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Table Of Contents - Honda CH250 Elite 1986 Service Manual

Table Of Contents

Table of Contents

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Table of Contents

General Information2

General Safety2

Model Identification3

Specifications4

Cable And Harness Routing9

Speedometer Cable12

Rear Brake Cable14

Ignition Coil14

Emission Control Systems16

Source Of Emissions16

Exhaust Emission Control System16

Crankcase Emission Control System16

Evaporative Emission Control System17

Noise Emission Control System17

Emission Control Information Label18

Vacuum Hose Routing Diagram Label18

Lubrication Service Information20

Lubrication Troubleshooting20

Lubrication Specifications20

Lubrication Torque Values20

Engine Oil Level21

Engine Oil Change21

Engine Oil Filter Screen Cleaning21

Oil Pump Removal22

Oil Pump Disassembly22

Oil Pump Inspection23

Oil Pump Assembly23

Oil Pump Installation24

Transmission Oil Level Check25

Transmission Oil Change25

Lubrication Points26

Control Cables26

Maintenance Schedules28

Throttle Operation30

Crankcase Breather32

Valve Clearance33

Radiator Coolant34

Radiator Core34

Cooling System Hoses & Connections34

Carburetor - Idle Speed34

Ignition Timing35

Cylinder Compression35

Belt Case Air Cleaner36

Brake Shoe Wear37

Brake Lock Lever38

Brake Light Switch/Starter Limiter Switch38

Headlight Adjustment39

Clutch Shoe Wear39

Nuts, Bolts, Fasteners40

Wheels, Tires40

Steering Head Bearings41

Fuel System Service Information43

Fuel System Specifications43

Fuel System Tool43

Carburetor Removal45

Auto·bystarter46

Vacuum Chamber47

Air Cut-Off Valve49

Float/Float Valve/Jets51

Valve Inspection51

Float Level Inspection52

Carburetor Installation53

Pilot Screw Adjustment54

Limiter Cap Installation54

Idle Drop Procedure54

High Altitude Adjustment55

Automatic Fuel Valve56

Fuel Strainer Cleaning57

Fuel Tank Insulator58

Air Cleaner Case60

Purge Control Valve Inspection61

Engine Removal/Installation64

Service Information64

Engine Removal65

Engine Installation68

Cylinder Head/Valves Service Information70

Cylinder Head/Valves Specifications70

Cylinder Head/Valves Torque Values70

Cylinder Head/Valves Tools70

Cylinder Head/Valves Troubleshooting71

Low Compression71

Compression Too High71

Excessive Noise71

Cylinder Head Cover Removal72

Cylinder Head Cover Disassembly72

Camshaft Removal73

Cylinder Head Removal74

Camshaft Inspection74

Camshaft Bearings74

Cylinder Head Disassembly75

Cylinder Head76

Valve Spring Free Length76

Valve Guide Replacement77

Service Limits77

Valve Seat Inspection And Refacing78

Valve Seat Grinding79

Cylinder Head Assembly80

Cylinder Head Installation81

Camshaft Installation82

Cylinder Head Cover Assembly83

Cylinder Head Cover Installation83

Cylinder/Piston Service Information86

Cylinder/Piston Troubleshooting86

Low Compression Or Uneven Compression86

Excessive Smoke86

Cylinder Removal87

Piston Removal88

Piston Ring Installation91

Cylinder Installation92

Drive Pulley Clutch/Driven Pulley Service Information94

Drive Pulley Clutch/Driven Pulley Troubleshooting95

Left Crankcase Cover Removal96

Left Crankcase Cover Installation96

Drive Pulley/Clutch/Driven Pulley96

Drive Belt Removal97

Drive Belt Inspection97

Drive Belt Installation97

Drive Pulley Removal98

Drive Pulley Disassembly98

Drive Pulley Inspection99

Service Limit99

Drive Pulley Assembly100

Drive Pulley Installation101

Clutch/Driven Pulley102

Clutch/Driven Pulley Disassembly103

Driven Pulley Disassembly103

Driven Pulley Face Bearing Replacement105

Clutch Assembly106

Driven Pulley Assembly107

Final Reduction Service Information110

Final Reduction Specifications110

Final Reduction Troubleshooting110

Final Reduction Tools110

Final Reduction Disassembly111

Final Reduction Inspection111

Final Reduction Assembly113

Alternator/Starter Clutch115

Alternator/Starter Clutch Service Information116

Alternator/Starter Clutch Specifications116

Alternator/Starter Clutch Torque Values116

Alternator/Starter Clutch Tools116

Right Crankcase Cover Removal117

Stator Removal117

Flywheel Removal118

