Description

Daihatsu CB-23, CB-61, CB-80 1987 Workshop Manual

If you are wrenching on a Daihatsu CB-23, CB-61, or CB-80 engine and you don’t have the factory Workshop Manual from 1987, you are guessing. I don’t care how many years you’ve been turning bolts—guessing on head bolt torque, timing marks, or fuel injection timing gets you comebacks or a rod through the block. This is the 294-page binder Daihatsu Motor Co. published in June 1987 for the CB series engines found in the Charade. Every spec comes straight from the engineer who signed off on the casting. No aftermarket interpretations, no “close enough” numbers. Page 1 shows the engine code breakdown. You need that if you are sourcing parts or cross-referencing gaskets.

Let me walk you through what is actually inside this manual and why you want it on the bench next to your torque wrench, not a PDF you scroll on a phone with greasy fingers.

Engine Overhaul Coverage

Section 2 (The Engine Proper) and Section 5 (Engine Mechanicals) cover disassembly, inspection, and reassembly of the block, head, rotating assembly, and valve train. If you are replacing pistons, rings, bearings, or doing a valve job, you need the factory clearances. The manual lists them in inch-pound and foot-pound values—no metric-only nonsense. For example, the rod bolt torque spec is given on page 26 along with the sequence. Do not skip the angle-tightening procedure if your rebuild requires it. The manual warns you about it.

Fuel System: Carburetor and Injection Data

Section 6 (Fuel System) covers both the carbureted CB-23 and the fuel-injected versions. Float height, jet sizes, idle mixture screw settings—all there. If you are chasing a lean misfire or rich stumble, this section tells you where to start. The manual also includes the Manual Transmission”>manual transmission linkage adjustments? No—this is engine only. But it does reference the flywheel and clutch housing specs.

Cooling System: Thermostat, Fan, and Radiator Flow

Section 8 (Cooling System) is not a paragraph. It’s a full chapter with flow diagrams, thermostat opening temperature (test procedure included), and water pump torque values. Overheating kills these little engines fast. The manual tells you the correct coolant capacity and mix ratio. Do not use a generic chart.

Does This Manual Cover the Turbocharger System?

Yes. Section 9 (Turbocharger System) is specific to the CB-80 turbo engine. Wastegate actuator rod length, compressor housing bolt torque, oil feed and drain line routing—all in there. If you are rebuilding a CB-80 turbo, you need the oil clearance specs for the center housing. This manual gives them. Do not use a generic rebuild kit without checking those numbers.

Electrical System: Wiring Diagrams and Component Tests

Section 10 (Engine Electrical System) covers the alternator, starter, ignition system, and sensors. Cranking voltage, resistance values for the pick-up coil, distributor cap alignment marks—all from the factory. If you are diagnosing a no-start on a Charade with a CB-61, the manual walks you through the ignition timing procedure with a timing light. it even shows the spark plug gap range in inches.

Who Needs This Manual?

If you are a DIYer pulling a Daihatsu CB engine from a junkyard Charade and dropping it into a tube-frame buggy, you need the Daihatsu Charade Chassis Workshop Manual 1987″>Daihatsu Charade Chassis Workshop Manual 1987 for the mounts and drivetrain. But for the engine itself, this is the only source that has the correct valve adjustment procedure (Section 3) and the compression test specs. Professional mechanics will appreciate the exhaust emission control section (12) for pre-catalytic converter adjustments.

Related manuals you should check: Daihatsu 4 Wheel Drive Workshop Manual”>Daihatsu 4 Wheel Drive Workshop Manual if your Charade is a 4WD variant, and the Massey-Harris-Ferguson TEF20 1956 Workshop Manual – OEM Specs”>Massey-Harris-Ferguson TEF20 1956 Workshop Manual – OEM Specs if you are into old iron. But that’s a different flavor.

Source Authenticity: Why OEM Matters

This is a scanned copy of the actual Daihatsu Motor Co. publication No. 9173-GE. No aftermarket rewrite. No third-party “compilation.” The Manual Transmission”>manual transmission section does not appear because this is an engine-only manual. That is honest. If you trust a Haynes manual to tell you the correct piston-to-wall clearance, you are rolling dice. Haynes use generic ranges. This book gives the specific value for each bore size grade. That is the difference between a engine that lasts 100,000 miles and one that burns oil at 20,000.

What torque values are specified in the manual?

Foot-pounds for head bolts, main bearing caps, connecting rods, and flywheel. Inch-pounds for smaller fasteners like intake manifold bolts and valve cover. The manual also gives turn-of-nut angles for rod bolts where required. All values are in imperial units.

Does the manual include a troubleshooting guide for the fuel system?

Section 6 includes a fuel system diagnosis table. It lists symptoms like “engine hesitates on acceleration” and gives the likely cause (clogged jet, incorrect float level, leaking vacuum line) and the corrective action. It also includes carburetor adjustment specifications for idle speed and mixture. For fuel-injected versions, it covers throttle position sensor resistance and fuel pump pressure.

That is the honest summary. I have been burned by aftermarket manuals that skip the one torque value you need. This book has it. If you are working on a CB-23, CB-61, or CB-80, don’t take shortcuts. Access the Factory Manual and have the specs on your bench.