Honda CB250K3 Manuals

Manuals and User Guides for Honda CB250K3. We have 1 Honda CB250K3 manual available for free PDF download: Shop Manual

Honda CB250K3 Shop Manual (180 pages)

Honda Motorcycle CB250/350, CL250/350, SL350

Brand: Honda | Category: Motorcycle | Size: 36.12 MB

Contents
5
Technical Data
14
Special Tools
28
Minor Model Change Table of Principal Modifications
32
Engine
42
Main Features
42
Power Transmission System
42
Dismounting the Engine
42
Remounting the Engine
43
Valve Mechanism
44
Description
44
Disassembly
44
Inspection
46
Compression Pressure
46
Adjusting the Engine to the Proper Compression Pressure
46
Valve Tappet Clearance Inspection and Adjustment
46
Camshaft Side Clearance
47
Cam Diameter
47
Camshaft Mounting End
48
Rocker Arm Pin Diameter
48
Deformation of the Gasketing Surface
48
Carbon Removal
48
Valve Seat Contact
49
Valve Stem Clearance
50
Valve Stem Diameter
50
Valve Guide Replacement
50
Valve Spring Dimension
50
Reassembly
51
Valve Timing
51
Pistons and Cylinders
52
Cylinder Boring and Honing
53
Piston Dimension
53
Piston Ring Side Clearance
53
Piston Ring End Gap
54
Piston Ring Thickness
54
Piston Pin Bore
54
Piston Pin Diameter
54
Cam Chain Tensioner (Hydraulic Type) Description
55
Cam Chain Tensioner (Hydraulic Type) Disassembly
56
Cam Chain Tensioner Inspection
56
Cam Chain Tensioner Reassembly
56
Lubricating System Description
57
Lubricating System Disassembly
58
Lubricating System Inspection
59
Engine Oil Check and Change
59
Cleaning Air Filter
59
R. Crankcase and Oil Filter Inspection
60
Oil Pump Body Bore Dimension
60
Oil Pump Plunger Dimension
60
Lubricating System Reassembly
61
Clutch Description
61
Clutch Disassembly
62
Clutch Inspection
62
Clutch Reassembly
63
Friction Disc Dimension
63
Clutch Plate Warpage
63
Clutch Spring Dimension
63
Crankshaft and Connecting Rods Description
64
Crankshaft and Connecting Rods Disassembly
64
Crankshaft and Connecting Rods Inspection
65
Measure Amount of Bend
65
Main Bearing Diametrical Clearance
65
Connecting Rod Diametrical Clearance
65
Crankshaft and Connecting Rods Reassembly
66
Transmission Description
66
Transmission Disassembly
66
Connecting Rod Small End Bore
66
Transmission Inspection
67
Measuring Backlash
67
Wear to Transmission Gear
67
Clearance between Gear and Sahft
67
Transmission Reassembly
68
Gear Shift Mechanism Description
68
Gear Shift Mechanism Disassembly
69
Gear Shift Mechanism Inspection
69
Gear Shift Mechanism Reassembly
70
Kick Starter Description
70
Kick Starter Disassembly
70
Kick Starter Reassembly
70
Crankcases Description
71
Oil Separator Operation
71
Crankcases Disassembly
71
Crankcases Inspection
71
Crankcases Reassembly
72
Carburetor Description
72
Sectional View of Carburetor
72
Carburetor Disassembly
73
Carburetor Inspection
73
Idling Adjustment
73
Synchronizing the Throttle Valve
73
Frame
74
Handlebar Description
74
Handlebar Disassembly
74
Handlebar Inspection
75
Handlebar Reassembly
75
Fork Top Bridge Description
76
Fork Top Bridge Disassembly
76
Fork Top Bridge Inspection
76
Fork Top Bridge Reassembly
76
Front Cushion (Piston Type) Description
77
Front Fork Assembly
77
Front Cushion Description
78
Front Fork Unit
78
Front Cushion Operation
79
Front Cushion Disassembly (Piston Type)
79
Front Cushion Inspection (Piston Type)
80
Front Fork Oil Change
80
Inspect for Oil Leak
80
Inspect Front Cushion Spring
80
Front Cushion Reassembly
81
Front Fork Piston Diameter
81
Front Fork Bottom Case Diameter
81
Front Cushion Description (Rod Type)
82
Front Cushion Disassembly
82
Front Cushion Inspection
83
Steering Stem Description
84
Steering Stem Disassembly
84
Steering Stem Inspection
84
Steering Stem Reassembly
84
Fuel Tank Description
85
Fuel Tank Disassembly
85
Fuel Tank Inspection
86
Fuel Tank Reassembly
86
Frame Body Description
86
Frame Body Disassembly
87
Frame Body Inspection
87
Frame Body Reassembly
87
Seat Description
87
Seat Disassembly
88
Seat Inspection
88
Seat Reassembly
88
Stands and Brake Pedal Description
88
Stands and Brake Pedal Inspection
89
Stands and Brake Pedal Reassembly
89
Exhaust Pipes and Mufflers Description
89
Exhaust Pipes and Mufflers Disassembly
90
Exhaust Pipes and Mufflers Inspection
90
Exhaust Pipes and Mufflers Reassembly
90
Air Cleaner Description
90
Rear Fork and Rear Fender Description
91
Rear Fork and Rear Fender Disassembly
91
Rear Fork and Rear Fender Inspection
92
Rear Fork and Rear Fender Reassembly
92
Rear Cushion Description
93
Rear Cushion Operation
93
Rear Suspension Adjustment
93
