“'1 'T7 "fl "fl '“I '“I ‘TTI 7:3 773 TE? TY ’:flt ET? HONDA 250R HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 14 describe parts of the motorcycle, grouped according to location Find the section you want on this page, then turn to the table ol contents on page 1 01 that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. 'he subsequent pages give detailed procedures for the section I! you don’t know what the trouble is, go to section 15, TROUBLESHOOTING. This shop manual IS based on the 1979 250R, SuL‘r sequent year models service procedures and data are given With addendums, beginning with section 16. ALL INFORMATION AND ILLUSTRATIONS IN~ CLUOEO IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILA~ SLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO” LTD. RESERVES THE RIGHT . TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGA- TION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRO- : DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR COT, LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION .51 LUBRICATION E INSPECTION AND ADJUSTMENT I] ENGINE FUEL svsrem :3 ENGINE REMOVAL 8. INSTALLATION E CYLINDER HEAD/VALVE l3 CYLINDER/PISTON E2 CLUTCH/GEARSHIFT SPINDLE [:1 AC GENERATOR El TRANSMISSION/CRANKSHAFT Ill CHASSIS FRONT WHEEL/BRAKE/SUSPENSION IE! REAR WHEEL/BRAKE/SUSPENSION ‘4 SEAT 8t FUEL TANK IE IGNITION SYSTEM ‘1' TROUBLESHOOTING : ‘80—'31 ADDENDUM ‘ I '82 ADDENDUM fig Date of Issue September, 1981 © Honda Motor Co, Ltd, HONDA Z 50R MEMO D-tl of luv-1 509., 1990 © HONDA MOTOR CO , LTD I“. l-.. L“ l... L lam I. A 'L— I.“ 1., l... I... 1.. I.” F j TY] 773 ":3 'TTL ‘77 "T3 ‘7? T71 ":3 “"3 HONDA 250R GENERAL . INFORMATION GENERAL SAFETY SERVICE RULES SPECIFICATIONS TORQUE VALUES TOOLS WIRING DIAGRAM CABLE AND HARNESS ROUTING MAINTENANCE SCHEDULE 1-5 1—6 1—3 GENERAL SAFETY l o If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exhaust can tains poisonous carbon monoxide gas. 0 Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flame: or sparks in your work area. SERVICE RULES . Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do not meet HONDA's design specifications may damage the motorcycle. . Use the special tools designed for this product. Install new gaskets, O-rings. cotter pins, lock plates, etc. when reassembling. . When torquing bolts or nuts, begin with the larger diameter or inner bolt first, and tighten to the speCIfied torque diagonally in 2—3 steps, unless a particular sequence is specified. before reassembly. Dot. of In" 1 Sm 1978 . After reassembly, check all parts for proper installation and operation. , Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. . Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces Z50R GENERAL INFORMATION SPECIFICATIONS HON DA Item Metric Engllsh I DIm;SIOnS I Overall length 1,300 mm 51.2 in I ‘7 Overall wldth 623 mm 24.5 In 1 ‘ Overall height 360 mm 33.9 in I 3 Wheel base 895 mm 35.2 ln Seat height 590 mm 23.2 in I ' F at oeg height 220 mm 8.7 in 1 . rcono clearance 140 mm 5.5 m ‘ i Dry weight 52 kg 115 lb Frame Type Backbone I I Front suspension Telescopic fork 1 I Rear suspension Swing arm I I Front tire size 3.50—3~21>R I I Rear tire size 3.50—3-2PR I From 1.0 kg/cm’ 14 psi ‘ Cold tire pressures Rear 1.0 kg/cm2 14 psi I Front brake V Internal expanding shoe 1 I Hear brake Internal expanding shoe I I Fuel capacity 4.5 lit 1.19 us gal I 3 Fuel reserve capaclty 1.0 lit 0,26 us gal : CasteTIDegrees lrorn'norizomal) 25° 1 ‘ Trail 42 mm J 1.7 in I From fork oil Grease 2 Engine lLrype Air-cooled, 4 stroke OHC I Cylinder arrangement Single 80° inclined from vortrcel I Bore and stroke 39.0 x 41.4 mm 1.535 x 1.6301n Disp|acement 49 cm2 3.0 cu m 1. Compression ratio 8.8xi ' Valve train ‘ Oil capacity Chain driven overhead camshaft 0.8 lit If 0.21 us gal Lubrication system Forced and wet sump I Cylinder head compression pressure 120 kg/cmz 71,000 rpm I 163 psi I Opens 7° BTDC (at 1mm Iiitl . Intake valve 0 t Closes 12 ABDC (at 1mm lift) I Opens 22“ eeoc lat 1mm lirtl I Exhaust valve e ‘ I Closes 2 ATDC lat hm hm ‘ 1N 0.05 mm 0.002 in I Valve clearance (cold) _ , EX 0.05 mm 0.0021n 1 Idle speed 1500: 100 rpm I I Engine dry weight 17 kg I 37511: . Dita 1978 J J lmhhhhlmlg..l.m L... I... I“. L; HONDA Z 5 O R 5“ GENERAL INFORMATION 17 " E ltern Metric English ‘L ‘Carburetlon ‘ Carburetortvpe Piston valve r l 1 Venturi dlarrreter 11 mm 0.43 ln \ i ‘ Setting number E Air screw opening fl ‘ Float level 12.7 mm 0.50 in I‘ :Drlve tram Clutch Wet mu!ti—plate automanc (centrilugall F ‘ Transmission 3-speed constant mesh : Primary reduction mm) 3,722 __ Gear ratio | 3,181 l - 1 Gear ratio ll_ 1,823 ‘ ‘ Gear ratio lll 1,190 l— 1 Bar ratio IV — t: l Gear ratio V — A Flnal reduction ratio 3,083,37/12 f ‘ Gear shift pattern Left foot operated return system N~1—2—3 \ ‘Elactrlca! lgnltion Flywheel magneto i— ‘ Alternator Flywheel ’~ Starting system Kick start 5“ spark plug U.S.A. type NGK CGH DENSO U2OFS ; Canada tvpe NGK caeHs DENSO UZOFSR-L ’ 3 . Spark plug gap 0.6—0.7 mm (1024—0028 m l l ,_ l t 5— I ,7 V t , , l ,_ um al Issue :Sen. I978 . _ a GENERAL INFORMATION 150R HONDA TORQUE VALUES ENGINE Item Q'ty Thread dia (mm) Torque kg»m (ft-lb) 1 Valve adjusting hole cap 2 I 30 1.0~ 1.4 17 ~ 101 1 Valve adjusting lock nut 2 5 0.7 ~ 1.1 15 ~ 81 1 ' 1m; head cover nut 4 a 0.9 ~ 1.2 (7 ~ 91 am sprocket bolt 3 5 08 ~12 16 ~ 9) :Eylinder 5011 1 6 03 ~12 15 ~ 91 1 "tea ciérrkcase cover screw 3 e 0.7 ~ 1.1 15 ~ 81 1 I F1vwhee1 nut "_H 1 10 3.0 ~ 3.8 122 ~ 271 1 Eiilticr‘amgguvev screw ‘ a e 0.7 ~ 1.1 15 ~ 8] 1 r1:100:11 outer nut 1 14 3.5 ~ 4.5 125 ~ 331 Shift drum stopper bolt 1 6 0.9 ~ 1.4 (7 ~ 10) [ rDram pTug 1 12 2.0~3.o 115~221 1 BK; 2513:1352,“ 2 e 0.8 ~ 1.2 16 ~ 91 FRAME Item o‘ty Thread die (mm) Torque kg-m [flvlbl 1 Steering stern nut 1 24 6.0 ~ 8.0 143 ~ 581 1 131159 bridge boIt 2 10 1.s~2.5 113~101 irgmafliiuz 1 12 3.5~5.0 125~361 A Rear mm ‘ 1 12 3.5~5.0 125~3e1 IS;;<7absorberir11:t ’ I‘m 4 10 2.5 ~ 3.5 110 ~ 251 ‘1 '51Erm 511011 .11 J 1 10 2.5~3.5 110 ~ 251 Engme hanger huh I 2 s 2.0 ~ 2.5 115 ~ 181 ; Dr1ven sprocket bolt 3 s 1.8 ~ 2.3 113 ~ 171 1 Torque specifications listed above are for the most important items. If a torque Specification is not listed, 1ollow the standards given below. STANDARD TORQUES Item Torque kg-m (ft-lb) Item Torque kg-m (ft-lb) 5 mm 501:, nut 0.45 ~0.6 13.3 ~ 4.31 5 mm screw 0.35 ~ 0.5 12.5 ~ 3.614 5 mm 5011, nut 0.8~1.2 1e~91 6mm screw o.7~1.1 15~81 ._§_m_m MEAEM” 1.8 ~ 2.5 113 ~ 18) 6 mm flange bolt, nut 1.0 ~14 17 ~10) >10 migi; 11141 3.0 ~ 4.0 122 ~ 291 8 mm flange bo|1,nut 2.4 ~ 3.0 117~ 221 j 12 mm bolt, nut 5.0 ~ 6.0 136 ~ 431 10 mm flange boh, nut 3.0 ~ 4.0 122 ~ 291 J C I... I. ... l.. 1 I! I3. I“... I... L... L- ‘uu 0.] """il ewe] ll ”“7 ""l ""0 ,"1'1 NT") "‘7“; ’ W... “flvf‘j “"l ”l HONDA Z 5 O R ‘(jENEVRAL INFORMATION TOOLS SPECIAL TOOLS COMMON TOOLS Tool name Tool No. Tool name Tool No. Float level gange 72401~0010000 <—'—~ _ Plrl spanner, 36 mm 0790240010000 Pin Spanner 07702~0010000 I ‘ Valve adjusling socket wrench l l 07908—001000!) Tappet adjusting (B) Tappet adiusting wrench 8 x 9 07708—0030400 0770870030100 ‘ Lock nutwrench. 14 mm i777 ,. 07716—0010100 a ‘ Flywheel holder 07925—0010001 Universal holder 07725—0010101 i Flywheel puller 07933—0010000 Flywheel & Rotor puller 07733—0010000 l Valve guide remover 07942—3290100 Valve guide remover l5.5 mm) 07742—0010100 ‘ Valve gulde drlver 0794 2—3290200 Valve guide driver [Bl 07742—0020200 Bearlng drlver 0794 7—0450000 Bearing driver outer 32 x 35 Bearing driver pilot (12 mm) 07746—0010100 0774670040200 l l r l ‘ Driver handle 07949—2860000 Bearing dr'wer handle (A) 07749—0010000 Valve sorlng compressor 07757—0010000 (h.— ‘ Valve guide reamer 548 mm 07984~0980000 <——_ l Clutch Outer holder 07923—040000!) Universal holder 07725v001010l ‘ Shock absorber compressor 07959—3290001 Ball race driver/remover 07944~1150001 9.— Dlu 0! Imt : Sop. |97E re) HONDA Moron Cu. LYD. 1-5 m. o H 250R GENERAL INFORMATION WIRING DIAGRAM ,4- 41 4' a! 4i 1:— .s- .2- 3.. In .I- is 4‘ g— :35 225%»; 5.5 OIIIO io :31 OIIO to o m c. w I o m :3:onIot>>w88m262m 03:55 . a %._. > 5252393315.: >80 3: 3m _ ism _ 88¢ _ _ doozoEzo. IMM— 2233.35 :35 18:5 “65 555 v.35 222,285 322: fingWIILA 223185 520 LV. r620 DIII of lull :SIIL 1973 (E) HONDA MDYOR ‘30., LTD. 1-8 MT} A-_ J 0”} 1"] "4'3 "N“: 7"} 7'7 ”"1 ""T ”(A'Ml ”3 ””1 ""7 "WW " “’3 HONDA é Z50R CABLE AND HARNESS ROUTING THROTTLE CABLE GENERAL INFORMATION ‘)\\’ C II. WI RE BAND / WIRE HARNESS HIGH TENTION WIRE o‘ . w IGNITTION COIL :‘ \ - PRIMARRY LEAD ‘x \ x / \ V F UELBREATHER A.C‘ GENERATOR TUBE WIRE j ‘ CRANKCASE BREATHER TUBE BRAKE CABLE om. of|sn:$op.1978 ,. 1.- 7 - .mum ulhvfln »n .v.‘ ' Mw ,‘. HONDA ZSOR GENERAL INFORMATION MAINTENANCE SCHEDULE The maintenance lntervales shown in the following schedule are based upon average riding conditions. Machines sublecled to severe use, or ridden in unusually dusty areas, require more frequent servicing, Items marked ”should be serviced by an author» lzed Honda dealer, unless the owner has prover tools and is mechanically qualilied. OKher maintenance iiems may be serwced by the owner. CA UTIOfl I To maintain ihc safety and reliability of your HONDA motorcycle, do not modify the motorcycle and me genuine HONDA ‘ part: or their equivalent when xervl'cz’rzg or repairing. 