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CBR250RR service manual .pdf



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CBR250FOUR (MC14)

NH·138
NO.1

CBR250FG (MC14-1 000014-1015467)

P8·1270·U
NO.3

NH·l
NO.2

CBR250FG-YA (MC14-1000060-1015767)

CBR250R(H) (MC17) 1987

NH·206·M
NO.4

NH·196
NO.6

NH·196
NO.5

CBR250RH (MC 17-1 000006-1 025449)

CBR250R(J) (MC19) 1988

PB·184M·U
NO.7

CBR250RJ (MC19-1000006-1023630)

NH·193P
NO.9

PB·190
NO.8

CBR250RJ (MC19-1011439-1023630)

CBR250R(K) (MC19) 1989

P8·184M-U
NO.l0

NH·193P
NO.12

NH-193P
NO.ll

CBR250RK(MC19-1050006-1067954)

CBR250RR(L) (MC22) 1990-1991

NH-193P
NO.1

PB-184M
NO.2

PB-184M
NO.4

PB-193P
NO.3

CBR250RRL(MC22-1000001-1020576)

CBR250RR(N) (MC22)

CBR250RR(R) (MC22)

,



NH-193P
NO.5

NH.237P
NO.6

CBR250RRN (MC22-1050001-1056770)

1992-1993

R-210C
NO.8

NH-196
NO.7

CBR250RRR (MC22-11 00001- )

1994-1996*

'Any CBR250RR(R) Bought new after 1996 was actually built in 96 and labelled the CBR250RR(R-II)

CBR250R,RR
INDEX
Maintenance Information
Inspection Adjustment
ENGINE

Oil lubrication system
Fuel system
Cooling system
Engine attach/detachment
Cylinder head valve
Crank case
Cylinder, piston, crankshaft
Clutch, AC generator
Gear shift linkage
Transmission
FRAME

Front wheel suspension steering
Rear wheel, brake, suspension
Braking system (Disc Brake)
Exhaust pipe, rear fender
ELECTRICAL SYSTEM

Battery, alternator
Ignition system
Self starter system
Light, meters, switches
SUPPLEMENTAL

CBR250R(H)
CBR250R(J)
CBR250R(K)
CBR250R(L)
CBR250R(R)

CBR250R,RR

• Preface
This service manual includes the service information for HondaCBR250FOUR and
CBR250R. However, only the part which differs from 250FOUR is described for 250R.
Amended points from CBR250R(H) are described for CBR250R(J), so for CBR250R(K).
Differences such as the outlook are not mentioned as they do not affect the maintenance.

Section 1 - includes general cautions for maintenance work. Please use this manual after
reading the section.

Section 2 - describes about procedures for inspection and adjustments. Please conduct
regular inspection by following the procedure.

Section 3 - and onwards describes procedures for inspection and assembly/disassembly
of individual parts.
In the first pages of each sections, you find the figures, maintenance information,
troubleshooting charts for your convenience.

Please note:
The contents may change without prior notice due to modifications of the model.

CBR250R,RR

1. Maintenance Information

• SERVICE INFORMATION
Location of Serial number and color
labels
Specifications

1-1

Exclusive / Common tools

1-16

1-2

Applying Oil

1-19

Summary of structure

1-3

Circuit Diagram

1-20

General cautions

1-6

Wiring

1-21

Tightening Torque

1-14

Troubleshooting

1-24



LOCATION OF SERIAL NUMBER AND COLOR LABLES

Top right figure:----------------------------------- Frame Serial Number Label
Bottom left figure:---------------------------------. Engine Serial Number Label
Bottom right figure:------------------------------- Colour label
When ordering the colored part, use the model name and the color code.

-

Frame Serial Number

-••••

1-1

1. Maintenance Information

CBR250R,RR


Specifications
Item

Specification

Model Code
Len th
Width

Heiqht
Wheel-base
Power-plant model
Total displacement
Fuel type
Front Axle
Rear Axle
Total

Veh icle empty weight
Maximum capaclt,

Front Axle
Rear Axle
Total
Front
Rear

Veh icle gross weight
Tyre
Minimum clearance
Brakin Distance
Minimum turning radius
Starter type
Type of enqine
C Iinders
Configu ration
Valve operation
Bore X Stroke
Com oression ratio
Compression Pressure
Maximum output
Maximum torque
Powerplant
Valve operation time

Intake
Valve
Exhaust
Valve

Valve Clearance
Idle Speed
Lu brication
Oil filter
Oil pump
Oil ca oaclt,
Coolinq System

