Caja PDF

Comparta fácilmente sus documentos PDF con sus contactos, la web y las redes sociales.

Compartir un archivo PDF Gestor de archivos Caja de instrumento Buscar Ayuda Contáctenos



Honda VT 250 F,FII Service Manual ENG .pdf



Nombre del archivo original: Honda VT 250 F,FII Service Manual ENG.pdf
Título: Honda VT250 F,FII Service Manual ENG
Autor: Mosue

Este documento en formato PDF 1.6 fue generado por Adobe Acrobat 7.0 / Adobe Acrobat 7.0 Image Conversion Plug-in, y fue enviado en caja-pdf.es el 17/04/2012 a las 05:35, desde la dirección IP 201.246.x.x. La página de descarga de documentos ha sido vista 16544 veces.
Tamaño del archivo: 29.4 MB (307 páginas).
Privacidad: archivo público




Descargar el documento PDF









Vista previa del documento


HONDA
VT25OF

CONTENTS
SECTION
GENERAL INFORMATION
LUBRICATION
MAINTENANCE
ENGINE
• FUEL SYSTEM
• ENGINE REMOVAL/INSTALLATION
• COOLING SYSTEM
• CLUTCH
• GEARSHIFT LINKAGE
• ALTERNATOR

1
2
3
4
5
6
7
8
9

•

CYLINDER HEAD/VALVE

10

•

CRANKCASE

11

•
•

CRANKSHAFT/PISTON
TRANSMISSION

12
13

CHASSIS
• FRONT WHEEL/SUSPENSION
• HYDRAULIC BRAKE
• REAR WHEEL/SUSPENSION/BRAKE
ELECTRICAL
• BATTERY/CHARGING SYSTEM
• IGNITION SYSTEM
• ELECTRIC STARTER
• SWITCHES
• WIRING DIAGRAM
TECHNICAL FEATURES
TROUBLESHOOTING
VT25O-F II ONLY

14
15
16
17
18
19
20
21
22
23
24

GENERAL INFORMATION

SPECIFICATIONS
DIMENSION
S

FRAME

ITEM
Overall length
Overall width
Overall height
Wheelbase
Seat height
Ground clearance
Dry weight
Curb weight

(79.8 in) 2027mm
(29.5 in) 750 mm
(46.3 in) 1176 mm
(54.5 in) 1385mm
780 mm (30.7 in)
160 mm (6.3 in)
149 kg (328.5 Lb)
162 kg (357 lb)

Type
Front suspension, travel
Rear suspension, travel
Front tire size
Rear tire size

Double cradle
Telescopic fork 140mm (5.5 in)
SwingarmlPro-link 100 mm (3.9 in)
100/90 - 16 54s
110/80 - 18 58s
Front
Rear

225 kPa (2.25 kg/cm2, 32 psi)
225 kPa (2.25 kg/cm2, 32 psi)

Driver
Front
and one
Rear
passenger
Front brake, lining swept area
Rear brake, lining swept area
Fuel capacity
Fuel reserve capacity
Caster angle
Trail
Front fork oil capacity
Type
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train

225 kPa (2.25 kg/em2, 32 psi)
280 kPa (280 kg/crn2,40 psi)

Cold tire
Pressures

ENGINE

Driver
only

Oil capacity
Cooling system capacity
Lubrication system
Air filtration
Cylinder compression
Intake valve
Opens
Closes
Exhaust valve
Opens
Closes
Valve clearance (Cold)
Engine weight
Idle speed

1-2

Disc brake, 24 cm2 (3.7 SI in)
Drum brake, 132 cm2 (20.5 sq in)
12 liter (3.1 US gal, 2.6 Imp gal)
2.5 liter (0.6 US gal, 0.5 Imp gal)
26°30’
91 mm (3.6 in)
265 ± 2.5 cm3 (16.2 ± 0.15 cu in)
Water-cooled 4-stroke DOHC engine
2 cylinders 900V
60.0 x 44.0mm (2.36 x 1.37 in)
248 cm (15.1 cu. in)
11:1
Silent, multi-link chain drive and OHC with
rocker arms
2.5 liter (2.6 US qt, 2.2 Imp qt) After
disassembly
1.4 liter (1.5 us qt, 1.2 Imp qt)
Forced pressure and wet sump
Paper element
1275±196 kPa (13±2 kg/cm2, 185±28 psi)
80 BTDC
420ABCD
430 BBDC
70ATDC
IN. 0.10mm (0.004 in)
EX. 0.15mm (0.006 in)
48kg (106 lb)
1300±100 min (rpm)

HONDA
VT25O
GENERAL INFORMATION

ITEM
CARBURATION

DRIVE TRAIN

ELECTRICAL

LIGHTS

Carburetor type
Identification number
Pilot screw initial
setting
Float level
Clutch
Transmission
Primary reduction
Final reduction
Gear ratio I
Gear ratio II
Gear ratio III
Gear ratio IV
Gear ratio V
Over drive
Gear shift pattern
Ignition
Ignition timing F mark
Full advance
Starting system
Alternator
Battery capacity
Spark plug
Standard
Cold climate (<5°c),
Extended high speed
Spark plug gap
Fuse/Main fuse
Headlight (high/low
beam)
Tail/stoplight
Front turn signal
Rear turn signal
Instruction lights
Neutral indicator
Turn signal indicator
High beam indicator
Position light

Vacuum piston valve type
VD6 x 2
2 turns out
6.8 mm (0.27 in)
Wet multi-plate
6-speed with over drive
2.821
3.214
2.562
1.850
1.478
1.240
1.074
0.965
Left foot operated return system 1-N-2-34-5-OD
Full transistor ignition
120 BTDC at 1300 min’ (rpm)
370 BTDC/3300 min’ (rpm)
Starter motor
AC. generator 12V 0.34 kw/5000 min
(rpm)
12V—14AH
NGK
NIPPEN DENSO
NGK DPR8EA-9 ND X24EPR-U9
NGK DPR7EA9
ND X22EPR-U9
NGK DPR9EA-9 ND X27EPR-U9
0.8—0.9 mm (0.031—0.035 in)
15A x 4/30A
12V 60/55W
21/5W
21W
21W
3W x3
3W
3W
3W
4W

