Honda REBEL 250 Manuals

Honda REBEL 250 Manuals

Manuals and User Guides for Honda REBEL 250. We have 1 Honda REBEL 250 manual available for free PDF download: Service Manual

Honda REBEL 250 Service Manual

Honda REBEL 250 Service Manual (264 pages)

Brand: Honda | Category: Motorcycle | Size: 7.32 MB

Table of Contents

A few Words about Safety
1
Service Information
1
Table of Contents
3
Symbols
4
General Information
5
- General Safety
  5
- Gasoline
  5
- Hot Components
  5
- Battery Hydrogen Gas & Electrolyte
  6
- Service Rules
  6
- Model Identification
  7
- Specification
  8
- General Item
  8
- Lubrication System Item
  10
- Fuel System Item
  10
- Cylinder Head/Valves Item
  11
- Cylinder/Piston Item
  11
- Crankshaft/Transmission Item
  12
- Clutch/Gearshift Linkage Item
  12
- Front Wheel/Suspension/Steering Item
  13
- Rear Wheel/Brake/Suspension Item
  13
- Hydraulic Brake Item
  13
- Battery/Charging System Item
  14
- Ignition System Item
  14
- Electric Starter Item
  14
- Lights/Meters/Switches Item
  15
- Torque Values
  16
- Engine
  16
- Frame
  17
- Tools
  18
- Lubrication & Seal Points
  20
- Cable & Harness Routing
  22
- Emission Control System Routing (California Type Only)
  29
- Exhaust Emission Control System
  30
- Crankcase Emission Control System
  30
- Source of Emissions
  30
- Emission Control System
  30
- Evaporative Emission Control System (California Type Only)
  31
- Noise Emission Control System
  31
- Emission Control Information Labels (U.S.A. Only)
  32
- Vehicle Emission Control Information Update Label
  32
- Vacuum Hose Routing Diagram Label ('96-'04 California Type Only)
  32
- Frame/Body Panels/Exhaust System
  34
- Body Panel Locations
  34
Frame/Body Panels/Exhaust System
35
- Side Cover Removal/Installation
  36
- Seat Removal
  36
- Seat Installation
  37
- Fuel Tank Removal/Installation
  37
- Front Fender Removal
  38
- Rear Fender Removal
  38
- Rear Fender Installation
  39
- Exhaust System Removal
  39
- Exhaust System Installation
  40
Maintenance
42
- Maintenance Schedule
  44
- Fuel Line
  45
- Throttle Operation
  45
- Carburetor Choke
  46
- Air Cleaner
  46
- Crankcase Breather
  47
- Spark Plug
  47
- Inspection
  47
- Valve Clearance
  48
- Replacing a Spark Plug
  48
- Engine Oil
  50
- Oil Level Inspection
  50
- Engine Oil Change
  51
- Engine Oil Strainer Screen
  51
- Engine Idle Speed
  52
- Drive Chain Slack Inspection
  53
- Adjustment
  53
- Cleaning and Lubrication
  53
- Replacement
  54
- Sprocket Inspection
  54
- Brake Fluid
  56
- Brake Shoe/Pad Wear
  57
- Front Brake Pad/Rear Brake Shoe
  57
- Brake System
  57
- Brake Pedal Free Play
  57
- Brake Light Switch
  58
- Headlight Aim
  58
- Side Stand
  59
- Clutch System
  59
- Front/Rear Suspension
  60
- Nuts, Bolts, Fasteners
  60
- Wheels/Tires
  61
- Steering Head Bearings
  61
- Lubrication System Diagram
  62
- Lubrication System
  63
- Oil Pump Removal/Disassembly
  64
- Oil Pump Inspection
  65
- Oil Pump Assembly
  66
- Oil Pump Installation
  67
- Fuel System View
  68
- Fuel System
  69
Fuel System
70
- Carburetor Removal
  72
- Carburetor Disassembly
  72
- Starting Enrichment (SE) Valve
  72
- Diaphragm/Vacuum Piston
  73
- Float and Jets
  73
- Carburetor Assembly
  75
- Float Level Inspection
  76
- Carburetor Installation
  79
- Pilot Screw Adjustment
  80
- Idle Drop Procedure
  80
- High Altitude Adjustment
  81
- Air Cleaner Housing Removal
  82
- Air Cleaner Housing Installation
  83
- Engine Removal/Installation View
  84
- Engine Removal/Installation
  85
Engine Removal/Installation
86
- Engine Installation
  88
- Cylinder Head/Valves View
  90
Cylinder Head/Valves
91
- Cylinder Compression Test
  93
- Rocker Arm/Camshaft Removal
  93
- Cylinder Head Removal
  97
- Cylinder Head Disassembly
  98
- Valve/Valve Guide
  99
- Valve Spring
  99
- Cylinder Head Inspection
  99
- Valve Guide Replacement
  100
- Valve Seat Inspection/Refacing
  101
- Valve Seat Refacing
  102
- Cylinder Head Assembly View
  104
- Cylinder Head Installation
  105
- Camshaft/Rocker Arm Installation
  106
- Rocker Arm Holder Assembly
  106
- Camshaft Installation
  107
- Camshaft Holder Installation
  108
- Cylinder/Piston View
  111
Cylinder/Piston
112
- Cylinder/Piston Removal
  114
- Cylinder/Piston Inspection
  114
- Cylinder/Piston Installation
  117
- Piston Ring Installation
  117
- Piston Installation
  118
- Clutch/Gearshift Linkage View
  120
Clutch/Gearshift Linkage
121
- Right Crankcase Cover Removal
  123
- Clutch Lifter Removal/Installation
  123
- Clutch Removal
  124
- Clutch Inspection
  125
- Clutch Lifter Bearing
  125
- Clutch Spring
  125
- Clutch Outer/Clutch Outer Guide
  126
- Clutch Disc
  126
- Clutch Pate
  126
