“SHOP MANUALIMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. {CAUTION] _ Indicates a possibility of personal injury or equipment damage if instructions are not followed. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe, Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. ‘Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.FL250 . TECHNICAL FEATURES-::-- . SPECIAL TOOLS . SERVICE DATA . ENGINE REMOVAL/INSTALLATION » ENGINE ---- . FRAME: . ELECTRICAL DIAGRAM ::- . 80 ADDENDUM --- . 81. ADDENDUM -- HONDA TABLE OF CONTENTS . GENERAL INFORMATION A. Frame/Engine Number Identifications and Number Locations ----- 1-1 B. Lift and Support Points --- A. Required Maintenance Schedule +--+ B, Lubrication Points------ . TECHNICAL DATA A. Standard Tolerances and Wear Limit: B. Torque Specifications ---- . GENERAL DATA A, Overall Vehicle Dimensions: B. General Specifications: Date of Issue: November, 1980) {& American Honds Motor Co, fac. 1980 - All Rights eservesHONDA 1 eEeso GENERAL INFORMATION A. Frame/Engine Number Identifications and Number Locations ENGINE SERIAL NUMBER IDENTIFICATION L260 E - 1000000 J ] MODEL exone—J | SERIAL NUMBER ENGINE NUMBER FRAME NUMBER IDENTIFICATION FL250— 1000000 mover — SERIAL NUMBER — FRAME NUMBER 141 HONDA GENERAL INFORMATION FL 250 B. Lift and Support Points FRONT Ge ‘Always use safety stands when working for under a vehicle that is supported by onl a jack, FRONT HAS NO JACK POINTS JACK POINT. LIFT HERE BY HAND Z FRONT SUPPORT POINT ) J REAR SUPPORT POINT 12HONDA 2 FL250 TECHNICAL FEATURES CONTROLS INTEGRATED STEERING WHEEL ENGINE: Air cooled, 2 stroke single — eylinder 248 cc (18.4cu. in.) INDEPENDENT SWING ARM SUSPENSION BELT CONVERTER DISC BRAKE LOW PRESSURE TIRE 241Z) HONDA c FL250 3 SPECIAL TOOLS Frame — FIGURE ‘TOOL NUMBER DESCRIPTION REFERENCE 07046 — 3600000 | Orv Aruchment | 1 a7816~8180000 | Tre Diswenbly Tool 7644 9950900 |r Sorig Pin Driver 3 o7e45 3590100 | _DrverArachment * 07959 ~ 5260000 | Front Shack Absorber Comoro 5 Eons Sr DESCRIPTION | nea 07923 — 0010000 Rotor Holder = 7833 0010000 | Rowe Puler | 7 745 3390900 Diver | Fi 07933 — 9500000 ~ 9 e t Frame and Ensine TOOL NUMBER DESCRIPTION aE ves —e110000 | Dre Avachmert Henle 10 SALSBURY's nt anverer Too. NuMBER DESCRIPTION ne Salsbury #602112 ‘SPANNER m1 2 CLUTCH PULLERTOOL 2 {aren ous a a [SPIDER INSTALLATION GU 8 — [rotten are is SCREW (1/420 x23) “8 sre puuc 7 —scnew 1ve0x8a—) | SeRING SeaTiNG TooL : SPECIAL SCREW [out 1220) = 7 FLATWASHER a ‘700237 | CAM RETAINER | 2 341HONDA : SPECIAL TOOLS FL 250 € — REAR BRAKE TIRE Driver Atachment Tire Disastembly Too! 7048 ~ 3600000 07916 ~ 9180000 {For instalation of rear brake bearing (For dsasembly of te) bed. oll seal. Used with 07049 — 110000 (Fig. 10.1 Fig. | Fig 2. FRONT SUSPENSION lal | = {6mm Spring Pin Driver | Driver Attachment Front Shock Absorber Compressor 07944 — 9350300 07945 — 3330100 (07969 — 3290000 (For removal of front arm {For installation of front (For disassembly and Installation and pivot pipe.) hub bearing and oil seal. (of front shock absorber.) Used with 07949 — 6110000 (Fig. 10.) ] Fig 3. Fig 4 Fig. 5.Z\ HONDA FL250 SPECIAL TOOLS Engine ROTOR Rotor Holder Rotor Puller ‘07923 — 0010000 (07933 — 0010000 (For disassembly and installation of (For removal of rotor) rotor retaining nut) Fig. 6 Fig. 7 CRANKSHAFT CRANKCASE | Bearing Driver Case Puller 07945 — 3330300 07933 — 9500000 {For installation of crankshaft bearing (For disassembly of R/L crankcase) Used with 07949-61 10000 (Fig. 10) ] Fig 8 Fig.FRAME AND ENGINE SPECIAL TOOLS HONDA FL250 BELT CONVERTER Driver Attachment Handle (07949 — 6110000 [Used with (07946 — 3600000 (Fig. 1), (07945 — 3330100 (Fig. 4), 07945 — 3330300 (Fig. 8)] Fig 10 ‘Spanner Salsbury #602112 (For holding drive pulley) Fig. 11 BELT CONVERTER BELT CONVERTER —aEe Clutch Puller Too! ‘Salsbury #602090 (For drive pulley dismounting) Fig 12 Taper Plug Salsbury #703463, {For securing drive pulley) Fig 13HONDA FL250 BELT CONVERTER SPECIAL TOOLS BELT CONVERTER Spider Installation Cup Salsbury #704229 (For spider installation) Puller Plate Salsbury #704233 (For disassembly of spider end disassembly of driven pulley) (For use of puller pl disassembling spider when Fig. 16 Fig. 14 Fig. 15 BELT CONVERTER BELT CONVERTER | | Screw (1/4 — 20x 2 ~ 3/4) Step Plug Salsbury #900403 Salsbury #704232 (For disassembling of spider) Fig.17SPECIAL TOOLS HONDA FL250 BELT CONVERTER BELT CONVERTER ‘Screw (1/2 — 20 x 5-1/2) ‘Spring Seating Too! Salsbury #001836 Salsbury #703446 (For spider installation} Fig. 18 (For seating of roller arm return spring) Fig. 19 BELT CONVERTER BELT CONVERTER ey) Special Sorew Salsbury #602114 (For securing of driven pulley) 96° Nut Salsbury #901840 Flat Washer Salsbury #704236 (For disassembly and reassembly of driven pulley) Fig. 21 3-6HONDA FL250 SPECIAL TOOLS BELT CONVERTER Cam Retainer Salsbury # 704237 (For retaining of driven pulley cam) Fig. 22 3-1€ HONDA 4 Bez SERVICE DATA A.REQUIRED MAINTENANCE SCHEDULE The maintenance intervals shown in the following schedule are based upon average riding conditions. Machines subjected to severe use, of ridden in unusually dusty areas, require more frequent servicing. Items marked * should be serviced by an authorized Honda dealer, unless the owner has proper tools and a HONDA ODYSSEY shop manual, and is mechanically proficient. Other maintenance items are simple to perform and may be ser by the owner. INITIAL SERVICE PERIOD (FIRST WEEK OR 15 HOURS OPERATION WHICHEVER COMES FIRST) ‘© “CONTACT POINTS AND IGNITION TIMING — Clean, check, and adjust or replace if necessary. © “CARBURETOR — Check and adjust if necessary. © "BELT CONVERTER ~ Check operation. © POLYURETHANE FOAM AIR FILTER ELEMENT — Clean and cil, Service more frequently if operated in dusty areas. BRAKE CONTROL LINKAGE — Check linkage and adjust if necessary. TIRES — Inspect and check air pressure or circumference. © ALL NUTS, BOLTS, AND OTHER FASTENERS — Check security and tighten if necessary. REGULAR SERVICE PERIOD EVERY 3 MONTHS OF OPERATION ‘SPARK PLUG — Clean and adjust gep, or replace if necessary. “CONTACT POINTS AND IGNITION TIMING — Clean, check, and adjust or replace if necessary. POLYURETHANE FOAM AIR FILTER ELEMENT — Clean and oll. Service more frequently it operated in dusty aress. “CARBURETOR — Check and adjust if necessary. “BELT CONVERTER — Check operation. - BRAKE CONTROL LINKAGE — Check linkage and adjust if necessary. TIRES ~ Inspect and check air pressure or circumference. ALLNUTS, BOLTS, AND OTHER FASTENERS ~ Check security and tighten if necessary. “REDUCTION GEAR CASE ~ Check oil evel and out teakage. weeecceee EVERY YEAR © FUEL LINE — Check. © STEERING SYSTEM — Check operation and adjust if necessary. (© “BRAKE SHOES AND PADS — Inspect and replace if worn, ‘® SPARK ARRESTOR ~ Check for carbon build-up and clean if necessary. 441HONDA ‘ SERVICE DATA FL250 € B. LUBRICATION POINT PARKING BRAKE LEVER PARKING BRAKE WIRE GUIDE REAR BRAKE BEARING FRONT ARM KINGPIN STEERING SHAFT BUSHINGS: SEAT ADJUSTER RECOIL STARTER, DISC BRAKE RATCHET TIE-ROD BALL. JOINTS Disc PAD LEVER SHAFTS FRONT BEARING REDUCTION CASE LUBRICATION POINT LUBRICANT INTERVAL Reduction case ‘A.P.I. Service Classification SE SAE 10W- 40 or SAE 10W- 30 Recoil Starter ‘Steering Shaft Bushings Lever Shafts Front Arms King Pins [Front Hub Beari [Seat Adjusters Parking Brake Lever Parking Brake Wire Guide ear Brake Bearings Disc Brake Ratchet Disc Pads Silicon Grease KS 62M Tie-Rod Ball Joints “Texaco Molytex Grease 2 ‘Multipurpose Grease 4-2€ HONDA FL250 A Standard Tolerances and Wear Limit 5 TECHNICAL DATA 0.0. = Outside Diameter LD. = Inside Diameter Unit : mm (in,) SUBJECT OR ITEM \EASUREMENT STANDARD Cylinder 1.0. 700-7001 (2.7558 -2.7868) | 7 Piston 0.0. €8.93-69.95 (2.7531 -2.7539) | Piston pin hale 1. 