GENERAL INFORMATION

TORQUE VALUES
ENGINE
Item
Oil pipe bolt
Oil drain bolt
Oil filter mounting bolt
Oil pressure switch
Engine mounting nut
A
B
Front exhaust pipe joint nut
Rear exhaust pipe clamp bolt
Muffler mounting bolt
Exhaust chanter mounting bolt
Muffler clamp bolt
Side frame mounting bolt
Cylinder head cover bolt
Can~ sprocket bolt
Rocker arm shaft bolt
Cylinder head mounting bolt
Camshaft holder mounting bolt
A
B
Upper crankcase bolt
Lower crankcase bolt
Crankshaft clamp bolt
Connecting rod cap nut
Starter clutch bolt
Clutch lock nut
Starter clutch cover
Flywheel bolt
CHASSIS
Item
Clutch oil hose bolt
Clutch lever pivot nut
Handlebar holder
Front axle shaft holder
Front axle shaft
Front fork socket bolt
Front fork bolt
Top bridge pinch bolt

1-4

Torque
Thread
Dia.(mm) N.m
10mm
20—25
35—45
15—20
15—20

kg-m
2.0—2.5
3.5—4.5
1.5—2.0
1.5—2.0

ft-lb
14—18
25—33
11—14
11—14

10mm
10mm
6mm
8mm
8mm
8 mm
8mm
8 mm
6mm
7mm
22 mm
8mm

35—45
45—60
8—14
10—28
18—28
12—16
18—28
35—45
8—12
18—20
45—55
30—34

3.5—4.5
4.5—6.0
0.8—1.4
18—2.8
18—2.8
1.2—1.6
1.8—2.8
3.5—4.5
0.8—1.2
1.8—2.0
4.5—5.5
3.0—3.4

25⎯33
33—43
8—10
13—20
13—20
9—12
13—20
26⎯33
6—9
13—14
33—40
22—25

8mm
8mm
6mm
8mm
6mm
8mm
8mm
8mm
10mm
20 mm
8mm

21—25
30—34
10—14
21—25
10—14
21—25
21—25
30—34
50—60
60—70
26—30

2.1—2.5
3.0—3.4
1.0—1.4
2.1—2.5
1.0—1.4
2.1—2.5
2.1—2.6
3.0—3.4
5.0—6.0
6.0—1.0
2.8—3.0

16—18
22—25
7—10
15—l8
7—10
15—18
15—18
22—25
36—43
43—51
19—22

10mm

50—60

5,0—6.0

36—43

Thread
Torque
N.m
Dia.(mm)
10mm
6 mm
8 mm
8 mm
14 mm
6mm
8mm
7mm

25—35

5⎯7
40—50
15—25
55—65
15—25
16—30
9—13

Remarks

Apply Locktite
271 to the thread

Apply Locktite
271 to the thread
UBS
UBS
UBS

UBS
UBS
Apply Locktite
271 to the thread
UBS
Remarks

kg-m
2.5—3.5
0.5—0.7
4.0—5.0
1.8—2.6
5.5—6.5
15—2.5
1.5—3.0
09— 1.3

ft-lb
18—25
4—5
29—36
11—18
40—47
11—18
11—22
7—9

HONDA

VT25O

GENERAL INFORMATION
Item
Bottom bridge pinch bolt
Steering stem nut
Rear shock absorber,
Upper
Lower
Swing arm pivot bolt,
Right
Left
Swing arm pivot locknut
Rear axle nut
Cushion arm,
Swing arm
Link arm
Cushion link
Broke arm bolt
Brake pedal bolt
Foot peg holder
Brake oil hose bolt
Brake pad pin bolt
Disc cover nut
Brake caliper pin
Upper
Lower
Coolant drain bolt side frame
Fuel tank mounting bolt
Air cleaner mounting bolt

Thread Dia.
(mm)
8mm
24mm

Torque
N.m
18⎯25
90⎯120

Kg-m
Ft-lb
1.8⎯2.5 13⎯18
9.0⎯12.0 65⎯87

10mm
10mm

50⎯60
50⎯60

5.0⎯6.0
5.0⎯6.0

36⎯43
36⎯43

25mm
25mm
25mm
16mm

14⎯18
80⎯110
80⎯110
70⎯100

1.4⎯1.8
8.0⎯11.0
8.0⎯11.0
7.0⎯10.0

11⎯13
58⎯80
58⎯80
51⎯72

10mm
10mm
10mm
6mm
6mm
8mm
10mm
6mm
6mm

60⎯70
60⎯70
60⎯70
8⎯12
8⎯12
18⎯28
25⎯35
15⎯20
8⎯12

6.0⎯7.0
6.0⎯7.0
6.0⎯7.0
0.8⎯1.2
0.8⎯1.2
1.8⎯2.8
2.5⎯3.5
1.5⎯2.0
0.8⎯1.2

43⎯51
43⎯51
43⎯51
6⎯9
6⎯9
13⎯20
18⎯25
11⎯14
6⎯9

8mm
8mm
6mm
8mm
6mm

20⎯25
15⎯20
7⎯8
20⎯24
6⎯10

2.0⎯2.5
1.5⎯2.0
0.7⎯0.8
2.0⎯2.4
0.6⎯1.0

14⎯18
11⎯14
5⎯6
14⎯17
4⎯7

Remarks

Torque specifications listed above are for important fasteners. Others should be tightened to the
standard torque values listed on the next page.
STANDARD TORQUE VALUES
Item
5 mm bolt and nut
6mm bolt and nut
8 mm bolt and nut
10mm bolt and
nut
12mm bolt and
nut

1-5

Torque Values
N.m (kg-m, ft-lb)
4—6
(0.4⎯0.6, 3⎯4)
8—12
(0.8⎯1.2, 6⎯-9)
18—25
(1.8⎯2.5 13⎯18)
30—40
(3.0—4.0, 22—29)
50⎯60
(5.0—6.0, 36—43)

