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Honda 1985-1988 Elite CH250 Manual

Honda 1985-1988 elite ch250

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4

Specifications

Table of Contents

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Table of Contents

1
Contents
2
General Information
2
General Safety
2
Service Rules
3
Model Identification
4
Specifications
6
Torque Values
7
Tools
8
Common
9
Cable and Harness Routing
16
Emission Control Systems
16
Source of Emissions
16
Exhaust Emission Control System
16
Crankcase Emission Control System
17
Evaporative Emission Control System
17
Noise Emission Control System
18
Emission Control Information Label
18
Emission Control Information Update Label
18
Vacuum Hose Routing Diagram Label
20
Lubrication
20
Lubrication Troubleshooting
20
Oil Level too Low
20
Oil Contamination
21
Engine Oil
21
Engine Oil Filter Screen Cleaning
21
Oil Level
21
Oil Change
22
Oil Pump Removal
22
Oil Pump Disassembly
23
Oil Pump Inspection
23
Oil Pump Assembly
24
Oil Pump Installation
25
Final Reduction Oil
25
Oil Level Check
26
Lubrication Points
26
Control Cables
27
Maintenance
28
Maintenance Schedules
32
Fuel Lines
32
Fuel Filter
32
Throttle Operation
33
Air Cleaner
34
Crankcase Breather
34
Spark Plug
35
Valve Clearance
36
Radiator Coolant
36
Radiator Core
36
Cooling System Hoses & Connections
36
Carburetor Idle Speed
37
Ignition Timing
37
Cylinder Compression
38
Drive Belt
38
Belt Case Air Cleaner
39
Brake Shoe Wear
39
Brake System
39
Front Brake
40
Brake Lock Lever
40
Brake Light Switch/Starter Limiter Switch
40
Rear Brake
41
Headlight Adjustment
41
Clutch Shoe Wear
41
Side Stand
42
Suspension
43
Nuts, Bolts, Fasteners
43
Wheels/Tires
43
Steering Head Bearings
45
Fuel System
45
Fuel System Service Information
45
Fuel System Specifications
46
Fuel System Troubleshooting
46
Fuel System Tool
46
Engine Cranks but Won't Start
46
Rough Idle
47
Carburetor Removal
48
Auto-Bystarter
49
Vacuum Chamber
49
Auto Bystarter Valve Inspection
51
Air Cut-Off Valve
52
Pilot Screw
53
Float/Float Valve/Jets
53
Float Valve Inspection
54
Float Level Inspection
55
Carburetor Installation
56
Pilot Screw Adjustment
56
Limiter Cap Installation
56
Idle Drop Procedure
57
High Altitude Adjustment
58
Automatic Fuel Valve
59
Fuel Tank
59
Fuel Strainer Cleaning
60
Fuel Unit Removal
60
Fuel Unit Installation
60
Fuel Tank Insulator
61
Fuel Tank Installation
62
Air Cleaner Hose
63
Purge Control Valve Inspection
65
Engine Removal/Installation
66
Engine Removal/Installation Service Information
66
Engine Removal/Installation Specifications
66
Engine Removal/Installation Torque Values
71
Cylinder Head/Valves
72
Cylinder Head/Valves Service Information
72
Cylinder Head/Valves Specifications
72
Cylinder Head/Valves Torque Values
72
Cylinder Head/Valves Tools
73
Cylinder Head/Valves Troubleshooting
73
Low Compression
73
Compression too High
73
Excessive Noise
74
Cylinder Head Cover Removal
74
Cylinder Head Cover Disassembly
74
Rocker Arm
74
Rocker Arm Shaft
75
Camshaft Removal
76
Cylinder Head Removal
76
Camshaft Inspection
77
Cylinder Head Disassembly
78
Cylinder Head Inspection
78
Valve Spring Free Length
78
Valve Stem
79
Valve Guide Replacement
79
Valve Guides
80
Valve Seat Inspection and Refacing
81
Valve Seat Grinding
82
Cylinder Head Assembly
83
Cylinder Head Installation
84
Camshaft Installation
85
Cylinder Head Cover Assembly
85
Cylinder Head Cover Installation
87
Cylinder/Piston
88
Cylinder/Piston Service Information
88
Cylinder/Piston Troubleshooting
88
Cylinder/Piston Specifications
88
Excessive Smoke
89
Cylinder Removal
90
Piston Removal
90
Cylinder Inspection
91
Piston Inspection
93
Piston Installation
93
Piston Ring Installation
94
Cylinder Installation
95
Drive Pulley/Clutch/Driven Pulley
96
Drive Pulley/Clutch/Driven Pulley Service Information
96
Drive Pulley/Clutch/Driven Pulley Specifications
96
Drive Pulley/Clutch/Driven Pulley Torque Values
96
Drive Pulley/Clutch/Driven Pulley Tools
97
Drive Pulley/Clutch/Driven Pulley Troubleshooting
97
Engine Starts but Scooter Won't Move
97
Engine Stalls or Scooter Creeps
97
Poor Performance at High Speed or Lack of Power
98
Left Crankcase Cover
99
Drive Belt Removal
99
Drive Belt Inspection
99
Drive Belt Installation
100
Drive Pulley Removal
100
Drive Pulley Disassembly
100
Drive Pulley Inspection
