Info Honda CBR250 CBR250R CBR250RR, MC14 MC17 MC19 MC22 Specification's and Maintenance

Found this file online, not sure if it has been posted here before?







Covering Models


· CBR250(F) – MC14

· CBR250R(H) – MC17

· CBR250R(J, K) – MC19

· CBR250RR(L, N, R) – MC22




Written By: DOS–Boy

Date: 25th March 2001

Updated: 28th September 2003

Email: dos_boy250@hotmail.com

Title Art Work by: “Unknown”

Model Photos : www.honda.co.jp

Web Site: www.cbr250.com (Rory’s page)





Disclaimer: Only use this as a guide; I don’t take any responsibility for incorrect information that may result in damages. Information Translated from the Japanese Service Manual, Produced by the Honda Corporation & Honda Japan’s Web Site.


Specifications
· Model Identification – These are all the models Honda officially made according to the CBR250 Japanese Manual;
Note: There is only electrical loom & paint scheme differences between the
CBR250R(J) and CBR250R(K) – Models, and only paint scheme differences between the CBR250RR(L) and CBR250RR(N) – Models


CBR250(F) : 1986;

Aka : CBR250 Four

Engine Number : MC14E – 1000001 ~

Frame Number : MC14 – 1000001~









CBR250R(H) : 1987;

Aka : CBR250 Hurricane

Engine Number : MC14E – 1000001~

Frame Number : MC17 – 1000001~






CBR250R(J) : 1988;

Aka : CBR250 Single R

Engine Number : MC14E – 1000001~

Frame Number : MC19 – 1000001~









CBR250R(K) : 1989;

Aka : CBR250 Single R

Engine Number : MC14E – 1000001~

Frame Number : MC19 – 1000001~








CBR250RR(L) : 1990 – 1991;

Aka : CBR250 Double R

Engine Number : MC14E – 1140001~

Frame Number : MC22 – 1000001~









CBR250RR(N) : 1992 – 1993;

Aka : CBR250 Double R

Engine Number : MC14E – 1140001~

Frame Number : MC22 – 1050001~










CBR250RR(R) : 1994 – 1999;

Aka : CBR250 Double R

Engine Number : MC14E – 1400001~

Frame Number : MC22 – 1100001~

Note: CBR250RR(RII) – Models are just post 1997 CBR250RR(R) – Models







HRC – None of these models have been officially confirmed by Honda Japan.

CBR250R(J or K) – Rumoured to rev to 24,000rpm. Exhaust consisted

of just header pipes, only known race was in the late 80’s “Isle of Man TT”. Different to the CBR250R’s raced in the “All Japan Series”.



HONDA – Only known information is unseen Microfiche of engine.
CBR250RR(?) – Rumoured to have the MC16E engine in a MC22
frame. Was thought to be the next model, but never eventuated.



OTHER – Yet to be confirmed actually exists, as only external pics seen.
CBR250RR(L, N or R) Turbo – Private owner, rumoured to still be
in Japan. Blow-through system instead of EFI. Power expected around the 92BHP at the rear wheel, with modified engine internals.



· Restrictions
Speed Restriction;

CBR250(F) + CBR250R(H+J+K) + CBR250RR(L+N+R) : ~180km/h
POSH Moto Firm and M–Parts make Black Boxes
OR
Remove Trigger Disc inside the Speedo
Power Restriction (Deliberate Restrictions made by Honda Corporation
to comply with Japanese Law);

CBR250(F) + CBR250R(H+J+K) + CBR250RR(L+N) : None

CBR250RR(R) : Inlet Port sizes reduced

Rev–Limit Restriction;

CBR250(F) + CBR250R(H+J+K) + CBR250RR(L+N+R) : 18,500rpm


· General


Cylinder numbering (from left to right when sitting on bike) : 1 – 2 – 3 – 4
Firing Order : 1 – 2 – 4 – 3

Spark Plugs :
Type : NGK CR9EH–9 or (CR9EHVX–9)

Gap : 0.8 – 0.9 mm

Top Speed : 180km/h (speed limited), unrestricted 200km/h (approx.)



