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    Honda CBR250R [2011] Service Manual

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    2 views499 pages

    Honda CBR250R (2011) Service Manual

    Uploaded by

    Socrates Machado

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 499
    CONTENTS MAINTENANCE. LUBRICATION SYSTEM 2 |_ FUEL SYSTEM (PGM-FI) & | COOLING SYSTEM w Le 5 2 |_ENGINE REMOVAL/INSTALLATION a © | CYLINDER HEAD/VALVES a Z| CYLINDERIPISTON 2 | CLUTCHIGEARSHIFT LINKAGE 2 a ALTERNATORISTARTER CLUTCH Ea REAR WHEEL/SUSPENSION HYDRAULIC BRAKE = "ANTFLOCK BRAKE SYSTEM (ABS) BATTERYICHARGING SYSTEM [IGNITION SYSTEM ELECTRIC STARTER | LIGHTS/METERS/SWITCHES ELECTRICAL ~ WIRING DIAGRAMS TROUBLESHOOTING = 1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION ~ GENERAL SPECIFICATIONS LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM (PGM-Fl) ‘SPECIFICATIONS COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVES SPECIFICATIONS - CYLINDERIPISTON SPECIFICATIONS CLUTCHIGEARSHIFT LINKAGE SPECIFICATIONS ALTERNATORISTARTER CLUTCH ‘SPECIFICATIONS CRANKCASE/CRANKSHAFT/ TRANSMISSION/BALANCER SPECIFICATIONS FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 4-10 REAR WHEEL/SUSPENSION SPECIFICATIONS----~ 1-40 HYDRAULIC BRAKE SPECIFICATIONS~1-10 BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS: 141 IGNITION SYSTEM SPECIFICATIONS ~~~ 1-14 ELECTRIC STARTER SPECIFICATION 1-14 LIGHTS/METERS/SWITCHES SPECIFICATIONS: TORQUE VALUES 112 LUBRICATION & SEAL POINTS 116 CABLE & HARNESS ROUTING 118 EMISSION CONTROL SYSTEMS ~ 4-47 GENERAL INFORMATION SERVICE RULES 1. Use Honda Genuine or Honda-recommencied parts and lubricants or their equivalents, Parts that do not meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this producto avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Insta new gaskets, O-rings, cotter pins, and lock plates when reassembiing, When tightening bolts or nuts, begin with the larger clameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified Clean pars in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. ‘After reassembly, check al pers for proper installation and operation. Route all electrical wires as shown in the Cable and Hamess Routing (page 1-18). Do nat bend or twist control cables. Damaged control cables wil not operate smoothly and may stick or bind ABBREVIATION Throughout this manvel, the following abbreviations are used to identify the respective parts or systems. Ful arm —__| Antitock Brake System Crankshaft Poston sensor Data Link Connector ‘Diego Trouble Cod Eig Cond Weta — Ege Cooler Toe ePanFS FOr octal Erasable Programmable Read Only Meme Evaporaiee Eriscor Honda Dsghosti System le A Control Vane Vehicle Speed sensor GENERAL INFORMATION MODEL IDENTIFICATION CBR250RA shown: SERIAL NUMBERS ‘The Vehicle Identification Number (VIN) [1] is stamped on the right side of the steering head. ‘The ongne serialnumber [1] stampod on the lover let sce of the GENERAL INFORMATION ‘The throtle body identification number [1] is stamped on the lower left side of the thrattie body. i LABELS ‘The Safety Certification Label [1] I located on loft side of the frame. ‘The color label [1] is attached on the frame under the passenger seat. When ordering color-coded parts, always spectty te designated color code. ‘The Emission Contr information Label is attached on the rear fender. + USA/Canada type [1] + Canada type only [2] 1-4 GENERAL INFORMATION GENERAL SPECIFICATIONS FRAME ENGINE | FUEL DELIVERY SYSTEM DRIVE TRAIN rn TE ‘Overall Tengtn Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Maximum weight capacity Frame type eS Front suspension Front axle travel Rear suspension Rear axle travel Tire size Tite brand Front brake Rear brake Caster angle Trail length Fuel tank capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens. closes Exhaustvalve opens closes Lubrication system il pump type Cooling system Airfitetion Engine dry weight Type Trrottle bore Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern cBR250R CBR250RA, CBR250R CBR250RA Front Rear Front Rear at 1.0 mm (0.04 in) lit at 1.0 mm (0.04 in) lft at 1.0 mm (0.04 in) lft at 4.0 mm (0.04 in) it tet 2nd 8rd ath sth ath SPECIFICATION 2,086 mim (60.1 in) 720 mm (28.3 in) 4,425 mm (44.3 in) 41,370 mm (63.9 in) 780 mm (30.7 in) 328 mm (12.9 in) 445 mm (67 in) 162 kg (657 Ibs) 166 kg (366 Ibs) 217 kg (478 Ibs) 219 kg (483 Ibs) “Twin-spar Telescopic fork 118 mm (4.8 in) ‘Swingarm. 