7712 use of other replacement parts which are no! ofeqmvalcrliquall’ry may impair the operation of your motorcyclei ! WARNING To prevent personal injury, always make certain the engine is stopped and the motorcycle is supported securely on a level Surface prior to performing any maintenance. \ FREQUENCY ”INITIAL 4‘0 ‘ or y l “9%" gr REFERENCE l -\ /\\ (3 l 43$ -\ PAGE r ITEM to ‘0 0“ l Fuel Llne I 4—1 1 Thronle Operation I I 3—4 r . Carburetor Choke I l — 1 Air Cleaner 0 3—6 l Valve Clearance I I 3-3 l l Clutch I I 3—5 l l Contact Breaker Points/Ignition ‘: Timing I I l 3‘2 Carbureior Idle Speed I I 345 l ” Engine Oil R 2—2 3 Drive Chain I, L I, L 2—5 l Brake Svslem I l I 3—6 3 ; Tires I I 11—2, 12—2 ‘1 Nuts, Bolts, Fasteners l 1 1—4 r 1 Spark Arrester c 3—3 1 ll Sleerlng Head Bearing A 11:3 ‘1 - FlrSl week of operation “ Replace englne oil every 30 operating, days or 3 monlhs, whichever comes first. l lnspei, Clean, Adjust, Lubrlcale or Replace if necessary c Clean R ~ Replace A: Adjust L: Lubricate 1 -R Dat- cHsfin : Sun. 1978 muonnA MO‘YOR no in) ,3 I...l a... a; I... L; I, I m w H 250R F? F ‘ .H MEMO 7:5 F 1,: AL! 7. ,z r: F: Pin, f . in r; .11 L T: ,‘ Data oi Isue ‘San 1978 « ,M HONDA zson LUBRICATION BIL PUMP RIGHT CRANKCASE RIGHT CYLINDER _ CYLINDER CYLINDER HEAD HEAD SIDE coven CAMSHAFT CRANKCASE l i RIGHT CRANK- CLUTCH ADJUST- CENTRIFUGAL CASE COVER _‘ me BOLT _ OIL FILTER CRANKCASE O h am 0919:. ~5np. 1973 I», 4;..‘ Em C.“ ””1 ”"1 T"? ”“1 "“"l """I ”‘”'I ”“7 "’"J r T"? 7"] "INT "”1 7"”) ""1 ""I ""1 "T HONDA Z 5 O R 2. LUBRIOATION SERVICE INFORMATION 2—1 OIL PUMP REMOVAL/ 2—3 DISASSEMBLY TROUBLESHOOTING 2—1 I on. PUMP INSPECTION 24 ENGINE OIL LEVEL 2—2 I OIL PUMP ASSEMBLY/ 2—5 ; ENGINE OIL CHANGE 2—2 INSTALLATION I E ENGINE OIL ROTOR FILTER/ 2-2 DRIVE CHAIN 2—5 I SCREEN i LUBRICATION POINTS 2—7 I GENERAL INFORMATION The on pump can be disassembled with the engine in the framer V SPECIFICATIONS Forced and wet sump 0.8 lit (0.21 us qt) HONDA 4~STROKE OIL or an equivalenk API service cIassIfication — SE Vlscoslty: General, all temperamres SAE row-4o Alternate ‘ Above 15°C (60°F) SAE 30 40° — +15°c (15°—60°F) SAE 20 or 20w Above “10°C (15°F) SAE zowso I Below 0°C (32°F) SAE 10w STANDARD SERVICE LIMIT iOTJTEr roxomobody clearance 0.10—0.15 mm (coca—0.006 in) 0.20 mm [0.008 In] } TIp clearance 0.15 mm (0,006 in! 0.20 mm (0.008 in) I Rotor-to-cover clearance 0024.07 mm mom—0.003 in) 0,12 mm (00005 In) TROUBLESHOOTING OII level mol low I Normal oil consumption 2 External OII leaks 3 Worn piston rmgs Low on pressure 1 Plugged oil screen 2 Main on pump worn High oil prassure 1 Plugged oil screen, gallery, or oil control orifice 2 Incorrect ail being used No ail pmsuro 1 Oil level (00 low 2 Oil pump shaft pin sheared or missing Due 01 Imu- , Sap. I973 re~ HONDA MOTOR co,, LTD. LUBRICATION ENGINE OIL LEVEL Stop the engine and hold the motorcycle upright. Check the CHI level with the filler cap/dip- stick after 245 mlnules, if the level IS below the lower level mark on the dipstick, fill to the upper level mark. NOTE UPPER LEVEL MARK LOWER LEVEL MARK i l SPECIFIED LEVELl .33?“ screw in the esp when making (his check ENGINE OIL CHANGE NOTE i Drain the oil with the engine warm. Remove the oil filler cap dipstick and drain plug, and draln the oil. install the dram plugr FlII the crankcase with the recommended oil. Check the oil level with the filler cap/dip- stick after 2—3 minutes. Install the Oil filler cap. ENGINE OIL FILTER AND SCREEN Drain the engine oil, Remove the foot pegs and kick starter arm. Remove the right crankcase cover. Remove the clutch outer cover, CENTRIFUGAL FILTER CLEANING Clean the clutch outer cover and the inside cl the clutch outer using a clean, lintfree cloth. [Q11 Do not allow dust and dirt to enter the crankshaft oil passage. Do not use compressed airt OIL FILTER SCREEN CLEANING Remove the oil filter screen from the crank- C3564 Clean the filter screen, DRAIN PLUG 2.0—3.0 kg-m (15—22 I‘L-lb) 2-2 om oflmio:Sop.1578 © HONDA MOTOR 00., LTD. I I 1...: h J i ""1 7'7 ”“1 "'7') "WI "”1 ”-7, reel ,‘w " ‘1 HONDA 250R LUBRICATION OIL PUMP REMOVAL /DISASSEMBLY Dram the engine oil. Remove the kick starter pedal and foot peg; Remove the right crankcase cover. Pull out the clumh lever, lifter, ball retainer and dutch cam. Remove the c‘urch outer cover and clutch assemb‘y Remove me three oil pump mounting screws and oil pump. Remove the khree cover screws and remove the oi! pump cover. Pull out the pump shah and remove the inner and outer rotors from the pump body, Date a! Issue :Sep. 1975 0 Q OIL PUMP INSPECTION Check the inner and outer rotors. Replace as a se‘ if damaged or scratched. Measure the pump tip clearance Measure me pump bodv clearanoe‘ Measure the pump side clearance. HONDA Z 5 O R LUBRICATION SERVICE LIMIT 02mm (0008 In) SERVICE LIMIT 0,2mm (11008 In) SERVICE LIMIT onmmoooS/ + On. o! In" 1 Sup. 1978 I.“ I.“ LA In} I...» L‘I l... lab. Is... hI [W W I“? I... In“ 1..-! L; In“; ‘10" {‘3 'M 7 WW] """I ""‘l "‘7 "“‘I ”WI ""1 I— i : ”TI “TI ""1 "I HONDA 250R LUBRICATION OIL PUMP /ASSEMBLY INSTALLATION Install the outer and inner rotors into the pump bodv‘ Install the pump shaft. Install a new cover gasket. Secure the gasket and cover with the three screws. NOTE I Make sure that the pump rotates freely. OIL PUMP INSTALLATION Install the oil pump with the gasket under It by aligning the rotor shaft with the groove of the cam chain guide spindle. CAM CHAIN GUIDE SPINDLE DRIVE CHAIN NOTE Commercial aerosol type drive chain brlcants are recommended, Normally, drlve chaln Iubricatlon is performed at the time of chain adjustment. Saturaxe each chain link ioints so that the lubricant penetrates between the link plates, pInS, bushings and rollers. LUBRICANTS Date of Ini- :Sopv I978 4‘ HnNnfl Mn'rnn [‘0 IT“ LUBRICATION When the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication. Carefully remove the master link retaining clip with a plier. Do not bend or twist the clip. Remove the master link. Remove the drive chain from the motorcycle. Clean the drive chain in nan-flammable or high flash point solvent and brush, and allow to dry. Inspect the dllVe chain for possible wear or damage. Replace any chain that is excessively worn or damaged. Inspect the sprocket teeth for possible wear or damage. Replace it necessary. Never install a new drive chain on badly wom xprockerx or a badly worn chain on new sprockets. Both chain and ‘ sprockets must be in gaad condition, or The new replacement chain or sprockets will wear rapidly. Lubricate the drive chain. Install the drlve chain. For ease ol assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. install the master link retaining clip so that the closed end of the clip will face the direction of torward wheel rotation. AdjuSl the drive chain free play (Page 3—8). FREE PLAY: 15—25 mm [5/8—1 in) Check brake pedal tree play and adiust, if necessary. MM Z KEROSENE \: WIPE DRY MIMIWIWIM LUBRICATE 2-6 Date at In. :59», I973 © HONDA MOTOR 00., LTD i In... l...‘ L‘ L; 3 m o H Z5OR LUBRICATION LUBRlCATlON POINTS mOZE> XmOu kzbmu fix 02Em._ m¥E @1 7.: ._.O>_a_ 4> Fir, FM) r- x Dau of |sn : Saw 1973 F; . é HONDA 250R MEMO n... "v Ime - Sen 1978 L. In; I“ h“ ‘M In L..‘ I... I“- I... In; In», I.“ L; L.‘ I.“ ‘Im. .M. T'TfiI “”1 7'] "‘"I ”"I ”'I """I ”TI “"1 ""7 "TI '7") “"' ""I ”4"] “'7 "WI "”1 ggRNDA 3 INSPECTION & . ADJUSTMENT SERVICE INFORMATION 3—1 CABURETOR IDLE SPEED 3—5 CLUTCH 3—5 SPARK PLUG 3—2 CONTACT BREAKER POINT/ 3—2 AIR CLEANER 3—6 IGNITION TIMING FRONT BRAKE 3—6 VALVE CLEARANCE 3—3 REAR BRAKE 3—7 CAM CHAIN TENSION 3—4 j DRIVE CHAIN 3—3 1 THROTTLE OPERATION 3—4 ‘ 3_5 SPARK ARRESTER 3_3 CARBURETOR IDLE MIXTURE SERVICE INFORMATION SPECIFICATIONS Spark plug gap Spark plug Iype USA Iype Canada tvpe Valve cleavance IN EX Comact breaker poII'II gap Thvoule free play Idle speed Dnve chaIn free play Fvont brake free plav Rear brake free play 0.6—0.7 mm (0.024v~0‘028 in) NGK: C6H ND: U20FS NGK: CRGHS ND: UZDFSR—L 0.05 mm [0,002 in) 0.05 mm (0.002 in) 0.3—0.4 mm I0.012—0.016in) 2»6 mm [118»1/4 In) [500 t 100 rpm 15—25 mm (5/8—1 in) 10’20 mm (3/8—3/4 in) 10—20 mm (3/8—3/4 In) TIRE-pressure: Cold we pressure Front 1.0 (141 kg/cmz lpsil Rear LG (141 "Tne‘glze ‘ “Ifggmflfiaiao—a—2PH _,,, 7 I._,.__.. Rejf 3,5o—a_2z>n TORQUE VALUES Valve adIustIng hole cap Valve adIustIng screw lock nut OII dram plug Rear axle nut 1‘0—1.4kg-m (7—10ft-lb) 0.74.1 kg-m [5—8beI 2‘0—2‘5 kg-m (15—18mm 3.5—5.0 kg-m [25—36 mm) Dam uIlssua Sen 1978 é HONDA 250R INSPECTION & ADJUSTMENT SPARK PLUG Disconnect the spark plug cap and remove the spark plug Vlsualiy inspect the spark plug electrodes for wear The center electrode should have square edges and the side electrode should not be eroded. Discard the spark plug if there is apparent wear or if the insulator is cracked or chippedt Measure the gap with a Wire-type teeler gauge, Adlust the spark plug gap by carefully bend< ing the side electrode, RECOMMENDED SPARK PLUG: U.S,A Type Canada Type NGK CGH CRGHS ND UZOFS UZOFSR—L Install the spark plug, tighten it by hand, then with a spark plug wrencht Connect the spark plug cape CONTACT BREAKER POINT/ IGNITION TIMING IGNITION TIMING Remove the left crankcase cover. inspect the contact point surfaces. If they are level but grayish in color or are slightly pitted, file or sand them lightly. It they have a noticable transfer of metal from one surface to the other, have evidence of heavy arcing, or are worn at an angle, the pom! set should be replaced. Adlusl as follows: Disconnect the A. C. generator wires. Connect a continuity light to the black lead and to a battery positive terminal. Connect the battery negative terminal to a convenient frame ground, Rotate the flywheel counterclockwise and align the "F” mark With the crankcase index mark The timing is correct if the light becomes dim when both marks align. (16—07mm [OHM—0.028 in) CHECK: gap CHECK: sealing ‘ deposit 1 damage ‘ dirt wear /CHECK: damage : crack INDEX MARK l BASE PLATE LOCKING SCREW BASE PLATE SCREWDRIVER Data at ism :5”, 1973 as ”mm name IV'V V‘Vh lug“ l J ,3 i I...