Table of Contents
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Chapters
Table of Contents
Related Manuals for Honda CBR250RJ
Summarization of Contents
Maintenance Information
Service Information
Details on service procedures, serial numbers, and color labels.
Specifications
Technical data including dimensions, engine, tires, and braking system.
Structure Description
Overview of the vehicle's structural components.
General Caution
Important guidelines for maintenance and assembly procedures.
Symbols and Meanings
Explanation of symbols used in the manual for warnings and procedures.
Tightening Torque
Engine Torque Specifications
Torque values for engine component bolts and nuts.
Frame Torque Specifications
Torque values for frame component bolts and nuts.
Tools
Exclusive Tools
Specialized tools required for specific maintenance tasks.
Common Tools
General purpose tools commonly used in motorcycle maintenance.
Measurement Tools
Tools used for measuring various parameters during inspection.
Valve Seat Cutting Tools
Specialized tools for valve seat maintenance.
Lubrication
Engine Components Lubrication
Recommended oil grades and lubrication points for engine parts.
Frame Lubrication
Lubrication points for chassis and suspension components.
Electrical System
Wiring Diagram
Schematic representation of the motorcycle's electrical system.
Wiring Routing
Diagrams showing the correct routing of electrical wires and harnesses.
Troubleshooting
Failure/Difficult to Start
Diagnosing and resolving starting issues.
Rough RPM
Troubleshooting engine speed irregularities.
Rough RPM (High RPM)
Diagnosing engine RPM issues at high speeds.
Charging Problem (Overcharge)
Diagnosing and resolving issues related to overcharging the battery.
Engine Does Not Start
Step-by-step guide for diagnosing engine start failures.
Tachometer Issues
Diagnosing and resolving problems with the tachometer.
Water Temperature Gauge Issues
Troubleshooting the water temperature gauge system.
Fuel Flows After Shutting Engine Down
Diagnosing fuel flow issues after the engine is stopped.
Failure to Start (Cold Engine)
Diagnosing starting problems when the engine is cold.
Difficult to Start (Hot Engine)
Diagnosing starting problems when the engine is hot.
Unstable Idling (After Warm-Up)
Troubleshooting unstable engine idle after warm-up.
No Combustion in Some Cylinders (Idle)
Diagnosing and resolving combustion issues in specific cylinders at idle.
Extremely Low Vacuum at Idle
Diagnosing and resolving extremely low vacuum readings at idle.
RPM Does Not Decrease Fast
Troubleshooting issues where engine RPM does not decrease quickly.
High RPM Unstable (After Warm-up)
Diagnosing and resolving engine instability at high RPM after warm-up.
Carburettor Overflow
Troubleshooting fuel overflow issues from the carburettor.
Inspection/Adjustment
Service Schedule Overview
Provides a schedule for regular inspections and recommended maintenance.
Drive System Inspection
Checks for the front wheel, rear fork, and related components.
Shock Absorbing System Inspection
Inspection of rear suspension components like cushion and springs.
Transmission Inspection
Checks for clutch lever, oil, and chain condition.
Electrical System Inspection
Checks for spark plugs, ignition coils, and battery condition.
Powerplant Inspection
Checks for engine oil, fuel system, and cooling system status.
Fuel System Inspection
Checks for air filter, carburettor, and fuel tank condition.
Cooling System Inspection
Checks for radiator, thermostat, and water pump condition.
Steering System Inspection
Checks for smooth steering movement and steering head bearing.
Brake Pedal Inspection and Adjustment
Adjusts brake pedal height and checks free movement.
Brake Lever and Fluid Check
Checks brake fluid level and lever operation.
Brake Disk and Pad Inspection
Inspects brake disc thickness and pad wear.
Wheel Inspection
Checks tire pressure, wheel nuts, and rim condition.
Damper Inspection
Inspects front fork and rear cushion for oil leaks and damage.
Front Fork Air Pressure Adjustment
Adjusts air pressure in the front fork for optimal performance.
Clutch Inspection and Adjustment
Checks and adjusts clutch lever free play.
Chain and Sprocket Maintenance
Inspects and adjusts drive chain tension and sprockets.
Ignition System Inspection
Checks spark plugs and ignition system components.
Spark Plug Inspection
Inspects spark plugs for damage, dirt, and proper gap.
Ignition Timing and Battery Check
Checks ignition timing and battery status.
Engine Idling and Acceleration Adjustment
Adjusts engine idling speed and throttle response.
Air Cleaner Case Maintenance
Inspects and replaces the air cleaner element.
Valve Clearance Inspection and Adjustment
Measures and adjusts valve clearance for optimal engine performance.