Item
5mm screw3
6 mm screw
6 mm flange bolt and nut
8mm flange bolt and nut

10mm flange bolt and
nut

Torque Values
N.m (kg-m ft-lb)
3—5
(0.3—0.5, 3—4)
7— 11
(0.7—1.1, 5—8)
10—14
(1.0—1.4, 7—10)
20—30
(2.0—3.0, 14—22)
30—40
(3.0—4.0, 22—29)

HONDA.
VT25O
GENERAL INFORMATION

TOOLS
SPECIAL TOOLS

Tool Name
Oil seal driver
Oil seal driver attachment
Vacuum gauge adapter
Carburetor adjusting wrench
Compression gauge attachment
Oil pressure gauge attachment
Valve compressor attachment
Valve guide reamer
Valve guide driver/remover
Circlip pliers
6mm follow set wrench
Fork seal driver attachment
Ball race remover
Steering stem driver
Steering stem driver
Bearing driver
Bearing driver
Oil seal driver attachment
Bearing remover set

Tool Number
07965-KE80100
07965-KE80200
07510-3000100
07908-4220201
07510-MB00101
07510-4220100
07957-8340100
07984-MA60000
07942-MA60000
07914-3230001
07917-3230000
07947-KA20200
07953-3330000
07946-MB00000
07946-3710601
07945-3330300
07946-3290000
07965-MA60100
07936-8890100

Remarks
Newly
provided for
VT25OF

Ref. Sect.
16
16
3
3
3
2
10
10
10
7,15
14
14
14
14
14
14
14
16
16

Tool Number
07708-0030100
07708-0030400
07757.0010000
07725-0030000
07718-0020300
07718-0020500
07746-0020100
07410-0010000
07746-0010300
07748-0040300
07749-0010000
07747-0010100
07716-0020400
07702-0010000
07746-0010200
07746-0040400
07746-0040500
07733-0020001

Remarks

Ref. Sect
3
3
10
9
7
7, 14
13
4
14, 16
14
14, 16
14
14
14
16
16
16
9

COMMON TOOLS

Tool Name
Tappet adjusting wrench 8 x 9mm
Tappet adjuster
Valve spring compressor
Universal holder
Lock nut wrench 17 x 27mm
Extension bar
Bearing driver handle outer B
Float level gauge
Bearing driver outer 42 x 47 mm
Driver pilot 15 mm
Driver handle outer A
Fork seal driver body
Lock nut wrench 30 x 32mm
Pin spanner
Bearing driver outer 37 x 40mm
Driver pilot 17mm
Driver pilot 20mm
Flywheel puller

1-6

Honda
VT25O
GENERAL INFORMATION
VALVE SEAT CUTTER
Tool Name
Valve seat cutter ⎯ 24.5 mm
Valve seat cutter ⎯ 22.5 mm
Valve seat interior cutter ⎯ 22.3 mm
Valve seat flat cutter ⎯ 24mm
Valve seat flat cutter ⎯ 22.5mm
Cutter holder ⎯ 5mm

1-7

Tool Number
07780-0010100
07780-0010700
07780-0014201
07780-0012500
07780-0012600
07781-0010400

Remarks
Valve seat IN.
Valve seat EX.
IN. EX.
IN.
EX.

Ref. Sect.
10

GENERAL INFORMATION

CABLE AND HARNESS ROUTING
Note the following when routing cables mid wire harnesses
• A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to
be sure it is secure.
• Do not squeeze wires against the weld or end of its clamp when a weld-on clamp is used.
• Secure wires and wire harnesses to the frame with their respective wire bands at the
designated locations. Tighten the bands so that only the insulated surfaces con tact the
wires or wire harnesses,
• Route harnesses so that they are not pulled or have excessive slack.
• Protect wires and harnesses with electrical tape or tube if they are in contact with a sharp
edge or corner. Clean the attaching surface thoroughly before applying tape. Do not use
wires or harnesses with a broken insulator. Repair by wrapping them with a protective tape
or replace them.
- Route wire harnesses to avoid sharp edges or corners.
• Also avoid the projected ends of bolts and screws.
• Keep wire harnesses away from the exhaust pipes and other hot parts.
• Be sure grommets are seated in their grooves properly.
- After clamping, check each harness to be certain that it is not interfering with any moving
or sliding parts.
• After routing chock that the wire harnesses are not twisted or kinked.
• Wire harnesses routed along the handlebars should not be pulled taut, have excessive
slack, be pinched, or interfere with adjacent or surrounding parts in all steering positions.

2. LUBRICATION
SERVICE INFORMATION
2—2 OIL STRAINER CLEANING
2—5
TROUBLESHOOTING
2—3 OIL PUMP
2⎯7
ENGINE OIL LEVEL
2⎯4 CONTROL CABLE LUBRICATION 2⎯11
ENGINE OIL & FILTER CHANGE 2⎯4 LUBRICATION POINTS
2⎯11
OIL PRESSURE
CHECK
2⎯4
SERVICE
INFORMATION
GENERAL
• This section covers oil pump servicing. These procedures are can be serviced with the engine
installed in the frame.
• When the oil pump is removed avoid substance falling into the engine.
• Replace the oil pump drive chain and sprocket after the clutch is removed.
• To remove the oil pump, turn the water pump drive shaft groove to right angles. If the drive
shaft groove is not at right angles, remove the water pump when the oil pump is removed.
SPECIFICATIONS
Engine Oil
Oil capacity
1.9 liter 2.0 US qt, 1.7 Imp qt) after draining
2.0 liter (2.1 US qt 1.8 Imp qt) at oil filter change
2.5 liter 2.6 US qt. 2.2 Imp qt) after disassembly
Oil
API service classification: SF or SF
recommendation Viscosity: SAE 1OW—40
(General all temperature)

Other viscosities shown in the chart
may be used when the average
temperature in your riding area is
within the indicated range
Oil pressure

441.4 kPa. (4.5kg/cm2, 64psi) at 6000 min (rpm) (80°C/176°F)

Oil Pump
Rotor tip clearance
Pump body clearance
Pump end clearance

STANDARD
0.15mm (0.006 in)
0.15—0.22mm (0.006—0.009 in)
0.02—0.07mm (0.001—0.003 in)