Max Power : (BHP = PS * 0.986) (kW = BHP * 0.7457)

CBR250(F) : 45PS at 14,500rpm

CBR250R(H+J+K) : 45PS at 15,000rpm
CBR250RR(L+N) : 45PS at 15,000rpm

CBR250RR(R) : 40PS at 14,500rpm

Max Torque : (Lb/ft = kg/m * 7.233) (Nm = kg/m * 9.804)

CBR250(F) : 2.5kg/m at 10,500rpm

CBR250R(H+J+K) : 2.6kg/m at 10,500rpm

CBR250RR(L+N) : 2.5kg/m at 12,000rpm

CBR250RR(R) : 2.4kg/m at 11,500rpm



Carburettor Type : Keihin 4 x CV

Starter : Electric

Clutch : Wet Multi–Plate

Transmission : 6–speed Constant Mesh

Final Drive : Chain



Bore x Stroke : 48.5mm x 33.8mm

Displacement : 249cm3



Tyre Pressure (unless indicated on tyre sidewall);

CBR250(F) + CBR250R(H);

Front : 2.0kg/cm2

Rear : 2.5kg/cm2

CBR250R(J+K) + CBR250RR(L+N+R);

Front : 2.25kg/cm2

Rear : 2.5kg/cm2

Tyres :

CBR250(F+H);

Front : 100/80–17 52H

Rear : 130/70–17 62H

CBR250R(J+K);

Front : 100/80–17 52H

Rear : 140/70–17 66H

CBR250RR(L+N+R);

Front : 110/70R17 54H

Rear : 140/60R17 63H



Front Suspension : Conventional Forks - 37mm Diameter (No Adjustments)

Rear Suspension : Mono Shock (Preload only adjustments)





Front Brake;

CBR250(F)+CBR250R(H):???mm Dual disc,2 piston Hydraulic callipers

CBR250R(J+K) : ???mm Single disc, 2 piston Hydraulic callipers

CBR250RR(L+N+R) : 275mm Dual disc, 2 piston Hydraulic callipers

Rear Brake;

CBR250(F) : 141mm Cable Drum Brake

CBR250R(H+J+K) + CBR250RR(L+N+R) : 220mm Single disc, 1 piston

Hydraulic calliper

Dimensions : (Length x Width x Height)

CBR250(F) : 2000x685x1120

CBR250R(H) : 2000x680x1120mm

CBR250R(J+K) : 2020x685x1075mm

CBR250RR(L+N+R) : 1975x675x1080mm

Wheel Base :

CBR250(F) : 1370mm

CBR250R(H) : 1365mm

CBR250R(J+K) : 1365mm

CBR250RR(L+N+R) : 1345mm

Ground Clearance :

CBR250R(F+H) : 140mm

CBR250R(J+K) : 135mm

CBR250RR(L+N+R) : 130mm



Weight (Dry) :

CBR250(F) : 153kg (77kg – Front, 76kg – Rear)

CBR250R(H) : 155kg (78kg – Front, 77kg – Rear)

CBR250R(J+K) : 154kg (77kg – Front, 77kg – Rear)

CBR250RR(L+N) : 157kg (80kg – Front, 77kg – Rear)

CBR250RR(R) : 158kg (81kg – Front, 77kg – Rear)

 

· Engine (Liq.–cooled,4–stroke,16–valve DOHC,inline 4 Cyl.)

Engine Oil Type : API grade SE, SF or SG motorcycle oil
Engine Oil Viscosity : SAE10W–40 or SAE20W–50

Oil Capacity :

Oil change : 2.2 litres

Oil and Filter change : 2.4 litres

Engine overhaul with new filter : 2.7 litres

Oil Pressure : 4.0 – 5.0kg/cm2 at 6,000rpm, oil at 60oC

Inlet Valve (1mm Lift);

Opens (Before Top Dead Centre);

CBR250(F) : 10˚ BTDC

CBR250R(H) : 18˚ BTDC

CBR250R(J+K) + CBR250RR(L+N) : 19˚ BTDC

CBR250RR(R) : 20˚ BTDC

Closes (After Bottom Dead Centre);

CBR250(F) : 40˚ ABDC

CBR250R(H) : 34˚ ABDC

CBR250R(J+K) + CBR250RR(L+N) : 33˚ ABDC

CBR250RR(R) : 20˚ ABDC


Exhaust Valve (1mm Lift);

Opens (Before Bottom Dead Centre);

CBR250(F) : 30˚ BBDC

CBR250R(H+J+K) + CBR250RR(L+N) : 36˚ BBDC

CBR250RR(R) : 29˚ BBDC

Closes (After Top Dead Centre);

