Honda CB-1 1989 Service Manual Download Page 1

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Summary of Contents for CB-1 1989

Page 1: ...I 1 ri i1 in I ffl 1 r lilt 1 I it i S i ifSittBm i HIM M im t ill sjUlifli Ml Vi illUBIlIl1 Jii 1 18 I i m t 1 i J 1 is i iiiili A 1 1 4 f m i 4 I A f m i r J T I a 1 I1 a li r I I u m Ilk i ufSLL I...

Page 2: ...es for removal installation of com ponents that may be required to perform service de scribed in the following sections While section 4 through 18 desetibe parts of the motor cycle grouped according t...

Page 3: ...rs The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken Refer to the next page for the meaning of each symbol mark Also in the illu...

Page 4: ...grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote 1 BR 2 plus manufacture...

Page 5: ...of cunsciuusness and may lead to death Run the engine in an open area or with an exhaust evacua tion system in an enclosed area Brake Dust Never use an air hose or dry brush to clean brake assemb lies...

Page 6: ...prevent the possibility of an explosion release the ni trogen by pressing the valve core Then remove the valve stem from the shock absorber reservoir Dispose of the oil in a manner acceptable to the E...

Page 7: ...er is stamped on the right side of the crankcase The Vehicle Identification Number VIN is located on the safety certification label on the right side of the frame tube I 4 CARBURETOR IDENTIFICATION NU...

Page 8: ...ar Tire brand IRC Front Rear Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Hydraulic disc brake Hydraulic disc brake 25u30 99 mm 3 9 in 11 5 lit 3 04 U...

Page 9: ...Gear ratio 5th Gear ratio 6th Gear ratio reverse Gearshift pattern Wet multi plate Mechanical type 6 speed constant mesh 2 181 96 44 2 733 41 15 3 307 43 13 2 352 40 17 1 875 30 16 1 590 35 22 1 434 3...

Page 10: ...0 02 0 07 0 001 0 003 0 15 0 006 0 35 0 014 0 10 0 004 3 y Fuel system Carburetor identification number VG06B VG06C 105 I California Main jet High altitude 2 3 1 4 Front Rear Slow jet Jet needle crip...

Page 11: ...041 3 775 3 790 0 1486 0 1492 3 755 3 770 0 1478 0 1484 3 800 3 812 0 1496 0 1253 3 800 3 812 0 1496 0 1253 3 70 0 146 3 69 0 145 3 89 0 153 3 89 0 153 0 04 0 002 0 05 0 002 EX Valve guide I D IN EX S...

Page 12: ...0 0 04 0 002 0 06 0 002 0 08 0 003 0 08 0 003 0 5 0 02 0 5 0 02 1 1 0 04 13 994 14 000 0 5509 0 5512 0 002 0 014 0 0001 0 0006 0 016 0 040 0 0006 0 0016 0 015 0 050 0 0006 0 0020 0 015 0 050 0 0006 0...

Page 13: ...9 27 92 1 099 22 07 0 869 25 07 0 987 0 10 0 004 0 10 0 004 0 10 0 004 0 10 0 004 0 10 0 004 21 93 0 863 21 93 0 863 M6 C2 C3 C4 Transmission gear bushing O D M5 M6 C2 C3 C4 Transmission gear busing I...

Page 14: ...hing O D Centrifugal clutch center guide I D O D Centrifugal clutch center guide collar height Centrifugal clutch weight lining thickness Centrifugal clutch spring free length Clutch lining thickness...

Page 15: ...5 5 8 1 DID525V8 104 RK525SM4 104 Front suspension Fork spring free length Fork spring free length A 318 12 5 324 5 12 78 B Fork spring direction Fork tube runout Recommended fork oil Furk oil level F...

Page 16: ...caliper piston O D brake drum I D brake lining thickness 4 8 5 2 0 19 0 20 4 0 0 16 0 4 0 02 14 06 0 554 13 95 0 549 38 24 1 506 38 09 1 500 14 000 14 043 0 5512 0 5529 13 957 13 984 0 5495 0 5506 38...

Page 17: ...i III II 30 A 1 illli 10 A 4 IrHlJlll HI 12 V iMi ih iijij Hllll Hjlll l ill l i 1 ill ii j i l lilllili Ii 11ii l i ii mi i ll llh ill l l iill lili IIIplitl lll il l i 1 ll i i IP 5 12 V 2 I I i 11...

Page 18: ...l filter boss Oil filter Cylinder head cylinder piston Cylinder head cover bolt Camshaft holder bolt Cylinder head cover breather plate bolt Cylinder head special nut Cylinder head mounting bolt Cylin...

Page 19: ...sorber lower joint lock nut Swingarm pivot nut Brake Front caliper pad pin plug pad pin bracket bolt pin bolt bracket pin bolt Front mo3tcr cylinder reservoir cover screw Front brake disc bolt Rear ca...

Page 20: ...protector Valve spring compressor Valve spring compressor attachment Valve guide reamer 3 8 mm 3 I 4 ror equivalent commer daily available in JU S A 4 4 14 16 5 5 6 6 U S A only U S A only I 6 8 07JM...

Page 21: ...49 3710001 07746 0010200 07946 MB00000 07746 0050500 07746 0010700 07746 0040400 07746 0041000 07GME 0010000 1 1 11 11 1 1 12 12 12 12 Not available in U S A 07959 3290001 12 screw assembly Shock abso...

Page 22: ...sealant to the oil pressure switch thread head as shown Gear teeth Shaft journals Sliding surface Engine oil FRAME Material Point Remarks Center stand pivot Side stand pivot Brake pedal pivot Gearshif...