SERVICE LIMIT
0.20mm (0.008 in)
0.35mm (0.014 in)
0.10mm (0.004 in)

TORQUE VALUES
Engine oil drain bolt:
35—45 N.m (3.5—4.5 kg-m, 25—32 ft-lb)
Oil filter mount bolt:
15—20 N.m (1.5—2.0 kg-m, 11—14 ft-Ib)
Oil pressure switch:
15—20 N.m (1.6—2.0 kg-m, 11—14 ft-lb)
Apply 3~BOND® or equivalent to the thread of the pressure switch.
TOOLS
Special
Oil pressure gauge
07506—3000000
Oil pressure gauge attachment 07510—4220100

2-2

Honda

VT25OF
LUBRICATION

TROUBLESHOOTING
Oil level too low
1. External oil leaks
2. Worn piston rings
3. Worn valve guide or seal
4. Oil consumed
Oil contamination
1. Oil or filter not changed often enough
2. Head gasket faulty
3. Worn piston rings
Low oil pressure
1. Oil level low
2. Pressure relief valve stuck open
3. Plugged oil pick-up screen
4. Oil pump worn
5. External oil leaks
6. Incorrect oil being used
High oil pressure
1. Pressure relief valve stuck open
2. Plugged oil filter, gallery, or metering orifice
3. Incorrect oil being used
No oil pressure
1. Oil level low
2. Oil pump drive chain broken
3. Oil pump faulty
4. Internal oil leakage
5. Defective oil pump drive chain

2-3

LUBRICATION

ENGINE OIL LEVEL
Clean the oil level inspection
window by wiping the wiper with a
screwdriver.
Run the engine and allow to idle for
2—3 minutes.
Stop the engine and support the
motorcycle on the center stand.
Check the oil level at the engine oil
inspection window on the right side
cover after a few minutes.
If the level is below the lower level
mark on the inspection window,
remove the filler cap and fill to the
upper level mark.
Check the oil pressure with the
warning indicator switch after the
engine starts. The indicator should
go off after one or two seconds. If it
does not, check the oil pump
function and/or oil circuit.

ENGINE OIL &
FILTER CHANGE
NOTE:
Change engine oil with the engine
warm and the motorcycle on its
center stand to assure complete and
rapid draining.
Stop the engine.
Remove the oil filler cap.
Drain the engine oil.
Remove the oil filter mount bolt
and oil filter element.
Remove the 0-rings from the oil
filter cap and mount bolt.
Install new 0-rings onto the oil
filter mount bolt and cover.
After completely draining the oil
replace the oil filter with new one.
Make sure the sealing washer is in
good condition and install the drain
plug.
TORQUE
35—45 N.m (3.5—4.5 kg-m,
25—32 ft-lb)
Install the new oil filter with the oil filter mount bolt.
TORQUE:
15⎯20 N.m (1.5⎯2.0 kg-m, 11⎯14 ft-lb)
Fill the crankcase with recommended oil.
OIL CAPACITY:
2.0 liter (2.1 US qt 1.8 Imp qt) after oil filter change.
Starter engine and let it idle for 2—3 minutes, then stop the engine.
Make sure that the oil level is at the upper level mark in the inspection window.
Make sure there are no oil leaks

2-4

LUBRICATION

OIL
CHECK

PRESSURE

Warm the engine up to normal
operating temperature (approximately
80°C/176°F).
Stop the engine and disconnect the oil
pressure switch Wire.
Remove the oil pressure switch and
connect an oil pressure gauge to the
pressure switch hole (page2-5).
Check the oil level.
Start the engine
Check the oil pressure at rpm.
OIL PRESSURE:4.5±0.8kg/cm2 (64
± 11 psi) at min(rpm) (800C/176° F)
Stop the engine.
Apply 3BOND® sealant or equivalent
to the pressure switch threads and
install.
TOROUE: 1.6—2.0 kg-m (11—l4ftlb)
Connect the oil pressure switch wire.
Start the engine.
Operate the warning indicator switch.
Cheek that the oil pressure-warning
indicator goes out after one or two
seconds.
If the oil pressure warning indicator
stays on, stop the engine immediately
and determine the cause.

OIL
STRAINER
CLEANING
NOTE
The oil strainer can be removed with
the engine in the frame.
Remove the exhaust pipe flange nuts and
flange at the front cylinder.
Loosen the exhaust pipe clamp.

2-5

LUBRICATION
Remove the exhaust chamber mount
bolt.
Remove the right and left muffler
mount bolts and mufflers.

Drain the engine oil (page 2-4).
Remove the oil pan by removing the oil
pan mounting bolts.
NOTE
Remove the oil pan after removing the
oil filter mount bolt.
Remove the oil pan gasket.

Remove and clean the oil Strainer.
Check the operation of the pressure
relief valve.
Make sure the O-ring is in good
condition whenever
the relief valve is removed.
Install the oil strainer and oil pan.
Install the exhaust pipe.
Fill the crankcase with the
recommended oil (page
2-2)

2-6

LUBRICATION

OIL PUMP
REMOVAL
NOTE
The oil pump can be removed with
the engine in the frame.
Remove the exhaust pipe and muffler.
Drain the engine oil.
Remove the right crankcase cover by
removing the cover mounting bolts.
Remove the oil pump driven sprocket
mount bolt.
Pull out the driven sprocket from the
oil pump shaft.
NOTE
Oil pump drive sprocket and drive
chain are to be removed after the
clutch is removed.
Remove the water pump.

Remove the oil pan and oil strainer
(page 2-6).
Remove the 0-rings and relief valve.
Remove the oil pass pipe.
Make sure the 0-rings are in good
condition.
Remove the oil pump mounting bolts.
Remove the oil pump.

2-7

LUBRICATION
Remove the dowel pin, dowel pin and
O-ring.

DISASSEMBLY
Remove the cover mount bolts and
cover.

Remove the dowel pin.
Remove the thrust washer.
Pull out the pump drive shaft and
remove the drive
pin from the drive shaft.
Remove the inner and outer rotors.

