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VTR 250

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Psu Chandasiri
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187 views

VTR 250

Uploaded by

Psu Chandasiri
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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2@HONDA VTR 250 Service Information Exterior Parts, Mufiler Inspection and Adjustment Engine Lubrication System | Fuel System Engine Removal / Installation Cylinder Head, & Valve | Clutch & Starter Clutch Gearshift Linkage Crankcase & Transmission Crankshalt, Cylinder & Piston Frame Front Wheel, Suspension and Steering Rear Wheel, Suspension Brake System Electrical System Battery & Charging System Ignition System : | Starter System Lamps, Instruments and Switches Circuit Diagram Troubleshooting VTR 250 Symbol Marks ‘Symbol Weaning Symbol Meaning Important: = arl| er Its neglect may lead to serious injuries, damaging the parts. ‘General Caution ‘General caution: Tips of the work ‘Symbol ‘Meaning ‘Symbol ‘Apply oil: Uniess specified, use designated or recommended oil. ER Apply sealant ‘Apply Molybdenum solution: The solution is a mixturo of engine cil and Molybdenum grease at Rg Replace with new parts whenever disassembled, ‘Apply multi-purpose grease, (Lithium soap based NLG #2 a Apply brake fluid. ‘equivalent. Use recommended Example: SHELL Albania grade ___EP-2 LE" (bors) ‘Apply Molybdenum grease Mitsubishi multi purpose M2 Dow Corning Molycoat BR 2 PLUS Apply recommended cushion oll ‘Apply Molybdenum paste. (40% or more Disulphide Molybdenum. NLGI#2 equivalent) Local paste Motycote G-n Paste (Dow Coming) o 8 2 Use exclusive tools ‘Apply silicone grease OP. (Option) tool, aa tie |’ ntcied ogutatny ARB AS specified. Silicone grease G40M [OR TOR Refer to parts list as, (ShinEtsu) these tools are considered to be parts. ‘Apply screw locker. Use medium class unless > 34 Reference pages. Special grease not mentioned above are described each time without using symbols VTR 250 S1Units This service manuel is written in both industrial mettic units and SI units. About SI Unit Basically, SI unit is an expansion of the traditional metric unit. In an industrial metric unit, the unit of kg was used for both mass (kg) and force (kg/kgf), while the SI units separate these to mass (kg) and force (N). Weight means a gravitational force acting on an object in SI unit. Thus, the ‘weight’ in SI is a multiplication of a mass and gravitational acceleration. Please note, therefore, the SI “weight” is not the same as the one in industrial metic units. Format in this manual SI unit is a primary unit, while industrial metric unit is expressed in brackets. Example: 98kpa 1.0kaf/cm:) Si Industrial metric unit Force in industrial metric unit is expressed as “kgf” in order to distinguish from mass “kg” for SI unit. Example: 10N-m (1.0kgf-m) ‘Some examples of SI format: tem Example Notes oe 200 KPa (2.00 Kotlar?) T kaflom? = 98.0665 kPa, 1 KPa = 1,000 Pa te __| 33 kPa (250 mmHa) 183.922 Pa ='0.1333322 kPa Torque 48N-m (1.8 kgF-m) 80665 N-m Volume ar ‘podlanae Force 12N(1.2kah) 1 kaf = 9.80665 N Specification and other data are based on the units initially specified. Resin Parts All resin parts with their mass of 100g or above have material identification labels. Label Format Information consists of resin identification and supplemental notes symbol. * Ifthe supplemental identification is *~", itis followed by strengthener identification. If it is “itis followed by the resin material characteristics. Refer to the following page for the symbols. If the part consists of (multiple) different materials, the name of the component for the material is also spaci Example: LENS > PMMA < HSG > ABS < Component — The lens consists of PMMA and the housing consists of ABS. VTR 250 z Mi lentification e Tail amp unit >PPe Air iter >PCRESINe Headlamp caso element SACRYL RESIN Spe Sree Airfiter case Chain case Loft crankcase rear cover a Speedometer Radiator Reservoir Upper care: >AES< >PE< Inner case: >PP< Frame: >PP< \ re Aree Rear fender >pr< Front fender Rear seat cow! >aBs< VTR 250 1. Service Information 1-16 General 1-1 Torque Settings... Serial Number/ Colour Label. 1-6 Special Tools... 1-19 Specifications 1-7 Oil/ Grease / Sealant. 1-21 Service Standards... 1-9 Routing Diagrams... 1-25 General Sate! ion Exhaust fume is toxic. Make sure the working area 1s well ventiated if the engne is to be operated. Battery fluid (sulphuric acid) ie highly toxie. Never allow battory fluid to touch your skin, eyes, and ‘clothing. In case your eyes or skin should contact the flud, lush with water and change the clothing if necessary. Then, consult the specialist. Keep the battery/battery fluid out of reach of children. Wear appropriate protective clothing, cap, and footwear. Wear goggles, mask and gloves and required. Engine component and muffler are hot immediately after engine shutdown. Wear long sleeved work ‘wear and gloves when servicing these parts. Coolant is toxic. Koop it away from eyes, skin or ‘othes. In cage your clothes or skin should contact the coolant, rinse with soap and water. If the coolant gets in your eyes, rinse with water and consult a doctor. I itis swallowed, Induce vomiting, gargle and consult a doctor. Keep te coolant out of reach ot children, Petiolis highly inflammable. Keep any fire/spark away. Ventilate the working area as vaporisad petrol \s explosive VTR 250 1. Service Information Battery gonorates oxplosive Hydrogen gas whie Dust on brake drums contains asbestos. Do not charging. Ventilate tho area whon charging tho ‘loan the drum with compressed ir to prevent battory, asbestos entering your lungs. Use brake cleaner available in market. Exercise caution wien servicing drive chain or | When working in pairs, always confirm your Sprockets not o catch your nancs or clothes. | partners safely. VTR 250 1. Service Information + Use genuine Honda or recommended parts | « and fluids. Clean dirtdust prior to starting servicing. eS ‘+ Sort and tag each part soas to insial them | « to the correct place, measuring. Apply ilo contact area before installing them, me m Replace gaskets. O-Rings, piston pin clips and cotter pins when disassembled. Overstressed snap pins may fall off ater re- installation. Do not re-use deformed snap rings. | * Inspect, clean and dry the paris before ‘+ Conduct necessary inspection and measurement when disassembling in order to assemble to original status. ‘+ Ifthe length of bolts are confusing, setall | « bolts so as to have same thread length to tighten. ‘When sorewing bolts /nuis / screws, temporarily screw them then screw to specitied torque in oriss cross order. a 3 y VTR 250 1. Service Information ‘* Replace rubber parts when requited. Some | + tubber parts get damaged by petrol or kerosene. Avoid the parts. a Apply recommended grease fo designated — parts. required, Ifthe bearing balls experienced force when removing the bearing, do not re-use the bearing, G + 1-4 + Rolate the bearing with fingers to check > smooth rotation, Replace the bearing if the fitting is too loose. Ifthe rotation is not smooth, clean with cil and replace itif there is no improvement. (double-sealed type cannot be cleaned) Replace it if the mount is loose. 4 oie t Waich out for the installing direction of single side sealed bearings. For unsealed / double sealed bearings, face the labelled surface outwards, Single-sealed _Double-sealed ban 3 3 ‘Manufacturer, ‘ee labe! > Donotlet the race rotate when cleaningit | + with compressed air. Excessive revaluation may damage the bearing. Apply oil/ grease before installing the bearings. = When installing snap rings, install the round comer side to the loading surface. Do not re-use deformed snap rings. After installation, rotate the ring to confirm itis set to the ring groove. man VTR 250 1. Service Information + After assembling the parts, check their ft ‘and operation. Brake fluid and coolant damage painted surface and rubber / plastic parts. Clean the 8 wah water he fc ices ihe pas ‘+ Install olf seals 50 as to have manufacturer names outside (not oil side). - Do not peel or damage oil seal lips when installing, Apply grease before installing. Manufacturers SH ‘When connecting tubes, push the tube all the way to the joint root. Set the tube clip to the dent on the tube. Replace the tube if its ‘end is loose. aad ak ‘i __ TL. + Do not let dit/debris enter the engine or hydraulic system. Remove old gasket before insialing new ‘ones. Roughness on the mating surfaces should be smoothened by an oil stone. eh re + Do not bend or twist cables hard. Damaged cables may cause failure. x x x ie Install boots whenever the boot groove exists. VTR 250 1. Service Information ‘Serial Number and Colour Label Frame #: — MG33 - 1000001~ Engine #: MC15E-1500001~ VTR 250 1. Service Information ‘Specification Ttem ‘Specification Modal Honda MC33 Length 2,040mm_ Width 720mm Height 4,050mm_ ‘Wheelbase 4,410mm Powerplant model MC15E Total cisplacement 0.249 Tires Fuel type Patrol Front 74 kg Vehicle empty weight Rear | 79kq Total 153 kg Maximum capacity 2 Front 92kg Vehicle gross weight Rear_| 171 kg Total 263 kg Front 110/70—17 54H oe Rear | 140/70—17 66H Minimum clearance 470mm Minimum turning radius 2.7m Siarter type Self stat Type of engine Petrol 4 cycle Cylinders 2 abreast ‘Combustion chamber Roof type DOHC chain driven aise cheteien) Inlet:2 Exhaust: 2 } Bore X Stroke 60.0 x 44.1mm. Compression ratio [11.0 Maximum output $2 PS/10,500 rpm Powerplant [Maximumtorque 2.4 kgf-m / 8,500 rpm Inlet Open 10° BTDC (1mm lifted) fis os Close 20° ABDC (1mm lifted) Valve operation time - [pen | 65° BBOC (imma) Close | 0° BTDC (Imm lifted) Total flow, screen & er Oi filter Mee sa Ol pump Tolocoid Cooling system Water cooled electrical Radiator Closed type 1-7 VTR 250 1. Service Information SS Specification Air filter Type | Filter paper Model [vp10 Fuel system | carburetor Throttle valve dia.