04.Adjustments and Service

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IV. ADJUSTMENTS AND SERVICEIV- l IGNITION TIMING ADJUSTMENT

Check ignition li ming and contact breaker po int surfaces every TwO o r three mont hs Faultytim ing o r bod poin t sur faces resul t in poor performa nce and er rat ic engine revolutions. Th etiming of idling speed at 80 0 -900 rp m is 5 degrees before top dead cen te r, the momentthe F mark aligns with the indicator. Timing begins advancing at 1200 rpm and t he fulladvance o f 45 degrees BTDe is obt a ined 01 2300 rpm. To adjust timing : Fig . IY- J )

1 Remove the co ntact b reaker cove r , ro lo te the cronk shaft un til B res ts on the peaKof com C and od iust the pa in; gap to 0.3- 0.4 mm 10 .0 12-0.016 1.

2) To adjust the po int gap, loose n screw D and move screw E to the left or r ight.The gap is decreased by turning the screw in and increased by turning it out .

13 1 To ad just ign iti on timing . ro ta te the crank shaft until the red mark F on the ro tora ligns wi th the mark J on the genera to r sta lo r . l oosen the 2 G screws , one a t

E ~,

,

d ; . .

Fig. IV - I Whole view of contoct breake r point

t he top o f the pl ate and the o ther 0 1 the bOllom . I Ol a te the plate assemb ly to apositi on where the points iust cl ose and t ig hten f h ; 2 G screws.

4 1 Us e a tester or small ligh t to determine the exact instant the po ints clos e.Fig. IV- 2

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Fig. IV - 2. U sing mini a tur e lomp 60 V checking timing

( 5) For checking the t iming dy namica ll y w hi le the e ngine IS revo lving , the timing light inthe se rvice teste r p. 12 2) IS useful. This l ight con also be used to check the stat eof t iming advance rel a ti ve to en g ine rpm. P. 108 1

( 6) A fter adjustment IS com pleted . tu rn the cronk shaf t a few turns and recheck theign it io n timing.

( 7) Burned or pitted point s s lould be sm oo th ed with a fil e, and a ny oi l wiped from thesurfaces with a clean, d ry dot h.

[ 8 I App ly a smal l o mout o f good grease to the o il slipper dur ing regu lar mointenonceserv ice.

I 9 I Whe re co ncern is on ly l o r power 01 high rpm using megapho ne exhaust pipes andspec ial ra cing kit corburetter jet s on the CB92 . it is advisab le to set the timing at10 degrees BTDe, by marking a point on the dynamo rotor 10 degre es from the" T mark co unt er-clockw ise o r at the some distance from " T to f " on the c ircum-fer ence.

IV - 2. VALVE TAPPET CLEARAN CE ADJUSTM ENTToppet clearance is important to correct operation of the valves As it affects valv e timing ,if the clearance is too small the engine w ill not run smo ot hly. If the cl earance is too lorge ,loppet noise is heard.

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( 1 ) Remove the co ntoc t breaker cover and align the po inter on the generator wi th theb lock T mark on the rotor.

( 2 Remov e the four caps with on axel wre nch or open end wrench , loosen the locknuts and turn the adjusting screw with the special wrench provided to obta in thespecified clearance. ( ig. IV - 3

1

Fig. IV 3 Adjusting toppe t clearance

Turn the adjusting screw in to de cr ea se and out to increa se clearance . The prop ercl earance fo r both in tok e and ex haust valve tapp ets when t he engine is cold is 0 . 1mm . Ched clearance wi th the thickness 9u0ge in the toot kit.

I 3 Ho lding the adjusting screw in posi tion , light e n the lock nut. Rotate the cr onk shohone revolut ion and make the same adjustment as on the opposite side.

( 4 J After the adjustment is co mp leted, depress the kick starter several times and recheckthe clearance.

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f ig. IV 5. Adjusting clut h

( 4 The main adjustment ca n be mode by steps 1 through 3, but to facilitate thead justment of fr ee ploy in th e lever a coble adjuster in provided on the CB92 c lutchcob le. IFig. IV-61

Fig . IV- 6. Clvlch ca b le ICB92)

IV- S DRIVE CHAIN ADJUSTMENTCorrect ad justment of the dr ive choin offects the power ou tput 1 the rear wh eel gr eatly a ndalso the durabili ty of the choin.W hen the choin is too l ight it decr eases pOwer tran sm iss ion. o td when it IS too loose it causesexcess ive wear .