2-8

3. MAINTENANCE
SERVICE INFORMATION
MAINTENANCE SCHEDULE
<ENGINE>
FUEL LINES
FUEL STRAINER
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER
CRANKCASE BREATHER
SPARK PLUGS
IGNITION SYSTEM
VALVE CLEARANCE
CARBURETOR SYNCH
CARBURETOR IDLE SPEED
RADIATOR COOLANT
RADIATOR CORE

3—1
3—3
3—4
3—4
3—5
3—6
3—6
3—7
3—7
3—8
3—8
3—11
3—12
3—12
3—12

COOLING SYSTEM HOSES &
CONNECTIONS
CYLINDER COMPRESSION
<CHASSIS>
DRIVE CHAIN
BATTERY
BRAKE FLUID
BRAKE SHOE/PAD WEAR
REAR BRAKE PEDAL
BRAKE LIGHT SWITCH
HEADLIGHT AIM
CLUTCH
SIDE STAND
SUSPENSION
WHEELS
STEERING HEAD BEARINGS
NUTS, BOLTS, FASTENERS

3—13
3—13
3—14
3—15
3—15
3—16
3—17
3—17
3—18
3—18
3—18
3—19
3—20
3—21
3—21

SERVICE INFORMATION
GENERAL
• Engine oil
See page 2-4
• Engine oil filter Seepage 2-4

SPECIFICATIONS
<Engine>
Spark plugs:
Standard
For cold climate (<5°C/ 41°F) For extended high speed riding
NGK
ND
NGK
ND
NGK
ND
DPR8EA-9 X24EPR-U9 DPR7EA-9 X22EPR-U9
DPR9EA-9 X27EPR-U9
Spark plug gap: 0.8—0.9 mm (0.03—0.04 in)
Ignition timing
• At idle:
120BTDC 1300 min’ (rpm)
• Full advance:
37C BTDC at 3300 min< (rpm)
Valve clearance
• Cold (Below 35°C, 95°F):
Idle speed:
1300 ± 100 min (rpm)
Carburetor synchronization:
Cylinder compression:
28 psi)
Throttle grip free play:

3-1

IN. 0.10mm (0.004 in)
EX. 0.15mm (0.006 in)
All carburetors within 60 mm (2.4 in) Hg
1,275.3 ± 196.2 kPa (13.0 ± 2.0 kg/cm2. 185 ±
2—6mm (1/8—1/4 in)

Honda
VT25OF
MAINTENANCE
<CHASSIS>
Rear brake pedal free play: 20—30mm (3/4—1-1/4 in)
Tire:
Tire size
Cold tire pressure
KPa (Kg/cm2, psi)
Tire brand

Driver only
Driver and
one passenger
Bridgestone
Dunlop

Suspension air pressure;

Front
110/90-1654S
225 (2.25, 32)
225 (2.25, 32)

Rear
110/80-1858S
225 (2.25, 32)
280 (2.8, 40)

L303
F11

G510
K527

Front 20— 60 kPa (0.2—0.6 kg/cm2, 3—9 psi)
Rear 200— 400 kPa (2.0—4.0 kg/cm2 ,28—57 psi)

TOOLS
Special
Vacuum gauge set
Carburetor pilot screw wrench
Compression gauge attachment

07404—0020000
07908—4220201
07510—MB00100

Common
Tappet adjuster
Tappet adjust wrench 8x9 mm

07708—0030400
07708—0030100

3-2

MAINTENANCE

FUEL LINE
Replace any parts that show
deterioration,
damage or leakage.

FUEL STRAINER
warning
Gasoline is flammable and is
explosive under certain
conditions.
Do not smoke or allow flames or
sparks in your working area
Turn the fuel valve OFF.
Remove the fuel cup, 0-ring and
strainer and drain the gasoline into
the suitable container from the fuel
cup.
Wash the filter screen and cup in
clean
non-flammable or high flash point
solvent.
Reinstall the strainer, 0-ring and fuel
cup into the fuel valve body, making
sure that the 0-ring is in place.
Hand tighten the fuel cup and then
Torque it to specified torque.
TORQUE:
3-5 N.m (03—0.5 kg-m, 2—4 ft-lb)
NOTE:
Do not over-tighten the fuel cup.
After installing, refill the tank and turn the fuel valve ON
and check that there are no leaks.

3-4

MAINTENANCE

THROTTLE
OPERATION
Check for smooth throttle grip full
opening and automatic full closing
in all steering positions. Check the throttle
cables and replace them if
they are deteriorated, kinked or damaged.
Lubricate the throttle cables (page 2-1 1),
if throttle operation is not smooth.
Measure throttle grip free play at the
throttle grip flange.
FREE PLAY: 2—6mm (1/8—1/4 in)
Adjustment can be made at either end of
the throttle cable.
Minor adjustments are made with the
upper adjuster and major adjustments are
made with the lower adjuster after
removing the fuel tank.
Adjust by loosening the locknut and
turning the adjuster.
Tighten the locknut and recheck throttle
operation.

Install the fuel tank.

3-5

MAINTENANCE

CARBURETOR
CHOCK
The VT25OF choke system uses a fuel
enriching circuit controlled
by a bystarter valve. The bystarter valve
opens the enriching
circuit via a cable when the choke Lever
on the handlebar is pushed
up. Check for smooth upper choke lever
operation.
Lubricate the choke cable if operation is
not smooth.

Loosen the choke valve nuts on the
carburetor. Remove the choke
valves from the carburetors. Push the
choke lever on the handlebar
up all the way to fully open and make sure
that the choke valve
moves to the valve nut side and there is no
free play.
To adjust, loosen the lock nut and turn the
cable elbow at the
handlebar choke lever housing. Tighten
the lock nut and recheck.
Thread the choke valves in by hand and
tighten the choke
valve nut 1/4 turn with a wrench.

AIR CLEANER
Remove the right and left side covers.
Remove the seat and fuel tank.
Remove the screw and air cleaner case
cover.
Pull out the air cleaner element.
Replace the element if it is excessively
dirty, torn or damaged.

3-6

MAINTENANCE
Set the element on to the air cleaner
case.
Reinstall the air cleaner cover and
cover screws.
install the fuel tank and seat.
Install the right and left side covers.