How to Select a Shim
Procedure for selecting the correct shim for valve clearance adjustment.
Cylinder Compression Measurement
Measures cylinder compression to assess engine health.
Oil Quantity and Condition Check
Checks engine oil level and condition.
Engine Oil Change
Procedure for draining and refilling engine oil.
Oil Filter Replacement
Procedure for replacing the engine oil filter.
Throttle and Choke Lever Check
Inspects throttle and choke lever operation.
Clogged Fuel Strainer Maintenance
Cleans or replaces the fuel strainer.
Cooling System Water Level Check
Checks the coolant level in the reserve tank.
Headlight Adjustment
Adjusts vertical and horizontal aim of the headlight.
Stop Light Adjustment
Adjusts the rear stoplight switch timing.
Side Stand Inspection and Maintenance
Inspects side stand operation, spring, and rubber wear.
Oil Lubrication System
Oil System Assembly
Exploded view and assembly steps for the oil system.
Lubrication System Diagram
Diagram illustrating the oil flow through the lubrication system.
Maintenance Information and Standards
General cautions, standards, and specifications for the oil system.
Tightening Torques
Specified torque values for oil system components.
Lubrication Tools
List of exclusive and common tools for oil system maintenance.
Oil System Troubleshooting
Diagnosing and resolving issues related to oil level, pressure, and quality.
Oil Pressure Inspection
Procedure for measuring engine oil pressure.
Oil Strainer and Pressure Relief Valve Maintenance
Details on removing, cleaning, and installing the oil strainer and relief valve.
Oil Pump Detachment
Steps for removing the oil pump assembly.
Relief Valve Disassembly and Inspection
Disassembly and inspection of the oil pressure relief valve.
Oil Pump Disassembly and Inspection
Disassembly and inspection of the oil pump components.
Oil Pump Assembly
Steps for assembling the oil pump components.
Oil Pump Attachment
Steps for attaching the oil pump assembly to the crankcase.
Oil Strainer and Pressure Relief Valve Attachment
Steps for attaching the oil strainer and pressure relief valve.
Oil Strainer Attachment
Steps for attaching the oil strainer.
Oil Pan Attachment
Steps for attaching the oil pan with new gaskets.
Final Oil System Checks
Final steps including filling oil, attaching exhaust, and checking for leaks.
Fuel System
Fuel System Assembly
Exploded view and assembly of fuel system components.
Fuel System Maintenance Information
General cautions, standards, and specifications for the fuel system.
Fuel System Tightening Torques
Specified torque values for fuel system components.
Fuel System Tools
List of common and measuring tools for fuel system maintenance.
Fuel System Troubleshooting
Diagnosing and resolving fuel system issues.
Fuel Tank Removal and Installation
Steps for removing and installing the fuel tank.
Fuel Auto Cock Inspection and Disassembly
Inspection and disassembly of the fuel auto cock.
Fuel Strainer Maintenance and Assembly
Cleaning and assembling the fuel strainer.
Carburettor Removal
Steps for removing the carburettor assembly.
Air Cleaner Case Removal
Steps for removing the air cleaner case.
Air Cleaner Case Attachment
Steps for attaching the air cleaner case.
Carburettor Disassembly
Disassembly of the carburettor components.
Carburettor Vacuum Chamber Service
Service procedures for the carburettor vacuum chamber.
Carburettor Float Chamber Service
Service procedures for the carburettor float chamber.
Carburettor Bistarter Valve Service
Service procedures for the carburettor bistarter valve.
Carburettor Assembly
Steps for assembling the carburettor unit.
Carburettor Jet Holder and Float Level Check
Installing jet holder and checking carburettor float level.
Carburettor Vacuum Piston Assembly
Assembling the vacuum piston and related components.
Connecting Carburetors
Steps for linking multiple carburettors together.
Carburettor Bistarter and Synchronization Adjustment
Adjusting the bistarter valve and synchronizing carburettors.
Pilot Screw Adjustment
Procedure for adjusting the carburettor pilot screws.
Carburettor Synchronization
Procedure for synchronizing the carburettors.
Cooling System
Cooling System Assembly
Exploded view and assembly steps for the cooling system.
Cooling System Maintenance Information
General cautions, standards, and specifications for the cooling system.
Cooling System Tightening Torques
Specified torque values for cooling system components.
Cooling System Troubleshooting
Diagnosing and resolving cooling system issues.
Radiator Liquid Properties
Specific gravity and mixture tables for radiator liquid.
Radiator Hose Inspection
Inspects radiator hoses and clamps for damage or wear.