CBR250(F) : 10˚ ATDC

CBR250R(H+J+K) + CBR250RR(L+N) : 11˚ ATDC

CBR250RR(R) : 3˚ ATDC

Cam Lobe Diameter;

CBR250(F) + CBR250R(H) :

IN : 29.15mm

Service Limit : 29.00mm

EX : 28.85mm

Service Limit : 28.70mm

CBR250R(J+K) :

IN : 29.44 – 29.68mm

Service Limit : 29.41mm

EX : 28.96 – 29.20mm

Service Limit : 28.85mm

CBR250RR(L+N) :

IN : 28.94 – 29.18mm

Service Limit : 28.91mm

EX : 28.51 – 28.75mm

Service Limit : 28.48mm

CBR250RR(R) :

IN : 28.72 – 28.80mm

Service Limit : 28.69mm

EX : 28.51 – 28.75mm

Service Limit : 28.48mm

Cam Journal Diameter : 19.978 – 19.993mm

Service Limit : 19.970mm

Cam Journal Oil Clearance;

Cylinders 1,2,4 : 0.015 – 0.057mm

Service Limit : 0.06mm

Cylinder 3 : 0.025 – 0.067mm

Service Limit : 0.07mm

Head INLET;

Stem Diameter :

CBR250(F) : 3.970 – 3.995mm

Service limit – 3.965mm

CBR250R(H) : 3.478 – 3.492mm

Service limit – 3.473mm

CBR250R(J+K) + CBR250RR(L+N+R) : 3.481 – 3.495mm

Service limit – 3.47mm

Guide Bore Diameter :

CBR250(F) : 4.000 – 4.012mm

Service limit – 4.065mm

CBR250R(H+J+K) + CBR250RR(L+N+R) : 3.500 – 3.512mm

Service limit – 3.565mm

Stem to Guide Clearance :

CBR250(F) : 0.005 – 0.042mm

Service limit – 0.1mm

CBR250R(H) : 0.008 – 0.034mm

Service limit – 0.092mm

CBR250R(J+K) + CBR250RR(L+N+R) : 0.005 – 0.042mm

Service limit – 0.1mm

Seat Width : 0.8mm

Service limit – 1.3mm

Head EXHAUST;

Stem Diameter :

CBR250(F) : 3.950 – 3.975mm

Service limit – 3.935mm

CBR250R(H+J+K) + CBR250RR(L+N+R) : 3.460 – 3.475mm

Service limit – 3.445mm

Guide Bore Diameter :

CBR250(F) : 4.000 – 4.012mm

Service limit – 4.065mm

CBR250R(H+J+K) + CBR250RR(L+N+R) : 3.500 – 3.512mm

Service limit – 3.565mm

Stem to Guide Clearance :

CBR250(F) : 0.005 – 0.050mm

Service limit – 0.13mm

CBR250R(H) : 0.025 – 0.052mm

Service limit – 0.132mm

CBR250R(J+K) : 0.005 – 0.050mm

Service limit – 0.13mm

CBR250RR(L+N+R) : 0.020 – 0.047mm

Service limit – 0.13mm

Seat Width : 1.0mm

Service limit – 1.5mm

Valve Spring Free Length (IN and EX) :

CBR250(F) : 37.3mm

Service limit – 36.3mm

CBR250R(H) : 38.58mm

Service limit – 37.6mm

CBR250R(J+K) : 37.3mm

Service limit – 36.3mm

CBR250RR(L+N+R) : 37.65mm

Service limit – 36.65mm

Inlet Port Diameter :

CBR250(F) : 28mm ???

CBR250R(H) : 30mm ???

CBR250R(J+K) : 32mm ???

CBR250RR(L+N) : 30mm ???

CBR250RR(R) : 25mm ???

