1994-2003 Honda VT250C (V25 Custom) Motorcycle Workshop Repair Service Manual BEST

Table of Contents Service Information 1 Exterior parts and muffler 2 Inspection and adjustment 3 Lubrication System 4 Cooling System 5 Fuel System 6 Engine Mounting / Dismounting 7 Cylinder heads and valves 8 Clutch 9 Gear shift linkage 10 Engine Crankshaft, piston and transmission 11 Front wheel, suspension and steering 12 Rear wheel, suspension 13 Frame Brake System 14 Charging system, alternator 15 Ignition System 16 Starting system, starter clutch 17 Lamp, instruments and switches 18 Wiring diagrams 19 Electrical System Troubleshooting 20

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-1 Serial number, Colour label……... 1-1 Exclusive tools………………….. 1-14 Specifications…………………….. 1-2 Oil, grease and sealant………… 1-16 Maintenance……………………… 1-4 Wiring Diagram…………………. 1-18 Torque settings…………………… 1-11 Serial Numbers, Colour Label When ordering coloured parts, specify a model name and a colour code.

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-2 Item Specification Name Length Width Height Wheel base Powerplant type Total displacement Fuel Vehicle weight Front axle Rear axle Total Seating Positions Gross weight Front axle Rear axle Total Tyre Front Rear Minimum clearance (ground) Brake – stop distance (initial speed) Minimum turning radius HONDA VT250/V25 2,315mm 845mm 1,055mm 1,620mm MC15E 0.249 Petrol/Unleaded 83kg 100kg 183kg 2 103kg 190kg 293kg 120 / 80 – 17 61S 150 / 80 – 15M/C 70S 130mm 14.0m (initial 50km/h) 3.1m Powerplant Starting method Type of the powerplant Cylinder Combustion chamber Valve operation Bore X stroke Compression ratio Maximum output power Maximum torque Valve operation timing Inlet Open Close Exhaust Open Close Lubrication Oil pump Oil filter Cooling system Radiator Water pump Electric Petrol 4 cycle/stroke V 2 abreast Pentroof D O H C chain driven 60.0 x 44.1mm 11.0 27 PS / 10,000rpm 2.3kg-m / 7,500rpm 15° BTDC (1mm lifted) 20° ABDC (1mm lifted) 30° BBDC (1mm lifted) 0° TDC (1mm lifted) Compress splash combined Trochoid Total flow filter net-paper combined Water cooled (electric fan) Colgate type (closed-sealed) Centrifugal pump Fuel System Air cleaner Carburettor Type Gas valve dia. Venturi dia. Filter paper type VDD2 32mm Variable (max lift 29mm)

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-3 Item Specification Transmission Clutch Type Operation Initial reduction Type Reduction ratio Gear shift system Type Operation Gear ratio First Second Third Fourth Fifth Final reduction Type Reduction ratio Multiple wet plate coil spring Mechanical Gear 1.821 (79/28) Full time contact Left foot pedal 2.733 (41/15) 1.800 (36/20) 1.375 (33/24) 1.111 (30/27) 0.965 (28/29) Chain 2.714 (38/14) Wheels Caster Trail 35°00 159mm Steering Steering angle Left Right 38° 38° Brake system Type Front Rear Hydraulic disc Mechanical leading / trailing shoe Shock absorbing system Suspension Front wheel Rear Telescopic type Swing arm type Frame Frame number Engine number Double cradle MC29 – 1000001 MC15E – 1200001

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-4 ♦ Maintenance Date Lubrication Item Standard Service Limit Engine oil capacity Total capacity Oil change Oil and filter change Recommended oil (select the proper viscosity grade which matches your operating temperature range) Oil pressure (at the oil pressure switch mount area) Oil pump  tip clearance  body clearance  side clearance 2.4 1.9 2.1 Honda Genuine GP (4 cycle motorcycle) SAE10W-40 or SAE20W-50 5.0-6.0kg/cm² (5,000rpm/80°c) 0.15mm 0.15 – 0.22mm 0.02 – 0.07mm 0.20mm 0.35mm 0.10mm Cooling System Item Standard Service Limit Coolant Total Reserve tank capacity Standard density Radiator cap valve opening pressure Thermostat Valve opening temp (initial) Valve full-open temp. Full open lifting 1.1 0.2 30% 1.1 – 1.4kg/cm² 80 - 84°c 95°c 8mm or more Fuel System Item Standard Service Limit Fuel tank capacity Carburettor Setting mark Main jet Front Rear Slow jet Pilot screw opening Standard After idle drop Float level Inter cylinder synchronised pressure difference Base carburettor Idling rpm Throttle grip free play (at the grip flange) 11 VDD2A #110 #108 #35 3 revs rewind 1 rev rewind 6.8mm 40mm Hg or less Rear cylinder carburettor 1,200 + 100rpm 2 – 6mm

