Honda 1994 NSR 250 SP Setup Manual Download Page 1

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Summary of Contents for 1994 NSR 250 SP

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Page 2: ...inaccuracies may have occurred during translation Please verify any part numbers with the supplying dealer or original HRC Manual before ordering These parts are specially manufactured for racing Ther...

Page 3: ...tor 1 11 ii Installing the radiator set 1 11 9 Steering Damper set 1 12 i Steering stopper 1 12 ii Installing the steering damper 1 12 10 Front Brake Hose set 1 13 i Removing the standard brake hose 1...

Page 4: ...h ii Hold handlebars and tilt the machine on either side two or three times to drain the air inside iii Top up the radiator with cooling water if the level has become to low iv Fit the cap tightly v C...

Page 5: ...ift the gear lever into first vi Raise the choke lever vii Start the engine pushing the machine bump start viii Slowly warm up the engine Lower the coke lever when exhaust gas is released CAUTION It i...

Page 6: ...e speed idling when in neutral 4 Points to check when running i Is the indication on the temperature indicators and the tachometer appropriate ii Do all the controls work smoothly iii Do brakes work p...

Page 7: ...ipes Cone plugs 4x5 96205 04005 2 Overflow drain tube Remove the overflow drain tube then fix the cap in the kit Cap 16215 MV4 000 Parts to be exchanged 1 Power jet needle jet holder Remove the front...

Page 8: ...le valve then turn down the throttle valve iii Remove the valve plate and the jet needle from the throttle valve iv Assemble the parts by the reverse process CAUTION A washer must be fitted between th...

Page 9: ...MJ number JN grade AS reverse degree adjustment check OK Select main jets by straights check adjust sizes check OK Select jet needles straights getting starts at a corner Select jet needles grades fro...

Page 10: ...the holes on both sides of the box with a screwdriver viii Ensure that the 100 jet of the Y joint is fixed to the No 1 solenoid 50 jet is fixed to No 2 solenoid ix Insert the tube in the Y joint then...

Page 11: ...ol petroil is used therefore remove it and press the sealing plug 20 in Sealing plug 20 91201 NH3 003 Apply adhesive to the cone plug 4 5 x 8 then press it in the crank case Cone plug 4 5x8 90807 NKD...

Page 12: ...ghtening torque 1 0kgf m 7 A C GENERATOR 1 Installing the A C generator in the kit i Remove the L crankcase cover ii Remove the standard flywheel with specialist tool Flywheel puller 07733 0010000 Fly...

Page 13: ...the radiator stay to the radiator iv Fix the mounting rubber collar to the mounting stay v Install the radiator in the body so that the wiring harness stays outside the upper mounting stay vi Temporar...

Page 14: ...e bolt of the handle bar and remove R L iii Fix the steering damper stay iv Cut the stopper boss of the handle bar attach it to the front fork and fasten the bolt temporarily v Fit the top yoke Tighte...

Page 15: ...olt does not affect steering operation and brake hoses then fasten the hoses with tie wrap iv Loosen the bleed nipple of the callipers pour brake fluid in with a syringe until fluid comes out in the b...

Page 16: ...changed in a set Ensure that abrasion of the pads is measured before using The pads Z22W for racing is abraded faster than TT2501 owing to its importance of controlling Exchange pad securing pins regu...

Page 17: ...htening torque 1 2kgf m v Fix the R rear set to the frame body vi Install the L foot peg hanger with a collar adjusted Thickness of collars UP LOW UP t 10 LOW t 15 Length of bolts R L R 8x28 L 8x34 Ti...

Page 18: ...ght of the exhaust port both sides if it does not adjust it by adjuster A v Turn the adjuster B of the power valve cable until the pulley does not shake vi Tighten the lock nut D E of the adjuster A B...

Page 19: ...mm Position of rebound adjuster Reverse 7 clicks from MAX Reverse 7 clicks from MAX Brand of Oil lot number Honda fork oil 10 Honda fork oil 10 Honda fork oil 10 A kit is set up to the standard spring...

Page 20: ...om case protected it with a cloth to prevent oil from scattering Never loosen the locknut of the damper COMP Carrying out exchanging R L sides separately Closely coiled side of the spring should face...

Page 21: ...net Standard k 12 0kgf mm Kit k 11 0 13 0kgf mm 5 Exchanging the rear shock absorber i Insert a jack between the step stand or rear type and the seat rail to prevent the frame from dropping ii Remove...

Page 22: ...e straight of the course It is unnecessary to adjust tension of the chain when exchanging tyres however check it every time you drive Ensure that the lock nut has been tightened then lock it with wire...

Page 23: ...ove taping of the SP harness and connect it iv Pass the harness through the frame body the fix them with tie wraps CAUTION Wiring work should be done carefully do not damage by the edge of frame etc v...

Page 24: ...P 0 1 0 q Using the same card as before Display of water temp below 35 C C digital display over 35 C actual temp SP approx 0 5sec C ready to run P 0 1 0 ii When digital display shows P101 the machine...

