Honda CH250 1989 Service Manual Download Page 31 | Manualshive

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Summary of Contents for CH250 1989

Page 1: ......

Page 2: ...tions While Section 4 through 18 describe parts of the motor cycle grouped according to locations Find the section you want on this page then turn to the table of contents on the first page of the sec...

Page 3: ...stalled but the subsequent steps like cylinder head removal require engine removal the callouts are grouped in numerical and alphabetical orders The illustrations may contain symbol marks to indicate...

Page 4: ...io 1 Use multi purpose 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...

Page 5: ...ission Control Information Labels U S A Only 1 14 1 19 1 21 Used Engine Transmission Oil Used engine oil or transmission oil in two strokesl may cause skin cancer if repeatedly left in contact with th...

Page 6: ...de of the crankcase 3 VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number VIN is located on the left side of the front inner box 4 CARBURETOR NUMBER 5 COLOR CODE LABEL Carburetor identific...

Page 7: ...ar wheel travel I 81 6 13 21 Front damper Rear damper I Front tire size 100 90 10 61J Rear tire size 120 90 1065J I Tire brand Bridgestonel FRIRR ML35 ML36 Tire brand Dunlop FR RR K488F K488 I Tire br...

Page 8: ...fug clutch I al r tCh sy tem l Primary reduction I Final reduction _____ J rratio Electncal I Ignition system 1 000 6 418 l_v matlc 2 100 0 880 I DC COl CapacItIve Dischaged Ignition _ II Starting sys...

Page 9: ...I I i I Fuel System Carburetor identification number VE41A California VE42A Main jet 112 High altitude 110 Slow jet 40 Jet needle clip position Pilot screw initial opening 2 1 B California 2 1 8 fina...

Page 10: ...931 EX I 4 955 4 970 10 1951 0 19571 49010 1931 Valve guide 1 0 IN I 5000 5 012 10 1969 0 19731 5 03 10 198 EX 5 000 5 012 10 1969 O 19731 5 03 10 1 981 Stem ta guide clearance IN I 0 010 0 037 10 000...

Page 11: ...012 8346 2 8350 1 With IN mark facing the intake side 71 970 71 99012 8338 2 83421 10 10AI from the bottom 17 002 17 00810 6694 0 66961 0 010 0 040 10 0004 0 00161 16 994 17 00010 6691 0 66931 0 002 0...

Page 12: ...111 251 619 911 Rear sh ck absorber sprlng_d_i_re_c_t_i o_n LW i t h t ig h t ly_wLo L dLco _il e n_d_t a_c_in g d o_w_n_ Brakes Front brake fluid brake lever free play 10 2010A 0 BI brake pad wear in...

Page 13: ...imary at 20 C 68 F Secondary with plug cap Secondary without plug cap Pulse generator resistance At 20 C 68 F Lights Meters Switches Main fuse Headlight high low beaml Tail brake light License light P...

Page 14: ...I Threed di ml Torque I N m kg m ft Ibl t Remarks Lubrication I Right crankcase flange bolt I 10 I 6 1211 2 91 Right crankcase cover flange bolt I 11 I 6 1211 2 91 I Oil pump cover attaching SCrew oi...

Page 15: ...1 11...

Page 16: ...der i 07923 KM10000 10 Ball race bearing driver attachment 07945 3330300 10 11 Clutch spring compressor attachment 07960 KM 10000 10 Crankshaft assembly shaft 07965 1660200 10 Driver 07749 0010000 10...

Page 17: ...eedle bearings 1 cc 10 03 US ozl Oil seal lips O ings L ywhe t_0reads __ _ _ _ _ _ Valve stem valve guide sliding surface I Molybdenum disulfide oil Camshaft journals and cam lobe I Starter clutch gea...

Page 18: ...General Information Cable Harness Routing ill IGNITION SWITCH 121 HEADLIGHT WIRE 181 SIPHON TUBE 151 HORN v 1 161 FRONT BRAKE CABLE i41 _171 SPEEDOMETER CABLE 1 14...

Page 19: ...TENSION CORD 131 1131 IGNITION COIL SIPHON TUBE 141 FAN MOTOR SWITCH lSI RADIATOR HOSE 161 FAN MOTORITHERMO SWITCH WIRE 171 HEATER TUBE 4 I r I 114 CLAMP 181 THROTTLE CABLES 115 FUSE CONNECTOR 191 __...

Page 20: ...E 8 FUEL STRAINER 14 PULSE GENERATOR WIRE 13 MAIN WIRE HARNESS 11 FUEL TUBE 12 HEATER TUBE 9 THERMO SENSOR WIRE CONNECTOR 10 FUEL PUMP VACUUM TUBE 6 IGNITION COIL 5 HIGH TENSION CORD 4 THROTTLE CABLES...

Page 21: ...S 7 HEATER TUBE 8 FUEL PUMP BREATHER TUBE 9 HIGH TENSION CORD 15 PULSE GENERATOR t 0 _ 11 FUEL TUBE WIRE 16 STARTER RELAY 14 A C GENERATOR 12 MAIN WIRE HARNESS SWITCH CORD WIRE 13 AUTO BYSTARTER WIRE...

Page 22: ...FRONT BRAKE LIGHT 3 TURN SIGNAL RELAY SWITCH WIRE 4 LEFT TURN SIGNAL WIRE CONNECTOR 5 SPEEDOMETOR CABLE I lCALIFORNIA MODEL ONLYl 12 PURGE CONTROL VALVE 9 PURGE CONTROL VALVE VACUUM TUBE 8 FUEL VAPOR...

