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Table Of Contents - Honda 1985-1988 Elite CH250 Manual

Honda 1985-1988 elite ch250

Table Of Contents

Table of Contents

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Table of Contents

General Information2

General Safety2

Model Identification3

Specifications4

Cable And Harness Routing9

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

Emission Control Information Update Label18

Vacuum Hose Routing Diagram Label18

Lubrication Troubleshooting20

Oil Level Too Low20

Oil Contamination20

Engine Oil Filter Screen Cleaning21

Oil Pump Removal22

Oil Pump Disassembly22

Oil Pump Inspection23

Oil Pump Assembly23

Oil Pump Installation24

Final Reduction Oil25

Oil Level Check25

Lubrication Points26

Control Cables26

Maintenance Schedules28

Throttle Operation32

Crankcase Breather34

Valve Clearance35

Radiator Coolant36

Radiator Core36

Cooling System Hoses & Connections36

Carburetor Idle Speed36

Ignition Timing37

Cylinder Compression37

Belt Case Air Cleaner38

Brake Shoe Wear39

Brake Lock Lever40

Brake Light Switch/Starter Limiter Switch40

Headlight Adjustment41

Clutch Shoe Wear41

Nuts, Bolts, Fasteners43

Steering Head Bearings43

Fuel System Service Information45

Fuel System Specifications45

Fuel System Troubleshooting46

Fuel System Tool46

Engine Cranks But Won't Start46

Carburetor Removal47

Auto-Bystarter48

Vacuum Chamber49

Auto Bystarter Valve Inspection49

Air Cut-Off Valve51

Float/Float Valve/Jets53

Float Valve Inspection53

Float Level Inspection54

Carburetor Installation55

Pilot Screw Adjustment56

Limiter Cap Installation56

Idle Drop Procedure56

High Altitude Adjustment57

Automatic Fuel Valve58

Fuel Strainer Cleaning59

Fuel Unit Removal60

Fuel Unit Installation60

Fuel Tank Insulator60

Fuel Tank Installation61

Air Cleaner Hose62

Purge Control Valve Inspection63

Engine Removal/Installation65

Engine Removal/Installation Service Information66

Engine Removal/Installation Specifications66

Engine Removal/Installation Torque Values66

Cylinder Head/Valves71

Cylinder Head/Valves Service Information72

Cylinder Head/Valves Specifications72

Cylinder Head/Valves Torque Values72

Cylinder Head/Valves Tools72

Cylinder Head/Valves Troubleshooting73

Low Compression73

Compression Too High73

Excessive Noise73

Cylinder Head Cover Removal74

Cylinder Head Cover Disassembly74

Rocker Arm Shaft74

Camshaft Removal75

Cylinder Head Removal76

Camshaft Inspection76

Cylinder Head Disassembly77

Cylinder Head Inspection78

Valve Spring Free Length78

Valve Guide Replacement79

Valve Seat Inspection And Refacing80

Valve Seat Grinding81

Cylinder Head Assembly82

Cylinder Head Installation83

Camshaft Installation84

Cylinder Head Cover Assembly85

Cylinder Head Cover Installation85

Cylinder/Piston87

Cylinder/Piston Service Information88

Cylinder/Piston Troubleshooting88

Cylinder/Piston Specifications88

Excessive Smoke88

Cylinder Removal89

Piston Removal90

Cylinder Inspection90

Piston Inspection91

Piston Installation93

Piston Ring Installation93

Cylinder Installation94

Drive Pulley/Clutch/Driven Pulley95

Drive Pulley/Clutch/Driven Pulley Service Information96

Drive Pulley/Clutch/Driven Pulley Specifications96

Drive Pulley/Clutch/Driven Pulley Torque Values96

Drive Pulley/Clutch/Driven Pulley Tools96

Drive Pulley/Clutch/Driven Pulley Troubleshooting97

Engine Starts But Scooter Won't Move97

Engine Stalls Or Scooter Creeps97

Poor Performance At High Speed Or Lack Of Power97

Left Crankcase Cover98

Drive Belt Removal99

Drive Belt Inspection99

Drive Belt Installation99

Drive Pulley Removal100

Drive Pulley Disassembly100

Drive Pulley Inspection100

Drive Pulley Assembly102

Drive Pulley Installation103

Clutch/Driven Pulley Removal104

Clutch/Driven Pulley Inspection104

Clutch/Driven Pulley Disassembly105

Driven Pulley Face Bearing Replacement107

Clutch Assembly108

Driven Pulley Assembly109

Driven Pulley Installation110

Final Reduction111

Final Reduction Service Information112

Final Reduction Troubleshooting112

Final Reduction Specifications112

Final Reduction Tools112

Final Reduction Disassembly113

Final Reduction Inspection113

Final Reduction Assembly115

Alternator/Starter Clutch117

Alternator/Starter Clutch Service Information118

Alternator/Starter Clutch Specifications118

Alternator/Starter Clutch Torque Values118

Alternator/Starter Clutch Tools118

Right Crankcase Cover Removal119

Stator Removal119

Flywheel Removal120

Starter Clutch120