8,002. 18,008 (0.7087 - 8.7090). Piston pin 0.0. 17.992 - 18.000 _ (0.7088 - 0.7087) Piston ring side Top|0.045 -0075 (0.0018 0.0030) clearance __[2nd0.025- 0.055 (0.0010 0.0022) | 0.07 (0.0028) Piston ring gp [Ton] 02-04 (0.0079 -0.0157) | 0.5 (0.0197) Engine a 2nd/0.2-0.4 (0.0079 0.0187) | 05 10.0197) ‘Connecting rod small end ENGINE oer 21.997- 22.009 (0.866 - 0.8665) eee far (0.0079- 0.0187) | 0.6 (0.0236) Connecting rod bigend 9,010-0.022 (0,001 - 0,000) | 0.03 (0.0012) ‘Crankshaft runout 0.04 max. (0.00157) = Carburetor | Float heisht 20 (0.79) - point gap {6/3000 pm (0.24)73,000 rom _| 8/500 rpm (0:20)/600 rom Electrical [Point oap 03-04 (012-0016) | 02-06 (0.008- 0.024) [Plug gap 07-08 (0.028 - 0.32) = Throttle lever free play | 8 (0.20) 2-10 (0.08- 0.39) Throttle lever full travel | 96 (0.06) 31-41 (122-161) Sweering (String whee force [— 05-1.1Kg (1.10-242616) Shaft O.0. =a {0.7070- 0.7087) [17,7 _ (0.6968) lumn bushing LO. 177: (0.7047 -0.7208) | 185 (0.7283) ___| Shaft bushing 1 18.08 - 18.081 (0.71102-0.7118) |182 (0.7165) ‘Shock absorber spi frevtength 229.4 (9.03) 205 (807) | Front arm 1-2 ] Front Pivot pipe 42.58.4262 __(1.6764- 1.6780) |428 (1.6850) | suspension King-pin 14,03- 14.08 (0.5524 - 05535) [14.15 (0.5570) | = 3 318) 0-13 (0-051 FRAME 42.47 -42.50 (1.6721 - 1.6732) |423 (1.6653) i 13.97-13.98__ (0.5500 -0.5504) |129 (0.5472) Rear wheel | pear wheel axle band _ 30 (a.1181) | ‘Brake lever fee play 1=8 (004-020, | Brake lever full travel 2= 78 (244-3.07) Brake lever remaining above 23 (above 0.90) Brake [Parking brake eee j Dise runout : 03 (0.0118) ise thickness 32 (ai260)_ [30 (a.1181) Brake lining thickness 126 (0.1673) 1.5 (0.0591) | Brake drum LD. 130.9. 140.1 (6.5079-55157) | 140.6 (6.5354)TECHNICAL DATA B. Torque Specifications HONDA FL250 € sunecr| eM ocscneTion a TAG Generator rotor wr2 | 450-500 | 29-98 Gylinder head Ranged nut 6} 100 = 190 | 7=9 Cylinder hood seca ut wa | 200-250 | 15-18 enone [SOK lua Mid 150-200 | 11-16 Cylinder head sealing bolt M14 200-300 | 15-22 Crankcase retaining bolt M6 go-120 | 6-9 Recoil starter rope guide nut wa [0-00 | 2-3 Engine hanger bolt : ‘M10 360-430 | 25-31 ENGINE [Carburetor | Insulator band WS 50-70 | 4-5 Mutter | Retaining nut - Me 150— 200_| 11-15 Retaining bot wa | “190 = 260 [ 1418 Reduction cone retaining bolt we —| 90 = 260 | 1418 Oitcheck bot 8 70-120 | 5-9 Reduction [Ramp plate mounting screw - — Ti0- 140 | 8-10 unit Roller arm retaining bolt 70 — 100 §-7 Driven pulley retaining bolt Ms 230-310 | 17-22 [Drive pulley retaining bolt Miz 500 — 700_| 35 — 50. Laver to sat Ms wo | 3-6 ‘Lever shaft to arm, ~ “MS: 40-80 | 3-6 Steering wheel and aati wi2_| 350 450 [ 25 = 33 Ball joint and front arm M10: 360 — 430 Tierod lock nat io | 360 = 420 steering [Front shock absorber (op) i2_| 400 = 600 tnd front [Front shock absorber and rant rm (Bown) Mi0_| 360 = 490 =ene 150 — 200 Front hub lok nut T 190 = 250 Front rin 190 = 250 Front tre 190 = 250 | Frame [Front hub w1a—| 600 — 00 Front wm sopper wa | 190 - 250 Rear rin ‘Ma__|190=250 [Rear hub ook at Me | 190 = 250 Rear hub wia_| 600 = 200 Power Train [Rear brake bearing heldr Ma | 180 — 260 and brake tire — MB. 190 — 250 Me 70 = 120 Ma |j90 ~ 250 Ma [~ 190-260 Fuel ak to guard pipe Me 70 ~ 120 Fuel system | Fuel valve Me| wo 100 | 6-7 Me 70-120 | 6-8€ HONDA FL250 svesect) rem oescrTion rwnen0 014, jg TORE Gd ie oli we e760 8 Rear ‘Me 190-260 | 14-18 | Roll bar to rear roll bar MB 190-250 | 14-18 a me ——| wos 8 Rear roll bar to guard pipe MB 190-250 | 14-18 Front bumper Me 190 — 250 Frame Parts | Seat back to adjuster MB 150 — 200 FRAME. Adjuster cover = ‘M6 70 — 120 ‘Seat cushion stay we 190 — 260 Sateen we oat [Adjuster a MB 190 — 250 Seren oy we |= 0 Seatbelt - 300 — 360 Drive belt cover = [70 720 oa nat Engine Engine rubber mounting i 70 — 120 5 mounting | Engine rubber mounting to ‘M10 350-430 | 25-31HONDA 6 Se/FL250 GENERAL DATA A.Overall Vehicle Dimensions REAR VIEW fF 1230 (48.43) 125 (60.04) —— (| Gp | iy @ i | E : UPPER VIEW 1496 (66,50)-—__-| SIDE VIEW FRONT VIEW 6-1HONDA 8 GENERAL DATA FL250 € B. General Specifications DESCRIPTION SPECIFICATION eral rath 2006 mm (8248 in) Overall width 1,230 mm (4843 in) Overall eight 1.525 my (60.08 in.) Whee! base 1,435 mm (56.50 in.) roa £288 690 mm (2661 in) m7 950 mm G740in) Ground clearance 140 mm { 5.51 in.) Min. turing cle eas 43m (17.30%) night drnion = 65 Ke (148.4 be weight Rear 115 Ka (258.5 be) Max. laden weight 265 Kg (584.3 Ibs) Max, sabized inclination, rahe ry . Max. climbing angle 36° ‘Stopping distance zim eel Ene) BEB (ot 34.26 moh) WODEL FL 2806 TYPE Aircooled, Bavoke Cylinder arrangement ‘Single-cylinder 18° inclined from vertical Bore and Stroke 7010. 644 mn (2.7663 2.895 ms) Displacement (248 ce (15.1 cu. in.) Compresion Ratio ae Compression Pressure 9 Kg/cm® /800 rpm oe Fuel Gasoline 20 : oil 1 (mixed) (orton tina 5 eTOC Open ‘80° BTDC a" ‘ar ATOC Open 87° BBDC Pereira «| ex —O72_—_|__A7 9808 Open eo" BBC | ce eo" ABDC [€ HONDA FL250 GENERAL DATA in ‘a ae —- Ss ee wren os ome ea an ae [Belt converter _ SALSBURY'S Torque sensitive belt converter Engine dry weight 22 Kg (48.51 Ibs.) Fuel tank 12 lit. (0.317 US gal., 0.264 Imp. gal.) Sew Reduction unit 0.5 lit, (1.057 US pt., 0.88 Imp. pt.) ‘Starting system Recoil starter Se nee Serer — = ELECTRICAL |— Generator ‘AC Generator [7 Spark plug NGK B7ES Spark plug gap 0.7 — 0.8mm (0.0276 — 0.0315 in.) Max. turning angle, right/left 4° weome Psat atheroma Steering angle —=* z ae 2 rm as SUSPENSION [Fear oa Wheel axial ype Side slip (ridden) Omm (0in.) ae ee Camber r Front Caster s ALIGNMENT peace e sane es ‘Camber 0°HONDA € GENERAL DATA FL 250 DESCRIPTION SPECIFICATION Main brake Self-adjusting cable actuated dise Parking broke ‘Cable actuated leading walling shoe and drum Mile Dis gttective diameter 220 mm (8.661 in.) Parking brake drum diameter 140 mm (5.512 in.) tront 140 x 203mm (8.51 x Bin.) Rim, width x diameter, rear 210% 203 mm (827 x8 in.) ‘ont | 508x178 203mm (20x 7 Bin) ply) TIRES Tire, 0.0. x width x LD., = rear | 650 280 — 208 mm (22 11—Bin.) (aly) front 0.36 Ke/em? (6.0 pei) Pressure eae LiGHTS Heaatignt : 6-41 ENGINE REMOVAL/ INSTALLATION @ ROLL BAR «© Before removing, make sure to perform the following operations; «= Remove the seat back. + Set the parking brake. Drain the fuel line and carburetor. emove in (1) 2), ++ = sequence. ie O®®O . 150 — 200 Kg-em (11 — 16 Ib-ft) «GD PULLEY COVER (@ MUFFLER ASSY. 190 — 250 Keem (14-18 1b) @FueL Line ® prive BELT cover {at carburetor side) @® CARBURETOR 30 —120Kgem (with connecting tube) (6-91) 9 ORIVE BELT ‘© Removal, see BELT CONVERTER sec, > “AWENGINE HANGER BOLT 350 ~ 430 Kgem ZB — 31 Ife) > ~\ ‘1 GROUND WIRE N\ © Loosen, 190-250 Kgem | (14-18 tbe) ~~ S Grove Guide nur NL @ wine connectors 20-40 Koem IGNITION cont ae 1 2-3 hf i PARKING BRAKE 5]HONDA 8 FL250 ENGINE A.AIR CLEANER & MUFFLER ‘COVER ELEMENT SEAL PLATE ELEMENT © Cleaning, Fig 3 ELEMENT HOLDER Fig 1 AIR CLEANER DISASSEMBLY/REASSEMBLY SPARK ARRESTER "© Decarbonizing, Fig. 4 PROTECTOR __— MUFFLER © Decarbonizing, Fig. 4 190-280 Keen CrCl Fig. 2. MUFFLER DISASSEMBLY/REASSEMBLY BRACKET8 HONDA ENGINE FL 250 @ Wash in clean stoddard solvent. ® Dry thoroughly. @ Soak in clean gear oil (SAE 80-90) until saturated. @ Squeeze out excess ol © Use propane torch to burn off oil from carbon deposits. Do not use torch near flammable material. Do not use uxyacetylene torch to burn off oil ®) Hold muffler in vertical position and tap it on @ wood block to shake out carbon deposits. @® Clean spark arrester with wire brush. Fig. 4 Muffler and Spark Arrester Decarbonizing 8-2HONDA 8 FL 250 ENGINE B. CARBURETOR 1. Before disassembly, clean around carburetor and be sure to drain. 