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Honda CB250K4 Manuals Manuals and User Guides for Honda CB250K4. We have 1 Honda CB250K4 manual available for free PDF download: Shop Manual

Honda CB250K4 Shop Manual (180 pages)

Honda Motorcycle CB250/350, CL250/350, SL350 Brand: Honda | Category: Motorcycle | Size: 36 MB

Table of Contents

• Contents 5
• Technical Data 14
• Special Tools 28
• Minor Model Change Table of Principal Modifications 32
• Engine 42
• Main Features 42
• Power Transmission System 42
• Dismounting the Engine 42
• Remounting the Engine 43
• Valve Mechanism 44
• Description 44
• Disassembly 44
• Inspection 46
• Compression Pressure 46
• Adjusting the Engine to the Proper Compression Pressure 46
• Valve Tappet Clearance Inspection and Adjustment 46
• Camshaft Side Clearance 47
• Cam Diameter 47
• Camshaft Mounting End 48
• Rocker Arm Pin Diameter 48
• Deformation of the Gasketing Surface 48
• Carbon Removal 48
• Valve Seat Contact 49
• Valve Stem Clearance 50
• Valve Stem Diameter 50
• Valve Guide Replacement 50
• Valve Spring Dimension 50
• Reassembly 51
• Valve Timing 51
• Pistons and Cylinders 52
• Cylinder Boring and Honing 53
• Piston Dimension 53
• Piston Ring Side Clearance 53
• Piston Ring End Gap 54
• Piston Ring Thickness 54
• Piston Pin Bore 54
• Piston Pin Diameter 54
• Cam Chain Tensioner (Hydraulic Type) Description 55
• Cam Chain Tensioner (Hydraulic Type) Disassembly 56
• Cam Chain Tensioner Inspection 56
• Cam Chain Tensioner Reassembly 56
• Lubricating System Description 57
• Lubricating System Disassembly 58
• Lubricating System Inspection 59
• Engine Oil Check and Change 59
• Cleaning Air Filter 59
• R. Crankcase and Oil Filter Inspection 60
• Oil Pump Body Bore Dimension 60
• Oil Pump Plunger Dimension 60
• Lubricating System Reassembly 61
• Clutch Description 61
• Clutch Disassembly 62
• Clutch Inspection 62
• Clutch Reassembly 63
• Friction Disc Dimension 63
• Clutch Plate Warpage 63
• Clutch Spring Dimension 63
• Crankshaft and Connecting Rods Description 64
• Crankshaft and Connecting Rods Disassembly 64
• Crankshaft and Connecting Rods Inspection 65
• Measure Amount of Bend 65
• Main Bearing Diametrical Clearance 65
• Connecting Rod Diametrical Clearance 65
• Crankshaft and Connecting Rods Reassembly 66
• Transmission Description 66
• Transmission Disassembly 66
• Connecting Rod Small End Bore 66
• Transmission Inspection 67
• Measuring Backlash 67
• Wear to Transmission Gear 67
• Clearance between Gear and Sahft 67
• Transmission Reassembly 68
• Gear Shift Mechanism Description 68
• Gear Shift Mechanism Disassembly 69
• Gear Shift Mechanism Inspection 69
• Gear Shift Mechanism Reassembly 70
• Kick Starter Description 70
• Kick Starter Disassembly 70
• Kick Starter Reassembly 70
• Crankcases Description 71
• Oil Separator Operation 71
• Crankcases Disassembly 71
• Crankcases Inspection 71
• Crankcases Reassembly 72
• Carburetor Description 72
• Sectional View of Carburetor 72
• Carburetor Disassembly 73
• Carburetor Inspection 73
• Idling Adjustment 73
• Synchronizing the Throttle Valve 73
• Frame 74
• Handlebar Description 74
• Handlebar Disassembly 74
• Handlebar Inspection 75
• Handlebar Reassembly 75
• Fork Top Bridge Description 76
• Fork Top Bridge Disassembly 76
• Fork Top Bridge Inspection 76
• Fork Top Bridge Reassembly 76
• Front Cushion (Piston Type) Description 77
• Front Fork Assembly 77
• Front Cushion Description 78
• Front Fork Unit 78
• Front Cushion Operation 79
• Front Cushion Disassembly (Piston Type) 79
• Front Cushion Inspection (Piston Type) 80
• Front Fork Oil Change 80
• Inspect for Oil Leak 80
• Inspect Front Cushion Spring 80
• Front Cushion Reassembly 81
• Front Fork Piston Diameter 81
• Front Fork Bottom Case Diameter 81
• Front Cushion Description (Rod Type) 82
• Front Cushion Disassembly 82
• Front Cushion Inspection 83
• Steering Stem Description 84
• Steering Stem Disassembly 84
• Steering Stem Inspection 84
• Steering Stem Reassembly 84
• Fuel Tank Description 85
• Fuel Tank Disassembly 85
• Fuel Tank Inspection 86
• Fuel Tank Reassembly 86
• Frame Body Description 86
• Frame Body Disassembly 87
• Frame Body Inspection 87
• Frame Body Reassembly 87
• Seat Description 87
• Seat Disassembly 88
• Seat Inspection 88
• Seat Reassembly 88
• Stands and Brake Pedal Description 88
• Stands and Brake Pedal Inspection 89
• Stands and Brake Pedal Reassembly 89
• Exhaust Pipes and Mufflers Description 89
• Exhaust Pipes and Mufflers Disassembly 90
• Exhaust Pipes and Mufflers Inspection 90
• Exhaust Pipes and Mufflers Reassembly 90
• Air Cleaner Description 90
• Rear Fork and Rear Fender Description 91
• Rear Fork and Rear Fender Disassembly 91
• Rear Fork and Rear Fender Inspection 92
• Rear Fork and Rear Fender Reassembly 92