Page 25: ...l has been carved as an indication of the marking position DRIVE DRIVEN 14T 15T 16T 36T 37T 38T 106L 39T 40T 41T 108L 42T 43T 110 108 L Recommended Ratio Tsukuba A Set up the transmission of KV3 90 94...

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Page 29: ...t brake pad 2 9 F 4 Rear sets 2 10 F 5 HRC card set 2 11 F 6 Spark plug set carburettor box set 2 12 F 7 Engine mounting rubber set 2 13 F 8 Radiator set 2 14 F 9 Connecting hoses 2 15 Lot number inde...

Page 30: ...with in quantity column are optional parts Composition of part numbers e g General Parts 77777 777 77 7 77 Main lot number Model Alteration Part colour Manufacturer division e g Bolts nuts and other...

Page 31: ...the connecting hose in block N F 9 Ind N Part N Items Price Y Quantity Note Ind N Part N Items Price Y Quantity Note 1 06121 KV3 950 Cylinder set A 37 900 2 Cylinder Piston adapting list 06122 KV3 95...

Page 32: ...ntake rectifier 500 2 3 15611 NH3 000 Oil filler cap 350 1 4 19300 NKD 970 Thermostat seal 300 1 5 23801 NH3 000 Drive sprocket 15T 2 900 1 23802 NH3 000 Drive sprocket 16T 3 020 1 6 31100 NKD 970 A C...

Page 33: ...W 15T 10 900 1 23210 NKD 951 Main Shaft COMP D 15T 10 900 1 3 23421 NKD 940 Counter shaft first gear 36T 9 500 1 1 4 23451 KV3 830 Main shaft third fourth gear 19T 21T 6 200 1 1 5 23481 KV3 830 Count...

Page 34: ...101 393 1850 Main jet 185 300 2 16132 NKD 970 Jet needle J8YB mark 1 260 2 2 765 99101 393 1880 Main jet 188 300 2 16133 NKD 970 Jet needle J8Yc mark 1 260 2 2 775 99101 393 1900 Main jet 190 300 2 99...

Page 35: ...00 1 3 53700 NF5 762 Steering damper ASSY 23 700 1 4 53705 NF5 760 Steering damper holder ASSY 10 000 1 5 53710 NF5 752 Steering damper stay ASSY 6 760 1 6 53713 NC8 000 Steering damper spacer 540 3 7...

Page 36: ...drive sprocket 37T 8 530 1 41238 NL0 841 Final drive sprocket 38T 8 530 1 41239 NL0 841 Final drive sprocket 39T 8 530 1 41240 NL0 841 Final drive sprocket 40T 8 530 1 41241 NL0 841 Final drive sproc...

Page 37: ...rice Y Quantity Note 1 06451 NKD 970 Brake hose set 8 500 1 2 45105 MN8 006 Brake pads COMP TT2501 2 750 4 endurance 45105 NKD 970 Brake pads COMP Z22W 2 600 4 racing 3 45124 NKD 970 L front brake hos...

Page 38: ...08050 0A Hexagonal nut 8x50 50 1 21 92201 08055 0A Hexagonal nut 8x55 50 1 6 46501 ND4 750 Pedal rubber 380 2 22 94002 08020 0S Hexagonal nut 35 1 7 50222 ML0 000 Engine hanger front upper collar 350...

Page 39: ...ity Note Ind N Part N Items Price Y Quantity Note 1 06111 NK3 971 HRC card set 0 0 22 000 1 2 30440 NK3 970 PGM HRC memory card 010 15 500 1 Dry 3 30440 NK3 980 PGM HRC memory card 020 15 500 1 Wet 4...

Page 40: ...1 06113 NKD 970 Spark plug set 12 000 1 2 17210 NKD 970 Carburettor box set 35 000 1 3 30700 ND5 751 Noise suppresser cap ASSY 2 600 2 4 31930 ND5 003 Spark plug 10 2 600 2 5 31940 ND5 003 Spark plug...

Page 41: ...ains all the components of F 7 Ind N Part N Items Price Y Quantity Note Ind N Part N Items Price Y Quantity Note 1 06460 NKD 970 Engine mounting rubber set 28 000 1 2 50210 NKD 970 Rubber mount A 5 60...

Page 42: ...06022 00 Flange bolt 6x22 50 1 4 19052 KA3 830 Radiator mounting collar 215 2 19 96300 06025 00 Flange bolt 6x25 50 1 5 19100 NKD 970 Radiator COMP 120 000 1 6 19112 NKD 970 Upper radiator front cover...

Page 43: ...place of a front head COMP for kit radiator NOTE 2 No 2 rear thermo hose is used in the same way as No 1 water hose A for standard radiator Ind N Part N Items Price Y Quantity Note Ind N Part N Items...

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Page 47: ...1 970 x 650 x 1 045mm Wheelbase 1 340mm Seat Height 770mm Ground Clearance 130mm Caster Angle Trail 23 00 85mm Front 41mm rwu telescopic forks adjustable preload adjustable rebound Suspension Rear Pro...

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Honda 1994 NSR 250 SP, Setup Manual

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