Honda CB250N Скачать руководство пользователя страница 1 | Manualshive

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Содержание CB250N

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 25: ...General Information...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...Lubrication System Lubrication System Diagram...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 45: ...Fuel System...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 68: ...Clutch Gearshift Linkage...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 83: ......

Страница 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...

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

Страница 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...

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

Страница 88: ...Front Wheel Suspension Steering...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 98: ...3ear Wheel Suspension...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 110: ...nr KH oysierri...

Страница 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...

Страница 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...

Страница 113: ...Brake System 1 2 1...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 151: ...CB250 E...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 168: ...CB250 Addendum 19 16...

Страница 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...

Страница 170: ...CB250 Addendum...

Страница 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...

Страница 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...

Страница 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...

Страница 174: ...C3250 Addendum 19 22...

Страница 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...

Страница 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...

Страница 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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