404 mm (4.1 in) 110/70-47MUC 548 +140/70-17MIC 66S RX-O1FD (IRC) RX-OIRZ (IRC) Hydraulic single disc Hydraulic single disc 25° 30) 98.6 mm (3.88 in} 13,0 ters (3.43 US gal, 2.86 Imp gal) Single cylinder inclined 20° from vertical 76.0 x 85.0 mm (2.99 x 2.47 in) 2496 om? (16.2 cu-in) 40.731 Chain driven DOHC with rocker arm 20° TDC. 35° ABDC 40° BBDC or TD Forced pressure and wet sump Trochoid Liquid cooled Viscous paper fiter 35:4 kg (78.0 Ibs) PGM-FI 38 mm (1.5 in) Malt-plate, wet Cable operating Constant mesh, 6 speeds 2.808 (73/26) 2.714 (38/14) 3.399 (40/12) 2.197 (36117) 41871 (33/21) 4.304 (30/23) 1.115 (29/26) 0.962 (28/27) Left foot operated return system 1-N-2-3-4-5-6 1-5 GENERAL INFORMATION ITEM ELECTRICAL Tonition system Starting system Charging system Regulatovrectiner Lighting system_ __'SPECIFICATION Computer controlled digital transistorized with electric advance Electric starter motor Triple phase output alternator ‘SCR shorted, triple phase fullwave rectification Battery GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) TEM STANDARD SERVICE LIMIT Engine oll eapectty ‘At draining “a tters (11S US af, 1.2 Imp qi) Sree Aoi fiter change 1.Slters (16 US at 1.3 imp qi) - ‘Atdisassembly 1.8 liters (7.9 US qt, 1.6 Imp qi) = Recommended engine ch 2 ro Honda GNA 4-stioke oil (U.S.A and Canada) or equivalent motor of [API service classification: SG or Higher = “JASO T 903 standard: MA. __| Viscosity: SAE TOW30 ‘Oirpump rotor Tipdearance (0.15 (0.006) 0.20 0.008) Body dearance (0,180.22 (01008 =0,008) 0:35,(0.014) ‘Side clearance 0.02- 0.09 (0.001- 0.004) 0.10 (0.004) FUEL SYSTEM (PGM-Fl) SPECIFICATIONS ces = Tem 2 = ‘SPECIFICATION (Tihioie body Wienteation number r= Con INE os] Engine idle speed 7/400 + 100 rpm : “Throtte grip treeplay im (1116 = 14 in) "Fe! injector resistance (20°C/68°F) 1-130 Fuel pressure at idle a daar ~ 284 KPa (8.0 kgliom?, 43 psi) Fuel pump flow (at *2V) 5 {692 Gat" @.34 US 02, 2.44 Imp 02) minimurn/i0 seconds UR control solenoid valve resistance (20°CI66°F) =i “24-260 EVAP purge control solenoid valve resistance (20°C/65°F) e 30-340 COOLING SYSTEM SPECIFICATIONS IE cee a SS = ‘SPECIFICATION Coolant capacty Radiaior and engine 40 ers (1.16 US gt, 087 Imp a) At draining O.7alitar (0.83 US qt, 0.70 Imp at) Reserve tank 0.25 liter (0.26 US qt, 0.22 Imp at) oe Radiator cap relief pressure E 2.6 KPa (0,951.25 kgticm, 13.5 ~ 17.8 psi) “Thermostat "| Begin to open ‘81 ~ 84°C (178 ~ 183°F) Fully open ee oreo me Valve lift 1 ~a.5 mm (0.18 in) minima Recommended anliresze Pio Honda HP Coolant or an equivalent high qually ethylene — alycol antifreeze containing siicate-ree corrosion inhibitors ‘Standard coolant concentration =< z “11 (mixture with istiled water) GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS ITEM _ Cylinder compression at 480 rpm. eens 2 & Valve, valve Valve stem OD. IN Valve guide height | IN/EX [Valve seat width IN/EX Valve spring Free length Inner ~ Rocker arm, ‘Arm 1.D. IN/EX Camshaft ‘Cam lobe height IN x Oil clearence — (Gyiinder head warpage 0,005 — 0.042 (0.0002 4.204 KPa (182 188 pai) 0:16 = 0.03 (0.006 + 0.001) 0.27 £003 (0.011 = 0.001) 4.470 — 4 495 (0.1760 ~ 0.1770) 4.460 4.485 0. 4500 = 4.512 (0.1772 0.1776) 34.58 (1.361) 40.37 (1.589) 9,987 (0.3926 ~ 0.3932) 0.018 0.049 (0.0005 - 0.0017) 30.931 - 31.171 (1.2178 — 1.2272) 12236) ) CYLINDER/PISTON SPECIFICATIONS rem Cylinder 1D. ‘Outofround Taper __| "Wearpage Piston,piion | Piston OD. at 11 mm (Oa) om pin. plson_ettom ing Piston pin hole [D._ Pision pin OD. 3 “Pistonto-iston pin clearance — Piionrngend Top ep Second Osi raip Piston rngtoving |Top groove seerance |” Second Cylindsto-ision clearance Connecting rod small end 1D. Connecting roe-o-psion pin clsarancs [17002 = 17-008 (0.6684 ‘STANDARD "76000= 76.010 (2.9924 = 9925) 75.980 ~ 75.980 (2.9905 - 2.9913) 0.20=0.70 (0,008 - 0.028) 0.040 = 0.080 (0.0016 - 0.0082 “0.015 = 0.050 (0.0006 - 0.0020) 0.020 = 0.050 (0.0008 = 0.0020) 47,016 — 17.034 (0.6699 - 0.6706) 0.616 = 0.040 (0,0006 - 0.0016) — CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS TEMES eae ‘Cush fever teoplay ~Cluien “Spring fee length Dise thickness Plate warpage Clutch outer guide 1D. Mainshaft 0.0. at cuich outer guide 4.2 STANDARD 70-20 = 13/16) 41.5 (1.63) 2:30~2.50 (0087 70,000 = 20.024 (0.78 49,967 = 19.960 (0.7861 7882) = 0.7865) = 10,075 (03087-03043) 0-40 (0.004) Unit: mm Cin) 446 (0.176) 4.45 (0.175) 4.540 (0.1787) (0.07 (0.008) : 0.08 (0,003) 4.50 (0.059) 32.85 (1.203) 38.35 (1.510) 70.10 (0.396) 9.75 (0.384) 10.10 (0.004) TT BOTT (T2170) ~ 30.819 (1.2133) 0.10 (0.004) 0.05 0.002) Unit: mm (in) VICE LIMIT 76.04 (2.984) 0.070 (0.0004) (0.010 (0.0004) 0.05 (0.002) 75.89 (2.988) 47.080 (0.6705) 16.980 (0.6685) 0.08 (0.003) 0.40 (0.016) 028) 1-40 (0.043) 0.40 (0.004) 0.09 (0.004) 0.09 (0.004) 17.06 (0872) 37.5 (1.48) 2.27 (0.089) 030.01) 20.04 (0.789) 19.947 GENERAL INFORMATION ALTERNATORISTARTER CLUTCH SPECIFICATIONS eis = Unit mm in) zs TEM STANDARD SERVICE LIMIT |" Starter anven gear TB: BANOO 34073 (7.8386 - 73503) 34.033 (1.3399) OD. z 51.705 — 51.78 (2.0356 - 2.0364) 57.605 (2.0948) CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS : fara Unit: mm (n) TEM ‘STANDARD SERVICE LIMIT Crankshaft | Runout eae = 0.03 (0.001) Connecting rod big end radialGlearance | 0.008 — 0,076 (0,0002- 0.0006) 0.05 (0.002) “Connecting rod big end sie clearance — 0.05 ~ 0.50 (0,002 - 0.020) 0.85 (0.033) Main journal oft clearance (0.018 - 0.045 (0.0007 ~ 0.0018) 0.978 (0.0030) Main journal 0. 33.985 ~ 34,000 (1.3380 ~ 1.3386) 33.975 (1.3876) ‘ain journal Beating ares 1. 38.000 - 38.098 (7.4961 ~ 7.4968) 38.036 (1.4975) Transmission | Gear |. 23,000 = 23.021 (0.9055 - 0.9083) 23.07 (0.006) 3.020 23,041 (0.9063 - 0.9071) 23,09 (0.908) 25.000 — 25.021 (0.9843 — 0.9851) 25.04 (0.986) 28,000 = 28.021 (7.1024 1.1082) 28.04 (1.104) Bushing O-D- 22.959 - 22.980 (0.9039 = 0.9047) 22:51 (0.902) 22.984 ~ 23,005 (0.9040 = 0.9087) 22.47 (0.885) 24,959 ~ 24,980 (0.9820 ~ 0.9835) 24.90 (0,980) 27.959 — 27.980 (1.1007 1.1016) 27.95 (1.100) ieee 0.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) 0.015 ~ 0.057 (0.0006 - 0.0022) 0.100.008) Bushing LD. MB, C1 20,000 = 20,021 (0.7874 = 0.7882) 20.08 (0.780) 2,000 ~ 22.024 (0.8681 = 0.8670) 22.07 (0.888) income 25,000 — 25.021 (0.9843 — 0.9851) 25.04 (0.986) Mainshatt/ atMS bushing 19.959 — 19.980 (0.7858 - 0.7866) 49.91 (0.784) countershaftO.D. at Ci bushing 19.959 = 19,980 (0.7858 - 0.7868) 19.91 (0.784) atG2bushing | 21.959 21.980 (0.8645 — 0.8653) 24.94 (0.863) at G3 bushing | 24.959 ~ 24 980 (0.9626 — 0.9635) 24.90 (0.980). Bushinge-shatt ys, c1,c2,C2 | 0,020—-0.082 (0.0008 - 0.0024) 0.10 (0.004) Shift fork Shit fork shaft O.. es 11.957 — 11.968 (04707 = 0.4712) 41.95 (0.470) shit fork Shit for 1. = ~ | 12.000 12.018 (0.4724 - 0.4731) 72,05 (0.474) shaft | Shift ork claw thigkness 4.98 — 5.00 (0.194 — 0.197) 4.82 (0.190) Shitéum | Shitdumoo. — Leftsde 13,066 ~ 13.984 (015496 — 0.5506) 73,94 (0.549) Shik comm Jouenal il afierade 14,000 14.027 (0.8512 - 0.5622) 14.06 (0.554) 7 Shittdumo-shit Blea i ‘rum journal Left side 0.016 ~ 0.061 (0.0006 - 0.0024) 0.08 (0.003) slearance 1-9 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Wheel rim runout | Wheel balancer weight aa Fork ‘Spring free length Pipe runout STANDARD Pa (2,00 ken, 29 psi) 200 KPa (2.00 Kalle, 29 psi) “| a37.8 664) Recommended fork aid | Fluid capacity ‘Sleeting head bearing preoad_ REAR WHEEL/SUSPENSION SP! Minimum tire thread depth Cold tire pressure Radial ‘Axial ‘Sizelink [Sisk fS EM Front | Specified brake fd = arpage es Master cylinder 1D. | CBRA5OR __caR250R4 ‘Master piston 0.D. 3R250R, ____|-CBRZs0RA (Caliper cyinder'.D.(CBR250R) CalpercyinderD. | Calipor GyinderA (CBR250RA) | Caliper cylinder B Caliper piston 0.0. (CBR250R) Caliperiston 0.0. | Caliper piston A ef pision B Rear Brake pad w Brake disc thickness. | [Caliper piston O: Brake pedal hel Pro Honda Suspension Fluid S 15063) _ 331 22.5 cn" (11.2 £0.08 US 07, 11.7 + 0.09 Imp oz) L157 = 24.5N(1.6-25kgf, 35-551) | ECIFICATIONS rANDAR! 20 KPa (2.00 Khem 29 psi) 225 KPa (2 DIDS20VF-108LE RKS20KLO-108LE 20 | DoT SerD0T 3-47 (017-01 47,000 17,043 (0.4331 = 42,700 — 12.743 (0.5000 = 12.857 - 12.68 25.400 ~ 25.450 (7.0000 “72.585 = 20.518 (0.8602 =0.5 (1.0508 = 7.0817) 38.18 - 38.23 (1.503 — 1.505) 36,096 28.148 (1.4900 — 1.5 55-8 (TON) aliem! 