Valve Clearances (COLD Engine, i.e. leave engine overnight)

Inlet valves : 0.16mm ± 0.03mm

Exhaust valves : 0.23mm ± 0.03mm

Cylinder Compression :

CBR250(F) + CBR250R(H+J+K) : 11.0 to 1

CBR250RR(L+N+R) : 11.5 to 1

Cylinder Head : Warpage (max) – 0.10mm


Bore to Piston Clearance : 0.01mm – 0.04mm

Service Limit – 0.1mm

Clutch;

Friction Plates : 7

Plain Plates (Steelies) : 6

Friction Plate Thickness : 2.6mm

Plain Plate Warpage : 0.3mm

Spring Free Height : 33.79mm

Chain;

CBR250(F) + CBR250R(H) : 520 Pitch, 108 Links

CBR250R(J+K) + CBR250RR(L+N+R) : 428 Pitch, 136 Links

Gear Box;

Primary Reduction Ratio : 2.966

Ratios;

1st : 2.733 (41/15T)

2nd : 2.000 (38/19T)

3rd : 1.590 (35/22T)

4th : 1.333 (32/24T)

5th : 1.153 (30/26T)

6th : 1.035 (29/28T)

Final Reduction Ratio;

CBR250(F) : 2.500 (35/14T) – 520 Pitch

CBR250R(H) : 3.142 (44/14T) – 520 Pitch

CBR250R(J+K) : 3.176 (54/17T) – 428 Pitch

CBR250RR(L+N+R) : 3.058 (52/17T) – 428 Pitch



· Cooling System
Coolant Capacity :

CBR250(F+H) : 1300cc (1100cc – Radiator, 200cc – Engine)

CBR250R(J+K) : 1500cc (1300cc – Radiator, 200cc – Engine)

CBR250RR(L+N+R) : 1570cc (1350cc – Radiator, 220cc – Engine)

Coolant : 50% Distilled Water and 50% Pure Coolant (containing corrosion

inhibiter, anti–freeze and anti–boil properties)

Pressure Cap Opening;

CBR250(F) + CBR250R(H) : 0.75 – 1.05kg/cm2

CBR250R(J+K) : 0.95 – 1.25 kg/cm2

CBR250RR(L+N+R) : 1.10 – 1.40kg/cm2

Fan Switch;

Cut In : 98 to 102oC

Cut Out : 93 to 97oC

Coolant Temperature Sensor Resistance at;

50oC : 153.9W

80oC : 51.9W

120oC : 16.1W

Thermostat;

Opening Temp : 80 to 84oC

Valve Lift : 8mm at 95oC


· Fuel


Fuel Capacity;

CBR250(F) + CBR250R(H) : 14 Litres + 2.5 Litre Reservoir

CBR250R(J+K) : 13 Litres + 2 Litre Reservoir

CBR250RR(L+N+R) : 13 Litres + 1.6 Litre Reservoir

Fuel Grade : Unleaded min. 91 RON (Research Octane Number)

Engine Idle Speed : 1,500rpm ± 100rpm



Carburettor Synchronisation (max difference) : 40mmHg

Carburettor ID Code (Keihin):

CBR250(F) : VG01A

CBR250R(H) : VG03A

CBR250R(J+K) : VG05A

CBR250RR(L+N) : VP20A

CBR250RR(R) : VP20B

Carburettor Throat Diameter :

CBR250(F) : 25mm

CBR250R(H) : 27mm

CBR250R(J+K) : 28.5mm

CBR250RR(L+N+R) : 29mm

Float Heights (When measured at 30o or needle valve seated and spring NOT compressed):

CBR250(F) : 7mm

CBR250R(H) : 7mm

CBR250R(J+K) : 8mm

CBR250RR(L+N+R) : 13.7mm

Carburettor Jet Sizes :

CBR250(F) ;

Main Jet : #85

Pilot Jet : #35

CBR250R(H);

Main Jet : #88

Pilot Jet : #35

CBR250R(J+K);

Main Jet : #85

Pilot Jet : #35

CBR250RR(L+N);

Main Jet : Cylinders 1+4 : #105

Cylinders 2+3 : #102

Pilot Jet : #35

CBR250RR(R);

Main Jet : Cylinder 1+4 : #112

Cylinder 2+3 : #110

Pilot Jet : #35

Carburettor Pilot Screw Mixture Settings (Stock Air-Filter,Exhaust,Ports,Jets)

CBR250(F) + CBR250R(H): 2½ screws

CBR250R(J+K) : 15/8 screws

CBR250RR(L+N) : 1¾ screws

CBR250RR(R) : 21/8 screws


· Suspension

Fork Oil : 10W Fork Oil

Fork Oil Height (from top when fork fully compressed with spring and spacer removed) :

CBR250(F) : 114mm or 290ml ± 2.5ml

CBR250R(H) : 100mm or 302ml ± 2.5ml

CBR250R(J+K) : 95mm ± 6mm or 362ml ± 2.5ml

CBR250RR(L+N+R) : 83mm or 383ml ± 2.5ml

Fork Rake;