Page 23: ...of Emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when sub...

Page 24: ...ing acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into...

Page 25: ...Label California Model Only The Vacuum Hose Routing Diagram Label is located on the back of the seat 11 EMISSION INFORMATION LABEL 21 UPDATE LABEL VEHICLE EMISSIOH COHTROL IHFORMITION UPDATE HONDA MO...

Page 26: ...em Installation of the frame body panels is in the reverse order of removal unless noted otherwise When removing the cover be careful not to damage the tabs and or grooves Alway replace the exhaust pi...

Page 27: ...te the proper order for component removal I CENTER COVER I I REAR CENTER COVER I I LUGGAGE BOX I I BODY PROTECTOR COVERJ II FRAME BODY COVER I 10 FLOOR PANEL I EL TANK UNDER GUARD I FORK COVER I I FRO...

Page 28: ...llation Remove the four screws from the frame and upper cover Disconnect the both turn signal wire connectors Remove the front cover 6 SCREW Install the front cover in the reverse order of removal Han...

Page 29: ...wly Remove the front inner fender A Installation is the reverse order of removal NOTE stallation insert the claws of the fender B into thel II II h les in the fender A securely to avoid breaking the I...

Page 30: ...oor panels page 2 7 radiator reserve tank page 6 4 Disconnect the fuse box wire connector and remove the nut r 4 SCREW Remove the inner box by unhooking its upper end from the steering stem 3 AIR OUTL...

Page 31: ...the center cover Installation is the reverse order of removal NOTE 0 W h e n r e in s t a II in g t h e c o v e r m a k e s u re th a t i ts ta b s a r e correctly positioned through the luggage box g...

Page 32: ...abs from the body cover sliding the floor panel forward then remove the left floor panel Remove the right floor panel in the same way Install the floor panel in the reverse order of removal Fuel Tank...

Page 33: ...arks Removal Order Installation is the reverse order of removal ll COl unit wire 1 Disconnect the wire connector from the COl unit 2 Taillight turn signal wire 1 Disconnect the wire connector 3 Fender...

Page 34: ...Requisite Service Body protector cover removal installation page 2 6 Procedure Q ty Remarks Removal Order Installation is the reverse order of removal 1 Muffler joint bolt 1 Loosen the bolt 2 Rear mo...

Page 35: ...Frame Body Panels Exhaust System Fuel Tank Removal Installation 1 13 12 Rf 8 2 10...

Page 36: ...pipe mounting bolt nut 2 Center cross pipe 3 Fuel level switch wire 4 Fuel strainer 51 Left floor board mounting bolt nut 51 Left floor board 17 Right floor board mounting bolt nut 8 I Right floor bo...

Page 37: ...buretor Idle Speed 3 6 Maintenance Schedule 3 4 Headlight Aim 3 6 Air Cleaner 3 5 Side Stand 3 6 Spark Plug 3 5 Service Information Refer to the Common Service Manual for service procedures on items n...

Page 38: ...ample AIR CLEANER Contamination clogging replacement Part Side cover The parts that must be removed for service Fuel tank 2 THROTTLE GRIP Operation free play 3 BRAKE LEVER Operation free play 1 TIMING...

Page 39: ...K Coolant level 4 FINAL REDUCTION OIL CHECK BOLT Oil level 7 BRAKE LIGHT SWITCH Operation 5 REAR BRAKE Shoe wear 6 FINAL REDUCTION OIL DRAIN BOLT 8 SPARK PLUG Oil replacement 11 FRONT BRAKE Wear damag...

Page 40: ...ance while the engine is cold below 35 C 95 F Remove the center cover and body protector cover Section 2 Remove the inspection hole cap and belt case air cleaner case page 10 21 Remove the two luggage...

Page 41: ...ed by local laws 1 and regulations I It is not necessary to remove the front upper cover to I make the horizontal adjustment Insert the screw driver through the front inner box hole as shown and adjus...

Page 42: ...I _ When removing and installing the oil pump use cafe not to allow dust or dirt to enter the engine If any Dortion of the oil pump is worn beyond the specified service limits replace the ail pump ClS...

Page 43: ...lubrication System Lubrication System Diagram 11 CAMSHAFT OIL THROUGH 21 CRANKSHAFT OIL THROUGH 131 OIL STRAINER SCREEN 4 OIL PUMP 4 2...

Page 44: ...the reverse order of removal 1 Oil separator cover bolt 1 2 Oil separator cover 1 At installation fit the tab of the separator cover into the slit of the separator 3 Circlip 1 At installation set it i...

Page 45: ...to page 1 3 for specifications Requisite Service Oil pump removal installation page 4 3 Procedure Disassembly Order 1 Pump cover attaching screw 2 Pump cover 3 Dowel pin 4 Oil pump shaft 5 Inner roto...

Page 46: ...ator removal installation page 15 8 Procedure Q ty Remarks Disassembly Order Assembly is the reverse order of disassembly 1 Oil filler cap 21 Oil filler cap O ring 131 Timing hole cap 1 41 I Timing ho...

Page 47: ...ation Refer to section 2 for fuel pump removal and installation When disassembling fuel system parts note the locations of the O rings Replace them with new ones on reassembly Before disassembling the...

Page 48: ...es of the emission control system faulty California model only Lean Mixture Purge control valve faulty California model only Fuel jets clogged Float valve faulty Afterburn On Deceleration Float level...

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