Starter Idle Gear/Driven Gear Removal120

Starter Clutch Inspection121

Flywheel Installation123

Stator Installation124

Right Crankcase Cover Installation124

Crankcase/Crankshaft126

Crankcase/Crankshaft Service Information127

Crankcase/Crankshaft Troubleshooting127

Crankcase/Crankshaft Specifications127

Crankcase/Crankshaft Torque Value127

Crankcase Separation128

Crankshaft Inspection129

Crankcase Assembly130

Cooling System133

Cooling System Service Information134

Cooling System Troubleshooting134

Cooling System Specifications134

Cooling System Tools134

System Testing135

Coolant Replacement135

Radiator Cap Inspection135

Radiator Inspection136

Radiator Removal/Installation137

Radiator Disassembly/Assembly138

Bracket Removal/Installation138

Mechanical Seal Inspection139

Water Pump Removal139

Water Pump Shaft Removal140

Mechanical Seal Replacement141

Water Pump Shaft Installation141

Water Pump Impeller Installation142

Thermosensor Removal143

Thermosensor Installation143

Frame Covers145

Frame Covers Service Information146

Body Center Cover147

Floor Panel, Side Rail, Floor Lower Cover148

Front Upper Cover150

Front Lower Cover151

Rear Carrier151

Steering/Front Wheel/Brake/Suspension152

Steering/Front Wheel/Brake/Suspension Service Information153

Steering/Front Wheel/Brake/Suspension Specifications153

Steering/Front Wheel/Brake/Suspension Torque Values153

Steering/Front Wheel/Brake/Suspension Troubleshooting154

Steering/Front Wheel/Brake/Suspension Tools154

Hard Steering154

Front Wheel Wobbling154

Handlebar Removal155

Handlebar Installation156

Front Wheel Removal158

Front Wheel Inspection158

Wheel Bearings158

Bearing Replacement159

Front Brake Removal161

Front Brake Inspection161

Front Brake Disassembly161

Front Brake Assembly162

Front Suspension Removal164

Pivot Arm Disassembly164

Front Shock Absorber Disassembly165

Shock Absorber Inspection166

Front Shock Absorber Pivor Arm Assembly166

Front Fork/Steering168

Ball Race Replacement169

Bottom Cone Race Replacement170

Rear Wheel/Brake/Suspension172

Rear Wheel/Brake/Suspension Service Information173

Rear Wheel/Brake/Suspension Specifications173

Rear Wheel/Brake/Suspension Torque Values173

Rear Wheel/Brake/Suspension Tools173

Exhaust Muffler174

Swing Arm Bearing175

Wheel Hub Removal/Installation176

Drum Inspection177

Lining Inspection177

Rear Brake Pedal/Brake Lock System179

Parking Brake Lock Inspection/Adjustment179

Rear Shock Absorber180

Parking Brake Adjustment180

Parking Brake Lock Removal/Installation180

Electrical Equipment183

Electrical Equipment Service Information184

Electrical Equipment Specifications184

Electrical Equipment Troubleshooting185

Intermittent Current185

Battery Removal/Installation186

Battery Voltage Check186

Battery Charging186

Charging System187

Charging Circuit187

Charging Voltage Inspection187

Alternator Inspection188

Regulator/Rectifier Inspection188

Ignition System189

Ignition System Circuit189

Cdi System Inspection189

Ignition Coil Inspection190

Exciter Coil Inspection190

Pulse Generator Inspection190

Starting System191

Starting Circuit191

Starter Relay Inspection191

Starter Motor Removal192

Motor Inspection192

Commutator Inspection193

Case Inspection193

Starter Motor Installation195

Bulb Replacement196

Battery Replacement197

Turn Signal Light199

Front Turn Signal Light Bulb Replacement199

Rear Turn Signal Light Bulb Replacement199

Taillight/License Plate Light200

Ignition Switch200

Handlebar Switches201

Engine Stop Switch201

Starter Switch201

Front Brake Switch201

Rear Brake Light Switch202

Turn Signal Switch202

Dimmer Switch202

Fuel Unit/Gauge203

Thermostatic Switch203

Fuel Unit Inspection203

Fuel Gauge Inspection203

Thermosensor204

Tempreature Gauge204

Wiring Diagrams205

Technical Features210

Plenum Chamber210

Torque Link Type Anti-Drive Front Suspension211

Damper-Link Type Engine Mount212

Ignition Switch Light213

Carburetor Heater214

Troubleshooting215

Engine Does Not Start Or Is Hard To Start215

Engine Lacks Power216

Poor Performance At Low And Idle Speeds217

Poor Performance At High Speed217

Engine Noise218

Drive And Drive Pulleys218

Poor Suspension Performance219

Poor Brake Performance219

Pointer Does Not Register Correctly220

Pointer Fluctuates Or Swings220

Starter Motor Will Not Turn221

Starter Motor Turns Slowly221

Starter Motor Won't Stop Turning221

Digital Speedometer Malfunction222

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Table of Contents

Troubleshooting