HONDA ATC 250ES BIG RED Workshop Repair Manual 1985

B5-B7 ATC25DES BIGREC

HOW TO USE THIS MANUAL Sections 1 through 3 apply [0 the whole ATe, white sections 4 through 18 describe parts of the ATC, grouped according to location, Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. If you don't know what the source of the trouble is. refer to section 19, Troubleshoot- ing. w Z to Z w -' <t u a: .... frl -' w CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION !rn INOER HEAO/V ALVES CYLINOER/PISTON CLUTCH/OIL PUMP/KICK STARTER IGNITION SYSTEM BATTERY/CHARGING SYSTEM STARTER SYSTEM LIGHTS/SWITCHES WIRING OIAGRAMS L-= ~============ TROUBLESHOOTING INDEX

1. GENERAL INFORMATION GENERAL SAF ET Y SERVICE RU LES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALU ES TOOLS CABLE & HARNESS ROUTING NOISE EMISSION CONTROL SYSTEM GENERAL SAFETY l' f4W@i 1/ the engint' must be running to do som" work, make sure the Ufeu is ... efl-~'entilared. Never run t he engine in a closed QUO. The exhaust contains poi sonous carbon monoxide gas. GW.!;!.l!wa The bal/uy gtneralu hydrogen gas which can be highly ex- plash-e. Do nOl smoke or aliait' flames or sparks near the battery, especially while charging It. SERVICE RULES ,-, ,-, ' -2 ' -3 ' -5 ' -9 ,- l' ,- 17 "'"-"""' /s. ;X"","'''/) /lammable and is f'XpfosiI'f! under certain conditions. Do not smoke or allow flames or sparks in )'our work area. The baltery electfolyu contains sui/uric acid. {',otect )' OU1 eyes, skin and clo/hing. In case 0/ contact, /lush ,horollghly wilh water and call a doctor if electrol yte gelS in your eyes. , . 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 ATC. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing this ATC. Metric bolts, nuts, and screws are not interchangeable with English fastener s. 4 . Install new gaskets, O-rings, cotter pins, lock plates, when reassembling. 5. When tightening bolts or nuts , begin with larger-diameter or inner bolts first. Then tighten to the specified torque diagonal- ly in 1 - 5 steps, unless a particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION VEH ICLE IIDENTIFICATICIN head's left side. ENGINE SERIAL NUMBER The engine serial number is stamped on the crankcase lower right side. 1-2 The frame serial number is stamped on the steering head right side. CARBURETOR IDENTIFICATION The carburetor identification number is on the carburetor body left side.

SPECIFICATIONS DIMENSIONS FRAME ENGINE CARBURETOR Overall length Overall width Overall height Wheel base Rear tread Seat height Foot peg h eight Ground clearance Dry weight Type Front suspension, travel Rear suspension, travel Rim size Front tire size, pressure Rear lire size, pressure Front brake Rear brake Fuel capacity Fuel reserve capacity Caster Trail Front fork oil capacity Type Cylinder arrangement Bore x stroke Displacement Compression ratio Valve train Maximum horsepower Maximum torque Oi l capacity Lubrication system Cylinder compression Intake valve Exhaust valve Valve clearance (Cold) Engine dry weight Type Venturi dia. Main jet Primary jet Starter fuel jet Pi lo t screw opening Jet needle Float level Idle speed Front Rear Opens Closes Opens Closes Intake Exhaust GENERAL INFORMATION 1,887 mm 174.3 in) 1,137 mm ( 44.8 in) 1,038 mm (40.9 in) 1,237 mm \48.7 in) 840 mm (33.0 in) 705 mm 127.8 in) 267 mm (lO.S in) 165 mm (6 .5 in) '85 : 184 kg (406 Ibl A ft er '85: 186 kg (41 0 Ib) Semi-doub le cradle Te l escopic fork, 115 mm 1 4.5 in) Swingarm, 110 mm (4.3 in) 9 in 9 in 25 x 12.00 - 9,0.15 kg / cm 2 (2.2 psi) 25 x 12.00-9 , 0.15 kg / cm 2 12.2 psi) Cable operated leading shoe Cable operated leading shoe 12 liters (3.2 US ga l, 2.6 Imp gal) 2.0 liters (0.53 US gal, 0.44 Imp gal) 19.5 ° o mm (0 in) 113+2.5 cc (3.8+0.08 oz) Gasoline, air- coiled 4 -s troke Single cy l inder inclined 20° 74.0 x 57 .3 mm 12 .91 x 2.26 in) 246 cc ( 15 .0 cu in) 9 1 Overhead camshaft chain drive 17.8 BH P!7000 rpm (18PS!7000 rpm) 1.9 kg-m / 6000 rpm (1 3.7 ft - lb/ 6000 rpm) 2.5 l iter (2 .6 US qt, 2.2 Imp qtl after disassembly 2.1 liter (2.2 US qt, 1.8 Imp qtl after draining Forced pressure and wet sump 12 - 13 kg/ cm 2 ( 170 - 185 psi) 8° BTDC 35° ABDC 40 ° BBDe 5° ATDC 0.08 mm (0.003 in) 0.08 mm (0.003 in) 46.3 kg ( 102 Ib ) Dual valve 27 mm n .06 in) #130 #45 see page 4-' 2 turns out 4 DB - 2nd groove 18.5 mm (0.73 in) 1 ,400± 1 00 rpm mm lift 1-3