2. Before assembly, clean carburetor and related parts using comprested ai. (joe @ _ToP SET Y eee STARTER VALVE SET | ¢ Note Exing potion Qo. INSULATOR CLAMP ‘THROTTLE VALVE SET * Avoid contact with dust and dirt. | 80-70Ksem | (4-5 bt) AIR SCREW! Adjustment, Fig. 5 | CONNECTING TUBE — THROTTLE STOP SCREW © Adjustment, Fig. 5 FLOAT CHAMBER ‘© Removal, Fig. 2 2 Fig. 1 Carburetor Disassembly/R8 HONDA ENGINE FL 250 Carefully handle jets, needles and other small parts. SEALING BOLT VALVE SEAT SET PLATE © Do not install upside down. BAFFLE PLATE. FLOAT VALVE © Check for wear or breakage and replace if necessary. MAIN JET (#120) JET HOLDER VALVE SEAT JET NEEDLE: SLOW JET (#58) © Bend up lock tabs to secure jet needle. FLOATSET © Inspection, Fig. 3 © Adjustment, Fig. 4 © Check for proper operation. ‘© Replace any damaged or leaking float. Blow jets to check for clogging. Fig. 2 Float Chamber Disassembly/ReassemblyENGINE D Place in upright position Float arm tang @ When the float arm tang just closes the float. valve, without compressing the spring loaded plunger, measure the float height. [ Standard: 20 mm (0.79 n.) Spring loaded plunger ~Float level gauge Fig. 3 Float Height Inspection © Carefully bend the float arm tang to adjust to proper float level. Fig. 4 Float Height Adjustment ‘© Before adjusting, perform the following steps. © Attach a suitable tachometer (© Set the parking brake. © Check to see that the ignition system and ‘engine compression are in good condition. © Do not compensate for other faults by carburetor adjustment, ® Start the engine and allow to idle until operating temperature is reached, ® Adjust the throttle stop screw at approx. 1,500 "pm. @ Turn the air screw clockwise until the engine begins to miss or decrease in speed, @ Turn the air screw counterclockwise until the engine begins to miss or decrease in speed. @® Set the air screw exactly between these two extreme positions, The correct setting will be found to be approximately 2 turns open from the fully closed position. © If the idle speed changes, readjust the throttle stop THROTTLE STOP SCREW : Specification : 1,500 ¢pm £180 rpm Ai SCREW SS 7 Fig. 5 Idle Speed Adjustment 8-58 HONDA ENGINE FL250 C. RECOIL STARTER ‘© Note how to knot. HANDLE ROPE GUIDE NUT ROPE GUIDE TUBE Ay. | Be careful not to allow spring to jump out. FRICTION SPRING RATCHET ROPE, © Note how to knot. Fig. 1 Recoil Starter DisassemblyHONDA FL 250 ENGINE ZENE use cloves to assemble the recoil starter. NOTE ‘Turn the case to wind the spring in. @ Wind the starter rope around the pulley. @® Take the rope end out of the slot. @ Set the pulley inside the case engaging the spring end ‘and projection on the pulley as shown on page 8 - 6. ® Wind pulley 2% turns. ® Knot rope end as shown on page 8- 6. BN D> © After assembling, check that the starter works x )) properly. Fig 2 Recoil Starter Reassembly 8-78 HONDA ENGINE FL 250 D. GENERATOR & IGNITION SYSTEM SPARK PLUG WOODRUFF KEY i) © Install as shown, 180 — 200 Kgem | (11-15 1b) © Inspection/Cleaning, Fig. § NOISE SUPPRESSOR IGNITION COIL ASSY, © Inspection, Fig. 3,4 CONTACT BREAKER ASSY. © Inspection, Fig. 7 and 8 450 — 500 Kg-cm STATOR (33 — 36 Ib-Ft) © Inspection, Fig. 6 OIL FELT © Check for wear ‘SPARK ADVANCER ASSY. © Check for proper operation. ROTOR’ ‘© ‘Make sure not to interfere with stator STARTER PULLEY Fig, 1 Generator/Ignition System Disassembly/Reassembly FLYWHEEL PULLER, (Eiax) CLUTCH OUTER HOLDER (Too! No, 07833 - 0010000) (Tool Ne, 07923 - 0010000) Fig. 2 Rotor RemovalENGINE w Be eee 5 Pare ea @® Connect wires in accordance with instructions pro- Soars (oe eres aaa ‘Standar + 6mm (0.24 in.) at 3,000 rpm Sa eS oes f Connect high tension cable to tester in-reverse direction. — Fig. 4 Ignition Coil Performance Test oe L praca (essen eee ace) . Poe8 HONDA ENGINE FL 250 © Check for breakage. Fig. 6 Stator Cable Continuity Test i ABNORMAL F © Check for damage or burning. «© Polish with emery cloth or point file if burned, pitted ‘© Replace if beyond specification. Standard 0.3- 0.4mm (0.012 ~ 0.016 in.) Service limit : 0.2—0.6 mm (0.008 — 0,024 in.) Fig. 8 Point Gap InspectionENGINE © Remove the recoil starter and the starter pulley. 10 the test light lead and the the positive battery terminal, ‘and ground the negative terminal @® Turning the rotor clockwise, the light should become ddim when the “F* mark and the matching mark align. @® To adjust, slightly loosen screw (A), move rotating plate direction using a standard screwdriver inserted in the cutout (B) and retighten screw (A) where the test light starts to dim. @ Remove the recoil stata. ® Connect the wires in accordance with the instructions Drovided withthe service tester. @ Start the engine by using @ rope wound around ‘the starter pulley. Check the ignition timing a idle. Fig. 10 Ignition Timing Dynamic Inspection 8-118 HONDA ENGINE FL 250 E, CYLINDER & PISTON Nore: ‘Before disassembly, remove dust, dirt and mud from around the engine. FLANGED NUT SEALING BOLT 100 - 130 Keer 200 ~ 300 Kg-om oe (7-914) (15 — 22 bt) 200 — 250 Kaen (15 — 18 Fo) CYLINDER HEAD. © Cleaning, Fig. 5 INSERT BAR 4 INSERT | pe (© Tighten equally in criss cross patern. EXHAUST PIPE JOINT EXHAUST PIPE SPRING STAY cyuinoeR Inspection, Fig. 7 and 14 EXHAUST RING ist fe omoralFi3 Pete oo ee an ‘@ Installation, Fig 4 + Shaded area Inspection, Fig, 9 and 10 Inspection, Fig 6, 8,12 DOWEL PIN Waist eIN CLIP @ Removal, Fig. 2' INTAKE WRIST PIN, © Inspection, Fig. 11 { SCAVENGING NEEDLE BEARING Selection, Fig. 13 © Check for looseness. © Port timing Fig. 1 Cylinder/Piston Disassembly/Reassembly 8-12ENGINE Place @ rag under the piston to keep the ist pin clip from dropping into the crankcase , Fig. 2. Wrist Pin Clip Removal ‘© Remove from direction opposite of gap. install marked side up. Be careful to use the proper rings. (Note sectional view.) Fig. 3 Piston Ring Disassembly/Reassembly Insta the piston with the dowel pins facing ‘toward the intake port J Fig. 4 Piston Installation 8-138 HONDA ENGINE FL250 (© Decarbonize with a scraper, screwdriver or wire brush taking care not to score or scratch. Fig 5 Cylinder Head/Exhaust Port Decarbonizing Standard: 69.93 — 69.95 mm (2.7531 — 2.7839 in.) [ Service timit 6.8mm (2.7480 Fig. 6 Piston 0.0. Inspection Standard: 70.0 — 70.01 mm (2.7569 — 2.7563 in.) Service limit: 701mm (2.7588 in.) Fig. 7 Cylinder ILD. inspection — 8-14€ HONDA 8 FL250 ENGINE Check for carbon deposits. ‘Check for scores, cracks or carbon deposits. Fig, 8. Piston Inspection Top [0.2 — 04 mm (0.0079 — 0.0187 in.) 0.2 — 0.4 mm (0.0079 0.0157 in.) 05mm _ (0.0197 in) “0.6 mm (0.0197 in.) Fig 9 Piston Ring Gap Inspection onaag | 12° [O85 ~ 0075 mm 0018-00000] pa 2nd | 0.025 — 0.050 mm (0.0010 — 0.0022 in.}| —[ op] 808 mm (L005 in) Service limit Fa | 0.07 mm (00026 in) Standard 17.982 — 18,000 mm (0.7083 — 0.7087 in.) ‘Service limit 17.98mm (0.7079 Fig 11. Wrist Pin 0.0. Inspection 8-158 HO} ENGINE FL 250 € ‘Standard Timit £18,002 ~ 18,008 mm (0.7087 — 0.7090 in.) Tatmm (0.7126 in.) Fig. 12. Wrist Pin Hole I.D. Inspection © Since the wrist pin and connecting rod are selective-fitted, ‘the proper needle bearing should be selected in accordance with the following table, BEARING SELECTION TABLE Wrist pin cd Without notch small end ILD. 1 notch Red = 2 notches Blue Red 3 notches White Blue Fig, 13 Con-Rod Small End Bearing Selection Before checking, make sre thatthe engine i warmed up andthe throttle is fully opened. ‘© Low compression is usually caused by one of the following: © Defective or sticking piston ring. © A blown cylinder head gasket. © Unusually high compression pres- sure is due to excessive carbon deposits in the combustion cham: ber or on the piston head. © The engine must be disassembled for complete inspection or repair if the compression exceeds the limit. © Pull ther To avoid compression rope until the gauge leaks, tighten gauge needle reaches the securely in the spark highest reading. a plug hole. ‘Specified pressure: Set parking brake. 