__| 32mm. = Venturi diameter _ | Variable (maximum lift: 29mm) Typo Multiple wet plate coil spring ce Operation Mechanical Engine transmission linkage Engine — clutch — transmission Engine to transmission reduction ratio | 2.821 Type | Full time contact | aera Operation Left pedal saan Low 2.738 Transmission |g, [Second [1.800 rag. Lthird _ 17.375 Fourth [4.114 = Top fons Fiet (Sear ype iA] Reduction: First | ear Pe Driving Caster smn Front wheel axle as Steering Left iene Steering angle [ight Type Braking + system Operating system and braking wheels mee SNS Tote Bee teat ‘Shock Front wheal Telescopic absorbing —_| Suspension astm Rear wheel Swing arm Frame Type Diamond VTR 250 1. Service Information Servi fication Lubrication System Item Standard Service Limit ‘Total capacity | 2a tires [eee Engine oil capacity Oil change 1.9 litres. = Oil and filter change 2.4 litres = Recommended engine oil oo (select suitable viscosity grade based on your re cs : SPPSE NG He Srony: a API — SF class engine oil ‘490 — 588 kPa Oil pressure (at the oil pressure switch attachment) | (5.0 — 6,0 kgf-om?) - 5,000 rpm /80% Tip clearance 0.15mm_ 0.20mm_ Oil pump | Body clearance 22mm, 0.35mm. Side clearance 07mm 0.10mm_ Cooling System Item ‘Standard Service Limit Disassembled {6 litres = Coolant capacity ‘Coolant change 0.96 litres = Reservoir capacily | 0.4 litres = Coolant standard density 50% = Radiator cap valve opening pressure A : Valve opening temperature > Thermostat Full open temperature 95°C = Full open lift 8mm of above: = Fuel System Item Standard Service Limit Model VD10L = Setting mark VD10LA = Main jet (front/rear) #115 x Carburetor ‘Slow jet (front/rear) #35 = Pilot screw | Standard 1%: winds back = setting Idle drop | %4 winds back 5 Float level 6.8mm =a Idling rpm 4,300 + 100 rpm = Throttle grip free play (grip flange) 2—6mm = Maximum carburetor synchronisation pressure difference 2,664 kPa (20mm Hg) - Referential carburetor for synchronisation Rear carburetor : 1-9 VTR 250 1. Service Information : Head and Valve ? far Item I ‘Standard ‘Cylinder compression [1,323kPa (13.5kgtom!)As0ipm = Maximum compression diference [200 kPa (2.0kateme) = : ‘Cylindor head warpage I = 310mm locker arn shafthole diameter | 10.075mm 10.025mm Rockeram | Rocker am shait diameter [ss72—a.se7mm_ 9.96amm Ai mt 017+ 008mm = = Mneseree as (022 + 003mm eee oe [92.4612 - 32.6212mm. 32.4412mm any ite beg 32.3085 — 32 4685mm_ 32.2885mm Flonout : 0.6mm Cam shait Journal ameter (centro 21.861 — 22.882mm 21.851mm Journal diametor (both onda) 21.049 — 21,070mm. 21.909mm Joumal ol clearance (centre) [0.118 —0.181mm, 0.20imm, Journal ol Giearance (poth ends) | 0.030 — 0.091mm_ 0.11 4mm IN| 96.47mm 34.77mm- Valve sping | Relaxed langth Bees ; Here IN| 4975 — 4.990 497mm Selveitom Seppe EX | 4.955—4.970mm ‘495mm IN | §000—5.012mm 5.4mm. ike Louie condi EX | §.000=5.012mm 5.4mm Vave'gude | Valve stom guide IN [.010—0.037mm 0.07mm: clearance EX | 030—0.057mm 0.c8mm iN 9- tann 1.5mm Valve seat contact width |} 881-2 4-50 Valve guide instalation height 11.4 1.6mm z = Clutch E Item Standard Service Limit ‘Clutch lever fro0 ply 70 = 20mm ‘Clutch spring rolaxed Tongih 34.79mm ‘Small bore Guitch dsc thickness | Fes pore —T p53 -a.Gam ‘Giutch plate warpage = Clutch | mien [21995 —22.07emm | Clutch outer guide ae | ‘Clutch outer bore min ‘Main shaft diameter (at clutch oi utr) | 21.980 — 21.993mm Gil pump dhive sprocket bore 29.025 ~ 29.076mm VTR 250 1. Service Information Transmissi: item Standard Service Limit [a5 25.000 - 25.02imm_ 25.05mm_ Gearbore [er 23,000-=23.021mm | 93.05mm 62,63 28.000 — 28.021mm | 28.05mm Ma, 24950 — 24.980mm | 24.9amm Bush diamotor Ct 22.959 22.980mm | 22.92mm 02,03 27.989 — 27.960mm | 27.samm Ma 21.985 — 22.006mm | 22.07mm Bush bore Ci 20,020 = 20.041mm —| 29.06mm = "25.000 = 25.021mm | 25.05mm- Transmission . | Wain shaft dameier Mabush 21,959 21.960mm | 21,9omm Ci bush 49.987 20.000mm | 19.97mm Contes seh ae eee C2 bush 24.967 ~ 24.980mm_ 24.95mm_ M4, 5 bush 0.020~0.06mm | 0.1mm. ae ee C1, 2, 3bush 0.020 — 0.062mm_ 0.40mm_ Na bush 0.005 = 0.047mm | 0.1mm. See cee Ci, 2 bush 0.020 - 0.054mm_ 0.1Smm_ SRE Gatch thohness | 5.93 = 6.0mm. S.6omm Shafthole bore | 12.000 12.0¢imm | 12.04mm ‘Shift fork shaft diameter 11.969 - 11.980mm_ 41.90mm_ VTR 25 0 1. Service Information Crankshaft, Cylinder and Piston Item ‘Standard Service limit Bore 1060 ~ 60.016 10mm cinder [Tepesuface wage : o.10mm Outof round 0.5mm Taper : 206mm Piston diameter measuring poston | Tor fom the skit ower end : Piston diamotor $9.70 —69.090nm 5am Oyinder piston dearance {010 0.646mm om | Piston pin ole dameter 16.002 16.c06m ‘6.028 as Piston pin date 15.904 16.000nm 1s.semmn Piston'Ring | Connecting rod small end bore 16.016 16.034mm_ 16.08mm and Piston Pin | Platon=Pltenpinlerance ao02=o.t4mm | eoeemn | Connecting ed Pston pin dearance 0.016 0.c4Gmm 0.10mm Paonia [10 2026 ~0.060mm 0-10 wove gap [Second | 0028 0.056mn 00mm Paton ra etaling ection ake uta ‘ | Connecting | Crank pin oll clearance 0.028 — 0.052mm ‘007mm rod —__| Bigend side clearance 04 -0.amm [o4mm unt 0am VTR 250 1. Service Information Front Wheel, Suspension and Steering tem’ Standard Service limit Troad depth = 1.6mm boas (One person ‘200 kPa (2.00kgt fem) = Front tyre Two people 200 KPa (2.00KgH/ em?) 3 Type ‘riagestone (G501F Tubeless = Size 110/70 ~ 17 54H e. x Front ade runout : 20mm | im runout | Hada — oe - | Front whoet ‘Adal 2 2.0mm | Balance weight : 80g oF less | Spring relaxed length 230,3mm, 324mm | instaing rection ~__[ Tapered end toward botiom ronttone | Oh guanty 460: 2.50m8 g Ol level 105mm : Oil type. Honda ultra cushion oil # 10 - Tube bent Damm Steering load 10 16N (1.0 - 1.64g/) = Rear 1 & Suspension Item Standard | Service limit [ Tread depth = 2.0mm | ae One person | 225 KPa @25Kgt/em) __—_—| Rear tyro Two people 205 KPa (2.25kgt / em?) Tee Bridgestone G02 Tuveless : Size 1401 70-17 66H Roar ane ranout 220mm Radal 2 2.0mm Rear wheel Berens | Axial 2.0mm Balance weight = 609 es, Slack = 25— 36mm A | Privectain oe ime [DO 520 V6/ 104 inks AK 520 MOZ6 / 104 tks z Drive chain dider thickness 2 To wear lint 1-13 VTR 250 1. Service Information Brake System item ‘Standard Service lir [Recommended brake fluid cor4 : Pad thickness | = To wear tinting Disc thickness [45mm 3.5mm Front Brake [DS Runt 3 0.3mm | Master cylinder bore [111.000 -47.04amm 11.06mm Master piston dlamotor 10.957 — 10.984mm 10.38mm Caliper cylinder bore [27.000 27.060mm 27.06mm, Caliper pston diameter 26.918 — 26.968mm 26.91mm Feconesed ake ort : Pade : Tonear inne Gis ticres Zon ‘nm notte [BST : 03mm Has eda ow ‘a0 127m "ae50m aster psn Gamat Te87 ren ‘een Caliper cylinder bore [38.180 — 38.236mm 38.24mm Caleta dat 3856-98. sean Battery & Charging System Item Standard Service limit Capacty 72V—6AH : sate [seen 2: mn er os : Charging current / time (rapid) 0A / 1h = Charge curr emma [0875 —Toh : Regulator? | Tne Lee : ee Regulated voltage | 14.0 - 16.0 V/ 5,0007pm_ = [ Type Three phase AC = avenato: [ou daze 8 00 : Charging coll resistance 01-100) 1-14 1. Service Information Ignition System tem Standard Standard CRBEH — 9 (NGK), U24FERS (DENSO) : Spark plug | OP (High epeod operation) _| OROEH —9 (NGK), UZ7FERS (DENSO) zi [Pig gap (0.8=0.8mm 5 Type Fall transitorbaitory ignition s ‘onion ting BTOG 10°/1,300—pm = Ignition coll Peak votiage 100V or above 2 gomnrator _| Peak voltage 0.7V or less : Starting System { tem Standard Service limit [Starter motor brush length 10.0 10.5mm, 3.6mm Lamps, Instruments & Switches Item Standard Service limit Fuses el 0A : Sub 10A x4 : Headlamp Z 12V = 60/5507 = Brake /Taillamp 12V—23/av! : Front tum signa amps 12V— 16/5 x2 | 5 ear hirtagrallonpe a Te (==. Instrument iluminating lamp 12V I F | Bubs Tum sigralpiotlamp wosew id = [High boam pilot amp [av "Neutral plot lamp 12V—3.4¥7 5 Oil pressure lamp 12V—3.4V" E