33s) STANDARD “40,957 = 10.964 (0.4314 - 0.4924) (0.4963 -0.4994) Unit: mm (in) iT SERVICE LI 1.5 (0.06), 0210.01) 2,0 (0.08) 2.00.08) 6Ogmex. (0:20 (0.008) “Unit: mm (in) SERVICE LIMIT 2.0 (0.08) 02 (001) 2.0 (0.108) 2.00.08) 609 mex | Unit: mm (in) ICE LIMIT | jo gtoove (35 @14) 03(0001) 47.055 (0.4963) 42.7585 (0.5022) 40.945 (0.4309) 412.645 (0.4978) — ‘8) 017) Ta groove 4.0 (0:16) 0:3 (0.01) z 141085 (05533) 43.948 (0.5490) — 36.28 (1.506) 38.00 (1.500) ITEM Battery Type. ‘Capacity ‘Current leakage Vottage (20°C/ 68°F) Needs Charging current ‘Riternator | Capacity Charging col resistanes (20-Ci6s°F) GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS SPECIFICATION YDXTL-BS 12V-6 Ah 0.34 mA max 730-182 Below 123 CAB 70h SNth 0138 kW, 000 em o1=190 IGNITION SYSTEM SPECIFICATIONS ITEM Spark plug ‘Spark plug gap ~ Ignition coil peak voltage (CKP sensor peak voltage Tonitfon timing °F" mark) _SPECIFICAT ‘SIMRBAQ (NGK) {0.80 =0.90 mm (0.031 - 0.036 in} 100V minimum 0.7V minimum 40°BTDC atidle ELECTRIC STARTER SPECIFICATION x Tem Siarfer motor brush length TEM Bulbs Headlight Poston ight ‘Brakertal ight Tum signal ignt Tur signal indicator High beam indicator Neutal indicator MIL ‘ABS indicator (CBR250RA) Fuse Main fuse ‘Sub fuse (CBR250R (CBR250RA LIGHTS/METERS/SWITCHES SPECIFICATIONS ‘SPECIFICATION 12.V- 60155 W 12V-5Wx2 42V-2165W T2V-21Wx4 12V-5W LeD eo LED. 2V-17W LED ze LED 30A HOAx5 BOAx2, 10Ax6 3 Unit: mm (in) STANDARD ‘SERVICE LIMIT 118 - 12.3(0.46-0.48) 65 (0.26) 1-11 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES z TORQUE _ FASTENER TYPE Nm (kgm, Ibe) bolt and nut 52 (0.5, 38) 6 mm bolt and nut 10 (1.0, 7) {Incudes SH flange bot) 8 mmbolt and nut 2222, 18) 40mm bolt and nut 24 (35,25), 42mm bolt and nut 54(55, 40) ENGINE & FRAME TORQUE VALUES + Torque specifications listed below are for important fasteners. + Others should be tightened to standard torque values listed above FRAME/BODY PANELSIEXHAUST SYSTEM THREAD TORQUE FASTENER TYPE ecatre “Simm screw 42 (04, 3.1) 6 mmscrow 9.0(0.9, 66) ‘6 mm flange bolt (8 mm head, large flange) and nut 12.(1.2.9) 8 mm flange bolt and nut 27 (28, 20) 410mm flange bolt and nut 39 (4.0, 29) TORQUE Tem prt oe elena a REMARKS Rearview mirror mounting socket bolt 4 o 52 (05,38) Feta | Front turn signal light mounting nut 2 10 24 (24, 15) Headlight mounting serow 6 5 4.40.08) Front side reflector stay mounting nut 2 6 4500211) | Uut Brakettal ight mounting sre 4 5 4.1(01,08) Side reflector mounting nut 4 6 15(0211) | Unt Reflector mounting nit 1 5 4502.41) | Urut Muffler band bolt 1 3 225(@3,17) Exhaust pipe joint nt 2 8 18.1.8, 13) Exhaust pipe stud bot zd bE Be = _| see page 222 MAINTENANCE THREAD TORQUE [ TEM aren eany Re REMARKS ‘Spark plug Te 10 16 (1.6, 12) a. Crankshaft hole cap 1 30 80(08.59) Apply enginecilto the treacs Oil rain bot 1 2 24 (24,18) Throttle cable A adjuster lock nut (rip side) 1 7 38 (04,28) Throttle cable A adjuster lock nut (throttle ody see) 1 6 003,22) Air cleaner cover screw 10 5 4.4 (01,08) Drive chain adjuster lock nut 2 8 21 (24, 16) Sicostand pivot bolt 1 10 10(1.0.7) Sidestand pivet lock nut ase -90(34.22) | nut FUEL SYSTEM (PGW-Fi) sy | THREAD TORQUE Trem Ses are Te ayant me) _ REMARKS ~O: sensor 1 25 (2.5, 18) = Insulator band screw z 42(04,31) | Seepage 5-49 Tarot cabo stay serew 2 34 (03,25) Camper stay screw 1 34 (0.3.25) IACV setting plate tore screw z 2.4 (02,1.) ‘Sensor uni ore sere 3 34 (03,25) Fuel injector joint mounting belt 2 541 (05.38) ECT sensor 1 25 (26, 18) Fuol pump seting plato rut 6 12(12,9) Seepage 5-42 Throte cable Ajoin nut (grip side) =| 46(02,1.1) Throtte cable B joint nut (rip side) 1 4§(02,4.1) Throtle cable B (throttle body side) 4 30 (03.2.2) Bank angle sensor mounting ut 2 40(1.0.7) 4.12 GENERAL INFORMATION COOLING SYSTEM iTem Water pump impeller Water hose band screw Fan motor shroud mounting bott Fan molor screw Cooling fan nut ENGINE REMOVALJINSTALLATION rem Front engine mounting nut Front engine hanger plate bolt Rear engine mounting nut Drive sprocket fixing plate bolt CYLINDER HEADIVALVES Tem Gylinder head cover bolt ‘Camshaft holder mounting bolt (Cylinder head mounting nut PAIR check valve cover bolt Cam chain tonsioner liter plug CYLINDERIPISTON “TEM Cynder stud Bot fi CLUTCHIGEARSHIFT LINKAGE = TEM ‘Gluten center lock nut Primary drive gear lock nut ‘Shift drum stopper arm bolt ‘Shift drum stopper plate bolt Clutch liter plate bolt Gearshift spindle return spring pin ALTERNATORISTARTER CLUTCH rem lutch socket bolt Siai Flywheel bolt ‘Stator mounting socket bolt ‘CKP sensor mounting socket bolt THREAD DIA. (men) 7 THREAD DIA. (mm) 70 10 10 THREAD DIA. (mm) 6 6 0 THREAD DIA. (mm) 10 "THREAD |_DIA. (mm) 6 6 THREAD DIA. (mm) 8 2 TORQUE Nem (kgm, bf-) 40(1.0, 7) 85 (09,63) 2.8 (0.3, 2.1) 1.4 (0-1, 0.8) TORQUE _Nim (kgm, Ibf) 45 (4.6, 33) 45 (4.6, 33) 45 (4.8, 33) 40(1.0, 7) TORQUE Nem (kgm, br) 40(1.0, 7) 12 (12,9) 51 (62, 38) 52 (05,38) 42 (04,31) TORQUE