Honda rebel 250 Service Manual

A Few Words About Safety

Service information

The service and repair information contained in this manual is intended for use

by

qualified,

professional technicians.

Attempting

service or

repairs

without the

proper

training, tools,

and equipment

could cause injury to you or others. It could also damage the vehicle or create an unsafe condition

This manual

describes

the proper methods and

procedures for

performing service, maintenance, and

repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any

person who intends to use a replacement part, service procedure or a tool that is not recommended by

Honda, must

determine

the risks to

their personal

safety

and the safe operation

of the

vehicle.

If

you need to

replace

a part, use

genuine Honda parts with the correct part number

or an

equivalent

part.

We strongly recommended that you do not use replacement parts of inferior

quality.

For Your Customer's Safety

Proper service and

maintenance

are

essential to the customer's safety and

the

reliability of the vehicle. Any error or

oversight while servicing

a

vehicle can

result in faulty

operation,

damage to

the

vehicle, or injury to others.

For Your Safety

Because

this manual is intended for the

professional service technician, we do not

provide warnings about many basic shop

safety practices

(e.

g

.

Hot parts

-

wear

gloves). If you have not received shop

safety training or do not feel confident

about your

knowledge of safe

servicing

practice, we recommended that you do

not attempt to perform the procedures

described in this manual.

Some of the most important general

service

safety

precautions

are

given

below. However, we cannot warn you of

every conceivable hazard

that can

arise in

performing service and repair procedures

Only you can decide whether or not you

should perform

a

given

task.

Important Safety Precautions

Make sure you have a dear

understanding of all

basic shop safety practices and

that

you are

wearing

appropriate clothing and using safety equipment. When performing any service task, be especially

careful

of the

following:

• Read all of the instructions before

you

begin, and make sure

you

have the tools, the replacement

or

repair

parts,

and the skills

required

to

perform

the tasks

safely and completely.

• Protect your

eyes by

using proper safety glasses, goggles or face shields

any

time

you

hammer

drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy

components If there

is any doubt, put

on

eye

protection

AWARNING

Improper sen/ice or repairs can create an unsafe

condition that can cause your customer or others to be
seriously hurt or killed.

Follow the procedures and precautions

in this

manual

and ether service materials carefully.

AWARNING

Failure to

properly follow Instructions and precautions

can cause you to be seriously hurt or killed.

Follow the procedures

and

precautions in

this

manual carefully.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or

sharp parts can

cause

severe burns or

cuts.

3efore

you

grab something that looks like

it

can hurt

you, stop and put on gloves.

•

Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the

vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack

stands.

Make sure the engine

is

off before you begin any servicing procedures, unless the instruction tells you

to do otherwise. This will help eliminate several potential hazards:

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers

and clothing are

out

of the way.

Gasoline vapors and

hydrogen

gases from batteries are explosive. To reduce the possibility of a fire or

explosion, be careful when working around gasoline of batteries.

•

Use

only a nonflammable solvent, not gasolire, to clean parts.

. Never drain or store gasoline in an open container.

•

Keep

all cigarettes

sparks

and flames

away

from

the

battery and all fuel-related parts.

Your safety, and the safety of others, is very important. To help you make informed decisions we

have

provided safety messages and other information throughout this manual. Of course, it is not practical or

possible

to

warn

you

about all the hazards associated with servicing this vehicle. You

must use

your

own good judgment.

You

will

find

important

safety

information in

a variety of forms

including:

. Safety Labels

-

on the vehicle

•

Safety Messages preceded

by

a safety alert symbol

&

and one of three signal words.

DANGER.

WARNING,

or

CAUTION.

These

signal words

mean:

ADANGER

AWARNING

ACAUTION

You WILL be KILLED or SERIOUSLY HURT if you don't follow

instructions.

You CAN

be

KILLED

or

SERIOUSLY HURT if

you

don't follow

instructions.

You CAN be HURT if you don't follow instructions.

• Instructions

-

on how

to

service this vehicle correctly and safely.

As you read this

manual,

you

will find information

that

is

preceded by a

LNPTICE_

symbol.

The purpose

of this message is

to

help prevent damage

to your

vehicle, other property,

or

the environment

ALL INFORMATION, ILLUSTRATIONS. DIRECTIONS AND SPECIFICATIONS INCLUDED IN

THIS PUBLICATION ARE BASED ON THE LATEST 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

REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR

PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA

MOTORCYCLES. MOTOR SCOOTERS OR ATVS.

CHASSIS

CONTENTS

GENERAL

INFORMATION

FRAME/BODY PANELS/EXHAUST

SYSTEM

MAINTENANCE

LUBRICATION SYSTEM

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

CLUTCH/GEARSHIFT LINKAGE

ALTERNATOR/STARTER CLUTCH

CRANKSHAFT/TRANSMISSION

FRONT WHEEL/SUSPENSION/

STEERING

REAR WHEEL/BRAKE/SUSPENSION

HYDRAULIC

BRAKE

BATTERY/CHARGING SYSTEM

IGNITION

SYSTEM

ELECTRIC STARTER

LIGHTS/METER/SWITCHES

WIRING DIAGRAM

TROUBLESHOOTING

INDEX

2

_

£
£

5

_

6

_

]_

8

9

1

£

21
21

21

21

21

21

2Z
21

19

20

21

SYMBOLS

The symbols used throughout this

manual show specific service procedures. If supplementary information is required

pertaining to these symbols, it would be explained specifically in the text

without

the use of

the symbols.