Water temperature waring lamp 12V-3aw eee] Speedometer warring lamp (option) | 12V—S.4v/ Z Thomo ewich & Spouse” | OFF + ON 112-118 tomp (coolant | 5y_, eral oraiy S0%)_ | ON > OFF 108°¢ or above : Fan motor anmotor | OFF -+ ON 98-102 ae. operating [coor acpaatng | ON-OFF 99-97 2 ij VTR 250 1. Service Information ‘Torque Settinas Standard Tor in Torque setting | Torque setting Type Nem (kgf-m) ee |__N-m (kgf-m) : mm) 50.8) Smmsorew 4(0.4) emm) 10 (1.9) emm screw, SH bot 9(09) mm) botts/ nuts 22(22) emm) 0.2) 10mm ) 4 (35) 8mm ) flange bolt / nut 26 (2.7) [x2mm) 54(55) 40mm) 394.0) The above standard values should be used unless specified below, Notes: 1. Apply engine oll to thread and seat 2 U=nut 3. —_Alloc bolt (replace when removed) 4. Apply screw locker 5. Apply sealant 6. Apply grease Engine Thread dia | Torque setting | Remark ene me (mm) Nem (kgf-m) (noted) Lubecation system Drain bot 1 12 298.0) ill purrp driven sprocket bolt 1 6 18 (1.5) 4 Oilfiter centre batt 1 12 18(1.8) Oil pressure switch 1 Pr vs 42(12) 5 il pump mourt tot 3 6 12(1.2) il pump covor bolt 3 6 491.3) Oil proseure switch connector belt 1 ae 2(02) Coaling system ‘Water pump drain bolt 1 e 19(1.3) Water pump mount bot 3 6 13(13) Fuel system Vacuum plug 2 5 3(03) arburettor insulator strap 4 5 40.1) 4t1mm Engine mount dismounting Drive epreckat bot 1 10 51(6.2) ‘Guutch/ starter dutch Timing hole cap 1 45 18(1.8) 6 CCutch centre lock nut 1 20 83 (8.5) 1 ‘Starter cutch mount bot 1 10 83 (85) 1 Starter cutch bolt 3 8 27 (28) 4 1-16 VTR 250 1. Service Information Engine = = ae aty | Thread dia |” Toraue seiting | Remark Lt (mm) Nem (kgf-m) {notet) Gear shit inkage Shit drum contre bot 1 8 23(2.9 4 Shit raturn spring pin 1 8 24 (2.4) Gylindor head, valve Cyfindor head sealing bot 2 2 3283) 4 Camahatt helder bot 8x 120mm 8 8 29°23) 1 Gyfindor head bot 8 x 20mm 4 8 | RG3 1 | Cam shaft holder 8 x 15tmm 4 8 32(83) 1 Cam shat holder 6x mm 4 6 12(12) 1 Cam sha hoiger 6x 3mm 4 6 12(12) 1 Cynder nead cover 8 6 10(19) Cam sprocket 8 7 19(19) 4 Valve adjust lock nut 8 5 10(10) 1 Rocker arm shaft bolt 4 20 49 (5.0) 4 |_ Spark plug _ 2 10 12(1.2) ‘Crankcase / Transmission Crankease bolt (mm) 7 8 232.3) 1 CGrankcase boit (&mm) " 6 12(12) 1 Lower erankease sealing bolt 1 8 1258) a Crankshaft, cylinder & piaton Connecting rod cap nut 4 f 2424) 1 Charging system Flywhoet 1 10 8385) 1 Sharing system Starer metor terminal nut 1 6 12(1.2) ‘Starter motor front cover bolt 2 5 ___5(05) Tamps, instruments & switches |_Neutal switch 1 10 12(12) Others: 6mm SH flange bolt _ a1 6 10(10) Frame 2 a fia | Torque setting | ‘Remark ‘ase oF. (mm) Nan (kaf-m) | (notes) Exterior & Muffler ‘Seat rail flange nut 3 10 44 (45) Battery box screw 2 6 12(12) Roar fonder screw 2 6 1242) Exhaust pipe joint nut 4 6 13(13) Mulor mount bok 1 8 29 (30) Muflor int bot 1 8 20 (20) Rear cow screw 2 5 4(04) Fear cow tapping sorew 8 s | 3i63) Cooing System Raalator mount bolt (SH bot) 2 © 12(12) Thermo suaten 1 Pr 18 9(09) Fan motor switch 1 is | 1818) Fuel Sysiom Air cleaner case cover screw 6 5 4(0.4) Fuel au lock 1 2 34(85) Fuel cock iver serew 1 5 4 (0.4) VTR 250 1. Service Information Frame Threaddia | Torque setting | Remark = a (eum) Nem (kgf-m) (notes) Engive mount asmounting ] Front engine mount bot 2 12 74 (75) Front engine hanger plate bolt 3 10 44 (45) Rear engine mount bott 4 12 54(55) Rear engine mount bolt / nut 2 12 54(55) Lower engine mount bot nut 1” 10 42(43) 2 |_shift pedal bol 4 6 19(19) Front wheel, Suspension & Steering Stearing top thread 1 26 25 (25) 1 Stooring stam rut 1 24 103 (10.5) Fork bottom bridgo split bolt 2 10 39(40) Fork top bridgo spit bot 2 8 22(22) Front axte nut 1 2 59(60) Front axle hoider bot 1 8 22(22) Front brake disc bolt 6 10 29(30) Fotk cap bolt 2 37 22(22) Fork socket tort 2 8 20(20) 4 Handlebar mount bolt 4 8 26(27) Front fender bot ao} 256 12(12) Fear Wheel Suspension Rear axle nut 1 16 38 (90) 2 Rear brake disc bolt 4 8 41 (42) Driven sprocket nut 6 8 30(31) 2 Chain case screw 1 8 70.7) Swing arm pivot nut 1 ‘4 38 (90) 2 Chain adjuster lock nut 2 8 2121) Rear cushion upper nut 1 10 96(37) lower nut 1 10 36(37) Pivot bracket bolt 2 12 44(45) Step arm cap bolt 2 8 22 (22) Brake System Brake Nose ol bor 4 10 34(35) Front caliper mount bot 2 8 30(31) 3 Front master cylinder mount bolt 2 6 12(1.2) Rear master cyinder mount bolt 2 8 12(1.2) Rear brake hose quide screw 2 5 4104) Pad pin i 8 18(18) Pad pin plug 1 10 303) Caliper bleader 2 8 6 (0.8) Rer caliper main slide pin bolt 1 12 28 (29) Roar calpor sub side pin bolt 1 8 2222) Front mastor cyinder cap serow 2 4 210.2) Front master cylinder brake switch screw 1 4 10.1) Brake lever pivet bol 1 6 10.1) Nut 1 8 610.8) Rear master cylinder joint screw | mae 210.2) Push fod lock nut 1 8 I(T Lamps, instuments & Switches Ignition switch, 2 8 25 (25) Others: ‘Sido stand pivot bott 1 10 10(10) Side stand pivot nut 1 10 29(30) ‘Side stand switch bott 1 8 40(4.0) VTR 250 1. Service Information Special Tools Tool name ‘Tool number Section | Float level gauge 97401 - 0010000 6 ll pressure gauge (07506 - 3000000 4 ll pressure gauge attachment (07510 ~ 4220100 4 Wrench 8 x 9mm 07708 0030100 8 ‘Wrench 17x 27mm 0716 0020300 9 Extension bar 07716 -0020500 9 Universal holder 07728 — 0030000 16 Rotor puller 07733 0020001 16 ‘Outer driver 37 x 40mm (07746 0010200 14 ‘Outer driver 42 x 47mm 07746 0010300 13,14 ‘Outer driver 82 x 55mm 07746 0010400 13 Inner handle 07746 —-0020100 " Pilot 15mm 07746 — 0040300 13 Pilot 17mm 7746 0040400 14 Pilot 25mm 07746 —-0040600 14 Bearing remover shaft 07746 — 0050100 13,14 Remover head 15mm 7746 — 0050400 13 Bearing remover head 17mm 07746 ~ 0050500 14 Driver Mande A (07749-00100, 13,14 Valve spring compressor 07757 - 0010000, 8 Valve seal cutter 45° IN 24mm ‘00780 - 0010600 8 45° EX 22mm 07780 -0010701, 8 32° IN 25mm 07780 — 0012000 8 32° EX 22mm (07780 —-0012601 a 60" IN/ EX 3Gmm (07780 — 001.4000 8 ‘Cutter holder Smm. (7781 —0010400 a Valve adjust wrench 07908 MJ60100 a VTR 250 1. Service Information f [ira re Section sap ing pers 079143230001 's Stoztng stom socket orate s7i0101 3 | Vawve guise crver 7942 MAs0000 8 Outer diver 32 35mm 07946010100 4 28x30mm o7a46— 1870100 4 Bal race remover 07946 3710500 3 ‘Steering stem driver 07946 — MBO0000 13, Remover shat Graus— Mno1co ‘4 Fork eal civer rex? — KAso100 ‘3 Fork seal diver attachment orer7— KFo01c0 13 | Driver handie attachment 07949 ~ 3710001 14 Diver attachment reso maroreo t3 Diver hand o7esa— myta200 ‘3 Piston slider 079543740000 2 Valve spring compressor attachment 7959 —KwG0101 8 | Valve guide remover (5mm) 07964 -_Magoo01 8 Cute centre holder o7ame 170101 9 Cam sat ter O7GMG —KV00100 8 Peak voltage adaper OTH — 0020100 7 Needle beating ramover set omMc—Kv30200 4 1. Service Information Oil, Grease and Sealant Engine item Type of tuts Crankcase mating surface Sealant (tree bond 12078) oF oquivaont Fight crankcase cover | mating surface Let crankcase cover mating surface | Cylinder head cover Sealant Mating surface (three bond 5211C) F or S=T0mm |] SHINETSU (KE4s) or | ecuivalent | | | j | 1] | | | | 1 | | | H Apply tothe area spectied inthe above igure 1-21 VTR 250 1. Service Information Engine Item Remarks Type of fluid Do not apply 3 to 4am, Sealant il pressure switch thread fromthe tread end. Crankcase sealing bolt Screw locker Cylinder head sealing bolt Rocker arm shatt thread ‘Cam sprocket bolt thread ‘Cam chain tensioner holder bolt thread Cam chain guide bolt thread (Oil pump driven sprocket thread ‘Shift drum centre bolt ‘Shift drum set plate mount bolt Starter clutch bolt Crankshaft main bearing Molybdenum Solution ‘Connecting rod bearing, ‘Connecting rod small end ‘Camshaft (cam, moving surtace) IN / EX valve stem Rocker am: Clutch outer C1 / C2 /C3 gear collars Md./MS gear colars Each gear /bearings Timing hole cap thread Multi-purpose grease Ol seal lio VTR 250 1. Service Information Engine "tem Remarks ~ Type of fluid Cylinder head bolt thread (8mm bolt) Piston ring, piston pin Connecting rod cap nut thread / seat Flywheel mount bolt thread / seat Starter clutch mount bolt thread / seat Valve clearance adjust lock nut thread / seat Clutch friction dise Clutch contro bolt | Clutch centre lock nut thread / seat Main journal mount bolt thread / seat Cylinder head mount boll thread / seat Camshaft holder mount bolt thread / seat Gear teeth Bearngs O-Rings Crankcse tt tread Eng VTR 250 1. Service Information Frame A tem Remarks Type of fluid Drive chain Gear oil | Rear whee! hub / flange, O-Ring Multipurpose grease | Each dust seal lips ‘Swing arm needle bearing Side stand pivot Clutch lever pivot Throttle grip cable ond R/L stop holder Roar brako pedal Head pine bearing ‘Speedometer gear box Molybdenum grease Top thread Engine oil Driven sprocket nut Master cylinder intetior surface Brake fluid Master cylinder piston cap Front/rear caliper pin Brake lever, piston contact area | Stlicone