Radiator Removal
Steps for removing the radiator.
Radiator Attachment
Steps for attaching the radiator.
Radiator Disassembly
Steps for disassembling the radiator.
Radiator Assembly
Steps for assembling the radiator.
Radiator Attachment and Checks
Attaching radiator, checking pressure, and inspecting for leaks.
Thermostat Removal
Steps for removing the thermostat.
Thermostat Inspection and Attachment
Inspects and attaches the thermostat.
Thermal Sensor Detachment and Specification
Detaches and checks the thermal sensor.
Water Pump Inspection and Removal
Inspects mechanical seals and removes the water pump.
Water Pump Inspection and Attachment
Inspects and attaches the water pump assembly.
Reservoir Tank Detachment and Attachment
Steps for removing and installing the coolant reservoir tank.
Engine Installation/Removal
Engine Assembly
Exploded view and assembly steps for engine installation.
Engine Installation/Removal General Information
General cautions, maintenance standards, and torque specs for engine work.
Engine Torque Specifications
Torque values for engine mounting bolts.
Engine Dismounting Procedure
Step-by-step guide for removing the engine from the frame.
Engine Refit Procedure
Steps for installing the engine back into the frame.
Cylinder Head Valve
Cylinder Head Assembly
Exploded view and assembly steps for the cylinder head.
Cylinder Head Maintenance Information
General cautions and service information for the cylinder head.
Cylinder Head Service Standards
Specifications for compression, camshaft, valve, and cylinder components.
Cylinder Head Torque Specifications
Torque values for cylinder head component bolts.
Cylinder Head Tools
List of exclusive and common tools for cylinder head service.
Cylinder Head Troubleshooting
Diagnosing and resolving cylinder head and valve issues.
Cylinder Head Cover Detachment
Steps for removing the cylinder head cover.
Camshaft Detachment
Steps for removing the camshaft.
Camshaft Inspection
Inspects camshaft gear, journals, and lobe height.
Camshaft Oil Clearance Inspection
Measures and inspects camshaft oil clearance.
Cam Shaft Holder Removal
Steps for removing the camshaft holder.
Cam Gear Train Detachment
Steps for detaching the cam gear train.
Cylinder Head Detachment
Steps for removing the cylinder head.
Cylinder Head Disconnection and Removal
Disconnecting hoses and removing cylinder head bolts.
Cylinder Head Disassembly
Disassembly of the cylinder head components.
Tappet Hole Protector Attachment
Attaching tappet hole protectors to the cylinder heads.
Cylinder Head Inspection
Inspects for carbon, gasket pieces, cracks, and distortion.
Valve Lifter Bore and Lifter Inspection
Inspects valve lifter bore and lifter for wear and damage.
Valve Spring and Stem/Guide Inspection
Inspects valve spring relaxed length and stem/guide for wear.
Valve Guide Measurement and Replacement
Measures and replaces valve guides.
Valve Seat Inspection and Adjustment
Inspects and adjusts valve seat contact.
Valve Seat Adjustment Procedures
Procedures for adjusting valve seat width using cutters.
First Cam Gear Detachment
Steps for detaching the first cam gear.
First Cam Gear Disassembly
Disassembly of the first cam gear components.
First Cam Gear Assembly
Assembly of the first cam gear components.
First Cam Gear Attachment
Steps for attaching the first cam gear.
Camshaft Holder Bolt Tightening
Tightens camshaft holder bolts in sequence.
Ignition Timing Alignment
Aligns ignition timing marks on the crankshaft and camshaft.
Cylinder Head Cover Attachment
Steps for attaching the cylinder head cover.
Final Assembly Steps
Final steps including attaching spark plug caps and radiator.
Crankcase
Crankcase Assembly
Exploded view and assembly steps for the crankcase.
Crankcase General Information
General cautions, standards, and torque specs for crankcase work.
Crankcase Torque Specifications
Specified torque values for crankcase bolts.
Crankcase Tools
List of exclusive and common tools for crankcase service.
Crankcase Separation
Steps for separating the crankcase halves.
Bearing Replacement
Steps for replacing bearings in the crankcase.
Crankcase Assembly
Steps for assembling the crankcase.
Crankcase Bolt Tightening Sequence
Specifies the correct sequence for tightening crankcase bolts.
Final Crankcase Installation Checks
Final checks after assembling the crankcase.
Cylinder, Piston, Crankshaft
Engine Component Assembly
Exploded view and assembly steps for engine components.
Cylinder, Piston, Crankshaft Service Information
Cautions and service standards for these engine components.
