Honda CB250N Shop Manual Download Page 9

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Summary of Contents for CB250N

Page 1: ...T a v HIS 11 f y 3 k ill 1 mm...

Page 2: ...tents on the first page of the section Viost sections describe the service procedure through system illustration Refer to the next page for details on icw to use this manual f you don t know the sourc...

Page 3: ...sented numerically are diffferentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately For ex ample if the steps prior and up to camshaft re...

Page 4: ...with the ratio 1 1 Use multi purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Lxa...

Page 5: ...y Diamond Telescopic fork 123 mm 4 8 in Swingarm 110 mm 4 3 in Conventional type oil damper 90 100 18 54S 120 90 16 63S FR RR FR RR FR RR FR RR FR RR K300MA K327AG MT65 MT65 Hydraulic single disc Mech...

Page 6: ...ear ratio 3rd Gear ratio 4th Gear ratio 5th Gear ratio 6th Gear ratio reverse Gearshift pattern Multi plate wet Mechanical type 5 speeds 3 631 69 19 2 214 31 14 2 846 37 13 1 777 32 18 1 333 28 21 1 0...

Page 7: ...3 CARBURETOR IDENTIFICATION NUMBER The engine serial number is stamped on the lower left side The carburetor identification number is stamped on the left of the crankcase side of the carburetor body i...

Page 8: ...ot Components A WARNING Engine and exhaust system parts become very hot and remain hot for some time after the engine is run Wear insulated gloves or wait until the engine and exhaust system have cool...

Page 9: ...rand Dunlop FR RR K300MA K327AG Tire brand Yokohama FR RR Tire brand IRC FR RR V Front brake Hydraulic single disc Rear brake Internal expanding shoe Caster angle 28 30 Trail length 1 09 mm 4 3 in Fue...

Page 10: ...on Third reduction Final reduction 0 9 1 A t a 1 1 A1 Gear ratio 1 st Z 07D J 1 Ol Gear ratio 2nd 1 77ft 59 1 Rt jca 1 a u u m i 1 3 7 3 5 1 OOJ ZO Z 1 J Gear ratio 4th Gear ratio 5th 0 913 21 23 Gear...

Page 11: ...g area is within the indicated range 0 15 0 006 0 15 0 18 0 006 0 007 0 03 0 1 1 0 001 0 004 0 20 0 008 0 25 0 010 0 14 0 006 Fuel System 1 Carburetor identification number Main jet High altitude 2 3...

Page 12: ...shaft O D IN EX Rocker arm to rocker arm shaft clearance Sub rocker arm to rocker arm shaft clearance Valve lifter O D Valve lifter bore I D Hydraulic lash adjuster assist spring free length Hydraulic...

Page 13: ...0 040 0 0006 0 0016 0 015 0 040 0 0006 0 0016 0 15 0 30 0 006 0 012 0 30 0 45 0 012 0 013 0 2 0 7 0 01 0 03 N mark side facing up N mark side facing up 53 10 2 091 0 05 10 002 0 05 0 002 0 05 0 002 52...

Page 14: ...79 20 000 0 7866 0 7874 16 516 16 534 0 6502 0 6509 0 020 0 062 0 0008 0 0024 19 959 19 980 0 7858 0 7866 19 959 19 980 0 7858 0 7866 16 446 16 484 0 6475 0 6490 19 959 19 980 0 7858 0 7866 0 040 0 08...

Page 15: ...3 8 3 4 26 000 26 012 1 0236 1 0241 25 959 25 980 1 0220 1 0228 20 000 20 021 0 7874 0 7882 37 8 1 49 2 8 2 9 0 11 0 15 26 04 1 025 26 90 1 020 20 05 0 789 36 0 1 421 2 6 0 10 0 20 0 00B Cooling Syst...

Page 16: ...06 2 0 0 08 0 2 0 01 2 0 0 08 2 0 0 08 60 g 2 1 oz max 60 g 2 1 oz max i Front Suspension Fork spring free length Fork spring free length A 59 7 2 35 58 2 3 B 488 7 19 24 479 18 86 Fork spring direct...

Page 17: ...ss DOT 3 or DOT 4 10 20 3 8 3 4 To the groove T 4 0 10 16 1 1 000 1 1 043 0 4331 0 4348 10 957 10 984 0 4314 0 4324 27 000 27 050 1 0630 1 0650 26 935 26 968 1 0604 1 061 7 3 5 0 14 0 30 0 012 1 1 06...

