Honda CB250 - Shop Manual

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Contents5
Technical Data14
Special Tools28
Minor Model Change Table of Principal Modifications32
Engine42
Main Features42
Power Transmission System42
Dismounting the Engine42
Remounting the Engine43
Valve Mechanism44
Description44
Disassembly44
Inspection46
Compression Pressure46
Adjusting the Engine to the Proper Compression Pressure46
Valve Tappet Clearance Inspection and Adjustment46
Camshaft Side Clearance47
Cam Diameter47
Camshaft Mounting End48
Rocker Arm Pin Diameter48
Deformation of the Gasketing Surface48
Carbon Removal48
Valve Seat Contact49
Valve Stem Clearance50
Valve Stem Diameter50
Valve Guide Replacement50
Valve Spring Dimension50
Reassembly51
Valve Timing51
Pistons and Cylinders52
Cylinder Boring and Honing53
Piston Dimension53
Piston Ring Side Clearance53
Piston Ring End Gap54
Piston Ring Thickness54
Piston Pin Bore54
Piston Pin Diameter54
Cam Chain Tensioner (Hydraulic Type) Description55
Cam Chain Tensioner (Hydraulic Type) Disassembly56
Cam Chain Tensioner Inspection56
Cam Chain Tensioner Reassembly56
Lubricating System Description57
Lubricating System Disassembly58
Lubricating System Inspection59
Engine Oil Check and Change59
Cleaning Air Filter59
R. Crankcase and Oil Filter Inspection60
Oil Pump Body Bore Dimension60
Oil Pump Plunger Dimension60
Lubricating System Reassembly61
Clutch Description61
Clutch Disassembly62
Clutch Inspection62
Clutch Reassembly63
Friction Disc Dimension63
Clutch Plate Warpage63
Clutch Spring Dimension63
Crankshaft and Connecting Rods Description64
Crankshaft and Connecting Rods Disassembly64
Crankshaft and Connecting Rods Inspection65
Measure Amount of Bend65
Main Bearing Diametrical Clearance65
Connecting Rod Diametrical Clearance65
Crankshaft and Connecting Rods Reassembly66
Transmission Description66
Transmission Disassembly66
Connecting Rod Small End Bore66
Transmission Inspection67
Measuring Backlash67
Wear to Transmission Gear67
Clearance between Gear and Sahft67
Transmission Reassembly68
Gear Shift Mechanism Description68
Gear Shift Mechanism Disassembly69
Gear Shift Mechanism Inspection69
Gear Shift Mechanism Reassembly70
Kick Starter Description70
Kick Starter Disassembly70
Kick Starter Reassembly70
Crankcases Description71
Oil Separator Operation71
Crankcases Disassembly71
Crankcases Inspection71
Crankcases Reassembly72
Carburetor Description72
Sectional View of Carburetor72
Carburetor Disassembly73
Carburetor Inspection73
Idling Adjustment73
Synchronizing the Throttle Valve73
Frame74
Handlebar Description74
Handlebar Disassembly74
Handlebar Inspection75
Handlebar Reassembly75
Fork Top Bridge Description76
Fork Top Bridge Disassembly76
Fork Top Bridge Inspection76
Fork Top Bridge Reassembly76
Front Cushion (Piston Type) Description77
Front Fork Assembly77
Front Cushion Description78
Front Fork Unit78
Front Cushion Operation79
Front Cushion Disassembly (Piston Type)79
Front Cushion Inspection (Piston Type)80
Front Fork Oil Change80
Inspect for Oil Leak80
Inspect Front Cushion Spring80
Front Cushion Reassembly81
Front Fork Piston Diameter81
Front Fork Bottom Case Diameter81
Front Cushion Description (Rod Type)82
Front Cushion Disassembly82
Front Cushion Inspection83
Steering Stem Description84
Steering Stem Disassembly84
Steering Stem Inspection84
Steering Stem Reassembly84
Fuel Tank Description85
Fuel Tank Disassembly85
Fuel Tank Inspection86
Fuel Tank Reassembly86
Frame Body Description86
Frame Body Disassembly87
Frame Body Inspection87
Frame Body Reassembly87
Seat Description87
Seat Disassembly88
Seat Inspection88
Seat Reassembly88
Stands and Brake Pedal Description88
Stands and Brake Pedal Inspection89
Stands and Brake Pedal Reassembly89
Exhaust Pipes and Mufflers Description89
Exhaust Pipes and Mufflers Disassembly90
Exhaust Pipes and Mufflers Inspection90
Exhaust Pipes and Mufflers Reassembly90
Air Cleaner Description90
Rear Fork and Rear Fender Description91
Rear Fork and Rear Fender Disassembly91
Rear Fork and Rear Fender Inspection92
Rear Fork and Rear Fender Reassembly92
Rear Cushion Description93
Rear Cushion Operation93
Rear Suspension Adjustment93
Rear Cushion Disassembly95
Rear Cushion Inspection95