Replace the

parti

s)

with

new onels)

before assembly.

Use recommended

engine oil. unless otherwise specified

Use

molybdenum oil solution (mixture of the engine

oil

and molybdenum groase in a

ratio

of 1 : 1).

Use

multi-purpose grease (Lithium based

multi-purpose

grease NLGI

#2

o*

equivalent).

Use molybdenum

disulfide grease (containing more than 3% molybdenum disulfide, NLGI 02 or

equivalent).

Example; Molykote*

BR-2

plu9

manufactured by Dow Corning. U.S.A.

Multi-purpose M-2

manufactured

by

Mitsubishi Oil

Japan

Use

molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or

equivalent).

Example: Molykote*

BR-2 plus, manufactured

by

Dow Coming, U.S.A.

Honda Moly 60 (U.S.A. only)

Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico

Lubricant.

Jap

an

Use silicone grease.

Apply a

locking agent. Use a middle strength locking agent unless

otherwise specified.

Apply sealant.

Use brake fluid. DOT 4. Use the rocommended

brake fluid, unless otherwise specified.

Use Fork or

Suspension Fluid.

1. GENERAL

INFORMATION

GENERAL SAFETY

1-1 TOOLS

1-14

SERVICE

RULES

1-2

LUBRICATION & SEAL POINTS

1-16

a

MODEL

IDENTIFICATION

1-3

CABLE & HARNESS ROUTING

1-18

SPECIFICATIONS

1-4

EMISSION CONTROL SYSTEMS

1-26

TORQUE VALUES

1-12 EMISSION CONTROL INFORMATION

LABELS (U.S.A. ONLY)

1-28

GENERAL SAFETY

CARBON MONOXIDE

If the engine must be running to do some work,

make

sure

the area is well ventilated. Never run the engine in

an enclosed area

•

The exhaust contains poisonous carbon monoxide

gas that

can cause loss

of

consciousness andmay lead to death.

Run the engine in an open area or with an exhaust evac-

uation

systeminan enclosed

area.

GASOLINE

Work in

a

well ventilated area. Keep cigarettes, flames

or sparks away

from

the work

area

or where

gasoline is

stored.

A

•

Gasoline is extremely flammable and is explosive under cer-

tain conditions. KEEP

OUTOF

REACH OF CHILDREN.

HOT

COMPONENTS

Awaruwj

•

Engine and exhaust system parts become very hot and

remain

hot for

some

lime after the

engine is run. Wear insu-

lated gloves or wail until the engine and exhaust system have

cooled before handling these parts.

USED ENGINE OIL

it WARNING

•

Used engine oil may cause sltln cancer

If

repeatedly left in

contact with the skin

for

prolonged periods. Although this

is

unlikely unless you handle used oil on a daily basis, it is still

advisable

la

thoroughly wash your

hands

with soap and

water at soon as possible after handling usedoiL KEEP OUT

OF REACH

OF CHIIDREN.

BRAKE DUST

Never use an air hose or dry brush to clean the brake

assemblies.

Use an

OSHA-approved

vacuum

cleaner

or

alternate method approved by OSHA. designed to mini-

mise the hazard

caused by

airborne

asbestos

fibers.

•

Inhaled asbestos fibers have been found to cause respiratory

disease and cancer.

BRAKE

FLUID

CAUTION

•

Spilling

fluid

on painted, plastic or rubber parts will damage

them

Place a clean shop towel over these parts

whenever

the

ifOm is

serviced. KEEP

OUT OF REACH OF

CHILDREN

1-1

GENERAL INFORMATION

BATTERY HYDROGEN GAS & ELECTROLYTE

*

WARNING

•

The

battery

gives

off

explosive gases;

keep sparks,

flames

and

cigarettes away. Provide adequate ventilation

when

charging.

•

The battery contains sulfuric acid

(

electrolyte). Contact with skin

or eyes may cause

severe bums. Wear protective clothing and a

face shield

—

If

electrolyte gets on your skin, flush with water.

—

If

electrolyte

gets in

your eyes,

flush

with water

for

at least IS

minutes and call a physician immediately.

•

Electrolyte is poisonous.

—

If

swallowed, drink large quantitiesofwater or milk and fol-

low with milk

of

magnesia or vegetable oil and call

a

physi-

cian. KEEP OUT

OF

REACH OF CHUJMEN.

SERVICE RULES

1. Use genuine HONDA

or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet

HONDA’s design specifications may cause damage to the motorcycle.

2. Uso the special tools designed for this product to avoid damage and incorrect assembly.

3.

Use

only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with

English

fasteners.

4. Install new gaskets. O-rings. cotter pins,

and

lock plates

when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the 6pecifiod torque

diagonally in incremental

steps

unless a particular sequence is specified.

6. Clean

parts

in

cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly

7. After roassembly. check all parts for proper Installation and operation.

8. Route all electrical wires as show on pages

1-18

through

1-25.

Cable and Harness Routing.