Page 18: ...22FSR U NIPPONDENSO 0 60 0 70 0 024 0 028 10 BTDC 1 500 min 1 rpm 10 1 700 min rpm 25 3 QD0 min rpm 25 3 0O0 min 1 rpm 100 V minimum 100 V minimum 0 7 V minimum 50 180 a 0 1 0 3 fi 6 5 9 7 kSl 2 8 3 4...

Page 19: ...urface 1 0 UBS bolt 1 1 U nut 1 2 Alock bolt Do not reuse I L L iiijiiie Thread Torque Item Q ty dia mm N m kg m ft lb Remarks Lubrication System Oil pump mounting screw 3 6 10 1 0 7 Cylinder Head Cyl...

Page 20: ...14 60 6 0 43 Note 1 1 Rear axle nut 1 14 60 6 0 43 Note 1 Brake arm torque link bolt 2 8 22 2 2 16 Driven sprocket nut 4 10 45 4 5 33 Note 1 1 Brake system Pad pin plug 1 8 3 0 3 2 2 Pad pin 1 8 18 1...

Page 21: ...ng remover set 15 mm 07936 KC10000 Bearing remover 15 mm 07 936 KC 10000 Remover assembly 1 5 mm 07936 KC10500 Remover shaft 15 mm 07936 KC10100 Remover head 15 mm 07936 KC10200 Remover weight 07741 0...

Page 22: ...07914 3230001 Charging System Alternator Flywheel holder 07725 0040000 Flywheel puller 07733 0020001 Electrical Equipment Digital multimeter KOWA 0741 1 0020000 Peak voltage adaptor 07HGJ 0020 100 or...

Page 23: ...surface Cam lobes M3 4 gear spline CI gear CI bushing sliding surface M4 C3 C5 shift fork grooves Molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease Oil passage p...

Page 24: ...General information Cable Harness Routing 7 IGNITION SWITCH CONNECTORS SIDE STAND INDICATOR 1 19...

Page 25: ...General Information...

Page 26: ...General Information DRAIN TUBE 1 91...

Page 27: ...Genera Information 3 STARTER MOTOR CABLE 4 RIGHT TURN SIGNAL WIRE 6 TAIL BRAKE LIGHT CONNECTOR 1 22...

Page 28: ...the work area or where gasoline is stored can cause a fire or explosion This section covers removal and installation of the frame body panels fuel tank and exhaust system Always replace the exhaust p...

Page 29: ...lers can be removed individually Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 4 Exhaust pipe joint nut At installation install ail fasteners loosely and tighten...

Page 30: ...h the frame hooks and push the seat forward Press the rear of the seat down firmly and be sure the seat is locked on securely CAUTION Be careful not to pinch the wire harness between the seat and fram...

Page 31: ...conditions Remove the seat page 2 3 Turn the fuel valve OFF Disconnect the fuel tube Remove the mounting bolt and collar Remove the fuel tank Install the fuel tank in the reverse order of removal Aft...

Page 32: ...5 Service Access Guide 3 2 Valve Clearance 3 5 Maintenance Schedule 3 4 Oil Fiiter Screen Cleaning 3 6 Service Information Refer to Common Service Manual for items not included in this manual Refer t...

Page 33: ...n clogging replacement Parts Rear Fairing j The part required to be removed for service Seat T 13 CLUTCH LEVER Free play 12 STEERING HEAD BEARINGS Damage 11 CARBURETOR CHOKE Operation 10 HEADLIGHT Aim...

Page 34: ...free play 3 BRAKE LEVER Air bubbles in system 4 BRAKE CALIPER P3d wear 11 TIRE Wear damage pressure 10 BRAKE LIGHT SWITCH Operation 9 BRAKE PEDAL Free play height 8 THROTTLE STOP SCREW Idle speed adju...

Page 35: ...6 Carburetor Idle Speed I 1 1 I I 1 1 Note 6 Drive Chain EVERY 600 mi 1 000 km l L Note 5 Brake Fluid Note 4 1 1 R I 1 R Note 5 Brake Shoe 1 I I 1 Note 5 Brake System 1 1 I Note 5 Brake Light Switch...

Page 36: ...of removal 2 TUBE 1 SET SPRING Valve Clearance NOTE Inspect or adjust the valve clearance while the engine is cold below 35 C 95 F Remove the cylinder head cover page 7 2 Remove the crankshaft and tim...

Page 37: ...ting wrench 8 x 9 mm 07708 0030100 Valve adjusting wrench B 07708 0030400 or 07908 KE90200 Torque 10 N m 1 0 kg m 7 ft lbl Recheck the valve clearances Turn the crankshaft counterclockwise one full tu...