grease Rear master cylinder push rod, piston contact area Fork socket bolt | Screw locker Fork oll seal Honda Ultra Cushion Oil # 10 Fork dust seal lip, Fork cap O-Ring R1/L Handlebar grip inner surface Honda Bond A or Cemedine #540 VTR 250 = Routing Ignition switch coupler (3° Btack) Right handlebar swatenes coupler (@P Brown) | Lett hanatebar Sitches coupler — certian mata cup snes compe vie remy ene Brake hose my DS \ ae <—ee Fz —— Throttle cable ‘Choke cable (©) Speecometer atte 1. Service Information VTR 250 1. Service Information VTR 250 1. Service Information Main rear hamess Rear ignition eoit ratcase FAN Metor coupler ‘Theerios 1 Fuse box Tum signal Starter motcreable ORY ((2P Green} sidestand {Alternator coupler (3P White) sswiten Front ignition coit Connector cover RegulatonRectifier (Neutral switch, oil pressure) (Pulse generator (4P Black) couple) (Rear stop switch (2P Black) coupler) Chitch cable Neutral switch Oil pressure switch lead 1-27 VTR 250 1. Service Information Front carburettor air vent tube Rear ignition coil Radiator reservoir breather tube ‘main wire hamess Spark plug cap Starter réay switch Battery Spark unit Choke cable Front ignition coil primary lead VTR 250 1. Service Information VTR 250 2. Exteriors & Muffler [ Service information. | Troubleshooting. | Seat. Fuel tank, 2-1 Rear fender.. 2-3 2-1 — Battery Box 2-4 Be OP Seat all cocci cece cartes etatieittetigces 2-3 Mutftler / Exhaust Pipe. raul 2-5 Service Information General + Petrol is highly inflammable. Keep any fire/spark away. Ventilate the working area as vaporised petrol is explosive. © Service the muffler when it is cool This section describes the procedure to remove/install exterior parts, muffler and fuel tank, Refer to (1-25) when routing cables/tubes. Replace gaskets when the muffler is removed After installing the muffler, temporarily set all bolts/nuts. Screw joint nuts first, then mount bolts. Check exhaust leak after installing the muffler. que Setting Seat rail flange nut Battery box screw 12 Rear fender screw 12 Exhaust pipe joint nut 13 Muffler mount bolt 29 Muffler joint bolt 20 Rear cowl screw 4 Rear cow! tapping sorew 3 ‘Troubleshooting Exhaust noise too loud Muffler fault Exhaust leak Lack of power Muttler deformation Exhaust leak Muttler 44 Nm(4.5kgf-m) (1.2kgf-m) (1.2kgf-m) (1.3kgt-m) (3.0kgf-m) (2.0kgt-m) (0.4kgf-m) (0.3kgf-m) VTR 250 2. Exteriors & Muffler Remo Uniock the seat lock with an ignition key. Lift the seat up to the back to remove. Installation Set the seat hook to the frame hook. insert the hook by pushing the seat forward. Push the seat down until it is secured (click noise). Notes + Make sure there is no obstruction between the seat and the frame before installing tho seat. * Donot catch wire hamess between the hookiframe and the seat. a Seat Hook ‘Seat After installing the seat, push it in all directions to confirm itis secured. Disassembly Remove the seat (see above). Unscrew eight tapping screws and two screws to disassemble the seat. Assembly install a rear counter to the seat. Set tapping screws / washers and screws / washers / collars. Tighten the tapping screws and screw to specified torque, Torque: Rear cowl screw AN.m (0.4kgf-m) Rear cowl tapping screw —3N.m (0.3kgf-m) ore VTR 250 2. Exteriors & Muffler Fuel Tank + Inflammablo + Wipe of spilt fuel immediately. Remove a seat (2-2). Tum a fuel cock “OFF”. Unscrew fuel tank bolts and lift the tank up. Disconnect a fuel auto cock vacuum tube, @ fuel tube and a breather tube from the tank. Lift the tank straight up to remove. Installation Reverse the removal procedure for installation Fyel tank Bolt Fuel auto cock Removal Remove a seat (2-2). Disconnect tail lamp coupler and turn signal connector. Unscrew to remove the rear fender. Installation javerse the removal procedure for installation. 2-3 VTR 250 2. Exteriors & Muffler Battery Box Removal Remove a battery (16-5). Unstrap a spark unit and remove it. Remove a fuse box and a starter relay switch. Unscrew bolts to remove a seat lock. Disconnect a seat lock cable and remove a battery box. Installation Reverse the removal procedure for installation. Notes Set the battery box clamp to the frame when installing, 2N.m (1.2kgt-m) Removal Remove the following parts: - Rear fender (2-3) Battery box (see above) Unscrew to remove a rear master cylinder reservoir. Release two wire straps and clamps to separate the reservoir main hamess trom a seat rail Unscrew seat rail flange nuts/bolts to remove the seat rail Installation Reverse the removal procedure for installation. Torque: Seat rail flange nut: 44N.m (4.5kgf-m) 2-4 Fuse box/starter lay switch Bott VTR 250 2. Exteriors & Muffler Muffler / Exhaust Pipe Muffler Bemoval Unscrew exhaust pipe joint nuts. Loosen a muffler joint bolt Unscrew a muffler mount bolt/nut to remove the muffler. Installation Install a new exhaust pipe gasket. Temporatily set a muffler mount bolt. Tighten exhaust pipe joint nuts and a muffler joint bolt to specified torque. Torque: Exhaust pipe joint nut: 13N.m (1.3kgf-m) joint bolt Muffler joint bolt: 20N.m (2.0kgf-m) Tighten a muffler mount nut to specitied torque. Torque: 20N.m (3.0kgf-m) Exhaust Pipe Removal Remove a muffler (see above). Unscrew exhaust pipe joint nuts to remove the exhaust Pipe. Remove an exhaust pipe gasket. Installation Install a now exhaust pipe gasket. Install the exhaust pipe and temporarily secure the joint nuts. Install a mutfler (see above). Notes Temporarily tighten all bolts when installing a muffler. Tighten exhaust / muffler joint nuts to specified torque. Torque: Exhaust pipe jointnut: —13N.m (1.3kgf-m) Muttler joint bolt: 20N.m (2.0kgf-m) Tighten the muffler mount bolt. Torque: 29N.m (3.0kgf-m) 2-5 VTR 250 3. Inspection / Adjustment | Regular parts replacement 3-1 Drive chain. 3-9 | Service schedule 3-2 Electrical system... 3-14 Steering stem. ie 3-4 Lubrication system 3-14 Brake... 3-4 Fuel system... 3-16 Wheel. Pritt 3-7 — Cooling system. 3-18 SUSPENSION. cessenesesneins cuceme 3-8 Exterior lamps... 3-19 QUICH nee 3-8 Others. 3-19 * Exhaust fume contains toxic gas such as CO. Do not run the engine for a long period in poorty ventilated room. + Engine/muffior are extremely hot immediately after shutting down the engine. Wear proper protective clothes if it is necessary to service while they are hot. * Petrol is highly inflammable. Keep any fire/spark away. Ventilate the working area as vaporised petrol is explo: * Do not catch your arms/clothes in driving parts or other moving parts. * Check the coolant level at the reservoir, not at the radiator. If the engine is suspected to be hot (above 100°c), do not open a radiator cap as the coolant may spurt. * Cooling system should be serviced when the engine is cool. * Coolant is toxic. Do not driniet it touch your skin, eye or clothes. - Ifthe coolant touches your skin or clothes, rinse with soap and water. If the coolant gets in your eyes, rinse with water and consult a specialist. Ifthe coolants swallowed, Induce vomiting, gargle and consult a specialist. * Keep the coolant away from small children. Notes Park the vehicle on level and flat surface and support it with its side stand or maintenance stand. Reqular Parts Replacement Replace the parts when the distance/time reached the schedule (whichever the earlier). =p clin Schedule s Notes Hydraulic brake related parts Quadrennial ‘Master cylinder cup and rubber parts on adise caipor Brake fad zi Siena as Ai fitoreomant Every 20,000«m Vieeous ype Engine of inal T0D0km or one month, then ‘very 8,000km Oi Geaner ina 13 000K, Then Gv 12,000km Coon ——— Guadiennia 3-1 VTR 250 3. Inspection / Adjustment Service Sch :Mandatory —: Manufacturer recommendation ll: Does not apply : ‘Schedule ; Parts tem 4\e0% Standard soe el | 2g ‘Operation i. 25 a Damage 5 ° be fandiebar [Steering stem atlachment e o Steering stom bearing e Brake pedal& | Free play elele = lever Effectivensss elele Rods7 cables ° Hose/pipo | Leak, damage and mount ele ra Front. above lower iit Reservoir Fluid level @| | @ | Rear: between upperower § limit ines % | Master cyinder & | Function, wear and damage Fee | @ | disc caliper © | Broke cum & ie a 2 e Disc pad clearance Pad wear [re | Wear limit ine F: Sid thickness 4.5mm Brake disc Service limit: 3.5mm Diss nae eae © | R: Std thickness 5.0mm | % Service limit: 4.0mm, Front 200kPa (2.0kgtiom?) Roar: 225kPa (2.26kat/om!) . Tyre pressure @ | © | @ | One person: § Front 200kPa (2.0kglcm) % | Rear: 225«Pa (2.25kgtlom*) 2! wheat [ye erack damage: fel te = ‘Tyre tread depth and unusual wear | @ ce) esr near arpeate one 6 Wheel nut/ bolt iting ele Front wheel bearing fiting [ Te Rear wheel bearing fiting tel 3 4 3 Suspension arm | Joint ting ana arm damage ° | 2] Shock absorber | Oil leak and damage e 5 | ctuten lever © | © | 10mm - 20mm at lever end ‘ 3 | Clutch 5 Operation é = - © | Transmission — ore is e VTR 250 Service Schedul 3. Inspection / Adjustment Parts Standard 25 — 36mm al midway Chain slack with Chain & sprockets oe oe cece Sprocket altachmeni & wear . ~ [gation system [Stk [e | Pius gap:08—0.9mm Se 3 gq Battery by Terminal connection e Wiring | Connection damage [Te Starting and noise el le Hain component {2 SH8ed and acceleration © | [ee | iaing rpm 7,300 + 100 rom Exhaust ele 2 Lubrication | Oil leak B| system | Of quality level 2 Fuel leak | | uatsysiom | Carburetorlinkage es alte orp free play 6mm Throttle / choke valve status oes: 5 Coolant level elele Cooling system [Coolant leek e Exteriorlamps | Operation elele Hom and Lock | Operation ° instruments ‘Operation e Exhaust Pipo and | Attachment & damage ° Muffler ‘Muffer function e Frame Looseness & damage e Others Lubrication e DaFecis discovered on ‘previous day —_| Serviced © VTR 250 3. Inspection / Adjustment Steering System Lift the front wheel from surface. ‘Move the axle forward and backward to check its fitting. If the fitting is loose, re-tighten the steering stem nut or service the stem (13-24). Lift the front wheel and turn the handlebar slovily to each side to check smooth steering. If there is partial jamming, check wires and cables routing Ifthe wires or cables are not interfering with the stem, disassemble the steering stem and Inspect the stem cone race (13-24). Brake Brake free play Depress brake lever/pedal hard to chock there is no air in the brake system. Ifthe lever/pedal is soft, bleed air (15-4) Brake pedal height adjustment Loosen a locknut and tum a push rod to adjust the height of the brake pedal. Notes Check the operation of a stop lamp switch after adjustment. VTR 250 3. Inspection / Adjustment Ifthe pedal needs to be lowered, adjust the Pedal so as to have al lease 1mm clearance between the lower end of the push rod and the pedal joint. Lock nut If the pedal needs to be elevated, do not elevate beyond the height where the lower end of the push rod is at the same level with the lower joint thread. Notes The push rod lower end should Not ao into the lower joint thread. Firmly tighten the lock nut after adjusting, Toraue: 17N.m (1.7kgf-m) Inspect the brake effectiveness and the stop lamp switch operation. Rleservoir fluid level check Inspection window Front Level the master cylinder. Check the fluid level from an inspection window. Re Support the vehiccie vertically to level the reservoir. Check the fiuid level in the reservoir I the brake fluid level is close to the lower limit, inspect brake pads for wear. If the pads are not worn out and the fluid level is ow, inspect the hydraulic system for leakage and then fill the reservoir, VTR 250 3. Inspection / Adjustment Filling Brake Fluid Upper lienit Front Level the master cylinder and unscrew two screws. Remove a reservoir cap, a set plate and a diaphragm. Fill the recommended brake fluid to the upper limit, Rear ‘Support the vehicle vertically and remove a reservoir cap, a set plate and a diaphragm. Recommended brake fluid: Honda brake fluid bors * Do notlet the brake fluid contaminated by water or debris * Do not mix different products of brake fluid. + Keep painted, plastic or rubber surfaces away from the brake flui Install the diaphragm, the set plate and the reservoir cap after filling the fluid. Wear limit tines Brake pad wei Front Inspect brake pads trom behind the caliper. Replace pads in a pair if one of them is worn to the wear limit (See. 15). Rear inspect brake pads from behind the caliper. Roplace pads in a pair if one of them is worn to the wear limit (Sec, 15). 3-6 VTR 250 3. Inspection / Adjustment Wheels ‘Tyre air pressure Measure the tyre air pressure when tyres are cold. Tparsen | Nenagh epee 02.00 Zeon ‘Nomad 2012.00) we Bridoesions ‘GEOiF Tubslese Excessive loading o1 may burst the tyre. speed operation with low tyre pressure: continuous high Wheel bearing fittings Front Lift the front wheel. Fully steer either to the left or right, and shake the wheel in axial direction. If the fitting is quite loose, remove the front Wheel to inspect the wheel bearing (13-8). Lift the rear wheel. Shake the wheel in axial direction. If the fitting is quite loose, remove the rear wheel to inspect the whe Notes el bearing (14-3). pivot, Identify which is Looseness may come from swing arm is the cause. VTR 250 3. Inspection / Adjustment Suspension Operation Apply front brake and push the handlebar to compress the front suspension for a few times. f there is any loose fit or noise, inspect the steering stom or the front fork, Inspect the front fork oil seal for oil leak and the fork tube for any damage. Push the rear end of the seat for a few times to compress the rear suspension. If there is any loose fit or noise, inspect the swing arm pivot and the rear shock absorber mount for loose fittings. Inspect the rear shock absorber for oil leak and damage. Joint fitting Lift the rear wheel. Hold near the axle and shake vertically to check the fitting of reer suspension joint. Clutch Clutch free play Measure the free play at the lever end, Free play: 10- 20mm. VTR 250 3. Inspection / Adjustment Mejor adjustment should be done on the clutch arm end. Loosen a lock nut and tum the adjustment to adjust the free play of the lever. Note Fully tighten the top adjuster (lever end) so as to allow easy adjustment for the next tme (can be adjusted at the top adjuster. Fix the adjust nut and screw the lock nut after adjusting. Precise adjustment should be done by loosening the lock nut and turning the adjuster. Notes If the screw thread is exposed more than 8mm, fully tighten tho adjuster and adjust at the clutch arm end as the screw may break. If the free play cannot be adjusted to the standard or the clutch slips at the standard, service the clutch. Drive chai Itis critically important to shut down the engine when servicing the drive chain for your own safety. ‘Support the vehicle with a side stand. Measure the chain slack at the midpoint between the sprockets. Free play : 25 — 35mm Loosen the wheel nut to enable the wheal to. move. Loosen lock nuts on both sides and tum the adjust nut to adjust the slack. The adjuster has a scal Otherwise the wheel . Both left and right sides should have some scale readings. be misaligned and it will be hard to control the direction. 3-9 VTR 250 3. Inspection / Adjustment Tighten the rear axle nut to specified torque. ‘Torque : 88N.m (8.0kaf-m) Check the chain slack again. Tighten the adjust nut and the lock nut. Torque : 21N.m (2.1kgf-m) If the mark on the adjuster falls into the red zone on the chain indicator label, replace the drive chain. ning / Lubrication / inspection Clean the chain with detergent and dry it Apply #80 or #90 gear oil to the chain. Wipe off excessive oil Notes Do not conduct the following works, as the drive chain is equipped with O-Rings. + Use of steam or high pressure water jet + Use of chain spray containing solvent or use of petrol. Inspect the chain for sticking links. If the stuck part is not hard, loosen it in washing oil or kerosene. Dry it after loosening. If the partis still stuck and the link is not moving ‘smoothly, or if there is any damage on links or rollers, replace the chain. 3-10 VTR 250 3. Inspection / Adjustment Drive Chain Replacement + Use exclusive replacement chain and special tool. ‘+ Never use a clip type chain. Loosen the drive chain. Assemble the special tool Special tools Drive chain staking tool 07HMH - MR10103, Link plate holder 07HMH - MR10130 Notes * Read the instructions before using the staking tool + Donot re-use a master link, O-Rings and a link plate, Link plate holder Drive chain staking tool Set the tool to the staked part of the drive chain to, cut the stake. ‘Special tool Drive chain staking tool 07HMH ~MR10103 By using the staking tool, adjust the number of links to the standard. Notes Count in the master link. ‘Standard links : 104 links Designated replacement chains: DID : 520 - va AK : 520 MOZB Masfer Link’ [7 Drive chain staking too! VTR 250 3. Inspection / Adjustment Install the drive chain after adjusting the Dr arn link number. Install new O-Rings to the new master link and install the link from inner side of the chain. Set O-Rings and a link plate and measure the distance from the link plate to the master link joint pin (see the figure). Standard: 9 RK: 1.2—-1.4mm DID: 1.15—1.55mm Notes * The labeled surface on the master link should face outward. © Donot catch O-Rings when | installing, Stake the end of master link joint pins by oretchain Using the staking tool ‘Staking tool Measure the staked area with a caliper. Staked area: RK : 5.50 - 5.80mm DID : 5.40 -5.60mm It the measured value is out of the above range, re-stake with a new master link, link plate and O-Rings. Cracks Inspect the staked area for crooks. Re-stake with a new master link, link plate and O-Rings if there is any crack. Never use a clip type chai 3-12 VTR 250 3. Inspection / Adjustment Adjust the chain siack after replacing the drive chain, Align the beginning of the green zone (opposite side of the red zone) on the chain indicator label and stick the label. Drive chain slider inspection Remove a drive sprocket cover (7-4). Inspect a drive chain slider for its wear and damage. Replace iif itis worn to the wear lirit Notes Ifthe drive chain contacts the swing arm, it may damage both of them. Thus, early replacement is recommended. Wear limit Sprocket attachment and wear Inspect the drive/driven sprockets for wear and damage. oF Replace both chain and sprockets at the same time. A combination of stretched chain and a new sprocket, or vice versa does not bring firm catch and result in damaging the worn side. Inspect drive/driven sprockets mount bolts/nuts for their tension. 