1-2

GENERAL INFORMATION

MODEL

IDENTIFICATION

‘96 -

2000 shown; After 2000 similar

<3)

The engine serial number is stamped on

the

lower

left side of the crankcase.

(2) The vehicle identification

number <VIN) is attached

on the

left side of the down

tube as

shown.

151 COLOR LABEL

14) CARBURETOR

IDENTIFICATION

NU

(4)

The carburetor identification numbers are stamped

on the left side of the carburetor body.

(5)

The color

label

is attached

to

the air cleaner

housing

cover

as

shown. When ordering color-coded parts,

always specify the designated color code.

1-3

GENERAL INFORMATION

SPECIFICATIONS

p

GENERAL

ITEM SPECIFICATION

DIMENSIONS Overall length

Overall width
Overall height

Wheelbase

Seat

height

Footpeg height

Ground clearance

Dry

weight

Curb weight

Maximum weight Except

Canada type

capacity Canada type

2.115 mm (83.3 in)

835 mm (32.9

in)

1.080 mm (42.5 in)

1,450 mm (57.1 in)

675 mm (26.6 in)

300 mm (11.8 in)

150 mm (6,9 in)

141

kg (311 lbs)
150 kg (331 lbs)
156

kg

(345

lbs)

161

kg (355 lbs)

FRAME Frame type

Front

suspension

Front wheel travel

Rear suspension
Rear

wheel

travel

Front tire si?e

Rear tire

site

Tire brand (Bridgestone)

(Dunlop)

Front brake

Rear brake

Caster angle

Trail length

Fuel tank

capacity

Fuel tank

reserve

capacity

Semi double cradle

Telescopic fork

116 mm (4.6 in)

Swingarm

74

mm (2.9 In)

3.00

-

18 47P

13Q90

-15M/C

66P

Front:

L303A/Rear: G508

Front:

FI

1/Rear K627

Hydraulic single brake

Internal expanding shoo

30* 40‘

113 mm (4.4 in)

10.0

liter (2.64

US gal. 2.20 Imp gal)

2.7

liter

(0.71 US gal, 0.59 Imp

gal)

ENGINE Bore and stroke 53 x 53 mm (2.1 x 2.1 In)

Displacement 234 cm* (14.3 cu-in)

Compression ratio 9.2

:

1

Valve tram Chain drive and

OHC with

rocker

arm

Intake

valve opens

-5

C

BTDC

closes

35'

ABDC

Exhaust valve opens

35

r

BBDC

closes

-5®

ATDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Air cooled

Air filtration Paper filter

Crankshaft

type

Assembled

type

Engine dry weight 38.5 kg (84.9 lbs)

Cylinder arrangement Vertical twin, parallel

GENERAL INFORMATION

. r.FMCQAI trnnt'Wl

ITEM SPECIFICATION

CARBURETOR Carburetor type

Throttle bore

Constant velocity single carburetor

26

mm (1.0 ml

DRIVE TRAIN Clutch system Multi plate, wet

Clutch operation systom Mechanical type

Transmission Constant

mesh, 5-speed

Primary reduction 3.631 <69/19)

Final reduction

2.357

(33/14)

Gear ratio 1st 2 846 <37/13)

2nd

1.777

<32/18)

3rd 1.333(28/21)

4th

1.083 ( 26/24

j

5th 0.913(21/23)

Gearshift

pattern

Left foot

operated

return system. 1-N-2-3-4-5

ELECTRICAL Ignition system AC-CDI

Starling system Electric staner motor

Charging system

Triple

phase output alternator

Regulator/rectifier SCR shorted/triple phase full

wave

rectification

Lighting systom

Battery

1-5

GENERAL INFORMATION

At draining
At disassembly

Recommended engine

oil HONDA GN4 4-stroke oil or

equivalent motor oil

API service classification SF or

SG

Viscosity: SAE 10W

-

40

0.15(0.006) 0.20 (0.008)

Body clearance

0.15-0.21

(0.006-0.008) 0.25 (0.010)

End clearance 0.05 -0.13

<0.002-0.005) 0.14 (0.006)

LUBRICATION SYSTEM

Engine

oil

capacity

STANDARD

1.5

liter

(1.6 US qt. 1.3 Imp qt)

1.8 liter (1.9

US qt,

1.6 Imp

qt)

Unit: mm (in)

SERVICE LIMIT

Oil pump rotor

_ CIICI CVCTCM

Main

jet

#

108

Slow

jet

#38

Pilot screw Initial opening

2-3/4

turns out

High altitude setting 2-1/4 turns

out

Float level

Idle speed

Throttle grip free play

18.5 mm (0.73 In)

1.4001 100 rpm

2-6 mm (1/12

-1/4 in)

GENERAL INFORMATION

CYLINDER HEAD/VALVES

ITEM

STANDARD

Unit; mm (in)

SERVICE UMTT

Cylinder compression

1,100

kPa

(11.2

kgf/cm

1

,

169

pel)

at

600 rpm

Cylinder

head warpage 0.10(0.004)

Valve

and

valve

guide

Valve clearance INyEX 0.06-0.10(0.002-0.004)
Valve stem O.D. IN

EX

5.450

-

5.465 (0.2146

-

0.2152)

5.430-5.445 (0.2138-0.2144)

5.42(0.213)

5.40 (0.213)

Valve guide

I.D.

