1959–1966 Honda C92, CS92, CB92, C95 & CA95 Service Manual (P/N 622301)

This Honda service manual covers 1959–1966 C92, CS92, CB92, C95, and CA95 models in the Honda 125 and Honda 150 families. The preface is dated January 31, 1963, and carries the printed document code 622301.

• Engine repair: Engine removal and installation, cylinder-head disassembly, valve inspection, cam-chain installation, and cylinder, piston, crankshaft, and connecting-rod service.

• Clutch and transmission: Wet multi-plate clutch overhaul, transmission and kick-starter disassembly, shift-drum inspection, and rotary- versus return-type gear-change mechanisms.

• Fuel and lubrication: Carburetor cleaning and adjustment, model-specific jet tables, plunger oil-pump inspection, centrifugal oil-filter service, and crankcase breather arrangements.

• Chassis and brakes: Steering-head service, front-fork removal, suspension inspection, wheel and brake-panel repair, and CB92 front-brake cam synchronization.

• Electrical testing: A.C. dynamo output checks, ignition-coil and condenser tests, starter-motor service, over-running clutch inspection, and model-specific wiring diagrams.

• Tune-up and diagnosis: Ignition timing, valve tappet clearance, cam-chain adjustment, periodic maintenance schedules, and symptom-based engine, shifting, steering, and brake troubleshooting.

• CB92 Racing Kit: Engine and frame equipment, tachometer conversion parts, racing carburetor jets, camshaft changes, exhaust equipment, and alternative final-drive sprockets.

Written for Honda service mechanics, the manual covers work that uses measuring equipment, dedicated pullers, and the listed common and special workshop tools.

Cylinder Head, Crankshaft, and Transmission Repair

Cylinder-bore, piston-ring, and camshaft-journal inspections are paired with factory dimensions and repair limits. These references help determine whether worn components can be reused, reconditioned, or replaced.

The exploded cam-chain view and valve-guide air-vent section show internal relationships that matter during cylinder-head work. Tachometer-drive differences are documented for CB92 and CA95 engines, including cylinder-head interchangeability limits.

Valve-guide replacement is treated as shrink-fit work. Where suitable heating equipment is unavailable, the manual recommends replacing the complete cylinder head. Crankshaft rebuilding calls for a hydraulic press and a special jig.

The clutch section covers plate wear, distortion, spring condition, and the lifter mechanism. Transmission coverage extends to shaft bearings, bushings, gear teeth, selector forks, and shift-drum components, with gear-tooth and ratio tables distinguishing the documented configurations.

Carburetor, Oil Pump, and Breather Systems

Carburetor coverage separates Standard settings from the CB92 and CA95 power-jet arrangements. Low-, intermediate-, and high-speed adjustment discussions accompany float-level checks and sectional views.

The cleaning section warns against probing jets with metal tools, which can damage the nozzle openings. The lubrication chapter adds a lubricant-circulation diagram, oil-pump sectional views, and inspection procedures for the pump, centrifugal filter, and breather components.

Suspension, Wheels, and Brake Differences

Standard front forks and those used on CB92 and CA95 models are identified as noninterchangeable. The chassis sections distinguish CB92 rear-suspension adjustment and brake hardware from the Standard arrangements.

The front-shock section discourages dismantling the damper piston and specifies complete replacement when leakage or defects are found. Wheel-bearing checks, rim and drum runout inspections, and brake-panel service are covered alongside brake adjustment.

Verify planned work against the factory procedures and use suitable support and protective equipment for engine and brake work.

Charging, Starting, and Electrical Fault Finding

Separate wiring diagrams cover C92/C95 and CB92/CA95, supported by charging-circuit and distributor-versus-simultaneous-ignition schematics. Charging-output tables, service-tester functions, and ignition-component checks support fault isolation.

Starter coverage includes the reduction gears, brushes, magnetic switch, and over-running clutch. Harness installation notes address insulation damage at handlebar openings and the short-circuit risk of mismatched wire connections.

CB92 Racing Equipment and Production Changes

The Racing Kit chapter identifies high-compression pistons, reinforced exhaust valves, special jets, megaphone exhausts, and chassis equipment. It records the replacement of camshaft YB921416 by YB921416B with an integral tachometer-drive worm gear.

The Design Change appendix documents revised crankshaft and breather construction, pipe handlebars, and improved clutch-cable access, with the associated engine or vehicle-number references.

A Preview of Tappet and Oil-Service Data

These examples are a small selection of the adjustment and lubrication data in the manual.

The valve-adjustment section specifies 0.1 mm clearance for both intake and exhaust tappets with the engine cold.

The lubrication section distinguishes approximately 0.8 liter for a normal oil change from 1.2 liters when the oil passages and filter have been thoroughly drained.

Printable PDF, Navigation, and Wiring Detail

Text search and diagram detail: PDF text search and embedded bookmarks are not available. Small wire-color codes and closely spaced labels in the main wiring diagrams require zooming.

One printable, English-language 175-page PDF is supplied for download. The total includes 168 numbered service-reference pages, the two-page Design Change appendix, four preliminary pages, and one repeated Racing Kit page.