Table Of Contents - Honda NSR250R SERIES Service Manual

Table of Contents

Table Of Contents2
General Information3
Model Identification3
Engine Number3
Frame Number3
Specifications4
Summary Of Structure5
Rc Valve System6
Control Unit7
Cassette Transmission7
Crank Case Reed Valve8
Intake Chamber8
Oil Pump Solenoid9
Floating Disc Brake10
Flexible Joint Exhaust Chamber10
General Cautions11
Symbols18
Torque Values19
Tools21
Lubrication Points23
Cable & Harness Routing25
Troubleshooting28
Engine Does Not Start Or Is Hard To Start28
Engine Lacks Power29
Poor Performance At Idle And Low Speed30
Battery Undercharged (Poor Charging)30
Bad Charge31
No Spark Or Weak Spark To The Spark Plug31
Engine Malfunctions32
Smokes At Low Engine Speed33
Maintenance Schedule35
Steering Head Bearings39
Brake System39
Steering Fork39
Brake Pedal39
Disc Brakes, Pads40
Wheels40
Brake Pad Wear40
Tire Pressure40
Suspension41
Transmission41
Shock Absorber41
Front Fork Air Pressure41
Transmission Oil42
Oil Level Inspection42
Oil Change43
Drive Chain43
Drive Chain Slack Inspection43
Installation And Wear Of Sprockets44
Wear Of Chain Slider44
Electrical System45
Ignition System45
Spark Plug45
Ignition Timing45
Fuel System46
Battery46
Carburetor46
Idle Speed46
Cylinder Compression47
Lubrication System47
Engine Oil Strainer And Screen47
Oil Pump Control Cable Adjustment48
Throttle Operation49
Cooling System50
Clogged Fuel Filter50
Headlight50
Brake Light Switch51
Side Stand51
Rc Valve Control Cable Adjustment51
Lubrication Flow Diagram54
Lubrication System Service Information55
Lubrication System Specifications55
Lubrication System Troubleshooting55
Oil Pump Removal56
Oil Pump Inspection56
Oil Pump Bleeding57
Oil Pump Installation57
Oil Inlet Line/Oil Pump Air Bleeding57
Oil Tank Removal/Installation58
Oil Outlet Lines58
Fuel System Service Information59
Fuel System Specifications59
Fuel System Tools59
Fuel System Troubleshooting59
Fuel Tank Removal60
Fuel Tank Installation60
Air Box Removal61
Air Box Installation61
Carburetor Removal62
Carburetor Disassembly63
Air Screw Adjustment74
Carburetor Synchronization74
Cooling System Service Information76
Cooling System Specifications76
Cooling System Tools76
Cooling System Troubleshooting76
Coolant Fluid Density77
Coolant Ratio77
Cooling System Testing78
Coolant78
Radiator Cap Inspection78
Coolant Replacement79
System Pressure Test79
Thermostat Removal80
Thermostat Inspection80
Temperature Sensor Removal81
Temperature Sensor Inspection81
Temperature Sensor Installation81
Radiator, Hose Inspection81
Water Pump82
Radiator, Hose Removal82
Mechanical Seal Inspection82
Water Pump Removal82
Mechanical Seal Replacement83
Reserve Tank Removal84
Reserve Tank Installation84
Water Pump Installation84
Engine Removal85
Engine Installation87
Cylinder Head, Cyl, Piston, Rc Valve90
Cylinder Head, Cyl, Piston, Rc Valve Troubleshooting91
Cylinder Head Removal92
Cylinder, Piston Removal93
Front Cylinder Removal94
Piston Removal94
Piston Ring Removal94
Cylinder Inspection95
Cylinder And Piston Selection96
Piston Pin Inspection96
Piston Selection96
Rc Valve Disassembly97
Rc Valve Inspection97
Cylinder Selection97
Cylinder, Piston Installation98
Rc Valve Assembly98
Front Cylinder Installation99
Rear Cylinder Installation100
Cylinder Head Installation101
Clutch, Kickstarter, Gear Shift Linkage Service Information104
Clutch, Kickstarter, Gear Shift Linkage Troubleshooting105
Right Crankcase Cover Removal106
Clutch Removal106
Clutch Inspection107
Lifter Rod, Lifter Guide And Ball Bearing Inspection108
Clutch Outer Basket And Outer Guide Inspection108
Mainshaft Inspection108
Primary Drive Gear Removal109
Clutch Arm Removal109
Clutch Arm Inspection109
Kickstarter Removal110
Kickstarter Spindle Removal110
Gearshift Linkage Removal111
Gear Shift Linkage Inspection112
Gear Shift Linkage Installation113
Kickstarter Installation114
Kickstarter Idler Gear Installation115
Primary Drive Gear Installation116
Clutch Installation116
R. Crankcase Cover Installation118
Transmission Service Information121
Transmission Specifications121
Transmission Tools121