IN 5.475

-

5.485 (0.2156

-

0.2159) 5.50 (0.217)

EX

5.475-5.485 (0.2156

-

0.2159)

5.50 (0.217)

Stem-to-guide

clearance IN 0.010-0.035 (0.0004-0.0014)

0.08 (0.003)

EX 0.030

-

0.055 (0.0012

-

0.0022) 0.10 (0.004)

Valve seat

width IN/EX

1.0-

1.1 (0.039-0.043) 1.8 (0.07)

Valve spring

free

length

Inner IN/EX 29.9(1.18) 29.0(1.14)

Outer

IN/EX 38.2(1.50)

37.0 (1.46)

Rocker

arm

Rocker arm

I.D

IN/EX 10.000

-

10.015 (0.3937

-

0.3943) 10.10 (0.398)

Rocker arm shaft O.D IN/EX 9.972

-

9.987 (0.3926

-

0.3932) 9.91 (0.390)

Rocker arm-to-shaft clearance 0.013

-

0.043 (0.0005

-

0.0017) 0.05 (0.002!

Camshaft Cam lobe height IN 27.383

-

27.543 (1.0781

-

1.0844) 27.2(1.07)

EX

27.209-27.369 (1.0712

-

1.0775)

27.0(1.06)

Runout

Journal O.D.

19.967- 19.980(0.7861 -0 7866'

Bushing I.D. 20 063

-

20 083

(0

7899

-

0 7907)

0.05 (0.002)

19.92 (0.784)

20.20

(0

795)

CYLINDER/PISTON

STANDARD

Cylinder

Out of round

Taper

0.05 (0.002)

Warpage

IN"

mark

facing

toward

the intake side

52.970

-

52.990 (2.0854

-

2.0862)

10 mm (0.4 in) from bottom of skirt

15.002

-

15.008 (0.5906

-

0.5909)

52.90

(2.083)

15.05 (0.593)

0.15

-

0.30

(0.006

-

0.012)

0.30-0.45

(0.012-0.018)

0.90 (0.035)

0

10(0.004)

0.010-0.040

(0.0004

-

0.0016)

15.08 (0.594)

0.10(0.004)

Cylinder-to-piston clearance

Connecting rod small end I.D.

Connecting rod-to-piston pin clearance

GENERAL INFORMATION

CLUTCH/GEARSHIFT LINKAGE

ITEM

Clutch lever free play

STANDARD

10-20

13/8

-

3/4)

Clutch spring free length

Dutch disc thickness

37.8(1.49)

2.92

-

3.08 (0.115

-

0.121)

Clutch plete warpage

Dutch outer I.D. 26.000

-

26.021

(1.0236-

1.0244)

Dutch outer guide

I.D. 20.000

-

20.021 (0.7874

-

0.7882)

O.D. 25.959

-

25.980 (1.0220

-

1.0228)

Unit: mm (in)

SERVICE

LIMIT

36.0 (1.42)

2.6

( 0

. 10

)

0.20 (0.008)

26.04 (1.025)

20.05 (0.789)

25.90(1.020)

ALTERNATOR/STARTER CLUTCH

ITEM

Unit: mm (in)

STANDARD SERVICE LIMIT

22.010

-

22.022

(0.8665

-

0.8670)

22.08 (0.869)

36.975-37.000 (1.4557

-

1.4567) 36.90(1.453)

Starter driven

sprocket

I.D

Boss O.D.

CRANKSHAFT/TRANSMISSION

ITEM STANDARD

Crankshaft

Connecting rod big

end

Side clearance 0.10

-

0.40 (0.004

-

0.016)

Radial clearance 0.004

-

0.012 (0.0002

-

0.0005)

Runout At both ends

At bearing holder

Unit: mm (in)

SERVICE LIMIT

0.60 (0.024)

0.05 (0.002)

0.03 (0.001)

0.05 (0.002)

Transmission Gear I.D. M5 20.020

-

20.041 (0.7882

-

0.7890)

20.08 (0.791)

Cl 20.020

-

20.041 (0.7882

-

0.7890) 20.08 (0.791)

C4 20.020

-

20.041 (0.7882

-

0.7890) 20.08 (0.791)

Gear bushing O.D. Cl 19.979

-

20.000 (0.7866

-

0.7874) 19.93 (0.785)

Gear

bushing I.D. Cl 16.516

-

16.534 (0.6502

-

0.6509)

16.58

(0.863)

Gear-to-bushing clearance Cl 0.020

-

0.062 (0.0008

-

0.0024) 0.10(0.004)

Mainshaft O.D. M5 19.959

-

19 980 (0.7858

-

0.7866) 19.91 (0.784)

Countershaft

O.D. Cl 16.466

-

16.484 (0.6475

-

0.6490) 16.41 (0.646)

C4 19.959

-

19.980 (0.7858

-

0.7866) 19.91 (0.784)

Gear-to-shaft clearance

M5 0.040

-

0.082 (0.0016

-

0.0032) 0.10 (0.004)

C4

0.040

-

0.082 (0.0016

-

0.0032) 0.10(0.004)

Bushing-to-shaft clearance Cl

0.032

-

0.068 (0.0013

-

0.0027) 0.10(0.004)

Shift fork,

shaft

Fork

I.D.