‘ Lea" Int lea) i I HM] "~ ’7 ""1 f‘l ‘“'"l "'l ""l “‘l T"W H”) ‘73 "“l ”"1 ”fl “"l g HONDA 250R INSPECTION 8i ADJUSTMENT ll the ignition timing is incorrect, loosen the contact breakter locking screw and adiust the breaker point gap, Increasing paint gap will advance ignition timing. Decreasmg the gap Will retard ignition timing Tighten the locking screw and recheck the timing Replace the contact breaker poinu if the timing cannot be correctly adjusted while maintaining a minimum point ¥ gap of 0 3—0 4 mm l012—0.16inl. Connect the A C generator wires and install the left crankcase cover Use a stroboscoplc timlrig light to determine accurate ignition timing, NOTE The ”F" mark should align th the x mark at idle speed (LSOO rpm). VALVE CLEARANCE “LOIS, 1'7 inspect arid adjust the valve clearance 1. while the engine is cold (Below 35°C, L 95°F) Remove the lelt crankcase cover and valve adiusring caps Rotate the flywheel counterclockWIse and align the rotor ”T" mark and crankcase index mark Before checking, make sure that the piston is at TDC (Ton Dead Center) an the compres~ sron stroke (The rockers should be loose)‘ Check the intake and exhaust valve clearances bv Inserting a ieeler gauge between the adjusting screw and the valve stem. Adiust by loosening the lock nut and turning the screw until there is a slight drag on the feeler gauge. Tighten 'the lock nut and recheck the clearance SERVICE LIMIT: 005 mm (0.002m) (IN/EX) LOCK NUT FEELER GAUGE VALVE ADJUSTING WRENCH 07908-0010000 Dan at Isa - s», 1978 In i-irwna MOTOR cn in) INSPECTION 81 ADJUSTMENT HONDA 250R CAM CHAIN TENSION Start the engine and allow it to idle. Loosen the 8 mm lock nut and adjusting bolt A one half turn, It the cam chain is still noise, remove the cap bolt. With adiustmg bolt A still loosened, caretully screw in adjusting bolt B until the noise stops THROTTLE OPERATION Make sure that there is no deterioration, damage or kinks in the throttle cable, and that the throttle grip free play is 2—6 mm (1/8—1/4 in) at the outer edge of the throttle grip flange, Check for smooth throttle grip rotation from lullv open to automatic full closing in all steering positions. Adjust or replace, it necessary. To adjust, turn the adjuster in either direction. ADJUSTING BOLT ”B" CAP BOLT / 2—6mm (1/8—1/4 in) 3-4 on. of l-n : Sop. 1978 (Cl HONDA MOTOR 00., LTD I... ‘. t L“. I.“ 1‘ I ""l five] - a] -u- M‘ W "”1 7"] i" -w.) ""1 Mn] w, WW] ”'l awe] ”Tl my) 6 HONDA 250R INSPECTION & ADJUSTMENT GARBURETOR IDLE MIXTURE NOTE The carburetor idle mixture adjustment i should be made after the engine has i obtained operating temperature, and with the transmission in neutral. Turn the throttle stop screw to obtain the lowest stable idle rpm. Turn the air screw clockwise until you hear the engine miss or decrease in speed, then counterclockwise until the engine misses or decreases in speed, Center the air screw exactly between these two extremes, at the point which produces the highest idle rpm. (Usually 1-1/2 turns out from the fully closed position). NOTE Turning the air screw in produces a nch fuel mleyre: Turning the airscrew cut produces a lean fuel mixture. 1! the idle speed increases during mix~ ture adjustment, readjust the throttle stop screw to reduce rpm. Adjust the idle speed to the specified rpm, CARBURETOR lDLE smn Turn the throttle stop screw to obtain the specified idle speed, lDLE SPEED: 1,500 e 100 rp’m CLUTCH Loosen the lock nut and turn the adiusting screw one full turn clockwise, Turn the screw counterclockwise until resis- tance is felt. Then mm the adjusting screw 1/8 to 1/4 turns clockwlse. Tighten the lock nut. NOTE - Hold the adJUSUI'Ig screw while l tightening the lock nut l s After adjusting the clutch, check its operation. CLUTCH DISENGAGEMENT The clutch should be disengaged when the gearshift pedal is depressed 14—18 mm (1/2—3/4 in) measured at the pedal and. Data 0' In" : Son 1978 INSPECTION & ADJUSTMENT AIR CLEANER Remove lhe lwo screw: and the air cleaner cover. Remove the air cleaner elemenL Wash the elemem in non-flammable or high flash polnt solvent and allow it to dry then ouly‘ Soak lhe elemem in clean gear oil (SAE 80—90), Squeeze out the excess oil. Reinstall the element and the cover. lululu. I». lm‘ FRONT BRAKE Measure the from brake lever free play. « FREE PLAY: 10—20mm [3/8-—3/4in) 1 0—20mm (3/8—3/4 m) ' I... 1.... Link“ Dan 0! Inn : Sop. 1978 r: many-M wwnn rm y'rh W-) '”‘W . w. A) ,HW‘ "'1 “7"] ”fl ""1 TM) ‘1") ""1 ""7 ”"1 ”7‘7 7”“! “'1 “'1 " W) HONDA Z 50R INSPECTION & ADJUSTMENT Adjus‘ by turning the front brake adjusting { nut. ' REAR BRAKE Measure the rear brake pedal free play. FREE‘PLAY: 10—20 mm (3/8—3/4 in) 10—20mm (3/8—3/4 In) Adjust by mrnmg the rear brake adjusting “U1. Dun oilme :599 1978 % mm mm M ,7” 3-7 HONDA ‘2 Z 5 0 R INSPECTION 8t ADJUSTMENT DRIVE CHAIN Place the motorcycle on a support block and shift the transmission into neutralt Check the drive chain tree play. FREE PLAY: 15—25 mm (5/8—1 in) To adjust, loosen the axle nut, Turn both adjusting nuts an equal number of turns until the correct free play is obtained. NOTE ; Be sure that the index mark aligns with the same scale graduation on both sides. - a I Tighten the axle nut, TORQUE: 3.5—5.0 kgm (25—36 ft~|bI I l - TighXBn the adjusting nuts after the axle nut has been tlghtened. SPARK ARRESTER Remove the difiuser pipe by removing the securing bolt. Remove the clean»out port lid by removing the three securing bolts, Start the engine and rev several times while momentarily creating exhaust system back pressure by blocking the end of the exhaust pipe with a rag. After cleaning the carbon from the exhaust pipe, reinstall the clean-out port lid. .1 Remove the carbon from the diffuser pipe i and reinstaH. Ed. l‘ , a“ (3) CLEAN-OUT PORT LID q 8 am nttmuzsm I978 . - mununa annn H» v'rh "W """1 ""1 w") 71'”) l” "”1 7"” . J ”'1 "'1 .fl .1 MEMO Dale of Issue : Sep. 1978 HONDA ‘2 150R FUEL SYSTEM i U Turn the fuel valve OFF4 Drain fuel} from me carburetor by loosen- RUBBER CAP 1 ing the drain screw. 1 NOTE Before installation, check for l deterioration. AIR CLEANER .1 1 - Fuel Line Check for deterioration, cracking or other , faults. . Replace if necessary. i 1 " O-RING NOTE jfiepiaced used 0»rings. L. ' i THROTTLE STOP SCREW I i AIR SCREW ‘ I I‘lm INTAKE PIPE i at C DRAIN SCREW h. I“ Clean carburetor 12:5 and body with non-flammable or high flash pain: solvent before installation l.. Im‘ A. 0 Dan ollsu- 'Sop‘ 1978 _ m ummn Mon-u: r~n I Tn high” “WON 059 mp 93“ BARBURETOR ASSEMBLY/ DISASSEMBLY REMOVAL Turn the fuel valve OFF and disconnect rhe fuel line from the carburetor. Unscrew the lwo carburetor mounting bolts to remove lhe carburetor‘ Loosen the air cleaner tube connecflng clamp and separate rhe carburetor from xhe air cleaner assembly. Remove the cap and disconnect the throttle cable from the carburetorr FLOAL LEVEL Remove the float chamber by loosening the two screws. N l fuel by loosening the d cock l before performing thls maintenance. Measure the flnal level with the float level gauge FLOAT LEVEL: 12.7 mml0.50 in) Replace the float If the serwce limit is ex ceeded F LOAT LEVE L GAUGE: 72401-0010000 HONDA 250R FUEL SYSTEM CARBUR ETOR MOUNTING BOLT 11-9 rm. 0! um : Sop. 1973 [a mum. mwnn FA .-. I... In“ "TI 'f‘I ”"1 "f”I ”WI "" "'I ""I "'7 "" "WI ""3 "'A "“I ""I HONDA I i I! ENGINE REMOVAL 8- 150R , 5 . INSTALLATION I SERVICE INFORMATION 5-1 I ENGINE REMOVAL 5—2 I 1 ENGINE INSTALLATION 5-3 SERVICE INFORMATION GENERAL INFORMATION The engine musI be removed to service the folIowIng parts: Crankshah evankweigms Kick suite! Connecting rad Transmissi'on SPECIFICATION Engme weight 17 kg (375 lb), dry TORQUE VALUES Engme hanger 8 mm flange bolt 2.0—2.5 kgm (15—18 ft-Ib) Duo o1 Isa. scp, 1979 .hvna no I Tl’) ENGINE REMOVAL 81 INSTALLATION HONDA Z 5 O R ENGINE REMOVAL Drain the engine oili Remove the exhaust pipe nuts and hanger bolts Loosen the muffler assemblyt Remove the intake manifold bolts and mani- fold. Disconnect the spark plug cap and A, Q generaior wires. Remove the gearshift pedal. Remove the left crankcase cover mounting screws and remove the cover. Uniasten the drive chain master link and remove the chain. Remove the two engine hanger bolts and remove the engine from the frame, 5-9 Dill of Int. : Sept 1978 (53 HONDA MOTOR COV LVD I. A I” la. L- I“, I“. In. I... I“ In“. L- I.» In. I... I; ""3 “"1 f F ““1 "”1 7"”7 ”'1 ""1 ”TI ""1 "MI ""7 "““l 7"] ""I w"‘I HONDA 250R ENGINE REMOVAL & INVSTALLAIIVQN ENGINE INSTALLATION g .A The Installation sequence Is essentially the reverse of removal. NOTE I When installing the drive chain master g link, make sure that the open end of I the clip faces opposite the direction ‘ of nzlmal cham rotation. Direction of Rotation Dun atlme:5¢o.1978 5-? CYLINDER sen mus bolt slightly and lightly tap on Its head lo facilitate removal '0? the left side cover. / COPPER WASHER RIGHTSIDE COVER CYLKNDER HEAD COVER NOTE I! Install with the arrow f facing down (EX side). v I ) COPPER WASHER ROCKER ARM IICDBIIJIK 250R HEAD/CAMSHAFT VALVE COVER NOTE Before Installing, apply grease m the (heads. ROCKER ARM SHAFT 0.9—1‘2 kg~m (65-217mm) CAM SPROCKET % CAMSHAFT ‘ LEFT SIDE COVER 6-0 D." of In" : Son. 1973 m HONDA MOTOR CO LTD I. . l.‘ I... I... h. I“ Ln. In I... Is“ S a In "Ml "'1 ””1 "'"l """l ""T'l ”"1 "'"l ‘3'") "‘"l ””1 77'] ””J 7"") ""1 HONDA Z 5 O R OAMSHAFT 6 CYLINDER HEAD/ I If ' I SERVICE INFORMATION 6—1 i TROUBLESHOOTING 6—1 4 ROCKER ARM 81 ROCKER ARM SHAFT REMOVAL 6-2 , CAMSHAFT R EMOVAL 6—2 { VALVE DISASSEMBLY 6—3 l l TENSIONER PUSH ROD 6—4 SPECIAL TOOLS Valve Guide Remover/Installer 07942—3290100 Valve 00mg Reamer (IN/EX) 079044930000 Valve Sprlng Compressor 07757—0010000 Valve Guide Driver 0794273290200 SPECIFICATIONS :WV’ _ STANDARD SERVICE LIMIT I Camshaft lobe helght 26.07 mm (1.020 in) 25.59 mm 11.011 In) I ; Cvlmder head warpage — 0.05 mm (0.002 m I Valve seat width 1.0—1.3 mm (0.04-0.05 in) 2.0 mm 10.0810) ; Valve stem 0. 