Page 23: ...BLACK CONNECTOR IGNITION SWITCH ft 4 6P GREEN CONNECTOR TURN SIGNAL SWITCH 4 5 9P RED CONNECTOR STARTER SWITCH ENGINE STOP SWITCH 7 BRAKE HOSE I 8 CLUTCH CABLE O fa1 15 THROTTLE CABLE 9 LEFT HANDLEBAR...

Page 24: ...OSE oO 8 No 2 No 3 SPARK PLUG WIRES 16 SET THE No 2 No 3 SPARK PLUG WIRES SECURELY 7 Cl lITCH CABLE O o c 10 THROTTLE CABLES t TD 11 SET THE No 1 J No 4 SPARK PLUG WIRES SECURELY 9 CHOKE CABLE a Q 5sJ...

Page 25: ...CH WIRE ALTERNATOR WIRE O 7 CLAMP MAIN WIRE HARNESS REAR BRAKE LIGHT SWITCH WIRE 9 No 1 No 4 SPARK PLUG WIRES 6 RESFRVDIR HOSE v 10 AIR HOSE 11 SIDE STAND LS SWITCH 3P 36 CONNECTOR 8 PULSE GENERATOR N...

Page 26: ...2 50 1 WIRE GUIDE IGNITION COIL WIRE NEUTRAL SWITCH OIL PRESSURE SWITCH WIRE PULSE GENERATOR WIRE SIDE STAND SWITCH WIRE ALTERNATOR WIRE 9 PULSE GENERATOR WIRE 8 NEUTRAL SWITCH WIRE 7 SIDE STAND SWIT...

Page 27: ...UBE 7 No 4 TUBE 4 AIR SUCTION VALVE I 6 No 1 TUBE b RADIATOR RESERVE TANK OVERFLOW TUBE 12 No 3 INTAKE MANIFOLD 11 No 4 INTAKE MANIFOLD 18 TO PCV 19 TO AVCV 10 No 10 TUBES 13 0 RINGS 14 AIR INJECTION...

Page 28: ...GENERAL INhORMATION I m i 09 m 1 No 5 TUBES I 2 AIR INJECTION TUBE NO 15 r 4 No 4 TUBE 3 No 1 TUBE I 6 PCV 5 AVCV n P J Ml 9 No 10 TUBE 7 No 4 TUBE 8 3 WAY JOINT I 1 9 1...

Page 29: ...ffect I SOURCE OF EMISSIONS I The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemic...

Page 30: ...of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the air suction valve it cons...

Page 31: ...CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than fo...

Page 32: ...n update label on the rear fender as shown 3 VACUUM HOSE ROUTING DIAGRAM LABEL California model only I VACUUM HOSE ROUTING DIAGRAM LABEL California model only t VACUUM HOSE ROUTING 0 I AG RAM ENGINE F...

Page 33: ...is damaged Generally speaking plastic body panels cannot be repaired and therefore must he replaced It is possible that a front end collosion will bend the steering head of the frame but not the fork...

Page 34: ...and push the seat forward Press the rear of the seat down and lock the scot securely i 2 LEVER CAUTION 3 HOOKS Apply grease to the seat locking Be careful not to pinch the wire harness between the se...

Page 35: ...ver in the reverse order of removal NOTE It is not necessary to remove the bolt as shown 3 BOLT 2 BOLTS I EXHAUST SYSTEM REMOVAL INSTALLATION 1 RADIATOR Remove the radiator lower mounting bolts and lo...

Page 36: ...parks in the work area or where gasoline is stored can cause a fire or explo sion NUT c Remove the seat page 2 2 Turn the fuel valve OFF Remove the fuel tank mounting bolts and lift the tank up Discon...

Page 37: ...AIR CLEANER 3 1 SPARKPLUG 3 2 VALVE CLEARANCE 3 4 CARBURETOR SYNCHRONIZATION 3 5 SIDE STAND 3 5 3 5 3 8 3 8 I SERVICE INFORMATION Refer to the Common Service Manual for items not included in this man...

Page 38: ...eplacement Fuel tank Reserve Tank Cap Coolant filler Seat _ Throttle Grip Operation free play Master Cylinder Level check fluid replacement Brake Pedal Air bubbles in system Brake Hose Leakage degrada...

Page 39: ...olant level Headlight Aim 0 U Steering Head Bearings Damage Valve Clearance page 3 5 Suspension Loose wear damage jV Jy o 0 u X Drive Chain Free play lubrication replacement Suspension Loose wear dama...

Page 40: ...COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM I NOTE 5 NOTE 4 I EVAPORATIVE EMISSION CONTROL SYSTEM DRIVE CHAIN NOTE 5 I I NOTE 4 sami NOTE 5 US NOTE 5 NOTE 3 I I Y R li J BRAKE FLUID 5 I i i i NOTE 5 1...

Page 41: ...ide cover J 2 PLUG WRENCH Remove the front side covers page 2 3 The spark plug wrench is included in the tool kit Insert the plug wrench between the heat guard plate and cyl inder head cover as shown...

Page 42: ...cylinder piston Is at TDC Top Dead Center on the compression stroke go to Step 0 1 T MARK YELLOW COLORED LINE w 9jf o J x 2 INDEX MARK I Step 1 Insert the feeler gauge between the cam lobe and valve...

Page 43: ...er and record it NOTE 5 Sixty five different shims are available in thickness in tervals of 0 025 mm The thinnest is 1 200 mm the thickest is 2 800 mm To confirm your shim choice you may use the follo...

