Honda NX250 Shop Manual
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Honda NX250 Shop Manual

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  • Page 219 HYDRAULIC BRAKE 35 N w f3.5 ko-m, 25 fl-Ui! 1 ,S ft-lb} 14-0...

  • Page 220: Hydraulic Brake

    14. HYDRAULIC BRAKE SERVICE INFORMATION BRAKE PAD/DISC MASTER CYLINDER BRAKE CALIPER BRAKE FLUID RE PLACEMENT/BLEEDING 14-3 SERVICE INFORMATION GENERAL The brake pads can be removed without disconnecting the hydraulic system. Do not allow foreign material to enter the system when filling the reservoir. Always check brake operation hefore riding the motorcycle.

  • Page 221: Troubleshooting

    HYDRAULIC BRAKE TROUBLESHOOTING Brake \ever soft or spongy • Low fluid level Hydraulic sylem leaking • Clogged hydraulic system • Sticking pietonls) • Caliper slide pm slicking • Disc or wheel misaligned • P a d s cor ' ,IVI •...
  • Page 222 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/BLEEDING • A contaminated brake disc or pad reduces stopping pov*r. Dis- card contaminated pads and clean the disc with a high quality brake degreasing agent. CAUTION • Do not let foreign material to enter the system when filling the reservoir.
  • Page 223 HYDRAULIC BRAKE Pump up the system pressure with the brake lever until there are no air bubbles in the fluid flowing out of the reservoir small hole. Connect the bleed hose to the bleed valve and bleed the system as follows: NOTE - Do not release the brake lever until the bleed valve has been closed.
  • Page 224 HYDRAULIC BRAKE Make sure that the pad spring is installed in the position shown. Install new pads in the caliper. Install the pad pin and tighten it to the specified torque. TORQUE: 18 N m (1.8 kg-m, 13 ft-lb) Tighten the pad pin plug to the specified torque. TORQUE: 2.5 N-m |0.25 kg-m, 1.8 ft-lb} NOTE •...

  • Page 225: Master Cylinder

    HYDRAULIC BRAKE MASTER CYLINDER DISASSEMBLY Drain brake fluid from the hydraulic system (page 14-3). CAUTION * Avoid spilling fluid on painted, plastic, or rubber parts. Placea rag over these parts whenever the system is serviced. Remove the rear view mirror. Loosen the brake hose joint nut and disconnect the brake hose from the joint.
  • Page 226 HYDRAULIC BRAKE INSPECTION Check the primary and secondary cups for wear, deterioration or damage. Check the master cylinder and piston for scoring or other dam- age. Measure the master cylinder inside diameter. SERVICE LIMIT; 11 05b mm (0.4352 In) Measure the master piston outside diameter. SERVICE LIMIT: 10.945 mm (0.4309 in) NOTE •...

  • Page 227: Brake Caliper

    HYDRAULIC BRAKE Place the front brake master cylinder on the handlebar and in- stall the holder with the " U P " mark facing up. Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then tighten the lower bolt.
  • Page 228 HYDRAULIC BRAKE the dust and piston seals in and lift them out. ; - 7 an the seal grooves with clean brake fluid. • Be careful not to damage the piston sliding surfaces. (2> DUST SEALS SERVICE LIMIT: 26.89 mm (1,0587 in) Measure the caliper cylinder inside diameter.
  • Page 229 HYDRAULIC BRAKE Install the pivot boot on the caliper bracket and make sure that the boot is seated in the groove properly. properly. (2) RETAINER Install the pivot boot on the caliper and make sure that the (SILICONE) boot is seated in the groove properly. Install the pad spring.
  • Page 230 15. FAIRING/EXHAUST SYSTEM 15-1 REAR CARRIER (AFTER '88) 15-3 EXHAUST PIPE/MUFFLER SEAT & FAIRINGS 15-2 EXHAUST PIPE/MUFFLER • Do not service the exhaust pipe or muffler while they are hot. REMOVAL/INSTALLATION Remove the following: — right side cover (page 1 5-2) —...
  • Page 231 FAIRING/EXHAUST SYSTEM SEAT & FAIRINGS REMOVAL/INSTALLATION SEAT Unlock the seat lock from the hook latch while turning the key clockwise. Remove the seat by pulling it backward. Install the 3eat in the reverse order of removal. SIDE COVER Remove the side cover mounting bolt and unhook the cover hooks from the frame , then remove the side cover.
  • Page 232 FAIRING/EXHAUST SYSTEM REAR CARRIER (AFTER'88) (3) CAP REMOVAL [1) SOCKET (2) CARRIER BOLTS Remote the caps from the carrier Loosen the carrier base 6 mm SH bolts more than five threads. Remove the socket bolts and nuts. Remove the rear carrier assembly by pulling upward white spreading both lower ends.
  • Page 233 BATTERY /CHARGING SYSTEM (1) IGNITION SWITCH (3) MAIN FUSE (5t SUB FUSE (7) ALTERNATOR (6] REGULATOR/ RECTIFIER ID IGNITION SWITCH О (2) MAIN FUSE RIB\ (6) TO CDI UNIT 20 A © в 4P CONNECTOR -R/W C X J O (3) BATTERY 12 V 6 AH Y: Yellow...