Page 38: ...rviced with the engine in the frame The service procedures in this section must be performed after the engine oil is drained When removing and installing the oil pump use care not to allow dust or dir...

Page 39: ...Lubrication System Lubrication System Diagram...

Page 40: ...here are no oil leaks Requisite Service Engine oil draining refill Brake pedal removal installation page 1 2 1 0 Right crankcase cover removal installation page 8 2 Procedure Q ty Remarks Removal Orde...

Page 41: ...inspection information Refer to page 1 6 for specifications Requisite Service Oil pump removal installation page 4 3 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disass...

Page 42: ...Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged Refer to section 2 for fuel tank removal and installation When disassembling...

Page 43: ...osition Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated A Flooded carburetor Engine Stalls Hard To Start Rough idling Fuel line restricted Ignition malfunctio...

Page 44: ...explosion NOTE Before removal turn the fuel valve OFF Requisite Service Rear fairing removal installation page 2 3 Fuel tank removal installation page 2 4 Carburetor draining Procedure Q ty Remarks Re...

Page 45: ...Fuel System...

Page 46: ...on almost full open to avoid pinching the diaphragm wrth the chamber 3 Spring 1 4 Diaphragm vacuum piston 1 151 ipf npprilp hnlrier 1 T o J Spring 1 7 1 Float Chamber Disassembly Order Assembly is in...

Page 47: ...5 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Battery stay mounting bolt 2 2 Battery stay 1 3 GDI unit 1 4 Connecting Tube band screw 1 Only loosen 5 Air oil...

Page 48: ...screw adjustment CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Initial Opening 1 7 8 turns out 2 Warm up the engine to operating temperature Stop...

Page 49: ...ing engine removal installation be careful not to damage the wire harnesses or cables by pinching them between the engine and frame The following components can be serviced with the engine installed i...

Page 50: ...Engine Removal Installation Engine Removal Installation 6 2...

Page 51: ...ine ground cable 3 Afternator connector 4 Side stand switch connector 5 Pulse generator connector 6 Neutral switch connector 7 Excitor coil connector 8 Gear shift pedal 9 Drive sprocket cover TO Drive...

Page 52: ...od or stethoscope If performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Compression Too Low Hard Starting Or Poo...

Page 53: ...Cylinder Head Cylinder Piston Camshaft Removal 7 2...

Page 54: ...Timing hole cap o ring 1 7 Camshaft holder nut See next page 8 Cylinder head bolt 3 J Only loosen 9 Washer 8 10 Camshaft holder 2 Disassembly assembly page 7 5 11 Dowal pin 4 12 Cam sprocket bolt 2 NO...

Page 55: ...screws fully Turn the crankshaft counterclockwise and align the T mark on the flywheel with the index mark on the left crankcase cover 1 INDEX MARK 2 T MARK Loosen the camshaft holder nuts and cylinde...

Page 56: ...Remarks Disassembly Order Assembly is in the reverse order of disassembly m Rocker arm shaft 4 Thread a 5 mm screw into each of the rocker arm shafts and pull the rocker arm shaft out of the camshaft...

Page 57: ...Cylinder Head Cyiinder Piston Camshaft Installation...

Page 58: ...t bushings 2 Thrust washer 1 Aiign the tab with the groove in the camshaft end 3 Snap ring 1 4 Cam sprocket 1 installation see next page 5 Camshaft 1 5 Cam sprocket boit 2 7 Dowel pin 4 8 Camshaft hol...

Page 59: ...r head and install the cam chain over the sprocket Install the cam sprocket on the camshaft flange and align the cam sprocket bolt holes in the sprocket and camshaft Apply a locking agent to the threa...

Page 60: ...and bolts in the sequence shown in 2 3 steps Torque Nut 23 l m 2 3 kg m 17 ft lb Bolf 1 2 N m 1 2 kg m 9 ft lb Pour fresh oil into the oil pockets in the cylinder head until the cams are submerged Po...

Page 61: ...tion page 7 6 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Spark plug 2 2 Intake pipe nut 4 3 Intake pipe 1 4 O ring 2 5 Cam chain tensioner mounting bolt 2 6...

Page 62: ...ction 9 of the Common Service Manual Requisite Service Cylinder head removal installation page 7 10 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 1 Valve s...

Page 63: ...Cylinder Head Cylinder Piston Cylinder Piston Removal Installation y m m 7 12 i...

Page 64: ...Dowel pin 2 51 Piston pin clip 4 6 Piston pin 2 7 Piston assembly 2 NOTE At installation install the piston with the IN mark fac ing towards the intake side Piston Ring Removal OrdeT Installation is i...