Page 44: ...CARBURETOR No 2 CARBURETOR 1 PLUGS I 1 SYNCHRONIZATION SCREWS IV u 2 No 4 SCREW 4 No 1 SCREW 3 No 3 SCREW SIDE STAND 1 SIDE STAND SWITCH m 7 Check the side stand ignition cut off system Place the moto...

Page 45: ...on refer to section 25 of the Common Service Manual When removing and installing the oil pump use care not to allow dust or dirt to enter the engine After the oil pump hoa been installed check that th...

Page 46: ...fit tffi if 2 INTAKE CAMSHAFT J J L0 3 PISTON 4 CONNECTING ROD ll 5 CRANKSHAFT My 6 OIL PRESSURE SWITCH r I 14 OIL ORIFICE 7 OIL ORIFICE i 13 MAINSHAFT ill i s 12 COUNTER SHAFT WB 8 OIL PUMP 4 I 11 OI...

Page 47: ...ge 9 8 PROCEDURE Q ty REMARKS REMOVAL ORDER Oil pan bolt Installation is in the reverse order of removal At installation tighten the bolts in a gradual crisscross pattern 1 12 2 Oil pan Gasket Relief...

Page 48: ...n I REQUISITE SERVICE Oil pump removal installation page 4 3 REMARKS Q ty PROCEDURE Assembly is in the reverse order of disassembly NOTE Install the dowel pins then tighten the screws DISASSEMBLY ORDE...

Page 49: ...or cap except to refill or drain the system All cooling system service can be done with the engine in the frame Avoid spilling coolant on painted surfaces For coolant replacement refer to section 5 of...

Page 50: ...COOLING SYSTEM SYSTEM FLOW PATTERN I 3 RADIATOR CAP 2 THERMOSTAT 4 THERMO SENSOR 5 SIPHON TUBE 1 COOLING FAN s 6 RESERVE TANK o t 9 RADIATOR CL S o 8 FAN MOTOR SWITCH I 7 WATER PUMP I I R 9...

Page 51: ...completely from the system NOTE California model has the only left drain bolt 1 CYLINDER DRAIN BOLTS SFALING WASHERS Place a suitable tray under the siphon tube joint of the re serve tank and disconn...

Page 52: ...val installation page 2 4 Coolant draining page 5 3 REMARKS Q ty PROCEDURE Installation is in the reverse order of removal REMOVAL ORDER Ihermostat cover mountiny bolt Siphon tube Radiator ho3c Thermo...

Page 53: ...t refill section 5 of the Common Service Manual PROCEDURE Q ty REMARKS REMOVAL ORDER Radiator hose Fan motor switch connector Radiator lower mounting bolt Radiator upper mounting bolt nut Fan motor co...

Page 54: ...tabs with the shroud grooves At installation align four grille grooves with the radiator lugs At installation install the fan motor ground wire terminal properly as shown 2 2 1 Radiator grille 3 1 2...

Page 55: ...nual Coolant refill section 5 of the Common Service Manual Gearshift spindle joint removal installation page 9 6 Water pump side cover removal installation page 7 2 PROCEDURE Q ty REMARKS DISASSEMBLY...

Page 56: ...maged NOTE If vehicle is to be stored for more than one month drain the float chambers Fuel left in the float chambers may cause clogged jets resulting in hard starting or poor driveability When disas...

Page 57: ...idling Fuel line restricted Ignition malfunction Fuel mixture too lean rich Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Fuel pump malfunction Pilot screw misadjusted Slow ci...

Page 58: ...t with the ft mark forwards and with the TOP mark facing up 4 1 5 Air cleaner case bolt collar Crankcase breather tuhe Air hose Air injection tube No 15 Air cleaner case 2 2 6 2 7 Except California Mo...

Page 59: ...FUEL SYSTEM CARBURETOR REMOVAL INSTALLATION I 7 California Model Only AVCV 1 3 5 PCV 6 ey 4 w 1 8 0 D 2 tfup MARK I l fi ZL...

Page 60: ...allation page 6 3 Carburetors draining PROCEDURE Q ty REMARKS REMOVAL ORDER Insulator band Choke cable Throttle cable Fuel tube No 10 vacuum tube from the AVCV No 4 tube from The AVCV and PCV Carburet...

Page 61: ...FUEL SYSTEM CARBURETOR SEPARATION I No 4 CARBURETOR 14 13 10 5 a 9 2 15 3 4 1 mi 1 I V _ 1 7 J 11 3 20 0 sz I 4 8 a No 3 CARBURETOR 6 17 I 3 No 2 CARBURETOR IB No 1 CARBURETOR 16 f 19 t...

Page 62: ...arb synchronization spring Air joint pipe 3 way 0 ring Fuel joint pipe 3 way 0 ring 1 1 2 1 3 3 4 1 5 1 6 1 7 1 I 8 1 2 9 1 2 Separate No 3 carb from No 4 carb No 4 carb synchronization spring Thrust...

Page 63: ...FUEL SYSTEM CARBURETOR DISASSEMBLY ASSEMBLY S m DOWEL 2 PIN SIDE 20 3 21 22 14 5 6 3 a S 8 26 m 25 0 oj V 7 V 24 9 15 18 23 19 17 16 O 14 13 ALIGN DOWEL PIN SIDE OJ 12 c 11 i 10 fi R...

Page 64: ...nstallation first tighten the two screws on the dowel pin side 2 Vacuum chamber cover Spring Diaphragm vacuum piston Jet needle holder 1 13 1 4 1 5 Turn the holder 90 counterclockwise while pushing it...

Page 65: ...EL SYSTEM CARBURETOR COMBINATION I No 4 CARBURETOR 14 18 10 11 I 17 No 3 CARBURETOR V 191 22 13 24 2D N V 23 1 15 19 12 L tm 16 X t 20 21 0 s 2CX s W 6 I 7 19 21 5 No 2 CARBURETOR No 1 CARBURETOR i 6...