( 1 I Remove the rubber cop on the choin case and ad just the drive chain so there is10 20 mm 10.4-0.S 1 of ploy. (Fig. IV-71

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2 I To ad just Ihe d rive chain . loosen the med ium sized a x le nu t and large o xle sleevenu t and tu rn the ad juste r nut in the di rectio n needed. Tu rn the nu t in 10 t ig l en thedr ive chain and o ul 10 loosen it. {Fig . IV- B

fi g. IV- 7. Molt . deflection o f drive choin

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I

ig . V S. Ad justing drive cha in ad juster

t 3 ) Turn fhe adjuster s o n bo t h sides the same amount a l it t le at a time, checking th eploy in the c hoin , and be sure the no tch mar ks on both adjusters o re eve n. If theyor e not Ihe reo r wh eel w ill no t be str aigh t in the frome, re sul t ing in un stabl e riding .

V 6 CAM CHAIN ADJUSTMENTFaulty adjust ment of the com cho in re sults in com cha in noise and rout ine adjustmen t occasionally is recommende d.

I 1 ) Remov e the ru bbe r cop and loosen the com choin ad justi ng lock nu t and com choinad jus ting sc rew .

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2 Remove the toppe l ho le cap and w hil e wa tching the rocker arm , rotate thecronk shoft in the reverse direction and then in the normal directio n unt il the exhaustva lve roder arm storts to operate.

3 Turn the com chain ad justing screw in until the l ip just touches the cam chain tensionerspring guide.by fe el.

As this is not visable . dete rmine when the screw touches th e guide

4 1 Hol d the adjusting screw with a screw drive r and tighten the cam chain ad jus tin glock nut. IFig. IV-9J

,,

Fig. IV- 9 . Adjolling cam ( ho i

IV 7. BRAKE ADJUSTMENT

Re ar brake pedal ad justment corrects th e amount of free play in the brake pedal.th e brake does not drag and is not too loose .A. RE R BRAKE

Be sure

( 1 I Adiust the re ar brake peda l until the re is 30- 40 mm (1.2 1.6 1 free trav el b e forethe rear broke begins to ope rat e, Fig IV 101

121 To ad just. turn the rear broke adj usti ng nul in The needed direct ion. Turn the nut into reduce the peda l travel and ou l to increase the pe da l t rove l.

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1, _ _ _ _ -,Fig. IV lO. Adj\ntmEnt of rear broke

B FRONT BRAKEI) Adjust so there is 3-4 mm lO 12- 0 . 16 H j of free travel in the front broke lever before

the broke bog i s to o perate. ig. IV- ll21 To adjust , turn the front broke adjust ing nu t in the needed direct ion. Turn the nut

in to decrease and out to increase the free trove of the lever. {Fig. IV- i

I 3 J To adjust the CB92 front brake,3- 1 An ad juster is provided in the broke coble for minor brake lever play adjustments.3- 2 When the brake shoe s ore replaced connect the broke rod so thot the two

cams are synchronized . Adiust the broke rod at the joint 10 the length requiredso thot the distance between the upper brake orm a nd lowe r brok e orm is,co rrect. Afte r fill ing joint pins and co tl er pins, check. the b rok e rod side ploy.If the broke rod is too l ight be tween the arms, adiust the rod.

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-20-30mrn0.78-1.18 ;n

. _ . ~ . - -- _- -fig. IV-l1. Adjustment of front broke

Fig. IV-12. Front broke CB92)

3 3 Major adjustments are made at the coble adjuster at the end of the broke arm,as on standard models.

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W hen brakes ore given hard usage, such as in races. remove the front and rearair gu ide cops to cool the broke drums . For normal use, the cops shou ld beattached to prevent dirt and sand from getting info the brakes.

IV S. CLEANING AIR CLEANERThe oir cleaner should be kept clean and dry. When it is dirty. there is donger thot engi neperformance will be adversely affected or dirt get into the engine and couse rapid wear.Clean preiadically.

1) Remove the ai r cleane r elment as described on page 92.2) C lean a dirty element by topp ing it gently, blowing with compressed air or brushing

the outside with a soft brushI 3 I A cleaner element fo uled with oi l or waler will not clean the .0 properly. Be

carefu l not to get o il or grease o n the element.or grease or broken, ep lace it.

If the cleaner is fouled with oil

IV 9. CLEANING OIL FILTERI 1) Remove the oil filter and pull out the oil cleaner.2) Remove the oil filter cop and wash the dirty oil cleaner inside thoroughly with go

saline .

ig. V - 13.