9 Kg/em? (129 psi.)/800 rpm Fig. 14 Cylinder Compression InspectionHONDA 8 FL250 ENGINE F, CRANKSHAFT & CRANKCASE A } Shaded parts (© Tightening order L.CRANKCASE 80 120 Ks-em (6-9 Ibe) CONNECTING ROD fe Inspection, Fig. 3 and 4 and scratches. NEEDLE BEARING ‘© Check for looseness. © Selection, Fig. 7 R CRANKSHAFT Inspection, Fig 5 (¢ Removal Fig. CRANK PIN Presitted into © AIL crankshaft. R CRANKCASE Fig. 1 Crankshaft/Grenkease Disassembly/Reassembly —_@ Removal, Fig. 2 8-118 HONDA ENGINE FL250 CASE PULLER {Tool No. 07933 — 9600000) '© Used for R/L CRANKCASE pulling. BEARING DRIVER (Tool No. 07946 — 3330300) = Fig 2 Crankshaft/Crankcase Disassembly/Reassembly —/ENGINE (© Measure at two points in directions as shown with Standard (0,010 — 04022 mm (0.0004 — 0.0009 in.) Service init: 003mm (0.0012 in) Fig. 3 Connecting Rod Large End Radial Clearance Inspection 06 mm Fig. 4 Connecting Rod Large End Axial Clearance Inspection 8-198 HO: Z ENGINE FL250 € Standard : Less than 0.04 mm (0.00187 in.) Fig. 5 Crankshaft Runout Inspection Fig. 6 Connecting Rod Small End |.D. Inspection © Since the connecting rod large end and crank pin are selectiveritted, proper needle bearing should be replaced in accordance with the following table. BEARING SELECTION TABLE Crank pin 0.0. Con-rod) 2notches| 1 noteh | Without notch large end LD, _ ‘Without notch Red ~ T noteh Blue | Red 2 notches White | Blue notches | White Blue Fig. 7 Con-Rod Large End Bearing Selection ~ 8-20HONDA FL 250 ENGINE — Play play C~) ‘© Replace if excessively worn. RADIAL PLAY Fig. 8 Ball Bearing Play Inspection 8-21ENGINE G, REDUCTION UNIT Refer to FRAME section to remove rear wheels, rear axle, brake drum and disc brake system, ‘© Before disassembly, drain reduction case. ‘THRUST WASHER © Note fixing direction. REDUCTION COVER REDUCTION GEAR PRIMARY SHAFT "© Check for wear. © Check for scores or sratches, 190 ~ 250 Kg-em (14— 18 tft) NEEDLE BEARING '© Check for looseness. fe SK vn BALL BEARING © Inspection, Fig. 4 © Assembly, Fig 3 gi @ ’ oncueck sort 6@! 70 120 Kg-om (5-9 bet) |EDUCTION GEAR, s Bere Check for wear. REDUCTION GEAR "© Check for we: DRIVE CHAIN ——— © Check for wear DRIVEN SPROCKET ———— © Inspection, Fig. 5 (© Check for wear. THRUST WASHER ° © Note installation direction, A } Shaded parts REDUCTION CASE Grooved side must be facing the sprocket. Fig. 1 Reduction Unit Disassembly/Reassembly Revised February 1979 8-22 © Amencan Honda Motor Co, ne. 1979 Ali Rights ReservesHONDA 8 FL 250 ENGINE To assemble, follow (D , 2), @ +--+. in this sequence. ‘ After assembly, be sure that the chain rotates smoothly. AS Fig 2. Reduction Unit Reassembly Install bearing equally by driving outer edge. BEARING DRIVER (Too! No. 07945 ~ 3330300) WOT a Fig, 3 Ball Bearing Assembly 8.238 HONDA ENGINE FL250 © Replace if excessively worn. Fig. 4 Ball Bearing Play Inspection (FINAL DRIVEN SPROCKET) Goon! No Goon! ‘Check the drive chain for wear or other defects pay if the sprockets are abnormal. oa = WEAR Fig. 5 Driven Sprocket Inspection 8-24HONDA 8 FL250 ENGINE H. BELT CONVERTER * For more detailed instructions, refer to SALSBURY’s shop manual. Groove ‘© When removing drive pully from crankshaft eu HERE check position Use tool provided by SALSBURY. rior to disas sembly. MOVABLE FACE 5-7 lb-ft (70 100 Ke-em) a @ 500 — 700 Kg-em (35 — 50 Ibe) © Replace it worn. ROLLER ARM ‘© Check for wear seiner / naupruare / / comwasien 2 fee Ler 1 ove oe eee / ‘Check position prior to disassembly. /ARNIN When disassembling, hold securely to prevent sudden spring release / FIXED FACE ‘SHOE RAMP BUTTON 230 ~ 310 Kgem ~ TORQUE BRACKET (17 — 22 lb) ete earecoae yee Fig, 1 Belt Converter Disassembly / Reassembly 8-258 HONDA ENGINE FL250 ‘SPANNER, (Salsbury #602112), ® Remove the mounting bolt, lock washer, flat washer, and safety cup. ® Apply grease to threads of the clutch puller tool and insert it fully into the drive pulley bore and apply torque with 1-1/4 inch wrench, while holding the drive pulley with the special spanner. It may be neces- sary to inflict slight impact on the head of the puller tool with @ hammer to unseat the taper and remove the drive pulley. CLUTCH PULLER TOOL, (Salsbury #602090) Fig. 2 DRIVE PULLEY DISMOUNT 8-26ENGINE TAPER PLUG — (Salsbury #703463) @ Using a plastic mallet, insert the taper plug into the ‘taper of the drive pulley with a slight impact and place the taper plug flats in a bench vise, ® Bend the tabs of the lock plate away from the heads of the three 1/4-20 self-tapping ramp plate mounting screws with a chisel, ‘SPIDER @® Remove the three ramp plate mounting screws with a INSTALLATION 3/8 inch wrench. Remove the lock plate and the three cur flat washers. 704228) ae : @ Remove the snap ring from the hub with snap ring pliers. If the snap ring is tight, place the spider installation cup over the hub and onto the snap ring and hit the ring sharply with @hammer until the snap ring loosens. @® Remove the snap ring and the ramp plate, Be, + © Disongage the six roller arm return springs with a fat a blade serewdriver, ® Bend the lock plate tabs away from the heads of the three 114.20 am clamp mounting bolts witha chisel ® Remove the arm clamp mounting bolts with a 7/16 inch or 11 mm open end wrench, @® Remove the lock tabs, the three arm pivot pin clamps ‘and the three roller arms/springs/pins and bushing subassemblies. The drive pulley is now fully disas- ‘semblied for normal servicing, Fig. 3. DRIVE PULLEY DISASSEMBLY 8-218 HOND. ENGINE FL 250 € Spider removal for servicing the fixed face and hub, movable face assembly or the spider can be performed as per detailed instructions. However, it is impractical in most cases, i.e. if the movable face is worn, dictating replacement, the fixed face ‘and hub will probably be in the same condition. It is usually less expensive to replace the entire drive pulley when the faces require replacement. SCREW (1/4-20 x 2-3/4) 2 tou P0009 Disassembly: @ Place the stepped thrust block into the threaded end STEP PLUS of the crive hub, pace the puller stembly ints pos (Salsbury #704232) tion feupped side down) and run the three (14.20) PULLER PLATE — Dalle bolts fully into the threaded hole nthe sider (Salsury #704293), ith @ 7/1 inch of 11 mm open end wrench, ® Grease the puller bolts and tighten them in a clock- wise direction with a 1-1/8 wrench until the spider is free from the hub. SCREW (1/2-20 x 5-1/2) (Salsbury #901836) Reassembly: If the spider has been removed for servicing and is to be reused, replace the movable face on the hub, place the spider in position (on the hub) and place the spider in- stallation cup over the spider, cupped side down. ‘Thread the 1/220 x 5-1/2 inch bolt through the flat washer and the cup into the threaded taper plug. Continue tightening with a 3/4 inch open end wrench until the cup bottoms out on the end of the hub. Be sure that, during this pressing operation, the spider pins are aligned with the mating bearing in the movable face. A constant alignment of pins to bearings can be achieved by raising the movable face up against the spider and placing a small wad of paper between the fixed and the movable faces. SPIDER INSTALLATION. cur. Hydraulic Press Installation Install the movable face on the hub, lay the spider in position and place this assembly on a flat plate under hydraulic ram. Do not use the tapered plug. Center ,ider installation cup over the spider and carefully apply hydraulic pressure on the cup until it bottoms out fon the end of the hub, while maintaining spider pin/ bearing alignment. Fig, 4 SPIDER DISASSEMBLY/REASSEMBLYENGINE D Install the tapered plug into the