Page 66: ...carb with No 4 carb Fuel joint pipe 2 way 0 ring Air vent pipe 3 way 0 ring Air joint pipe rubber Thrust spring No 4 carb synchronization spring Front bracket screw 1 2 10 1 2 11 12 1 13 1 1 14 2 The...

Page 67: ...No 4 CARBURETOR 3 No 2 CARBURETOR 4 No 3 CARBURETOR 2 No 1 CARBURETOR 1 No 5 TUBE i Y V i 6 No 5 TUBES p i 7 PCV 1 12 No 5 TUBE 9 No fi TUBES 13 No 6 TUBES 11 AVCV 10 PCV 14 AVCV I 15 No 6 TUBfcS 16...

Page 68: ...l Only 2 PCV 1 AVCV EVAPORATIVE EMISSION CONTROL SYSTEM f PURGE CONTROL VALVE PCV AND AIR VENT CONTROL VALVE AVCV REMOVAL to Remove the following fuel tank page 2 4 air cleaner case page 6 3 carbureto...

Page 69: ...supply system refer to section 7 of the Common Service Manual P 3 PLUG 4 No 10l TUBE SPECIFIED VACUUM 360 mmHg 14 2 inHg AIR SUCTION VALVE ASV REMOVAL Remove two bolts and air suction valve as an asse...

Page 70: ...be serviced with the engine installed in the frame alternator Section 14 camshaft Section 8 carburetors Section 6 clutch Secliun 9 gearshift linkage Section 9 oil pump Section 4 pulse generator Secti...

Page 71: ...0 29 50 5 0 36 8 26 65 6 5 47 20 0 m 1 15 1 5 11 21 I II li 28 K v 24 J3 22 1 15 3 4 23 0 7 24 27 25 6 as 4 0 29 26 5 I c 19 7 45 4 5 33 LX2 DRIVE SPROCKET BOLT 24 17 11 14 40 4 0 29 N W y 0 SPEEDOMET...

Page 72: ...2 1 3 1 4 1 1 5 On the starter motor 6 1 2 2 7 8 1 0 At Installation align the punch marks on the joint and spindle 1 Water pump side cover Speedometer cable Drive sprocket cover 10 1 11 1 12 1 CAUTIO...

Page 73: ...same order they were installed so they can be reinstalled in the original posi tions E TROUBLESHOOTING ft Engine top end problems usually affect engine performance These can be diagnosed by a compres...

Page 74: ...val 1 1 2 At installation tighten the bolts in a gradual crisscross pattern Install them with the UP mark facing up Install with the mark forward NOTE Apply Three Bond 1521 or equivalent to the head c...

Page 75: ...the compres sion stroke r o 3 EX MARK LINE 4 IN MARK Csfits LINE I O 5 T MARK mi Yellow colored line ft JM i J lO 6 INDEX MARK Install the dowel pins onto the camshaft holders and install the camshaft...

Page 76: ...nut Cylinder head mounting bolt Cylinder head assembly Gasket Dowel pin Camshaft idle gear case bolt Camshaft idle gear ease dowel pin Sealing washer Camshaft idle gear case Carburetor insulator Inst...

Page 77: ...ith the gear case held the gear case should be lifted up slightly from the cylinder 3 TIMING GEAR Install a new sealing washer and mounting bolts Tighten bolts in a gradual as shown 1 BOLTS T ft 5 he...

Page 78: ...emoval installation page 7 2 Camshaft removal installation page 8 2 Cylinder head removal installation page 8 4 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Valve bucket Assembly is in the reverse order o...

Page 79: ...linder head bucket sliding surface LO VALVE BUCKET HOLE PROTECTOR 07JMG KY20100 r v 1 VALVE BUCKET HOLE PROTECTOR Install The valve spring compressor onto the valve and com press the valve spring Remo...

Page 80: ...CYLINDER HEAD CYLINDER PISTON CYLINDER PISTON REMOVAL INSTALLATION C10 1 0 7 g 4 1 5 o o 2 o o 7 6 3 o SO 11 12 o o o ijCl 3 5 TOOL 1 16 V o o 10 o o 7 cb 9 f i m 8 r 8 8...

Page 81: ...nt O ring Cylinder mounting bolt Cylinder Gasket Dowel pin Piston pin clip Piston pin Piston Piston top ring Piston second ring Piston oil ring set side rails and spacer Installation is in the reverse...

Page 82: ...crankcase Section 10 If it is no longer clear which bolt belongs in which hole insert all bolts in the holes and check the exposed length each should be exposed the same amount ft TROUBLESHOOTING Clut...

Page 83: ...CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL INSTALLATION i 2 I 6 Q 1 I I 6 4 3 5 A 10 1 0 7 114 4 ijiyj 13 10 c O Y0 7 0 7 5 12 ID 8 n 1 7 Q_9...

Page 84: ...2 1 3 NOTE At installation apply a locking agent to the two bolt threads Disconnect or connect the Alternator 3P connector 14 I 4 Right crankcase cover Gasket Dowel pin 1 5 1 6 2 Clutch lifter pin Ret...

Page 85: ...r spring clutch friction disc C clutch plate B clutch frictin disc B clutch plate A clutch friction disc A pressure plate 7 1 8 1 9 1 1U Larger I D disc Color black Color gray Smaller I D disc Color s...

Page 86: ...0A U S A only 2 CLUTCH LIFTER PLATE BOLTS 3 NUT WASHER Temporarily remove the tool and tighten nuts then reinstall the clutch center holder onto the hosses Use at least two clutch lifter plate bolts t...

