This repair manual covers Honda 2-Valve Twins, including:
- Honda CD185 Benly (CD185T), U.K. 1978-1979
- Honda CM185 Twinstar (CM185T), U.S. 1977-1979
- Honda CD200 Benly (CD200T), U.K. 1979-1985
- Honda CM200 Custom (CM200T), U.K. 1980-1984
- Honda CM200 Twinstar, U.S. 1979-1982
- Honda CM250 Custom (CM250C), 1981-1983
Note: This manual DOES NOT cover the CM250T-B Custom available in the UK from 1982-1984.
Book Excerpt: 1977-1985 Honda CD185, CM185, CD200, CM200, CM250 Benly, Twinstar Repair Manual
ENGINE, CLUTCH AND TRANSMISSION
CRANKSHAFT AND TRANSMISSION MAIN BEARINGS | REMOVAL
FRAME AND FORKS
- The crankshaft outer main bearings and transmission mainshaft and layshaft main bearings will all remain in the crankcase walls as their respective shafts are removed. The crankshaft central main bearing will remain in the bearing holder fitted in between the crankshaft webs. The main bearings are all of the ball journal type.
- If, on examination of the main bearings (refer to Section 21 of this Chapter), they require replacing, the outer bearings can be drifted out of position; they are a press fit in the crankcase castings.
- If the crankshaft left-hand main bearing required removal and renewal, the removal operation must be preceded by removal of the oil seal and the oil passage plate. Pry the oil seal from its position outboard of the left-hand main bearing; a wide bladed screwdriver will facilitate the removal of the seal.
Take care not to bruise the crankcase surface adjacent to the seal housing. Remove the three countersunk crosshead screws from the inside of the left-hand crankcase.
Note that an impact driver must be used on these screws to free them; they are tight and have a locking compound applied to their threads. Lift the oil passage plate out of the casing. The bearing can now be removed.
- The crankshaft center main bearing is, in effect, an integral part of the pressed-up crankshaft and is not available as a spare part. Because of this, and because Honda does not operate a service exchange scheme, if the center bearing wears a new crankshaft will be required.
It may be possible, however, to find an engineering specialist willing to separate the crankshaft, replace the bearing and then rebuild and true the completed unit.
FRONT FORKS | REMOVING THE FORK LEGS FROM THE YOKES
- Slacken the pinch bolts on the upper and lower yokes to allow the fork legs to be pulled down and clear of the frame. In order to make individual fork leg dismantling as easy as possible, the large chromed fork top bolts should be slackened before the fork legs are detached.
Lower the fork leg until the top of the leg is roughly halfway between the two yokes, and then retighten the lower yoke pinch bolt.
The fork top bolt can now be slackened without the fork legs rotating. If the legs prove reluctant to move, the fork top bolts can be tapped with a soft-headed mallet to jar the leg out of position, if, as in the case of the machine used in the preparation of this manual, serious corrosion has set in behind the painted metal stanchion shrouds (fitted to the CD models only), the fork legs may prove very difficult to remove.
Positioning a length of hardwood above the top yoke so it rests on the fork top bolt and then striking the hardwood with a hammer proved to be a crude but effective method of driving the fork legs out of the yokes.
The painted shrouds can be left in position unless the fork yokes are to be removed.
- If fork leg dismantling is now required, refer to Section 6 of this Chapter.
- Reassembly of the forks is tackled in the reverse order of that given for dismantling; refer to Section 8 for reassembly and refitting procedures.
Subject: 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985 Honda CD185, CM185, CD200, CM200, CM250 Benly, Twinstar service, maintenance, repair. ISBN-10: 1850103593 | ISBN-13: 9781850103592 | Haynes 572