Cylinder, Piston, Crankshaft Torque Specifications
Torque values for installing pistons, conrods, and crankshaft.
Cylinder, Piston, Crankshaft Tools
List of tools required for cylinder, piston, and crankshaft service.
Engine Component Troubleshooting
Diagnosing and resolving issues like engine noise and compression problems.
Piston, Conrod, Crankshaft Removal
Steps for removing the piston, conrod, and crankshaft.
Crankshaft Inspection
Inspects crankshaft for runout and journal wear.
Piston Disassembly
Steps for disassembling the piston from the conrod.
Piston Ring and Piston Inspection
Measures piston ring and groove clearance.
Conrod and Cylinder Inspection
Inspects conrod little end and cylinder bore for wear.
Cylinder and Piston Clearance Measurement
Calculates clearance between cylinder and piston.
Bearing Inspection and Selection
Inspects and selects crankshaft and conrod bearings.
Bearing Selection Procedure
Procedure for selecting bearings based on bore and crankpin codes.
Main Bearing Inspection and Installation
Inspects and installs main bearings.
Piston Ring Installation
Steps for installing piston rings onto the piston.
Piston and Conrod Assembly
Assembles the piston, conrod, and bearing caps.
Piston and Conrod Attachment
Attaches piston and conrod to the cylinder.
Crankshaft Attachment
Attaches the crankshaft to the cylinder block.
Conrod Bearing Cap Attachment
Attaches the conrod bearing caps.
Clutch, AC Generator
Clutch and AC Generator Assembly
Exploded view and assembly steps for clutch and AC generator.
Clutch and AC Generator Specifications
Standard values and limitations for clutch and AC generator components.
Clutch and AC Generator Torque
Specified torque values for clutch and AC generator components.
Clutch and AC Generator Tools
List of exclusive and common tools for clutch and AC generator service.
Clutch Troubleshooting
Diagnosing and resolving clutch engagement and operation issues.
Crankcase Detachment (for Clutch/AC Gen.)
Steps for detaching the crankcase cover for clutch/AC generator access.
Clutch Lifter Inspection
Inspects the clutch lifter mechanism for wear and damage.
AC Generator Detachment
Steps for removing the AC generator stator.
Flywheel Removal
Steps for removing the flywheel.
Clutch Detachment
Steps for detaching the clutch assembly.
Clutch Centre and Flywheel Service
Service procedures for the clutch centre, flywheel, and related parts.
Needle Bearing Inspection
Inspects the needle bearing for wear, damage, and loose fit.
Clutch Spring Inspection
Measures clutch spring resting length.
Clutch Disc and Plate Inspection
Inspects clutch disc thickness and plate distortion.
Clutch Centre and Spring Seat Inspection
Inspects clutch centre slits and spring seat.
Shudder Spring and Clutch Outer Inspection
Inspects shudder spring, clutch outer, and primary driven gears.
Clutch Outer Guide, Collar, and Bearing Inspection
Inspects clutch outer guide, collar, and needle bearing.
Oil Pump Drive Sprocket and Collar Inspection
Inspects oil pump drive sprocket and collar dimensions.
Main Shaft Inspection
Inspects clutch outer guide and drive sprocket collar contact surface.
Clutch and Oil Pump Attachment
Attaches oil pump drive sprocket collar, gear, chain, and sprocket.
Clutch Assembly Steps
Steps for assembling the clutch centre, springs, discs, and pressure plate.
Clutch Lock Nut and Spring Installation
Installs clutch centre lock nut and clutch springs.
AC Generator Attachment
Attaches the AC generator to the crankshaft.
Flywheel and Stator Attachment
Attaches flywheel to crankshaft and stator to crankcase cover.
Right Crankcase Cover Assembly
Assembles the right crankcase cover.
Final Assembly and Checks
Final steps for clutch/AC generator including connecting cables and filling oil.
Gear Shift Linkage
Gear Shift Linkage Disassembly
Exploded view and disassembly steps for the gear shift linkage.
Gear Shift Linkage Service Information
General cautions, torque settings, and troubleshooting for the gear shift linkage.
Gear Shift Linkage Torque
Specified torque values for gear shift linkage components.
Gear Shift Linkage Troubleshooting
Diagnosing and resolving issues with gear shifting and engagement.
Gear Shift Linkage Detachment
Steps for detaching the gear shift linkage components.
Gear Shift Spindle and Guide Plate Service
Inspection of gear shift spindle and assembly of guide plate.
Gear Shift Linkage Attachment
Steps for attaching the gear shift linkage components.
Final Gear Shift Linkage Assembly
Final assembly steps for the gear shift linkage.