Page 87: ...AGE GEARSHIFT LINKAGE REMOVAL INSTALLATION ALIGN I GUIDE PLATE DRUM SHIFTER ASSEMBLY A t g12l 2 9lj o OF a b Tr p 0 o o mto n NO 22 19 20 15 14 18 21 O f 9 6 5 0 4 o 17 16 k 7 8 10 11 SPINDLE ASSEMBLY...

Page 88: ...Gearshift spindle Spindle return spring Washer 1 4 1 5 1 6 Shifter collar Guide plate mounting bolt Guide plate dium shifter assembly guide plate ratchet pawl plunger spring drum shifter Collar Dowel...

Page 89: ...CLUTCH GEARSHIFT LINKAGE CLUTCH INSTALLATION E 15 1 5 11 5 wm O 1 m a 6 2 7K 2 4 J 9 10 15 12 16 14 18 18 19 IS TOOlr page 9 10 16 c 17 7 e 15 a 21 85 8 5 61 0 ry 20 23 22 Q_Q...

Page 90: ...the judder spring to the outside 1 11 4 12 4 13 1 14 1 15 1 16 1 17 1 18 Lock washer Clutch center lock nut Clutch spring Clutch lifter plate Clutch lifter plate bearing Clutch lifter plate bolt 1 Wit...

Page 91: ...7HGB 001000A U S A only 2 CLUTCH LIFTER PLATE BOLTS 3 NUT WASHER Hold the clutch center holder and torque the clutch center lock nut as shown a TORQUE 85 N m 8 5 kg m 61 ft lb 0A O Stake the lock nut...

Page 92: ...se halves apply a sealant to their mating surface Wipe off excess sealant thoroughly Mark and store the bearing inserts to be sure of their correct locations for reassembly If the inserts are improper...

Page 93: ...CRANKSHAFT TRANSMISSION CRANKCASE SEPARATION 3 3 2 a a r RL a jj L tl 2 B S 2 4 2 0 Zt 6 5 b 5 1 10 9...

Page 94: ...n the crankcase have sealing washers Bolts 12 psc have sealing washers 2 Lower crankcase bolt 6 mm 13 3 Lower crankcase bolt 8 mm Lower crankcase Dowel pin Oil orifice 13 4 1 5 3 6 2 I CRANKCASE BOLTS...

Page 95: ...ANKSHAFT TRANSMISSION CRANKSHAFT CONNECTING ROD REMOVAL INSTALLATION m f c s Icr O 7 I r A 0 6 0 D V 24 2 4 17 7J 0 0 7K 2 o d i 5 Ax jjO I 0 Oi m o 9 t 77 l OIL HOLE FACING TO INTAKE SIDE o 4 I 3 10...

Page 96: ...rod Connecting rod bolt Connecting rod bearing Crankshaft Crankshaft main journal bearing 1 8 I 2 4 3 4 4 8 Do not remove them without necessary Wipe all oil from the bearing seating areas 8 5 6 1 7...

Page 97: ...nk weight NOTE Numbers 1 or 2 on the crank weight are the codes for the main journal O D s from the left w m 1 MAIN JOURNAL O D CODE Cross reference the case and journal codes to determine the replace...

Page 98: ...on the upper crankcase are the codes for the crankpin O D s from the left n N 1 CRANKPIN O D CODE ft Cross reference the ciankpin and rod codes to determine the replacement bearing color code 1 CONNE...

Page 99: ...CRANKSHAFT TRANSMISSiON TRANSMISSION REMOVAL INSTALLATION i i OUT I to I II MI 19 I 15 i 18 11 A 14 5 16 9 0 6 2 13 12 0 7 BEND THE TABS UP ac 10 A A o pj o iO A 8 A r S3 i 4 3 H M I I 10 8...

Page 100: ...face the M6 gear engagement dogs for ward the M4 gear Mainshaft assembly Center shift fork bolt 8 I 1 9 1 Remove after bending down the lock washer tab Install and bend new lock washer tabs as shown I...

Page 101: ...ion 13 of the Common Service Manual for inspection information REQUISITE SERVICE Transmission removal installation page 10 8 PROCEDURE Q ty REMARKS MAINSHAFT DISASSEMBLY ORDER Needle bearing Thrust wa...

Page 102: ...gear 30T J3 spline bushing Lock washer Spline washei C4 gear 35T C4 spline bushing Spline washer Snap ring C6 shifter gear 32T Snap ring Spline washer C2 bushing C2 geai 40T Thrust washer Oil seal Be...

Page 103: ...CRANKSHAFT TRANSMISSION CRANKCASE INSTALLATION p 27 2 7 20 24 2 4 17 e 1 3 f SI a 4 c 4 12 1 2 9 12 1 2 9 3 C A 4 l 12 1 2 9 1 2 d r0 j O LCT 0 sO ey i 2 M i Q O G f 7 012 1 2 9 10 19...

Page 104: ...3 3 1 i 4 13 12 Crankcase installation see below 5 6 1 7 6 I CRANKCASE INSTALLATION Apply a light but thorough coating of sealant to the upper crankcase mating surface except to the main bearing jour...

Page 105: ...ly g 4 C5 SHIFTER IN O o n n r 5 M3 M4 SHIFTER Install the crankcase bolts and sealing washers as shown 1 BOLTS 26 psc JEM5 4 j jj NOTE Four 6 mm bolts marked A on the crankcase have sealing washers T...

Page 106: ...n the section 16 of the Common Service Manual If the motorcycle has been involved in an accident inspect the frame very carefully at the steering head and at the engine mounts These are the areas most...

