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Shop Manual
MC250/A
This book is Specific Shop Manual.
Refer to “Basic Shop Manual” for basic and
common maintenance instructions.
1. General Information
2. Fuel & Engine
3. Frame & Chassis
4. Electrical System
Addendum
5. MC250
Addendum
6. MC250/A/C/W
MC250/A-G (2016)
MC250-H (2017)
MC250/A/C/W-K (2019)
4. Electrical System
4. Electrical System
4. Electrical System
6-1
6. MC250/A/C/W-K ADDENDUM
A Few Words About Safety ···················· 6-2
How To Use This Manual························ 6-3
MODEL IDENTIFICATION ······················· 6-4
SPECIFICATIONS ···································· 6-5
TORQUE VALUE······································ 6-7
CABLE & HARNESS ROUTING ·············· 6-8
MAINTENANCE SCHEDULE················· 6-24
BODY PANELS ······································ 6-25
FRONT BRAKE······································ 6-27
PGM-FI SYSTEM···································· 6-32
ABS ························································ 6-34
LIGHTING SYSTEM ······························· 6-43
ELECTRICAL COMPONENT················· 6-44
MC250/A/C/W-K ADDENDUM
6-2
MC250/A/C/W-K ADDENDUM
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Improper service or repairs can create an unsafe
condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
MC250/A/C/W-K ADDENDUM
6-3
How To Use This Manual
This manual describes the service procedures for the MC250/A/C/W-K.
Refer to MC250-H SHOP MANUAL (No.62K31B0Z) for service procedures and data not included in this addendum.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message
is to help prevent damage to your vehicle, other property, or the environment.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: September, 2018
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided
safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you
about all the hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF
APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY
TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES,
MOTOR SCOOTERS OR ATVS.
MC250/A/C/W-K ADDENDUM
6-4
MODEL IDENTIFICATION
• Model name: MC250/A/C/W-K
TYPE MC250 MC250A MC250C MC250W
Code AG, LA BR BR LA
CBS – – –
ABS – – –
ETHANOL
INDICATOR
––
Code Destination
AG Argentina
LA Latin america
BR Brazil
ENGINE SERIAL NUMBER
COLOR LABEL (Except BR type)
VEHICLE IDENTIFICATION NUMBER
MC250/A/C/W-K ADDENDUM
6-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,065 mm
Overall width 753 mm
Overall height 1,072 mm
Wheelbase 1,386 mm
Seat height 784 mm
Footpeg height 320 mm
Ground clearance 192 mm
Curb weight STD 148 kg
CBS 149 kg
ABS 150 kg
Maximum weight capacity 175 kg
FRAME Frame type Diamond type
Front suspension Telescopic fork
Front axle travel 117 mm
Rear suspension Swingarm
Rear axle travel 108 mm
Front tire size 110/70R17M/C 54H
Rear tire size 140/70R17M/C 66H
Front tire brand DIABLO ROSSO II (PIRELLI)
Rear tire brand DIABLO ROSSO II (PIRELLI)
Front brake Hydraulic disc brake
Rear brake Hydraulic disc brake
Caster angle 25°33’
Trail length 101 mm
Fuel tank capacity 16.5 liters
Fuel tank reserve capacity 3.3 liters
ENGINE Cylinder arrangement Single cylinder 15° inclined from vertical
Bore and stroke 71.000 x 63.038 mm
Displacement 249.58 cm
3
Compression ratio 9.6 : 1
Valve train Chain driven, OHC
Intake valve opens 0° BTDC at 1 mm lift
closes 35° ABDC at 1 mm lift
Exhaust valve opens 40° BBDC at 1 mm lift
closes –5° ATDC at 1 mm lift
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Viscous paper filter
Engine dry weight STD 33.2 kg
CBS 33.2 kg
ABS 33.3 kg