tapered bore of the drive pulley and place the drive pulley assembly in a vise. Install the roller arms, springs, pins and bushing subassemblies into the appropriate nests in the movable face assembly. ® Install the roller arm pivot pin clamps, lock plates and 1/4-20 bolts. @ Tighten the 1/4.20 bolts to 110-140 Kg-om (8-10 Ib- 8) and bend the lock tabs against the bolt heads. @ Engage the six roller arm retum springs with the ‘Spring Installation Tool, while the movable face is Positioned against the spider. Placing a wad of paper ‘between the fixed and the movable faces may be helpful in maintaining this position, SEATING T Gan ene @ Install the ramp plate and the snap ring (ecom- mended soap ring spplication is Rater surface up Against the load side of the groove), noting that the tivee holes in the ramp plate are aligned with the holes in the spider © Install the flat washors, the lock plate and the three 1/4-20 self tapping bolts. Torque the bolts to 11 140 Kg-em (8-10 Ib-ft) and bend the lock tabs against the bolt heads. ® Mount the drive pulley on the crankshaft. Be cartain that both tapers are clean and dry. Fig 5 DRIVE PULLEY REASSEMBLY 8-238 HONDA é ENGINE FL250 @ Disengage the torsion/compression spring end from ‘the boss on the underside of the cam with a flat blade screwdriver. For total spring unloading repeat the preceding to disengage the spring from the second boss. NUT (1/2-20) (Salsbury #901840) @ Place the head of the special screw (1/220) in a bench vise. Place the driven pulley on the special FLAT screw. Place the puller plate, flat washer and 1/2.20 WASHER ‘nut on the special screw over the driven pulley (Salsbury #704236) PULLER PLATE / SPECIAL SCREW (Salsbury #602114) @ Tighten 1/2:20 nut until the puller plate bottoms out fon the end of the driven pulley hub. Install the cam retainer on the ends of the movable face casting and ‘the cam, CAM RETAINER (Salsbury #704237) @ Remove the 1/2-20 nut, flat washer and puller plate, @® Remove the snap ring. Check for burrs at the snap ring groove. If present, carefully remove them with a ‘lat file, © Replace the puller plate, flat washer and 1/2.20 nut (finger tight). ® Remove the cam retainer. Loosen the 1/220 nut slowly until the cam is free of the hub. Ifthe eam does not fee itself refer to paragraph (5). ® Remove the Morton Key with diagonal pliers. Now all ~ parts are loose and the movable face can be removed. Fig. 6 DRIVEN PULLEY DISASSEMBLY/REASSEMBLY 8-30€ HONDA 8 FL 250 ENGINE xevway © Puce she morale fae ovr he fed 68 hb CAM RETAINER @ ® ® Install the Morton Key. Place the head of the special 1/2-20 bolt in a bench vise. Place the fixed and the movable face assembly fon the screw (fixed face down). Hook the spring end over any one of the round bosses ‘on the internal side of the cam. While holding the ‘cam and spring, attach the other end of the spring to ‘any one of the three spring anchor points in the ‘movable face. Rotate the fixed face and hub until the key and the keyway are aligned. Place the puller plate flat washer and 1/2:20 nut over, the cam and depress the cam on the hub until it engages with the key, thus allowing the movable face 10 rotate without cam contact. Rotate the movable face counterclockwise to achieve 4 full 180° spring preload and hold it in this position. Continue depressing the cam until the puller plate has bottomed out on the end of the hub. Securely apply the cam retainer over the ends of the movable face casting and the cam. Remove the 1/2-20 nut, flat washer and puller plate, Install the snap ring (flattest surface up against the load side of the groove). Remove the cam retainer. Be certain that the cam is ‘against the snap ring. When remounting, no special procedure is required, Do not forget the key. Keep the pulleys clea, Never apply grease or oil When using the clutch puller tool or special screw (#602114), grease should be applied to the threads for ease of use and to extend their service Fig. 7 DRIVEN PULLEY DISASSEMBLY/REASSEMBLY 8-31HONDA € ENGINE FL 250 Before removing, set parking brake. DRIVE PULLEY @ Tum the movable face 90° counterclockwise, pull it riven Tord yout loon the ve belt and on te ‘Soares ewe our nb cor ® While holding the movable face on described in step , take off the loosened belt from lower side with ‘your other hand, @® After removing the belt at the driven pulley side, remove the belt completely from the drive pulley ® When reassembling, after installing on the drive pulley, install the belt on the driven pulley from the ‘upper side, Replace the drive belt if it is excessively worn as shown below. When speed When speed decreases increases ey NORMAL, BELT } WORN BELT © A. worn belt requires high- fr engine speed for engage- © A worn belt will not move ment and reduces the to the largest section of vehicle speed, the drive pulley. Fig. 8 Drive Belt Removal & Replacement 8-32DRIVEN SIDE ENGINE ‘© At low speeds, the V-belt position of the drive pulley maintains a smaller diameter which with @ corre: sponding larger diameter on the driven pulley, creates a “low gear” ratio. © As speed increases, centrifugally actuated roller weights follow the contour of a bow-shaped plate, closing the drive pulley sheaves and creating a “high gear" ratio {note the position of the cam actuator). If the load is increased (such as climbing @ hill) ater the vehicle is up to speed, the cam actuator on the driven pulley takes over and automatically “down ifts” without loss of engine speed, ‘Then, the engine remains at power range for al but the ‘most severe loads, at which time it will shift into peak: torque range. Fig. 9 How Salsbury Belt Converters Work 8-33Z) HONDA 9 FL 250 FRAME A. Steering ENGINE STOP SWITCH HEADLIGHT SWITCH Only lightly pressfitted EMBLEM © Only lightly press fitted 40 — 8 Kem (3-6 ety ‘© Inspect serrations for wear or damage Ap ] \ 4 — 20K¢-0m \G-emy) 350 — 450 Ko-em (25 — 33 Ib-t) © Inspect serrations ~~ for wear oF damage DUST SEAL a Sore z STEERING WHEEL ‘THROTTLE SHAFT AMON © Installation, Fig. 3 THROTTLE LEVER Lock NuT © Inspect serrations for wear or damage ADJUSTING BOLT GROMMET BRAKE LEVER THROTTLE CABLE © Adjustment, Fig. 4 coLuMN-—~ BUSHING. \ —— 40 ~ 80 Kg-em BRAKE SHAFT (3 6 b-te) \ # Installation, Fig 3 eee Lock NUT ADJUSTING BOLT '© Inspect serrations for ‘BRAKE CABLE wear or damage D) STEERING SHAFT — © Installation, © Inspect, see sec. 9. € 2 3 Fig.2 / ~ STEERING COLUMN t © Inspect, Fig. 6 ‘TO CARBURETOR | © See sec. 8B, > _\__ STEERING \_ SHAFT ~ BUSHING 2 ‘O-D Dime mp To vise anaKe © See sec. 9 E Fig. 1 Steering Wheel and Column Disassembly/Reassembly 9.19 HONDA FRAME FL250 © Adjustment, Fig. 4 _gcRe couumn G—astecrins SHAFT © Install from bottom Fig, 2. Steering Shaft Installation BRAKE SHAFT Fig. 3 Lever and Shaft Installation 9-2PLAY, LEVER SIDE POMS aes CARBURETOR SIDE Lover Free Play ‘© Adjust the lever with the adjusting bolt, FRAME dX FREEPLAY FULL TRAVEL Lover Full Travel @ Measure full travel @ To adjust, remove lever and adjust posi- tion a required. Then install the lever. See Fig. 3 shown above, [Senior iit = a4 wm 0.22 etm) [fect 2= wen doa Fig. 4 Throttle Lever Adjustment 9-3FRAME | Service li 17.7. mm (0.6968 in.) Fig 5. Steering Shaft 0.0. ‘SPRING GAUGE af @ Raise the front wheels off the ground. Turn the steering wheel with a spring ‘gauge and note the reading If the reading exceeds the service limit, inspect the steering shaft and the front bub. | Sarvion limit : 0.5 — 1.1 Kg (1.10 ~ 24.26 Ib) Fig. 7. Steering Whee! Force Check HONDA FL250 ‘SHAFT BUSHING 22 mm (0.87 in.) Tes ‘mm (0.31 in.) om STEERING COLUMN BUSHING Service mit: 18,5mm (0.7283 in.) STEERING SHAFT BUSHING — 7 Service limit: 18.2.mm (0.7165 in.) Fig, 6 Steering Column 1D. 9-4HONDA 9 FL250 FRAME B. Front Suspension BING = enlace 190 — 250 Kg-em (1: 18 Ib-ft) eee 400 ~ 500 Kgem (29 — 36 1-4) Locking eww FRONTARM —_/ ® Replace FRONT SHOCK ABSORBER a sPAING PIN TE-ROD — © Installation, Fig. 7 © Adjustment, Fig. 12 / L. BALL JOINT © Installation, Fig. 7 Replace 350 — 430 Kg-em (25 — 31 lb-ft) 320 440 gen NQ (25 — 31 bot Y R.BALLJOINT ‘© Check for looseness KING-PIN © Inspection, Fig, 11 _——BUSHING _— DUST-SEAL __-KNUCKLE © Installation, Fig. § ee KINGPIN BOLT + rote FRONT WHEEL ASSY.