102
Drive Pulley Assembly
103
Drive Pulley Installation
104
Clutch/Driven Pulley Removal
104
Clutch/Driven Pulley Inspection
105
Clutch/Driven Pulley Disassembly
107
Driven Pulley Face Bearing Replacement
108
Clutch Assembly
109
Driven Pulley Assembly
110
Driven Pulley Installation
111
Final Reduction
112
Final Reduction Service Information
112
Final Reduction Troubleshooting
112
Final Reduction Specifications
112
Final Reduction Tools
113
Final Reduction Disassembly
113
Final Reduction Inspection
115
Final Reduction Assembly
117
Alternator/Starter Clutch
118
Alternator/Starter Clutch Service Information
118
Alternator/Starter Clutch Specifications
118
Alternator/Starter Clutch Torque Values
118
Alternator/Starter Clutch Tools
119
Right Crankcase Cover Removal
119
Stator Removal
120
Flywheel Removal
120
Starter Clutch
120
Starter Idle Gear/Driven Gear Removal
121
Starter Clutch Inspection
123
Flywheel Installation
124
Stator Installation
124
Right Crankcase Cover Installation
126
Crankcase/Crankshaft
127
Crankcase/Crankshaft Service Information
127
Crankcase/Crankshaft Troubleshooting
127
Crankcase/Crankshaft Specifications
127
Crankcase/Crankshaft Torque Value
128
Crankcase Separation
129
Crankshaft Inspection
130
Crankcase Assembly
133
Cooling System
134
Cooling System Service Information
134
Cooling System Troubleshooting
134
Cooling System Specifications
134
Cooling System Tools
135
System Testing
135
Coolant Replacement
135
Coolant
135
Radiator Cap Inspection
136
Radiator Inspection
137
Radiator Removal/Installation
138
Radiator Disassembly/Assembly
138
Bracket Removal/Installation
139
Water Pump
139
Mechanical Seal Inspection
139
Water Pump Removal
140
Water Pump Shaft Removal
141
Mechanical Seal Replacement
141
Water Pump Shaft Installation
142
Water Pump Impeller Installation
143
Thermosensor Removal
143
Thermosensor Installation
143
Thermostat
145
Frame Covers
146
Frame Covers Service Information
147
Rear Cover
147
Body Center Cover
148
Floor Panel, Side Rail, Floor Lower Cover
149
Inner Box
150
Front Upper Cover
151
Front Lower Cover
151
Rear Carrier
152
Steering/Front Wheel/Brake/Suspension
153
Steering/Front Wheel/Brake/Suspension Service Information
153
Steering/Front Wheel/Brake/Suspension Specifications
153
Steering/Front Wheel/Brake/Suspension Torque Values
154
Steering/Front Wheel/Brake/Suspension Troubleshooting
154
Steering/Front Wheel/Brake/Suspension Tools
154
Hard Steering
154
Front Wheel Wobbling
155
Handlebar Removal
156
Handlebar Installation
158
Front Wheel Removal
158
Front Wheel Inspection
158
Wheel Rim
158
Wheel Bearings
159
Bearing Replacement
161
Front Brake Removal
161
Front Brake Inspection
161
Front Brake Disassembly
162
Front Brake Assembly
164
Front Suspension Removal
164
Pivot Arm Disassembly
165
Front Shock Absorber Disassembly
166
Shock Absorber Inspection
166
Front Shock Absorber Pivor Arm Assembly
168
Front Fork/Steering
169
Ball Race Replacement
170
Bottom Cone Race Replacement
172
Rear Wheel/Brake/Suspension
173
Rear Wheel/Brake/Suspension Service Information
173
Rear Wheel/Brake/Suspension Specifications
173
Rear Wheel/Brake/Suspension Torque Values
173
Rear Wheel/Brake/Suspension Tools
174
Exhaust Muffler
174
Rear Wheel
175
Swing Arm Bearing
176
Wheel Hub Removal/Installation
177
Drum Inspection
177
Lining Inspection
179
Rear Brake Pedal/Brake Lock System
179
Parking Brake Lock Inspection/Adjustment
180
Rear Shock Absorber
180
Parking Brake Adjustment
180
Parking Brake Lock Removal/Installation
183
Electrical Equipment
184
Electrical Equipment Service Information
184
Electrical Equipment Specifications
185
Electrical Equipment Troubleshooting
185
No Current
185
Low Current
185
Intermittent Current
186
Battery Removal/Installation
186
Battery Voltage Check
186
Battery Charging
187
Charging System
187
Charging Circuit
187
Charging Voltage Inspection
188
Alternator Inspection
188
Regulator/Rectifier Inspection
189
Ignition System
189
Ignition System Circuit
189
CDI System Inspection
190
Ignition Coil Inspection
190
Exciter Coil Inspection
190
Pulse Generator Inspection
191
Starting System
191
Starting Circuit
191
Starter Relay Inspection
192
Starter Motor Removal
192
Motor Inspection
193
Commutator Inspection
193
Case Inspection
195
Instruments

Troubleshooting

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