GENERAL INFORMATION DRIVE TRAIN Clutch Wet multi·plate, semi · automatic Transm ission 5-speed constant mesh wi th reverse Primary reduction 2.407 (65/27) Gear rat io SL 4.083 (49/ 12) , 2.389 (43/18) II 1.609 (37/23) "' 1.179 (33/28) ,v 0.906 (29/32) Reverse 7.333 (34/12) (44/ 17 ) Final reduction 5.684 (19 / 13) (35 /9) Gearshift pattern left foot operated return system, Forward: N·$L·,·2 ·3-4 Reverse N-R ELE CTRICAL Ignition C.D.I. Ignition timing Init ial 13 0 BTDC at idle Full advance 31 0 BTDe at 3,500 rpm Alternator Capacity 200 W/ 5,OOO rpm Battery 12V- 10 AH Spark plug OA8ES-L (NGK) X24ESR-U (NO) Spark plug gap 0.6- 0.7 mm (0,024-0.028 in) Headlight 12V SOW/BOW Taillight 12V5Wx2 Neutral indicator 12V 3W Reverse indicator 12V 3W 1-4

TORQUE VALUES '85 ENGINE Item Cylinder head socket bolt Cylinder head cap nut Crankcase SH bolt Gearshift return spring pin Output gear case socket bolt Output driven gear bearing holder socket bolt Output gear bearing outer lock nut Output driven gear bearing outer lock not Output gear bearing inner lock nut Kick starter stoppe r plate socket bolt Flywheel bolt Pulse generator screw Right crankcase cover SH bolt Left crankcase cover SH bolt Oil separator plate SH bolt Manual clutch lock n ut Clutch lifter cap bolt Centrifugal clutch lock nut Cylinder base SH bolt Cam sprocket bolt Cylinder head cover SH bolt Valve adjusting lock nut Cam chain holder socket bolt Spark plug Intake manifold band screw Oil filter cover SH bolt Neutral/Reverse switch Starter clutch socket bolt Cam chain tensioner lifter SH bolt Alternator stator SH bolt Breather plate socket bolt Clutch adjusting screw lock nut Cam chain tensioner lifter sealing bolt Q'ty Thread Size (mm) 3 B , 1 .25 • lax 1 .25 ,. 6 , 1 .0 1 B , 1 .25 3 8 )( 1.25 3 8 )( 1.25 1 64)( ' .5 1 60 x 1.5 1 28)( '.0 2 6 x 1.0 1 12 )( 1.25 2 5)( 0.8 12 6, 1.0 11 6 x 1.0 2 6 x 1.0 1 18 x 1 .0 • 6 x 1.0 1 20 x 1.0 2 6, 1 .0 2 7 , 1 .0 7 6,1 .0 2 6 x 0.75 1 6, 1.0 3 7, 1.0 1 12xl.25 1 5 x 0.8 3 6 x 1.0 2 lOx 1.25 6 8 x 1.25 2 6 x 1.0 3 6 x 1.0 1 6 x 1.0 1 8 x 1.25 1 6 x 1.0 GENERAL INFORMATION Torque N'm kg -m ft -Ib 22- 28 2.2-2.8 16 - 20 35-45 3.5 - 4.5 25 - 33 8- 12 0.8 - 1.2 6- 9 18 - 25 1.8-2 .5 13- 18 20 - 25 2.0 - 2.5 , 5- 18 20 - 25 2.0 - 2.5 15 - 18 90 - 110 9.0-11 .0 65-80 90 - 1 10 9.0 - 11 .0 65 - 80 70 - 80 7.0-8.0 51 - 58 10-14 1.0-1.4 7- 10 100 - 120 10.0-12.0 72-87 8-12 0.8 - 1.2 6- 9 8- 12 0.8 - 1.2 6- 9 8- 12 0.8-1.2 6- 9 8- 12 0.8-1.2 6- 9 100 - 120 10 - 12 72 - 87 10 - 14 1.0-1.4 7- 10 110 - 130 11.0 -1 3.0 80 - 94 8- 12 0.8 - 1 .2 6- 9 17 - 23 1.7 - 2.3 12 - 17 8- 12 0 .8 - 1.2 6- 9 15 - 18 1.5 - 1.8 11 - 13 8- 12 0.8 - 1.2 6- 9 8- 12 0 .8 - 1.2 6- 9 15 - 20 1.5 - 2.0 11-15 3- 5 0.3 - 0.5 2- • 8- 12 0.8-1.2 6- 9 11 - 15 1.1 - 1.5 8- 11 18 - 25 1.8-2.5 13 - 18 8- 12 0.8 - 1.2 6- 9 8- 12 0.8-1.2 6- 9 10- 14 1 .0 -1 .4 7- 10 19 -25 1.9-2 .5 14 - 18 8 - 12 0.8-12 6- 9 1-5