Page 65: ...djustsd dutch cable Damaged or bent shift fork Bent shift fork shaft Incorrect engine oil viscosfty Incorrect gearshift spindle assembly Damaged shift drum cam grooves Transmission Jumps Out Of Gear W...

Page 66: ...Clutch Gearshift Linkage Right Crankcase Cover Removai lnstaliation R 9...

Page 67: ...allation is in the reverse order of removal 1 Clutch cable 1 2 Screw 1 3 Tachometer cable 1 4 Oil cap level gauge 1 5 Crankcase cover bolt 10 6 Clutch cable stay 1 7 Right crankcase cover 1 8 Gasket 1...

Page 68: ...Clutch Gearshift Linkage...

Page 69: ...ce towards the inside and OUT SIDE mark facing out n 1 1 B Judder spring 1 Install as shown on page 8 4 9 Spring seat 1 f TO Clutch plate B 0 v_ oat witn clean engine on DeTore assemoiy 11 Clutch fric...

Page 70: ...mm Extension bar 07GMB KT70100 07716 0020100 07716 0020500 Torque 53 N m 5 3 kg m 38 ft ibl Stake the lock nut 1 CLUTCH CENTER HOLDER 3 EXTENSION BAR 2 LOCK NUT WRENCH Primary And Oil Pump Drive Gear...

Page 71: ...the reverse order of removal 1 Gearshift pedal bolt 2 Gearshift pedal 3 Gearshift spindle assembly Pull out spindle while pushing the gearshift plate in 4 Stopper arm bolt 5 Stopper arm 6 Washer 7 Spr...

Page 72: ...e bearing inserts to be sure of their correct locations for reassembly If the inserts are improperly installed they will block the oil holes causing insufficient lubrication and eventual engine seizur...

Page 73: ...efore separating the crankcase Procedure Q ty Remarks Separation order Assembly is in the reverse order of separation 1 Side stand bracket bolt 2 2 Side stand assembly 1 3 Left crankcase bolt 16 x 40...

Page 74: ...while turning the shaft Requisite Service Crankcase separation page 9 21 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal Shift fork shaft 1 2 Shift fork 3 Install...

Page 75: ...ot use worn snap rings which could easily spin in the groove They may be too loose to property seat In the groove Aiign the gap in the snap ring with the groove of spline Requisite Service Transmissio...

Page 76: ...embly is in the reverse order of disassembly 1 Collar 1 IZ d t gear 37TI 1 3 rptybushing 1 4 C3 gear 128T 1 C5 Snap ring 1 Align gap with groove of spline as shown above 6 Spline washer 1 Install with...

Page 77: ...ransmission removal installation page 9 3 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal Crankshaft mounting nut 1 Crankshaft mounting bolt 5 Crankshaft 1 Ciip 1...

Page 78: ...er weight as shown Pass the cam chain between the guide insertion part and crank balancer weight then pass it between the cam chain tensioner pin and crank balancer weight Installation is in the rever...

Page 79: ...Disassembly Order Assembly is in the reverse order of disassembly 1 Dust sea 2 At installation apply grease to the dust seal lips 2 Speedometer gear retainer 1 At installation align the tabs with the...

Page 80: ...e note the norma rotating direction When servicing the front wheel fork or steering stem support the motorcycie securely with a jack or other support under the engine Troubleshooting Hard Steering Ste...

Page 81: ...Front Wheei Suspension Steerirtg Handlebar Removal m...

Page 82: ...end weight 7 7 Handle grip E 8 Brake switch wires 2 V Jiii 9 Right handlebar switch housing screw Z no Right handlebar switch housing 1 mi Throttle cable end 2 Disconnect from the throttle grip flange...

Page 83: ......

Page 84: ...bolts first then the rear bolts 4 Handlebar weight assembly 2 5 Front brake master cylinder assembly 1 CAUTION Keep master cylinder upright to prevent air from entering the system 6 Master cylinder h...

Page 85: ...Front Wheel Suspension Steering Front Wheel Removal Installation 10 fi...

Page 86: ...depress the brake lever when the caliper is removed or it wil be difficult to refit the disc between the brake pads Procedure Q ty Remarks Removal Order Installation is in the reverse order of remova...

Page 87: ...Front Wheei Suspension Steering Front Wheel Disassembly Assembly 5 6 10 R...

Page 88: ...Front Wheel Suspension Steering...

Page 89: ...ks Removal Order Installation is in the reverse order of removal 1 Hose clamp bolt 1 2 Brake hose clamp 1 CAUTION Do not hang the caliper from the brake hose 3 Front fender bolt 4 4 Front fender 1 5 F...