Nem (kgm, Ib) TORQUE Nem (kgm, IbF-A) 108 (11.0, 80) 108 (11.0, 80) 40(1.0,7) 10 (1.0, 7) 12(1.2, 9) 30 (3-1, 22) TORQUE Nem (kgf, tb) 30 (3-1, 22) 128 (13.0, 94) 10(1.0, 7), 10 (1.0, 7) REMARKS See page 6-10 Apply locking agent to the threads, REMARKS REMARKS Apply engine oiltothe threads ‘and seating surtace. Apply engine olltothe threads ‘and seating surface. REMARKS ‘See page S86 REMARKS Lock nut: replace with a new fone and stake. Apply engine olltothe threads and seating surface, Apply engine oiltothe threads ‘and seating surface. Apply locking agent to the threads. Apply lacking agent to the threads. Apply lacking agent to the threads. REMARKS ‘Apply locking agent to the threads. Apply engine oil tothe threads ‘and seating surface. ‘Apply locking agent to the threads. Coating width: 6.5 + 1.0 mm (0.28 = 0.04 in) from tip 1-13 GENERAL INFORMATION ‘CRANKCASEICRANKSHAFT/TRANSMISSIONIBALANCER. | THREAD Tem [aT | oan fom) ‘Cam chaln tensioner pvat bolt 7 é Balancer shat nut 1 4 FRONT WHEELSUSPENSIONISTEERING ace | ary | THREAD j rem eral arte) Handlebar pinch bolt 2 8 Handlebar switch housing screw 4 5 Front axle nut 1 12 Front axle pinch bolt 1 8 Front pulser ring mounting bolt 3 5 (CBR250RA) Front brake disc bolt 6 6 Fork bot 2 3 Fork socket bot 2 8 Steering stem nut 1 4 Steering stem adjusting nut 1 26 |Top bridge pinch boit 2 8 Bottom bridge pinch bolt 2 10 Front brake hose slay bolt 4 6 Brake hose mounting bolt (CBR2SORA) | 1 8 Clutch lever pivot bolt 1 6 Clutch lever pivot nut z iat 6 REAR WHEELISUSPENSION = ay THREAD | cs Tew ory linear od ees ‘8 Driven sprocket nut 6 10 Rear pulser ring mounting bolt 4 5 | (cBR250RA) Reser brake disc bolt 4 8 | Shock absorber mounting nut 2 10 Shock aera nut 1 10 Shock ink nut 2 10 Swingarm pivot rut 1 14 Rear brake hose guide mounting screw | 1 5 1-14 TORQUE 44 (45,92) threads. Coating width: 6.54 1.0mm | (0.28 = 0.04 in) from tip | Apply engine olto the threads ‘and seating surface. TORQUE 59 (6.0, 44) 22 (22, 16) 7.0 (07,52) 20 (2.0, 15) 22.22, 16) 20 (2.0, 15) 103 (10.5, 76) 2222, 16) 32(8.3, 24) 121.2, 9) 10(1.0,7) 1.0 (0.1,0.7) TORQUE ‘Nim (kam, bf) 88 (9.0, 65) 75(76, 55) 70(07.52) 42 (43,31) 36 7.27) 75(7.6.58), 757.6, 58) 88 8.0, 65) 430-1, 1.0) REMARKS U-nut ALOC bolt; replace with anew ‘ALOC bolt; replace with anew Apply locking agent to the threads. Apply engine ol to the threads. See page 13-33 ‘Apply locking agent to the threads. ‘Apply molybdenum disulfide ‘grease tothe sliding surface. REMARKS. Una Usnut ‘ALOCbot replace with anew ALOC bot replace witha now U-nut U-nut Umut Usnut ALOC screw; replace with a GENERAL INFORMATION HYDRAULIC BRAKE mem ary ~ Brake hose oil bolt (CBR250R) Brake hose oil bolt (CBR250RA) Brake caliper bleed valve (CBR250R) Brake caliper bleed valve (CBR250RA) Front master cylinder reservoir cover screw Front master cylinder holder bolt Front brake light switch screw Brake lever pivot bolt Brake lever pivot nut Front brake caliper mounting bott 2 Front brake caliper bracket pin 7 Front brake caliper pin 1 Front brake pad hanger pin 1 Pad pin plug (CBR250R) 1 Rear reservoir cover screw Rear master cylinder mounting bolt 2 Rear master cylinder push rod lock nut 1 Rear master cylinder hose joint screw 1 Rear reservoir mounting bolt fl Rear brake pad hanger pin 1 Rear brake caliper pin 1 Main stop holder mounting socket bolt | 4 Main step cap bolt 2 Passenger step holder mounting socket 4 bolt ANTI-LOCK BRAKE SYSTEM (ABS) (CBR250RA) Tew ary (Brake pipe ont nat 44 PCV mounting bot 2 Delay valve mounting bok A IGNITION SYSTEM Tem ary | ining oe cap + ELECTRIC STARTER Tew ary Ngative brush sorew aa Starter motor assembly bolt 2 LIGHTSIMETERSISWITCHES ITEM ee tan Rear turn signal ight mounting nut 2 Igntion switen mounting bolt 2 Combination meter mounting sew 3 Neutral swtcn 4 THREAD ORQUE DIA, (mm) Nem (kgm, IDFR) REMAN) es 34 (35, 28) 40 34 (35,26) 8 54 (08,40) 8 54 (06,40) 4 1902.11) | 6 4212.9) 4 42(0.1.09) 6 10 (01,07) | Apply 0.10.9 (0.004 oz) Slicone grease to the slicing surface. 6 59 (08.44) 8 30 (3.1.22) | ALOC bolt replace with anew 8 43(13,10) Apply locking agent to the threads 8 22(22,16) __Aoply locking agent to the throace 10 48 (1.6, 19) 40 24 (02. 18) 4 1.5(02, 1.4) 6 12(42.9) 8 A717, 13) 4 15(02\11) Apply locking agent tothe threads 6 10(40,7) ‘o 4701.7.13) 2 27 (28, 20) 8 27 (28, 20) 8 41 (1.4.8) 3 27 (28,20) THREAD TORQUE | DIA. (wm) | Nmi(gtm, ibe) | __ REMARKS 10 14 (14.10) Apply brake fui othe threads. 