Table Of Contents - Honda rebel 250 Service Manual

Table of Contents

A Few Words About Safety1
Service Information1
Table Of Contents3
Symbols4
General Information5
General Safety5
Gasoline5
Hot Components5
Battery Hydrogen Gas & Electrolyte6
Service Rules6
Model Identification7
Specification8
General Item8
Lubrication System Item10
Fuel System Item10
Cylinder Head/Valves Item11
Cylinder/Piston Item11
Clutch/Gearshift Linkage Item12
Crankshaft/Transmission Item12
Front Wheel/Suspension/Steering Item13
Rear Wheel/Brake/Suspension Item13
Hydraulic Brake Item13
Battery/Charging System Item14
Ignition System Item14
Electric Starter Item14
Lights/Meters/Switches Item15
Torque Values16
Engine16
Frame17
Tools18
Lubrication & Seal Points20
Cable & Harness Routing22
Emission Control System Routing (California Type Only)29
Emission Control System30
Source Of Emissions30
Exhaust Emission Control System30
Crankcase Emission Control System30
Evaporative Emission Control System (California Type Only)31
Noise Emission Control System31
Emission Control Information Labels (U.s.a. Only)32
Vehicle Emission Control Information Update Label32
Vacuum Hose Routing Diagram Label ('96-'04 California Type Only)32
Frame/Body Panels/Exhaust System34
Body Panel Locations34
Side Cover Removal/Installation36
Seat Removal36
Seat Installation37
Fuel Tank Removal/Installation37
Front Fender Removal38
Rear Fender Removal38
Rear Fender Installation39
Exhaust System Removal39
Exhaust System Installation40
Maintenance42
Maintenance Schedule44
Fuel Line45
Throttle Operation45
Carburetor Choke46
Air Cleaner46
Crankcase Breather47
Spark Plug47
Inspection47
Replacing A Spark Plug48
Valve Clearance48
Engine Oil50
Oil Level Inspection50
Engine Oil Change51
Engine Oil Strainer Screen51
Engine Idle Speed52
Drive Chain Slack Inspection53
Adjustment53
Cleaning And Lubrication53
Sprocket Inspection54
Replacement54
Brake Fluid56
Brake Shoe/Pad Wear57
Front Brake Pad/Rear Brake Shoe57
Brake System57
Brake Pedal Free Play57
Brake Light Switch58
Headlight Aim58
Clutch System59
Side Stand59
Front/Rear Suspension60
Nuts, Bolts, Fasteners60
Wheels/Tires61
Steering Head Bearings61
Lubrication System Diagram62
Lubrication System63
Oil Pump Removal/Disassembly64
Oil Pump Inspection65
Oil Pump Assembly66
Oil Pump Installation67
Fuel System View68
Fuel System69
Carburetor Removal72
Carburetor Disassembly72
Starting Enrichment (Se) Valve72
Diaphragm/Vacuum Piston73
Float And Jets73
Carburetor Assembly75
Float Level Inspection76
Carburetor Installation79
Pilot Screw Adjustment80
Idle Drop Procedure80
High Altitude Adjustment81
Air Cleaner Housing Removal82
Air Cleaner Housing Installation83
Engine Removal/Installation View84
Engine Removal/Installation85
Engine Installation88
Cylinder Head/Valves View90
Cylinder Head/Valves91
Cylinder Compression Test93
Rocker Arm/Camshaft Removal93
Cylinder Head Removal97
Cylinder Head Disassembly98
Cylinder Head Inspection99
Valve Spring99
Valve/Valve Guide99
Valve Guide Replacement100
Valve Seat Inspection/Refacing101
Valve Seat Refacing102
Cylinder Head Assembly View104
Cylinder Head Installation105
Camshaft/Rocker Arm Installation106
Rocker Arm Holder Assembly106
Camshaft Installation107
Camshaft Holder Installation108
Cylinder/Piston View111
Cylinder/Piston112
Cylinder/Piston Removal114
Cylinder/Piston Inspection114
Cylinder/Piston Installation117
Piston Ring Installation117
Piston Installation118
Clutch/Gearshift Linkage View120
Clutch/Gearshift Linkage121
Right Crankcase Cover Removal123
Clutch Lifter Removal/Installation123
Clutch Removal124
Clutch Inspection125
Clutch Lifter Bearing125
Clutch Spring125
Clutch Center126
Clutch Disc126
Clutch Pate126
Clutch Outer/Clutch Outer Guide126
Clutch Installation127
Primary And Oil Pump Drive Gears129
Gearshift Linkage Disassembly130
Gearshift Linkage Assembly131
