Table Of Contents - Honda CB250 Shop Manual

Table of Contents

Features4
Frame5
Contents6
Technical Data12
Cb250 Driving Performance Curve14
Cb250 Engine Performance Curve14
Cl250 Driving Performance Curve15
Cl250 Engine Performance Curve15
Cb350 Driving Performance Curve16
Cb350 Engine Performance Curve16
Cl350 Driving Performance Curve17
Cl350 Engine Performance Curve17
Cb250/350 Dimensional Drawing18
Cl250/350 Dimensional Drawing19
Special Tools20
Engine22
Sectional View Of Engine22
Engine Construction24
Power Transmission24
Lubrication25
Oil Lubricating System25
Dismounting The Engine26
Remounting The Engine27
Cam Case And Cylinder Head28
Engine Disassembly29
Inspection30
Engine Reassembly31
Camshaft Construction32
Rocker Arm And Rocker Arm Pin33
Rocker Arm And Rocker Arm Pin Disassembly33
Rocker Arm And Rocker Arm Pin Reassembly33
Valve And Valve Spring Construction34
Valve And Valve Spring Disassembly34
Valve And Valve Spring Reassembly36
Sectional View Of Valve Seat36
Valve Seat Cutter36
Suction Cup Lapping Tool36
Cylinder Construction37
Cylinder Disassembly37
Cylinder Inspection37
Cylinder Reassembly38
Piston Description38
Piston Ring Construction39
Piston And Piston Ring Disassembly40
Piston And Piston Ring Inspection40
Dimension Of Piston41
Measuring The Piston Diameter41
Piston Groove And Piston Ring Clearance41
Piston Pin Diameter42
Piston Ring And Gap42
Ring Tension42
Ring Width And Thickness42
Piston And Piston Pin Reassembly43
Rolling The Piston Ring In The Piston Groove43
Manufacturer's Mark43
Setting The Piston Pin Clip43
Sectional View Of Cam Chain44
Cam Chain Tensioner And Guide Roller Construction45
Tensioner And Guide Roller Disassembly45
Crankcase Cover (Right) Construction46
Crankcase Cover (Right) Disassembly46
Tensioner And Guide Roller Reassembly46
Crankcase Cover (Right) Reassembly47
Oil Filter Construction47
Oil Filter Reassembly48
Clutch Construction49
Sectional View Of Clutch50
Clutch Adjusting Mechanism50
Oil Pump Construction51
Clutch Disassembly51
Clutch Inspection52
Clutch Reassembly52
Crankcase Cover (Left) Construction53
Crankcase Cover (Left) Disassembly53
Crankcase Cover (Left) Reassembly53
Upper And Lower Crankcase Construction54
Upper And Lower Crankcase Disassembly54
Oil Separator Operation54
Upper And Lower Crankcase Inspection55
Upper And Lower Crankcase Reassembly55
Crankshaft Construction55
Crankshaft Balance56
Connecting Rod Construction57
Crankshaft Disassembly57
Crankshaft Inspection58
Crankshaft Runout Measuring58
Measuring The Diametrical Clearance58
Crankshaft Reassembly59
Measuring The Connecting Rod Diametrical Clearance59
Measuring The Connecting Side Clearance59
Tightening The Bearing Cap Bolts59
Kick Starter Construction60
Kick Starter Disassembly60
Kick Starter Inspection60
Kick Starter Reassembly60
Transmission61
Transmission Disassembly62
Transmission Inspection62
Transmission Reassembly63
Gear Shift Construction63
Measuring The Gear Backlash63
Assembling The Gears63
Gear Shift Disassembly64
Gear Shift Mechanism64
Removing The Gear Shift Drum64
Gear Shift Inspection65
Gear Shift Reassembly65
Measuring The Flatness Of Gear Shift Fork65
Measuring The Outer Diameter65
Carburetor66
Air Flow66
Fuel Flow66
Operation And Adjustment67
Float System67
Choke67
Sectional View Of Carburetor67
High Speed System69
Maximum Speed System69
Carburetor Setting Table70
Handlebar Construction72
Handle Disassembly72
External View Of Handlebar72
Removing Brake Cable72
Handlebar Inspection73
Removing The Handlebar73
Removing The Throttle Cable73
Fork Top Bridge Construction74
Throttle Cable Play Adjustment74
Adjusting The Front Brake74
Joint The Electrical Leads74
Removing The Fork Top Bridge75
Component Parts Of Fork Top Bridge75
Top Bridge Holder Installing 8Mm Nut75
Front Cushion Construction76
Front Fork Assembly76
Cross-Section Of Front Cushion (Cl250/350)76