  • Page 234: Service Information

    The Honda Battery Tester {07GMJ—0010000} puts a " l o a d " on the battery so that the actual battery condition at the time of the load can be measured. This provides an accurate determination of the battery condition — good Igreen), fair (yellow), or poor (red).
  • Page 235 0.2 kw/5,000 rpm Charging start rpm 1,000 ± 100 rpm TOOLS Digital multimeter 07411 -0020000 or KS-AHM-32-003 (U.S.A. only) Circuit tester (SANWA) O730S-0O2O001 Circuit tester (KOWA) TH-5H Christie battery charger MC1012/2 (U.S.A. only) Honda battery tester 07GMJ-0010000 (U.S.A. only) 16-2...
  • Page 236 BATTERY/CHARGING SYSTEM TROUBLESHOOTING NOTE • If the battery is overcharged, check for — — Loose or poorly connected black wire terminal at the regulator/rectifier 3P connector — Open circuit in black wire — Faulty regulator/rectifier Battery undercharged ABNORMAL Perform the leakage current inspection (page Open or short circuit in wire haness 15-4).
  • Page 237 CHARGING NOTE • Refer to the Operation Manual for the Honda Battery Tester and Christie Battery Charger for details on battery charging steps. Turn the power switch OFF. Set the Battery Amp. Hr. selector switch for the size of the battery and set the timer to the posi- tion indicated by the Honda Battery Tester, Attach the clamps to the battery terminals —...
  • Page 238 BATTERY/CHARGING SYSTEM URGING SYSTEM (1) BATTERY NEGATIVE TERMINAL LEAKAGE CURRENT INSPECTION Check the battery for ampere leakage before making an charg- ing output inspection. Turn the ignition switch OFF. Remove the negative cable from the battery. Connect ammeter between the negative cable and battery negative (-) terminal, The ammeter should indicate below 1 mA with the ignition (2) BATTERY NEGATIVE...
  • Page 239 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION П) REGULATOR/RECTIFIER Disconnect the connector and remove the bolts and rectifier from the air cleaner case. 16-7...
  • Page 255 19. LIGHTS/METERS/SWITCHES REAR BRAKE LIGHT SWITCH SERVICE INFORMATION 19-1 19-6 TROUBLESHOOTING 19-2 CLUTCH SWITCH 19-6 HEADLIGHT 19-3 HANDLEBAR SWITCH 19-7 INSTRUMENT CASE 19-7 19-4 HORN TURN SIGNAL/TAIL LIGHT BULB IGNITION SWITCH 19-5 19-8 NEUTRAL SWITCH 19-5 THERMOSTATIC SWITCH 19-9 FRONT BRAKE LIGHT SWITCH 19-6 TEMPERATURE SENSOR 19-9...
  • Page 256 LIGHTS/METERS/SWITCHES TROUBLESHOOTING TEMPERATURE WARNING SYSTEM If the temperature warning light does not come on: Disconnect the wires from the temperature sensor and short to- gether the G/Bu and ground wires with a jumper wire. — Check the warning light with ignition switch ON. LIGHT DOES NOT COME ON LIGHT COMES ON -•-Faulty temperature sensor...
  • Page 257 LIGHTS/METERS/SWITCHES HEADLIGHT CAUTION • Do not leave fingerprints on the bulb; they may create hot spots. Wear clean gloves when installing the halogen bulb. If you do touch the bulb with bare hands, clean it with an alcohol- moistened cloth before installing it in the case. BULB REPLACEMENT Remove the dust cover.
  • Page 258 LIGHTS/METERS/SWITCHES INSTRUMENT CASE BULB REPLACEMENT Remove the front fairing and the headlight case (page 1 9-3). Remove the bulb socket from the case then replace the bulb with a new one. METER REPLACEMENT Remove the fuel tank (page 4-3). Remove the connector box cover and disconnect the meter connectors.