Gear Shift Spindle and Cover Installation
Installation of the gear shift spindle and change cover.
Final Drive Sprocket and Pedal Installation
Installation of the drive sprocket cover and change pedal.
Transmission
Transmission Disassembly
Exploded view and disassembly steps for the transmission.
Transmission Service Information
General cautions and service information for the transmission.
Transmission Service Standards
Specifications for backlash, gear bore, shaft, and fork dimensions.
Transmission Troubleshooting
Diagnosing and resolving gear selection and engagement issues.
Transmission Disassembly Steps
Steps for disassembling the transmission components.
Shift Fork and Drum Service
Inspection and service of shift forks and shift drum.
Transmission Component Inspection
Inspection of shift drum bearing, shift fork, and main shaft bearing.
Shaft and Gear Inspection
Inspects main shaft, counter shaft, gears, and bushes for damage.
Bush and Gear/Shaft Clearance
Measures clearance between bushes, gears, and shafts.
Transmission Assembly
Steps for assembling the transmission components.
Mainshaft and Bearing Installation
Installs the mainshaft and bearings.
Shift Fork and Shaft Installation
Installs the shift forks and shaft.
Front Wheel, Suspension and Steering
Front Wheel, Suspension and Steering Disassembly
Exploded view and disassembly steps for the front wheel, suspension, and steering.
Fairing and Front Assembly
Assembly of fairing and front-end components.
Front Wheel, Suspension, Steering Service Info
General cautions, standards, torque, and tools for front-end service.
Front Wheel, Suspension, Steering Torque
Specified torque values for front-end components.
Front Wheel, Suspension, Steering Tools
List of exclusive and common tools for front-end service.
Front Wheel, Suspension, Steering Troubleshooting
Diagnosing and resolving issues with steering, wheel, and suspension.
Fairing Detachment
Steps for removing the fairing components.
Fairing Attachment
Steps for attaching the fairing components.
Steering Stay Detachment
Steps for removing the steering stay.
Steering Stay Attachment
Steps for attaching the steering stay.
Handlebar Detachment (Left and Right)
Steps for removing the left and right handlebars.
Handlebar Attachment (Left)
Steps for attaching the left handlebar.
Switchgear and Handlebar Attachment
Attaching switchgear and handlebar components.
Handlebar Attachment (Right)
Steps for attaching the right handlebar.
Handlebar Switch and Master Cylinder Installation
Installing handlebar switches and master cylinder.
Front Wheel Detachment
Steps for removing the front wheel.
Front Axle and Wheel Inspection
Inspects front axle and wheel for deformation.
Wheel Balance Procedure
Procedure for balancing the front wheel.
Wheel Disassembly
Steps for disassembling the front wheel components.
Bearing and Collar Service
Service for wheel bearings and distance collars.
Brake Disc and Gearbox Retainer Attachment
Attaches brake discs and gearbox retainer.
Wheel and Gearbox Assembly
Assembles the wheel, gearbox, and related parts.
Front Wheel Installation
Steps for installing the front wheel.
Axle Nut and Caliper Tightening
Tightens axle nuts and caliper bolts.
Front Fork Detachment and Caution
Steps for removing front forks and important safety precautions.
Front Fork Removal and Disassembly
Steps for removing and disassembling the front fork.
Front Fork Disassembly Steps
Detailed steps for disassembling the front fork components.
Fork Spring and Component Inspection
Inspects fork spring length and other components for wear.
Fork Pipe and Bushing Inspection
Inspects fork pipe and guide bush for damage.
Front Fork Reassembly Steps
Steps for reassembling the front fork components.
Front Fork Oil Seal and Spring Installation
Installs oil seals, guide bushes, and cushion springs.
Top and Bottom Bridge Attachment
Attaches the top and bottom bridges to the fork pipes.
Fork Bolt and Front Fender Tightening
Tightens fork bolts, front fender bolts, and brake caliper bolts.
Brake Caliper and Front Wheel Attachment
Attaches the brake caliper and front wheel.
Steering Stem Detachment
Steps for detaching the steering stem.
Steering Stem Bearing Inspection and Replacement
Inspects and replaces steering stem bearings.
Ball Race Replacement
Procedure for replacing ball races using special tools.
Bearing and Collar Service
Installs bearings, collars, and dust seals.
Brake Disc and Gearbox Retainer Attachment
Attaches brake discs and gearbox retainer to the wheel hub.
Wheel and Gearbox Assembly
Assembles the wheel, gearbox, and related parts.
Front Wheel Installation
Steps for installing the front wheel.
Axle Nut and Caliper Tightening
Tightens axle nuts and caliper bolts.