0. IN SASS—5.465 mm (0,2149—0.2152.n) 5.40 mm (0.213 In) E EX 5430—5445 mm (02138—02144 in) 5.40 mm 10.21311») ‘LVaIve guide 10 IN/EX 5475—5485 mm (0.2155—021501nl 5.50 mm (0.217 In) I Valve sDrIng Free length Inner 22.7 mm (0.30 in) 23.9 mm (0.94 in) ; ‘ Outer 24.9 mm (0.98 in) 26.9 mm (1.06 in) L Valve clearance IN/EX 0.05 mm (0.002 in) TROUBLESHOOTING Engine tooend problems can usually be diagnosed by a compression test. Noise problems can usually be traced to (he top-end of an engine with a sounding rod or stethoscope. Low compression or uneven compression 1 Valves — Incorrect valve adjustment 7 Burned or bent valve — Incorrect valve tlming — Broken valve sprlng 2 Cvlinder head — Leaking or damaged head gasket — Warped or cracked cylinder head 3 Cylinder and piston (Refer to Section 7) Compresslon too hiwh 1 Excessive carbon build-up on piston or combustion chamber Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn rocker arm or cam Loose or worn cam chain Warn or damaged cam chain tensionar Loose balanoer chain Worn oam sprocket teeth cam chain min 1 Excessive free play 2 Guide roller worn \lmulbqu—p Duo 0' Inn : Sop. 1978 8-1 HONDA 250R CYLINDER HEAD/CAMSHAFT ROCKER ARM AND ROCKER” ARM SHAFT REMOVAL Remove the rocker erm shaft by screwing in an 8 mm bolt and pulling out. ROCKER ARM SHAFT Install the rocker arm shaft with its threaded end facing 3mm BOLT the right side. CAMSHAFT REMOVAL Remove the camshaft by aligning the cam lobes with the wtouts in the cylinder head. VALVE TIMING Allgl’l the ”T“ mark on the flywheel with the index mark‘ Allgn the camshaft sprocket index mark With the cutout in the cylinder head. Q _ r, on: or sums-p, 1979 l- I.” L... Le. l.‘ l... I..- I... I... L- Im f7”l"7‘fl“‘l"~l”"l,'“7"l"'l I r l "'“l ‘7'] """l ""1 "I ""3 "I HONDA Z 5 O R CYLINDER HEAD/CAMSHAFT VALVE DISASSEMBLY TOOL VALVE SPRING COMPR ESSOR 07757—001 0000 CA UTION , To prevent 1on of tension, do not Com- ;press the valve xpring more than neces- lxary (0 remove or to install [he valve l amen: Remove the valve and Inspect the face. II the Seal is too wide, too narrow, or has low spots, the seat must be ground. NOTE FAner Installing, check mm l these cutters are seated DIOA Lperlyl 1 Valve stem seal and cap are Lused only on me exhaust Side Follow the valve relacer manufacmrer’s I operanng Instrucllons. PILOT BAR"A" 07783—0010100 D.“ of I." : 50v. 1978 HONDA MOTOR co LTD VALVE snpmc SEAT 5, age VVALVE STEM SEAL CAP \\Q.//VALVE STEM SEAL % O‘RING INTAKE VALVE EXHAUST VALVE VALVE SPRINGS 9‘ VALVE GUIDE GRIDING STONE l N 2 07783—0050l00 EX 1 07783—0050l00 63 5 | N Z 07783-0030200 EX 2 07783—0030l00 37.5‘ I N Z ONES—0040200 EX 1 07783—0040I00 45‘ 6-3 CYLINDER HEAD/CAMSHAFT TENSIONER PUSH ROD ‘nsxall me push rod with .the taper facing bolt “A“. TENSIONER ADJUSTING BOLT B DJUSTVNG BOLT “A" 8mm LOCK NUT 0‘8 kg-m (6 Mb) The end of adiusfing bolt must not contact this surface. CAP BOLT "B” ADJUSTING BOLT “B" CRANKCASE 6-4 DIN of In. :Sop‘ 1978 (a HONDA MOTOR CO LTD I_L..l_lm. lal‘LaLmlmLmlnthl.-.l..l.ul‘ “filial.“ MEMO warm .7" an: of lsim ' Son 1978 é HONDA 250R rIkrVrtrrlhrltrhfilxrtFlritgrltFIthkClt~xi.Frryi—.rl CYLINDER/PISTON HONDA 250R CHAIN GUIDE ROLLER 8 x14 mm DOWEL PIN GUIDE ROLLER PIN 6mm EOLT o 9-1 4 km 1 TORQUE: 0,9—12 kg-m (7—10 ft-lbl ‘ (7—9 mm NOTE Tighten this screw loossnly during cylinder assembly. Tighten to the specified torque after tightening the cylinder head. 16mm O-RING CYLINDER PISTON PIN CIRCLIP Don 00 Issue : $09. 1978 m uoNnA MOTOR (:0 Hr) la. 1...... In. I.‘ I.. lam I_L I_L I__ I«.V I.“ l._‘ |.L Ink Ie_e IL_ I.LL [LS I.“ "7"1 ""1 ”"1 7"” I 'T’I .I ""1 "f" ,.._..] H NDA c N R / ° YLI DE / - PIST , SERVICE INFORMATION 7—1 PISTON RINE} REMOVAL 7-2 i I l . ‘ TROUBLESHOOTING 7—1 PISTON RING INSTALLATION 7—2 ( PISTON REMOVAL 7—2 CYLINDER INSTALLATION 7A3 I ‘ CAM CHAIN GUIDE ASSEMBLV 7—3 3 I I SPECIFICATIONS 1 STANDARD SERVICE LIMIT 1 Cylmder l. D. 38005—39015 mm (15356—15360 inI 39.05 mm (1,537 In) ‘ Piston CD. at skirt 39.980—39.000 mm (15346—15354 in) 38.90 mm (1.5321n) ‘ ‘ Pmon pin bore 11002—13008 mm (05119—05121 in) 13.10 mm (0.516 IN I Piston ring Width Top 1.70—1.90 mm (0067—0075 in) 1.60 mm (0.063 InI I Second 1.70—1.90 mm ((1067—0075 in) 1.60 mm (0.063 mI ‘ I Plston rlng End gap Top 0.10—0.30 mm (0.004—0012 in) 0.50 mm (0.020 In) , ! Second 0.10—0.30 mm (0.004—0.0121n) 0.50 mm (0,020 In! ( Pinon ring-(o-groove clearance Top 0010—0045 mm (00004—00018 in) 0.12 mm (0.005 In] I Second 01010-11045 mm (00004—03018 in) 0.12 mm (0.005 In! valon pm 0. D. 11994—11000 mm (0.5116—051181n) 12.98 mm (0,511 In! I Compression too Iow or unstable Overheating 1 Worn cylinder or piston 1 Excessive carbon build-up on piston or combustion chamber wall Excesswu smoke I Worn cylinder or pisxon Knocking or abnormal min 2 Improper installatio of piston rings 1 Worn piston and cylinder 3 Scored or-scratched pis‘on or cylinder wall 2 Excessive enrbon build-up °1.L".".‘.§'."gl°’§n m. 7 - 1 PISTON REMOVAL NOTE r—*—‘————. I Install the ClrcIlp so that us end gap l 1 and the cutout are not aligned. Install the piston with the marking "V" facing the exhaust side. PISTON RING REMOVAL PISTON RING INSTALLATION Clean the rmg grooves and oil holes throughly. NOTE I Afker inslaflafion, the rings should be free to male in the ring grooves. \__ NOTE I DO not interchange ringsl Space (he ring end gaps 120° apart, avoiding xhe DISH)" pm and mrust sides. CVLINDER/PISTON PISTON PIN CIRCLIP Remove the piston rings by lifting in the direction shawn. Install the rings mm the markings facing up. Data of Inw- : Sap. |978 m ”mum Mn'rnn rm .7" l..l....L.I.a-..I._In.h Lmkhkh‘khu I... "“r'l T'T’l '“l TT‘I ”TI T'"I ""1 ""1 ""1 ””1 ""l 77'1”"? " '1 w.‘ w»! ”,1 -. “WI “IV-I'dNDA 250R _ g CYLINDER/PISTON CYLINDER INSTALLATION Apply a thin coating of oil to the piston rings and cylnnder wall, and compress the pismn rIngs so they will enter the cylinder. NOTE , When the cylinder is halway over the pISIOfl, route :he cam chain through I We hole In the cylinder. NOTE Do 00‘ allow the 16 mm O-ring to become misposifionedI r I CVLINDER’G'ASKET CAM CHAIN GUIDE ASSEMBLY I TIghIen the guide roller pin after installing the guldel 7.5 mm RUBBER PACKING CAM CHAIN GUIDE 16 mm O»L|NG GUIDE ROLLER PIN j mu uf Ism- :5». 197a 7-.‘3 HONDA é 250R 6 HIGHTCRANKCASE /;»\ K ' L131: \ CLUTCH/GEARSHIFT SPINDLE PIVOT BOLT Toe—1.2 kg-m 3 (6—9 fit-Ib) Apply sealer to the 'threads. L FILTER SCREEN Clean in semen! afm ramming. 14mm LOCK NUT (LE—4.5 kgm (28—33 be) CLUTCH OUTER COVER CLUTCH 9AM CLUTCH BALL RETAINER CLUTCH LIFTER CLUTCH ADJUSTING BOLT Install with the mark "OUTSIDE" facing out. Duo ollmo : W‘ 1978 R - 0 m unklnA un'rnn rn v'v-n I»“ I.“ h L“. I.» I... I... l". I“. l- I“. L. I..- I.. ""1 ”7'1 "TI ”TI ""1 ""7 H". ”TI ""7 """I "'"J ”'1 ' ““I HONDA Z 50R 8 OLUTCW - GEARS IFT SPINOLE SERVICE INFORMATION TROUBLESHOOTING CLUTCH REMOVAL CLUTCH DISASSEMBLY CLUTCH INSPECTION GEARSHIFT SPINDLE ASSEMBLY 8—2 8—2 8—3 SERVICE INFORMATION GENERAL INFORMATION ThIs section covers clutch removal and Installation Service can be accomplished with the engine in the frame. SPECIAL TOOLS 14mm Lock Nut Wrench Clutch Outer Holder 0771643010100 07923—0400000 SPECIFICATIONS l_ STANDARD SERVICE LIMIT I Clutch spring free length 21.1 mm (0.33 in) 19.4 mm (0.75 in) I Clutch disc thickness 3.45 mm (0.136 in) 315 mm (0.124 In) TROUBLESHOOTING Faulty clutch operation can usually be corrected by proper adjustment Clutch slips when accelerating I No free play 2 DIscsworn 3 SprIngs weak Clutch will not disengage 1 Plate warped Clutch drags when dlsenosged 1 LIiter mechanism damaged Data o! Is!" :Sop. 1978 m I—mNnA Mfi‘l’nn (‘n I-rn HONDA 250R CLUTCH/GEARSHIFT SPINDLE CLUTCH REMOVAL TOOLS: CLUTCH OUTER HOLDER 07923—0400000 14mm LOCK NUT WRENCH 07716—0010100 Straigmen the lock washer tab holding xhe nut, NOTE 3 Do nox re-use the lock washer when assembling. L___ Remove ‘he look nut. CLUTCH DISASSEMBLY CLUTCH FRICTION DISC DIS- ASSEMBLY/ASSEMBLY Replace the clutch discs if (hey Show signs of scoring or discoloration Measure the disc thickness, SERVICE LIMITS: Dim : 3.15 mm (0,124In) CLUTCH OUTER DISASSEMBLY/ ASSEMBLV NOTE ‘Tlghten the screws In a crlss-cross I panern in 2-3 steps. CLUTCHPLATE"A"~ ’ FRICTION DISCS “A" § CLUTCH PLATE "C" CLUTCH SPRING CLUTCH CENTER DRIVE GEAR OUTER CLUTCH DAMPE R SPRING 5mm SCREW 8-2 Dal. cl In}. :SIIL 1978 ((3) HONDA MOTOR CO , LTD I.¢ I‘mA 'Km I._ I‘m. L. In. qu‘ lwe I“. I... I... I“ 5""! 7'1 “”1 K" "I ""1 ”TI “,1 CLUTCH/GEARSHIFT SPINDLE CLUTCH INSPECTION Check the clmch spring free length. SERVICE LIMIT 2 19.4 mm (0‘76 in) CLUTCH PLATE A, DRIVE PLATE AND 8 x 10 mm ROLLER INSPECTION Check the rollers and plates for excessive wear, Replace if necessary‘ GEARSIFT SPINDLE ASSEMBLY DRUM STOPPER PLATE INSTALLATION NOTE Inna" me stopper plate aligning the hole with the stepped dowel. DAMPER‘SPRING CLUTCH SPRING DRIVE PLATE I 'DRIVE PLATE B x 10 mm —® _ HOLLEH CLUTCH/GEARSHIFT SPINDLE GEARSHIFT SP\NDLE 1NSTTALAT|ON NOTE ' Do not rotate the spindle as the lip of r the ail seal may be scored or scratched. DRUM STOPPER INSTALLATION install the drum stopper looselv‘ Posmon the stopper omo the drum as shown. Tighten the stopper pivot bolt securely. 7 8-4 on. of In. :Slp. 1973 a nmmn Mn‘rnl: rh w-m I._I.._I...._ I...» I... LLI thnh»h_l_L.~ I.