Page 107: ...the reverse order of removal 2 1 2 1 Align the holder end with the punch mark on the handle bar and face the holder UP mark upward Tighten the upper bolt first then the lower bolt Tighten the front sc...

Page 108: ...with the punch mark on the handle bar and face the holder UP mark upward Tighten the upper bolt first then the lower bolt Tighten the front screw first then the rear screw Left handlebar switch housi...

Page 109: ...um cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers CAUTION Do not use the oil filter as a jack point NOTE Do not depress the brake lever...

Page 110: ...ervice Manual REQUISITE SERVICE Front wheel removal installation page 11 4 ft Q ty ASSEMBLY REMARKS PROCEDURE Assembly is in the reverse order of disassembly Longer collar Shorter collar Wipe off all...

Page 111: ...FRONT WHEEL SUSPENSION STEERING FORK REMOVAL INSTALLATION f 6 rm f GROOVE n 18 c11 1 1 8 TOP BRIDGE UPPER SURFACE D 7 c 9 50 5 0 36 3 4 27 2 7 20 m D 2 5 11 6...

Page 112: ...lebar removal installation page 11 2 Left handlebar removal installation page 11 3 REMARKS Q ty PROCEDURE Installation is in the reverse order of removal REMOVAL ORDER Front fender bolt Front fender B...

Page 113: ...FRONT WHEEL SUSPENSION STEERING FORK DISASSEMBLY iD D 2 n 10 t 3 0 U 12 4 0 18 17 5 e 13 6 CD 71 119 14 t SB 16 A 8 4 14 0...

Page 114: ...remaining fork oil When removing them do not damage the fork tube 5 1 6 1 IT 7 1 8 NOTE Temporarily install the spring and fork cap bolt if difficulty is encountered in removing the socket bolt 1 Seal...

Page 115: ...FRONT WHEEL SUSPENSION STEERING FORK ASSEMBLY 2 3 17 19 12L S 1 18 4 17 3 161 Tighter Coils Down I 15 7 14 14 1 13 131 12 S TOOL ii 12 I page 1 17 diH in j 10 10 8 9 2 0 14 2 2 18 11 1n...

Page 116: ...bolt is tightened 1 1 10 Slider bushing Back up ring Oil 6eal ID 1 NOTE Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal during the oil seal installation Drive in it secure...

Page 117: ...ING STEERING STEM REMOVAL INSTALLATION 105 10 5 76 5 1 Is TOOL page 1 17 4 j 6 m 2 7 0_ g g 8 6125 2 5 18 3 page 1 17 9 17 11 12 6 16 page 1 17 Is o 1 page 1 17 15 V os cs 8 c SHORTER TABS Bend down L...

Page 118: ...removed 1 Use race remover attachment 07953 MJ1000A with driver 07949 3710001 and attachment 37 x 40 mm 07746 0010200 for upper outer race removal Use race remover 07946 3710500 with driver 07949 3710...

Page 119: ...ease and cancer Never use an air hose or dry brush to Clean brake assemblies Use an OSHA approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne...

Page 120: ...stos fibers NOTE Put the motorcycle on its center stand Do not depress the brake pedal when the caliper is removed or it will he difficult to refit the disc between the brake pads Support the removed...

Page 121: ...CE Rear wheel removal installation page 12 2 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Right side collar Left side collar Right dust seal Left dust seal Assembly is in the reverse order of dis...

Page 122: ...lightest loads before removing the shock absorber from the frame REQUISITE SERVICE Fuel tank removal installation page 2 4 PROCEDURE Q ty REMARKS REMOVAL ORDER Shock absorber mounting bolt upper Shock...

Page 123: ...st the shock absorber to position I for lightest loads before removing the shock absorber from the frame For lower joint needle bearing replacement see next page REQUISITE SERVICE Shock absorber remov...

Page 124: ...the lower joint securely onto the damper rod Hole the lower joint and torque the lock nut TORQUE 68 N m 6 8 kg m 49 ft lb 3 ALIGN Make sure the Lower Joint is aligned with the seat stopper pin and rem...

Page 125: ...ith a piece of wire so that it does not hang from the brake hose Do not twist the brake hose If necessary loosen the rear engine mounting nut near the swingarm pivot to ease the swingarm removal insta...

Page 126: ...tion page 12 2 ASSEMBLY REMARKS Q ty PROCEDURE Assembly is in the reverse order of disassembly Install them with the UP mark facing up and the index mark facing out DISASSEMBLY ORDER Drive chain adjus...

Page 127: ...A DRIVER SHAFT r or BUSHING REMOVER M967X 038 XXXXX 07949 3710001 m DRIVER 3 NEEDLE BEARING REMOVER ATTACHMENT I Prose the noodle bearing into the swingarm with the marked side facing out 1 DRIVER 2 A...

Page 128: ...ery careful whenever you remove the reservoir cap make sure the front reservoir is horizontal first Never allow contaminants dirt water etc to get into an open reservoir Once the hydraulic system has...

Page 129: ...hazard caused by airborna asbestos fibers After replacement operate the brake lever to seat the caliper pistons against the pads NOTE Do not depress the brake lever when the caliper is removed or it...

Page 130: ...e pedal to seat the caliper pistons against the pads NOTE Do not depress the brake pedal when the caliper is removed or it will be difficult to refit the disc between the brake pads Replace brake pads...

Page 131: ...ize the hazard caused by airborne asbestos fibers NOTE If you remove the caliper pistons remove the caliper bracket bolts 4 before disconnecting The brake hose 3 and place a pan under the caliper to c...

Page 132: ...OSHA designed to minimize the hazard caused by airborne asbestos fibers NOTE Before diooonnoGting the brake hose 1 place a pan under the raliper to catch the draining fluid and squeeze the brake leve...