Front Fork Detachment and Caution
Steps for removing front forks and important safety precautions.
Front Fork Removal and Disassembly
Steps for removing and disassembling the front fork.
Front Fork Disassembly Steps
Detailed steps for disassembling the front fork components.
Fork Spring and Component Inspection
Inspects fork spring length and other components for wear.
Fork Pipe and Bushing Inspection
Inspects fork pipe and guide bush for damage.
Front Fork Reassembly Steps
Steps for reassembling the front fork components.
Front Fork Oil Seal and Spring Installation
Installs oil seals, guide bushes, and cushion springs.
Top and Bottom Bridge Attachment
Attaches the top and bottom bridges to the fork pipes.
Fork Bolt and Front Fender Tightening
Tightens fork bolts, front fender bolts, and brake caliper bolts.
Brake Caliper and Front Wheel Attachment
Attaches the brake caliper and front wheel.
Steering Stem Detachment
Steps for detaching the steering stem.
Steering Stem Bearing Inspection and Replacement
Inspects and replaces steering stem bearings.
Ball Race Replacement
Procedure for replacing ball races using special tools.
Bearing and Collar Service
Installs bearings, collars, and dust seals.
Steering Stem and Lock Nut Adjustment
Adjusts steering stem nut and lock nut torque.
Front Fork and Handlebar Installation
Installs front fork and handlebar components.
Steering Load Measurement
Measures steering load to check bearing adjustment.
Rear Wheel, Brake & Suspension
Rear Wheel, Brake & Suspension Disassembly
Exploded view and disassembly steps for rear wheel, brake, and suspension.
Rear Wheel, Brake, Suspension Service Information
General cautions, standards, and torque values for rear wheel service.
Rear Wheel, Brake, Suspension Torque
Specified torque values for rear wheel, brake, and suspension components.
Rear Wheel, Brake, Suspension Tools
List of exclusive and common tools for rear wheel service.
Rear Wheel, Brake, Suspension Troubleshooting
Diagnosing and resolving issues with rear wheel, brake, and suspension.
Rear Wheel Detachment and Axle Inspection
Steps for removing rear wheel and inspecting axle bend.
Wheel Rim and Bearing Inspection
Inspects wheel rim deformation and bearing fit.
Final Drive Sprocket Inspection
Inspects final drive sprocket for wear and damage.
Rear Wheel Disassembly
Steps for disassembling the rear wheel components.
Wheel Bearing and Collar Removal
Removes wheel bearings and collars.
Bearing and Flange Assembly
Installs bearings, collars, and damper rubber.
Brake Panel and Drive Chain Attachment
Attaches brake panel and connects drive chain.
Rear Brake Drum Inspection
Measures brake drum inner diameter and lining thickness.
Rear Brake Disassembly
Steps for disassembling the rear brake shoes and panel.
Brake Cam and Anchor Pin Lubrication
Lubricates the brake cam and anchor pin.
Rear Brake Shoe and Panel Assembly
Assembles the brake shoes, springs, and panel.
Brake Pedal Detachment and Attachment
Steps for removing and installing the brake pedal.
Rear Cushion Removal
Steps for removing the rear cushion (shock absorber).
Rear Cushion Disassembly
Disassembly of the rear cushion components.
Needle Bearing Replacement
Replaces needle bearings in cushion arms and conrods.
Rear Fork Assembly/Disassembly
Assembly and disassembly of the rear fork components.
Needle Bearing Replacement (Suspension Linkage)
Replaces needle bearings in the suspension linkage.
Pivot Bearing Replacement
Replaces pivot bearings in the rear fork.
Rear Fork Installation
Installs the rear fork and related components.
Brake Pedal Removal
Steps for removing the brake pedal.
Braking System (Disc Brake)
Disassembly
Exploded view of the disc brake system for disassembly.
Service Information
General cautions and service standards for the braking system.
Service Standards
Specifications for brake disc and caliper components.
Torque
Specified torque values for braking system components.
Exclusive Tool
List of exclusive tools for brake system service.
Troubleshooting
Diagnosing and resolving poor brake performance, heavy lever, and noise issues.
Brake Fluid Replacement / Air Bleed
Procedure for replacing brake fluid and bleeding air from the system.
Brake Pad / Disk
Procedure for replacing brake pads.
Master Cylinder
Detachment and inspection of the master cylinder.
Brake Lever Adjuster
Procedure for adjusting the front brake lever.
Brake Caliper
Detachment, disassembly, inspection, and assembly of the brake caliper.