——_ © Disassembly, see sec. 9. D. FRONT HUB © Disassembly, ion, Fig. 6 600 — 800 Kgem ! 190 ~ 250 kgem (43 — (43 — 58 Ib-fe) (14-78 bf) Fig. 1 Front Suspension Removal/Installation 9-59 HONDA FRAME FL 250 5 onsenr RAINS Frowraue drm sprinc rin oaiven f- ~ (Too! No. 07944-8350300) a / i ‘SPRING PIN \ / 7 row ani ee Fig. 2. Spring Pin Removal Fig. 3. Front Hub Disassembly UPPER METAL FRONT SHOCK ABSORBER COMPRESSER j] ‘Tool No. 07959-3280000) © Apply a coat of sealant, (© Tighten firmly UPPER METAL ‘ PULLOUT Lock NUT Fig 4 Front Shock Absorber DisassemblyKINGPIN BOLT ” BALL JOINT © Install the ball joint with “L"” mark toward canter, DRIVER ATTACHMENT HANDLE {Too No. 07949-6110000) Install tievrod with groove BEARING OR OIL SEAL BEARING/OIL SEAL DRIVER ATTACHMENT (Tool No. 07845-3330 100) (© After tightening the lock nuts, make sure that the FRONT HUB ball joints can be operated properly by rotating Fig. 6 Front Hub Bearing and Oil Sea! Installation Fig 7 Tie-flod Installation 9-19 HONDA FRAME FL 250 A al FREE LENGTH FREE LENGTH ‘Standard 229.4 mm (9.03 in.) Service mit : 205 mm (8.07 in.) Fig. 8 Shock Absorber Spring Free Length PIVOT PIPE KINGPIN Standard 42.58 — 42.62 mm (1.6764 — 1.6780 in. | | standard 14,03 — 14.06 mm (0.5524 ~ 0.5535 in.) Service limit 42.8 mm ( 1.6860 in.) | Seven init: 14.15 mm ( 0.5670 in.) Fig. 9 Front Arm LD.FRAME Standard: 42.47 ~ 42.50 mm (1.6721 ~ 1.6732 in.) Service limit 42.3 mm ( 1.66653 in ‘| Fig. 10 Pivot Pipe 0.0. Standard 13,97 — 13.98 mm (0.5600 — 0.5504 in.) Service limit 13.9 mm ( 0.5472 in.) Fig. 11. KingPin 0.0. 9.9FRAME Place the vehicle on level ground wit front wheels in a straight ahead posi TOE-IN GAUGE @ Align the toe-in gauge with the marks on the tires as shown, @ Check the readings on the scales of the gauges. Z At y Z- 0K Nut bbe operated proper ly by, rotating the : the rod. © Wen the toe-in does not meet the speci fication, adjust it by changing each length cof the tie rods equally while measuring HONDA FL250 @ Mark the centers of the tires with chalk to indicate the center height of an axle, CENTER OF WHEEL @ Slowly move the vehicle back and rotate ‘the wheels 180° until the marks on the tires are aligned with the height of the 2Uge on the rear side. @© Measure the toein on the rear part of the tires at the same points. Toein : 8-8 TOE-IN ‘Se 0-13 mm (0 -0.51 in.) the toe‘ . Fig. 12 Toein Adjustment 9-10€) HONDA 9 FL250 FRAME C. Rear Wheel Axle {© Inspect the splines for REAR WHEEL ASSY. wear or damage © Disassembly/Reassembly, see sec. 9. D. . ee see sec. 8.6. 1 Inspect the spines for wear or 190 — 250 kg-em (14 — 18 Ibtt) REAR WHEEL AXLE i Removal: D Wheels Rear hubs (Rear axle spacer and axle colar ~~ @ Rear brake deum assembly Rear wheel axle © Inspection, Fig. 2 REAR BRAKE DRUM ASSY. ‘© Removal/Installation, © Inspect the splines for wear or damage —S 2 Fig, 1 Rear Wheel Axle Removal/InstallationFRAME | Service limit: 3.0mm —( 0.1181 in.) a Fig. 2 Rear Wheel Axle Bend 9-12€ HONDA 9 FL 250 FRAME D. Wheel TIRE ‘© Inspect for wear, cuts tears, or any other defects. © Disassembly, Fig. 2 190 ~ 250 Kgem (14 ~ 18 Ib-t) OUTER RIM © Inspect for damage ‘SUPPORT PLATE INNER RIM © Inspect for damage After reassembling, check to see that the tire beads fit properly all the way around the rims. SUPPORT PLATE PATCH VALVE ‘© Replace when removed Fig. 1 Wheel Disassembly/Reassembly TIRE DISASSEMBLY TOOL, (Tool No. 07916-9180000) WEIGHT. WHEEL RIM If itis hard to remove the bead or if rust has formed on the bead, apply @ coat of lubri ant to the periphery of the rim before removing the tire, When reassembling, wipe off oll from the tire and the tim using @ cloth, Fig. 2 Tire Disassembly 9-13FRAME @ Check tire tread for nails or other pune- turing objects; chalk mark punctured area, Remove nails or puncturing objects. ROLLER @ Remove dirt and roughen punctured area with sandpaper or wire brush. Clean area with gasoline, ® Apply rubber cement around torn area and allow it to dry. Remove the lining from the patch and center it over the Puncture. Press the patch against the puncture using a special roller Fig. 3 Cold-Patch Repair RUBBER PLUG @ Remove nails or other puncturing objects. @ Insert @ rubber plug through the eye in the inserting needle ® Center the needle on the plug and insert until the plug is all the way in the tire; ‘twist the needle several times. SPECIAL TTOOL. RUBBER PLUG @ Pall the needle straight out so that the plug is about 10mm (0.294 in.) above ‘wead surface. Trim the plug 2mm {0.079 in.) above the surface. Repeat the above procedure if the puncture is large. Nos ‘This method is for emergency purposes only. ‘After driving repair injury with cold patch. 9-14FRAME Position the tire on the rim half which has the valve @® Press the O-ring into place in the groove in the rim. ® Install the other rim half. Be sure to align the rim bolt holes. Fig. 8 O-Ring Installation FRONT TIRE REAR TIRE Recommended Pressure Recommended Pressure 0.35 kg/om? (5.0 Psi) 0.21 kg/em? (3.0 Psi) Max, Pressure ‘Standard Tire Cireurnference OS kgiem? (7.0 Psi) 1.84.m (72 in.) Min. Pressure Max. Circumference O.3ko/em? (4.5 Psi) 2.00 m (78.7 in.) Standard Tire Circumference Min. Circumference 1.57 m (61.8in.) 1.80 m (71.0 in) Fig. 6 Tire Inflation 9-159 HONDA FRAME FL250 E. Brake DISC BRAKE © Removal/Installation, Fig. 1 and 4, © Inspection, Fig. 7. © Adjustment, Fig 6 BRAKE LEVER inspection, Fig. 9 © Adjustment, Fig. 11. BRAKE DRUM ‘© Removal/Installation, Fig. 3 © Inspection, Fig. 8 © Installation, Fig. 5. Installation, Fig. 2 jon/Adjustment, Fig. 10 9-16HONDA 9 FL 250 FRAME BRAKE DISC ‘After tightening the lock plates with © Removal the nuts, bend the locking tabs. Remove the reduction case and the LOCK PLATE disc © Installation, Fig. 4 CALIPER BODY ADJUSTING RATCHET RATCHET SPRING CALIPER GASKET PAD SET -—\ NOTE fe Replace pad A and Basa st, ‘O-RING if necessary. ‘© Replace |e When replacing only the pads, itis not neces, a tary to discon: ect the Gaur pn |_ able “*eovER ) case | THrusteuare —‘araKE ARM * Disesembiy/Reasemby, | GUIDE Inston, Fig 4. -— ADJUSTING BOLT - 100 250 Koa (4 180 Fig. 1 Disc and Caliper Disassembly/Reassembly 9-179 HONDA FRAME FL 250 PARKING BRAKE S covER - PARKING BRAKE 190 — 250 Kem (14 — 18 lb-ft) PARKING BRAKE CABLE Fig, 2. Parking Brake Removal/Installation 9-18FL 250 FRAME : 9-19HON: 8 FRAME FL 250 € PUNCH MARK O-RING BRAKE ARM ‘ADJUSTING BOLT PADA © Install pad A with O-ring: TEES © 20, @ cont oF about 050 (0.01802) silicon grease KS62M to the outer circumference of| the pad, ‘© Apply 2 coat of 0.6 — 11g (0.021 — 0.035 oz) icon grease KS62M to the backing plate of ‘the pad and caliper body, BRAKE ARM ZL DRIVER ATTACHMENT HANDLE ee BEARING/OIL SEAL (Too! No. 07948-6110000) “p DRIVER ATTACHMENT (Too! No. 07946-3600000) ADJUSTING BOLT © Back off the adjusting bolt 8s far as it will go. Fig. 6 Brake Arm Adjustment BEARING OR OIL SEAL ‘© Squeeze the brake lever about ton times ‘0 that the automatic adjuster can oper- ate properly. At this time slightly squeeze the lever as in bleeding operation. The lever free play is now automatically adjusted, See Fig. 9 BEARING HOLDER Fig. 5 Rear Brake Bearing and Oil Seal Installation. 