Table Of Contents - Honda ATC250R Shop Manual

Table of Contents

Important Safety Notice3
Contents4
General Information: Contents5
General Safety5
Service Rules5
Model Identification6
Specifications7
Standard Torque Values10
Tools11
Cable And Harnes Routing12
Optional Parts List17
Noise Emission Control System (Usa Only)17
Maintenance: Contents19
Service Information19
Transmission Oil19
Maintenance Schedule20
Periodic Replacement Parts21
Transmission Oil Level Check22
Transmission Oil Change22
Air Cleaner23
Element Holding Bracket Screw23
Spark Plug24
Carburetor Idle Speed24
Radiator Coolant25
Radiator Core26
Cooling System26
Fuel Line26
Fuel Strainer Screen27
Cylinder Compression27
Ignition Timing27
Throttle Operation28
Drive Chain Inspection28
Drive Chain Adjustment29
Drive Chain Slider30
Front Suspension31
Rear Suspension31
Swing Arm Bearings32
Brake System32
Rear Brake Pedal Height33
Parking Brake33
Brake Pads34
Brake Fluid35
Clutch System35
Spark Arrester (Usa Only)36
Lighting Equipments37
Tires37
Steering Head Bearings37
Nuts, Bolts, Fasteners38
Control Cable Lubrication38
Lubrication Points39
Fuel System: Contents42
Fuel System: Service Information42
Fuel System: Troubleshooting42
Fuel Tank Removal43
Fuel Tank Installation44
Air Cleaner Case Removal45
Air Cleaner Case Installation46
Crankcase Breather47
Carburetor Removal/Disassembly48
Throttle Valve48
Carburetor Body49
Carburetor Assembly/Installation51
Float Level Inspection53
Air Screw Adjustment54
Altitude And Temperature Adjustment55
Carburetor Removal56
Carburetor Disassembly56
Connecting Tube Bands56
Carburetor Assembly60
Carburetor Installation62
Reed Valve Removal64
Reed Valve Inspection64
Reed Valve Installation64
Carburetor Theory65
Float Chamber65
Starting/Idle Circuit65
Slow Circuit65
Main Circuit66
Carburetor Operation66
Idle Mixture And Idle Speed66
Engine Removal/Installation68
Engine Removal/Installation: Contents69
Engine Removal70
Engine Installation72
Cylinder Head/Cylinder/Piston74
Cylinder Head/Cylinder/Piston: Contents75
Cylinder Head/Cylinder/Piston: Service Information75
Cylinder Head/Cylinder/Piston: Troubleshooting76
Cylinder Head Removal77
Cylinder Head Inspection77
Cylinder Head Installation78
Cylinder/Piston Removal79
Cylinder/Piston Inspection80
Cylinder/Piston Installation83
Alternator86
Alternator: Table Of Contents87
Alternator: Service Information87
Alternator Removal88
Rotor Removal88
Alternator Installation89
Stator Removal/Installation89
Rotor Installation89
Clutch/Gearshift Linkage/Kick Starter92
Clutch/Gearshift Linkage/Kick Starter: Table Of Contents93
Clutch/Gearshift Linkage/Kick Starter: Service Information93
Clutch/Gearshift Linkage/Kick Starter: Troubleshooting94
Clutch95
Right Crankcase Cover Removal95
Clutch Disassembly95
Clutch Inspection97
Clutch Installation99
Right Crankcase Cover Installation102
Clutch Lifter103
Shift Linkage Removal104
Clutch Lifter Inspection104
Shift Linkage Inspection106
Shift Linkage Installation107
Kick Starter Removal108
Kick Starter Inspection109
Kick Starter Installation110
Transmission/Crankshaft/Balancer112
Transmission/Crankshaft/Balancer: Contents113
Transmission/Crankshaft/Balancer: Service Information113
Transmission/Crankshaft/Balancer: Troubleshooting114
Balancer Removal115
Balancer Inspection116
Bearing Replacement116
Balancer Installation117
Crankcase Separation118
Transmission Removal119
Transmission Inspection119
Transmission Installation121
Crankshaft123
Crankshaft Inspection124
Crankshaft Installation125
Bearing Replacement: Right Crankcase125
Bearing Replacement: Left Crankcase126
Crankcase Assembly127
Cooling System: Overview130
Cooling System: Contents131
Cooling System: Service Information131