Starter Clutch118

Starter Idle Gear/Driven Gear Removal118

Starter Clutch Inspection119

Starter Driven Gear119

Installation120

Flywheel Installation121

Stator Installation122

Right Crankcase Cover Installation122

Crankcase/Crankshaft Service Information125

Crankcase/Crankshaft Troubleshooting125

Crankcase/Crankshaft Specifications125

Crankcase/Crankshaft Torque Values125

Crankcase Separation126

Crankshaft Inspection127

Crankcase Assembly128

Cooling System131

Cooling System Service Information132

Cooling System Specifications132

Cooling System Torque Value132

Cooling System Tools132

System Testing133

Radiator Cap Inspection133

Coolant Replacement133

Radiator Inspection134

Cooung System135

Bracket Removal/Installation136

Mechanical Seal Inspection137

Water Pump Removal137

Water Pump Shaft Removal138

Mechanical Seal Replacement139

Water Pump Shaft Installation139

Water Pump Impeller Installation140

Thermosensor141

Frame Covers Service Information144

Body Center Cover145

Floor Panel, Side Rail, Floor Lower Cover146

Front Upper Cover148

Front Lower Cover149

Rear Carrier149

Steering/Front Wheel/Brake/Suspension150

Steering/Front Wheel/Brake/Suspension Service Information151

Steering/Front Wheel/Brake/Suspension Specifications151

Steering/Front Wheel/Brake/Suspension Torque Values151

Steering/Front Wheel/Brake/Suspension Tools151

Steering/Front Wheel/Brake/Suspension Troubleshooting152

Handlebar Removal153

Handlebar Installation154

Bearing Replacement157

Front Suspension Removal162

Pivot Arm Disassembly162

Front Shock Absorber Disassembly163

Shock Absorber Inspection164

Front Shock Absorber Pivot Arm Assembly164

Front Fork/Steering166

Ball Race Replacement167

Bottom Cone Race Replacement168

Rear Wheel/Brake/Suspension170

Rear Wheel/Brake/Suspension Service Information171

Rear Wheel/Brake/Suspension Troubleshooting171

Rear Wheel/Brake/Suspension Torque Values171

Rear Wheel/Brake/Suspension Tools171

Exhaust Muffler Removal172

Exhaust Muffler Installation172

Rear Wheel Removal172

Swing Arm Bearing173

Wheel Hub Removaljinstallation174

Drum Inspection175

Lining Inspection175

Rear Brake Pedal/Brake Lock System177

Parking Brake Lock Inspection/Adjustment177

Rear Shock Absorber178

Parking Brake Adjustment178

Parking Brake Lock Removal/Installation178

Electrical Equipment181

Battery Removal/Installation184

Battery Voltage Check184

Battery Charging184

Charging System185

Charging Circuit185

Current Test185

Alternator Output Test185

Alternator Inspection186

Regulator/Rectifier Inspection186

Ignition System187

Ignition System Circuit187

Ignition Coil Inspection187

Exciter Coil Inspection188

Cdi Unit Inspection188

Pulse Generator Inspection188

Starting System189

Starting Circuit189

Starter Relay Inspection189

Starter Motor Removal190

Motor Inspection190

Commutator Inspection191

Case Inspection191

Brush Holder192

Instruments Removal193

Starter Motor Installation193

Bulb Replacement195

Turn Signal Light197

Front Turn Signal Light Bulb Replacement197

Rear Turn Signal Light Bulb Replacement197

Taillight/License Plate Light197

Ignition Switch Inspection198

Ignition Switch Removal198

Ignition Switch Installation198

Handlebar Switches199

Engine Stop Switch199

Front Brake Switch199

Turn Signal Switch199

Rear Brake Light Switch200

Fuel Unit/Gauge200

Fuel Unit Inspection200

Thermostatic Switch201

Fuel Gauge Inspection201

Temperature Gauge202

Wiring Diagrams203

Technical Features206

Plenum Chamber206

Torque Link Type Anti-Dive Front Suspension207

Damper-Link Type Engine Mount208

Ignition Switch Light209

Carburetor Heater210

Troubleshooting211

Engine Does Not Start Or Is Hard To Start211

Engine Lacks Power212

Poor Performance At Low And Idle Speeds213

Engine Noise214

Clutch, Drive And Driven Pulleys214

Poor Suspension Performance215

Poor Brake Performance215

Starter Motor217

Starter Motor Will Not Turn217

Starter Motor Turns Slowly217

Starter Motor Won't Stop Turning217

Digital Speedometer Malfunction218

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Table of Contents

Troubleshooting

This manual is also suitable for:

Ch250 1986