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-5 Cylinder Head, Valve Item Standard Service Limit Cylinder compression Valve clearance IN EX Cylinder head distortion Cam shaft  Cam height IN EX  Deflection (at journal) Journal external dia. A, C B Cam shaft journal oil clearance A, C B Locker arm internal diameter Locker arm shaft external diameter Valve stem external dia. IN EX Valve guide internal dia. IN EX Valve stem guide clearance IN EX Valve guide installation height (h) Valve seat contact width Valve spring relaxed length 13.0 + 2.0kg/cm² - 400rpm 0.15 – 0.19mm 0.20 – 0.24mm 32.4612 – 32.6212mm 32.3085 – 32.4685mm 21.949 – 21.970mm 21.861 – 21.882mm 0.030 – 0.091mm 0.118 – 0.181mm 10.000 – 10.015mm 9.972 – 9.987mm 4.975 – 4.990mm 4.955 – 4.970mm 5.000 – 5.012mm 5.000 – 5.012mm 0.010 – 0.037mm 0.030 – 0.057mm 11.4 – 11.6mm 1.0mm 36.42mm 0.10mm 32.4412mm 32.2885mm 0.02mm 21.939mm 21.851mm 0.111mm 0.201mm 10.025mm 9.962mm 4.97mm 4.95mm 5.04mm 5.04mm 0.07mm 0.09mm 34.72mm Clutch Item Standard Service Limit Clutch lever free play Clutch outer internal diameter Clutch outer guide External diameter Internal diameter Oil pump drive sprocket internal dia Clutch spring relaxed length Clutch disc thickness A B Clutch plate distortion 10 – 20mm 29.000 – 29.021mm 28.967 – 28.980mm 21.995 – 22.015mm 29.025 – 29.075mm 34.79mm 3.62 – 3.70mm 2.9 – 3.0mm - 29.06mm 28.93mm 22.05mm 29.11mm 33.9mm 3.3mm 2.6mm 0.30mm

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-6 Transmission Item Standard Service Limit Gear shift pattern Gear internal dia. M4,M5 C1 C2, C3 Gear bush external dia. M4, M5 C1 C2, C3 Gear bush internal dia. M4 C1 C2 Gear bush clearance M4,M5,C1,C2,C3 Main shaft external dia. M4 bush Counter shaft external dia. C1 bush C2 bush Bush shaft clearance M4 bush C1, C2 bush Shift fork Catch thickness Internal diameter Shift fork shaft external diameter 1 – N – 2 – 3 – 4 – 5 25.000-25.021mm 23.000-23.021mm 28.000-28.021mm 24.959-24.980mm 22.959-22.980mm 27.959-27.980mm 21.985-22.006mm 20.020-20.041mm 25.000-25.021mm 0.020-0.062mm 21.959-21.980mm 19.987-20.000mm 24.967-24.980mm 0.005-0.047mm 0.020-0.054mm 5.93-6.00mm 12.000-12.021mm 11.969-11.980mm 25.05mm 23.05mm 28.05mm 24.92mm 22.92mm 27.92mm 22.07mm 20.06mm 25.05mm 0.10mm 21.92mm 19.97mm 24.95mm 0.15mm 0.15mm 5.60mm 12.04mm 11.90mm

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-7 Cylinder, Piston Item Standard Service Limit Cylinder Internal diameter Top surface distortion True-circle True-cylinder Piston External diameter (D) D-measuring point (H) Pin hole diameter (d) Cylinder – Piston clearance Piston pin external diameter Piston – Piston pin clearance Piston pin – Conrod clearance Piston ring Ring groove-ring clearance Top Second Ring cut out Top Second Side rail Installing – direction work Top Second 60.000 – 60.015mm - - - 59.970 – 59.990mm - 16.002 – 16.008mm 0.010 – 0.045mm 15.994 – 16.000mm 0.002 – 0.014mm 0.016 – 0.040mm 0.025 – 0.060mm 0.025 – 0.055mm 0.20 – 0.35mm 0.20 – 0.35mm 0.20 – 0.70mm R mark towards top R N mark towards top 60.10mm 0.10mm 0.05mm 0.05mm 59.86mm - 16.028mm 0.10mm 15.98mm 0.048mm 0.10mm 0.10mm 0.10mm 0.65mm 0.50mm 0.85mm - - Crankshaft Item Standard Limitation Crankshaft type Crankshaft bearing type Conrod smaller end internal diameter bigger end side clearance Crankpin oil clearance Conrod bearing selection Main journal oil clearance Main bearing selection Forged one-piece crankshaft Split plane bearing 16.016 - 16.034mm 0.1 – 0.3mm 0.028 – 0.052mm ( 11-14) 0.028 – 0.052mm ( 11-14) - - 16.08mm 0.4mm 0.07mm - 0.07mm -

VT250C 1. Service Information ________________________________________________ ________________________________________________ 1-8 Front / Rear Wheel Item Standard Service Limit Tyre groove depth Front Rear Tyre air pressure one person (normal/high speed) Front Rear two people (normal) Front Rear Front axle deflection Wheel rim deflection Radial Side balance weight Front Drive chain free play (when using a sidestand) Size / links DID RK 2.00kg/cm² 2.00kg/cm² 2.00kg/cm² 2.00kg/cm² 25 – 35mm DID520V6 / 110 RK520SMOZ2 / 110 1.5mm 2.0mm 0.2mm 2.0mm 2.0mm 60g Front suspension Item Standard Service Limit Fork Stroke Pipe diameter Spring relaxed length Pipe bent Oil type Oil level Oil capacity Steering load 150mm 41mm 329.2mm Honda Ultra Cushion Oil #10 150mm 477cc 0.93 – 1.40kg 319.3mm 0.20mm Rear Suspension Item Standard Service Limit Rear suspension stroke Rear cushion damper type 57.5mm conventional type Brake System Item Standard Service Limit Front brake Lever free play Brake fluid type Pad thickness Disc thickness Disc deflection Master cylinder internal diameter Master piston external diameter Caliper cylinder internal diameter Caliper piston external diameter Rear brake Pedal free play Lining thickness Drum internal diameter 10 – 20mm DOT 4 4.8 – 5.2mm 11.000 – 11.043mm 10.957 – 10.984mm 25.400 – 25.450mm 25.335 – 25.368mm 20 – 30mm 5.0mm 160.0 – 160.3mm Up to the wear limit groove 4.0mm 0.1mm 11.055mm 10.945mm 25.460mm 25.310mm 2.0mm 161mm

1994-2003 Honda VT250C (V25 Custom) Motorcycle Workshop Repair Service Manual BEST

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