1986-1998 Honda CBR250RR Service & Repair Manual

CBR250FOUR (MC14) CBR250R(H) (MC17) 1987 P8·1270·U NO.3 CBR250FG-YA (MC14-1000060-1015767) NH·l NO.2 CBR250FG (MC14-1 000014-1015467) NH ·138 NO.1 NH·196 NO.6 NH·206·M NH·196 NO.4 NO.5 CBR250RH (MC 17-1 000006-1 025449) CBR250R(J) (MC19) 1988 PB·184M·U NO.7 CBR250RJ (MC19-1000006-1023630) PB·190 NO.8 NH·193P NO.9 CBR250RJ (MC19-1011439-1023630) CBR250R(K) (MC19) 1989 NH·193P NO .12 P8·184M-U NH-193P NO.l0 NO.ll CBR250RK(MC19-1050006-1067954) CBR250RR(L) (MC22) 1990-1991 PB-184M NO.4 PB-184M PB-193P NO.2 NO .3 CBR250RRL(MC22-1000001-1020576) NH-193P NO.1 CBR250RR(N) (MC22) CBR250RR(R) (MC22) CBR250RRR (MC22-11 00001- ) 1994-1996* R-210C NO.8 NH-196 NO.7 • NH-193P NH.237P NO .5 NO .6 CBR250RRN (MC22-1050001-1056770) 1992-1993 , 'Any CBR250RR(R) Bought new after 1996 was actually built in 96 and labelled the CBR250RR(R-II)

CBR250R,RR INDEX Maintenance Information Inspection Adjustment ENGINE Oil lubrication system Fuel system Cooling system Engine attach/detachment Cylinder head valve Crank case Cylinder, piston, crankshaft Clutch, AC generator Gear shift linkage Transmission FRAME Front wheel suspension steering Rear wheel, brake, suspension Braking system (Disc Brake) Exhaust pipe, rear fender ELECTRICAL SYSTEM Battery, alternator Ignition system Self starter system Light, meters, switches SUPPLEMENTAL CBR250R(H) CBR250R(J) CBR250R(K) CBR250R(L) CBR250R(R)

CBR250R,RR • Preface This service manual includes the service information for HondaCBR250FOUR and CBR250R. However, only the part which differs from 250FOUR is described for 250R. Amended points from CBR250R(H) are described for CBR250R(J), so for CBR250R(K). Differences such as the outlook are not mentioned as they do not affect the maintenance. Section 1 - includes general cautions for maintenance work. Please use this manual after reading the section. Section 2 - describes about procedures for inspection and adjustments. Please conduct regular inspection by following the procedure. Section 3 - and onwards describes procedures for inspection and assembly/disassembly of individual parts. In the first pages of each sections, you find the figures, maintenance information, troubleshooting charts for your convenience. Please note: The contents may change without prior notice due to modifications of the model.

CBR250R,RR 1. Maintenance Information • SERVICE INFORMATION Location of Serial number and color 1-1 Exclusive / Common tools 1-16 labels Specifications 1-2 Applying Oil 1-19 Summary of structure 1-3 Circuit Diagram 1-20 General cautions 1-6 Wiring 1-21 Tightening Torque 1-14 Troubleshooting 1-24 • LOCATION OF SERIAL NUMBER AND COLOR LABLES Top right figure:----------------------------------- Frame Serial Number Label Bottom left figure:---------------------------------.Engine Serial Number Label Bottom right figure:------------------------------- Colour label When ordering the colored part, use the model name and the color code. Frame Serial Number - - ••• • 1-1

CBR250R,RR • Specifications 1. Maintenance Information Item Specification Model Code Honda MC14 Len th 2.000mm Width 0.685m Heiqht 1.120m Wheel-base 1.370m Power-plant model MC14E Total displacement 0.249 Iitres Fuel type Petrol Front Axle 77k Veh icle empty weight Rear Axle 76 kg Total 153 kg Maximum capaclt, 2 people Front Axle 97 kg Vehicle gross weight Rear Axle 166 kq Total 263 kq Tyre Front 100/80 - 17 52H Rear 130/70 - 17 62H Minimum clearance 0.140m Brakin Distance 14.0m 50km/h Minimum turning radius 2.6m Starter type Electric Type of enqine Petrol 4 Stroke C Iinders 2 abreast Configuration Inline 4 cylinder Valve operation DOHC Bore X Stroke 48 .5 x 33.8mm Com oression ratio 11.0 Compression Pressure 13.0kg/cm 2 - 400rpm Maximum output 45 PS 1 14,500 rpm Maximum torque 2.5 kq-rn 1 10,500 rpm Powerplant Intake Open 10° BTDC 1mm lifted Valve Close 40 ° ABDC 1 mm lifted Valve operation time E xhaust Open 30 ° BBDC 1 mm lifted Valve Close 10° BTDC 1mm lifted Valve Clearance In 0.16mm cold) Out 0.23mm cold Idle Speed 1,500rpm Lubrication Forced Pressure Oil filter Total flow Oil pump Trochoid Rotor Oil ca oaclt, 2.7 litres Coolinq System Liquid cooled 1-2