Page 90: ...ront Wheel Suspension Steering Fork Disassembly 81 10 12...

Page 91: ...removal installation page 10 10 Procedure Q ty Remarks Disassembly Order 1 Fork cap 2 O ring 3 Fork spring A 4 Joint plate 5 Fork spring B After removing pour put any remaining fork oil 6 Dust sea It...

Page 92: ...Front Wheel Suspension Steering Fork Assembly 10 14...

Page 93: ...1 NOTE If the socket bolt turns with the fork piston temporarily install the fork spring and fork cap and tighten the socket bolt 9 Back up ring 1 10 Oil sea 1 NOTE Wrap vinyl tape around the fork tub...

Page 94: ...ront VVheei Suspension Steering Peering Stem Removal Installation 0 16...

Page 95: ...earings 21 12 Lower bearings 21 13 Lower bearing inner race 1 Replace if they were removed 14 Dust seal 1 Use ball race remover 07944 1 1 5O001 for upper and 15 Washer 1 lower outer race removal 16 Up...

Page 96: ...tment nut Tighten the bearing adjustment nut j S TOOL Steering stem nut wrench 07916 3710100 Torque 18 N m 1 8 kg m 13ft b Move the steering stem right and left lock to lock five times to seat the bea...

Page 97: ...ck absorber or swingarm removal a hoist or other support is required to support the motorcycle Tubeless tire removal repair and remounting procedures are covered in the section 1 6 of the Common Servi...

Page 98: ...3ear Wheel Suspension...

Page 99: ...djust the drive chain free play after installing the wheel Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Brake adjusting nut 1 2 Brake rod 1 3 Spring 1 4 Brake...

Page 100: ...Rear Wheei Suspension Rear Wheel Disassembly Assembly 1 4...

Page 101: ...set For wheel bearing replacement refer to the section 1 of the Common Service Manual Requisite Service Rear wheel removal installation page 11 2 Procedure Q ty Remarks Disassembly Order Assembly is...

Page 102: ...o support the motorcycle Requisite Service Rear fairing removal instailation page 2 3 Muffler removal installation page 2 21 Procedure Q ty Remarks Removal Order Installation is in the reverse order o...

Page 103: ...removal installation page 2 2 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 11 Drive chain cover 1 2 Right footpeg mounting bolt 2 3 Right footpeg assembly 1 4...

Page 104: ...ssembly is in reverse order of disassembly 1 Drive chain adjuster 2 2 Cotter pin 1 3 Nut 1 4 Plain washer 1 5 Rubber cushion 1 6 Brake stopper arm bolt 1 71 Brake stopper arm 1 18 Drive chain slider 1...

Page 105: ...contaminated pads shoes and clean a contaminated disc drum with a high quality brake degreasing agent Spilled brake fluid will severely damage meter lenses and painted surfaces It is also harmful to s...

Page 106: ...nated brake pad disc Misaligned wheel Clogged restricted brake hose joints Warped deformed brake disc Caliper not sliding properly Poor Brake Performance Improperly adjusted brake Worn brake linings W...

Page 107: ...t operate the brake lever to seat the caliper pistons against the pads NOTE I The brake pads can be replaced wfthout disconnecting the hydraulic system Replace the brake pads as a set I Apply a thin c...

Page 108: ...Brake System Front Brake Caliper Disassembly Assembly 1 2 4...

Page 109: ...fluid draining air bleeding Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Brake hose bolt 1 2 Sealing washer 2 3 Brake hose 1 4 Pad 2 Removal installation...

Page 110: ...nr KH oysierri...

Page 111: ...piston cups and spring must be installed as a set Requisite Service Front brake fluid draining air bleeding Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 11...

Page 112: ...Requisite Service Rear wheel removal installation page 11 2 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Brake arm pinch boij nut 1 1 f2l Brake arm 1 3 Br...

Page 113: ...Brake System 1 2 1...

Page 114: ...ke pedal slit 6 Swingarm pivot nut 17 Right footpeg mounting bolt 8 Right footpeg assembly 1 Right passenger footpeg mounting bolt 1 110 Right passenger footpeg 1 mi Brake switch spring 12 Right footp...

Page 115: ...TION The battery caps should not be removed Attempting to remove the sealing caps from the cells may damage the battery The battery can be damaged if over charged or undercharged or of left to dischar...

Page 116: ...System Location 4 ALTERNATOR System Diagram 4 ALTERNATOR 13 2...