“ L... I... I... 7'"? ”"7 "'71 '” '"T "w ””1 T‘"\ "W ” ”ml 2“"? MEMO om 04mm hr, mm HONDA Z 5 O R A.C. GENERATOR CAM CHA!N TENSlONER ROL‘LER \ TENSIONER ARM TENSIONER PUSH ROD NOTE Make sure that the woodruff key seats in me kevway properly‘ STATO R FLYWHEEL ADJUSTING BOLT "A” / 3.0—3.8 kg-m (22—27 ft-Ibl I C9D TENSIONER SPRING "A TENSIONER SPRING "B" CAP BOLT ADJUSTING BOLT "B” NOTE LEFT CRANKCASE COVER Make sure that no metal objects are amacted by the magnets inside the flywheel‘ Do not hammer. Q _ 0 pm oi lsuc : $09. 1973 I...“ l- .3 J J I“ I... I» l-. W1 "“1 ""TI ”WI 1 ""“I ""1 "'"I 1""1 "'1 Am] 6"") :“"l ‘T'I 7"] ""I HONDA 9. A.0.0ENERATOR SERVICE INFORMATION TROUBLE SHOOTING A. C. GENERATOR REMOVAL/DISASSEMBLY CONTACT BREAKER POINT INSPECTION 9—1 9—1 9—2 I I I I I I I SERVIOEINFORMATION GENERAL INFORMATION This section covers A. C. generator removal and installation, Service can be accomplished with The engine in the frame‘ SPECIAL TOOLS Flywheel Holder 07925—0010001 F lywhee| Puller 07933—0010000 TROUBLESHOOTING Wear or no spark 1 Fouled Conlacl breaker points 2 Improper breaker point gap 3 Faulrv condenser A.C. GENERATOR A.C.GENERATOR REMOVAL/DISASSEMBLY 10 mm NUT REMOVAL TOOL FLYWHEEL HOLDER D7925v0010001 F LYWHEEL REMOVAL TOOL FLYWHEEL PULLER 07933—0010000 CONTACT BREAKER POINT INSPECTION NOTE Do not forget to install xhe bakelite washers to insulate this terminal from ground‘ 9-9 on. at Inn : s». 1973 m ununn Mn'rnn rn I... I... in. I... 1.. la“ L. I...“ C... I.“ l“. I..- hhhklk‘m“ ”W "“1 "”1 ”W ‘WW WW 3 ""7 F HONDA ZSOR A.C.{ GENERATOR If xhe on felt is dry, apply one or two drops otcwanengneon, : Clean the point surface wnh a point file. Replace the palms if there is ex- ; cessive metal transfer, POINT GAP STANDARD: 03—011 mm (0.012—0‘0165n) NORMAL WEAR PARTIAL CONTACT FOULING @ METAL TRANSFER ‘ D“: 04 last. ' SID. I978 A uthA wwnn on .w. 9-3 HONDA 150R TRANSMISSION/CRANKSHAFT LEFTCRANKCASE l ‘ ‘ ' DRIVESPROCKET CAM CHAIN GUIDE SPROCKET KICK STARTER SPINDLE NOTE Make sure that the gaskn is not disxodged during assembw. J *4 RETAINER 1 O 0 Data u“nuz$cp,1978 - ta wwnn Mnrnn rn v‘rn L_ I.“ L.‘ I.“ I... In. I...“ , L”. l... . I“; .m)‘: Ira. I..." m. I... I”; I.“ F 9 WI “"1 T") "T"l 7'1 ""1 "'71 ""7 ..,_..] ” ""l ”“l "'"l '7'? ""‘l HOfiDA Z 5 O R IO TRANSMISSION/ - ORANKSHAFT SERVICE INFORMATION ‘ TROUBLESHOOTING DISASSEMBLY ASSEMBLY KICKSTARTER DISASSEMBLY/ASSEMBLY 10—1 10—1 1 0—2 10—2 10—3 SERVICE INFORMATION GENERAL INFORMATION For (mernal transmission and crankshaft repairs, the crankcase must be separated, SPECIFICATIONS r STANDARD SERVICE LIMIT J 1 Crankshaft runout 0.05 mm (0.002 rn) l 1 Connecting rod side clearance 0.10—0.35 mrn (0.004—0.014in) QB mm (0.03 ml Connecting rod radial clearance 0—0.012 mm (0—0005 in) 0.05 mm (0.002 in) r ‘ Crankshaft ball bearing play Axial 0.10 mm (0004 m) Radial 0,05 mm (0,002 in) » Gear ro shart clearance —— 0.10 mm 10.0040.) j Shift fork | D. 34.00—34.025 mm (13390—13396 in) 34,065 mm (1.3411 rnl‘ “Shin (ark uawl thickness L!" 486—434 mm (0a1919—0a195in) 4150 mm (0181 m) ‘ 3 Right 5.86—534 mm (0.231—0234 in) 560 mm (0.221 ml ( Shift drum 0. D. 33350—31975 mm (13366—13376 in) 33330 mm (1.3353 In]: Rim" drum groove width 610—610 mm (0240—41244 in) 6.30 mm [0,248 ”In TROUBLESHOOTING Excessive noise Transmission jumps out of gear 1 Crankshaft 1 Gear dogs worn - Excessive crankshaIt journal bearing play 2 Shift shaft bent 4 Excessive crankpin bearing play 3 Shift drum stopper broken 4 Shift forks bent Hard to shift into gear I Improper clutch adiustment 2 Shrft forks bent 3 Shift spindle bent 4 Shift drum stopper bent 5 Shih drum cam grooves bent .r..‘_,.. a... mm 4 A’ a HONDA 250R TRANSMISSION/ORAN KSHAFT/KICK STARTER DISASSEMBLY TRANSMISSION GEARS SHIFT DRUM ASSEMBLY TRANSMISSION GEARS/SHIFT DRUM Install the drum and transmission In (he L~ crankcase as an assembly. NOTE ‘ After assembly, rmate the mainshafl :0 make sure lhal the gears retake freely. INDIE ,7 , ,, ,,_,,, InstaIl me washer whiIe holdmg II to pvevenl II from becoming dIsplaced I COUNTERSHAFT I TOP GEAR SECON D G EAR LOW GEAR I I I MAINSHAFT ‘I RIGHT FQRK LEFT FORK SHIFT DRUM GUIDE PIN CLIP SHIFT FORK GUIDE PIN MAINSHAFT SHIFT DRUM COUNTERSHAFT I I q ‘NEUTRAL SWITCHI HOIOR r\ / Align with the C4 neutral switch, } I I I I \llflJjRAL SWITCH \ 14 mm THRUST WASHER . 10-? um uf Isa. I s». 1973 flHONDA MOTOR CO ITO L‘L‘lmhkhhh'klw'h,l.;|w hkhk.m4 I.“ "' 7 "‘"l ‘ wl "WI ""1 ""i ""l 7"? Tm] "'Ti ""1 "WI ”‘1 E"? " "I “"1 HONDA ZS 0R TRANSMISSIQN/CRANKSHAFT/KICK STARTER KICK STARTER DISASSEMBLY/ASSEMBLY Disassemble the kick starter. Check the driven ratchet, pinion, and spindle for excessive wear. KICK STARTER ASSEMBLY Assembie the kick starter spindle, Install the spindle assembly and pinion gear. Hook the end of the friction spring over the case abutment. SPRING RETAINER INSTALLATION After assembling the crankcase, install the sunny retainer and spring on the spindle. Hook the end ol the spring on the crankase abulment while holding the spring retainer as shown. KICK STARTER SPINDLE 2D mmS Set the s KICK STARTER ratchet. PINION 20 mm SET RlNG ET RING STARTER DRIVENE FRICTION SPRING RATCHET _‘ pring in the groove in the starter driven Pics this and of the fric- tion spring in the cutout In the case. Data of Isuv :Sop. I978 a I HONDA 250R MEMO 11-,11‘ {cam-Iii. 41‘ 1‘14.in- {incl-41d;- D1" of Inn :Sep. 1978 "'1 TT"! ‘7‘} "5'3 """I ”*1 7T ""7 w" ”'77 """I WWI "'I “'1 .'""I ““7 HONDA Z 5 OR 1 ‘l FRONT WHEEL/BRAKE/ . SUSPENSION I ’ ' SERVICE INFORMATION 11—1 I TROUBLESHOOTING 11—1 I .0 FRONT WHEEL/FRONT BRAKE 11—2 l I 'HAND‘LE’BARS 11—2 I STEERING STEM 11—3 I FRONT FORKS 11—3 I l r . SERVICE INFORMATION SPECIAL TOOLS 35 mm Pll'l Spanner 07902—001000!) Bearlng Drlver 07947—045000!) Bali Race Driver/Remover 079444150001 Driver Handle 07949—2360000 SPECIFICATIONS STANDARD SERVICE LIMIT Axle shaft runout Front wheel rlm runout Front wheel bearing Tree play Radial Axial Brake lmmg thickness r lake drum | D, _ 0.20 mm (0.008 In] _ 0.5 mm (0.02 mI - 0.05 mm (0.002 ml _ 0.10 mm (0.004 ml 4.0 mm (0.16m) 2-0 mm I0 03m) 110mm (433 In) 111 mm (4.37 m) TROUBLESHOOTING Hard steering 1 Steering stern nut too tight 1 Faulty steering stem nut 3 Damaged steering stern ball race and/0r cone race 4 Insufficient tire pressure Front wheel wobbln 'l Distorted rim 2 Worn front wheel bearing 3 Faulty tire 4 AxIe not tightened preperly Steers to one side or does not track straight 1 Unevenly adjusted right and left shock absorbers 2 Sent front forks 3 Bent front axle; wheel installed incorrectly Soft mspanslon 1 Weak fork springs Frnot suspension min 1 Shock absorber case binding 2 Loose front shocks or springs FRONT WHEEL / FRONT BRAKE DISASSEMBLY AND ASSEMBLY Ralse the front wheel off the ground by placmg a block or safety stand under the engine. Remove the front brake cable, Remove the front axle nut, pull out the front axle, and remove the front wheel. Remove the brake arm, cam, and shoe springs and remove the brake shoes from the brake panel. Remove the oll seal and remove the ball bearmgs and distance collar. Remove the it re valve Remove the 8 mm bolts and remove the front wheel hub HANDLEBARS DlSASSEMBLY AND ASSEMBLY DlSEOnnECE the brake cable, upper end. Dlsoonnect the engine stop switch, Dlsconnect the throttle cable. Remove the throttle grip and engine stop switch assembly. Remove the handlebar upper holders and handlebars to remove the fork top bridge. FRONT WHEEL/BRAKE/ SUSPENTlON Z50R HONDA (1) WHEEL BEARING (2) DISTANCE COLLAR (3) FRONTWHEEL HUB (Al RIGHTWHEELHIM (5) TIRE (6) AXLE (7) FRONT BRAKE ARM (Bl FRONT BRAKE PANEL (9) BRAKE CAM (10) BRAKE SHOES (1) THROTTLE GRIP PIPE (Z) ENGINE STOP SWITCH (3) HANDLEBAR (4) BRAKE CABLE (5) THROTTLE CABLE l6) ENGINE STOP SWITCH WIRE 11.0 D"- o! In" 1 Sept 1978 I... I... LLIM'L..L.:I..,I_. I...“ I1... I... J J ”"I ”'1 MT") ”") """i ““i r s I i’ W") T") ""I HONDA 150R STEERING STEM DISASSEMBLY/ASSEMBLY Remove the front wheel and front brake cabier Remove the front fork bolt and circlips, Pull out the front fork tube assemblies. Remove the handlebars. Remove the fork lop bridge from the steer- .ng stem Remove the steering head top thread and steering top cone race. Pull out the steering stern and the ball bearings, Remove the steering top and bottom races, INSPECTION Check the contact surfaces of the steering top and bottom races and the top bell race for scores, scratches or wear, TOOLES' PIN SPANNER WRENCH: U7902¥0010000 BALL RACE DRIVER/REMOVER: 07944—1150001 FRONT FORKS DISASSEMBLY Remove the fork tube assembly. Pull out the spring pin and disassemble each fork tube. INSPECTION Check the spring stops for scores, scratches or breakage. ASSEMBLY Assembly is essentially the reverse of dis- assembly. lion; 1 The spring pin must be flush wit the end l of the piston. FRONT WHEEL/BRAKE/ ;‘ §USPENTION (I) STEERING TOP THREAD I2) TOP CONE RACE (3) TOP RACE (4) BOTTOM RACE (5) N416 BALL BEARING I6) BOTTOM CONE RACE (7) DUST SEAL (S) DUSTSEALWASHER I9) STEERING STEM I1) FORK TUBE GUIDE I2) THRUSTWASHER I3) CIRCLIP I4) DUSTSEAL I5) FRONT FORK SLIDER IS) UPPER SPRING GUIDE (7) DAMPER I8) SPRING l9) LOWER DAMPER (10) LOWER SPRING GUIDE (11) SPRING PIN (12) FRONT FORK ASSY Dan at Isu- : Sop. I978 ®HONDA MOTOR co. LTD. 11-3 2‘ 11(33i131k 250R zadla-idjda-iiuuldiiu MEMO 11‘ I!- J {an i:- 1,- 5.‘ 14‘ JA- Dm o! In: vs”. 1973 ”'TI “’71 ”‘1 "7"} ""3 "'71 'I w'I ’TWI 7"”I iiONDA REAR WHEEL/BRAKE/ 25” 12 ' SUSPENTION SERVICE INFORMATION 12—1 : E TROUBLESHOOTING 12—1 E E REAR WHEEL/BRAKE 12—2 E E swme ARM 12—2 E SHOCK ABSORBERS 12—3 E SERVICE INFORMATION SPECIAL TOOLS Bearing DI'IVEI’ 07947—0450000 Shock Absorber Compressor 07959—3290001 DI'IVEr HandIe 07949—2860000 SPECIFICATIONS E STANDARD SERVICE LIMIT ‘ Axle shaft'runour — 0.20 mm (0.008 m) ‘ Rear wheel rim runou! — 0.5 mm ((102 In) E Rear wheel bearing free play Radial — 0.05 mm (0,002 m) E Aanl — 0.05 mm (0.002 ml ‘ Brake Immg thickness 4.0 mm (0.16 in) 2.0 mm IOTOB m) ’ LBrake drum L0. 