• Rear Cushion Description 93
• Rear Cushion Operation 93
• Rear Suspension Adjustment 93
• Rear Cushion Disassembly 95
• Rear Cushion Inspection 95
• Rear Cushion Reassembly 96
• Front Wheel Description 96
• Front Wheel Disassembly 97
• Front Wheel Inspection 97
• Front Wheel Reassembly 98
• Front Axle Bend 98
• Radial Clearance of 6302R Ball Bearing 98
• Thickness of Brake Lining 98
• Front Wheel Disassembled 100
• To Serve Front Wheel 100
• Front Wheel Torque Specifications 100
• Front Wheel Assembly 102
• Disassembly of Calipers and Master Cylinder 104
• Master Cylinder Disassembled 106
• Inspection of Calipers and Master Cylinder 106
• Assembly of Calipers and Master Cylinder 107
• Measure the Caliper Cylinder and Piston 107
• Measure the Master Cylinder and Piston 107
• Adjustment of Disc Brake 108
• Check the Brake Fluid Level 108
• Bleed the Brake Lines 109
• Rear Wheel Description 109
• Rear Wheel Disassembly 110
• Rear Wheel Inspection 111
• Rear Axle Bend 111
• Rear Brake Drum Inside Diameter 111
• Rear Wheel Reassembly 112
• Electrical Parts 114
• Ignition System 114
• Ignition Coil Description 114
• Ignition Coil Removal 114
• Ignition Coil Reassembly 115
• Ignition Coil Inspection 115
• Ignition Coil Inspection with a Service Tester 115
• Breaker Point Description 116
• Breaker Point Disassembly 116
• Breaker Point Inspection 116
• Breaker Point Reassembly 118
• Condenser Description 118
• Condenser Removal 118
• Condenser Inspection 118
• Spark Plug Description 119
• Spark Plug Removal 120
• Spark Plug Inspection 120
• Spark Plug Installation 120
• Noise Suppressor Description 121
• Noise Suppressor Removal 121
• Noise Suppressor Inspection 121
• Noise Suppressor Reinstallation 121
• A.C. Generator Performance Characteristics 122
• Silicon Current Regular Description 122
• Silicon Current Regular Disassembly 122
• Silicon Current Regular Inspection 123
• Silicon Current Regular Reassembly 123
• Rectifying System Description 123
• Rectifying System Disassembly 123
• Rectifying System Reassembly 124
• Battery Description 124
• Battery Removal 125
• Battery Inspection 125
• Battery Charging Procedure 125
• Battery Charging 126
• Quick Charger 126
• Battery Trouble Shooting and Corrective Action 128
• Starting System 128
• Starting Motor Description 128
• Starting Motor Disassembly 129
• Starting Motor Inspection 129
• Armature Insulation Test 129
• Measure the Starting Current 129
• Starting Motor Specification 130
• Starting Motor Reassembly 130
• Starting Clutch Description 130
• Starting Clutch Inspection 130
• Starting Clutch Reassembly 131
• Starter Magnetic Switch Description 131
• Starter Magnetic Switch Removal 131
• Starter Magnetic Switch Inspection 131
• Safety Equipment 132
• Horn Description 132
• Horn Removal 132
• Horn Inspection 132
• Headlight Description 133
• Headlight Removal 133
• Headlight Inspection 133
• Headlight Reassembly 134
• Tail/Stop Light Removal 134
• Tail/Stop Light Inspection 134
• Tail/Stop Light Reassembly 134
• Winker Relay Description 135
• Winker Relay Removal 135
• Winker Relay Inspection 135
• Winker Relay Reassembly 135
• Switches 136
• Ignition Switch Removal 136
• Stoplight Switch Removal 136
• Stoplight Switch Inspetion 136
• Starter Switch Button and Lighting Switch Removal 137
• Starter Switch Button and Lighting Switch Reassembly 137
• Starter Switch Button and Lighting Switch Inspection 137
• Turn Signal and Horn Control Switch Disassembly 137
• Neutral Switch Inspection 138
• Neutral Switch Removal 138
• Neutral Switch Reassembly 138
• Wiring Diagram 138
• Wiring Harness Description 139
• Wiring Harness Removal 139
• Wiring Harness Inspection 139
• Wiring Harness Reassembly 139
• Engine (SL350) 140
• General Description of the SL350 140
• Dismounting the Engine (SL350) 140
• Remounting the Engine (SL350) 140
• Primary Kick Starter 141
• Carburetor Specifications (SL350) 142
• Carburetor Circuits 142
• Main Circuit 143
• Float Circuit 143
• Idle Speed Adjustment (SL350) 144
• Float Level Adjustment (SL350) 144
• Frame (SL350) 145
• CB250K4 Wiring Diagram 156
• CB350K4 Wiring Diagram 157
• CB350K4 Wiring Diagram (General Type) 158
• CL350K4 Wiring Diagram 159
• CL350K4 Wiring Diagram (General Type) 160
• SL350K2 Wiring Diagram 161
• CB350G Wiring Diagram 162
• Maintenance Schedule 164
• Tightening Torque Standard 165
• Trouble Shooting 166
• Engine Does Not Start or Hard Starting 166
• Loss of Speed and Drop in Power 167
• Improper Running of Engine (Particularly at Low Speed and Idling) 169
• Improper Running of Engine (High Speed) 170
• Excessive Oil Consumption 172
• Exhaust Smoke 172
• Clutch Operates Faulty 173
• Shift Operates Faulty 173
• Engine Runs with Unusual Noise 174
• Vehicle Steers Faulty 174

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