Emission control system Crankcase emission control system
Three-way catalytic converter
FUEL SYSTEM Type PGM-FI
Throttle bore 34 mm
MC250/A/C/W-K ADDENDUM
6-6
FUEL & ENGINE SPECIFICATIONS
FUEL SYSTEM
FRAME & CHASSIS SPECIFICATIONS
FRONT WHEEL/SUSPENSION/STEERING
Unit: mm
HYDRAULIC BRAKE
Unit: mm
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission 6 speed
Primary reduction 2.863 (63/22)
Final reduction 3.076 (40/13)
Gear ratio 1st 2.846 (37/13)
2nd 1.777 (32/18)
3rd 1.272 (28/22)
4th 1.083 (26/24)
5th 0.961 (25/26)
6th 0.851 (23/27)
Gearshift pattern Left foot operated return system
1 - N - 2 - 3 - 4 - 5 - 6
ELECTRICAL Ignition system Full transistorized ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full wave rectification
Lighting system Battery
ITEM SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number GQB8A
ITEM STANDARD LIMIT
Fork Recommended fluid MOBIL ATF 200R –
ITEM STANDARD LIMIT
Front Specified brake fluid DOT3 or 4 brake fluid –
Caliper cylinder I.D. STD, ABS 25.400 – 25.450 –
CBS Upper, Lower 25.400 – 25.450 –
Center 22.650 – 22.700 –
Caliper piston O.D. STD, ABS 25.318 – 25.368 –
CBS Upper, Lower 25.318 – 25.368 –
Center 22.585 – 22.618 –
Rear Specified brake fluid DOT3 or 4 brake fluid –
Caliper cylinder I.D. STD, ABS 32.030 – 32.080 –
CBS 33.96 – 34.01 –
Caliper piston O.D. STD, ABS 31.948 – 31.998 –
CBS 33.878 – 33.928 –
MC250/A/C/W-K ADDENDUM
6-7
ELECTRICAL SYSTEM SPECIFICATIONS
BATTERY/CHARGING SYSTEM
LIGHTS/METERS/SWITCHES
TORQUE VALUE
BODY PANELS
FRONT BRAKE
ITEM SPECIFICATIONS
Battery Type STD YTZ7S
CBS, ABS DTZ6
Capacity STD 12 V – 6 Ah (10 HR)
CBS, ABS 12 V – 5 Ah (10 HR)
Voltage
(20°C)
Fully charged 12.8 V minimum
Needs charging Below 12.3 V
Charging
current
Normal STD 0.6 A/5 – 10 h
CBS, ABS 0.5 A/5 – 10 h
Quick STD 3 A/1 h
CBS, ABS 5 A/0.5 h
Current leakage 0.10 mA maximum
ITEM SPECIFICATIONS
Bulbs (LED) Front turn signal light LED
Rear turn signal light LED
Fuse Main fuse 20 A
Sub fuse 10 A x 4
ABS fuse
(ABS type)
Main 10 A
Sub 20 A x 2
ITEM Q'TY DIA TRQ REMARKS
Rearview mirror adapter bolt 2 10 20
ITEM Q'TY DIA TRQ REMARKS
Front brake hose oil bolt (CBS type) 3 10 34
Brake pipe joint nut (CBS type) 4 10 14
MC250/A/C/W-K ADDENDUM
6-8
CABLE & HARNESS ROUTING
Front
Front
Parallel.
FRONT BRAKE HOSE
LEFT HANDLEBAR
SWITCH WIRE
THROTTLE CABLE A
THROTTLE CABLE B
RIGHT HANDLEBAR
SWITCH WIRE
Contact.
CLUTCH SWITCH WIRES
FRONT BRAKE
SWITCH WIRES
CLUTCH CABLE
MC250/A/C/W-K ADDENDUM
6-9
MAIN WIRE HARNESS
MAIN WIRE HARNESS
8P (BLACK) CONNECTOR
(to FRONT SUB HARNESS)
SPEEDOMETER
20P (GRAY) CONNECTOR
INSIDE BOOT CONNECTORS:
· LEFT HANDLEBAR SWITCH 9P (BLACK)
· RIGHT HANDLEBAR SWITCH 6P
· IGNITION SWITCH 3P
· FRONT BRAKE SWITCH
MC250/A/C/W-K ADDENDUM
6-10
THROTTLE CABLE A
THROTTLE CABLE B
FRONT BRAKE HOSE
THROTTLE CABLE A
THROTTLE CABLE B
CLUTCH CABLE
FRONT BRAKE HOSE
Contact.
Contact.
FRONT BRAKE PIPE B
CLUTCH CABLE
THROTTLE CABLE B
THROTTLE CABLE A
FRONT BRAKE PIPE
ABS TYPE
MC250/A/C/W-K ADDENDUM
6-11
THROTTLE CABLE B
THROTTLE CABLE A
FRONT BRAKE HOSE
THROTTLE CABLE A
FRONT BRAKE HOSE
THROTTLE CABLE B
CLUTCH CABLE
Contact.
Contact.
CBS BRAKE PIPE B
CBS BRAKE PIPE
CLUTCH CABLE
THROTTLE CABLE B
THROTTLE CABLE A
CBS TYPE
MC250/A/C/W-K ADDENDUM
6-12
STD TYPE
THROTTLE CABLE A
THROTTLE CABLE B
FRONT BRAKE HOSE
THROTTLE CABLE A
THROTTLE CABLE B
CLUTCH CABLE
THROTTLE CABLE A
THROTTLE CABLE B
CLUTCH CABLE
MC250/A/C/W-K ADDENDUM
6-13
FRONT WHEEL
SPEED SENSOR WIRE
Contact.
Contact.
FRONT BRAKE HOSE
Contact.
FRONT BRAKE HOSE
FRONT WHEEL
SPEED SENSOR WIRE
FRONT WHEEL
SPEED SENSOR WIRE
FRONT WHEEL
SPEED SENSOR WIRE
FRONT WHEEL
SPEED SENSOR WIRE
FRONT BRAKE HOSE
Contact.