110 mm (4.33 m) m mm (4.37 m) ' TROUBLESHOOTING Rear wheel wobble Rear suspension noise 1 Bent rim 1 Slider binding 2 Worn rear wheel bearing 2 Loose shocks or springs 3 Axle nut tightened improperly Sofr suspension ' 1 Weak shock absorber spring 2 Worn hub dampers REAR WHEEL/BRAKE DISASSEMBLY Loosen the axle nut and drive chain adjusting nuts, Disconnect the rear brake rod and drive chain master link. Remove the axle nut and pull out the axle. Remove the wheel. Remove the brake panel assembly. Remove the three 8 mm nuts and driven sprocket. Pull out the oil seal, bearing and distance collar. Remove the 8 mm bolts and hub from the wheel Remove the we valve. Remove the wheel hub bolts and separate ma rlm and tire ASSEMBLY Assembly is essentially the reverse of dis~ assembly. NOTE When installing the drive chain master link clip, make sure that the open end I of the 0le (aces opposite the direction 0! normal chain rotation. SWING ARM DISASSEMBLY Remove the rear wheels Remove the shock absorber cap nuts and shock absorber assembliest REAR WHEEL/BRAKE/ SUSPENTION 250R HONDA (1) (2) (3) (4) (5) (6) RIGHTWHEEL RIM TIRE AXLE DRIVEN SPROCKET REAR BRAKE ARM REAR BRAKE CAM (7) (8) (9) (10) (11) (12) (13) REAR BRAKE PANEL BRAKE SHOE BALL BEARING REAR WHEEL HUB DISTANCE COLLAR OILSEAL LEFT WHEEL RIM 12-2 Dm a! In“ :Sap. 1978 (e) HONDA MOTOR co hL.“L.I...I..,Im-. J .‘i Ia.L—_I.".lm 1.- ”7") 7'") "'TT) ' ~"I 7W] ""7 m R") "‘71 w") (7"? ""‘I 1 'f) 1"“) ""7 HONDA Z 5 O R REAR WHEEL/BRAKE/ SUSPENTION Pull om the comer pin and disassemble the brake pedal and brake rod. Remove (he pivot bolt nut and remove the swlng arm. SHOCK ABSORBERS DISASSEMBLY USII’IQ (he special (col, loosen the locking nut, remove the upper holder and disassemble each shock. TOO LS SHOCK ABSORBER COMPRESSOR: 07959—3290001 ASSEMB LY Assembly is essentially the reverse 0) dis» assembly. NOTE Install the spring with the tightly wound calls up‘ Apply a locking agem m the upper ‘ holder. Install the shock absorbers and secure wi‘h the cap nuts‘ lnnall the rear wheel. (1) SWING ARM (2) REAR BRAKE ROD (3) REAR BRAKE PEDAL (4) PIVOT RUBBER BUSHING (5) SWING ARM PIVOT BOLT (2) LOCKING NUT (I) SHOCK ABSORBER UPPER HOLDER (3) SHOCK ABSORBER COMPRESSOR (I) UPPER HOLDER (2) RUBBER BUSHING (3) COLLAR (4) UPPER LOCK NUT (5) DAMPER (6) SPRING GUIDE (7) SPRING (8) DAMPER (9) SHOCK ABSORBER ASSY D." of In" :Sep. 1973 19-0 é HONDA 150R MEMO Dau of Issue :Sup 1978 I... I.» I.” In“ L. I...“ L... I... L. lash- L“ La LL I... Ix. I... I.“ "”1 7'1 "T”? ”7"} ""1 Wj "I"? -fi ""1 ”7"] ”"1 ""3 My] .53"” 13. SEAT.,.&EUE|.-,TAN.K SEAT AND FUEL TANK 13—2 um 01 um. :3”. 197a . 1 3 _ 1 I... HONDA 150R SEAT AND FUEL TANK SEAT AND FUEL TANK DISASSEMBLY Remove the seat belt and nut and loosen the Inul. shock absorber upper cap nu‘sL i Remove the seat. ‘ SEAT BOLT ‘ Turn the fuel valve OFF and disconnect the fuel line. 3 Remove the fuel tank mounting bolt and i fuel tank. I... MI... INSPECTION Check the fuel tank tor leakage. Also check the fuel tank cap breather hole for clogging, the fuel valve and strainer cap gaskets for deterioration or damage, and the luel line FUEL TANK (or deteriorallon or breakage. ' » - . V7 MOUNTING BOLT NOTE Flush the tank with gasolin hhhh- I“. l..- I... I”- I.....I_m ln Dan oils). :5. L 1373 1 3-2 a mm m!” M .m |_ "‘7 ””1 "'l W'I ”TI ”7"] "1 5’1 7"] " "'I ”WI “"7 ”"l HONDA 250R c‘_]4.‘lGNlTl0N SYSTEM SERVICE INFORMATION IGNITION COIL I CONDENSER TROUBLESHOOTING 14—1 14—1 14—2 SREVIOE INFORMATION GENERAL INFORMATION Be sure to connaci each wire properly. Ensure that the contact breaker points are clean and in good condition. SPECIFICATION 1 Spark plug USA model NGK: C6HS DENSO: UZDFS Canada model NGK: CRGHS DENSO: UZDFSR-L Plug gap 0.6—0.7 mm (0324—0028 in) Enition coil spark gap Condenser capacity ‘ Contact breaker pomt gap 6 mm (0.24 in) min 0.27—0.33 uF 0.3—0.4 mm (0.012—0‘016in) TROUBLESHOOTING Engine will not start 1 Engine stop switch OFF 2 No spark at plug 3 Improper ignition timing No spark at plugs Engine stop sWItch OFF Pomts not opening Points burned, wet fouled or dirty bum—- — Loose or broken wire — Faulty engine stop Swltch Plug fouled Faulty plug Wire Cori weak or inoperative Faulty condenser macaw No primary current to points and coils Engine start: but runs poorly 1 Ignition primary circuit -— Points dirty or fouled — Incorrect point gap Faulty coil Faulty condenser — Loose wire connection intermittent shortcircuit in switch 2 Ignition secondary circuit ~ Plug fouled or worn — Faulty plug wires 3 Ignition timing - Improper ignition timing Dau oiInm 25.9. 1978 munNnA un'rnn rn nu 14.1 IGNITION SYSTEM 250R HONDA IGNITION COIL SPARK GAP TEST Tesl (he coil output as per the tester manu» facmrer’s Instruction: The coil is satisfamory if sparks jumps across me gap specified‘ CONDENSER CONDENSE R CAPACITY NOTE r————-——:——* .The condenser must be discharged ‘: befiore IesKing the maxim GROUND WIRES SERVICE TESTER SECONDARY WIRE (+I PRIMARV ELECTRODE J_ 6mm t (0.24 in} T.— < SPARK SECONDARY ELECTRODE DISCHARGING CONDENSER 14-9 on: ails-"150D. 1978 m unNnA un‘rnn en nu h... 1..“ I... I..- I“. I.“ I“ I.“ h, I... I...» I... I1”. I... I... I... L... I.“ "W 5" f7 HONDA Z5OR , IGNITION SYSTEM Measure the condenser capacity. If it is om of (he speclfied limit, replace the condenser CAPACITY: 0.27—0.33 HF COIL CONTINUITY TEST Remove the spark piug cap bv turning u coumreciockwise Check the coil for continuity as shown, CONTINUITY: Good NO CONTINUITV: Replace Check the Drlmarv coil for continuity as shown‘ CONTINUITV: Good NO CONTINUITV: Replace Check the secondary coll for continuity as shown CONTINUITY: Good NO CONTINUITV: Replace aim-Jaw, fiflfla!:=?L————— ll SJ IJ £4 id id SJ ll 1d .IJ 14 Id id 3d 3d id ii 3i ii HONDA 250R MEMO "TIT—IT? ‘3] ”TI 'T'I V'TT'T'I'T'I % HONDA Z 50R I _ I5. TROUBLESHOOTING ENGINE DOSE NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFOMANCE AT LOW AND IDLE SPEEDS ENGINE LACKS HIGH SPEED PEFORMANCE SMOKY EXHAUST FAULTY CLUTCH OPERATION FAULTY TRANSMISSION OPERATION ENGINE NOISE STEERS TO ONE SIDE OR DOSE NOT TRACK STRAIGHT IMPROPER FRONT/REAR SUSPENTION 15—2 15—2 15—4 15—5 15—6 15—6 15—7 15—7 15—3 15—8 .0 N. 1': é TROUBLE SHOOTING HONDA 250R vENGlNE DOES NOT START OR IS HARD TO START SYMPTOM +_____¥4___ ‘ Fuel reachlng carburetor “‘9' "°‘ 'ml‘il‘g ‘ carburemr 4 . E; " ' Good spark Weak or no spark l l <— ——————— l CompreSSIon normal Loss ol compression 1 Check .r luel is reaching car—l ‘1 buretor by looseningdrain I (ll FR) Lscrew (3) V_~—.____l:l4l (1) TEESZJJEQ I; *7 (z) Ltrv spark tesr _l (3) (4) _ --(5) l6) ___________ _l l—Test cylinder compression l (7) _l by operating kick miner l (3, ‘— ——————————— J (9) l1] (2) ,——__———f———____‘ (3) 1 Stan by lollowmg narmel l Ffll l (4) Lfijrflnipfcjifle____J U 2 E x 2 e u - ENGINE LACKS POWER SYMPTOM r- Tlre pressure normal Tire pressure is too r ——————————— —l Restart with choke applied Jl CHECK __’ _________ l Try rapid accelerariun horn ‘ i Dyiaiegvf _____ J Engine speed lowered when 2 gear changed Engine speed nor changed when gear changed l~__'+ —————————— l Ligmly acceleraleengine l 15-2 L. _________ J PROBABLE CAUSE No fuel in fuel lanl. Clogged fuel line or fiuel filler Clqgged carburetor lets Clogged fuel tank can breather hole Faulty spark plug Fouled spark plug Fouled contact breaker points Improve! breaker pom! gap Faulty condenser Broken or shorted l'llgh ten5|on cord Broken or shorted lgnlllan coil Faulry main switch Improper lgnmon liming Valve clearance too small Ban: valve 1 open Worn cyllnder and prsron rings Leaking cylinder head gasket Improper valve ‘lmlng Misuse of choke Carburetor pilot screw excessively closed Manifold air leak Carburetm overfluoded Carburetor choke excessively closed Thronle valve excess-vely open PROBABLE CAUSE Punctured rire Fauny tire valve Clutch sllpping Worn clutch dlsc Clutch disc warped Date oflmo : Sop. 197E e unnh/l «mean rm rvn hhhhl‘k hkn‘mL-hu I“... ‘hlu J .l "‘lfl""‘l""'lm'l"—'l ' 1'73 F 37"1 “l ' "."l Engine speed lncreased ~. TROUBLE SHOOTING Englne speed not in- creased sufficiently F——A—‘fi i lm ro er n'tlon Ignition tlmlng ls correct . E p '9 I l timing —‘ — ——— v———-| |_Clreck valve clearance i l ____________ J >l1l l 4 Valve clearance is normal Valve clearance is not correct F . i Compression Is normal l Test cvlinder compression _____ _— ——-—~——, by operating kick starter and l :4 Lining compression gauge l —l2) i —(‘ll '(2) Compression is low 1.. ______ F—'——‘——l i Carburetor is not clogged Carburetor ls clogged 3 Spark plug is not fouled or Spark plug is fouled or discolored l or dlscolored F—‘“‘ i Oil pressure normal r i . l Normal all pressure Low oil pressure l1 ..l FCheck carburetor lor clogg- l J9 I l ____________-_l r———————————————l l Removes ark In 3 l Lafi__”_-3_':' _____ .J Lcheck oil level and rouleng l ————————— —4 h k ll t l 1 C°_*:_l::"9_m:2v:_e_=_s [ Englne ls not overheated -l3) ~i4l ‘(Sl Englne overheats Engine does not knock i “(1) ‘(3l Engine knock! '(4) ‘(Sl Carburetor choke closed Dirty air cleamr Restricted fuel flow Clogged fuel tank breather cap hole Clogged muffler improper contact breaker point 95p Improper valve clearance Worn valve seat Bent valve Worn evllnder and plston rings Leaking cylinder head gasket Flaws in cylinder head Improper valve timing Fuel filter not servlced frequently enough Use of low quality fuel Plugs no! serwced lrequently enough Use of plug wrth Improper hear range plug on level (00 high Oll level too low Contaminated oil Clogged Oli passage Poor oil pump delivery Excessive carbon bulld~up on combustion chamber wall Use or low quality fuel Clutch slipplng Fuel-air mixture too lean Worn plston and cyllrlder Fuel air mixture too lean Use 0' low quality fuel Excessive carbon build-up in combustlorl chamber lgnition timing advanoed Date 0' lguo :Sopr 197B - “mm. mwnrs an 15-3 TROUBLE SHOOTING II(JFWI)IL 250R OPOOR PERFORMANCE AT LOW AND IDLE SPEEDS SYMPTOM l Normal I L‘E'ief'ia’f'fi _____ J __L—Check carburetor pilot Lmrew adiustmen! l I Not leaking Leaking F — Tr svarktest 1L_y_4.._,____7___l Good spark Weak or intermittent spark PROBABLE CAUSE Improper valva clearance Improper lgnmon tlmlng Fuel air Mixture loo lean Fuel air mlxture (00 ”Ch Deteriorared Insulalor Loose carbureror Defective, carbon or war fouled spark plug Fouled breaker poms Condenser shorted Law battery 15-4 0! In 5.9, 1978 Laklulm.lu.k‘lmhhlnlmhh.h 7"] ""3 "'1 """l "NWT-l 1"? TwlT’T'l 250R HONDA T ROUBLESHOOTINGM 0 ENGINE LACKS HIGH SPEED PERFORMANCE SYMPTOM Q + ___________ #1 lrrmmg and clearance ‘lnormal Timing and clearance improper 1 Not clogged Clogged J Remove carburetor and J CHECK TcTieEIGnTrfifiFni—nfiij Lvalve clearance 1 : Check for clogging bv dis‘ l l _______ ’l connecting fuel line at = l l carburetor L__’ e _ 7* E e- ___ l inspect jets l L ___________ l l—'_7"—"l Fuel flows out freely Fuel flow restricted l“ _ 'E"____’_‘ll l <— ————————— —4 Replace carburetor jet: 1 l L ___________ l Condfllon aggravated] Condition Improved L__ l___ _,e f:— : Timing normal _: f Engine our of time .