brown 77
• Cd125s 77
• G green 77
• Lb light blue 77
• Lg light green 77
• Or grey 77
• Orange 77
• P pink 77
• W white 77
• Y yellow 77
• Tl i 25 79
• Tl125 special tools 79
• I maintenance operations 81
• Ii engine 87
• Engine 89
• In engine chassis and electrical 89
• Fig 33 90
• The transmission used on tl 125 is essentially the same as those used on cb cl sl100 and cb cd sl 125s except for the gear arrangement on the main shaft and the resultant changes in the shift drum groove fig 33 disassembly inspection and assembly procedures will not be shown here since these are identical to those of cb100 see pages 32 thru 35 90
• Transmission 90
• Chassis 91
• Electrical system 94
• Accessories 96
• Inspection of electrical 96
• Table of optional parts 97
• Maintenance schedule 98
• Specifications 99
• Tl 125 wiring diagram 100

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1 I PROCEDURE OF PERFORMING THE WORK I When performing an overhaul all the parts which have been disassembled should be separated in their respective groups so that they will not become mixed 2 All packings gaskets and cotter pins which have been removed should be replaced with new items when reassembling Any snap rings which are deformed shoud also be replaced 3 All engine parts should be cleaned after disassembly Metal surfaces which are subject to friction must be coated with oil 4 The work should be performed with special tools for better results 5 All nuts and bolts are normally torqued starting from those of large diameter and from inside to outside symmetrically 6 Refer to torque values shown in the following table UNIT kg m ft lb Frame Engine Item Cylinder head Spark advance Cam sprocket Cylinder mount bolt 6 mm Left crank case cover A C rotor A C generator mounting screw Cam chain tensioner arm Right crank case cover screw Oil filter cover screw Oil filter lock nut 16 mm Oil pump gear cover bolt Clutch mounting bolt Gear shift drum stopper bolt Gear shift drum cam bolt Torque values 1 8 2 0 11 5 14 5 0 8 1 2 5 8 8 7 0 8 1 2 5 8 8 7 1 2 1 8 8 7 13 0 0 8 1 2 5 8 8 7 2 6 3 2 18 8 23 2 0 8 1 2 5 8 8 7 0 8 1 2 5 8 8 7 0 8 1 2 5 8 8 7 0 8 0 4 2 2 2 9 4 0 5 0 29 0 36 0 0 4 0 6 2 9 4 4 0 8 1 2 5 6 8 7 0 8 1 2 5 6 8 7 0 8 1 2 5 6 8 7 Item Front axle nut Rear axle nut Rear fork pivot bolt Engine mounting bolt Handle mounting bolt Steering stem nut Front cushion mounting bolt Rear cushion mounting nut Torque link mounting bolt Top bridge lock nut Final driven sprocket Seat mounting bolt Standard parts Bolt hex 6 mm Screw cross 6 mm Nut 6 mm Screw cross 5 mm 0 8 1 2 kg m 5 8 8 7 0 8 1 2 kg m 5 8 8 7 0 8 1 2 kg m 5 8 8 7 0 3 0 4 kg m 2 2 2 9 Torque values 4 0 5 0 29 0 36 0 4 0 5 0 29 0 36 0 3 0 4 0 21 7 29 0 2 0 2 5 14 5 18 8 0 9 1 1 6 50 7 95 6 0 8 0 43 3 57 8 4 0 5 0 29 0 36 0 3 0 4 0 21 7 29 0 2 0 2 5 14 5 18 0 4 0 4 8 29 0 34 7 2 0 2 5 14 5 18 0 2 0 2 5 14 5 18 0