CRANKCASE
BREATHER
Remove the plug from the drain tube
to empty any deposits.
Install the drain plug.
NOTE:
Service more frequently when riding
in rain or at full throttle, or if the
deposit level can be seen in the
transparent section of the drain tube.

SPARK PLUGS
RECOMMENDED SPARK PLUG
Standard
For cold
climate(<
5°C,41°F)
extended
rapid
riding

NGK
DPR8EA-9

ND
X24EPR-U9

DPR7EA-9

X22EPR-U9

DPR9EA-9

X27EPR-U9

Disconnect the spark plug caps.
Clean any dirt from around the spark
plug base.
Remove and discard the spark plug.
Measure the new spark plug gaps
using a wire type feeler gauge.
SPARK PLUG GAP:
0.8—0.9mm (0,031—0.035 in)
Adjust by bending the side electrode
carefully. With the plug washer
attached, thread each spark plug in by
hand to prevent cross threading.
Tighten the spark plugs another 1/2
turn
with spark plug wrench to compress the plug washer.
Connect the spark plug caps.

3-7

MAINTENANCE

IGNITION SYSTEM
NOTE:
The ignition system is transistorized
and cannot be adjusted. If the
ignition timing is incorrect, check
the spark unit and pulse generator
and replace any faulty parts (Section 19).
Warm up the engine.
Remove the timing hole cap from the
right crankcase cover.
Connect the timing light to the hightension wire cord of the No.2 cylinder.
Start the engine and raise the engine
speed to 2,000 min —l (rpm).
Timing is correct if the “F’ mark (‘T2”
side) aligns with the index mark.
Disconnect the timing light and
reconnect the timing light to the
high-tension wire cord of the No. 1
cylinder.
Timing is correct if the’ F’’ mark (‘‘T1’
side) aligns with the index mark

VALVE CLEARANCE
NOTE:
Inspect and adjust valve clearance
while the engine is cold.

(Below 35°C, 95°F)
Remove the right and left side covers.
Remove the fuel tank and seat.
Drain coolant from the radiator (page 63).
NOTE:
Drain the coolant into a clean
container
for reuse. Scheduled coolant
replacement
is every 2 years or 24,000 miles
(38,400 km).
Remove the right and left side covers and remove seat.
Turn the fuel valve ‘OFF’ and remove the fuel tank

3-8

MAINTENANCE

Remove the ignition coil mount stay.
Remove the bolt and ignition coil with
the mounting stay.
Remove the inner plate.

Remove the radiator (page 6-5).
Remove the cylinder head cover mount
bolts and
Remove the front and rear cylinder head
covers.

Remove the alternator cover mount bolts
and cover.
Remove the timing hole cap from the
right crankcase cover

3-9

MAINTENANCE
Turn the crankshaft counterclockwise at
the alternator side and align the T2 mark
with the index mark.
Make sure that the No. 2 cylinder is at
TDC (Top Dead Center) on the
compression stroke.
Check and record the valve clearance for
the No. 2 (front) cylinder using a feeler
gauge.
VALVE CLEARANCE:
IN 0.10 mm (0.004 in)
EX 0.15mm (0.006 in)
Adjust by loosening the lock nut and
turning the adjusting screw until there is
a slight drag on the feeler gauge.
Hold the adjusting screw and retighten
the lock nut.
Recheck the valve clearance.
Rotate the crankshaft 270’ counterclockwise to align the “T1” mark with
the index mark and check for valve
clearance for rear (No. 1 cylinder.
Check and adjust the valve clearance
using the procedure for the No. 2
cylinder.

Install the removed parts in the reverse
of removal.

3-10

MAINTENANCE

CARBURETOR
SYNCHRONIZATION
NOTE

Synchronize the carburetors with
the engine at normal operating
temperature, transmission in
neutral and motorcycle on the
center stand.
Connect the tachometer.
Remove the plug from the front cylinder and
connect the vacuum gauge adapter.
Connect the vacuum gauge.
Start the engine.
Clip the vacuum tube for automatic fuel
valve and stop the engine.
Disconnect the automatic fuel valve line
from the rear (No.1)cylinder and remove the
vacuum tube joint and install the vacuum
gauge adapter and
connect the vacuum gauge.
NOTE:
The No. 2 (for front) carburetor
cannot be adjusted; it is base
carburetor.
Start the engine and adjust the idle speed.
IDLE SPEED: 1300 ± 100 min (rpm)
Check that all carburetors are within 60 mmHg (2.4in Hg).
Adjust if necessary by turning the adjusting
screws with carburetor adjusting wrench.
Recheck the idle speed and synchronization.
Remove the gauge and adapters.
Reinstall the removed parts in the reverse of
removal.

3-11

MAINTENANCE

CARBURETOR IDLE SPEED
NOTE:
Inspect and adjust idle speed after all
other engine adjustments are within
specifications.
The engine must be warm for accurate
adjustment. Ten minutes of stop-andgo riding is sufficient.
Warm up the engine, shift to neutral and
place the motorcycle on its center stand.
Turn the throttle stop screw as required to
obtain the specified idle speed.
IDLE SPEED: 1,300± 100 min1 (rpm)

RADIATOR COOLANT
Place the motorcycle on its center stand.
Remove the frame left side cover. Check
the coolant level of the reserve tank with
the engine running at normal operating
temperature.
The level should be between the ‘FULL
and “LOW” level lines.
If necessary, remove the reserve tank cap
and fill to the FULL’’ level line with a
50/50 mixture of distilled water and antifreeze.
Reinstall the cap and frame side cover.

RADIATOR CORE
Check the air passages for clogging or
damage.
Straighten bent fins, remove insects, mud
or any obstruction with compressed air or
low water pressure.
Replace the radiator if the airflow is
restricted over more than 20% of the
radiating surface.