3-13 VTR 250 3. Inspection / Adjustment Ignition system ‘Spark plua status Remove a spark pg cap. Clean the plug seat with compressed air before ‘emonng the pug. Then remove the pug to inspect tominais for wear, comosion and damaye. Replace the pug t necessary, Designated plugs - ‘CRSEH=BINORT—] ern UrTFERD DENS] —] (Clean the plug gap area wit @ wire brush ora plug lean, Measure the plug gap win @ wire type plug gauge ‘and adjust the gap by bending the sde terminal Standard: 0.8 = 0.9m Notes rderto prevent damagirg the Cylinder nead thvead, set tha plug to the ofinder head by rand, nen Yghten wit te plug wrench, If the plua is new, tahien Yirev, ater the sealing washer tcuches the seat. Tighten to the spectied toraue for reusing plugs. Torque: 12N.m (1.2kgf-m) Lubrication System Engine oltcheck Warm up the engine Shut down the engine and eave the venice for a few minutes. Suporte vehicle vertically and chock the ail lave from the nepection window. ‘The ail level should be between upper and lower lit, VTR 250 3. Inspection / Adjustment If the oil level is at or below the lower limit, il Filler Cao. remove an oil fter cap and fill recommended engine oil to the upper limit. Recommended ol: + Genuine Honda Ultra GP (4 cycle motorcycle) Temperature & Viscosity SAE 10W ~40 or 20W - 50 If the equivalent product is to be used, follow the standards below: + API classification : SF class engine oll * SAE standard : select from your operating temperature range. Firmly secure the oil filer cap. 000930 we Outside Air Temperature Engine oil change ‘Warm up the engine. Shut down the engine and remove an oil filler, cap. Unscrew oil drain bolt and support the vehicle vertically to drain oil. After draining all oil, install new sealing washer and screw a cleaned drain bolt Torque: 29N.m (3.0kgf-m) ‘Supply specific amount of recommended engine oil from the oi filer. il quantity: 1.9 ttrs (oil change) 2.1 ltrs (oil fiter change) 2.4 Itrs (total capacity) Start the engine and inspect the engine for oil leak ‘Shut down the engine and measure the oil level (3-14). 3-15 VTR 250 3. Inspection / Adjustment Qil Filter Change Drain engine oll (3-15). Unscrew a bolt to remove an oil filter cover. Remove an oil filter. Remove O-Rings from an oil filter mount bolt and an oil fter cover. Install new O-Rings and apply oil Install a spring and a new oil fiter. Set the oil filter cover. Tighten the oil filter centre bolt to the specified torque. Torque: 18N.m (1.8kgf-m) Oil Fiter Fill engine oil. Check there is no oil leak and then check the oil level (3-14). Fuel System Fuel system status Remove a fuel tank (2-3). Inspect a fuel tube from a fuel cock to a carburetor. Replace the tube if the tube is wom or damaged. Air filter element change Notes The air filter element cannot be cleaned. Replace the element in certain driving distance interval (3-1) Remove a fuel tank (2-3), Unscrew six screws to remove an air filter case cover. 3-16 VTR 250 3. Inspection / Adjustment Remove the air filter element. Air Filter Element Reverse the procedure to install the air filter element. Notes Clean the interior of the air filter case before installing the air fitter element. Torque: Air filter case cover screw : 4N.m (0.4kgf-m) Idling adjusti Warm up the engine. ‘Support the vehicle straight on a fiat level surface, as the vehicle inclination affects the idling rpm Monitor the idling rpm after sufficient warm up. Idling rpm : 1300 + 100 rpm Tum the throttle stop screw on @ carburetor to adjust. Idling status check Snap a few times while idling to see the response of rpm. Idling rpm should be the same after snapping, Steer fully to the left and right to check the idling is not affected. If the idling is affected by the steering, check the routing of the throttle cable and the throttle grip free play. Throttle grip inspection ‘Operate the throttle grip to check smooth operation. Ifitis not smooth, inspect the throttle cable for damage and the inner cable for rust. Make sure the grip itself is not stuck. Measure the grio free play at the flange external surface of the grip. ‘Throttle grip free play : 2 - 6mm VTR 250 3. Inspection / Adjustment Adjust the free play if the measured value is out of the range. Throttle rip free play adjustment Adjust at the carburetor end, Loosen a lock nut and turn adjusters to adjust the free play. Tighten the lock nut after adjusting. Cool a system Coolant level check should be done at the reservoir instead of the radiator. The coolant may spurt if the radiator cap is removed when the engine is hot. ‘Warm up the engine. Shut down the engine and support the vehicle vertically. Remove a reservoir cap / level gauge. Check the reservoir coolant level is between upper and lower limits. Ifthe coolant level is below the lower limit, fill coolant to the upper limit. Recommended coolan Genuine Honda Ultra Radiator Fluid (original or supplement) ‘Standard density: 50% (the value affects freezing temp) Adjust the density to your operating Temperature (5-4) es Do not use tap water instead of recommended cooiant as the tap water may corrode / freeze and result in damaging the engine. Inspect a radiator hose, water pump and water hose for coolant leak. Service the cooling system if any leak was found (Sec. 5). Inspect the radiator / water hoses for wear and damage. Rubber hoses decay by head and time. Decayed hoses may split under pressure. Pick the hose and inspect for cracks. 3-18 VTR 250 3. Inspection / Adjustment Exterior Lamps Headlamp axis adjustmont For vertical adjustment, loosen a headlamp mount bolt and tilt the lamp to align the punched mark on the bracket with the line on the case. Turn the horizontal adjust screw on the headlamp trim to adjust horizontally Rear brake lamp operation adjustment Operate rear brake pedal, The lamp should illuminate slightly before the brake is applied, Adjust if necessary by turing the adjust nut on the rear brake lamp switch. Do not turn the switch itself when adjusting as it may cause internal open circuit. Hold the switch when turning the nut. hers Frame Lubrication Check the operation of all moving parts and lubricate with recommended fluid if necessary. ‘lutch Lever a Site Stan Prot BOR Say ake ara 3-19 VTR 250 4. Lubrication System Front cylinder Exhaust Cammshatt Piston cam chain Tensioner Front cytinder Intake Camshar 1 crank = Rocker ae r Adm Sha { f HEI Moin shart ‘Gil Pump 4 Counter Shaft Presiure Reliel Valve Oi Strainer on Fittor ‘Shin Fork Saft VTR 250 4. Lubrication System General. 4—1 [Oil strainer & pressure relief valve....... | 4—4 Troubleshooting. 4-2 |Oilpump | 4-7 [ Oil pressure chock. 4-3 General Caution: + The oil pump can be serviced without removing it from the frame. * If the oll pump is wom, replace whole Assy. * Refer to Saction 19, for oil pressure warning lamp check, + Do not allow any objects to enter the engine when removing / installing the pump. © Check oil leak and pressure after installing the pump. Standard: Tem Standard Service Limit] | Tova eapacty 2aL = Engine ol capacity hange 1b Gil filer change BAL 2 Recommended oil. Select suitable viscosity grade from your operating Genuine Honda Ultra GP (4 cycle motoreycie) SAETOW: ; 20 or 20W-60 [ests + _API-SF class engine ol! 490 — 58 pressure at the opressure suiten mur (6.0~ 6.0 kallon®) / 5000rpmn80"0 S | Tip clearance 0.1mm ‘ozo Ol pump Body clearance 0:15—0.22mm 035mm, Side clearance 0.02—0.07mm o.10mm Torque Settings: Drain bolt 29Nm (3.0kgt-m) il filter centre bolt il pump driven sprocket il pressure switch il pump mount bolt ll pump cover bolt il pressure switch connector bolt ‘Special Tools: Oil pressure gauge Oil pressure gauge atlachment 4-1 18Nm (1.8kgt-m) 15Nm (1.5kgi-m) 12Nm (1.2kgt-m) 42Nm (1.2kgf-m) 13Nm (1.3kgt-m) 2Nm (0.2kgf-m) 07508-3000000 07510-4220100 VTR 250 4. Lubrication System Troubleshooting Insufficient amount of oil + Normal oil consumption Oil leak (external) Piston ring wom / badly attached Valve guide / stem worn Valve stem seal damaged * Cylinder and piston wear Dirty oil * Oilhas not been changed * Piston ring wear ‘+ Head gasket fault Buming engine Low or no oil pressure Oi orifice / passage clogged internal oil leak improper cil grade ssive oil pressure * Oil pressure relief valve does not open ‘* Ollorifice / passage clogged ‘+ Improper oil viscosity No oil pressure Insufficient amount of oil © Oil pump drive chain / drive / driven sprocket fauit * Internal oil leak Oil pressure warning remains illuminated * Oil pressure switch fault + Indicator wiro short circuit ‘+ Little or no oi pressure VTR 250 4. Lubrication System Notes il pressure may over-read when the engine and the oil are cold. Measure after warm up. ‘Shut down the engine. Remove an oil pressure switch cover and its screw. Disconnect oll pressure warning lamp wiring. Remove the oll pressure switch. Set an attachment to the oil pressure switch hole and connection oil pressure gauge. ‘Special Tool: Oil pressure gauge 07508-3000000 Oil pressure gauge attachment 07510-4220100 Measure the oil level. Start the engine and measure the oil pressure. ‘Standard: 490 — 588kPa (5.0-6.0kgf/cm?) @ ‘Apply to the thread exceptfor 34mm from the end 5000rpm @ 80°c. ‘Shut down the engine and disconnect tho gauge attachment. Apply sealant to the thread on the oll Pressure switch and tighten to the specified torque Torque: 12Nm (1.2kgf-m) a= Overtightening may damage the crankcase. Connect oll pressure switch leads and screw the bolt Torque: 2Nm (0.2kgf-m) Start the engine and check the oil pressure warning lamp turns off 1-2 seconds after starting the engine. Check oil level and fill if necessary. VTR 250 4. Lubrication System Oil Strainer & Pressure Relief Valve Removal Remove a muffor (2-5). Drain oil (3-15). Remove an oil filter (3-16). Unscrew 9 bolts and remove an oil pan. Remove O-Rings and collars. Remove an oll strainer from the pump and clean the strainer. Remove an oil pressure relief valve. Remove an O-Ring. VTR 250 . Lubrication System ief ssembli Remove a snap ring to disassemble the relief valve body. if valve inspection / assembly Inspect the spring for deformation and damage, Inspect the valve and the body for damage and wear. Assemble the relief valve. Inspect the O-Ring for wear and damage. Install the snap ring. ‘Snap ring \ \ Relief vaive ody / Wester ee o/ Relief valve body Fe pring ‘Snap ring ~ Soap ing \ VTR 250 4. Lubrication System Installation Apply oil to the O-Ring for the pressure reliet valve. Install the O-Ring. Apply oil to the O-Ring for the oil strainer. Install the oil strainer by aligning its cutout with the pin on the oll pump. Apply oil to O-Rings and collars before installing them. Install the oil pan and screw nine oil pan mount bolts. Install the oil filter (3-16). Fill engine oil (3-15). Install a muffler (2-5). Start the engine and check for oil leak. VTR 250 4. Lubrication System Oil Pump Removal Remove oil strainer and a pressure relief valve. Remove a bolt and a washer. Remove a driven sprocket together with drive chain from an oil pump drive shaft. Unscrew three bolts and remove the cil pump. Remove a knock pin, an orifice and an O-Ring, Disassembly Unscrew three bolts to remove an oil pump cover. & Pump Cover VTR 250 4. Lubrication System : Remove the following parts: - knock pin - inner rotor outer rotor é = pump shaft - — drivepin - washer spection Tip Clearance Notes Measure at several places and take the maximum value. Measure the tip clearance (the clearance between an inner and an outer rotor), with a thickness gauge. ‘Service Limit: 020mm Measure the side clearance (the clearance between the rotor end and the pump body), with a straight edge and the thickness gauge. Service Limit: 0.35mm Measure the side clearance (the clearance between the rotor end and the pump body) with a straight edge and the thickness gauge. ‘Snap ring Relief valve Relief valve body Pump boay Outer rotor Inner rotor Clean all parts with engine oil prior to. assembling, Install an outer rotor to the pump body by facing its punched mark to the pump cover. Install an inner rotor by facing its groove to the pump cover. Install a washer and a drive pin to the Pump shaft. Align the drive pin to the inner fotor groove to install the rotor to the shaft. Install knock pins and the pump cover. Screw three pump cover bolts. Check tor smooth operation of the pump shaft. 4. Lubrication System Pump shatt Drive pin Washer Pumé cover VTR 250 4. Lubrication System lation Apply oll to the O-Ring and install an orifice, the O-Ring and a knock pin. Align the cutout of the water pump shaft and oil pump shaft to install the oil pump. ‘Screw three bolts. Set the drive chain to the oil pump driven sprocket and install the sprocket to the drive shait by aligning cutouts, Apply screw locker to the oil pump driven sprocket bolt thread, Install a washer and screw the bolt. Torque: 15Nm (1.5kgf-m) Install an oil strainer and a pressure relief valve (4-6). VTR 250 5. Cooling System VTR 250 5. Cooling System Service information. .| 5-1 | Reservorr...... 5-6 Troubleshooting... ssusseusen | 52 | Thermostat. 5-6 Performance Check. 5-3. | Radiator. 5-8 Coolant Change, Air Bleeding... | 5-4 | Water Purp... 5-12 Service Information General Do not open the radiator cap if the coolant temperature is suspected to be at or above 100°c or the boiled coolant may spout out. Wait for the coolant to cool down. Wrap the cap with a cloth and slowly open the cap. Service when the engine is cold. Coolant is toxic. Keep it away from your eyes, skin and clothes. - Ifthe coolant touches your skin or clothing, rinse with soap. Ifthe coolant gets in your eyes, rinse with water and consult a specialist. Ifthe coolant was swallowed, induce vomiting, gargle and consult a specialist, Keep the coolant away from small children. Do not remove the radiator cap unless the coolant needs to be filled / drained, Cooling system can be serviced without removing it from the engine. Keep painted surfaces away from coolant. Rinse with water if the coolant touched the surface. After disassembling / assembling the cooling system, check for leakage by using a radiator cap tester. Thermo switch is quite sensitive. If the switch was dropped or it received any shock, check its operation before installing it. Refer to Section 19 for the fan motor switch and thermo switch service. ‘Standard item ‘Standard Service Limit Disassembled 116 5 Coolant capacity [ Ceolant change 0.961. = ___[ Reservoir Oat ‘Standard specifi gravity (densi 50% = Rladiator cap valve opening pressure 108 — 1S7kPa(1.1 — 1.axgiem®) = Valve opening temperature | 85° = ‘Themostat Full open temperature 95% 5 Full open lifting ‘8mm or above cs Torque Settings: Water pump drain bolt 13Nm (1.3kgf-m) Water pump mount bolt 13Nm (1.3kgf-m) Radiator mount SH bolt 412Nm (1.2kgf-m) Thermo switch 9Nm (0.9kgf-m) Fan motor switch 18Nm (1.8kgf-m) Ded VTR 250 5. Cooling System ‘Troubleshooting Excessive coolant temperature Water temperature gauge or thermo sensor fault Ar in cooling system Thermostat fault (doas not open) Radiator, hose, or water jacket clogged Fan motor fault Water pump fault Fan shroud attachment fault Insufficient amount of coolant Water temperature does not / hardly rises ‘* Water temperature gauge or thermo sensor fault * Thermostat fault (does not open) * Fan motor switch fault Coolant leak * Water pump mechanical seal (water sea!) fault © O-Ring worn + Hose attachment fault VTR 250 5. Cooling System Performance Check Make sure the coolant is cool before removing the radiator cap. Coolant specific gravity check Remove a fuel tank (2-3) Remove a radiator cap Measure the coolant specific gravity with a hydrometer and make sure the coolant density is adequate to your operating temperature (5-4). Inspect the coolant for dirt. Radiator cap inspectic Remove a raciator cap (read above). Notes Apply water to the cap seal when Use a radiator cap tester to find out the serviceability of the cap. The cap should be able to hold the valve ‘opening pressure for six seconds. Radi val ir ressure: 108 — 137kPa (1.1 — 1.4 kgfiom?, Radiator pressurisation test By using the radiator cap tester, apply radiator cap valve opening pressure to the cooling system. The system should be able to hold the pressure for six seconds. oi Do not apply pressure beyond 137kPa. Excessive pressure may cause damage. If the system cannot hold the pressure, inspect each joint, water pump attachment, water hole inspection window (5-12) for water leak 5-3 attaching the radiator cap to the tester. F&* iw Radiator cap tester VTR 250 5. Cooling System Radiator © Coolant is toxic, Keep it away from your skin, eyas and clothes. If the coolant touches your skin or clothes, rinse with soap. I the coolant gets in your eyes, rinse with water and consult a specialist. If the coolant was swallowed, induce vomiting, gargle, then oe Badlaior Fuld Maduro Ratio + _Keep and store it away from children, marinon”T waiaure | Honda ira | Soft Pa pent Ratio Radator uid | Water Notes 2 |r 30% [316 [ai - 2 oe ix the radiator fluid and soft water with re af s00__| 580 the ratio shown in the table. Apply 5°c aes a oo margin to the minimum temperature. Lean the radiator fluid with eoft water to product coolant. Hecommended radiator fluid: Honda Ultra Radiator fluid ‘Standard density (mixture ratio): 50% Coolant total capacity: 1.16 litres Coolant Change and Air Bleeding Remove a radiator cap after confirming the coolant is cool Remove a fuel tank (2-3). Remove a radiator cap. Unscrew a water pump drain bolt to drain coolant. Install a new sealing washer and the drain bolt after draining, VTR 250 Remove a carburetor (6-5). Disconnect a water hose from a filler neck. Unscrew a bolt to remove the filler neck Remove a reservoir and drain coolant. Clean the interior surface of the reservoir with water. Reverse the removal procedure to install the reservoir. Install the carburetor (6-18). Fill coolant from the filler hole to the mouth. Straighten up the vehicle and fill coolant to the upper limit line on a reservoir cap / level gauge. Bleed air in the following manner: 1, Set the transmission to neutral. Start the engine and idle for a few minutes. 