  • Page 259: Neutral Switch

    LIGHTS/METERS/SWITCHES TURN SIGNAL/TAIL LIGHT BULB TURN SIGNAL LIGHT BULB REPLACEMENT Remove the turn signal lens attaching screw. While pushing in, turn the bulb counterclockwise to remove. Replace the bulb, if necessary. Install in the reverse order of removal. NOTE • Seat the rubber gasket properly.

  • Page 260: Rear Brake Light Switch

    LIGHTS/METERS/SWITCHES FRONT BRAKE LIGHT SWITCH Disconnect the front brake light switch connectors and check for continuity. У The switch should show continuity with the front brake ap- plied. Replace the switch if necessary. REAR BRAKE LIGHT SWITCH Disconnect the rear brake light switch and check for continui- The switch should have continuity with the rear brake applied and no continuity with the released.
  • Page 261 LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH 11) LEFT HANDLEBAR SWITCH Disconnect the left handlebar switch connector (9P) and check for continuity between terminals. Continuity should exist between the color coded wires in each chart. Dimmer Switch О О COLOR Bu/W (1) RIGHT HANDLEBAR SWITCH Turn Signal Switch О...

  • Page 262: Ignition Switch

    LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the fuel tank (page 4-3|. Disconnect the igqition switch wire connector. Check for continuity should exist between the terminals in each swich position. Continuity should register as shown: BATi BAT2 О О О LOCK COLOR R/BI Bu/O (1) IGNITION SWITCH...
  • Page 263 LIGHTS/METERS/SWITCHES THERMOSTATIC SWITCH The cooling fan motor is actuated by the thermostatic switch located in the bottom of the radiator. If the fan motor does not start, disconnect the 2P: Black con- nector from the switch. Connect together Black/Blue and Green terminals of the 2P connector with a suitable jumper wire.
  • Page 264 LIGHTS/METERS/SWITCHES Drain the coolant (page 5-4) and remove the temperature sen- 11) TEMPERATURE SENSOR sor. Suspend the temperature sensor in a pan of coolant over a heater and measure the resistance through the sensor as the coolant heats up. 50°C 100°C Temperature (122°F)
  • Page 265 STARTER • ENQNE STOP THERMO SWITCH 1 HIGH K A M INDICATOR 2 LEFT TURN SCNAL N 0 O T 0 R 4 NCUTBW. INDICATOR R BRAKE UGHT SWITCH SWITCH CONTNXTY IGMTON SWiTCM ENO'NE STOP SWITCH STARTER SWITCH SWITCH HORN SWITCH BAT6 FREE PUSH...
  • Page 266 21. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW HARD TO START 21-1 AND IDLE SPEEDS 21-3 ENGINE LACKS POWER 21-2 POOR PERFORMANCE AT HIGH SPEED 21-4 ENGINE DOES NOT START OR IS HARD TO START Probable Cause 1.
  • Page 267 TROUBLESHOOTING ENGINE LACKS POWER Probable Cause Brake dragging 1. Raise wheels off ground and spin WHEEL DOES NOT SPIN FREELY- Worn or damaged wheel bearing by hand. Wheel bearing needs lubrication WHEEL SPINS FREELY Drive chain too tight Rear axle nut excessively tightened 2.
  • Page 268 TROUBLESHOOTING 10. Remove oil level gauge and check OIL LEVEL INCORRECT - Oil level too high oil level. Oil level too low CORRECT 11. Remove and inspect lubrication. VALVE TRAIN NOT -• • Clogged oil passage LUBRICATED PROPERLY • Clogged oil control orifice •...

  • Page 269: Poor Performance At High Speed

    TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Probable Cause 1. Check ignition timing and valve INCORRECT Improper valve clearance clearance. Faulty CDI unit Faulty pulse generator CORRECT 2. Disconnect fuel line at carburetor. FUEL FLOW RESTRICTED Clogged fuel tube Clogged fuel tank breather tube FUEL FLOWS FREELY Clogged fuel valve Clogged fuel strainer...

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