GENERAL INFORMATION FRAME Item Q'ty Thread Size Torque (mm) N·m kg-m ft-Ib Handlebar upper holder bolt 4 8 , 1 .25 18- 30 , .8-3.0 13 - 22 Handlebar upper holder nut 2 10 x , .25 40 - 50 4.0-5.0 29 - 36 Fork bridge bolt 2 12 x 1 .25 50 - 70 5.0- 7.0 36 - 51 Steering stem nut 1 24 x 1.0 70 - 90 7.0 - 9.0 51 - 65 Steering bearing adjustment nut Unitisi) 1 24 x 1.0 25-35 2.5 - 3.5 18 - 25 (Final) 7-8 0.7-0.8 5- 6 Wheel nut 12 10 x 1. 25 50 - 60 5.0-6.0 36 - 43 Front axle 1 14 x 1.5 70-110 7.0-11.0 51 - 80 Rear axle nut 2 20 x '.5 80- 1 20 8.0 - 12.0 58-87 Rear brake panel nut 4 10 x 1.25 50 - 60 5.0 - 6.0 36-43 Rear shock absorber mount bolt 2 10x1. 25 50-60 5.0-6.0 36 - 43 Front fork mount bolt 4 10x1.25 50-.60 5.0-6.0 36-43 Swingarm right pivot bolt 1 30 x 1.5 16-20 1.6-2.0 12-15 Swingarm left pivot bolt 1 30 x 1.5 100 - 130 10,0 - 13.0 72-94 Swingarm pivot lock nUl 1 30 x 1.5 100 - 130 10 .0 - 13.0 72 - 94 Final gear case mount bolt 4 10xl.25 50-60 5.0-6.0 36-43 4 8 x 1.25 28 - 35 2.8-3.5 20 - 25 Rear left bearing housing bolt 4 8 x 1.25 28-35 2.8 - 3.5 20 - 25 Engine hanger bolt 9 10xl.25 45 - 65 4.5 - 6.5 33-47 Gearshift pedal bolt 1 6 x 1.0 10-14 1.0 - 1.4 7- 10 Foot peg bracket bolt 4 10xl.25 40-50 4.0-5.0 29-36 Intake manifold bolt 2 6 x 1.0 6- 9 0.6-0.9 5- 7 Muffler clamp bolt 2 8 x 1.25 18 -28 1.8-2.8 13-20 Front fork socket bolt 2 8 x 1.25 18-25 1 .8 - 2.5 13 - 18 Rear shock absorber rod lock nut 1 12 x 1.25 38-60 3.8 - 6.0 27 - 43 Final gear case cover bolt 2 10 x 1.25 45 - 50 4.5 - 5.0 25 - 36 6 8 xl.25 23 - 28 2.3 - 2.8 17 - 20 Pinion joint nul 1 16 x 1 .5 100 - 120 10.0-12.0 72 - 87 Pinion bearing outer race lock nut 1 60 x 1 .5 90-110 9.0 - 11.0 65 - 80 Torque specifications listed above are for the most impor tant tightening points. If a torque specification is not listed, follow the standards given below. STANDARD TORQUE VALUES Item Torque N'm (kg-m, ft-Ib) Item Torque N'm Ikg -m, ft-Ib\ 5 mm bolt, nut 4.5-6 (0.45 - 0.6, 3- 4) 5 mm screw 3.5 - 5 (0.35 - 0.5,2 - 4) 6 mm bolt, nut 8- 12 (0.8-1.2, 6-9) 6 mm screw, SH bolt 7- 11 (0.7 - 1.1,5 - 8) 8 mm bolt, nut 18 25 (1.8-2.5, 13 - 18) 6 mm flange bolt, nut 10 - 14 (1.0 - 1.4, 7- 10) 10 mm bolt, nut 30 - 40 (3.0-4.0, 22-29) 8 mm flange bolt, nut 24-30 (2.4 - 3.0,17 - 221 1 2 mm bolt, nut 50-60 (5.0-6.0, 36 - 43) 10 mm flange bolt, nut 35 - 45 (3.5-4.5, 25-33) 1-6