CBR250(F) + CBR250R(H) : 26000’’

CBR250R(J+K) : 25000’’

CBR250RR(L+N+R) : 24000’’

Fork Trail;

CBR250(F) + CBR250R(H) : 97mm

CBR250R(J+K) + CBR250RR(L+N+R) : 89mm

Rear Shock Spring Free Length;

CBR250(F) : 186.0mm ± 3.1mm

CBR250R(H) : 175.0mm ± 3.1mm

CBR250R(J+K) : 168.7mm ± 3.1mm

CBR250RR(L+N+R) : 140.9mm ± 3.1mm



· Wheels

Max Wheel Runout (front & back);

Axial (side to side) : 2.0mm

Radial (out of round) : 2.0mm

Max Axial Runout (front & back) : 0.2mm

 

· Fuses

Main/Ignition : 10Amp

Headlights : 15Amp

Tail Lights/Turn Signal Lights : 10Amp

Fan : 10Amp



· Bulbs

Headlights;

Aust/UK : 60/55Watt H4 Halogen

Japan : 60/35Watt Halogen

Park Lights;

Aust/UK : 5Watt

Japan : 1.7Watt

Brake/Tail Lights;

Aust/UK : 21/5Watt

Japan : 18/5Watt

Turn Signal Lights;

Aust/UK : 21Watt

Japan : 15Watt

Instrument Lights;

Aust/UK : 3.4Watt

Japan : 1.7Watt


· Ignition System

General : Full transistor type battery firing (CDI)

Firing Order : 1 – 2 – 4 – 3

Ignition Timing;

Idle (1,500rpm – Before Top Dead Centre);

CBR250(F) + CBR250R(H) : 20o BTDC

CBR250R(J+K) + CBR250RR(L+N): 23o BTDC

CBR250RR(R) : 20o BTDC

Full Advance : ???o BTDC



Pulse Generator Coils Resistance;

CBR250(F) + CBR250R(H+J+K) : 315 –385W @ 20oC

CBR250RR(L+N+R) : 340 – 420W @ 20oC



Ignition HT Coils :

Primary Winding Resistance;

CBR250(F) + CBR250R(H) : 2.6 – 3.2W @ 20oC

CBR250R(J+K) : 2.52 – 3.08W @ 20oC

CBR250RR(L+N+R) : 2.0 – 3.5W @ 20oC

Secondary Winding Resistance (with plug caps and leads);

CBR250(F) + CBR250R(H) : 21 – 29kW @ 20oC

CBR250R(J+K) : 11.7 – 14.3kW @ 20oC

CBR250RR(L+N+R) : 23 – 37kW @ 20oC

Secondary Winding Resistance (without plug caps and leads);

CBR250(F) + CBR250R(H) : 13 – 17kW @ 20oC

CBR250R(J+K) : 11.7 – 14.3kW @ 20oC

CBR250RR(L+N+R) : 13 – 17kW @ 20oC



· Electrical System

Battery :

CBR250(F) + CBR250R(H);

Type : 12V 8Amp

Current Leakage : 0.9Amp

Voltage : 13.0 – 13.2 Volt @ 20oC

CBR250R(J+K) + CBR250RR(L+N+R);

Type : 12V 6Amp

Current Leakage : 0.6Amp

Voltage : 13.0 – 13.2 Volt @ 20oC



Charging System;

Current Leakage : 1mA (max)

Regulator Voltage Output;

CBR250(F) + CBR250R(H+J+K) : 14 – 15V @ 1,900rpm

CBR250RR(L+N+R) : 14 – 15V @ 2,000rpm

Regulator Current Output;

CBR250(F) + CBR250R(H+J+K) : 18.5Amp @ 5,000rpm

CBR250RR(L+N+R) : 270W @ 5,000rpm

Stator Coil Resistance;

CBR250(F) + CBR250R(H+J+K) : 0.3 – 0.4W @ 20oC

CBR250RR(L+N+R) : 0.1 – 0.5W @ 20oC


· Miscellaneous

Chain;

CBR250(F) + CBR250R(H) : RK520??? or DID520???