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l. . '\./

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Fig. rV-1 4. Removal of oil fil te r

IV l0 ClEANING FU L STRAINER

o

Dirt in t he strainer con be seen fro m o ut side throug h the plas tic st rai ne r cup.st ra iner cup a nd clean the inside of the cup and the SCr e e 1 (Fig. IV-1 41

Fig . v - 15. Rem oving fue l co ck str ai ner

IV I I THROTTLE CABLE AND GRIP ADJUSTMENT

Remo ve the

( I I To adjust the free t ravel in the thro tt le gn p . loosen the nu t and lu rn the ad juster in the needed dir ect ion . A free pla y of about 5 mm (0.2 ) is re commended .IFig. IV- 161

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2 I Tw is l gr i p stiffness can be ad justed wi th the ad jus ting sc rew afte r the nu t isloosened . Aftr adjustment. t ighten the nut fi rmly . (Fig. IV 171

II

-- -Fig. IV- 16. Throttle ad justme nt C92)

cable .adjuster

Throttle adjuster

. fI _ .Fig . IY- 17. Thr ottle ad justment CB92)

IV - 12. ADJUSTMENT OF CHANGE PEDALThe change pedal position con not be adjusted on sta nda rd models, but the angle of the pedalmay be adjusted to fit the rider s foot on the CB92. Un sc rew the lo nut wit h a 10 mmwrench and turn the change rod by hand or with a pa i r of pl ie s Tighten the lock nut a ft erad i ustmen t (f ig . IV l8l

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Change

. jJpword,

Downward - . _. - 'Fig. V- lB. Adiusting change pedal

IV -1 3. BATTERY SERVICE

As maintenance of the batte ry is described on page 10 1 only routine service S listed here.( 1 The elect rolyte leve l should not be allowed to fall below the lower line mark ed on the

side of the battery case.( 2 ) When electro lyte becomes lo w , add dis tilled water to the upper leve l line. Do no t

use sulphuric acid .( 3 I Do not fill above the upper line.I 4 I Be sure the ven t pipe is not obs tructed.

IV-14. SPARK PLUG SERVICE

The co nditio n o f the spark plug affects engine pe rfo rm ance grea t ly , and p lugs shou ld be checkedregular ly. Cl eon th e e lectrode and adiust th e gop to 0.6- 0.7 mm 0.024-0.028 ) as describedon page 110 .

IV IS. ADJUSTMENT OF HEAD LIGHT AND STOP LIGHT TIMING

Th ese adjus tments or e desc ribed on page 117 an d page 12 1.- 1 8


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IV-16. LUBRICATIONI Engine il

As engine oil is absolutely p nl iol to satisfactory eng ine op e ra tion and engine li fe. ex t remecare should b e tok en in check ing and changing the oil regular ly. M ore frequent o il cho nge sor e reco mmended unde r severe service co ndit io nsI 1 Put the mo tor cycle on the main slond. remOve threaded drain plug fr om the under

crank case and drain all the o il from the eng ine.Dro in the oi l when the engine is at normal operating tempera ture.Replace the pl ug after all the oil hos drained.

2 I Remove o il cop and pour new o il into the engine to the level of the mark on Ihedip sl ick. No rmally on o i l change lakes abou t 0.8 li ter, but when the oil is dr ai nedthoroughly from all o il passages and the filter. it takes 1.2 lite rs Do not screw inthe o il dip sti ck when checking oil leve l Just insert it . Fig. 19)Crank t he engine and check the oil level ag ai n af ter running it.

Fig . IV 19. Checking oil level

3 I Heavy duty oi l of the fo llo w ing brands is rec ommendedSHEELPENNSYLV NI

NNZ OI L

RETIN X

PENNDR KE1 9

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CASTROL MOBIL OILand HONDA ULTRA OIL which is specially produced for Hondo machines.

( .4 I Grades recommended ore:Over lSoC (59FIBelow 15 C 159"FI

II rease service

( 1) Grease nipples

#30 S E#20 S E

Replenish grease periodically through all nipples with a grease gun. referring to Iheroutine maintenance chart. Fiber grease is recommended. Grease nipples are locatedal these points:

Front brake armFront broke panelFront arm pivot bushing R & UClutch adiusterRear broke armSpeedometer gear boxINipples on CB92 onlylFront brake arm (upper)Change pedal pivotBroke pedal pivotBrake coblelutch c ble

( 2 I Front and rear axle bearingsReplace grease in front and rear axle bearings every 5.000 miles. Pack greasebetween balls and pul a thin coot inside the wheel hubs.

{ 3 I Drive chainThe chain should be thoroughly cleaned and greased as described on page 89.

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04.Adjustments and Service