Claw

thickness

12.000-12.018

(0.4724

-

0.4731)

4.93-5.00 (0.194-0.197)

1 1 .976-1 1 .994 (0.4724

-

0.4731

)

12.05 (0.474)

4.80 (0.189)

11.93 (0.470)Fork shaft O.D.

FRONT WHEEL/SUSPENSION/STEERING

fTEM

Minimum tire tread

depth

Cold

tire

pressure

Up to 90 kg (200 lb)

load

Up to

maximum weight

capacity

Axle runout

Wheel

rim

runout

Radial

Axial

STANOARD

200

kPa

(2.00

kgf/cm-'.

29 ps.)

200

kPa

<2.00

kgf/cm'.

29

psil

Wheel hub-to-rim distance 30.751 1 (1.21 ±0.04)

Fork fluid level
Fork fluid

capacity

Steering head

bearing

preload

-

REAR WHEEL/BRAKE/SUSPENSION

fTEM

Minimum tire tread depth

Cold

tire pressure

Up to 90 kg <200 lb) load
Up to maximum weight

capacity

Axle runout

Wheel rim runout

Radial

Axial

Wheel hub-to-rim distanco

Brake pedal free play

129(5.1)

234

cm* (7.9 US oi, 8.2 Imp o?)

1.04

-

1.53 kg (2.29

-3.37

lbs)

STANOARD

200

kPa

(2.00 kgf/cm*. 29 psi)

200 kPa (2.00 kgf/cm*.

29

psi)

21.6: 1 (0.85 t

0.04)

20-

30

(3/4

-

1-1/4)

HYDRAULIC BRAKE

Specified brake fluid

STANDARD

DOT

3 or 4

Unit: mm

fin)

SERVICE UMIT

1.5 (0.06)

0.20 <0.0081

Fork spring

free

length

546.0(21.50)

535.1 (21.07)

Fork

tube

runout

0.20

(0.008)

Recommended fork fluid Pro Honda Suspension Fluid

SS-8

Unit: mm (in)

SERVICE UMIT

2.0 (0.08)

Brake drum I.D. 130.0 (5.12)

Brake lining thickness 4.5 (0.18)

0.20 (0.008)

2.0 (0.08)

2.0 (0.08)

131 (5.2)

2.0

( 0

.

00)

Unit- mm (in)

SERVICE UMIT

Brake disc thickness 4.0 (0.16) 3.5 (0.14)
Brake disc

runout

0.30 (0.012)

Master

cylinder

Cylinder I.D. 12. 700

-

12. 743 (0.5000

-

0.501

7) 12.75b

(0.5022)

Piston O.D. 12.667-12.684 (0.4983

-

0.4994)

12.645 (0.4978)

Brake

caliper

Cylinder I.D.

25.400-25.405(1.0000-1.0002)

25.450 (1.0020)

Piston

O.D. 25.353

-

25.368 (0.9981

-

0.9987)

25.300 (0

9961)

1-9

GENERAL INFORMATION

BATTERY/CHARGING SYSTEM

ITEM

attery

Capacity

Currant leakage

Voltage f

<20°CV88*F)

Charging cur-

rent

Fully charged

Needs

charging

Normal

Quick

Alternator

1

Capacity

Charging coll resistance

Regulator/rectifier regulated voltage

96-2000

After 2000

SPECIFICATION

12V

-

6

Ah

1 mA max

.

13.0-

13.2 V

Below

1 2.3 V

0.6

A/10

h

3.0 A/1

.Oh

190

W/5,000

rpm

0.2-0.6 0

13.5-

14.0

V/5,000 rpm

14.6-

15.6

V/5,000

rpm

mMiTtnai cvctcm

ITEM

SPECIFICATION

Spark

plug

NGK DENSO

—

Standard

For cold climate (below

5

0

C/41°F)

CR8HSA
CR5HSA

U20FSR-U
U16FSR-U

For extended high

speed

riding

CR7HSA

U22FSR-U

Spark plug

gap

0.6

0.7 mm (0.02

-

0.03 in)

Ignition coil peak voltage

Alternator exciter coil peak voltage

Ignition pulse generator peak voltage

Ignition timing

1

“F" mark

Full advance

100 V

minimum

100 V

minimum

0.7

V

minimum

10*

BTDC/1,400 rpm

25°

BTDC

-

ELECTRIC STARTER

ITEM

Starter motor brush spring tension
Starter motor brush length

STANDARD SERVICE LIMIT

780- 1,060

g

450g

12.5-13.0 (0.49-0.51) 8.5 (0.33)

GENERAL INFORMATION

Sub

fuse

GENERAL INFORMATION

TORQUE VALUES

FASTENER

TYPE

TORQUE

Nfli (kgfm, fofftj

FASTENER TYPE

TORQUE

Nm (kgf-m. Ibf-ftl

5 mm hex bolt and nut

6 mm hex bolt and nut
8 mm hex bolt and nut

10 mm hex bolt and nut
12 mm hex bolt

and nut

5 (0.5.