Cooling System: Troubleshooting131
Cooling System Inspection132
Coolant Replacement132
Water Pump134
Radiator Removal/Installation134
Mechanical Seal Inspection134
Water Pump Removal135
Water Pump Inspection136
Mechanical Seal/Bearing Replacement136
Water Pump Installation137
Front Wheel/Suspension/Steering138
Front Wheel/Suspension/Steering: Contents139
Front Wheel/Suspension/Steering: Service Information139
Front Wheel/Suspension/Steering: Troubleshooting140
Handlebar Removal141
Handlebar Installation142
Clutch/Parking Brake Lever Bracket143
Front Wheel Removal144
Front Axle Inspection145
Wheel Bearing Inspection145
Wheel Bearing Replacement145
Tire Removal147
Tire Repair148
Tire Assembly150
Front Wheel Installation151
Front Fork Removal152
Front Fork Disassembly152
Fork Spring155
Fork Tube/Slider/Piston155
Bushing/Back Up Ring Assembly156
Front Fork Installation159
Steering Stem Removal160
Steering Stem Installation163
Rear Wheel/Drive Mechanism166
Rear Wheel/Drive Mechanism: Contents167
Rear Wheel/Drive Mechanism: Service Information167
Rear Wheel/Drive Mechanism: Troubleshooting168
Rear Wheel Removal/Disassembly/Installation169
Rear Axle Removal169
Rear Axle Inspection172
Rear Axle Installation173
Rear Wheel Bearings175
Bearing Holder Removal175
Bearing Holder Installation177
Rear Suspension: Overview180
Rear Suspension: Contents181
Rear Suspension: Service Information181
Rear Suspension: Troubleshooting182
Shock Absorber Removal183
Shock Absorber Disassembly184
Shock Absorber Inspection184
Servicing The Reservoir186
Rear Suspension Installation191
Suspension Linkage Removal192
Suspension Linkage Inspection193
Suspension Linkage Installation193
Swing Arm Removal194
Swing Arm Inspection196
Pivot Bearing Replacement196
Swing Arm Installation197
Hydraulic Disc Brakes200
Hydraulic Disc Brakes: Contents201
Hydraulic Disc Brakes: Service Information201
Hydraulic Disc Brakes: Troubleshooting202
Brake Fluid Replacement/Bleeding203
Brake Fluid Draining203
Brake Fluid Filling/Bleeding204
Brake Pad Replacement206
Front Brake206
Rear Brake209
Brake Disc Inspection211
Brake Disc Removal/Installation212
Front Caliper Removal212
Front Caliper Disassembly213
Front Caliper Inspection214
Front Caliper Assembly214
Rear Caliper Removal215
Rear Caliper Disassembly216
Rear Caliper Inspection, Assembly217
Parking Brake Mechanism217
Front Master Cylinder Removal220
Front Master Cylinder Disassembly220
Front Master Cylinder Inspection220
Front Master Cylinder Assembly221
Front Master Cylinder Installation221
Rear Master Cylinder Removal221
Rear Master Cylinder Disassembly222
Rear Master Cylinder Inspection222
Rear Master Cylinder Assembly222
Rear Master Cylinder Installation223
Rear Brake Pedal Removal223
Rear Brake Pedal Installation223
Rear Fender/Seat/Exhaust System: Contents225
Rear Fender/Seat/Exhaust System: Service Information225
Rear Fender/Seat: Overview225
Rear Fender/Seat: Removal226
Rear Fender/Seat: Installation226
Exhaust System: Overview226
Exhaust Chamber Removal227
Exhaust Chamber Installation227
Exhaust Muffler Removal/Installation228
Electrical System Overview230
Electrical System: Contents231
Electrical System: Service Information231
Electrical System: Troubleshooting231
Ignition System232
Ignition Coil232
Exciter Coil233
Cdi Unit234
Headlight235
Headlight Bulb Replacement235
Pulse Generator235
Taillight Bulb Replacement236
Lighting Coil Inspection236
Ac Regulator237
Switches238
Wiring Diagram '85239
Wiring Diagram After '85240
Troubleshooting: Contents241
Engine Does Not Start Or Is Hard To Start241
Engine Lacks Power242
Poor Performance At Low And Idle Speeds243
Poor Performance At High Speeds244
Poor Handling244