Rear Cushion Reassembly96
Front Wheel Description96
Front Wheel Disassembly97
Front Wheel Inspection97
Front Wheel Reassembly98
Front Axle Bend98
Radial Clearance of 6302R Ball Bearing98
Thickness of Brake Lining98
Front Wheel Disassembled100
To Serve Front Wheel100
Front Wheel Torque Specifications100
Front Wheel Assembly102
Disassembly of Calipers and Master Cylinder104
Master Cylinder Disassembled106
Inspection of Calipers and Master Cylinder106
Assembly of Calipers and Master Cylinder107
Measure the Caliper Cylinder and Piston107
Measure the Master Cylinder and Piston107
Adjustment of Disc Brake108
Check the Brake Fluid Level108
Bleed the Brake Lines109
Rear Wheel Description109
Rear Wheel Disassembly110
Rear Wheel Inspection111
Rear Axle Bend111
Rear Brake Drum Inside Diameter111
Rear Wheel Reassembly112
Electrical Parts114
Ignition System114
Ignition Coil Description114
Ignition Coil Removal114
Ignition Coil Reassembly115
Ignition Coil Inspection115
Ignition Coil Inspection with a Service Tester115
Breaker Point Description116
Breaker Point Disassembly116
Breaker Point Inspection116
Breaker Point Reassembly118
Condenser Description118
Condenser Removal118
Condenser Inspection118
Spark Plug Description119
Spark Plug Removal120
Spark Plug Inspection120
Spark Plug Installation120
Noise Suppressor Description121
Noise Suppressor Removal121
Noise Suppressor Inspection121
Noise Suppressor Reinstallation121
A.C. Generator Performance Characteristics122
Silicon Current Regular Description122
Silicon Current Regular Disassembly122
Silicon Current Regular Inspection123
Silicon Current Regular Reassembly123
Rectifying System Description123
Rectifying System Disassembly123
Rectifying System Reassembly124
Battery Description124
Battery Removal125
Battery Inspection125
Battery Charging Procedure125
Battery Charging126
Quick Charger126
Battery Trouble Shooting and Corrective Action128
Starting System128
Starting Motor Description128
Starting Motor Disassembly129
Starting Motor Inspection129
Armature Insulation Test129
Measure the Starting Current129
Starting Motor Specification130
Starting Motor Reassembly130
Starting Clutch Description130
Starting Clutch Inspection130
Starting Clutch Reassembly131
Starter Magnetic Switch Description131
Starter Magnetic Switch Removal131
Starter Magnetic Switch Inspection131
Safety Equipment132
Horn Description132
Horn Removal132
Horn Inspection132
Headlight Description133
Headlight Removal133
Headlight Inspection133
Headlight Reassembly134
Tail/Stop Light Removal134
Tail/Stop Light Inspection134
Tail/Stop Light Reassembly134
Winker Relay Description135
Winker Relay Removal135
Winker Relay Inspection135
Winker Relay Reassembly135
Switches136
Ignition Switch Removal136
Stoplight Switch Removal136
Stoplight Switch Inspetion136
Starter Switch Button and Lighting Switch Removal137
Starter Switch Button and Lighting Switch Reassembly137
Starter Switch Button and Lighting Switch Inspection137
Turn Signal and Horn Control Switch Disassembly137
Neutral Switch Inspection138
Neutral Switch Removal138
Neutral Switch Reassembly138
Wiring Diagram138
Wiring Harness Description139
Wiring Harness Removal139
Wiring Harness Inspection139
Wiring Harness Reassembly139
Engine (SL350)140
General Description of the SL350140
Dismounting the Engine (SL350)140
Remounting the Engine (SL350)140
Primary Kick Starter141
Carburetor Specifications (SL350)142
Carburetor Circuits142
Main Circuit143
Float Circuit143
Idle Speed Adjustment (SL350)144
Float Level Adjustment (SL350)144
Frame (SL350)145
CB250K4 Wiring Diagram156
CB350K4 Wiring Diagram157
CB350K4 Wiring Diagram (General Type)158
CL350K4 Wiring Diagram159
CL350K4 Wiring Diagram (General Type)160
SL350K2 Wiring Diagram161
CB350G Wiring Diagram162
Maintenance Schedule164
Tightening Torque Standard165
Trouble Shooting166
Engine Does Not Start or Hard Starting166
Loss of Speed and Drop in Power167
Improper Running of Engine (Particularly at Low Speed and Idling)169
Improper Running of Engine (High Speed)170
Excessive Oil Consumption172
Exhaust Smoke172
Clutch Operates Faulty173
Shift Operates Faulty173
Engine Runs with Unusual Noise174
Vehicle Steers Faulty174

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