3.6)

10(1.0. 7)

22 (2.2. 16)

34 (3.5. 25)
54 (5.5.

40)

5 mm

screw

6 mm screw
6 mm flange bolt (8 mm head)
6 mm flange

bolt

(10

mm head) and nut

8 mm flange bolt and nut

10 mm flange

bolt and nut

4 (0.4. 2.9)
9 (0.9. 6.5)
9

(0.9,

6.5)

12(1.2.9)

26 (2.7. 20)

39 (4.0. 29)

•

Torque specifications listed below are

for important

fastenors.

•

Others should be tightened to standard torque values listed above.

NOTES: 1 . Apply a locking agent to the threads.

2.

Left hand

threads.

3. Stake.

4.

U-nut

5. ALOC bolt: roplace with

a

new

one.

ENGINE

ITEM Q'TY

THREAD

DIA

(mm)

TORQUE

Ntn (kgfm. Ibffti

REMARKS

Lubrication System:

Oil

pump

mounting scrow

3 6 10(1.0.71

Cylinder Head/Valves:

Spark

plug

2 10 12(1.2.

9)

Valve adjuster lock nut 4

5 10(1.0, 7)

Cylinder head/camshaft holder

nut 8 8 23

(2.3,

17)

Cylinder head bolt

3 6 12(1.2,9)

Cam

sprocket

bolt 2 7 20 (2.0, 14) Note 1

Cylinder head cover bolt

2 6 10(1.0, 7)

Clutch/Geershrft

Linkage

Clutch lifter bolt 4

6 12(1.2, 9)

Clutch center lock nut 1 16 74

(7.5,

64)

Note 2

Shift drum stopper arm bolt

1 6 12(1.2, 9)

Gearshift return spring pin 1

8 25 (2.5,

18)

Note

1

Primary drive gear

lock nut 1 16 53 (5.4, 39)

Crankcase/Crankshaft:

Drive

sprocket bolt

2 6 12(1.2, 9)

Oil

drain

bolt 1

12 25 (2.5,

18)

Crankshaft mounting bolt

5 8 23 (2.3, 17)

Crankshaft mounting nut

1 6 12(1.2, 9)

Oil

passage

plate mounting

screw 3 6 10 (1.0. 7) Note 1

AHernator/Starlar Clutch:

Flywheel

bolt 1 10 59

(6.0,

43)

Starter clutch mounting scrow

3 6 9 (0.9. 6.5) Note 1. 2

Stator mounting bolt

3 5 6(0.6, 4.3)

Stator wire clamp bolt

1 5 6 (0.6, 4.3)

Ignition pulse generator mounting bolt 2

6 10(1.0.7)

Starter motor terminal nut

1 6 6 (0.6, 4.3)

1-12

GENERAL INFORMATION

rnAmC

ITEM Q'TY

THREAD DIA.

(mm)

Frame/Body Paneis/Exhaust System

Steering lock mounting screw 2 6

Gearshift pedal pivot

cap

nut

1 8

Gearshift

pedal

link adjuster lock nut (front) 1 6

Gearahift pedal link adjuster lock nut

1 6

Side stand pivot

bolt

1 10

Side stand pivot nut 1 10

Fuel

valve lock nut 1 18

Fnglna Mounting

Engine

front mounting

nut 1 10

Engine rear mounting nut

2

10

Front Wheel/Suspension/Steering:

Steering stom nut 1 22

Steering stem bearing adjusting nut

1 22

Fork top pinch bolt 2 7
Fork bottom pinch bolt

2 8

Front axle bolt

1 12

Brake disc mounting bolt 6 8

Wheel spoko

36 BC 3.2

Tire

valve nut 1 8V1

Fork cap

2

28

Fork socket boh 2 8

Rear Wheel/Brake/Suspension:

Rear axle

nut 1 14

Wheel spoke 36 BC 3.2

Tire valve nut

1

8V1

Driven

sprocket mounting

nut 4 10

Shock absorber mounting bolt (upper)

2 8

(lower)

2 10

Swingarm pivot nut 1 14

Drive chain slider mounting self tapping screw

3 5

Drive chain

adjuster

lock nut 2 6

Hydraulic brake:

Caliper

pin boh 1 8

Caliper pin boh A 1

8

Caliper

bleed

valve

1 7

Pad pin

2

10

Pad pin plug

2 10

Caliper bracket

mounting boh 2 8

Brake hose bolt

2

10

Master

cylinder holder

bolt 2 6

Master cylinder reservoir cap screw 2 4

Brake

lover pivot bolt

1 6

Brake lever pivot nut 1

6

Brake switch mounting screw

1

4

Brake hose clamp bolt

2

6

Ughts/Meter/Swhchee:

Headlight

bracket mounting nut

1

10

Tall light unit mounting nut

2 8

TORQUE

N-m (kgfm, IbWt)

9 10.9. 8.5)

22

<2.2.

16)

10(1.0. 7)

10(1.0.7)
10(1.0.7)

29

(3.0.

22)

26 (2-7. 20)

62 (6.3. 46)

88 (9.0. 65)

74 (7.5, 54)

3

(0.3,

2.2)

11

(

1 . 1

.8)

34 (3.5,

26)

62 (6.3. 46)
39 (4.0, 29)

4

(0.4, 2.9)

3 (0.3. 2.2)

22(2.2,

16)

20 (2.0, 14)

88 (9.0, 651

4 (0.4, 2.9)
3 (0.3, 2.2)

64

(6.5, 48)

26

(2.7.