9-20€ HONDA 9 FL 250 FRAME Me ote Saencan aseest 2aare 30 mm (1.18 in.) Using a dial indicator mounted as shown, ” rotate the dise slowly and check the runout - Service limit : 0.3mm (0,0118in,) (© Replace the disc if it is worn beyond the al DIAL I woicator & | servies init. pise / MicromeTEeR Using a micrometer, mesure the disc thick. V7 . ness. at four points and 30mm (1.18 in.) = - trom the outer edge ofthe dae (SY V DISC THICKNESS 7 Standard: 3.2mm (0.126 in.) [ Service limit: 3,0.mm (0.1181 in.) © Replace the disc if its thickness is less than the service limit. 30 mm (1.18 in.) Fig. 7 Pad and Dise Inspection 9-21HONDA e FL250 eet Inspect the brake drum for scoring, cracks and concentricity. DRUM 1.0. BRAKE DRUM Service limit: 140.6 mm (6.5364 in.) LINING THICKNESS [ standard: 4.28 mm (0.1673 in.) | Service limit: 1,8mm (0.0891 in.) Fig 8 Brake Drum and Lining Inspection 7 FREE PLAY Le REMAINING LEVER EFFECTIVE TRAVEL Remaining Effective Lever Travel (© Pull the lever until contact is felt. ‘Measure distance as shown above. Service limit: above 23 mm (above 0,90 in.) © Pad-todisc clearance is automatically adjusted. Lever Free Play Measure lover foe play. Service limit: 1 ~ 5mm (0.04 ~ 0.20 in.) @ To adjust, loosen the lock nut of the brake lever and turn the adjusting bolt. led ser ed oe rae oe oe Fig. 9 Remaining Brake Lever Effective Travel/Free Play InspectionFL 250 FRAME ®t the proper adjustment cannot be obtained with the serration moving, is off the ground. ® Pill the parking brake lever up 1 — 5 inspect the BRAKE DRUM, BRAKE notches so that the rear wheels do not ‘SHOES and replace if necessary. turn. @ Release the brake lever and check that SPECIFICATIONS 1 —Snotches. Brakes fully engaged. the rear wheels do not drag when turned. @ If proper operation of the parking brake is not achieved by steps(@)and@) move ‘the brake arm serration only one notch 10 adjust. Fig, 10. Parking Brake Lever Inspection/Adjustment BRAKE SHAFT @ Measure the distance as above when the lever is free. @ To adjust, remove the lever and reinstall so that the proper lever position is achieved. 78mm (2.44 Service limit Fig. 11. Brake Lever Full Travel Adjustment 9-23g HONDA FRAME FL 250 F. Fuel System eueeian 70 — 120 Keem (5 —9 lb-ft) ce ® Roll bars ® Rear fenders ® Muffler assembly @ Air cleaner assembly SX 6 Bite eee GASKET ~ @ Reduction cave mounting fopbole o-nING lantion coi sembly 1 Replace when damaged N@ Storer knob nat © Guard pie . & Festa _~ a FROM CRANKCASE RETURN FUEL Y Was ~ e vacuum ‘ TUBE 70 — 120 Kg-em (5 — 9 Ib-ft) eae |” FUEL CHECK VALVE Disassembly/ } Reassembly, Fig. 2 eres ie FUEL TUBE TO CARBURETOR FUEL FILTER Fig. 1 Fuel Tank Removal/Instalation {Replace when damaged or deteriorated. S 10 ROM FUEL FI INF ples) Fig. 2. Fuel Pump Disassembly/Reassembly 2 caeemenen 9-24HONDA 9 FL250 FRAME G. Frame Parts UPPER FLOOR MAT LOWER FLOOR MAT SEAT CUTION (© Removal/Instalation, Fig. 2 70 ~ 120 Kgem (5 ~ 9 1b-t) 190 ~ 250 Kg-om (14 — 18 lb-ft) MUD-GUARD Fig. 1 Front Body Removal/Installation 9-259 HONDA FRAME FL250 300 — 350 Kg-em (22 — 25 lb-ft) 70 — 120 Kg-em (6 — 9 to-ft) , SHOULDER BELT PAD SEAT CUSHION SEAT ADJUSTING GUARD 180 — 200 Kgem (11-15 tbe) d 190 — 260 Kgem (14 ~ 18 b-ft) 100 — 250 Kgem (14 — 18 Ib-ft) 70 — 120 Kg-em (5 — 9 tot) . 300 — 350 Kgem| A . =p (22 — 25 tb-ft) 2 ‘SEAT CUSHION STAY 70 — 120 Kgem (6 ~ 9 tot) Fig. 2. Seat Back and Cushion Removal/Installation 9-26HONDA 9 FL 250 FRAME 70 - 120K: . (6-9 bt) REAR ROLL BAR ROLL BAR PAR 199 — 250 Keem (14— 18 ft) i REAR FENDER 190 ~ 250 Kgem (14 — 18 lb-ft) a *|\ PULLEY COVER 70 ~ 120 Kgem (5 ~9 lb-ft) 2 wage = 120Kgem__ © Ya! 6-8pn) Fe eas 9 lb-ft) ad | a poceee ~ 360 — 430 Kg-em (25 ~ 31 lb-ft) — Fig. 3 Rear Frame Parts Removal/Installation 9-779 HONDA FRAME FL250 H. Headlight p K ~ | HEADLIGHT CASE GROMMET WIRE TIES HEADLIGHT UNIT © Install with “TOP” mark up. Fig. 1 Headlight Removal/Installation VERTICAL ADJUSTMENT BOLTS 30m (Hoof) ‘Make sure that the parking brake is set to avoid forward motion. Fig. 2. Headlight Adjustment VY 9-28Sona 10 S/FL250 es EC TRICAL DIAGRAM = | | A.C. GENERATOR IGNITION COIL ec Y oe VellOw Gree Green Bk Black BemeBlue 7 ENGINE STOP SW } HEAD LIGHT SW. HEAD LAMP(6V 35W)SHOP MANUAL HONDA. DYSSEY FL 250 ADDENDUM POSTING THE FL250 ADDENDUM Follow these instructions so that your F250 Shop Manual is in order when You need to refer to it: ‘Start at the front of your shop manual —— 1. Remove the old cover. Replace it with the new cover (6295001), 2. Remove the old Table of Contents. Insert the new Table of Contents page (Date of Issue: Sep, 1979). ‘Move to the back of the shop manual —— 1. Insert the 1980 addendum directly behind page 10-1. 2, The FL250 addendum posting is now complete. You may now discerd this cover sheet, J HONDA MoTOR CO, LTD. 1979 62950002 PRINTED IN JAPAN ® 427007910HONDA 11 FL 250 1980 ADDENDUM FOREWORD This addendum describes major modifications to the Honda FL250 ODYSSEY starting with Frame No. TBO4-2000001 and Engine No, TBOE-2000001. TABLE OF CONTENTS GENERAL DATA A. Overall Vehicle Dimensions B. General Specifications: FRAME ELECTRICAL DIAGRAM Date of Ise: Sep i" CHONDA MOTOR CO.,LTD AHONDA qu a FL 250 GENERAL DATA-H—_ A. Overall Vehicle Dimensions REAR VIEW SIDE VIEW FRONT VIEW 1 Date of Issue: Sep. 2 HONDA MOTOR CO. LTD.HONDA FL250 € N 1980 ADDENDUM B. General Specifications DESCRIPTION ~ SPECIFICATION Overall enath 12.085 rm (6248 n) Overall width “Oral haght Wheel base 41,435 mm (56.50 in.) . 830 mm (96.61 in) al = ae Selene cron (Ground clearance 140mm ( 5:51 in) ‘Min. turning circle radius 43m (17.39 ft) mann denn FORE | 45 8) AST WEIGHT Rear 119kg (262.40 tbs.) _*120kg (264.60 Ibs.) Max. laden wei 270kg (595.35 Ibs.) °271kg (597.56 Ibs.}) Moe stabilize inclination, ghee | pce: Max. climbing angle 35° ] I 20m (at 60 Ki) | Stopping distance Sa = BLO 31.25 mph) | FL 250€ Aircooled, Zatroke | ‘Single-cylinder 15° inclined from vertical [700% 644 mm @756x 2596 in) 7 | | Displacement ee | Compression Ratio 6 | Compression Pressure a a Gaon 20 ot eo Ignition timing = 5° BTDC. — SS ian Open ‘80° BTOC Close ‘80° ATO | © pertinng | een 20 | e806 | — 87° ABDC 60° BBDC c L __Senere Giese | 00" ABDC “Canada Model Date of Issue: Sep, 1979 © HONDA MOTOR CO., LTD. 11311 1980 ADDENDUM HONDA FL250 € Camber DESCRIPTION SPECIFICATION [Idle speed 1,800 rpm Vat mechani Fiston conti ibrication system Forced Carburetor type Pw ENGINE Choke syst Stare Ait leaner type aaa ioe Fuel pump type : Diaphragm = Belt converter SALSBURYS Torque convertor | Engine dry weight 22 Kg (48.51 Ibs.| i Fuel nk (3.17 US ol, 264 Imo CAPACITIES: Reduction unit (1.057 US pt., 0.88 Imp. pt.) Starting syntem Recoil warer = Stopping system Ground suiteh ignition system Flywheel magneto ELECTRICAL Gopertar (AC Ganwrator Spark plug NGK BR7ES DENSO W22ESR Spark plug 9 : : 07 ~ 0.8mm (0.026 0.032 in} Max uring angle, Mahdi greening [Arms Knlicam rire Steering angle side . . outside a Tele sme i srg SUSPENSION ~ - ‘ Whee! exe type Front sherk sbsorber Col sring 8 Tesin @mm (0318 in.) Camber ° Front Caster s King pin angle . ALIGNMENT gene . Side of st 8mm (0356 ms) Coster eal 0mm (1.969 Side lip (iden) Omm (Om) Rear Teen Omm (On) 5 114 Date of Issue: Sep., 1979 © HONDA MOTOR CO., LTD.HONDA FL 250 € 1 1980 ADDENDUM DESCRIPTION SPECIFICATION “Tain brake Seikadjusting cable acuuated dise : Parking brake (Cable actuated leading-trallng shoe and drum 7 Disc effective diameter 220 mm (8.661 in.) | Parking brake drum diameter 140 mm (6.512 in.) | front 140 x 208mm (6.51 x Bin) Rim, width x diameter, ~ reer 10x 203 mm (827 x 8in) front | 608% 178— 203mm (20x7—8in) 2plv) TIRES Tire, 0.0. x width x LD. ‘ear | 559% 280-209 mm (22% 11-8 tr 0.35 Ke/em? 60 prewure ont afem rear (0.21 Ke/em? (3.0 psi) Headlight 12v-45W usiTs Tailight 12V—3W (Canada Model only) Date of Issue: Sep., 1979 © HONDA MOTOR CO.,LTD. 115HONDA " FL250 FRAME Headlight Headlight Removal/Installation 