40 (1.0.7) 40(1.0.7) TORQUE “DIA (mm) Nm (kgm, en) | —_REMARKS ‘4 30(06.44) | Anplyengine oto the tyeeds THREAD TORQUE DIA. (mm) Nem (kgm, nem) REMARKS 3 37 (04,27) 5 | 490836) THREAD TORQUE DIA. (mm) __ Nm (kgm, Ib) eS 40 2 (fats 8 24(24,18) | One-way bolt replace with a new one 5 44(04,08) 10 1212.9) GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE = LOCATION REMARKS Left crankcase mating surface ‘See page 12-25 12078, 1215 or equivalent) | Alternator/CKP sensor wire grommet sealing surface Scoee Liquid sealant (Three bond | Cylinder head semi-circular cut-out 5211C, SS KE45, 12078, | 1218 or equivalent) Engine oil (il pump rotor entre surface il pump shaft outer surface Water pump shaft outer surface Cam chain whole surface Cylinder inner surface Piston pin hole inner surface, ring groove and sliding surface Piston ring entire surface Clutch dise entre surface Gearshift spindle shaft outer surface Starter one-way clutch sprag Starter driven gear sliding surface Each ol seal lips Each bearing rotating area Each gear teeth Each O-ring pod vi a set % Mul-purpose grease Each ol seal lips (clutch lifer arm, gearshift spindle, [pases countershaft, water pump) Molybdenum oll solution (a | Valve stem sliding surface mixture of 1/2 engine oll and | Camshaft lobes and journal 112 melyodenum disulfide Rocker arm shaft outer surface ‘rease) Rocker arm inner surface, roller surface and slipper surface Piston pin outer surface Clutch outer guide inner surface Gutch iter arm sliding surface Starter reduction gear inner surface Starter reduction gear shaft outer surface Crankshaft main journal bearing siding surface Connecting rod big end slicing surface Connecting rod small end inner surface Left crankshaft needle bearing rotating surface Balancer driven gear and sub gear siding surface ‘Shift fork inner surface and guide pin Shift fork shat outer surface Shift crum journal outer surface and grooves M5, C1, C2, C3 goar bushing entire surace | M6, G4 gear bushing outer surface Ja. seem /Ceosking agent Mainsheft Bearing setting plate bot reads | Coating wares = LOmm = | (0250.04 in) from tip 1-16 GENERAL INFORMATION Urea based mult-purpose ‘grease with extreme pressure (example: Kyodo Yushi, Shell stamina EP2 or equivalent) Mull-purpose grease Silicone grease DOTS or DOT 4 brake Mid LOCATION Steering head bearing inner race and outer race rolling surface Steering head bearing dust seal lips Fale outer surface ‘Swingarm pivot needle bearing rotating area ‘Swingarm pivot bolt outer surfaco Shock linkage needle bearing rotating area Passenger seat catch hook sliding area Main step pivot pin siding surface Sidestand pivot sliding surface Gearshift tie ro sliding surface Gearshift pedal pivot sliding surface Throttle pipe flange cable groove Right handlebar switch housing sliding area Brake pedal pivot siding area Each dust seal ips Each O-ring Brake pad hanger pin O-ring Brake calipor and bracket pins sliding surface Brake caliper dust seal whole surface Brake lever contacting area (master piston) Rear master cylinder push rod contacting area (master cylinder piston and boot) Brake master piston siding area Rear master cylinder hose joint O-ring Brake caliper piston sliding area and piston seal REMARKS 3.05.0 g (0.11~—0.18 02) (04 g (0.01 02) minimum 0.10 g (0.004 oz) 0.40 g (0.004 o2) (Cable lubricant Fork fluid Honda Bond A or equivalent _ Brake pad retainer mating surface Throttle cable casing inside Fork bolt O-ring Fork ol seal ips Lefthandlebar and throlle pipe outer surface ( ‘contacting area) Air cleaner connecting boot matching surface 1-17 GENERAL INFORMATION CABLE & HARNESS ROUTING (CBR250R: COMBINATION METER 20P CONNECTOR FRONT BRAKE HOSE JUNCTION RIGHT HANDLEBAR | 12? CONNECTOR SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE ‘TURN SIGNAL POSITION RELAY {9P (BLACK) CONNECTOR FRONT SUB HARNESS 9 (BLACK) CONNECTOR BANK ANGLE SENSOR 3P CONNECTOR || FRONT BRAKE HOSE 1-18 ‘CBR250RA: RIGHT HANDLEBAR SWITCH WIRE re FRONT BRAKE LIGHT SWITCH WIRE THROTTLE CABLES FRONT SUB HARNESS: 9 (BLACK) CONNECTOR BANK ANGLE SENSOR 3P CONNECTOR, FRONT BRAKE HOSE JUNCTION 12P CONNECTOR GENERAL INFORMATION COMBINATION METER, 20P CONNECTOR | BRS CLUTCH SWITCH WIRE ‘CLUTCH CABLE ! LEFT HANDLEBAR ©) SWITCH WIRE ee IN | Ire scualiros hn retny ae — ah | | FRONT BRAKE HOSES FRONT WHEEL SPEED SENSOR WIRE 1-19 GENERAL INFORMATION FRONT SUB HARNESS. POSITION LIGHT WIRE ‘9P (BLACK) CONNECTOR FRONT SUB HARNESS, POSITION LIGHT WIRE HEADLIGHT 3P CONNECTOR LEFT TURN SIGNAL LIGHT RIGHT TURN SIGNAL LIGHT WIRE CONNECTORS WIRE CONNECTORS GENERAL INFORMATION FRONT SUB HARNESS. FRONT SUS HARNESS: TURN SIGNAL LIGHT WIRE | = ~ TURN SieNaL Licht WIRE FRONT SUB HARNESS. 