20)

42

(4.3, 31)

88 <9.0. 65)

3 (0.3, 2.2)

10(1.0.7)

22

{22.

16)

18(1.8,

13)

6 (0.6, 4.3)

18(1.8,13)

2 (0.2.

1.4)

30(3.1.22)
34 (3.5.

25)

12(1.2,9)

1 (0.1. 0.7)

6 (0.6, 4.3)
6 (0.6, 4.3)

1 10.1. 0.7)

12(1.2,9)

34 (3.5. 251

7(0.7, 5.1)

1-13

GENERAL INFORMATION

TOOLS

NOTES: 1. Equivalent commercially available in U.S.A.

2.

Not available In U.S.A.

3.

Alternative

tool.

DESCRIPTION TOOL NUMBER REMARKS REF.

SEC.

Carburetor float level gauge 07401

-

0010000

5

Wheel spoke wrench 07701

-

0020300 NOTE

2 12,

13

Valve adjuster wrench B

07708

-

0030400 NOTE 3:

07908

-

KE90200

3

Timing

cap

wrench 07709

-

0010001

3

Lock nut wrench, 20 x 24 mm

07716-0020100

9

Extension bar

07716-0020500

NOTE 1 9

Goar holder 07724

-

0010200

9

Flywheel holder 07725

-

0040000 10

Flywheel puller 07733

-

0020001 10

Valve guide driver, 5.5 mm 07742-0010100 7

Attachment,

32

x

35

mm 07746

-

0010100

11.

13

Attachment. 37 x 40 mm

07746-0010200 12

Attachment, 42 x 47 mm

07746-0010300

11. 12

Attachment,

52

x

55

mm 07746-0010400 11

Attachment,

62 x 68 mm

07746 -0010500 11

Pilot,

15 mm

07746-0040300

11, 12. 13

Pilot, 20 mm 07746 0040500 11

Pilot,

25 mm

07746

-

0040600 11

Pilot.

22

mm 07746- 0041000 11

Bearing remover head, 15 mm

07746

-

0050400

12, 13

Bearing remover shaft

07746-0050100

12, 13

Oil

soal driver 07747- 0010100 12

Oil seal driver attachment

07747-0010501 12

Driver

07749-0010000

11. 12. 13

Valve

spring compressor

Valve seat

cutter

07757

-

0010000

NOTE 1

7

Seat cuttor. 24.5 mm (45 INI

07780-

0010100 7

Seat cutter, 22 mm |45

:

EX)

07780-0010701

7

Flat cutter.

25

mm

(32'

IN)

07780

-

0012000 7

Flat

cutter.

21.5 mm 132’ EX)

07780-0012800

7

Interior cutter, 30 mm

(60'

IN/EX) 07780

-

0014000

7

Cutter holder.

5.5

mm 07781 -0010101 NOTE 1 7

Pilot

screw wrench 07908-4220201

5

Snap ring pliers

07914-

3230001

14

Steering stem socket

07916-3710101

12

Bearing remover set 07936

-

3710001 13

—

Romover handle

07936- 3710100

—

Bearing remover set

07936-3710600

—

Remover

weight

07741 -0010201 NOTE 3:

07936-3710200

Bearing remover set, 15 mm 07936 -KC10000 11

— Remover shaft, 16

mm

07936

-KC

10100 11

—

Remover head,

15

mm 07936

-

KC10200 11

—

Remover weight 07741

-0010201

NOTE 3:

07936-3710200

11

1-14

GENERAL INFORMATION

DESCRIPTION TOOL NUMBER REMARKS REF. SEC.

Ball race driver

07944-1150001

12

Stem beenng

driver 07946

-

GC40000

12

Needle bearing remover 07946

-

KA50000 13

Piston base 07958

-

3000000 8

Valve guide

reamer, 5.485

mm

07984

-

0980001 NOTE 3:

7

Clutch

center holder

07GMB

-

KT70101

07984

-

098000D (U.S.A. only)

9

Peak voltage adapter 07HGJ

-

0020100 NOTE 3: 16

Drive chain tool set 07HMH

-

MR10103

Imrie diagnostic tester

(model

625)

NOTE 3: 3

Analog

tester (SANWA)

Analog tester (KOWA)

SP-15D t—

TH-5H

1

07HMH

-

MR1010A (U.SA. only)

-NOTE 1

16. 17,

18

16.

17.

18

1-15

GENERAL INFORMATION

LUBRICATION

&

SEAL POINTS

-

ENGINE

LOCATION MATERIAL

|

REMARKS

Rocker arm and shaft sliding surface

Cam

chain

Transmission gear teeth and bushings

Piston pin hole
Piston pin surface

Connecting rod small end

Each bearing

Piston ring sliding surface
Piston

ring

and ring

groove

Crankshaft big end

Shift fork claw and

pivot

inner surface

Shift drum grooves

Clutch disc

Engine oil

Valve stem (valve guide sliding surface)

Valve guide

(valve stem

sliding

surface)

Camshaft bushing inner surface

Cam

lobes

M3.

