Honda NSR250R SERIES Manuals

Manuals and User Guides for Honda NSR250R SERIES. We have 1 Honda NSR250R SERIES manual available for free PDF download: Service Manual

Honda NSR250R SERIES Service Manual (481 pages)

Brand: Honda | Category: Motorcycle | Size: 49.7 MB

Table of Contents
2
General Information
3
Model Identification
3
Engine Number
3
Frame Number
3
Specifications
4
Summary of Structure
5
RC Valve System
6
Control Unit
7
Cassette Transmission
7
Crank Case Reed Valve
8
Intake Chamber
8
Oil Pump Solenoid
9
Floating Disc Brake
10
Flexible Joint Exhaust Chamber
10
General Cautions
11
Symbols
18
Torque Values
19
Tools
21
Lubrication Points
23
Cable & Harness Routing
25
Troubleshooting
28
Engine Does Not Start or Is Hard to Start
28
Engine Lacks Power
29
Poor Performance at Idle and Low Speed
30
Battery Undercharged (Poor Charging)
30
Bad Charge
31
No Spark or Weak Spark to the Spark Plug
31
Engine Malfunctions
32
Smokes at Low Engine Speed
33
Maintenance Schedule
35
Steering Head Bearings
39
Brake System
39
Steering Fork
39
Brake Pedal
39
Disc Brakes, Pads
40
Wheels
40
Brake Pad Wear
40
Tire Pressure
40
Suspension
41
Transmission
41
Shock Absorber
41
Front Fork Air Pressure
41
Transmission Oil
42
Oil Level Inspection
42
Oil Change
43
Drive Chain
43
Drive Chain Slack Inspection
43
Installation and Wear of Sprockets
44
Wear of Chain Slider
44
Electrical System
45
Ignition System
45
Spark Plug
45
Ignition Timing
45
Fuel System
46
Battery
46
Carburetor
46
Idle Speed
46
Cylinder Compression
47
Lubrication System
47
Engine Oil Strainer and Screen
47
Oil Pump Control Cable Adjustment
48
Throttle Operation
49
Cooling System
50
Clogged Fuel Filter
50
Headlight
50
Brake Light Switch
51
Side Stand
51
RC Valve Control Cable Adjustment
51
Lubrication Flow Diagram
54
Lubrication System Service Information
55
Lubrication System Specifications
55
Lubrication System Troubleshooting
55
Oil Pump Removal
56
Oil Pump Inspection
56
Oil Pump Bleeding
57
Oil Pump Installation
57
Oil Inlet Line/Oil Pump Air Bleeding
57
Oil Tank Removal/Installation
58
Oil Outlet Lines
58
Fuel System Service Information
59
Fuel System Specifications
59
Fuel System Tools
59
Fuel System Troubleshooting
59
Fuel Tank Removal
60
Fuel Tank Installation
60
Air Box Removal
61
Air Box Installation
61
Carburetor Removal
62
Carburetor Disassembly
63
Air Screw Adjustment
74
Carburetor Synchronization
74
Cooling System Service Information
76
Cooling System Specifications
76
Cooling System Tools
76
Cooling System Troubleshooting
76
Coolant Fluid Density
77
Coolant Ratio
77
Cooling System Testing
78
Coolant
78
Radiator Cap Inspection
78
Coolant Replacement
79
System Pressure Test
79
Thermostat Removal
80
Thermostat Inspection
80
Temperature Sensor Removal
81
Temperature Sensor Inspection
81
Temperature Sensor Installation
81
Radiator, Hose Inspection
81
Water Pump
82
Radiator, Hose Removal
82
Mechanical Seal Inspection
82
Water Pump Removal
82
Mechanical Seal Replacement
83
Reserve Tank Removal
84
Reserve Tank Installation
84
Water Pump Installation
84
Engine Removal
85
Engine Installation
87
Cylinder Head, Cyl, Piston, RC Valve
90
Cylinder Head, Cyl, Piston, RC Valve Troubleshooting
91
Cylinder Head Removal
92
Cylinder, Piston Removal
93
Front Cylinder Removal
94
Piston Removal
94
Piston Ring Removal
94
Cylinder Inspection
95
Cylinder and Piston Selection
96
Piston Pin Inspection
96
Piston Selection
96
RC Valve Disassembly
97
RC Valve Inspection
97
Cylinder Selection
97
Cylinder, Piston Installation
98
RC Valve Assembly
98
Front Cylinder Installation
99
Rear Cylinder Installation
100
Cylinder Head Installation
101
Clutch, Kickstarter, Gear Shift Linkage Service Information
104
Clutch, Kickstarter, Gear Shift Linkage Troubleshooting
105
Right Crankcase Cover Removal
106
Clutch Removal
106
Clutch Inspection
107
Lifter Rod, Lifter Guide and Ball Bearing Inspection
108
Clutch Outer Basket and Outer Guide Inspection
108
Mainshaft Inspection
108
Primary Drive Gear Removal
109
Clutch Arm Removal
109
Clutch Arm Inspection
109
Kickstarter Removal
110
Kickstarter Spindle Removal
110
Gearshift Linkage Removal
111
Gear Shift Linkage Inspection
112
Gear Shift Linkage Installation
113
Kickstarter Installation
114
Kickstarter Idler Gear Installation
115
Primary Drive Gear Installation
116
Clutch Installation
116
R. Crankcase Cover Installation
118
Transmission Service Information
121
Transmission Specifications