CBR250R(J+K) + CBR250RR(L+N+R) : RK428SMO or DID428VS1

Chain Slack : 20 – 25mm



Clutch Cable free play : 10 – 20mm

Throttle Cable free play : 2 – 6mm



Max. Brake Disc Warpage : 0.3mm

Brake Disc Minimum Thickness : Stamped on Disc

OR

Front/Rear : 4.0mm

Front/Rear – Service Limit : 3.5mm

Rear – CBR250(F) ONLY – Drum Brake Diametre : 141.0mm



Brake Disc Pad Minimum Thickness : 2.0mm

Drum Brake Pad Minimum Thickness : CBR250(F) ONLY – 2.0mm





· Lubricants

Brake Fluid : DOT4

Chain Lubricant : SAE80 or 90 gear oil, aerosol chain lube for O–ring chains

or chain saw oil.

Steering Head Bearing : Lithium–based multi–purpose grease

Wheel Bearings (unsealed, recommend using sealed) : Lithium–based

Multi–purpose grease

Swing–arm Pivot bearings : Molybdenum Disulphide grease

Suspension Linkage bearings : Molybdenum Disulphide grease

Bearing seal lips : Lithium–based multi–purpose grease

Gear–change lever/Clutch level/Rear brake pivot : Molybdenum

Disulphide grease or Dry film lubricant (graphite)

Front brake lever/Calliper piston tip : Molybdenum Disulphide grease or

Dry film lubricant (graphite)

Cables : Cable lubricant or 10W40 motor oil

Side–stand pivot : Molybdenum Disulphide grease

Throttle Grip : Multi–purpose grease or Dry film lubricant (graphite)

 

· Torque Settings for Important Fasteners



Standard Torque Values (measured from thread NOT head);

Item

Torque kg-m (ft-lb)

5mm Bolt/Nut

0.5kg-m (4ft-lb)

6mm Bolt/Nut

1.0kg-m (7ft-lb)

8mm Bolt/Nut

2.2kg-m (16ft-lb)

10mm Bolt/Nut

3.5kg-m (25ft-lb)

12mm Bolt/Nut

5.5kg-m (40ft-lb)

5mm Screw

0.4kg-m (3ft-lb)

6mm Screw and 6mm Flange Bolt with 8mm Head

0.9kg-m (7ft-lb)

6mm Flange Bolt/Nut

1.2kg-m (9ft-lb)

8mm Flange Bolt/Nut

2.7kg-m (20ft-lb)

10mm Flange Bolt/Nut

4.0kg-m (29ft-lb)





Engine;

Item

Torque (kg-m)

Remarks

Cylinder Head Cover Bolt

0.8 – 1.2kg-m


Camshaft Holder Bolt

1.2 – 1.6kg-m


Cam Gear Holder Base Bolt

1.8 – 2.2kg-m


Spark Plug

1.2 – 1.4kg-m


Cylinder Head Bolt

1.7 – 2.1kg-m

Apply Oil to Seat

Flywheel Rotor Bolt

8.0 – 9.0kg-m


Clutch Lock Nut

6.0 – 7.0kg-m


Crankshaft Bolts

2.1 – 2.5kg-m

Apply Oil to Seat

Crankcase Bolt

1.0 – 1.4kg-m

Apply Oil to Seat

Gearshift Lever Pinch Bolt

1.0 – 1.4kg-m


Drive Sprocket Bolt

5.2 – 6.0kg-m


Temp Sensor

1.0 – 1.4kg-m

Apply Sealant to Thread

Cooling Fan Switch

1.8 – 2.0kg-m


Oil Pressure Switch

1.0 – 1.4kg-m

Apply Sealant to Thread

Neutral Switch

1.0 – 1.4kg-m


Thermostat Cover Bolt

1.0 – 1.4kg-m


Radiator Mounting Bolt

1.0 – 1.4kg-m


Connecting Rod Nuts

1.5 – 1.9kg-m

Apply Oil to the Seat & Threads

Timing Hole Cover & Centre Plug

1.8 – 2.0kg-m

Apply Oil to the O-ring & Molybdenum Disulfide Grease to the Thread

Gearshift Drum Centre Bolt

2.1 – 2.5kg-m

Apply Locking Agent to Thread

Oil Drain Plug

3.5 – 4.0kg-m


Oil Filter Bolt

1.5 – 2.0kg-m


Oil Pump Sprocket Bolt

1.3 – 1.7kg-m


Alternator/Clutch Cover

1.2 – 1.4kg-m


Starter Motor Cover

1.2 – 1.4kg-m





Chassis;