- Clutch Center
  126
- Clutch Installation
  127
- Primary and Oil Pump Drive Gears
  129
- Gearshift Linkage Disassembly
  130
- Gearshift Linkage Assembly
  131
- Right Crankcase Cover Installation
  132
- Alternator/Starter Clutch View
  133
Alternator/Starter Clutch
134
- Flywheel Removal
  135
- Alternator Stator
  135
- Stator Removal
  136
- Starter Clutch Removal
  136
- Starter Clutch Disassembly/Inspection
  137
- Starter Clutch Assembly
  138
- Stator Assembly
  140
- Alternator Installation
  140
- Flywheel Installation
  141
- Left Crankcase Cover Installation
  141
- Crankshaft/Transmission View
  143
Crankshaft/Transmission
144
- Crankcase Separation
  146
- Transmission Removal/Disassembly/Inspection
  147
- Transmission Assembly
  149
- Transmission Installation
  150
- Crankshaft Removal/Inspection
  151
- Crankshaft Installation
  153
- Crank Case Bearing Replacement
  153
- Crankcase Bearing Locations
  156
- Crankcase Assembly
  156
- Front Wheel/Suspension/Steering View
  158
Front Wheel/Suspension/Steering
159
- Handlebar Removal
  161
- Handlebar Installation
  163
- Front Wheel Removal
  166
- Front Wheel Inspection
  167
- Front Wheel Disassembly
  168
- Front Wheel Assembly
  169
- Front Wheel Installation
  170
- Fork Removal
  171
- Fork Disassembly
  172
- Fork Inspection
  174
- Fork Tube/Slider/Piston
  174
- Fork Tube Bushing
  175
- Fork Assembly
  175
- Fork Installation
  179
- Steering Stem Removal
  180
- Bearing Race Replacement
  181
- Steering Head Bearing Preload
  183
- Rear Wheel/Brake/Suspension View
  185
Rear Wheel/Brake/Suspension
186
- Rear Wheel Removal/Inspection
  188
- Wheel Bearing
  189
- Driven Sprocket
  189
- Wheel Bearing Removal
  190
- Wheel Bearing Installation
  191
- Rear Brake Inspection
  194
- Rear Brake Disassembly
  195
- Rear Brake Assembly
  196
- Shock Absorber Removal/Inspection
  197
- Shock Absorber Installation
  198
- Swingarm Removal/Disassembly
  198
- Swingarm Inspection
  199
- Pivot Bushing Replacement
  199
- Swingarm Assembly
  200
- Swingarm Installation
  201
- Brake Pedal Removal
  201
- Brake Pedal Installation
  202
- Hydraulic Brake View
  203
- Hydraulic Brake
  204
- Brake Fluid Replacement/Air Bleeding
  206
- Brake Fluid Draining
  206
- Brake Fluid Filling
  206
- Brake Pad Replacement
  207
- Brake Bleeding
  207
- Brake Pad/Disc
  207
- Brake Disc Inspection
  209
- Master Cylinder Removal
  209
- Master Cylinder Disassembly/Inspection
  210
- Master Cylinder Assembly
  211
- Brake Caliper Removal/Disassembly
  213
- Brake Caliper Inspection
  214
- Brake Caliper Assembly
  214
- Brake Caliper Installation
  215
- Battery/Charging System View
  216
- System Diagram
  216
- Battery/Charging System
  217
- Battery Charging/Testing Equipment
  218
- Battery Removal/Installation
  220
- Voltage Inspection
  220
- Battery Testing
  220
- Battery Charging
  221
- Regulated Voltage Inspection
  223
- Leakage Inspection
  223
- Charging System Inspection
  223
- Alternator Charging Coil
  224
- Regulator/Rectifier
  224
- System Inspection
  224
- Regulator/Rectifier Replacement
  225
- Ignition System View
  226
- Ignition System
  227
- Ignition Coil Primary Peak Voltage
  230
- Ignition System Inspection
  230
- Exciter Coil Peak Voltage
  231
- Ignition Pulse Generator Peak Voltage
  232
- Ignition Coil Removal/Installation
  233
- Ignition Timing
  233
- Electric Starter View
  234
- Electric Starter
  235
- Starter Motor Removal/Disassembly
  238
- Starter Motor Inspection
  239
- Starter Motor Assembly
  241
- Starter Motor Installation
  244
- Ground Line/Voltage Inspection
  244
- Starter Relay Switch
  244
- Operation Inspection
  244
- Continuity Inspection
  245
- Diode Removal/Inspection/Installation
  245
- Lights/Meters/Switches View
  246
- Lights/Meters/Switches
  247
- Bulb Replacement
  248
- Tail/Brake Light
  248
- Headlight
  248
- License Light
  249
- Turn Signal
  249
Lights/Meter/Switches
249
- Indicator Bulbs on the Instrument Panel
  250
- Side Stand Indicator Bulb and Instrument Bulb
  250
- Speedometer Removal/Disassembly
  250
- Speedometer Removal/Installation
  252
- Speedometer Assembly/Installation
  252
- Ignition Switch Inspection
  252
- Handlebar Switches
  253
- Clutch Switch
  254
- Neutral Switch
  254
- Side Stand Switch Inspection/Removal/Installation
  255
- Horn
  256
- Turn Signal Relay Inspection
  256
- Wiring Diagram
  257
- 1985-2009 Honda CMX250 C CD Rebel 250
  257
Troubleshooting
258
- Engine Does Not Start or Is Hard to Start
  258
- Engine Lacks Power
  259
- Poor Performance at Low and Idle Speeds
  260
- Poor Performance at High Speed
  261
- Poor Handling
  261
Index
262

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