Exhaust Pipe, Rear Fender
Service Information
General caution and torque specifications for exhaust and fender components.
Exhaust pipe Detachment
Steps for removing the exhaust pipe and muffler.
Exhaust Pipe Installation
Steps for installing the exhaust pipe and muffler.
Rear Fender Detachment
Steps for removing the rear fender components.
Sub-frame Detachment
Steps for removing the sub-frame and related components.
Battery Charger
Wiring Diagram
Diagram of the battery and charging system wiring.
Service Information
General cautions, standards, and tools for battery and charging system.
Troubleshooting
Diagnosing and resolving charging system issues.
Battery Detach / attachment
Steps for removing and installing the battery.
Inspection of charged status
Measures battery voltage to check charge status.
Leak test
Tests for battery current leak.
Charging
Procedures and precautions for charging the battery.
Regulator voltage inspection
Inspects regulator voltage with a charged battery.
Conduction inspection
Tests conduction between regulator/rectifier couplers.
Alternator inspection
Measures alternator coil resistance.
Ignition System
Wiring Diagram
Schematic of the motorcycle's ignition system wiring.
Service Information
General cautions and service standards for the ignition system.
Ignition System Troubleshooting
Diagnosing and resolving ignition system faults.
Spark System Inspection
Checks spark plugs, caps, battery, switches, and fuses.
Ignition Coil Primary Voltage
Measures peak voltage of the ignition coil primary circuit.
Ignition Coil Inspection
Measures primary and secondary coil resistance.
Ignition Coil Replacement
Steps for replacing ignition coils.
Pulse Generator Coil Inspection
Measures pulse generator coil resistance and conduction.
Self Starter System
Wiring Diagram
Schematic of the self-starter system wiring.
Disassembly
Exploded view and disassembly steps for the starter motor.
Service Information
General cautions, standards, and torque for the starter system.
Troubleshooting
Diagnosing and resolving starter system faults.
Starter Motor Removal
Steps for removing the starter motor.
Brush Inspection
Inspects starter motor brush length and tension.
Needle Bearing, Dust Seal and O-Ring Inspection
Inspects needle bearing, dust seal, and O-ring for wear.
Armature Inspection
Inspects armature cores for color and conduction.
Assembly
Steps for assembling the starter motor.
Installation
Steps for installing the starter motor and connecting cables.
Magnetic Switch Inspection
Checks magnetic switch operation.
Diode Removal
Steps for removing the diode.
Left Crankcase Cover Removal
Steps for removing the left crankcase cover.
Pulse Generator Removal
Steps for removing the pulse generator.
Starter Clutch Removal
Steps for removing the starter clutch.
Disassembly / Inspection
Disassembly and inspection of starter driven gear.
Assembly
Steps for assembling the starter driven gear and drive gear.
Installation
Steps for installing starter drive gear, pulse rotor, and starter clutch.
Pulse Generator Installation
Correctly sets pulse generators and wire clamp.
Starter Clutch Cover Installation
Installs new gasket and knock pin for starter clutch cover.
Lights, Instruments & Switches
Service Information
General cautions and standards for lights, instruments, and switches.
Torque
Specified torque values for ignition switch, headlight, and instruments.
Troubleshooting
Diagnosing issues with lights, instruments, and switches.
Bulb Replacement
Procedure for replacing headlight bulbs.
Main switch Inspection
Checks conduction of the main switch.
Steering handle switches
Checks conduction of kill, starter, lighting, passing, horn switches.
Water temperature gauge
Checks water temperature gauge operation.
Tachometer
Inspects tachometer for faults.
Cooling fan switch
Checks cooling fan switch and motor operation.
Neutral switch
Checks neutral switch conduction.
Brake light switch
Checks front and rear brake light switch conduction.
CBR250R(H)
Service Information
Specifications differing from CBR250FOUR.
Torque settings (amended parts only)
Torque values for specific amended parts.
Exclusive Tools (Amended parts only)
List of exclusive tools for amended parts.
Existing exclusive tools
List of existing exclusive tools with part numbers and applications.
Common Tools
List of common tools for various applications.
Wiring
Diagram showing wiring routes for components.
Inspection / adjustment - Procedure
Procedure for inspection and adjustment based on schedule.
Brake System
Procedures for brake pedal height, lever adjustment, fluid level, and pad wear.
Transaxle system
Clutch and chain/sprocket maintenance procedures.
Powerplant
Idle speed adjustment and engine oil drain procedures.
Fuel system
Specifications and procedures for the fuel system.
Cooling system
Specifications and procedures for the cooling system.
Engine mounting / dismounting
Procedures for removing and installing the engine.