Item

Torque (kg-m)

Remarks

Sub-Frame Bolt

2.7 – 3.0kg-m


Engine Hanger Bolt

3.5 – 4.5kg-m


Engine Top Mount Bolts

4.5 – 5.5kg-m


Handlebar Pinch Bolt

2.5 – 3.0kg-m


Front Axle Nut

5.5 – 6.5kg-m


Front Axle Holder Nut

1.8 – 2.5kg-m


Steering Adjustment Nut

5.0 – 6.0kg-m


Steering Stem Nut

9.0 – 12.0kg-m


Fork Top Tree Bolt

0.9 – 1.3kg-m


Fork Bottom Tree Bolt

3.0 – 4.0kg-m

Apply Locking Agent to Thread

Fork Dampner Rod Allen Bolt

2.0 – 2.2kg-m

Apply Locking Agent to Thread

Handle Master Cylinder Bolt

1.0 – 1.4kg-m


Rear Brake Calliper Bolt

2.4 – 3.0kg-m


Rear Shock Absorber Top Mounting Bolt

5.0 – 6.0kg-m


Shock Link-to-frame Bolt

5.0 – 6.0kg-m


Shock arm-to-link Bolt

5.0 – 6.0kg-m


Shock Arm-to-Swing Arm Bolt

5.0 – 6.0kg-m


Rear Wheel Nut

8.0 – 10kg-m


Swing Arm Pivot Nut

6.0 – 7.0kg-m


Swing Arm Pivot Collar

1.0 – 2.0kg-m


Swing Arm Pivot Crown Nut

6.0 – 7.0kg-m


Front Brake Calliper Bolt

2.4 – 3.0kg-m

Apply Locking Agent to Threads

Brake Hose Bolt

3.0 – 4.0kg-m


Brake Calliper Bleed Valve

0.4 – 0.7kg-m


Brake Pad Pin

1.5 – 2.0kg-m


Foot Peg Stay

2.5 – 3.0kg-m


Exhaust Pipe Bolt

2.4 – 3.0kg-m


Exhaust Pipe Header Nut

1.0 – 1.4kg-m


Side Stand Bracket Bolt

3.5 – 4.5kg-m


Front Tank Mounting Bolt

0.8 – 1.2kg-m


Rear Tank Mounting Bolt

1.8 – 2.5kg-m


Air-Box Screws

0.6 – 1.0kg-m


Front Sprocket Bolt

5.5 – 6.0kg-m


Rear Sprocket Bolts

5.0 – 5.5kg-m













Aftermarket Parts Manufactures (1¥ = AUS$0.0148838)
· Exhaust Systems

NASSERT: Nassert–R (35,000¥ – 103,000¥), Nassert–Basic (35,000¥ – 98,000¥)

DAISIN: RCB–B (65,000¥ – 68,000¥)

EXTEC: S/O 100 (28,000¥), S/O 120 (36,000¥), S/O 130 (41,000¥)

TECHNICAL SPORTS: SP–RH (91,000¥), SP–H (79,000¥), SS–H (41,000¥), SS(S/O) (39,000¥)

YAMAMOTO: C11–Type (90,000¥), C–Type (80,000¥)

SUPER MONKEY: Super Sports (65,000¥), Racing (60,000¥)

ETHOS: 78,000¥ – 87,000¥

POSH: 30,000¥ – 35,000¥

SANSEI: SAL–JMCA (72,000¥), S–JMCA(S/O) (32,000¥), S–RS(S/O) (32,000¥)

VEGA SPORTS: 35,000¥

SECRET SPEED: 30,000¥ – 70,000¥

MUZZY: 103,000¥

FADDY DADDY: 33,000¥

JHA: 38,000¥

OVER: 43,000¥

DAYTONA: 29,000¥

OMEGA SPEED: 36,000¥

OX RACING: 44,000¥

· Handle-Bar Clip-Ons

HURRICANE: TYPEIII (12,000¥)

POSH: 37mm 15,000¥

· Speedometers

K’s: 300km/h (21,000¥ – Parts, 24,000¥ – Kit)

· Speed-Limit De-restrictors

POSH: RED REV (4,800¥)

M-PARTS: M-MAX (4,800¥)

KITAKO: REV 3,900¥

DAYTONA: CDI (3,900¥)