3-12

MAINTENANCE
COOLING SYSTEM HOSES
AND CONNECTIONS
Inspect the hoses for cracks
deterioration, and replace if necessary.
Check the tightness of all hose clamps.

or

CYLINDER COMPRESSION
Warm up the engine.
Stop the engine, then disconnect the spark
plug caps and remove the spark plugs.
Insert the compression gauge.
Open the choke and throttle valves fully
and crank the engine with the starter motor.
NOTE

Crank the engine until the gauge
reading stops rising. The maximum
reading is usually reached within
4⎯7 seconds.
COMPRESSION PRESSURE:
1,275.3 + 196.2 kPa
(13 ± 2 kg%cm2, 185 ± 28 psi)
If compression is low, check for the following:
— Leaky valves
— Improper valve clearance
— Leaking cylinder head gasket
— Worn piston/ring/cylinder
If compression is low, check for the following:
deposits have accumulated on the combustion
chamber and/or the piston crown.

3-13

MAINTENANCE

(CHASSIS)
DRIVE CHAIN
Place the motorcycle on its center stand
and shift the transmission in neutral, and
turn the ignition switch off.
Inspect the drive chain free piay at the
center of the sprockets on the lower chain.
FREE PLAY: 15—28 mm (5/8-1 in)
caution
excessive chain free play, 50 mm (2
in) or more, may damage the frame

ADJUSTMENT
Loosen the axle nut.
Loosen the lock nut and turn the adjusting
nut to obtain the specified free play.
Caution
Be sure that the rear of the swingarm
aligns with the same graduation of
the scale on both sides.
Tighten the axle nut.
TORQUE:
70—100 N.m (7.0-10.0 kg-m, 51-72 ft-Ib)
Tighten the adjusting nuts and lockouts.
Replace the drive chain when the red zone
on
the label aligns with the arrow.
Replacement chain:
• TAKASAGO: RK520SMO-104LE
• DM00:
DID52OVS-104LE
inspect the drive chain and sprockets for damage
or wear. A drive chain with damaged rollers,
loose pins, or missing 0-ring must be replaced.
Replace any sprocket which is damaged or
excessively worn.
NOTE:

Never install a new drive chain on worn
sprockets or a worn chain on new
sprockets. Both chain and sprockets must
be in good condition or the replacement
chain or sprockets will wear rapidly.

3-14

MAINTENANCE

BATTERY
Remove the right side, cover and inspect
the battery fluid level.
When the fluid level nears the lower level,
add distilled water to the upper level line.
Disconnect the negative cable at the battery
terminal. Then remove the positive cable.
Remove the battery holder plate bolt and
plate.
Pull out the battery and add distilled water
to the upper level line.
Reinstall the battery.
NOTE:
Add only distilled water. Tap water will
shorten the service life of the battery.
WARNING
The battery electrolyte contains
sulphuric acid. protect your eyes, skin,
and clothing. If electrolyte gets in your
eves, flush them thoroughly with water
and get prompt medical attention

BRAKE FLUID
Check the front brake fluid reservoir level.
If the level nears the lower level mark, fill
the reservoir with SAE J1703 or DOT-3
BRAKE FLUID to the upper level mark.
Check the entire system for leaks, if the
level is low.
CAUTION
• Do not remove the cover until the
handlebar has been turned so that
the reservoir is level
• Avoid operating the brake lever
with the cap removed. Brake fluid
will squirt out if the lever is pulled.
• Do not mix different types of fluid,
as they are not compatible.
Refer to section 16 for brake bleeding
procedures.

3-15

FUEL SYSTEM

BRAKE PAD /SHOE
WEAR
BRAKE PAD WEAR
Apply the brake several times, then check
the inner and outer pads for wear.
Inner Pad:
Replace the inner pad if the end of the
wear indicator aligns with the red zone.

Outer Pad:
Replace the outer pad if the surface (A)
(back of the brake pad) aligns with the
surface (B) as shown. Inspect the brake
hoses and fittings for deterioration, cracks
and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.

BRAKE SHOE INSPECTION
(WEAR INDICATOR)
Replace the brake shoes if the arrow on the
brake arm aligns with the reference mark
“∇” on full application of the rear brake
pedal.

3-16

MAINTENANCE

REAR BRAKE PEDAL
BRAKE PEDAL HEIGHT
Check the rear brake pedal height.
The brake pedal height should be 1 0—20
mm (3/8—3/4 in) below the top of the foot
peg.
Adjust if necessary by loosening the lock
nut and turning the adjusting bolt.
Retighten the locknut.

BRAKE PEDAL FREE PLAY
NOTE:
Perform brake pedal free play
adjustment after adjusting brake pedal
height.
Check the brake pedal free play.
FPEE PLAY: 20—20mm (3/4—1-1/4 in)
If adjustment is necessary, turn the rear
brake-adjusting nut.

BRAKE LIGHT
SWITCH
NOTE:
Perform brake light switch
adjustment after adjusting the brake
pedal play and height.
Adjust the brake light switch so that the
brake light will come on when the brake
pedal is depressed 20 mm (3/4 in), and
brake engagement begins. Adjust by
holding the switch body and turning the
adjusting nut.
Do not turn the switch body.
NOTE:
The front brake light switch does not
require adjustment

3-17

MAINTENANCE

HEADLIGHT AIM
Adjust vertically by turning the adjusting
screw below the fairing.
Adjust the horizontality by turning the
adjusting screw inside of the right fairing.

CLUTCH
check the clutch fluid reservoir level.
If the level nears the lower level mark, fill
the reservoir with SAE J1703 or DOT-3
BRAKE FLUID to the upper level mark.
Check the entire system for leaks, if the
level is low.
CAUTION

Do not remove the cover until the
handlebar has been turned so that
the reservoir is level
Avoid operating the clutch lever
with the cap removed Fluid will
squirt out if the lever is pulled.
Do not mix different types of fluid, as
they are not compatible

SIDE STAND
check the rubber pad for deterioration or
wear.
Replace if any wear extends to wear line
as
shown. Check the side stand spring for
damage and loss of tension, and the side
stand assembly for freedom of movement.
Make sure the side stand is not bent.
NOTE:
When replacing, use a rubber pad
with the mark ‘Over 260 lbs ONLY”.
Spring tension is correct if the
measurements fall within 2—3 kg
(4.4—6.6 lb), when pulling
the side stand lower end with a
spring scale.