4

gear spline

Cl gear. Cl 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

plate

screw threads

Starter

clutch

outer bolt threads

Gearshift stopper plate bolt threads

Locking agent

GENERAL INFORMATION

FRAME

LOCATION

Steering stem bearing area

Front wheel

dust

sesl lips

Rear wheel hub dust seal lips

Speedometer

gear inside

Wheel axle outer surface

Rear

wheel

O-ring

Driven flange

dust

seal lips

Rear brake anchor shaft

Brake

cam

Rear brake pedal pivot

shaft

Swingarm pivot shaft outer surface
Swingarm pivot dust seal lips
Swingarm pivot bushing

Throttle pipe

inner

surface

Side

stand

pivot

Gearshift pedal pivot
Clutch lever pivot bolt

Steering lock mounting screw threads

Drive chain case mounting bolt threads

Helmet

holder mounting

bolt

threads

Fork oil seal lips
Fork cap bolt O-ring

Brake

master

cylinder piston and cups

Caliper piston and piston seals
Caliper piston dust seals

Front brake lever pivot bolt

Handlebar grip Inner surface

MATERIAL

1

Multi purpose grease

Locking agent

Pro-Honda suspension

fluid SS-8 or

equivalent

DOT

3 or

DOT 4 brake

fluid

Silicone grease

Honda Bond A or
Honda

Hand Grip

Cement (U.S-A.only)

1-17

GENERAL INFORMATION

CABLE & HARNESS

ROUTING

(7)

LEFT HANDLEBAR SWITCH WIRE

18) CLUTCH

CABLE

(6)

RIGHT HANDLEBAR

SWITCH WIRE

16) WIRE BANDS

(9) CHOKE CABLE

THROTTLE CABLES

RIGHT TURN SIGNAL WIRE

(2) BRAKE HOSE

(10) LEFT TURN SIGNAL

WIRE

(11) SPEEDOMETER CABLE

(1)

MAIN WIRE HARNESS

1-18

(4>

SPEEDOMETER WIRE

(21

INDICATOR PANEL WIRE

(8) MAIN

WIRE HARNESS

1-19

1-21

13)

REGULATOR/RECTIFIER

CONNECTORS

(1) CLUTCH CABLE

12) CHOKE CABLE

(4)

FUEL

TANK BREATHER

TUBE

/

(5)

CARBURETOR

AIR VENT TUBE

/ /

(6)

CRANKCASE

BREATHER TUBE

(7)

ALTERNATOR/IGNITION

PULSE

18) SIDE STAND SWITCH WIRE

1-22

GENERAL INFORMATION

(4) REGULATOR/RECTIFIER

(3) CARBURETOR AIR VENT TUBE

(II

BATTERY NEGATIVE

CABLE

(21

BATTERY POSITIVE

CABLE

(81

REAR BRAKE SWITCH WIRE

/

|

(51

CARBURETOR OVERFLOW TUBE

/

(6) CRANKCASE

BREATHER SEPARATOR

TUBE

(7)

AIR CLEANER HOUSING DRAIN TUBE

(91

FUEL TANK BREATHER TUBE

1101

AIR

CLEANER TUBE

(3) CARBURETOR AIR VENT TUBE

(11) CRANKCASE BREATHER TUBE

7)

AIR CLEANER HOUSING DRAIN TUBE

(5)

CARBURETOR OVERFLOW TUBE

(61

CRANKCASE BREATHER SEPARATOR DRAIN TUBE

1-23

GENERAL INFORMATION

12) RIGHT TURN SIGNAL WIRE

(II

SUB HARNESS

(3)

LEFT TURN SIGNAL WIRE

1-24

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS

The

U S

Environmental Protection Agency and California Air Resources Board

(CARBl

requiro

manufacturers to certify that

their motorcycles

comply

with applicable

exhaust

emissions standards during their

useful life, when operated and maintained

according

to the instructions

provided,

and that motorcycles built

after

January 1, 1983 comply with applicable noise emission

standards for one year or 6.000 km (3.730 miles! after the time of sale

to

the ultimate

purchaser,

when

operated and main

tained accordingtothe instructions provided. Compliance with

the

terms

of the Distributor's Limited Warranty for Honda

Motorcyclo

Emission

Control Systoms is

nocessary

in order to koop tho omissions system warranty in effect.

SOURCE OF EMISSIONS

The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important

because,

under certain conditions, they react

to

form photochemical smog when

subjected to

sunlight. Carbon monoxide

does not icact

in the S8me

way, but

it is toxic

Honda Motor Co., Ltd. utilizes lean carburetor settings as well

as

other systems,

to

reduce carbon monoxide

and

hydro-

carbons.

EXHAUST EMISSION CONTROL SYSTEM

The

exhaust

emission control system is composed of a

lean carburetor

sotting, and no adjustments should bo mado

except idle speed adjustment with the throttle stop screw The exhaust emission control system is separate from tho

crankcase emission control system

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with

a

closed crankcase system which routes crankcase emissions through the

air cleaner

into

the combustion

chamber.

01

CARBURETOR

<2>

AIR

CLEANER

(3»

CRANK

CASE BREATHER

SEPARATOR

1-26