GENERAL INFORMATION AFTER '85: ENGINE Item G'ty Thread Size Torque (mm) N'm kg·m ft · lb Cylinder head socket bolt 3 8 x 1.25 22-28 2.2- 2.8 16- 20 Cylinder head cap nut 4 lOx 1.25 35-45 3.5-4.5 25-33 Crankcase SH bolt 14 6 x 1.0 8-12 0.8-1.2 6-9 Gearshift return spring pin bolt 1 8 x 1.25 18-25 1.8-2.5 13- 18 Output gear case boh 3 8)( 1.25 30-34 3.0 3.4 n 25 Output driven gear bearing 3 8)( 1. 25 20 -25 2.0-2.5 14- 18 holder socket bolt Output gear bearing outer lock nut 1 64)( 1.5 90- 110 9.0-11.0 65- 80 Output driven gear bearing outer 1 60)(1.5 90-110 9.0 - 11.0 65- 80 lock nut Output gear bearing inner lock nut 1 28 x 1.0 70-80 7.0-8.0 51 - 58 Kic k starter stopper plate socket bolt 2 6x1 .0 10-14 1.0- 1.4 7- 10 Flywheel bolt 1 12)(1.25 100-120 10.0- 12.0 72- 87 Pulse generator screw 2 5)( 0.8 5-7 0.5- 0.7 4- 5 Right crankcase cover SH bolt 12 6 x 1.0 8-12 0.8- 1.2 6- 9 Left crankcase cover SH bolt 11 6 x 1.0 8-12 0.8- 1.2 6- 9 Oil separator plate SH bolt 2 6 x 1.0 8- 12 0.8-1.2 6- 9 Manual clutch lock nut 1 18)( 1.0 100-120 10.0- 12.0 72- 87 Outch lifter bolt 4 6 x 1.0 10-14 1.0- 1.4 7-10 Centrifugal clutch lock nut 1 20 x 1.0 110-130 11.0- 13.0 80 - 94 Cylinder base SH bolt 2 6 x 1.0 8-12 0.8- 1.2 6- 9 Cam sprocket bolt 2 7 x 1.0 17-23 1.7 - 2.3 12- 17 Cylinder head cover SH bolt 7 6 x 1.0 8-12 0.8- 1.2 6- 9 Valve adjusting lock nut 2 6 x 0.75 15-18 1. 5- 1.8 11 - 13 Cam chain holder socket bolt 1 6 x 1.0 1 0-14 1.0 - 1.4 7-10 Oil pipe bolt 3 7 x 1.0 10- 14 1.0- 1.4 7- 10 Spark plug 1 12xl .25 15- 20 1.5- 2.0 11 - 14 Intake pipe band screw 1 5 x 0 .8 3-5 0.3- 0.5 2-4 Oil filter cover SH bolt 3 6 x 1.0 8-12 0.8- 1.2 6- 9 Neutral/ Reverse switch 2 10 x 1.25 11-15 1.1 - 1.5 8- 11 Starter clutch torx bolt 6 8 x 1.25 20-25 2.0-2 .5 14- 18 Cam chain tensioner lifter SH bolt 2 6 x 1.0 8-12 0.8- 1.2 6- 9 Alternator stator SH bolt 3 6 x 1.0 8-12 0.8- 1.2 6- 9 Breather plate socket bolt 1 6 x 1.0 10-14 1.0- 1.4 7- 10 Clutch adjusting screw lock nut 1 8 x 1.25 18 25 1.8- 2.5 13- 18 Cam chain tensioner lifter sealing bolt 1 6 x 1.0 8 12 0 .8 1.2 6 9 Engine oil drain plug 1 12 x 1.5 20-30 2.0-3.0 14 - 22 Intake p ipe bolt 2 6 x 1 .0 10- 14 1.0- 1.4 7- 10 Gear case drain bolt 1 8 x 1.25 10-14 1.0- 1.4 7- 10 Gear case filler cap 1 30 x 1.5 10-14 1.0-1.4 7- 10 1-7