2. Snap the throttle a few times to bleed air from the cooling system. 3. Fill coolanttto the mouth of the filler hole and install the radiator cap, 4. Straighten up the vehicle. Check and add coolant if necessary. Install reservoir cap Install a fuel tank (2-3) 5. Cooling System Filer Hole VTR 250 5. Cooling System Reservoir Removal / installation Remove a carburetor (6-5). Disconnect a water hose trom a filler neck. Unscrew to remove the filler neck. Remove a reservoir and drain the coolant. Reverse the removal procedure to install the reservorr. Install the carburetor (6-18), Reverse the removal procedure for installation. Fill coolant and bleed air (5-4) ‘Thermostat Removal Remove a carburetor (6-5). Drain coolant (5-4). Unscrew three thermostat cover bolts. Unscrew a thermostat mount bolt. Remove the thermostat cover. Remove an O-Ring. VTR 250 Remove the thermostat from the thermostat housing, When removing a thermostat housing, disconnect a thermo switch connector and a water hose to remove the housing. Notes The thermo switch is quite sen: the switch was dropped or it experienced any shock, check its operation before installation. if Thermo switch inspection (Sec. 19). Notes * Replace the thermostatif it is opened in normal temperature. + Tho sensor of the thermostat is small and it has thermal inertia. Maintain full open temperature for five minutes before measuring the valve opening lift. should not contact the bottom of testing container. ‘+ The thermostat and a thermometer Place the thermostat in the container. Gradually increase the water temperature to check the valve opening temperature. vi jing commencing temperature: 82°c Eully opened lift @ temperature: 8mm or above @ 95°c. Installation Face the air bleeding hole on the thermo: iin the direction shown in the photograph install the thermostat to its housing. stat to a8 5. Cooling System VTR 250 5. Cooling System Install a new O-Ring to the housing cover. Set the cover to the housing and screw cover bolts and mount bolt Note: The front two bolts earth the thermo switch, Use unpainted (Silver) bolts Fill coolant and bleed air (5-4) Install a fuel tank (2-3). Badiator Notes: Do not damage radiator fins. Removal Remove a carburator (6-5). Drain coolant (5-4). Disconnect a fan motor coupler. Disconnect Fan Notor Coupler VTR 250 5. Cooling System Disconnect a radiator lower hose. Unclamp a fan motor switch harness from the harness clamp. Unscrew radiator upper mount bolts. Remove a mount rubber from a cylinder head cover mount bolt to remove the radiator. Disassembly Disconnect a fan motor switch connector and unclamp a fan motor wire. Unscrew three shroud bolts and disconnect an earth lead to remove a shroud fan motor Assy. Fan motor switch inspection, removal / installation (Sec. 19). Unscrew a nut to remove a cooling fan. VTR 250 5. Cooling System Unscrew three screws to remove a fan motor. ca Badiator Inspection Inspect the radiator for core clogging and fin bending. crew [ Not | If the clogged cores are more than 20% of the total area, adjust or replace the radiator. Straighten the bent fins with a wiring screwdriver. Assembly ‘cBoting Fan Motor ehitn Lexa VTR 250 5. Cooling System Set the fan motor to the shroud and tighten or three screws. Set the fan to the shaft by aligning the flat part of the hole in the fan and the shaft. Apply screw locker to the nut thread and screw the nut. m) Install the shroud and the fan motor Assy to the radiator. Connect the earth lead to the position shown in the figure and screw three bolts. Connect a fan motor switch connector. VTR 250 5. Cooling System Installation Reverse the removal procedure to install. Torque: Radiator mount SH bolt: 12Nm (1.2kgf-m) Fill coolant and bleed air (5-4). Water Pump. Inspection Check the inspection hole at the bottom of a water pump for coolant leak. Ifthe coolant is leaking, the water pump Assy should be replaced as it indicates the mechanical seal is broken. Removal Drain coolant (5-4). Unscrew three water pump cover bolts to remove a pump cover. Remove an O-Ring. Disconnect a water hose from the water pump cover. 5-12 VTR 250 5. Cooling System Disconnect a water pipe from the crankcase and the water pump. Remove the water pump from the crankcase. Notes: Do not disassemble the pump further on. Replace the pump Assy if any defect was found Installation Apply engine oil toa new O-Ring. Install the water pump by aligning the cutoff on the water pump shaft end with the oil pump shaft end. Install new O-Rings to both ends of the water pipe. Install the water pipe. VTR 250 5. Cooling System Set a new O-Ring to the groove on the water pump body. Install a water pump cover and screw three mount bolts. Torque: 13Nm (1.3kg-m) Fill coolant and bleed air (5-5). 6. Fuel System VTR 250 VTR 250 6. Fuel System Service Information. Carburottor ASsOmbly...-seeso-- 6-12 1 Troubleshooting. 2. | Carburettor Uniting, 6-16 Fuel Auto Cock... 3. | Carburettor installation. 6-18 Carburettor Removal. 5 _| Carburetor Synchronisation... 6-20 Carburetor Separation. 8 | Pllot Screw Adustment.......osenssenese | 6-21 Carburetor Disassembly...... 9 Petrol is highly inflammable. Keep away from any flame/spark. Evaporated petrol is explosive. Ventilate the working area. * All service work in this chapter can be conducted without removing the engine from the frame. + Do not twist or bend cables hard. Deformed or damaged cables may cause failure. + Drain fuel from the carburettor by loosening the drain screw on a float chamber prior to disassembling the carburettor. * Replace O-Rings when disassembled. + Seal the carburettor intake port with a cloth or tape to prevent object falling into the engine. * Ifthe vehicle is to be stored for a month or longer, drain fuel from the float chamber. Dagraded fuel may clog the slow system and cause unstable idling. Service Standard tem Sia ‘Service Limit Type VOI0L = Setting mark VD10LA 5 : Main Jet (frontean) #115 at Carburetor ‘Slow jet (frontirear) #35 = Plotscrew | Standard | 1 fume rewind setting _[ Attar ile drop = Float level “Throttle grip free play (grip flange) Carburetor symchrorising vacuum pressure 2.864 Pa (2Ommbq) (Carburetor synchronisation reference Fear carburetor Sol VTR 250 Torque Setting Vacuum play Carburetor insulator strap Ai filter case cover screw Fuel auto cock Fuel cock lever scrow Special tool Float level gauge ‘Troubleshooting ‘The engine does not stat Fusl cock is “OFF” Fuel auto cock tube disconnected No fuel in the tank No fue! in the carburetior = Clogged fuel strainer — Clogged fuel tube = Stuck float vaive = Improper float level ‘+ Excessive amount of fuel in the cylinder Clogged air fitor Carburettor overtiow Sucking secondary alr Faulty auto bistarter valve Clogged siow sysiem or auto bistarter system Faulty ignition system (Sec. 17) The engine starts, but stops soon. Unstable idling Improper valve clearance Clogged fuel system Fault ignition eystom (Sec. 17) oo lean /too rich mixture Contaminated fuel Sucking secondary alr Improper idling rpm Improper pilot screw setting Clogged siow system Impraper float lavel Faulty carburotior synchronisation ‘Clogged fuel tank cap vent 6. Fuel System 3Nm (0.3kgf-m) 11Nm (0.1kgf-m) 4Nm (0.4kgt-m) 34Nm (3.5kgf-m) 4Nm (0.4kgf-m) 07401-0010000 Micture is too lean ‘Clogged fuel jets + Fault float valve * Too low float levet * Clogged fuel system * Clogged carburettor air vent tube * Sucking secondary air * Clogged fuel tank cap vent © Faulty vacuum piston Mixture is too tich Biotartor io activated Faulty float valve Too high float level Clogged ar jets Dirty air fiter Carburettor overtiow Backfire /Misfire ‘= Faulty ignition system (See. 17) + Too lean mixture After burn when using engine brake ‘Too lean mixture on slow system

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