3-18

MAINTENANCE

SUSPENSION
WARNING
Do not ride a vehicle with faulty
suspension. Loose, worn or damaged
suspension parts impair vehicle stability
and control.
FRONT
Check the action of the front forks by
compressing them several times. Check
the entire fork assembly for leaks or
damage. Replace damaged components,
which cannot be repaired.
Tighten all nuts and bolts.

Check the front fork air pressure when
the forks are cold.
Place the vehicle on its center stand.
Remove each air valve cap and measure
the air pressure.
AIR PRESSURE:
20—60 kPa (0.2—0.6 kg/cm, 3—9 psi)

REAR
Place the motorcycle on its center stand.
Move the rear wheel sideways with force
to see if the swing arm bearings are
worn.
Replace the bearings if there is any
looseness (page 17-4).
Check the shock absorbers for leaks or
damage.
Tighten all rest suspension nuts and
bolts.

3-19

MAINTENANCE

Remove the frame left side cover.
Remove the valve cap and measure the
rear shock absorber air pressure.
REAR SHOCK ABSORBER AIR
PRESSURE:
200—400 kPa (2—4 kg/cm 28—57 psi)
NOTE:
Check the air pressure when the
rear shock absorber is cold,

WHEELS
NOTE:
Tire pressure should be checked
when tires are COLD.
Check the tires for cuts, imbedded nails, or
other sharp objects.
Check the front and rear wheels for
trueness
(Page 15-21 and 17-5).
Measure the tread depth at the center of
the tires.
Replace the tires if the tread depth reaches
the
following limit:
Minimum tread depth:
Front:
1.5mm (1/16 in)
Rear:
2.0mm (3/32 in)
Tire size
Front
110/90-16 54S
Cold tire
Driver only
225 (2.25, 32)
pressure kPa Driver and
225 (2.25, 32)
(kg/cm, psi)
passenger
Tire brand
Bridgestone
L303
Dunlop
F11

3-20

Rear
110/80-18 54S
225 (2.25, 32)
280 (2.8, 40)
G510
K527

MAINTENANCE

STEERING HEAD
BEARINGS
NOTE
Cheek that the control cables do not
interfere with handlebar rotation.
Raise the front wheel off the ground and
check that the handlebar rotates freely.
If the handlebar moves unevenly, binds, or
has vertical movement, adjust the steering
head bearing by turning the steering head
adjusting nut (page 15⎯33)

NUTS, BOLTS,
FASTENERS
Check that all chassis nuts and bolts are tightened
to correct torque values Section 1).
Check all cotter pins, safety clips, hose clamps
and cable stays.

3-21

HONDA
VT250F

4. FUEL SYSTEM

SERVICE INFORMATION

4—1

CARBURETOR SEPARATION

4—10

TROUBLESHOOTING

4—2

CARBURETOR ASSEMBLY

4—11

CARBURETOR REMOVAL

4—3

CARBURETOR INSTALLATION

4—13

VACUUM CHAMBER

4—4

AIR CLEANER

4—15

FLOAT CHAMBER

4—6

FUEL TANK

4—16

FLOAT LEVEL INSPECTION

4—9

AUTOMATIC FUEL VALVE

4—17

SERVICE INFORMATION
GENERAL

WARNING
Gasoline is extremely flammable and is explosive under certain conditions. Work in a
well-ventilated area. Do not smoke or allow flames or sparks in the work area.
• When disassembling fuel system parts, note the locations of the o-rings. Replace them with
new ones on reassembly.
• The float bowls have drain plugs that can he loosened to drain residual gasoline.
TOOLS
Special
Carburetor Pilot Screw Wrench

07908—4220201

Common
Float gauge

07401⎯0010000

SPECIFICATIONS
Venturi dia
Identification No.
Float level
Main jet
Idle speed
Throttle grip free play
Pilot screw initial opening
Jet needle

4-1

Primary
11.0 mm (0.43 in)
Secondary
29.0 mm (1.14 in)
VD66A
6.8mm (0.27 in)
Front No 102
Rear No 100
1,300 ± 100 min-1 (rpm)
2⎯6mm (1/8⎯1/4 in)
2 turns out
Front 99D
Rear 99J

HONDA
VT250F

FUEL SYSTEM

TROUBLESHOOTING
Engine cranks but wont start
1. No fuel in tank
2. No fuel to carburetor
3. Engine flooded with fuel
4. No spark at plug (ignition system faulty)
5. Air cleaner clogged
6. Intake air leak
7. improper choke operation
8. Improper throttle operation

Lean mixture
1. Clogged fuel jets
2. Piston stuck closed
3. Faulty float valve
4. Float level low
5. Fuel cap vent blocked
6. Fuel strainer screen clogged
7. Restricted fuel Line
8. Air vent tube clogged
9.Intake air leak

Hard starting or stalling after starting
1. Improper choke operation
2. Ignition malfunction
3. Carburetor faulty
4. Fuel contaminated
5. Intake air leak
6. Idle speed incorrect
7. Incorrect carburetor synchronization

Rich mixture
1. Clogged air jets
2. Faulty float valve
3. Float level too high
4. Choke stuck clogged
5. Dirty air cleaner

Rough idle
1. Ignition system faulty
2. Idle speed incorrect
3. Incorrect carburetor synchronisation
4. Carburetor faulty
5. Fuel contaminated
Misfiring during acceleration
1. Ignition system faulty
Backfiring
1. Ignition system faulty
2. Carburetor faulty
Poor performance (drive ability) and poor fuel economy
1. Fuel system clogged
2. Ignition system faulty

4-2

FUEL SYSTEM

CARBURETOR
REMOVAL
Turn the fuel valve to OFF.
Remove the seat, left and right side
covers and fuel tank (page 4-15).
Remove the air cleaner case mounting
bolts and air cleaner case.

Remove the thermostat case mounting
bolt from the air cleaner base.

Loosen the carburetor connecting tube
band and pull the carburetor assembly
up.

4-3


Documentos relacionados


Documento PDF honda vt 250 f fii service manual eng
Documento PDF classes of business and legal english
Documento PDF classes of business and legal english
Documento PDF fire protection engineers bizhouse uk
Documento PDF used van sales bizhouse uk
Documento PDF engine diagnostics bizhouse uk


Palabras claves relacionadas