Right Crankcase Cover Installation132
Alternator/Starter Clutch View133
Alternator/Starter Clutch134
Alternator Stator135
Flywheel Removal135
Stator Removal136
Starter Clutch Removal136
Starter Clutch Disassembly/Inspection137
Starter Clutch Assembly138
Stator Assembly140
Alternator Installation140
Flywheel Installation141
Left Crankcase Cover Installation141
Crankshaft/Transmission View143
Crankshaft/Transmission144
Crankcase Separation146
Transmission Removal/Disassembly/Inspection147
Transmission Assembly149
Transmission Installation150
Crankshaft Removal/Inspection151
Crankshaft Installation153
Crank Case Bearing Replacement153
Crankcase Bearing Locations156
Crankcase Assembly156
Front Wheel/Suspension/Steering View158
Front Wheel/Suspension/Steering159
Handlebar Removal161
Handlebar Installation163
Front Wheel Removal166
Front Wheel Inspection167
Front Wheel Disassembly168
Front Wheel Assembly169
Front Wheel Installation170
Fork Removal171
Fork Disassembly172
Fork Inspection174
Fork Tube/Slider/Piston174
Fork Tube Bushing175
Fork Assembly175
Fork Installation179
Steering Stem Removal180
Bearing Race Replacement181
Steering Head Bearing Preload183
Rear Wheel/Brake/Suspension View185
Rear Wheel/Brake/Suspension186
Rear Wheel Removal/Inspection188
Wheel Bearing189
Driven Sprocket189
Wheel Bearing Removal190
Wheel Bearing Installation191
Rear Brake Inspection194
Rear Brake Disassembly195
Rear Brake Assembly196
Shock Absorber Removal/Inspection197
Shock Absorber Installation198
Swingarm Removal/Disassembly198
Swingarm Inspection199
Pivot Bushing Replacement199
Swingarm Assembly200
Swingarm Installation201
Brake Pedal Removal201
Brake Pedal Installation202
Hydraulic Brake View203
Hydraulic Brake204
Brake Fluid Replacement/Air Bleeding206
Brake Fluid Draining206
Brake Fluid Filling206
Brake Bleeding207
Brake Pad/Disc207
Brake Pad Replacement207
Brake Disc Inspection209
Master Cylinder Removal209
Master Cylinder Disassembly/Inspection210
Master Cylinder Assembly211
Brake Caliper Removal/Disassembly213
Brake Caliper Inspection214
Brake Caliper Assembly214
Brake Caliper Installation215
Battery/Charging System View216
System Diagram216
Battery/Charging System217
Battery Charging/Testing Equipment218
Battery Removal/Installation220
Voltage Inspection220
Battery Testing220
Battery Charging221
Charging System Inspection223
Leakage Inspection223
Regulated Voltage Inspection223
Alternator Charging Coil224
Regulator/Rectifier224
System Inspection224
Regulator/Rectifier Replacement225
Ignition System View226
Ignition System227
Ignition System Inspection230
Ignition Coil Primary Peak Voltage230
Exciter Coil Peak Voltage231
Ignition Pulse Generator Peak Voltage232
Ignition Coil Removal/Installation233
Ignition Timing233
Electric Starter View234
Electric Starter235
Starter Motor Removal/Disassembly238
Starter Motor Inspection239
Starter Motor Assembly241
Starter Motor Installation244
Starter Relay Switch244
Operation Inspection244
Ground Line/Voltage Inspection244
Continuity Inspection245
Diode Removal/Inspection/Installation245
Lights/Meters/Switches View246
Lights/Meters/Switches247
Bulb Replacement248
Headlight248
Tail/Brake Light248
License Light249
Turn Signal249
Lights/Meter/Switches249
Indicator Bulbs On The Instrument Panel250
Side Stand Indicator Bulb And Instrument Bulb250
Speedometer Removal/Disassembly250
Speedometer Assembly/Installation252
Ignition Switch Inspection252
Speedometer Removal/Installation252
Handlebar Switches253
Clutch Switch254
Neutral Switch254
Side Stand Switch Inspection/Removal/Installation255
Horn256
Turn Signal Relay Inspection256
Wiring Diagram257
1985-2009 Honda Cmx250 C Cd Rebel 250257
Troubleshooting258
Engine Does Not Start Or Is Hard To Start258
Engine Lacks Power259
Poor Performance At Low And Idle Speeds260
Poor Performance At High Speed261
Poor Handling261
Index262