1-2

Open
Close
Open
Close
In
Out

Honda MC14
2.000mm
0.685m
1.120m
1.370m
MC14E
0.249 Iitres
Petrol
77k
76 kg
153 kg
2 people
97 kg
166 kq
263 kq
100/80 - 17
52H
130/70 - 17
62H
0.140m
14.0m 50km/h
2.6m
Electric
Petrol 4 Stroke
2 abreast
Inline 4 cylinder
DOHC
48.5 x 33.8mm
11.0
2
13.0kg/cm - 400rpm
45 PS 1 14,500 rpm
2.5 kq-rn 1 10,500 rpm
10° BTDC 1mm lifted
40° ABDC 1mm lifted
30° BBDC 1mm lifted
10° BTDC 1mm lifted
0.16mm cold)
0.23mm cold
1,500rpm
Forced Pressure
Total flow
Trochoid Rotor
2.7 litres
Liquid cooled

1. Maintenance Information

CBR250R,RR


Specifications
Item
Air filter
Carburetor

Fuel system

Clutch

Transmission

Reduction: First
Tyre Pressure
Steering system

Steering stem
angle

Braking system
Shock
absorbing
system
Frame

Tlpe
Fuel Capacity
Carburettor
Piston size
Venturi diameter
Ignition Timing
Spark
NGK
Plug
ND
Plu Gap
Battery
Type
Ooeratlon
Primary Reduction
Type
1st
2nd
Gear
3rd
ratio
4th
5th
6th
Gear type
Reduction ratio
Front
Rear
Left
Riqht
Front
Rear

Specification
Viscous Paper
14.0litres
VG01
28mm
25mm
20° BTDC / 1,500 rpm
C8EH - 9, C9EH - 9
U24FE 9, U27FE 9
0.8 - 0.9 mm
12V 8AH
Multi-wet plate
Mechanical
2.966
Constant Mesh
2.733
2.000
1.590
1.333
1.153
1.035
Chain
3.071
26° 00'
97mm
35°
35°
Hydraulic Disc
Hydraulic Disc

Front wheel

Telescopic fork

Rear wheel

Swing arm

Type

Diamond

Suspension

1-3

1. Maintenance Information

CBR250R,RR
Structure Description
Engine

The vehicle is equipped with a water
cooled inline 4 cylinder engine. The
engine is inclined forward- 35° This
inclination enables an improved
straight intake manifold port, which
allows smooth flow of air-fuel
mixture gas.

Gear drive system was applied to the
cam shaft instead of chain drive system.
The gear system is optimised for high
speed operation.
In order to provide smooth valve
operation at high speed, the engine has
lower shim design. Also, carbon
hardened connecting rods used to
reduce friction loss.
Valve lifter

r--- 35•

Shim

/'

/'

-..
'

J~-----''L

Eclipse
cross-section
spring

\

I

To provide smooth valve operation in high speed, the valve spring was computer designed
to endure higher stress.
Conventional cross-section

Eclipse cross-section
/

(-,

,

»:

,

,

/"

<,

o

)

,

,

-

)

(-, )

I

,

./

"'

1-4

/'

CBR250R,RR

1. Maintenance Information

In order to reduce friction loss and to operate valves in accurate timing , gear driven cam
system is applied.
The figure below shows the linkage between the crankshaft and the cam gears.
The crankshaft power is transmitted to the cam gear through the primary driven gear
(clutch outer gear) , which is on the same axle for the transmission main shaft.
This mechanism is quite different from the V-gear drive system , which the crankshaft
directly drives cam gears.
Cam gear


3rd Cam gear
2nd Cam gear ---t1JMI~~~

1st Cam gear
Primary
driven
gear
(clutch outer
guide)

~

1-5

CBR250R,RR

1. Maintenance Information

Ignition System

A newly designed digital ignition unit with a built-in micro computer provides best ignition
throughout its operating speed range.
0for
A pulse rotor has seven projections. From (1) - (7) have 45°separation and 90
(7) to
(1). The engine rpm and crank position for each cylinder are detected from the relative
position of the seven projections and two pulser coils. The two pulser coils are installed so
as to have 15° inclination from level line for PC2 end, compared to PC1. This angular
offset is to detect crank positions.
The time when the pulse rotor's projection passes the PC1 pulser coil is referred as
"O-reference". By detecting the time required to have the projection at the pulser coil
again, the engine rpm is determined and the micro computer determines ignition timing.

r-

No.1 Ignition Coil
Kill Switch

---'-'- =-_---...--~~.:r-Ignition Switch

Main Fuse

Battery

--

L..-No.2
Ignition
Coil
Power Unit

"======~.§

-o_.
c:

ulse Rotor

-t'-I

No.2 Ignition Coil
Output Circuit

Micro
Computer
(Processor)

Memory

-

PC2
_

-

1-6

Spark Plug

4


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