GEN ERAL INFORMATION FRAME Item G'ty Thread Size Torque (mm) N·m kg-m ft·lb Handlebar upper holder bolt 4 a x 1.25 18-30 1.8-3.0 13-22 Handlebar lower holder nut 2 lOx 1.25 40-50 4.0-5.0 29-36 Fork bridge bolt 2 12 x 1.25 50-70 5.0- 7.0 36 - 51 Steering stem nut 1 24 x 1.0 70-90 7.0-9.0 51 - 65 Steering bearing adjustment nut (In i tial) 1 24)( 1.0 25-35 2.5- 3.5 18-25 (F inal) 7 -8 0.7- 0.8 5- 6 Wheel nut 12 10xl.25 60-70 6.0-7.0 43 -51 Front axle 1 14 )( 1.5 70-110 7.0-11.0 51-80 Rear axle nut 2 18xl.5 80-140 8.0-14.0 58-101 Rear brake panel nut 4 10)( 1.25 SO-60 5.0-6.0 36-43 Rear shock absorber mount bolt 2 10 x 1.25 50-60 5.0- 6.0 36-43 Front fork pi nch boh 4 10 x 1.25 50-60 5.0- 6.0 36-43 Swingarm right pivot bolt 1 30 x 1.5 16-20 1.6-2.0 12- 14 Sw ingarm left pivot bolt 1 30 x 1.5 100- 130 10.0- 13.0 72- 94 Swingarm pivot lock nut 1 30 x 1.5 100~130 10.0- 13.0 72-94 Final gear case mount bolt 4 10xl .25 50-60 5.0- 6.0 36-43 4 8 x 12.5 30-36 3.0 - 3.6 22-26 Left rear bearing housi ng bolt 4 8 x 1.25 30-36 3.0-3.6 22-26 Engine hanger bolt lOmm 9 10xl .25 45-65 4.5- 6.5 33-47 8mm 2 8 x 1.25 24-30 2.4- 3.0 17-22 Gearshih pedal bolt 1 6 x 1.0 14-18 1.4- 1.8 10-13 Foot peg bracket bolt 4 10 x 1.25 40 -50 4.0- 5.0 29- 36 Intake manifold bolt 2 6 x 1.0 10-14 1.0- 1.4 7- 10 Muffler clamp bolt 2 8 x 1.25 18- 28 1.8-2.8 13- 20 Front fork socket bolt 2 8 x 1.25 15-25 1.5- 2.5 11 - 18 Aear shock absorber rod lock nut 1 12 x 1.25 38-60 3.8- 6.0 27- 43 Final gear case cover bolt 10 mm 2 10 x 1.25 45 50 4.5 5.0 33 - 36 Smm 6 8 x 1.25 23 28 2.3 2.S 17 20 Pinion joint nut 1 16 x 1.5 100-120 10.0- 12.0 72- 87 Pinion bearing outer race lock nut 1 60 x 1.5 90-110 9.0- 11 .0 65 -80 Front axle holder nut 4 6 x 1.0 10- 14 1.0- 1.4 7- 10 .. Torque specifications listed above are for the most Important tightening pOints. If a torque speCification IS not hsted, follow the standards given below. STANDARD TOROUE VALUES Item Torque N·m (kg-m, ft·lb) hem Torque N·m (kg-m, ft·lb) 5 mm bolt, nut 4.5- 6 (0.45-0.6, 3-4) 5 mm screw 3.5 - 5 (0.35- 0.5,2- 4) 6 mm bolt, nut 8- 12 (0.8- 1.2, 6- 9) 6 mm screw, SH bolt 7- 11 (0.7- 1.1,5-8) 8 mm bolt, nut 18- 25 (1.8- 2.5, 13- 18) 6 mm flange bolt, nut 10- 14 (1.0-1.4, 7-10) 10 mm bolt, nut 30 40 (3.0 4.0,22 29) 8 mm flange bolt, nut 24 - 30 (2.4- 3.0, 17 -22) 12 mm boll, nut 50 6015.0 6.0,36 431 10 mm flange bolt, nut 35 45 (3.5-4.5,25-33) 1-8

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HONDA ATC 250ES BIG RED Workshop Repair Manual 1985

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