Cross-Section Of Front Cushion (Cb250/350)77
Front Cushion Operation77
Front Cushion Disassembly78
Removing The Front Fender78
Removing The Front Fork Assembly78
Removing 44Mm Circlip78
Front Cushion Inspection79
Front Cushion Reassembly79
Front Cushion Spring Measurement79
Component Parts Of Front Fork Pipe79
Driving Oil Seal80
Installing The Front Fork Into The Steering80
Steering Stem Construction81
Steering Stem Disassembly81
Steering Stem Inspection81
Sectional View Of Steering Stem81
Steering Stem Reassembly82
Fuel Tank Construction82
Schematic View Of Tank Rubber Cushion82
Fuel Tank Disassembly83
Fuel Tank Inspection83
Fuel Tank Reassembly83
Component Parts Of Fuel Strainer83
Frame Body Construction84
Schematic View Of Frame Body84
Frame Body Disassembly85
Frame Body Inspection85
Frame Body Reassembly85
Seat Construction86
Seat Disassembly86
Seat Inspection86
Seat Reassembly86
Stand, Brake Pedal And Step Bar Construction87
Stand, Brake Pedal And Step Bar Disassembly87
Exploded View Of Stand And Brake Pedal87
Stand, Brake Pedal And Step Bar Inspection88
Stand, Brake Pedal And Step Bar Reassembly88
Removing The Step Bar88
Fixing The Main Stand With 6Mm Bolts88
Muffler89
Air Cleaner89
Installing The Exhaust Pipe89
Cross-Section Of Exhaust Pipe And Nut89
Air Flow In Dual Type Air Cleaner90
Removing The Air Cleaner Case90
Rear Fork And Rear Fender Construction91
Exploded View Rear Fork And Rear Fender91
Rear Fork And Rear Fender Disassembly92
Rear Fork And Rear Fender Inspection92
Twist Measurement Of Rear Fork92
Removing The Rear Fork92
Rear Cushion Construction93
Sectional View Of Rear Cushion93
Cross-Section Of The Rear Fork Pivot Portion93
Feature And Performance94
Rear Cushion Adjustment94
Removing The Rear Cushion Assembly95
Disassembling Rear Cushion95
Component Parts Of Rear Cushion95
Assembling Rear Cushion95
Check Of Cushion96
Mounting Bolts And Nuts Of Rear Cushion96
Front Wheel Construction97
Front Wheel Disassembly97
Removing The Brake Stopper Arm97
Removing The Front Wheel Axle98
Removing The Oil Seal98
Removing The Front Brake Shoe98
Front Wheel Reassembly99
Checking The Front Wheel Rim For Runout99
Checking The Front Axle For Bend99
Installing The Tire99
Tapping Around The Tire100
Driving The Bearing100
Installing The Brake Arm100
Valve Angle100
Rear Wheel Construction101
Cross-Section Of Rear Wheel101
Rear Wheel Disassembly102
Removing The Drive Chain Joint102
Removing The Final Driven Sprocket102
Removing The Bearing Retainer102
Removing The Rear Brake Shoe103
Removing The Rear Wheel Tire103
Checking The Front Wheel Rin For Runout103
Checking The Rear Axle For Bend103
Measuring The Outside Of The Rear Brake Shoe104
Inspection The Inside Of Tire104
Rear Wheel Reassembly105
Installing The Bearing105
Assembling The Final Driven Sprocket105
Installing The Brake Shoe105
Setting The Chain Clip106
Rear Brake Pedal Play106
Adjusting The Rear Brake106
Adjusting Slack Of Drive Chain106
Electrical Parts108
Electrical Equipment108
Power Supply System108
Ignition Circuit108
Sectional View Of Ignition Coil109
Ignition System View109
Spark Characteristics109
Vertical Type Electrode Space109
Spark Advancer110
60 Degree Type Electrode Space110
Contact Breaker111
Spark Advancer Mechanism111
Spark Advancer Characteristics111
Condenser112
Spark Plug113
Cross-Section Of Spark Plug114
Electrode Construction115
Insulator Construction115
Spark Plug Thermal Characteristics116
Spark Plug Reach117
Heat Dissipation117
Comparison Of Hear Characteristics117
Noise Suppressor118
Power Circuit119
A.c. Generator119
Current Limiter119
Pointless Regulator120
Pointless Regulator Characteristics120
A.c. Generator Capacity For The Honda 250/350121
Pointless Regulator Circuit Diagram121
A.c. Generator Battery Changing Characteristics121
Selenium Rectifier122
Selenium Rectifier Stuck122
Construction Of Selenium Rectifier122
