HONDA CM185T TWINSTAR Service Repair Manual 1978-1979

GENERAL INFORMATION SPECIFICATIONS ITEM DIMENSIONS Overall length 1,960 mm (77.2 in.) Overall width 830 mm (32.7 in.) Overall height 1,130 mm (44.5 in.) Wheelbase 1,280 mm (50.4 in.) Seat height 730 mm (28.7 in.) Foot peg height 180 mm ( 7.1 in.) Dry weight 124 kg (273 lbs.) FRAME Type Diamond F. suspension, travel Telescopic fork 115 mm (4.53 in.) R. suspension, travel Swing arm 64 mm (2.53 in.) F. tire size, pressure 3.00-17 (4PR) 1.75 kg/cm 2 (25 psi) R. tire size, pressure 3.50—16 (4PR) 2.25 kg/cm 2 (32 psi) F. brake, lining swept area Internal expanding shoes, 110 cm 2 (17.05 sq. in.) R. brake lining, swept area Internal expanding shoes, 123 cm 2 (19.07 sq. in.) Fuel capacity 10.5 liters (2.8 U.S. gal.) Fuel reserve capacity 3.0 liters (0.8 U.S. gal.) Caster angle 62° Trail 92 mm (3.6 in.) Front fork oil capacity 125 cc (4.2 oz), 98 cc (3.3 oz) at draining ENGINE Type Air cooled 4-stroke Cylinder arrangement Parallel twin 20° inclined from vertical Bore and stroke 5 3 x 4 1 mm (2.09 x 1.61 in.) Displacement 181 cc (11.03cu. in.) Compression ratio 9.0 : 1 Valve train Chain drive overhead camshaft Maximum horsepower 15.0 BHP/9,500 rpm Maximum torque 1.28 kg-m (9.26 ft-lb.)/7,000 rpm Oil capacity 1.5 liters (1.6 U.S. qt.) Lubrication system Pressure and wet sump Air filtration Oiled polyurethane foam Cylinder compression 12.0 ± 2.0 kg/cm 2 (170 ± 28 psi) Intake valve Opens - 3 ° (B.T.D.C.) at 1mm lift. 45° (B.T.D.C.) at 0 lift Closes 34° (A.B.D.C.) at 1mm lift, 97° (A.B.D.C.) at 0 lift Exhaust valve Opens 33° (B.B.D.C.) at 1 mm lift, 94° (B.B.D.C.) at 0 lift Closes -4° (A.T.D.C.) at 1mm lift, 49° (A.T.D.C.) at 0 lift Valve clearance IN: 0.05 mm (0.002 in.) EX: 0.05 mm (0.002 in.) Idle speed 1,200 ± 100 rpm 1-2 Date of Issue: December, 1977 © HONDA MOTOR CO., LTD.

GENERAL INFORMATION Date of Issue: December, 1977 © HONDA MOTOR CO., LTD. 1-3 ITEM DRIVE TRAIN Clutch Transmission Wet, multi-plate type 4-speed constant-mesh Primary reduction 3.833 Gear ratio 1 2.769 Gear ratio II 1.722 Gear ratio III 1.272 Gear ratio IV 1.000 Final reduction 2.333(15/35) Gear shift pattern Left foot operated return system ELECTRICAL Ignition Battery and ignition coil Ignition timing "F" mark 15° B.T.D.C. at 1,200 rpm idle Full advance 37-40° B.T.D.C. at 3,100 rpm Starting system Motor and kick starter Generator A.C. generator 0.08 kw/5,000 rpm Battery capacity 6 V - 12AH Spark plug Spark plug For cold climate below 5°C(41°F) Standard For extended high speed driving ND NGK ND NGK ND NGK U20FS C6H U22FS C7HS U24FB C9H Headlight 25/35W Tail/stoplight 3/32 cp Turn signal light 21 cp Speedometer light 2 cp Neutral indicator light 2 cp Turn signal indicator light 1 cp High beam indicator light 1 cp

