Table Of Contents - Honda NX250 Shop Manual

Table of Contents

Important Safety Notice1
Contents2
General Information3
General Safety3
Service Rules3
Model Identification4
Frame/Engine Serial Number4
Carburetor Identification Number4
Color Label4
Specifications5
Torque Values7
Tools9
Cable & Harness Routing11
Lubrication15
Lubrication Service Information17
Lubrication Specifications17
Lubrication Torque Value17
Lubrication Troubleshooting17
Engine Oil Level Check18
Engine Oil & Filter Change18
Engine Oil Strainer Cleaning19
Oil Pump Removal19
Oil Pump Inspection20
Oil Pump Assembly21
Oil Pump Installation21
Lubrication Points23
Control Cable Lubrication23
Maintenance Service Information24
Maintenance Schedule26
Fuel Line27
Fuel Strainer Screen27
Throttle Operation27
Carburetor Choke28
Air Cleaner28
Crankcase Breather29
Recommended Spark Plugs29
Valve Clearance Inspection29
Shim Selection Chart31
Carburetor Idle Speed32
Radiator Coolant32
Cooling System33
Cylinder Compression33
Drive Chain Slack Inspection34
Drive Chain Adjustment34
Drive Chain Slider35
Brake Fluid35
Brake Shoe/Pad Wear36
Brake System36
Brake Shoe Inspection36
Brake Pedal Height/Free Play36
Brake Light Switch37
Headlight Aim Adjustment37
Clutch System37
Clutch Lever Free Play37
Side Stand38
Front/Rear Suspension39
Nuts, Bolts, Fasteners39
Wheels/Tires40
Tire Pressure40
Steering Head Bearings41
Fuel System42
Fuel System Specifications44
Fuel System Service Information44
Fuel System Troubleshooting45
Fuel System Torque Value45
Fuel System Tools45
Fuel Tank Removal46
Fuel Tank Installation46
Air Cleaner Case Removal/Installation47
Carburetor Removal48
Carburetor Disassembly49
Carburetor Assembly52
Carburetor Installation57
Pilot Screw Adjustment57
Accelerator Pump58
Cooling System Service Information61
Cooling System Specifications61
Cooling System Torque Values61
Cooling System Troubleshooting62
Cooling System Tools62
System Testing63
Coolant63
Radiator Cap/System Inspection63
Coolant Replacement64
Thermostat Removal64
Thermostat Inspection64
Thermostat Installation65
Radiator/Cooling Fan Removal65
Radiator/Fan Inspection66
Water Pump Mechanical Seal Inspection67
Water Pump Mechanical Seal Replacement67
Reserve Tank69
Engine Removal/Installation70
Clutch82
Clutch Service Information84
Clutch Specifications84
Clutch Troubleshooting85
Clutch Torque Values85
Clutch Tools85
Right Crankcase Cover Removal86
Clutch Lifter Removal/Inspection86
Clutch Removal87
Clutch Inspection88
Clutch Installation89
Primary Drive Gear91
Clutch Lifter Assembly91
Crankshaft Oil Seal91
Primary Drive Gear Removal91
Primary Drive Gear Installation92
Gearshift Linkage Removal/Installation92
Right Crankcase Cover Installation93
Alternator/Starter Clutch114
Alternator/Starter Clutch Service Information116
Alternator/Starter Clutch Torque Values116
Alternator/Starter Clutch Tools116
Left Crankcase Cover Removal117
Flywheel Removal118
Starter Clutch Removal119
Alternator Replacement119
Starter Clutch Inspection/Disassembly119
Starter Clutch/Flywheel Installation121
Left Crankcase Cover Installation122
Cylinder Head/Valve124
Cylinder Head/Valve Service Information126
Cylinder Head/Valve Specifications126
Cylinder Head/Valve Troubleshooting127
Cylinder Head/Valve Torque Values127
Cylinder Head/Valve Tools127
Cylinder Head Cover Removal128
Camshaft/Cam Chain Tensioner Removal128
Cylinder Head Removal131
Cylinder Head Disassembly132
Valve Guide Replacement135
Valve Seat Inspection/Refacing136
Valve Seat Cutters136
Valve Seat Refacing137
Cylinder Head Assembly138
Cylinder Head Installation140
Camshaft/Cam Chain Tensioner Installation141
Cylinder Head Cover Installation144
Cylinder/Piston145
Cylinder/Piston Service Information147
Cylinder/Piston Troubleshooting147
Cylinder/Piston Specifications147
Cylinder/Piston Torque Value147
Cylinder Removal/Inspection148
Piston Removal/Inspection149
Piston/Piston Ring Inspection149
Piston Ring Installation151
Piston/Cylinder Installation152
Crankshaft/Transmission153
Crankshaft/Transmission Service Information155
Crankshaft/Transmission Specifications155
Crankshaft/Transmission Torque Values156
Crankshaft/Transmission Tools156