Page 117: ...d ground line page 1 3 6 Incorrect Correct Abnormal Check the regulator rectifier unit page 13 7 i I Incorrect Correct Shorted wire harness Faulty ignition switch Faulty regulator rectifier Check the...

Page 118: ...t then remove the positive terminal Requisite Service Rear fairing removal installation page 2 3 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Negative termina...

Page 119: ...ing current do not turn the ignition switch ON A sudden surge of current may blow out the fuse in the tester Specified Current Leakage 1 mA max If current leakage exceeds the specified value a shorted...

Page 120: ...nd the positive cable a sudden surge of current to the starter motor could damage the ammeter Always turn the ignition OFF when conducting the test Disconnecting the ammeter or wires when current is f...

Page 121: ...battery if the test results are not as expected When using the KOWA multimeter remember vaiue that all readings should be multiplied by 1 00 Replace the regulator rectifier unit if the resistance val...

Page 122: ...Charging System Alternator Alternator Pulse Generator Removal Installation 13 8...

Page 123: ...1 Drive sprocket cover 1 1 n t I i euirai swiiori wire Lonncuiui 1 Mil nil Left crankesse cover bolt 7 12 Left crankcase cover assembly 1 1 J j basket 1 Ffywheel Removal Order Installation is in the r...

Page 124: ...it Always turn off the ignition switch before servicing Ignition timing cannot be adjusted since the CDI unit is non adjustable If ignition timing is incorrect check the system components and replace...

Page 125: ...ER COIL 11 NEUTRAL SWITCH 7 MAIN FUSE 20 A 8 FUSE 10 A 91 CLUTCH SIDE STAND DIODE 10 SIDE STAND SWITCH System Diagram 8 FUSE Br Bu 12 15 IGNITION 7 MAIN SWITCH FUSE 1 NEUTRAL INDICATOR 4 NEUTRAL DIODE...

Page 126: ...itch or engine stop switch Loose or poorly connected CDI unit connector Open circuit or poor connection in ground wire of the CD unit Faulty side stand switch circuit Faulty peak voltage adaptor Fault...

Page 127: ...switch When the side stand is up the side stand switch line b of the GDI unit passes to ground via the side stand switch The CDI unit monitors lines a and fb and provides spark only when one or both...

Page 128: ...der compression is normal and the spark plug is installed correctly in all cylinders Place the motorcycle on its center stand and shift into neutral Remove the spark plug caps from the plugs on cylind...

Page 129: ...same manner as at the CDI unit connector measure the peak voltage and compare it to the voltage measured at the CDi unit connector EXCITER COIL CONNECTOR BLACK RED 3 PROBE i If the peak voltage measur...

Page 130: ...ed at the CDI unit is abnormal and the one measured at the pulse generator is normal the wire harness has an open circuit or loose connections If both peak voltages measured are abnormal check each it...

Page 131: ...the Blue Yellow and Green White terminals Standard 50 T70 0 20 D C 68 D F Exciter Coil Inspection NOTE It is not necessary remove the exciter coil from the engine Remove the fuel tank page 2 4 Discon...

Page 132: ...of consciousness and may iead to death Start the engine and allow it to idle Inspect the ignition timing The timing is correct if the F mark aligns with the index mark ofi the crankcase at idle speed...

Page 133: ...the starter motor to turn it while the engine is not cranking over the starter motor may be damaged For the following component inspections refeF to the following pages for the parts locations see pag...

Page 134: ...TER RELAY SWITCH MAIN FUSE 20 A 4 STARTER MOTOR 8 CLUTCH SIDE STAND DIODE r Lg R 111 NEUTRAL SWITCH 1 91 NEUTRAL LB D 0DE 12 IGNITION SWITCH To Regulator Rectifier Br Bu 71 FUSE 10 A 12 SIDE STAND SWI...

Page 135: ...he relay coil ground wire lines as below for continuity 1 Green Red terminal clutch switch diode neutral switch fine with transmission in neutral and clutch lever released 2 Green Red terminal clutch...

Page 136: ...side stand switch Normal L Faulty side stand switch Open circuit in wire harness Loose or poor contact connector Starter Motor Turns Siowiy Low specific gravity in battery or dead battery Poorly conn...

Page 137: ...ARNiroG Turn the ignition switch OFF Requisite Service Alternator removal installation page 13 8 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Starter motor c...

Page 138: ...Electric Starter Starter Clutch Starter Motor Disassembly Assembly 15 6...

Page 139: ...y 1 3 O ring 1 4 Separator 1 5 Brush terminal holding nut 1 6 Washer 1 7 insulated washer larger 1 18 insulated washer smaller 2 9 O ring 1 lO Brush holder assembly 11 Brush and terminal 1 Align the h...