Page 133: ...moval installation page 13 2 Brake fluid replacement air bleeding section 17 of the Common Service Manual Front brake caliper removal installation page 13 4 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Pa...

Page 134: ...e fluid replacement air bleeding section 17 of the Common Service Manual Rear brake caliper removal installation page 13 5 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Pad spring Pivot collar Pivot boot C...

Page 135: ...rearview mirror Brake lever pivot bolt Brake lever Brake hose bolt Sealing washer Front brake light switch connector Master cylinder holder bolt Master cylinder holder Master cylinder assembly Install...

Page 136: ...ty PROCEDURE REMARKS REMOVAL ORDER Brake hose bolt Sealing washer Brake hose Master cylinder mounting bolt Footpeg biaukul bull Reservoir hose joint Q ring Push rod joint Master cylinder assembly Ins...

Page 137: ...eding section 17 of the Common Service Manual Front master cylinder removal installation page 13 8 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Reservoir cover Diaphragm plate Diaphragm Front bra...

Page 138: ...bleeding section 17 of the Common Service Manual Rear master cylinder removal installation page 13 9 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Push rod joint Assembly is in the reverse order o...

Page 139: ...ootpeg stay bolt Push rod joint Footpeg mounting bolt Wove washer Rear brakelight switch spring Brake pedal return spring Right footpeg Brake pedal Installation is in the reverse order of removal 1 2...

Page 140: ...o remove the sealing caps from the cells may damage the bat tery Battery can be damaged if overcharged or undercharged or if left to discharge for long periods These same conditions contribute to shor...

Page 141: ...RNATOR SYSTEM LOCATION 2 MAIN FUSE INTO STARTER RELAY SWITCH _ 1 ALTERNATOR fe9 m s 3 REGULATOR RECTIFIER i 4 BATTERY CIRCUIT DIAGRAM 2 MAIN FUSE 30 A 4 BATTERY Y Y Y G R W I I I I l 3 REGULATOR RECTI...

Page 142: ...nda Battery Tester I CORRECT INCORRECT Electric system overloading NOT CHARGING i Faulty battery Check the voltages of the regulator rectifier bat tery charging line and ground line page 14 5 Open cir...

Page 143: ...measuring current do not turn the ignition on A sudden surge nf r urrent may hlnw nut the fuse in the tester SPECIFIED CURRENT LEAKAGE 0 01 mA max If current leakage exceeds the specified value a sho...

Page 144: ...the ignition off when conducting the test Disconnecting the ammeter or wires when current is flowing may damage the ammeter A I Start the engine and increase the engine speed gradually REGULATED VOLTA...

Page 145: ...l type U S A only 07308 0020001 SANWA Analogue type TH 5H KOWA Analogue type Select the following range SANWA tester x kS2 KOWA tester x 100 0 0 5 10 30 500 30 500 10 200 10 200 0 5 10 30 500 30 500 0...

Page 146: ...ing right crankcase cover page 9 2 flywheel bolt washer flywheel woodruff key I 4 FLYWHEEL TTOOL page 1 17 3 BOLT s TOOL page 1 17 I Remove the bolt and stator wire harness clamp Remove the bolts and...

Page 147: ...gnition switch before servicing A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding Make sure the battery is adequately charged Using the...

Page 148: ...0 PULSE GENERATOR 8 SIDE STAND SWITCH CIRCUIT DIAGRAM 4 MAIN FUSE 30 A 12 IGNITION SWITCH r o R BI 2 ENGINE STOP SWITCH BI W o BI 5 FUSE 10 A Cu o Bl Br 1 SIDE STAND SWITCH INDICATOR down e 0 5 FUSE 1...

Page 149: ...it in wire harness Loose or poor contact of related circuit con nectors I BATTERY VOLTAGE MEASURED I Measure the pulse generator resistance at the unit connector page 15 6 ABNORMAL Check the pulse gen...

Page 150: ...nce of the ignition primary coil at spark unit connector page 15 6 Poor or loose contact of ignition coil 4P mini connector Open circuit between the unit and ignition coil GOOD Faulty spark unit No sp...

Page 151: ...h When the side stand is up the side stand switch line b of the spark unit passes to ground via the side stand switch The spark unit monitors lines a and b and provides spark only when one or both of...

Page 152: ...primary coil No 1 4 Black White and Yellow Blue No 2 3 Black White and Blue Yellow 2 4 Q 200C 68 F Neutral switch line Light Green Red and ground Continuity into neutral No continuity in any gear exc...

Page 153: ...20 C 68 F y Q 2 PRIMARY COIL I REMOVAL INSTALLATION 1 BOLT COLLAR 2 IGNITION COIL ASSEMBLY Disconnect the ignition coil 4P mini connector under the fuel tank Remove the bolts and collars 3 Y Bu l Dis...

Page 154: ...8 Remove the bolts and pulse generator 2 GROMMET Install the pulse generator and wire clomp and tighten the bolts securely Set the wire harness grommet into the cover groove O r o Install the left cr...

Page 155: ...n T I IGNITION TIMING Warm up the engine Stop the engine and connect a timing light to the No 3 cylin der 3pork plug wire I NOTE Read the instructions for timing light for operating O 0 o Remove the f...

Page 156: ...e starter motor to turn it while the engine is not cranking over the starter motor may he damaged For the following component inspections refer to the following pages for the parts locations see page...