Crankshaft/Transmission Troubleshooting157
Crankcase Separation158
Transmission Removal159
Transmission Disassembly159
Transmission Inspection160
Transmission Assembly162
Crankshaft/Balancer Removal163
Balancer Disassembly/Assembly163
Crankshaft Inspection164
Crankcase Bearings Replacement165
Crankcase Assembly167
Front Wheel/Suspension/Steering170
Front Wheel/Suspension/Steering Service Information172
Front Wheel/Suspension/Steering Specifications172
Front Wheel/Suspension/Steering Torque Values172
Front Wheel/Suspension/Steering Troubleshooting173
Front Wheel/Suspension/Steering Tools173
Handlebar Removal174
Handlebar Installation175
Front Wheel Removal177
Front Wheel Inspection177
Front Wheel Disassembly178
Front Wheel Bearing Replacement178
Front Wheel Assembly179
Front Wheel Installation181
Fork Removal181
Fork Disassembly182
Fork Inspection184
Fork Assembly185
Fork Installation188
Steering Stem Removal189
Steering Stem Bearing Replacement190
Steering Stem Installation192
Rear Wheel/Brake/Suspension195
Rear Wheel/Brake/Suspension Service Information197
Rear Wheel/Brake/Suspension Specifications197
Rear Wheel/Brake/Suspension Torque Values197
Rear Wheel/Brake/Suspension Troubleshooting198
Rear Wheel/Brake/Suspension Tools198
Rear Wheel Removal199
Rear Wheel Inspection199
Rear Wheel Bearing Replacement200
Rear Brake Removal/Inspection205
Rear Brake Disassembly205
Rear Brake Assembly206
Brake Pedal Removal/Installation207
Shock Absorber209
Shock Absorber Disassembly210
Shock Absorber Inspection210
Shock Absorber Disposal Procedure211
Shock Absorber Assembly211
Shock Absorber Installation212
Shock Linkage Removal213
Shock Linkage Bearing Replacement213
Shock Linkage Installation214
Swingarm Removal215
Swingarm Inspection216
Swingarm Pivot Bearing Replacement216
Swingarm Installation217
Hydraulic Brake Service Information220
Hydraulic Brake Specifications220
Hydraulic Brake Torque Values220
Hydraulic Brake Tool220
Hydraulic Brake Troubleshooting221
Brake Fluid Replacement/Bleeding222
Brake Fluid Draining222
Brake Fluid Filling/Bleeding222
Brake Pad Replacement223
Disc Thickness224
Disc Warpage224
Master Cylinder Disassembly225
Master Cylinder Inspection226
Master Cylinder Assembly226
Brake Caliper Disassembly227
Brake Caliper Inspection228
Brake Caliper Assembly228
Fairing/Exhaust System230
Exhaust Pipe/Muffler Removal/Installation230
Seat & Fairings Removal/Installation231
Rear Carrier Removal/Installation232
Battery/Charging System Service Information234
Battery Charging234
Battery Charging/Testing Equipment234
Battery/Charging System Specifications235
Battery/Charging System Tools235
Battery/Charging System Troubleshooting236
Battery Removal237
Urging System238
Leakage Current Inspection238
Regulated Voltage Inspection238
Alternator Inspection238
Ignition System240
Ignition System Service Information242
Ignition System Specification242
Ignition System Tools242
Ignition System Troubleshooting243
Ignition Coil Removal244
Ignition Coil Inspection244
Ignition Coil Installation244
Cdi Unit Inspection245
Pulse Generator Inspection246
Ignition Timing246
Electric Starter247
Electric Starter Service Information249
Electric Starter Specifications249
Electric Starter Troubleshooting250
Starter Motor Removal251
Starter Motor Disassembly251
Starter Motor Inspection251
Starter Motor Assembly252
Starter Motor Installation254
Starter Relay Switch Inspection254
Lights/Meters/Switches Service Information255
Lights/Meters/Switches Torque Values255
Lights/Meters/Switches Troubleshooting256
Temperature Warning System256
Headlight Bulb Replacement257
Headlight Case Removal257
Instrument Case Bulb Replacement258
Instrument Case Meter Replacement258
Turn Signal Light Bulb Replacement259
Tail Light/License Light Bulb Replacement259
Neutral Switch259
Front Brake Light Switch260
Rear Brake Light Switch260
Clutch Switch260
Handlebar Switch260
Left Handlebar Switch261
Horn261
Ignition Switch Inspection262
Ignition Switch Removal262
Thermostatic Switch263
Temperature Sensor263
Wiring Diagram265
Troubleshooting266
Engine Does Not Start Or Is Hard To Start266
Engine Lacks Power267
Poor Performance At Low And Idle Speeds268
Poor Performance At High Speed269