Page 140: ...ks Disassembly Order Assembly is in the reverse order of disassembly 1 Starter clutch mounting screw 3 NOTE Remove the clutch mounting screws with a impact driver At installation apply a locking agent...

Page 141: ...OFF Requisite Service Alternator removal installation page 13 8 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Starter drive gear 1 Starter driven gear setting...

Page 142: ...omponent locations see page 1 6 2 of this manual System Location for inspections refer to the ap plicable pages Component Inspection method Remarks Clutch switch Section 2 pf the Common Service Manual...

Page 143: ...Lights Meters S witches System Location 2 FRONT BRAKE LIGHT SWITCH SWITCH LIGHT SWITCH 1 6 2...

Page 144: ...the reverse order of removal 1 Screw 2 2 Setting collar 2 31 Headiight bulb socket 1 4 Position liynL bulb socket 1 5 Headlight assembly 1 6 Connectors Connection page 1 191 7 Headlight case bolt 2 18...

Page 145: ...reverse order of removal til Screw 2 2 Setting collar 2 3 Headlight bulb socket 1 141 Headlight assembly 1 5 Connectors Connection page 1 19 6 Headlight case bolt 2 7 Headlight case nut 2 8 Collar 2...

Page 146: ...lb from the socket by turning it counterclock wise and replace with a new one Installation is in the reverse order of removal 1 BULB Turn Signal Bulb Remove The mounting screw and turn signal lens Rem...

Page 147: ...edure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Meter connector 4 12 Speedometer tachometer cable 1 1 3 Meter mounting nut 4 4 Washer 4 5 Collar cushion rubber 4 4 6...

Page 148: ...installation page 1 6 3 or 16 4 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal ID Ignition switch connector 3 2 Indicator cover screw 2 3 Indicator cover 1 41 Ign...

Page 149: ...e Stand Switch Removal Installation Remove the fuel tank page 2 4 Disconnect the side stand connector 1 SIDE STANdV SWiTCH V CONNECTOR Remove the side stand switch mounting bolt and the side stand swi...

Page 150: ...NDICATOR 12V2 4W LEFT FRONT TURN S GNAL LIGHT I Turn signal dimmer l PASSlIMG HORN TURN SIGNAL PASSING DIMMER HORN SWITCH OLUTCH SWITCH SWITCH CONTINUITY STARTER SWITCH ST BA T2 FREE o o COt OB V R 61...

Page 151: ...CB250 E...

Page 152: ...park plug Wet Plug Possible Cause Clogged fuel tube or fuel strainer screen Sticking float valve Clogged fuel tank breather Faulty spark plug Fouled spark plug Faulty CDI unit Broken or shorted spark...

Page 153: ...ct lncorrect Clogged Fouled Or Discolored Incorrect Correct 10 Remove cylinder head cover and Valve Train Not Lubricated inspect lubrication Properly Brake dragging Worn or damaged wheel bearing Fault...

Page 154: ...Poor Performance at Low and Idle Speeds 1 Check ignition timing No Leak J 4 Perform spark test Good Spark Incorrect Correct I 2 Check carburetor pilot screw p Incorrect adjustment Correct 3 Check for...

Page 155: ...her Clogged fuel strainer screen Clean Incorrect Cam sprocket not installed properly Correct 5 Check valve springs Weak Faulty spring Not Weak Poor Handling Possible Cause 1 If steering is heavy 2 If...

Page 156: ...ge 0 15 0 006 0 15 0 18 0 006 0 007 0 03 0 11 0 001 0 004 Service Limit 0 20 0 008 0 25 0 010 0 14 0 006 Fuel System Carburetor identification number Main jet High altitude 2 3 11 4 Front Rear Slow je...

Page 157: ...D IN EX Rocker arm to rocker arm shaft clearance Sub rocker arm to rocker arm shaft clearance Valve lifter O D Valve lifter bore l D Hydraulic tash adjuster assist spring free length Hydraulic lash a...

Page 158: ...5 0 040 0 0006 0 0 0 1 6 0 015 0 040 0 0006 0 0016 0 15 0 30 0 006 0 012 0 30 0 45 0 012 0 018 0 2 0 7 0 01 ff 03 N mark side facing up N mark side facing up 53 10 2 091 0 05 0 002 0 05 0 002 0 05 0 0...