CBR250R,RR • Specifications 1. Maintenance Information Item Specification Air filter Tlpe Viscous Paper Fuel Capacity 14.0litres Carburetor Carburettor VG01 Piston size 28mm Venturi diameter 25mm Ignition Timing 20 ° BTDC / 1,500 rpm Spark NGK C8EH - 9, C9EH - 9 Plug ND U24FE 9, U27FE 9 Plu Gap 0.8 - 0.9 mm Battery 12V 8AH Type Multi-wet plate Fuel system Clutch Ooeratlon Mechanical Primary Reduction 2.966 Type Constant Mesh 1st 2.733 Transmission 2nd 2.000 Gear 3rd 1.590 ratio 4th 1.333 5th 1.153 6th 1.035 Reduction: First Gear type Chain Reduction ratio 3.071 Tyre Pressure Front 26 ° 00' Rear 97mm Steering system Steering stem Left 35° angle Riqht 35° Braking system Front Hydraulic Disc Rear Hydraulic Disc Shock Front wheel Telescopic fork absorbing Suspension system Rear wheel Swing arm Frame Type Diamond 1-3

CBR250R,RR 1. Maintenance Information Structure Description Engine The vehicle is equipped with a water cooled in line 4 cylinder engine. The engine is inclined forward- 35° This inclination enables an improved straight intake manifold port, which allows smooth flow of air-fuel mixture gas. Gear drive system was applied to the cam shaft instead of chain drive system. The gear system is optimised for high speed operation. In order to provide smooth valve operation at high speed, the engine has lower shim design. Also, carbon hardened connecting rods used to reduce friction loss. Shim Valve lifter - .. ' Eclipse cross-section spring /' r--- 35 • /' J ~-----''L \ I To provide smooth valve operation in high speed, the valve spring was computer designed to endure higher stress. Conventional cross-section Eclipse cross-section / ( ./ -, , ) /" <, ) ( ) -, /' , »: , , I , , "' - o 1-4

CBR250R,RR 1. Maintenance Information In order to reduce friction loss and to operate valves in accurate timing, gear driven cam system is applied. The figure below shows the linkage between the crankshaft and the cam gears. The crankshaft power is transmitted to the cam gear through the primary driven gear (clutch outer gear), which is on the same axle for the transmission main shaft. This mechanism is quite different from the V-gear drive system, which the crankshaft directly drives cam gears. Cam gear 2nd Cam gear ---t 1JMI ~~ ~ Primary driven gear (clutch outer ~ guide) • 3rd Cam gear 1st Cam gear 1-5

CBR250R,RR 1. Maintenance Information Ignition System A newly designed digital ignition unit with a built-in micro computer provides best ignition throughout its operating speed range. A pulse rotor has seven projections. From (1) - (7) have 45°separation and 90 0for (7) to (1). The engine rpm and crank position for each cylinder are detected from the relative position of the seven projections and two pulser coils. The two pulser coils are installed so as to have 15° inclination from level line for PC2 end, compared to PC1. This angular offset is to detect crank positions. The time when the pulse rotor's projection passes the PC1 pulser coil is referred as "O-reference". By detecting the time required to have the projection at the pulser coil again, the engine rpm is determined and the micro computer determines ignition timing. r- No.1 Ignition Coil Battery - - No.2 Ignition Coil Output Circuit Main Fuse Power Unit Micro Computer (Processor) -t'-I o _. L..-No.2 Ignition Coil Kill Switch ---'-'- =-_---...--~~.:r-- Ignition Switch ulse Rotor - "======~.§ c: - PC2 Memory - 4 _ Spark Plug - 1-6

CBR250R,RR General Caution 1. Maintenance Information • Replace gaskets, O-Rings, circlips and cotter pins when they are removed. • When screwing, temporarily tighten screws/bolts. Screw bigger diameter first, then smaller diameter. Inner ones first, then outer ones. Tighten in criss-cross way whenever possible. Apply designated torque. /0 ro 0" o • Use genuine Honda or recommended parts, lubricants, and other products. • Use special/common tools as instructed. • Disassembled parts are to be cleaned before the inspection/measurement. Apply oil to contact area when installing them. 1-7

1986-1998 Honda CBR250RR Service & Repair Manual

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