Honda CB250-360 Series Service & Repair Manual

• Covers Honda CB250, CB360, CL360, CJ250T, and CJ360T motorcycles in a 173-page PDF scan of Honda’s shop manual, including the model-specific supplements.
• Engine repair procedures cover on-frame servicing, engine removal and installation, cylinder-head disassembly, camshaft inspection, and cam-chain adjustment, supported by exploded-view assembly diagrams.
• Clutch and transmission repair extends to mainshaft and countershaft disassembly, shift-fork and shift-drum inspection, and the kick-start mechanism.
• Brake coverage includes front disc and drum systems, master-cylinder and caliper overhaul, hydraulic bleeding, lining inspection, and rear drum brake adjustment.
• Constant-vacuum carburetor work covers disassembly, vacuum-gauge synchronization, float-level setting, and throttle-linkage adjustment.
• Electrical fault-finding addresses the AC generator and silicon rectifier, ignition coil and condenser, plus starter-motor and starter magnetic-switch testing on electric-start models.

Model Variants and Production Changes

The base chapters cover the six-speed CB/CL drivetrain. The CJ supplement documents the five-speed, kick-start-only configuration and refers back to the main chapters for shared service procedures. Separate CJ market-version specification tables identify A, D/U, G, and F/E/ED types.

The CB360T/CL360K1 supplements cover revised fuel-cock markings, side-stand return checks, and rubber-pad replacement. Late-model material adds changed air-cleaner service procedures, crankshaft center-bearing identification marks, and revised rocker-arm shafts.

For the rocker-arm shaft changes, the listed starting engine numbers are CB250 K5/G 6022201, CB360G 1088381, CL360K1 2008449, and CB360T 2031164. These are component-change breakpoints, not the starting numbers for the manual’s overall coverage.

Technical Coverage: Engine and Lubrication

This documentation details the internal construction and operation of the air-cooled, 4-stroke OHC twin-cylinder engine. Beyond basic teardown, the chapters cover cylinder compression testing, valve-seat reconditioning, valve-guide replacement and reaming, cylinder-bore inspection, and oversize piston selection. Crankshaft inspection addresses runout and connecting-rod big-end clearances.

The Lubricating oil circuit and Lubrication to crankshaft illustrations explain the oil path through the trochoid oil pump, centrifugal oil filter, and crankshaft bearings. Service sections also address the oil-filter screen and rotor. The valve-service cautions identify a specific repair hazard: excessive spring compression can damage the valve-stem seals.

Carburetor and Chassis Service

The constant-vacuum carburetor chapter explains the starting, low-speed, and primary and secondary main circuits, along with vacuum-piston operation. Its Carburetor Setting Table separates setting marks and jetting by model; the CJ addendum supplies its own settings.

Chassis sections break down front telescopic fork disassembly and rear shock absorber adjustments for varying load conditions. Steering-stem bearing service, wheel and axle checks, and rear-fork pivot-bushing inspection extend the coverage beyond routine adjustments. The CJ section also documents its rear brake pedal linkage and exhaust chamber/muffler assembly.

Electrical Diagnosis and Wiring Diagrams

Charging-system troubleshooting distinguishes no charge, insufficient charge, excessive charge, and unstable output. The Battery charging test diagram and Timing advance chart support charging-output measurements, ignition-timing checks, and spark-advancer inspection. Switch-continuity tables address lighting, stop-lamp, neutral, and ignition circuits.

Model- and market-specific wiring diagrams cover U.S., general, U.K., French, German, and European configurations, with separate CJ general/Australian layouts. Harness and cable-routing illustrations provide installation references as well as circuit information. Honda specifically warns that using a megohmmeter to test the silicon rectifier can damage its diodes.

Specification Highlights and Special Tools

Factory data provides engine and frame tightening-torque tables, standard dimensions versus service limits, fluid capacities, lubrication recommendations, and electrical test specifications. Troubleshooting tables connect symptoms such as clutch slip, difficult shifting, unstable idle, and wheel wobble with probable causes and remedies.

The special-tool lists identify the rotor puller 07933-2160000 and vacuum gauge set 07504-3000100, alongside separate piston-ring compressors for the 250cc and 360cc engines. These references show which dedicated tools the documented bench work calls for.

Always ensure your workspace is well-ventilated and strictly follow standard shop safety protocols before servicing fuel or braking systems.