GENERAL INFORMATION SERVICE DATA ENGINE mm (in.) ITEM STANDARD SERVICE LIMIT Cylinder head warpage 0.1 (0.0039) Cylinder head height 72.75-72.85 (2.8642-2.8681) 72.6 (2.8583) Cylinder I.D. 53.00-53.01 (2.0866-2.0870) 53.1 (2.0905) Piston O.D. 52.960-52.990 (2.0850-2.0862) 52.86 (2.0811) Piston pin O.D. 13.994-14.000 (0.5509-0.5512) 13.98 (0.5504) Piston pin bore 14.002-14.008 (0.5513-0.5515) 14.05 (0.5531) Piston ring end gap Top/second 0.15-0.35 (0.0060-0.0138) 0.5 (0.0197) Piston ring end gap Oil 0.2-0.9 (0.0078-0.0354) Piston-to-piston ring clearance Top/second 0.015-0.045 (0.0006-0.0018) 0.12 (0.0048) Piston-to-piston ring clearance Oil 0.017 (0.0067) Valve stem O.D. IN 5.450-5.465 (0.2146-0.2152) 5.42 (0.2134) Valve stem O.D. EX 5.430-5.445 (0.2138-0.2144) 5.40 (0.2126) Valve guide I.D. IN 5.475-5.485 (0.2156-0.2159) 5.50 (0.2165) Valve guide I.D. EX 5.475-5.485 (0.2156-0.2159) 5.50 (0.2165) Valve spring free length Outer 36.45 (1.4350) 35.3 (1.3898) Valve spring free length Inner 29.9 (1.1772) 29.0 (1.1417) Valve seat width IN/EX 1.0 (0.0394) 1.5 (0.0590) Clutch disc thickness 3.0 (0.1181) 2.6 (0.1024) Clutch plate warpage 0-0.1 (0-0.0039) 0.2 (0.0079) Clutch spring free length 36.2 (1.4252) 33.1 (1.3031) Cam lift IN 27.695 (1.0904) 26.6 (1.0472) Cam lift EX 27.522 (1.0835) 26.5 (1.0433) Camshaft journal O.D. 19.967-19.980 (0.7861-0.7866) 19.92 (0.7843) Camshaft bushing I.D. 20.063-20.083 (0.7899-0.7907) 20.20 (0.7965) Crankshaft runout 0.1 (0.0039) Connecting rod small end I.D. 14.016-14.034 (0.5518-0.5525) 14.08 (0.5543) Connecting rod big end side clearance 0.1-0.4 (0.0039-0.0158) 0.6 (0.0236) Connecting rod big end radial clearance 0.004-0.012 (0.0002-0.0005) 0.05 (0.0020) Rocker arm shaft O.D. 9.978-9.987 (0.3928-0.3932) 9.17 (0.3610) Rocker arm I.D. 10.000-10.015 (0.3937-0.3943) 10.1 (0.3976) Oil pump Inner-to-outer rotor clearance 0.15 (0.0059) 0.2 (0.0079) Oil pump Rotor-to-cover clearance 0.01-0.07 (0.0004-0.0028) 0.12 (0.0048) Oil pump Outer rotor-to-body clearance 0.15-0.18 (0.0059-0.0071) 0.25 (0.0098) Shift fork I.D. 12.000-12.018 (0.4724-0.4731) 12.05 (0.4744) Shift fork guide shaft O.D. 11.976-11.994 (0.4715-0.4722) 11.96 (0.4709) Shift fork thickness (for end thickness) 5.00-5.07 (0.1969-0.1996) 4.70 (0.1850) Kick starter pinion gear I.D. 18.020-18.041 (0.7094-0.7103) 18.07 (0.7114) Kick starter spindle O.D. 17.959-17.980 (0.7070-0.7079) 17.93 (0.7059) 1-4 Date of Issue: December, 1977 ©HONDA MOTOR CO., LTD.

HONDA. CM 1 85T GENERAL INFORMATION FRAME mm (in.) ITEM STANDARD SERVICE LIMIT Front/rear axle bend 0.2 (0.0079) Front brake drum I.D. 140.0 (5.5118) 141.0 (5.5512) Rear brake drum I.D. 130.0 (5.1181) 131.0 (5.1575) Front/rear brake lining thickness 4.0 (0.1575) 2.0 (0.0787) Front fork spring free length 504.6(19.9) 495 (19.5) Front fork slider I.D. 31.042-31.104 (1.2221-1.2246) 31.165 (1.2270) Front fork tube O.D. 30.925-30.950 (1.2175-1.2185) 30.87 (1.2154) Swing arm pivot bushing clearance 0.2-0.3 (0.0079-0.0118) 0.5 (0.0197) Rear shock absorber spring free length 184.1 (7.2480) 175.6 (6.9133) Date of Issue: December, 1977 © HONDA MOTOR CO., LTD. 1-5