Page 159: ...0 000 0 7866 0 7874 16 516 16 534 0 6502 0 6509 0 020 0 062 0 0008 0 0024 19 959 19 980 0 7858 0 7866 19 959 1 9 980 0 7858 0 7866 16 446 16 484 0 6475 0 6490 1 9 959 1 9 980 0 7858 0 7866 0 040 0 082...

Page 160: ...36 1 0241 25 959 25 930 1 0220 1 0228 20 000 20 021 0 7874 0 7882 37 8 1 49 2 8 2 9 0 11 0 15 Unit mm in Service Limit 26 04 1 025 25 90 1 020 20 05 0 789 36 0 1 42 2 6 0 10 0 20 0 008 Cooiing System...

Page 161: ...2 0 0 08 0 2 0 01 2 0 0 08 2 0 0 08 60 g 2 1 oz max 60 g 2 1 oz max I Front Suspension Fork spring free length Fork spring free length A B Fork spring direction Fork tube runout Recommended fork oil F...

Page 162: ...DOT 3 or DOT 4 1 0 20 3 8 3 4 To the groove 4 0 0 16 11 0 11 043 0 4331 0 4348 10 957 10 984 0 4314 0 4324 27 000 27 050 1 0630 1 0650 3 5 0 14 0 30 0 012 11 05 0 435 10 95 0 431 27 06 1 065 26 918 2...

Page 163: ...NSO CR7HSA NGK U22FSR U NIPPONDENSO 0 60 0 70 0 024 0 028 10 BTDC 1 500 min 1 rpm 1071 700 min rpm 2573 000 mim rpm 2573 000 min 1 rpm 100 V minimum 100 V minimum 0 7 V minimum 50 180 fi o i o 3 n 6 5...

Page 164: ...surface 10 UBS bolt 11 U nut 12 Alock boit Do not reuse i tngine _____ Item Q ty Thread dia mm Torque N m kgf m Ib ft Remarks Lubrication System Oil pump mounting screw 3 6 10 1 0 7 Cylinder Head Cyli...

Page 165: ...mounting bolt Brake disc bolt Master cylinder reservoir cap screw Brake hose oil bolt Brake lever pivot nut Rear brake arm pinch bolt Other Fasteners Engine rear mounting bolt Exhaust pipe joint nut...

Page 166: ...ing inner surface Cam lobes M3 4 gear spline CI gear C1 bushing sliding surface MA C3 C5 sht fork grooves Molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease Oil p...

Page 167: ...CB250 Addendum Cable Harness Routing 1 CARBURETOR HEATER CONNECTOR 5 PULSE GENERATOR WIRE 15 PULSE GENERATOR DRAIN TUBE 19 15...

Page 168: ...CB250 Addendum 19 16...

Page 169: ...FF Route the tubes and wires properly page 19 15 Requisite Service Rear fairing removal installation page 2 3 Fuel tank removal installation page 2 4 Carburetor draining Procedure Q ty Remarks Removal...

Page 170: ...CB250 Addendum...

Page 171: ...lation hold the piston almost full open to avoid pinching the diaphragm with chamber 3 Spring 4 Diaphragm vacuum piston 5 Jet needle holder i 6 Spring i 7 Jet needle i Float Chamber Disassembly Order...

Page 172: ...t screw adjustment CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Initial Opening 1 5 8 turns out 2 Warm up the engine to operating temperature Stop...

Page 173: ...n the Brown Black and Yellow Brown terminals Standard 13 15 fl 20 C 68 F If the carburetor heater resistance is out of specification remove the carburetor page 19 17 and replace the carbu retor heater...

Page 174: ...C3250 Addendum 19 22...

Page 175: ...T SIDE mark facing out 7 Clutch center 1 i irtHpr trrtnnn J U U U C Lll EIIU 1 Install as shown on page 19 22 9 Spring seat 1 10 Clutch plate Coat with clean engine oil before assembly 11 Clutch frict...

Page 176: ...nut wrench 20 x 21 mm Extension bar O7GMB KT701OO 07716 0020100 07716 0020500 Torque 74 N m 7 6 kgf m 55 Lb ftJ Stake the lock nut 1 CLUTCH CENTER HOLDER 3 EXTENSION BAR 2 LOCK NUT WRENCH Primary And...

Page 177: ...CH CM KEATEB raw RIGHT REAR TURN SIGNAL LIGKT 12V 5 Z1W LEFT HEAR TURN SIGNAL LIGHT IGNITION COIL SIGNAL PULSE GENERATOR ALTERNATOR PASSING SWITCH HI 0AT7 Res usn Ch O color Eu ei 5 si BLACK I Br BROW...

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Honda CB250N, Shop Manual

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