121
Transmission Tools
121
Transmission Troubleshooting
122
Engine Noise
122
Gears Sticking
122
Gear Difficult to Engage
122
Transmission Removal
123
Transmission Inspection
124
Main Shaft, Counter Shaft, Gears, Collars
124
Transmission Bearing Replacement
125
Gear Shift Fork Inspection
125
Shift Fork Shaft Inspection
125
Gearshift Drum Inspection
125
Main Shaft Bearing
127
Transmission Assembly
128
AC Generator Service Information
132
Pulse Generator Removal
133
AC Generator Removal
133
AC Generator Installation
134
Pulse Generator Installation
134
Crankcase, Crankshaft Service Information
137
Crankcase, Crankshaft Troubleshooting
137
Crankcase Separation
138
Crankshaft Removal
138
Oil Seal Inspection
138
Crankshaft Inspection
139
Crankshaft Installation
139
Crankcase Assembly
140
Front Wheel, Suspension, Steering
142
Handlebars Removal
144
Handlebars Installation
144
Front Wheel Removal
147
Wheel Balance
148
Front Wheel Disassembly
148
Front Wheel Assembly
149
Front Wheel Installation
150
Front Forks
151
Form Removal
151
Bearing Replacement
160
Steering Head Bearing Preload
163
Rear Wheel, Suspension Service Information
165
Rear Wheel, Suspension Specification
165
Rear Wheel, Suspension Troubleshooting
166
Rear Wheel Removal
167
Shock Absorber Removal
171
Lower Joint Needle Bearing Replacement
172
Shock Absorber Disposal Procedure
174
Suspension Linkage
176
Shock Link Needle Bearing Replacement
177
Shock Arm Plate Inspection
178
Swing Arm Removal
178
Pivot Bearing Replacement
179
Shock Link Arm Bearing Replacement
182
Brakes (Disc Brakes) Service Information
186
Brakes (Disc Brakes) Specification
186
Brakes (Disc Brakes) Troubleshooting
187
Brake Fluid Replacement/Air Bleeding
188
Brake Fluid Draining
188
Brake Fluid Filling
188
Brake Pad/Disc
189
Front Brake Pad Replacement
189
Rear Brake Pad Replacement
191
Brake Disc Inspection
192
Front Master Cylinder Removal
193
Rear Master Cylinder Removal
196
Rear Master Cylinder Disassembly
197
Rear Master Cylinder Inspection
197
Rear Master Cylinder Assembly
198
Rear Master Cylinder Installation
199
Front Brake Caliper Removal
199
Front Brake Caliper Disassembly
199
Rear Brake Caliper Removal
201
Rear Brake Caliper Disassembly
201
Rear Brake Caliper Inspection
202
Rear Brake Caliper Installation
203
Brake Pedal Removal
203
Brake Pedal Installation
204
Frame/Body Panel/Exhaust System Service Information
206
Side Cover Removal
206
Side Cover Installation
207
Windscreen Replacement
207
Fairing
208
Lower Cowling
208
Upper Fairing
208
Sub Frame Removal
211
Sub Frame Installation
211
Exhaust System Removal
212
Exhaust System Inspection
212
Rear Fender Removal
213
Rear Fender Installation
213
Battery, Charging System Service Information
215
Maintenance Free Battery
215
Battery, Charging System Troubleshooting
216
No Current
216
Low Current
216
Intermittent Current
216
Battery Removal
217
Voltage Inspection
217
Battery Charging
217
Regulator/Rectifier
218
Current Leakage Testing
218
AC Generator Inspection
219
Ignition System Service Information
220
Ignition System Specification
220
Ignition System Tools
220
Ignition System Troubleshooting
221
CDI Unit Inspection
222
Ignition Coil Inspection
223
Ignition Coil Replacement
223
Pulse Generator Inspection
224
Lights, Meters, Switches Service Information
226
Lights, Meters, Switches Troubleshooting
226
Bulb Replacement
227
Turn Signal
228
Brake/Tail Light
228
Instruments
228
Ignition Switch Inspection
231
Ignition Switch Removal
231
Ignition Switch Disassembly
231
Handle Bar Switches
232
Ignition Switch Assembly
232
Ignition Switch Installation
232
Oil Warning System
233
Oil Warning Light Inspection
233
Oil Level Sensor Inspection
233
Temperature Gauge
234
Tachometer
234
Neutral Switch
235
Horn
235
Control Unit, Server Motor, Oil Pump Solenoid Service Information
237
Control Unit, Server Motor, Oil Pump Solenoid Troubleshooting
237
Servomotor
238
RC Valve Operation Inspection
238
Servomotor Inspection
238
Servomotor Replacement
239
Oil Pump Solenoid Inspection
240
Wire Harness Inspection
241
Control Unit Replacement
241
NSR250R (J) Supplement
243
NSR250R-SP (J) Supplement
313
NSR250R (K) Supplement
315
NSR250R-SP (K) Supplement
365
NSR250R (L, N) Supplement
384
NSR250R-SP, SE (L, N) Supplement
468

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Honda NSR250R SERIES Service Manual (481 pages)

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