GENERAL INFORMATION TORQUE VALUES ENGINE TIGHTENING POINT Q'TY THREAD DIA (mm) TORQUE kg-m (ft-lb.) Crankshaft holder bolt nut 5 6 1.0-1.4(7.2-10.1) Cylinder head nut 8 8 1.6-2.0(11.6-14.5) Cylinder head cover bolt 2 6 0.8-1.2 (5.8-8.7) AC generator rotor bolt 1 10 4.5-5.0 (32.5-36.2) Orive gear bolt 1 16 4.5-6.0 132.5-43.4) Cam sprocket bolt 2 7 1.7-2.3(12.3-16.6) FRAME TIGHTENING POINT Q'TY THREAD DIA (mm) TORQUE kg-m (ft-lb.) Steering stem nut 1 22 6.0-7.0 (43.4-50.6) Fork top bridge bolt nut 2 7 2.0-2.5 (14.5-18.1) Fork bottom bridge bolt nut 2 8 2.0-2.5 (14.5-18.1) Handlebar holder bolt 4 8 2.0-2.5 (14.5-18.1) Front axle nut 1 12 4.0-5.0 (28.9-36.2) Rear axle nut 1 12 4.0-5.0 (28.9-36.2) Engine hanger bolt nut 2 10 5.5-7.0 (39.8-50.8) Engine hanger bolt nut 7 8 2.0-2.5 (14.5-18.1) Rear brake torque link bolt nut 2 8 2.0-2.5 (14.5-18.1) Shock absorber nut 4 10 3.0-4.0 (21.7-28.9) Foot rest bolt 4 8 2.0-2.5 (14.5-18.1) Driven sprocket bolt nut 4 10 5.5-6.5 (39.8-47.0) Swing arm pivot bolt nut 1 12 5.0-6.0 (36.2-43.4) Torque specifications listed above are important tightening points. Others should be torqued to standard torques below. STANDARD TORQUES TYPE TORQUE kg-m (ft-lb.) TYPE TORQUE kg-m (ft-lb.) 5 mm bolt, nut 0.45-0.6 (3.3-4.3) 5 mm screw 0.35-0.5 (2.5-3.6) 6 mm bolt, nut 0.8-1.2 (5.8-8.7) 6 mm screw 0.7-1.1 (5.1-8.0) 8 mm bolt, nut 1.8-2.5 (13.0-18.1) 6 mm flange bolt, nut 1.0-1.4 (7.2-10.1) 10 mm bolt, nut 3.0-4.0 (21.7-28.9) 8 mm flange bolt, nut 2.4-3.0 (17.4-21.7) 12 mm bolt, nut 5.0-6.0 (36.2-43.4) 10 mm flange bolt, nut 3.0-4.0 (21.7-28.9) 1-6 Date of Issue: December, 1977 © HONDA MOTOR CO., LTD.

HONDA CM 1 85T GENERAL INFORMATION SPECIAL TOOLS SPECIAL TOOLS TOOL NAME TOOL NO. APPLICATION REF. PAGE 6 mm Allen wrench Clutch outer holder Ball race driver Shock absorber spring compressor Spring holder attachment Valve guide reamer Piston ring compressor Piston base 07917-3230000 07923-1070001 07944-1150001 07959-3290001 07967-1150100 07984-0980000 07954-4190000 07958-2500000 Front fork Clutch' Ball race Shock absorber Shock absorber Valve guide y Cylinder 11-16. 11-19 8-3. 8-7.9-6 11-22 1210, 12-11 12-10, 12-11 6-10, 6-11 7-10 7-10 COMMON TOOLS TOOL NAME TOOL NO. APPLICATION REF. PAGE Pin spanner Tappet adjusting Tappet adjusting wrench (8x9) Steering stem wrench (30x32) Extension bar Universal holder Rotor puller Valve guide driver/remover (5.5) Valve guide cutter Valve guide pilot (5.5) Bearing driver (32x35) Bearing driver (42x47) Bearing driver (52x55) Driver pilot (15) Driver pilot (20) Driver pilot (35) Driver handle B Driver handle A Fork seal driver body Driver attachment (C) Valve spring compressor Float gauge 07702-0010000 07708-0030400 07708-0030100 07716-0020400 07716-0020500 07725-0010101 07733-0020000 07742-0010100 07742-0030100 07742-0030200 07746-0010100 07746-0010300 07746-0010400 07746-0040300 07746-0040500 07746-0040800 07746-0020100 07749-0010000 07747-0010100 07747-0010400 07757-0010000 07401-0010000 Steering top thread } Tappet clearance adjustment Steering stem nut Steering stem nut Drive sprocket Rotor ^ Valve guide #6202 S #6302 #6006 #6302 > #6202 Wheel bearing. #6204 crankcase bearing #6006 J } Front fork oil seal Valve 11-22, 11-23 3-4 3-4 11-21, 11-23 11-21. 11-23 9-4 9-7 6-11 6-10. 6-11 6-10, 6-11 10-8 11-10. 12-4 10-9 11-10, 12-4 10-8 10-9 10-9 11-10, 12-4 11-19 11-19 6-8. 6-16 4-6 Date of Issue: December, 1977 ©HONDA MOTOR CO., LTD. 1-7

GENERAL INFORMATION CABLE & HARNESS ROUTING • CABLES FRONT BRAKE CABLE THROTTLE CABLE SPEEDOMETER CABLE CLAMP NOTE Clamp front brake cable and throttle cable. CLUTCH CABLE SPEEDOMETER CABLE CHOKE CABLE WIRE BAND NOTE Clamp wire harness, clutch cable and choke cable. WIRE BAND NOTE Clamp wire harness, choke cable, and throttle cable. FRONT BRAKE CABLE THROTTLE CABLE CLUTCH CABLE WIRE BANDS NOTE Clamp stop switch wire and starting switch wire. Date of Issue: December, 1977 © HONDA MOTOR CO.. LTD. 1-9

HONDA CM185T TWINSTAR Service Repair Manual 1978-1979

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