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