1980 ADDENDUM BRACKET 7 9 Ss fh HEADLIGHT CASE HEADLIGHT UNIT © Install with “TOP” mark up, SOCKET \ Z \ BULB (12V—45W) GnOwMeET serine Fig.1 Headlight Adjustment ‘Set the parking brake, start the engine, VERTICAL ADJUSTMENT BOLTS mpi ‘Adjust the headlight beam as shown, = 31.5 m (105 ft) ——~ To avoid forward movement, make sure the parking brake is set. Fig. 2 16 Date of ioe ep 1979 . © HONDA MOTOR CO., LTD.1 1980 ADDENDUM Taillight Removal/Installation Taillight (Canada Model only) TAILLIGHT STAY TAILLIGHT LENS TAILLIGHT BASE BRACKET FAILLIGHT BASE Fig. Seat “The new seat is equipped with a heat shield. The seat also has thicker padding and a covering that is flexible at low temperatures. Heat Shield Removal/Installation HEAT SHIELD Fig. a Date of sue: Sep., 1979 1 © HONDA MOTOR CO.,LTD. 1Nl 1980 ADDENDUM Engine Mounts Rebound limiters have been added to the front engine mounts, ond the engine protector has been enlarged for rebound limiter clearance. ENGINE MOUNT Rear Tire ‘The rear tires now have two reinforcing ribs on the side walls for inet sed rigidity and greater resistance against chafing, AC. Generator ‘The A.C. Generator was changed from 2 6V—35W to a new 12V—A5W type, Accordingly the taillight (Canada model) was changed from 6V—3W to 12V-3W. The headlight was changed from 6V~-35W to 12V-45W. 11-8 Date of sue: Sep 1979 : HONDA MOTOR CO., LTD.é HONDA FL250 SPARK PLUG ft ENGINE STOP SWITCH Greek od Ya oe ol ete HEADLIGHT SWITCH "1 1980 ADDENDUM ELECTRICAL DIAGRAM ©. GENERATO! i ~~ Hea LAMP (12-451) Date of Issue: Sep., 1979 © HONDA MOTOR CO.,LTD. 113Z\ HONDA qu see Ao0enoUN FL250 (Canada Model only) 11 Date of Issue: Sep, 1979 “10 © HONDA MOTOR CO., LTD.HONDA FL250 1981 ADDENDUM INTRODUCTION This addendum describes major modifications to the Honda FL250 ODYSSEY starting with Frame No. TB0400BC400001 and Engine No. B04 E-2400001. Refer to the base shop manu- al and the 1980 Addendum for service proce- dures and data not included here. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS IN- CLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT IN- FORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITH- OUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION. ....... Dimensions ........--00006 Specifications . . . REMOVAL/INSTALLATION. INSPECTION ..... FRAME WIRING DIAGRAM. . Date of Issue: November, 1980) {@ American Honds Motor Co, Ine. 1980- All Rights Reserved12 HONDA 1981 ADDENDUM FL250 GENERAL INFORMATION FRONT VIEW (6650 i 2,095 mm aa {82.5 in) 440 mm (5.5 in) 960 mm (37.4 in) REAR VIEW 121€ HONDA FL 250 1981 ADDENDUM 12 B. Specifications DESCRIPTION SPECIFICATION ‘Overall height 1,485 mm (67.7 in.) Min, turning cele radius 43m (1411 fe) Diy weight 192 Ka 1423 Tos) WEIGHT Becca Front 71.5 Kg (157.5 Ibs) Rear 120.5 Ka (265.5 ibs) ‘Compression Ratio 66:1 ENGINE Lubrication system Fue-oil mix Air cleaner ‘Semi-dry type. ELECTRICAL |_lmnition system CD ‘Spark plug) NGK BABES, OENSO W24ESR LIGHTS: Headlight 12V—60W, Date of Issue: November 7980 © American Honda Motor Co, Ine, 1980 All Rights Resoned 12.2| 2 HONDA REMOVAL/ 1981 ADDENDUM FL 250 INSTALLATION Sor eo seat back and harness muffler drive belt covers engine mounting bolts fuel lines “The air cleaner does not have to be removed. 190-250 Kgem (14-18 lb-ft) SEAT ADJUSTING GUARD 180-200 Kem (11-15 thst) DRIVE BELT COVER 3 MUFFLER ASSY (14—18 lb-ft) ‘SPARK PLUG CAP ROPE GUIDE NUT 30-40 Kg-em (2-3 ty WIRE CONNECTORS 2 sof oe Nore 12-3 | eeHONDA 12 FL250 1981 ADDENDUM ENGINE MOUNTING BOLT 350~830 Kg-em 125-31 ttt) CARBURETOR _ ) Fue unes 70-120 Kg-em 9 Ib ENGINE MOUNTING BOLT (5-9 1b) 350-430 Kg-em oa) DRIVE BELT COVER ENGINE REMOVAL Remove the engine by lifting. and turning it as shown, DRIVE BELT Sea a 12-412 HONDA © REMOVAL/ 1981 ADDENDUM FL250 oe lrhlrhlrrt—OCNMisCOCO‘i‘iNOCiCiC‘iW*NNCZCiCs AIR CLEANER cover ELEMENT {Cleaning page 8-2) ELEMENT HOLDER€) HONDA 12 FL 250 1981 ADDENDUM REMO VA L/ GENERATOR AND IGNITION SYSTEM INSTALLATION LAMP COIL PULSE COIL 450-500 Kg:em (33-36 lb-ft) WOODRUFF KEY * Install as shown = svatdn EXCITER COIL Rotor ‘Be sure that it doesn’t interfere with the stator. STARTER PULLEY IGNITION COIL ASSY NOISE SUPPRESSOR y -—— spark PLUG BRBES (NGK) W24ESR (ND) 150-200 Kecm (11-15 If) ©.D.1. UNIT (inspection page 8-9) rs of ian Nove 980 (@ Anwien Honde Meter Gane. 190- Al ig Reed 12-612 INSPECTION IGNITION COIL Check the resistances between the leads of the primary and secondary coils Primary coil: 0,2-089 Secondary coil: 8-18 k 2 EXCITER COIL Adjust the seat so that it is completely for wars. Disconnect the A.C. generator wire connec: tors from the main harness clipped to the right side of the frame (see page 12-13), Use an electrical tester to check continuity between the wites as shown. ‘The excitor coil is normal if there is conti: ruity between the black/red wire and ground, SPECIFIED RESISTANCE: 245 2 PULSE COIL Measure the resistance between the Blue/ Yellow ang Green wires. RESISTANCE: 20-602. LIGHTING COIL The lighting coil is good If there is conti: nuity between the yellow wire and ground, HONDA 1981 ADDENDUM FL250 ___— round BLACK/RED GROUND EXCITER COIL \ Y BLUE/YELLOW PULSE COIL GROUND YELLOW LIGHTING COIL 127 Date of issue: November, 1980 © American Honde Motor Co, Inc. 1980. All Rights ResonesCa HONDA FL 250 IGNITION TIMING Capacitive dischare ignition timing ie not adjustable, ftming i incortet, text he CDI Unit and the AC generetor, and replace the faulty pot 1, Remove the recoil starter 2. Wind a rope around the pulley and start the engine 3. Check the timing using @ strobe tight Timing is correct ifthe index mark aligns between the two advance marks st 1500 om CDI UNIT ©The CDI is fully transistorized, For accurate testing, it is necessary to use 8 specified electric ‘tester. Use of an im: proper tester may give a false reading. © Use SANWA ELECTRIC TESTER (P/N 7308-0020000) or KOWA ELECTRIC tester (TH—5H) Replace the CDI unit if the readings are not within the limits shown in the table. unit 1981 ADDENDUM 12 INDEX MARK. GREEN BLACK/RED. BLACK/YELLOW UPPER-SANWA (SP-10D)xk 2 LOWER: KOWA (TH-5H) X1009 ee ee RED 5.021000 | BLACK = ~ ° | CT co . = '5.0-100.0 10.0--300.0 Revised: June, 1982 American Honda Motor Co. Inc. 1962 - All Rights Reserved 12-812 HONDA eae 1981 ADDENDUM FL250 ROLL BAR 190-250 Kg-em ROLL BAR PAD eae REAR ROLL BAR FRONT ROLL BAR 190-250 Ka-em (1418 Ibe) Bo 190-250 Ka-em (14—18 lb-ft) SIDE ROLL BAR 12 Date of ese: November, 1980 9 {© American Honda Motor Ca, Inc. 1980- All Rights Reserved12 FL250 wou REAR FRAME 190-250 Kg-em (14-18 Itt) VS ROLL BAR PAD REAR ROLL BAR REAR FENDER 190-250 Kem (14-18 tbh) SS / 190-250 Kem Y (14-18 lb-ft) a BR. GROMMET GUARD PIPE PULLEY COVER 190-250 Kg-em (14-18 tbe) ENGINE BRACKET ——— | 190-250 Kgem (1418 t-te) 70-120 Ks-em (6-8 ib) REAR REFLECTOR 350-830 Kg-cm (25-31 ett) : 350-430 Ken L. SIDE PRoTEcron aes Da ot Tas November, 1060 €. Aman Honda Meter Ca ne. 18D- A FighaResened 12-1012 1981 ADDENDUM FL250 HONDA HEADLIGHT BULB (12V 6o/e0w) HEADLIGHT ASSY Rim so HORIZONTAL ADJUSTMENT SCREW © Tur the screw so the headlight beam is aimed straight ahead. HEADLIGHT SOCKET HOLDER = GROMMET HEADLIGHT STAY \ COLLAR HEAOLIGHT CASE i) cASE NUT ~— HORIZONTAL ‘ADJUSTMENT SCREW CASE STAY VERTICAL ADJUSTMENT BOLTS © Looten the bolts and align the embossed mark on the headlight case with the cut out in the headlight stay. 12-11 Date of lssue: November, 1980 1© American Hends Motor Co, Ine. 1980. All Rights Reseed1981 ADDENDUM 12 WIRING DIAGRAM ENGINE STOP SWITCH 2 g yy wy ° @ 8 a =| 2 él |. al Ae 8 | 88/8 | bs 5 a F] joa 8 > 7 2 g/- z az) (1 | . : z z = 5 el lelelals g 8] |8}2]2/8 Date of fssue: November, 1980 © American Honds Motor Co, Ine. 1980. All Rights Resoves 12-1212 Co 1981 ADDENDUM FL250 — HARNESS ROUTING 12-13