Selenium Symbol122
Battery124
Battery Construction124
Battery Charging Procedure125
Measuring The Specific Gravity125
Specific Gravity And Residual Capacity Chart125
Series Connection For Multiple Charging126
Preventative Maintenance127
Vacuum Sealed Dry Charged Battery128
Comparison Of Performances128
Care During Storage129
Instruction Before Use129
Aluminum Foil Packing Tight On The Battery129
Aluminum Foil Packing Loose On The Battery129
Electric Starter130
Starting Circuit130
Starting Motor130
Starting Motor Characteristics131
Starter Reduction131
Starter Circuit Diagram131
Starting Motor Reduction Gear Components131
Electric Starter Removal132
Electric Starter Servicing132
Starting Clutch133
Sectional View Of Commutator133
Commutator Correction133
Starter Solenoid Switch135
Starter Solenoid Switch With The Cover Opened135
Safety Devices136
Horn136
Horn Construction137
Horn Servicing138
Tail-Stoplight138
Cross-Section Of Tail/Stop Light138
Pilot Lamp139
Speedometer/Tachometer139
Characteristics Of The Speedometer/Tachometer140
Headlight141
Headlight Construction141
Flasher Relay Operation142
Combination Switch Closed142
Flasher Switch (Ws) Closed (Lights On)142
Point (P) Open (Light Off)142
Switches143
Combination Switch143
Point(P) Closed (Light On)143
Signal-Stat Flasher Relay143
Stoplight Switch144
Starter/Lighting Switch144
Winker-Horn Switch144
Neutral Switch144
Wire Harness145
Service Tester146
Meter Reading146
Meter Scale Panel146
Usage By Item147
Selector Switch147
Test Lead Wire Connection147
Continuity Test Of The Combination Switch147
Rectifier Resistance Measurement148
Condenser Insulation Test148
Rectifier Wiring Diagram148
Short-Circuiting Of The Condenser149
Condenser Capacity Measuring149
D.c. Voltage Measurement150
D.c. Current Measurement150
Engine Revolution Measurement151
Timing Measurement151
Connection Of The Timing Light Cord151
Coil Test Connection152
Coil Test (Negative Sparking)152
Coil Test (Positive Sparking)152
Starting Motor Current Measurement153
Battery Trouble Shooting And Corrective Action154
Inspection And Adjustment156
Preventive Maintenance156
Engine Tune-Up156
Compression Measurement156
Valve-Tappet Clearance Adjustment157
Rated Compression157
Aligning The 'Lt' Mark157
Adjusting Tappet Clearance158
Rocker Arm Pin Turning Direction158
Ignition Timing Adjustment159
Point Surface Correction159
Aligning The 'Lf' Mark160
Start Of Spark Advancing160
End Of Spark Advancing160
Spark Plugs161
Spark Gap Measuring161
Spark Plug Clearing161
Fuel System162
Cleaning Oil Filter162
Filler Cap Cross-Section Showing Breather Path162
Gasoline Flow Through The Fuel Cock162
Air Cleaner Element Cleaning163
Air Cleaner Case Removing163
Oil Filter Cover Installation163
Rotor Cap Installation163
Clutch Adjustment164
Clutch Lever Play164
Sectional View Of Air Flow164
Air Cleaner Cleaning164
Carburetor Cleaning And Adjustment165
Idling Adjustment166
Cross-Section Of Carburetor166
Throttle Valve Adjustment167
Oil Filter Cap167
Oil Drain Plug167
Grease168
Drive Chain Adjustment169
Front Fork Oil Change169
Drive Chain Slackness And Adjustment169
Front Fork Bolt169
Brake Adjustment170
Front Brake Lever Play170
Battery Inspection171
Rear Brake Adjustment171
Seat Latch171
Checking Parts For Tightness172
Spokes173
Retightening Spoke173
Left Side173
Right Side173
Periodic Inspection And Maintenance174
Trouble Shooting175
Engine Does Not Start Of Hard Starting175
Loss Of Speed And Drop In Power176
Improper Rpm178
Excessive Oil Consumption181
Clutch Operates Faulty182
Shift Operates Faulty182
Engine Runs With Unusual Noise183
Vehicle Steers Faulty183
Front Or Rear Suspension Functions Faulty184
Defective Brake184
Quick Expansion Of Drive Chain185
Wiring Diagram(General Type)186
Wiring Diagram (U.s.a. Type)187
Wiring Diagram (U.k. Type)188
Wiring Diagram (Germany Type)189