— ____E_A__ ‘—l l Tension normal Weak or brake" spring l (1) (1i (1) PROBABLE CAUSE Improper adiustmem Fuel line clogged el tank Fuel tank cap breether hole clogged Fuel filrer dirty Clean Mam jet xize too small If Improved with smaller size jet: 3) Air cleaner clogged bl Choke valve nor opening fullv Cam sprocket aligning marks not aligned Faulty valve spring Date of Isue : so». rare _ .mwm wwnn no iw‘ 15-5 TROUBLE SHOOTING HONDA 250R ‘ SMOKY EXHAUST SYMPTOM ? u ________ CHECK 7‘r h h d ' j! _7_ ——J '1 fl LLL33E:LUELSA_J ‘ Smoke disappeared I Smokv exhaust lfi _______ No white exhaust Wh esmoke em ed ummedrstely alter Lciosing grip F ____________ _l l _ I — —#4‘ Close throttle grip quickly : \_ __________ J F__—L _e.-_____ _____ ‘ r —- —————————— —LTry low speed running J " Ne smoke Lwhite smoke l 0 FAULTY CLUTCH OPERATION SVMPTOM V. |:(Zl PROBABLE CAUSE Worn cylinder and piston rings Crankcase oil level too hlgh Piston rings installed ups-tie down Scored or smiled prslon or cylinder wall Flaws in cylinder head (1) Worn intake valve guide or stem (1 (2 (3) Valve guide Owing not seated properly Worn exhaust valve stem and guide Exhaust valve guide improperly pressed in Worn exhaust valve stem seal PROBABLE CAUSE e," : : rcu h l' ~————————Eg; . utc 3 upping L__._._ (3) #Aeg—h l E Clutch drags l L, Weak clutch spring . Worn or warped clutch plate Worn or warped clutch disc Plates or discs warped Uneven clutch spring tension Dull ol lulu :SW‘ 1978 I... I.” hluehhkkelnlm In. I.“ I...“ I..." In. ""1 "‘1 ""I 7"} ""1 "‘1 '" "I ""1 ' “"1 ""1 7"“I HONDA 250R - FAULTY TRANSMISSION OPERATION SV MPTOM Hard to shift into gear , Gearshift pedal does not return 1—._—_ _______ (Clutch operates properly) reaJERUB'rE §lLQQTWG so _ PROBABLE CAUSE —12l ——(1I (2 I Transmission lumps out of gear I A . ENGINE NOISE SVMPTOM I—J Piston slap I l l A ”(3) Gearshift arm spring broken Shift fork: bent Shirt drum and shift lork binding Gear dogs broken or worn excessively Shift erm pawl out o! engagement with shift drum pin Drum stopper plate and drum stopper Improperly set Gearshift return spring broken Gearshift spindle interfering with crankcase or left cover Shilt guide lork pin worn Shift lurks bent or worn Shift drum stopper spring broken or weak PROBABLE CAUSE . (1) (1) w*—E (2) (3) (1) Corn chain noise —————————( Hard suspension __._...—. _.__ Excessive or abnormal noise 1 i___]_—T—_‘ _ Soil suspension —— L", ~______ A *4Tire pressure normal) (1) __Em (3) -——v—T(1) (2) EU) (2) PROBABLE CAUSE Weak spring Excessive load Incorrect weight oil in lront forks Faultv shock absorber damper velva From forks assembled incorrectly Damaged damper Front fork assembled incorrectly 15-8 DIII ohm. : 59p. I978 ® HONDA MOTOR co LTD I.. I..- I-.. I... L. I... I... I... I... I... I... I... I... LI.» h. L“ In.“ ”"1 'I " '"'I I 0...] m- "TI "I "'"I f" ”I "T”! 7") "W ""1 ZSOR HONDA 16.’80-’81 ADDENDUM i I l I SPECIFICATIONS SPARK ARRSTER CABLE AND WIRE HARNESS ROUTING MAINTENANCE SCHEDULE FUEL SYSTEM A.C. GENERATOR WHEEL'AND BRAKE HANDLEBAR WIRING DIAGRAM 16—2 16—4 16—5 16—6 16—7 16—8 15—9 16—11 16—12 INTRODUCTION ThIs Honda Shop Manual Addendum contains information for the '80 and ’81 250R. Refer to the base Shop Manual for service procedures and data not included in this addendum. ALL INFORMATION AND ILLUSTRATIONS INCLUDED ; IN THIS PUBLICATION ARE BASED ON THE LATEST 5 PRODUCT INFORMATION AVAILABLE AT THE TIME , OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRO- L DUCED WITHOUT WRITTEN PERMISSION. I_____ M ,7,,__,___ ._____.,._vfi¥A_I HONDA MOTOR CO, LTD. SERVICE PUBLICATIONS OFFICE Dale 0! Issue 5on,1980 1R-‘I HONDA é 150R '80-'81 ADDENDUM SPECIFICATIONS I lrem Metric English I I Dimensions Overall lengrn 1,300 mm 51.2 m I 3 I Overall widrlv 605 mm 23.3 in I I Overall height 810 mm 31.9 .n I I_Whee| base 895 mm 35.2 in I Seat height 575 mm 22.6 in I 1 Foot—Peg heigm 220 mm 9.7 in I Ground clearance r 140 mm 5.5 In I I: Dry weigrrr 7 49.5 kg 109.1 lb I Frame ‘ Type Backbone I From suspension Telescopic fork I I Hear suspension Swing arm 1 I I Front zire size 3.50—3-2PR I 3 Rear tire size 3.50—8—2PR I . Front 1.0 kg/cm’ 14 0:1 I Cold rrre pressures Rear 1.0 kg/cmi 14 psi I . Front brake Internal expanding shoe fir ‘ Re'a'rErake Internal expanding shoe Fuel capacity 5.0 lit 1.3 US gal . Fuel reserve capacity 0.7 II: 0.13 US gal. I I Casier [Degrees Irom horilontal) 25° ITl'rall 42 mm T 1.7 in "From fork oil Grease ' E nglne LType Air-cooled, 4 stroke OHC Cylinder arrangement Single 80° inclined from vertical Bore and srroke 39,0 x 41.4 mm 1.535 x1.630ln Displacement 49 cm’ 3.0 cu in Compression ratio 8.8 I Valve train Chain driven overhead camshaft Oil capacity 0.8 lit I 0.85 Us at Lubricafion system Forced and war sump Cylinder head compression pressure 12.0 kg/crn2 —1.000 rpm I 168 p5l I Opens 7° BTDC (a! 1mm lift) Intake valve Closes 12° ABDC (at 1mm 11m Opens 22° BBDC (at 1mm lim Exnausr valve Closes 2° ATDC (at 1mm IlftI IN 005 mm 0.002 In Valve clearance (cold) EX 0.05 mm 0.002 in I Idle speed 1500 2 100 rpm Engine dry weight 17 kg 37.510 4 fi‘“"4 Date of Issue‘ Sam I980 J I» I..cl I... leer. I»: 1.... le. 1...: 1...; In... l. l...‘ lens L.» I... I... ‘TJ‘T’l V") ”"7 w] .....] "'1 """l ”"1 ”ml 7"“1 I "l :7 HONDA Z 5 O R m ’30—’81 ADDENDUM Metric Item | English ‘ éCarburBfion Carburetor type Piston valve ‘ Venturi diameter 11 mm [ 0.43 In E Identification number PAosc . Air screw opening 1-1/2 Float level 12.711 mrn 0‘501004 m iDrive train L Clutch Wet multi~plate automatic (cantriiugail 1 ‘ Transmission knead constant mesh J Primary reduction ratio 3,722 ‘ 3 Gear ratio I 31 31 ‘ Gear ratio I! 1.823 ; 1 Gear ratio III 1.190 2 ‘1‘ Final reduction ratio 3.083 (37/12l E Gear shift pattern Left foot operated return system N—1—2—3 : 1 Electrical Ignition A,C. magneto l ' Generator Flywheel 1 Starting system Kick start i U.s.A. type NGK C6H ND UZDFS 3 Spark plug r Canada type NGK CRSHS ND U20FSR-L 5 Spark plug gap 0.8—0.7 mm OOH—0.028 In ‘ :9 ‘I Q . ’3 m... "r l«ua' Sun 1am) l.-_ é HONDA ZS OR '80—’81 ADDENDUM L; SPARK ARRESTER Remove the nght number plaxe. Remove ‘he spark arresler from the exhaust pipe. I.“ .5 I.m Remove the clean out can Ssart the engine and rev It abou: ten times while blocking the exhaust pipe with a shop towel. Fiemsrall the clean om cap. Clean the spark _ arrester and relnstall ! and the number late‘ , ‘ . ‘ ' p Y ‘ CLEAN OUT CAP hkhl... ' Do not perform this operarion immediately aher (he engine has been run because the exhaust system becomes very hot. Because of the increased fire hazard ensure that xhere are no combustible materials in the area when purging the spark arrester. Wear eye protection Never run the engine In a closed area. The exhaust consams poisonous carbon monox- rde gasc Lklmlm‘ u; t... L‘, 1R - 4 gassihwzifzm’fia“ .m ”"71 HONDA F 250R ‘ '30—'31 ADDENDUM, CABLE AND WIRE HARNESS RQIITING ””1 ENGINE STOP SWITCH WIRE F- I THROTTLE CABLE I” was BAND IGNITION COIL I PRIMARY LEAD L. P I , L v “'1 “'71 (“TI ““71 AC. GENERATOR ‘\ WIRE “"1 CRANKCASE i T BREATHER TUBE T F FRON BIZAKE CABLE WIRE BANDS xGNITIQN COIL I THROTTLE CABLE F t“ I I , ID \‘ Sn ' [— I F r r ENGINE STOP SWITCH i WIRE j / / I \/ 16-5 Date of Issue San , 1980 '80—'81 ADDENDUM HONDA zsoR MAINTENANCE SCHEDULE The mamtenance Intervals shown In me IolIowmg schedule are based upon average riding conditions. Machmes subjected to severe use, or Vldden In unusually dusty areas, require more frequem servicing. Items marked 'should be servrced by an aurhorlzed Honda dealer, unless the owner has proper tools and is mechanically qualified. —, To prevent persona! Injury, always make certain the engine is mapped and the motorcycle ix supported securely on Elm/81‘ ‘mrflzcc prior (0 performing any maintenance ”NOTE (I) r (YI Inspect and Clean, Adiust, Lubricate or Replace if necessary L: Lubricate Clean R~ Replace A' Adjust whlchever comes first. Replace every 30 operating days or every 3 momhs, Servlce more frequently when rlding m dusty areas. INITIAL SERVICE PERIOD (Firs! week of Operatlol’lrI REGULAR SERVICE PERIOD (Every 30 operatlng days.) ENGINE OIL NOTE II) (2] CONTACT BREAKER POINTS ' IGNITION TIMING VALVE CLEARANCE SPARK PLUG ‘ CARBURETOR AIR CLEANER ELEMENT NOTE (2) C THROTTLE OPERATION FUEL LINE I (EVERY YEARI ' FUEL FILTER SCREEN C: (EVERY YEAR! DRIVE CHAIN CLUTCH SPARK ARRESTER C BRAKE CONTROL LINKAGE l ' BRAKE SHOES l: (EVERY YEAR) ' STEERING HEAD BEARING A: (EVERY YEAR] TIRES ALL NUTS, BOLTS, FASTENERS 1G,,R 3 l.