1-21 GENERAL INFORMATION ‘CBR250R: FRONT BRAKE HOSE THROTTLE CABLES THROTTLE CABLES 1-22 ‘CBR250RA: GENERAL INFORMATION FRONT BRAKE HOSE THROTTLE CABLES aN <\ aN \\ i FRONT BRAKE HOSE vi \ \ : \ \ FRONT WHEEL ‘SPEED SENSOR WIRE FRONT BRAKE HOSES. FRONT WHEEL SPEED SENSOR WIRE 1-23 GENERAL INFORMATION (CBRZ50R: MAIN WIRE HARNESS. CLUTCH CABLE CLUTCH SWITCH WIRE {S_ LEFTHANDLEBAR 77 SNITCHWIRE TURN SIGNAL POSITION RELAY 9 (BLACK) CONNECTOR FUEL PUMP RELAY FAN CONTROL RELAY MAIN WIRE HARNESS FRONT BRAKE HOSE GENERAL INFORMATION ‘CBR250RA: MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE CLUTCH SWITCH WIRE MAIN WIRE HARNESS ‘TURN SIGNAL POSITION RELAY FAN CONTROL RELAY 9P (BLACK) CONNECTOR ROE Pae7 NN 7 FRONT WHEEL /, SPEED SENSOR WIRE ee FRONT WHEEL ‘SPEED SENSOR WIRE 1-25 GENERAL INFORMATION ‘THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE FUEL TANK DRAIN HOSE EVAP PURGE CONTROL SOLENOID VALVE One cat 2P CONNECTOR if yp K JZ. we DAZX RIGHT HANDLEBAR SBP\ swarcriwne at CLUTCH CABLE SIPHON HOSE AIR INLET HOSE WATER HOSE ELT (THER HOSE. ECM 39P (BLACK) CONNECTOR Ga ose VACUUM HOSE ECT SENSOR SP CONNECTOR CANISTER to-EVAP PURGE CONTROL, SOLENOID VALVE HOSE 1-26 GENERAL INFORMATION ——— RAL INFORMATION. (CBR250R: LEFT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR IGNITION swiTcH SP CONNECTOR RIGHT HANDLEBAR SWITCH 9P (GROWN) CONNECTOR © SENSOR 1P CONNECTOR LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR MAIN WIRE HARNESS FUEL TANK DRAIN HOSE 2 SENSOR Wi 0: SENSOR WIRE FAN MOTOR 2P (BLACK) CONNECTOR HORN CONNECTORS: 1-27 GENERAL INFORMATION ‘CBR250RA: LEFT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR IGNITION SWITCH SEOONNECTOR RIGHT HANDLEBAR SWITCH 9P (GROWN) CONNECTOR (02 SENSOR LEFT HANDLEBAR SWITCH 1P CONNECTOR 2P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR, FUEL TANK DRAIN HOSE MAIN WIRE HARNESS: FAN MOTOR. (Os SENSOR WIRE 2P (BLACK) CONNECTOR FRONT WHEEL SPEED Se HORN CONNECTORS FRONT WHEEL SPEED SENSOR 2 (BLUE) CONNECTOR 1-28 GENERAL INFORMATION (CBRZ50R: EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR BATTERY NEGATIVE (-) CABLE IAGV 4P (BLACK) CONNECTOR. ECM 33P (BLACK) CONNECTOR y : REAR BRAKE LIGHT SWITCH WIRE SIPHON HOSE CLUTCH CABLE 1-29 GENERAL INFORMATION (CBR250RA: FRONT BRAKE PIPE A FRONT BRAKE PIPE SIPHON HOSE FRONT BRAKE PIPE B. Scan weer EVAP PURGE CONTROL SOLENOID VALVE 2P (ORANGE) CONNECTOR: SP CONNECTOR ant _—— IACV 4P (BLACK) CONNECTOR 4 ge = WAY SNA BATTERY NEGATIVE (-) CABLE SIPHON HOSE REAR BRAKE LIGHT ‘SWITCH WIRE CLUTCH CABLE FRONT BRAKE PIPE C ECM 33P (BLACK) CONNECTOR (ABS MODULATOR to DELAY VALVE} FRONT BRAKE PIPE B (ABS MODULATOR to FRONT BRAKE CALIPER) FRONT BRAKE PIPE A, (ABS MODULATOR to FRONT MASTER CYLINDER) 1-30 GENERAL INFORMATION ‘CBR250R: BATTERY NEGATIVE (-) CABLE FUSE BOX STARTER RELAY SWITCH BATTERY POSITIVE (+) CABLE REGULATORIRECTIFIER '5P CONNECTOR MAIN WIRE HARNESS GROUND TERMINALS 1-31 GENERAL INFORMATION ‘CBR250RA: ABS FUSE BOX BATTERY NEGATIVE (-) CABLE ‘ABS 1P CONNECTOR BATTERY POSITIVE (+) CABLE REGULATORIRECTIFIER 5P CONNECTOR ABS SERVICE CHECK 3P CONNECTOR ‘GROUND TERMINALS [STARTER RELAY SWITCH MAIN WIRE HARNESS 1-32 GENERAL INFORMATION (CRANKCASE BREATHER HOSE AIR CLEANER HOUSING DRAIN HOSE VS) OZ ete My) 2 SIDESTAND SWITCH WIRE NEUTRAL SWITCH WIRE RESERVE TANK OVERFLOW HOSE EVAP CANISTER DRAIN HOSE FUEL TANK DRAIN HOSE 1-33 GENERAL INFORMATION (CBRZ50R: CLUTCH CABLE LEFT HANDLEBAR SWITCH - IGNITION COIL PRIMARY WIRE 9P (BLACK) CONNECTOR LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR IGNITION SwiTCH SP CONNECTOR FUEL TANK DRAIN HOSE FUEL PUMP 5P CONNECTOR MAIN WIRE HARNESS ¢ EVAP PURGE CONTROL SOLENOID VALVE PAIR CONTROL SOLENOID VALVE 2 (BLACK) CONNECTOR EIR FUEL INJECTOR 2P (GRAY) CONNECTOR 1-34 GENERAL INFORMATION ‘CBR250RA: CLUTCH CABLE LEFT HANDLEBAR SWITCH IGNITION COIL PRIMARY WIRE ‘9P (BLACK) CONNECTOR / LEFT HANDLEBAR SWITCH 2P (BLACK) CONNECTOR IGNITION SWITCH aP CONNECTOR RIGHT HANDLEBAR SWITCH 9P (BROWN) CONNECTOR FUEL TANK DRAIN HOSE FUEL POMP 5P CONNECTOR SPARK PLUG WIRE MAIN WIRE HARNESS EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR FUEL INJECTOR 2P (GRAY) CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR 1-35 GENERAL INFORMATION FUEL PUMP HOSE B. FUEL FEED HOSE FN oe 5P CONNECTOR 1-36 GENERAL INFORMATION (CBR250R: FUEL FEED HOSE INSIDE BOOT CONNECTORS: “ALTERNATOR 3P CONNECTOR = CKP SENSOR/NEUTRAL SWITCH 6P CONNECTOR. VS SENSOR 3P CONNECTOR = SIDESTAND SWITCH 3 (GREEN) CONNECTOR FUEL INJECTOR 2P (GRAY) CONNECTOR IACV 4P (BLACK) CONNECTOR, | SENSOR UNIT | 5P CONNECTOR ECT SENSOR SP CONNECTOR STARTER MOTOR CABLE GROUND CABLE FUELTANKDRAN |(" 7 | Vs SENSOR WIRE HOSE (CRANKCASE BREATHER HOSE 1-37 GENERAL INFORMATION CBR250RA; FUEL FEED HOSE FUEL INJECTOR INSIDE BOOT CONNECTORS: Bo eee o NET aE = ALTERNATOR 3? CONNECTOR — CKP SENSORINEUTRAL SWITCH 6P CONNECTOR: lacy ~VS SENSOR $P CONNECTOR 4P (BLACK) CONNECTOR = SIDESTAND SWITCH 3P (GREEN) CONNECTOR SIDESTAND SWITCH 3P (GREEN) Ea ontnn 5P CONNECTOR, iH e I ; s) FUEL TANK DRAIN Hose oD eo Ne a ECT SENSOR 3P CONNECTOR \\|| “| starter motor CARE AK ¥ [\ GROUND CABLE CRANKCASE BREATHER HOSE 1-38 GENERAL INFORMATION IACV 4P (BLACK) CONNECTOR PAIR CONTROL SOLENOID VALVE EVAP PURGE CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR 2P CONNECTOR ‘THROTTLE CABLES SECONDARY AIR SUPPLY HOSE FUEL INJECTOR 2P (GRAY) CONNECTOR: FUEL FEED HOSE 1-39 GENERAL INFORMATION EVAP CANISTER DRAIN HOSE SIDESTAND SWITCH WIRE AIR CLEANER HOUSING DRAIN HOSE. FUEL TANK DRAIN HOSE SIPHON HOSE RESERVE TANK OVERFLOW HOSE 1-40 GENERAL INFORMATION FUEL TANK BREATHER HOSE VACUUM HOSE PAIR CONTROL SOLENOID VALVE AIR INLET HOSE SECONDARY AIR, SUPPLY HOSES EVAP PURGE CONTROL SOLENOID VALVE CANISTER to-EVAP PURGE CONTROL ‘SOLENOID VALVE HOSE, AIR CLEANER HOUSING. EVAP CANISTER DRAIN HOSE AIR CLEANER DRAIN PLUG EVAP CANISTER DRAIN HOSE (CRANKCASE BREATHER HOSE 1-41 GENERAL INFORMATION CBR250RA: REAR WHEEL SPEED SENSOR WIRE REAR BRAKE PIPE B (0 REAR MASTER CYLINDER) FRONT BRAKE PIPE B (io FRONT BRAKE CALIPER) ‘ABS MODULATOR 25P GONNEGTOR FRONT BRAKE PIPE C (i DELAY VALVE) REAR WHEEL SPEED SENSOR WIRE EAR BRAKE PIPE C. ((o REAR CALIPER) REAR BRAKE PIPE A. (o PCV) 1-42 GENERAL INFORMATION (CBR250RA: FRONT BRAKE PIPE D DELAY VALVE FRONT BRAKE PIPE C FRONT BRAKE PIPE A FRONT BRAKE PIPE C FRONT BRAKE PIPE B. FRONT BRAKE PIPED 1-43 GENERAL INFORMATION ‘CBR250R: INSIDE BOOT CONNECTORS: =DLC —BRAKE/TAIL LIGHT 2P CONNECTOR “REAR TURN SIGNAL LIGHT CONNECTORS “LICENSE LIGHT CONNECTORS, BATTERY NEGATIVE (-) CABLE MAIN WIRE HARNESS FUSE BOX BATTERY POSITIVE (+) CABLE 1-44 GENERAL INFORMATION ‘CBR250RA: INSIDE BOOT CONNECTORS: =DLC —BRAE/TAIL LIGHT 2P CONNECTOR “REAR TURN SIGNAL LIGHT CONNECTORS: “LICENSE LIGHT CONNECTORS: p~ ABS FUSE BOX C MAIN WIRE HARNESS FUSE BOX BATTERY NEGATIVE (-) CABLE BATTERY POSITIVE (+) CABLE ABS SERVICE CHECK 3P CONNECTOR: 1-45 GENERAL INFORMATION ‘CBR250R: REAR BRAKE LIGHT _ SWITCH WIRE REAR BRAKE HOSE CBR250RA: REAR BRAKE LIGHT SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE 1-46 GENERAL INFORMATION EMISSION CONTROL SYSTEMS EXHAUST EMISSION REQUIREMENT ‘The U.S. Environmental Protection Agency (EPA), Califomia Air Resources Board (CARB) and Transport Canada require ‘manufacturers to certity that their motorcycles compiy with applicable exhaust emissions standards during their useful life, when ‘operated and maintained according tothe instructions provided. NOISE EMISSION REQUIREMENT ‘The EPA also requires that motoreyeles built after January 1, 1983 comply with applicable noise emission standards for one year or £3,730 miles (6,000 km) efter the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. WARRANTY COMPLIANCE ‘Compliance with the terms of the Distributors Limited Warranty for Honda Motoreycle Emission Control Systems is necessary in Corder to keep the emissions system warranty in effect. SOURCE OF EMISSIONS ‘The combustion process produces carbon monaxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Fuel evaporation produces hydrocarson emissions, The control of hydrocarbons and oxides of nitrogen is very important because, under certain ‘conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but tis tox Honda Motor Co., Ltd utlizes various systems (page 1-48) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM “The engine is equipped with 2 closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Biow-by gas is returned to the combustion chamber through the air cleaner housing ané throttle body. AIR CLEANER HOUSING THROTTLE BODY

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