Rear Cushion Disassembly
95
Rear Cushion Inspection
95
Rear Cushion Reassembly
96
Front Wheel Description
96
Front Wheel Disassembly
97
Front Wheel Inspection
97
Front Wheel Reassembly
98
Front Axle Bend
98
Radial Clearance of 6302R Ball Bearing
98
Thickness of Brake Lining
98
Front Wheel Disassembled
100
To Serve Front Wheel
100
Front Wheel Torque Specifications
100
Front Wheel Assembly
102
Disassembly of Calipers and Master Cylinder
104
Master Cylinder Disassembled
106
Inspection of Calipers and Master Cylinder
106
Assembly of Calipers and Master Cylinder
107
Measure the Caliper Cylinder and Piston
107
Measure the Master Cylinder and Piston
107
Adjustment of Disc Brake
108
Check the Brake Fluid Level
108
Bleed the Brake Lines
109
Rear Wheel Description
109
Rear Wheel Disassembly
110
Rear Wheel Inspection
111
Rear Axle Bend
111
Rear Brake Drum Inside Diameter
111
Rear Wheel Reassembly
112
Electrical Parts
114
Ignition System
114
Ignition Coil Description
114
Ignition Coil Removal
114
Ignition Coil Reassembly
115
Ignition Coil Inspection
115
Ignition Coil Inspection with a Service Tester
115
Breaker Point Description
116
Breaker Point Disassembly
116
Breaker Point Inspection
116
Breaker Point Reassembly
118
Condenser Description
118
Condenser Removal
118
Condenser Inspection
118
Spark Plug Description
119
Spark Plug Removal
120
Spark Plug Inspection
120
Spark Plug Installation
120
Noise Suppressor Description
121
Noise Suppressor Removal
121
Noise Suppressor Inspection
121
Noise Suppressor Reinstallation
121
A.C. Generator Performance Characteristics
122
Silicon Current Regular Description
122
Silicon Current Regular Disassembly
122
Silicon Current Regular Inspection
123
Silicon Current Regular Reassembly
123
Rectifying System Description
123
Rectifying System Disassembly
123
Rectifying System Reassembly
124
Battery Description
124
Battery Removal
125
Battery Inspection
125
Battery Charging Procedure
125
Battery Charging
126
Quick Charger
126
Battery Trouble Shooting and Corrective Action
128
Starting System
128
Starting Motor Description
128
Starting Motor Disassembly
129
Starting Motor Inspection
129
Armature Insulation Test
129
Measure the Starting Current
129
Starting Motor Specification
130
Starting Motor Reassembly
130
Starting Clutch Description
130
Starting Clutch Inspection
130
Starting Clutch Reassembly
131
Starter Magnetic Switch Description
131
Starter Magnetic Switch Removal
131
Starter Magnetic Switch Inspection
131
Safety Equipment
132
Horn Description
132
Horn Removal
132
Horn Inspection
132
Headlight Description
133
Headlight Removal
133
Headlight Inspection
133
Headlight Reassembly
134
Tail/Stop Light Removal
134
Tail/Stop Light Inspection
134
Tail/Stop Light Reassembly
134
Winker Relay Description
135
Winker Relay Removal
135
Winker Relay Inspection
135
Winker Relay Reassembly
135
Switches
136
Ignition Switch Removal
136
Stoplight Switch Removal
136
Stoplight Switch Inspetion
136
Starter Switch Button and Lighting Switch Removal
137
Starter Switch Button and Lighting Switch Reassembly
137
Starter Switch Button and Lighting Switch Inspection
137
Turn Signal and Horn Control Switch Disassembly
137
Neutral Switch Inspection
138
Neutral Switch Removal
138
Neutral Switch Reassembly
138
Wiring Diagram
138
Wiring Harness Description
139
Wiring Harness Removal
139
Wiring Harness Inspection
139
Wiring Harness Reassembly
139
Engine (SL350)
140
General Description of the SL350
140
Dismounting the Engine (SL350)
140
Remounting the Engine (SL350)
140
Primary Kick Starter
141
Carburetor Specifications (SL350)
142
Carburetor Circuits
142
Main Circuit
143
Float Circuit
143
Idle Speed Adjustment (SL350)
144
Float Level Adjustment (SL350)
144
Frame (SL350)
145
CB250K4 Wiring Diagram
156
CB350K4 Wiring Diagram
157
CB350K4 Wiring Diagram (General Type)
158
CL350K4 Wiring Diagram
159
CL350K4 Wiring Diagram (General Type)
160
SL350K2 Wiring Diagram
161
CB350G Wiring Diagram
162
Maintenance Schedule
164
Tightening Torque Standard
165
Trouble Shooting
166
Engine Does Not Start or Hard Starting
166
Loss of Speed and Drop in Power
167
Improper Running of Engine (Particularly at Low Speed and Idling)
169
Improper Running of Engine (High Speed)
170
Excessive Oil Consumption
172
Exhaust Smoke
172
Clutch Operates Faulty
173
Shift Operates Faulty
173
Engine Runs with Unusual Noise
174
Vehicle Steers Faulty
174

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Honda CB250K3 Shop Manual (180 pages)

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