“ L. I.“ I... I... I... I... lm I“ I... I...“ I...“ I“; ll. I.“ I1. ‘7' ”'1 "”1 ’“l 5?] "7'1 F l 7"") "'"J ‘W HONDA 150R ‘80—’81 ADDENDUM FUEL SYSTEM CARBURETOR SPECIFICATIONS WARN]: 1 Standard semn ‘ Gasolme ix exrremely flammable and ix explosive under Identification No. PADaC certain condirion; 0.0 not smoke or allow flame: or spark: Main jet #58 in your working area. —- ~—- Jet needle setting 2nd (from top? Alr screw opening 1-1/21urns out FIoat level 12.7 11 mm DISASSEMBLY AND ASSEMBLY Idle speed 1500 rpm For details, reler m the base 250R Shop Manual. NOTE iWhen disassembling fuel system parts, note the location ol the OArings‘ The float chamber has a dram plug that can be loosened to drain residual gasoline. . RUBBER CAP NOTE Before nstallation, check for AIR CLEANER dexerlorana Fuel Line Check for deterioration, cracking or other laults. Replace if necessarvl THROTTLE VALVE O-R ING NOTE Replace used O-rlngs. THROTTLE STOP SCREW / AIR SCREW F LOAT CHAMBER DRAlN SCREW 9M.“ Lsauefiw'm" , ~ . 1 6- 7 "my-n y-m ‘ h A.C. GENERATOR WOODRUFF KEY 3.0—3‘8 kg~m (22~27 ft-lb) LEFT CRANKCASE COVER 18-9 I‘MIMIMLA. I... L‘ I... La I... I.“ IN“ L. lg. L- L... 1..- l4“. W...) .7. 7"] ~71 "‘1 ”"1"”! "I ‘f'I "77 ”"1 "fl HONDA Z 5 O R '80—'81 ADDENDUM WHEEL/ BRAKE SPECIFICATIONS Item STANDARD SERVICE LIMIT Brake lining thickness (front/rear) 3.5 mm (0.4 in) 2.0 mm (003 In) Brake drum I,D (front/rear) 80.0 mm (3.15 in) I 8L0 mm (3 19 m) Front and rear axle nut torque [’81 model): 4,5—5‘5kg-m(33~40ft~1hI WHEEL RIM DUST SEAL \ \ DISTANCE \ COLLAR BEARING NOTE TherIarerarxrr1gisreréliedAj and laces om BEARING REAR WHEEL “”5 WHEEL RIM WHEEL RIM DRIVEN SPROCKET BEARING NOTE , , ,, M,“ SIDE COLLAI‘I The bearmg seaIed ‘ 6"? ”659354-74 WHEEL HUB / DISTANCE / / COLLAR ,, @ém BEARING DUST SEAL @ «Em mam BRAKE LINING |NSPECT|0N Remove the wheat Remove the brake panel from the wheel hub. Measure the brake Inning mickness. SERV‘CE LIMiT. 20 mm [0.08 in) Replace the brake shoes if necessary. mmvnvo VVVVVV _. _ ______, Keep grease ofifrhe inside of the wheel hub \‘ and brake Iimng surfaces. ; BRAKE SHOE REPLACEMENT Remove the shoe spring from the anchor pin‘ Remove the brake shoes from the brake panel. Remove the brake arm. Remove the brake cam and mdlcator tab. Apply grease to xhe brake cam and brake shoe anchor pm. BRAKE PANEL ASSEMBLY Assemble (he brake shoes in the reverse order 0! remova! BRAKE ARM IND CATOR TAB NOTE NOTE Align me punchRJk on ma Afign t-bfifiiicator HT?“ BRAKE CAM '80—’81 ADDENDUM HONDA 150R BRAKE SHOE SPRING DUST SEAL ANCHOR PlN arm With me punch mark on ‘ iwuh the Cut out in the (he camshafl IEfiEPETEE‘E“ BRAKE PANEL BRAKE SHOE BRAKE SHOE SPRING at: 4!“ gm of Issnu: 599., I930 Lu, L“! LA! Lu .i L‘) ‘1 4 - W“ “’1 7'7] ”'7 '7’} ""' W "“1 ““7 "7"] 7"! ""1 M') '7'”! '“W W W" "'"l "'1'? HONDA ZS OR BRAKE DRUM LD. '80—'81 ADDENDUM Clean the Inslde of brake drum usmg a clean cloth. Mesure Ihe brake drum LD‘ FRONT and REAR SERVICE LIMIT: 81‘0 mm (3.19m) HANDLEBAR @ FRONT BRAKE CABLE WIRE BAND THROTTLE GR‘P ENGlNE STOP SWITCH WIRE THROTTLE CABLE HANDLEBAR 3‘0—4‘5 kg-m (22—33 fl-Ibl 2353::me Sop” 1980 1 6- 1 1 n . IRD‘PflB on v'rn . HONDA ZS R ’80—'81 ADDENDUM o ENGINE STOP SWITCH OFF RUN OTC} Black/White Green Black hite Black/White |GN|T|ON COIL ENG‘NE STOP SWITCH CONTINUITY % V __ ' ’Iémflv'V’T‘ ‘95: O——-0 I l ifipflf ,7? 777777 HQFLWV O——“O L1 Colov Black/Whue Green SPARK PLUG A.C. GENERATOR 777177 16-12 Dom of lxuo: 309., I930 13 HoNnA MnTm: C“ MD I... I... 1.. I.“ I». I“ I... I... I... l-. I“ I.“ ”'"I ”'lflwf'"! ”Ml TO ""1 WW] 7'"? ”'T'I '"71 “I ("I 1 I "7”] "WI 7"] f” w»- HONDA Z 5 O R 17. ‘82 ADDENDUM INTRODUCTION This addendum contains only new information for the 1982 250R, Refer to the base shop manual for serVIce procedures and data not included here. ALL INFORMATION AND ILLUSTRATIONS IN~ CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL» ABLE AT THE TIME OF APPROVAL FOR PRINT» ING HONDA MOTOR C0,, LTD‘ RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- OUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE RE- PRODUCED WITHOUT WRITTEN PERMISSION‘ HONDA MOTOR C0., LTD‘ Service Publications Office CONTENTS I. SPECIFICATIONS .................. 17-2 M. LUBRICATION ................... 17-2 Ill. FUEL SYSTEM ..................... 173 IV‘ CYLINDER HEAD/VALVES ......... 17-5 Date of Issue: September, 1981 ¢ ”MAMA. m rm 17-1 HONDA ‘82 ADDENDUM 250R ITEM ENGINE Compression ralto 9 5.1 CARBURETION Carb tdenttficatton no. PAOJD DRIVE CHAIN FInal reductton ratio 2846 (37/13) ELECTRICAL Spark plug NGK CRSHS ND UZOFSRVU II. LUBRICATION SPECIFICATIONS Use HONDA 4VSTROKE OIL or equvvalent‘ API SERVICE CLASSIFICATION SE or SF VISCOSITY SAE10W~4CI Other VISCOSItIeS shown In the chart may be used when the average temperature m your Hmng area Is thhm the Indrcated range SAEZOW— 40, ZDW—SD SAEIOW—dO SAE IOW—SO OIL PUMP ASSEMBLY Ahgn the flat on the shaft Wlth the flat on the InnE'Y rotor Alter assemblmg, check that the shaft rotates freer wnhout bmdmg (9 INSTALLATION @ thh the gasket In place, Install the OH pump by aIIgmng the romr shaft groove wrm the (any on the cam chatn guide spdee ®m@o )m 0 is; 77—? Date of Issue September, 1981 ft Honda Motor (‘n t m lm.l.ul.wl....l...l...la_lu hhhkhkh‘tu l- I“ I”. "7'1"“? ""1 "“1 oil ”WI ""3 7""1 ”WI “’1 7"? '7'] 75"] 7'1 TI ”ml ”T'l T“? ""1 6 HONDA Z 5 O R ‘82 ADDENDUM III. FUEL SYSTEM CARBURETOR SPECIFICATIONS W Gasoline is extremely flarw mable and is explosive under certain condi- tions. Do not smoke or allow flames or spark: in your working area, AIR SCREW REMOVAL/ INSTALLATION Turn the air screw in and carefully count the number of turns before it seats lightly. Make a note of this to use as a reference when rein~ stalling the screw CAUTION: Damage to the air screw and seat WIII occur if the air screw is tightened against the seat. Inspect the air screw for wear and replace it necessary Then reinstall the screw and re~ turn it to its original position as noted during removal Perform the air screw adjustment if a new screw is installed ADJUSTMENT NOTE The air screw IS factory pressel and no adjustment is necessary unless the air screw is replaced Turn the aIr screw clockwise until It seats lightly and back it out to the specufication given Thls is an initial setting [liner to the tirial adjustment INITIAL OPENING: I 1/2 turns out CAUTION: Damage‘to the air screw and seat Will occur if the air screw is tightened against the seat, Warm the engine up to operating temperature. Stop and go riding for 10 minutes is suffici- ent. Connect a tachometer Ad|usl the idle speed With the throttle stop screw IDLE SPEED: LSOOLIOO rpm Turn the air screw in or out to obtain the highest engine speed Readtust the idle speed to 1500:.100 rpm, using the throttle stop screwr Date of issue. September, 1981 Standard setting Identification No, PAU3D Main jet #358 Jet needle setting 2nd (from top) Initial air screw opening 1 1/2 turns out Float level 12r7ilmm Idle speed 1,600 rpm 17-? '82 ADDENDUM HIGH ALTITUDE ADJUSTMENT For Sustained hlgh almude operation (above 2,000 (TI/6,500 fl) Install a # 55 mam jet, reset The )et needle Cllp, and readjust idle speed Remove the carburetor from the engme and remove the float chamber Replace the standard mam jet with the # 55 mt. almude mam je‘ Move the m needle chp to the firs: groove on the needle Assemble and msxall The carburetor Adluu Idle speed 10 15001100 rpm, usmg me (Home $100 screw CAUTION: Sustained operation at altitudes lower than 1,500 m (5,000 H) with the high altitude main iet ins‘alled may cause engine oveyheanng and damage. For sustalned opera» uon below 1,500 m (5,000 It], remslall the standard mam 12: I: 58L reset the jet needle clxp, and readpusl (he Idle speed. Sxandard ngh almude 2,000 m 1,500 m (6,500le max 15,000mmm I Mamlei #53 #55 :i‘p'me‘“? 2nd (fromlop) 15! Ifromtopl Idle speed 15001100 rpm I Arr screw onemng Factorv preset fl HIGH ALTITUDE $5 STANDARD SETTING 17/! Dateol Issue September, 193» Lg I... I...“ In" h- i I A "l w"I ""1 ""1 HONDA 250R '32 ADDENDUM IV. CYLINDER HEAD/VALVES"? DISASSEMBLY AND ASSEMBLY 6 mm BOLT Loosen Ihis bolt ingMIy and lightly tap on is head to facilitate removal of the la“ Slde cover. COPPE R WASHE R VALVE COVER NOTE: Before instaIIing, apply grease to the threads. RIGHT SIDE COVER VALVE CYLINDER HEAD CAM CHAIN SEALINGWASHERS ., GASKET HOUSING SEAL 0.9—1.2 kg-m (6.5—9 k-Ib) \/ A§\ I \ I 0‘"- ! v o‘- ; 119—12 kg—m 0.9—1.2 kg-m (6.5~9 ft-lbl CAM SPROCKET 0.3—1.2 kQ-m (5—9 Mb) \ (6.5—9 fi-Ib) ROCKER ARM CYLINDER HEAD COVER \ NOTE Install With the arrow faclng down (ex nae) ‘ / LEFT SIDE COVER Dale oI Issue. September, 1981 17- F. , HAN-n Mp”. PA 1m ‘82 ADDENDUM HONDA Z 5 O R SPECIFICATIONS L. L I... STANDARD SERVICE LIMIT Camshaft lobe hewght IN 27 945 mm (1.100 in) 27 55 mm H 085 In) J EX 25076mm(1026m) 25.69mm11011m) Vah/e sprmg free length Inner 251 mm (0 988 m) 219 mm (0.940 m) 4 ouier 28.1mm(1106m) 269mm (1 D59m) d I.” VALVE DISASSEMBLY Remove (he valve and mspecr (he iace VALVE SPRING SEAT 5', VALVE STEM SEAL CAP \ k VALVE 6% H :he sear Is [00 Wide, too narrow, or has low sums, me sear must be ground NOTE After mslalhng, check that the cotters arP sealed prooer‘y \\% SEAL INTAKE VALVE ”VALVE TEM s NQQ SPRINGS l... l“; I...“ I... NOTE renew the verve reracer manufacrur. J er’s operaung msrrucmons GRWDING STONE PILOT BAR "A" j 0773170010100 ‘ IN, EX: 07780-0010100 IN, EX' 077800014000 45° 17-5: Dare of Issue: September, 1981 m ”Adda“. n, \.. I...» l..._ I.” I... J