Page 157: ...WITCH j 10 STARTER MOTOR 9 NEUTRAL SWITCH s 8 SIDE STAND SWITCH CIRCUIT DIAGRAM 11 IGNITION SWITCH 4 STARTER RELAY SWITCH 6 BATTERY f e R BI R M 10 STARTER ivy MOTOR 5 FUSE P 5 P 10 A SFUSES yio Aj Bl...

Page 158: ...turn NO CLICK Faulty starter motor i Loose or disconnected starter motor cable Faulty starter relay switch Disconnect starter relay switch connector and check the lelay uuil ground wire lines as below...

Page 159: ...15 8 ABNORMAL Faulty side stand switch NORMAL Open circuit in wire harness Loose or poor contact of connector I Starter motor turns slowly Low specific gravity in battery or Dead battery Poorly connec...

Page 160: ...Turn the ignition switch OFF REQUISITE SERVICE Fuel tank removal installation page 2 4 REMARKS PROCEDURE Q ty Installation is in the reverse order of removal REMOVAL ORDER Starter motor cable Starter...

Page 161: ...ELECTRIC STARTER STARTER CLUTCH STARTER MOTOR DISASSEMBLY ASSEMBLY 8 t 10 OJ 11 13 14 15 12 s 16 1 2 3 m 17 19 18 0 W cT 7 4 O O o 0 5 6 I A ALIGN t 1 ft ft...

Page 162: ...tall with the groove side facing to the brushes Align the index marks on the rear cover and case 1 7 O iiny Lock washer Insulated washer Washer Armature Shims 1 8 1 9 1 10 1 11 1 12 Record and store t...

Page 163: ...CLUTCH STARTER CLUTCH REMOVAL INSTALLATION 3 to oj CLAMP p o Jff 4 w 2 u 14 c O J ti 1 1 13 I T B a Q HD 12 7 o 5 6 0 o I o 5 l s T 01 1 page 16 9 Q 85 8 5 61 t ALIGN THE WIDE GROOVE AMONG THE CRANKS...

Page 164: ...tch 9 1 I 10 1 11 1 At installation make sure the starter clutch roller is in stalled properly into the clutch housing 12 Spline washer Starter drive gear shaft Starter drive gear 1 13 1 14 1 I STARTE...

Page 165: ...A continuity test can be made with the switches installed on the motorcycle For the following component locations see page 17 2 of this manual SYSTEM LOCATION for inspections refer to the applicable...

Page 166: ...AUGE 3 FRONT BRAKELIGHT SWITCH 4 OIL PRESSURE SWITCH 6 BATTERY 1 IGNITION SWITCH 5 FUSE BOX I 15 CLUTCH SWITCH 14 HOR1 13 THERMO SENSOR I 12 FAN MOTOR SWITCH 11 NEUfRAL SWITCH 9 FUEL CUT 17 REAR RRAKF...

Page 167: ...as they may create hot spots on the bulb and cause it to break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install t...

Page 168: ...wise and remove it Turn the bulb counterclockwise and remove it o o J Install a new bulb in the reverse order of removal 5s i J 1Lis j 4 SOCKET 3 SCREW TAILLIGHT 1 BULB BULB REPLACEMENT Remove the scr...

Page 169: ...ffi 1 IT ro c I 3 REQUISITE SERVICE Headlight assembly removal page 17 3 PROCEDURE Q ty REMARKS REMOVAL ORDER Meter mounting bolt Speedometer cable Meter connector Meter oasembley Installation is in t...

Page 170: ...wire har ness 3 5 STAY 2 TERMINALS 3 WIRE HARNESS 4 NUTS Remove the screw and meter front cover 1 FRONT COVER V a i o K30 Ct 2 SCREW Remove the following two screws and tachometer trip meter reset kno...

Page 171: ...connector and spark unit connec ik4 tor Continuity exists at all times If there is no continuity replace the main wire harness If all checks are O K replace the tachometer SC 1 SPARK UNIT CONNECTOR SI...

Page 172: ...0 ET a f 3 S I 3zt 3se Rft3K i i 5 5 I f f j f ii 8 l i hi sEl 1 i IN fc l 9 u O o 1 s I lies 11565 I m u u tt tt s 5 J CW III CH 11 o 111 111 o s 1 1 _i r h i Q s 3 o j 5r o i 1 f nil ill 1 w ft sjiF...

Page 173: ...engine stop switch WEAK OR NO SPARK 2 Perform spark test GOOD SPARK Mixture too rich Carburetor flooded Carburetor choke excessively closed Cylinder flooded Air cleaner dirty Faulty Purge Control Valv...

Page 174: ...vent hole Faulty fuel pump Faulty fuel pump relay Loose broken or shorted wire or connection of pump relay 4 Accelerate lightly ENGINE SPEED INCREASES S Check ignition timing INCORRECT Faulty spark un...

Page 175: ...l Excessive carbon build up in com bustion chamber Ignition timing too advanced Faulty spark unit Lean fuel mixture ENGINE DOES NOT KNOCK POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE CAUSE t Check...

Page 176: ...jets CLOGGED Clogged jets t NO COLGGED JETS I 4 Check valve timing INCORRECT Camshaft not installed properly CORRECT 1 5 Check valve spring tension WEAK Faulty valve spring POOR HANDLING Check tiie a...

Page 177: ...ft Removal lnstallation Carburetor Combination Disassembly assembly Removal lnstallation Separation Synchronization Charging System Alternator Circuit Diagram Inspection Location Clutch Installation R...

Page 178: ...ging System Alternator Clutch Geaishift Linkage Cooling System Crankshaft Transmission Cylinder Head Cylinder Piston Electric Starter Starter Clutch Frame Body Panels Exhaust system Front Wheel Suspen...

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Honda CB-1 1989, Service Manual

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Summary of Contents for CB-1 1989

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