Transmission Troubleshooting122
Engine Noise122
Gears Sticking122
Gear Difficult To Engage122
Transmission Removal123
Transmission Inspection124
Main Shaft, Counter Shaft, Gears, Collars124
Transmission Bearing Replacement125
Gear Shift Fork Inspection125
Shift Fork Shaft Inspection125
Gearshift Drum Inspection125
Main Shaft Bearing127
Transmission Assembly128
Ac Generator Service Information132
Pulse Generator Removal133
Ac Generator Removal133
Ac Generator Installation134
Pulse Generator Installation134
Crankcase, Crankshaft Service Information137
Crankcase, Crankshaft Troubleshooting137
Crankcase Separation138
Crankshaft Removal138
Oil Seal Inspection138
Crankshaft Inspection139
Crankshaft Installation139
Crankcase Assembly140
Front Wheel, Suspension, Steering142
Handlebars Removal144
Handlebars Installation144
Front Wheel Removal147
Wheel Balance148
Front Wheel Disassembly148
Front Wheel Assembly149
Front Wheel Installation150
Front Forks151
Form Removal151
Bearing Replacement160
Steering Head Bearing Preload163
Rear Wheel, Suspension Service Information165
Rear Wheel, Suspension Specification165
Rear Wheel, Suspension Troubleshooting166
Rear Wheel Removal167
Shock Absorber Removal171
Lower Joint Needle Bearing Replacement172
Shock Absorber Disposal Procedure174
Suspension Linkage176
Shock Link Needle Bearing Replacement177
Shock Arm Plate Inspection178
Swing Arm Removal178
Pivot Bearing Replacement179
Shock Link Arm Bearing Replacement182
Brakes (Disc Brakes) Service Information186
Brakes (Disc Brakes) Specification186
Brakes (Disc Brakes) Troubleshooting187
Brake Fluid Replacement/Air Bleeding188
Brake Fluid Draining188
Brake Fluid Filling188
Brake Pad/Disc189
Front Brake Pad Replacement189
Rear Brake Pad Replacement191
Brake Disc Inspection192
Front Master Cylinder Removal193
Rear Master Cylinder Removal196
Rear Master Cylinder Disassembly197
Rear Master Cylinder Inspection197
Rear Master Cylinder Assembly198
Rear Master Cylinder Installation199
Front Brake Caliper Removal199
Front Brake Caliper Disassembly199
Rear Brake Caliper Removal201
Rear Brake Caliper Disassembly201
Rear Brake Caliper Inspection202
Rear Brake Caliper Installation203
Brake Pedal Removal203
Brake Pedal Installation204
Frame/Body Panel/Exhaust System Service Information206
Side Cover Removal206
Side Cover Installation207
Windscreen Replacement207
Fairing208
Lower Cowling208
Upper Fairing208
Sub Frame Removal211
Sub Frame Installation211
Exhaust System Removal212
Exhaust System Inspection212
Rear Fender Removal213
Rear Fender Installation213
Battery, Charging System Service Information215
Maintenance Free Battery215
Battery, Charging System Troubleshooting216
No Current216
Low Current216
Intermittent Current216
Battery Removal217
Voltage Inspection217
Battery Charging217
Regulator/Rectifier218
Current Leakage Testing218
Ac Generator Inspection219
Ignition System Service Information220
Ignition System Specification220
Ignition System Tools220
Ignition System Troubleshooting221
Cdi Unit Inspection222
Ignition Coil Inspection223
Ignition Coil Replacement223
Pulse Generator Inspection224
Lights, Meters, Switches Service Information226
Lights, Meters, Switches Troubleshooting226
Bulb Replacement227
Turn Signal228
Brake/Tail Light228
Instruments228
Ignition Switch Inspection231
Ignition Switch Removal231
Ignition Switch Disassembly231
Handle Bar Switches232
Ignition Switch Assembly232
Ignition Switch Installation232
Oil Warning System233
Oil Warning Light Inspection233
Oil Level Sensor Inspection233
Temperature Gauge234
Tachometer234
Neutral Switch235
Horn235
Control Unit, Server Motor, Oil Pump Solenoid Service Information237
Control Unit, Server Motor, Oil Pump Solenoid Troubleshooting237
Servomotor238
Rc Valve Operation Inspection238
Servomotor Inspection238
Servomotor Replacement239
Oil Pump Solenoid Inspection240
Wire Harness Inspection241
Control Unit Replacement241
Nsr250R (J) Supplement243
Nsr250R-Sp (J) Supplement313
Nsr250R (K) Supplement315
Nsr250R-Sp (K) Supplement365
Nsr250R (L, N) Supplement384
Nsr250R-Sp, Se (L, N) Supplement468