· Brakes

RK: 814-FA5 (4,600¥), 814-UA7 (4,800¥)

SBS: 3,800¥ – 6,000¥

POSH: 4,800¥ – 6,000¥

DAYTONA: 2,800¥ – 5,800¥

FERODO: STD (4,800¥), SS (5,700¥), CP (4,600¥)

PROJECT: Racing 177G (6,800¥)

DUNLOP: DP–115/118 (4,900¥)

· Rear-Sets

BEET: Super Bank (40,000¥), Full Bank (33,000¥)

COERCE: Fixed (30,000¥)

MACRANE: 31,000¥

POSH: 9,800¥

· Racing Sprockets

NANKAI: Front; 13T – 15T (2,000¥), Front; 16T – 18T (2,300¥)

Rear; 49T – 57T (2,800¥)

AFAM: Front; 15T – 18T (2,800¥)

Rear; 48T – 58T (6,900¥)

 

Daily (pre–ride)

· Engine/Transmission Oil Level Check

1. Start engine, allow to reach normal operating temp.

2. Stop engine and support bike in upright position for a few minutes to allow oil to settle.

3. Remove dipstick and clean.

4. Place dipstick back in but DO NOT screw in.

5. Check level should be between the two marks.



· Brake Fluid Check

1. Support bike in upright position and check that the front brake reservoir window has brake fluid in it with a small bubble towards the top.

2. Check that the rear brake reservoir level is between the two marks.



· Coolant Level Check

1. Start engine, allow to reach normal operating temp.

2. Support bike in upright position

3. Remove radiator cap using a rag and check radiator coolant level

4. Check that the coolant reservoir level is between the two marks



· Suspension, Steering and Final drive Check

1. Check that the suspension operates smoothly without binding.

2. Check that the steering moves smoothly from lock to lock.

3. Check for slack in chain and lubricate if necessary


· Tyre Check

1. Tyres must be checked when they are COLD for the correct pressure;

2. Measure depth of tread at the centre of the tyre with a depth gauge (Honda recommends min of 2mm)

3. Check wear indicator bar on sidewall of tyre (usually an arrow or triangle with the letters TWI)


· Safety Check

1. Check that the Headlights (High and Low beam), Taillights (Brake On and Off), Instrument lights and Turn Signals work correctly.

2. Check horn works

3. Check throttle grip rotates smoothly and snaps shut when released, in all steering positions.

4. Check engine stops when the Kill Switch is operated

5. Check that the side stand return spring holds the stand securely

6. Check the clutch and brake levels operate smoothly.

7. This may seem obvious, but check that you have enough fuel to complete your journey and check for fuel leaks.

8. Ensure you use ONLY UNLEADED FUEL (Honda recommends using Premium Unleaded or Higher)


Routine Maintenance and Servicing
Note: based on which comes sooner km’s or months.

· Every 1000km

Check chain slackness and lubricate

· Every 6000km or 6months

Check idle speed

Check clutch free play

Check spark plugs

Lubricate all levers, pivots and cables

Change engine oil (Recommend every 5000km)

Clean air filter

Check wheel and tyre condition

Check coolant levels

Check brake pads, fluid levels and lights

· Every 12,000km or 12months

Change engine oil and filter (Recommend every 10,000km)

Check fuel filter and fuel lines for leaks

Check battery terminals

Check choke and throttle cables

Renew spark plugs

Check carburettor synchronisation

Check headlight aim

Check side–stand spring

Check suspension (front and back)

Check steering head & wheel bearings

Check the tightness of all nuts, bolts and fasteners

Change brake fluid

Check valve clearances

Check chain and sprocket condition

· Every 18,000km or 18months

Renew air filter

· Every 24,000km or 2years

Change coolant

Renew brake master and calliper seals

· Every 4years

Renew fuel and brake lines

· Non–Scheduled

Check cylinder compression

Check engine oil pressure

Change fork oil

· After Re–build

Treat engine gently for first few kilometres so as to make sure oil has circulated around and parts have correctly started to seat in.

Distance (km)

Max. RPM

Riding Techniques

Up to 1000km

7,500rpm

Vary Throttle Position/Speed.

1000km to 1600km

10,500rpm

Vary Throttle Position/Speed. Use full throttle for short bursts.

Over 1600km

18,500rpm

Don’t exceed Red–Line

NOTE: Never allow the engine to labour while trying to wear it in!