Cylinder head and valve
Service information and procedures for cylinder head and valves.
Cam gear train detachment
Steps for detaching the cam gear train.
Cylinder Head Detachment
Steps for detaching the cylinder head.
Valve stem and valve guide inspection
Inspects valve stem and guide for wear.
Measure inner diameter of each guide
Measures inner diameter of valve guides.
Valve guide replacement
Procedure for replacing valve guides.
Cylinder head attachment
Steps for attaching the cylinder heads.
Cam gear train attachment
Steps for attaching the cam gear train.
Cylinder, piston and crankshaft
Service information for cylinder, piston, and crankshaft.
Crank pin bearing selection
Procedure for selecting crank pin bearings.
Piston, conrod and crankshaft installation
Steps for installing pistons, conrods, and crankshaft.
Clutch
Right crankcase cover detachment, lifter plate bearing replacement, clutch attachment.
Change cover attachment / detachment
Steps for attaching and detaching the change cover.
Front wheel, Suspension and Steering
Service information for front wheel, suspension, and steering.
Fairing
Detachment and attachment procedures for fairing components.
Rear wheel and Suspension
Service information for rear wheel and suspension.
Brake System (Disk Brake)
Service information and procedures for the disc brake system.
Brake fluid change / air bleeding
Procedure for changing brake fluid and bleeding air.
Brake pad change
Procedure for replacing brake pads.
CBR250R(J)
Specifications
Technical specifications differing from CBR250FOUR.
Torque Settings
Torque values for amended parts.
Exclusive / Common Tools
Lists of tools for amended parts.
Wiring
Diagrams showing wiring routes.
Inspection I Adjustment
Inspection and adjustment schedule based on time and mileage.
Front wheel, Suspension and Steering
Maintenance for front wheel, suspension, and steering.
Side Stand
Inspects side stand operation and disassembles for maintenance.
Fuel Tank removal / attachment
Steps for removing and attaching the fuel tank.
Air cleaner case attachment / detachment
Steps for attaching and detaching the air cleaner case.
Carburettor synchronisation adjustment
Procedure for adjusting and synchronizing carburettors.
Engine Mount / Dismount
Procedures for engine mounting and dismounting.
Cylinder Head, valve
Service information for cylinder head and valve.
Fuel system
Specifications and procedures for the fuel system.
Cooling system
Specifications and procedures for the cooling system.
CBR250R(K)
Wiring Diagram
Diagram of the wiring harness routing.
Circuit Wiring Diagram
Schematic of the motorcycle's electrical circuits.
CBR250RR (L)
Table of Contents
List of chapters and their corresponding page numbers.
Specifications
Technical specifications for the CBR250RR (L).
Description of the mechanism
Explanation of the VP carburetor mechanism.
Torque setting
Torque values for various engine and frame components.
Exclusive / Common tools
Lists of special and common tools required for service.
Wiring
Diagrams showing wiring routes for various components.
Maintenance data
Service data for lubrication, fuel, and cooling systems.
Troubleshooting
Diagnosing and resolving common issues.
Maintenance
Inspection and adjustment schedule.
Fuel System
Procedures for fuel tank, air cleaner, and carburettor service.
Engine Mount / Dismount
Procedures for removing and installing the engine.
Cylinder Head, valve
Service information for cylinder head and valve.
Front wheel, Suspension and Steering
Procedures for front wheel, suspension, and steering maintenance.
Rear wheel, Suspension
Procedures for rear wheel and suspension maintenance.
Brake System (Disc brake)
Procedures for front and rear brake system service.
Fairing and Exhaust Pipe
Procedures for fairing and exhaust pipe removal/installation.
Battery and Charging System
Procedures for battery and charging system maintenance.
Ignition System
Procedures for ignition system inspection and troubleshooting.
Lights, Instruments and Switches
Maintenance for lights, instruments, and switches.
CBR250RR (R)
Table of Contents
List of chapters and their corresponding page numbers.
Specification
Technical specifications for the CBR250RR (R).
Torque Settings
Torque values for engine and frame components.
Lubrication and Sealant
Application of lubricants and sealants to various parts.
Special and Common Tools
List of special and common tools.
Circuit Diagram
Schematic of the motorcycle's electrical circuits.
Routing Diagram
Diagram showing the routing of wires and hoses.
Service Standard
Standard values and limitations for various components.
Valve Clearance
Inspection and adjustment of valve clearance.
Drive Chain
Replacement procedures for the drive chain.
Radiator Disassembly
Steps for disassembling the radiator.
Clutch Disassembly
Exploded view and disassembly steps for the clutch.
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