Contact.
WHITE PAINT
ABS TYPE
TAPE
MC250/A/C/W-K ADDENDUM
6-14
Contact.
Contact.
Contact.
Contact.
Contact.
CBS BRAKE HOSE
FRONT BRAKE HOSE
Contact.
CBS TYPE
MC250/A/C/W-K ADDENDUM
6-15
STD TYPE
Contact.
Contact.
FRONT BRAKE HOSE
Contact.
MC250/A/C/W-K ADDENDUM
6-16
3 mm
CLUTCH CABLE
IGNITION COIL CONNECTOR
(BLACK TERMINAL)
REGULATOR/RECTIFIER
5P CONNECTOR
IGNITION COIL CONNECTOR
LEFT HANDLEBAR
SWITCH WIRE
Contact.
Contact.
HORN CONNECTORS
O2 SENSOR WIRE
MAIN WIRE HARNESS
MC250/A/C/W-K ADDENDUM
6-17
BANK ANGLE SENSOR
3P (BLACK) CONNECTOR
FUEL INJECTOR
2P (BLACK) CONNECTOR
FUEL PUMP 5P CONNECTOR
THROTTLE CABLE A
THROTTLE CABLE B
CLUTCH CABLE
FUEL HOSE (Feed)
MAIN WIRE HARNESS
IACV 4P (BLACK)
CONNECTOR
MC250/A/C/W-K ADDENDUM
6-18
EOT SENSOR
2P (BLACK) CONNECTOR
BATTERY DRAIN HOSE
BATTERY
POSITIVE (+)
CABLE
FRONT BRAKE PIPE B
Contact.
BATTERY
NEGATIVE (–)
CABLE
FRONT BRAKE PIPE A
CLUTCH CABLE
MAIN WIRE HARNESS
BATTERY NEGATIVE (–) CABLE
MAIN WIRE HARNESS
FRONT BRAKE PIPE B
FRONT BRAKE PIPE A
REAR BRAKE LIGHT
SWITCH WIRE
ABS 1P CONNECTOR
ABS TYPE
MC250/A/C/W-K ADDENDUM
6-19
EOT SENSOR
2P (BLACK) CONNECTOR
BATTERY DRAIN HOSE
BATTERY
POSITIVE (+)
CABLE
Contact.
BATTERY
NEGATIVE (–)
CABLE
CLUTCH CABLE
MAIN WIRE HARNESS
BATTERY NEGATIVE (–) CABLE
MAIN WIRE HARNESS
REAR BRAKE LIGHT
SWITCH WIRE
CBS BRAKE PIPE B
CBS BRAKE PIPE B
STD, CBS TYPE
(CBS TYPE shown)
MC250/A/C/W-K ADDENDUM
6-20
TURN SIGNAL LIGHT RELAY
FUEL PUMP RELAY
TURN SIGNAL LIGHT RELAY
ABS FUSE
ABS TYPE
STD, CBS TYPE
FUEL PUMP RELAY
FUSE BOX
FUSE BOX
MC250/A/C/W-K ADDENDUM
6-21
LEFT REAR TURN
SIGNAL WIRE
WHITE TAPE
LICENSE LIGHT WIRE
RIGHT REAR TURN
SIGNAL WIRE
STARTER MOTOR CABLE
REAR BRAKELIGHT
SWITCH WIRE
REAR WHEEL SPEED
SENSOR WIRE (ABS TYPE)
BATTERY NEGATIVE (–) CABLE
WIRE HARNESS
to EOT sensor and
VS sensor (STD, CBS TYPE)
INSIDE BOOT CONNECTORS:
- REAR BRAKE LIGHT SWITCH 3P
- ALTERNATOR 3P
- SIDESTAND SWITCH 3P (GREEN)
- NEUTRAL SWITCH 3P
MC250/A/C/W-K ADDENDUM
6-22
Contact.
Contact.
ABS TYPE
REAR WHEEL SPEED
SENSOR WIRE
REAR BRAKE HOSE B
Attach the clip to the end of the tube.
REAR BRAKELIGHT
SWITCH WIRE
REAR BRAKE HOSE A
REAR BRAKE
HOSE A
Contact.
Contact.
STD, CBS TYPE
REAR BRAKE
HOSE B
MC250/A/C/W-K ADDENDUM
6-23
FUEL TANK BREATHER HOSE
FUEL TANK DRAIN HOSE
BATTERY DRAIN HOSE
BATTERY DRAIN HOSE
FUEL TANK DRAIN HOSE
FUEL TANK BREATHER HOSE
FUEL TANK BREATHER HOSE
BATTERY DRAIN HOSE
FUEL TANK DRAIN HOSE
BATTERY DRAIN HOSE
FUEL TANK
DRAIN HOSE
FUEL TANK BREATHER HOSE
(Facing the cut face rearward.)
MC250/A/C/W-K ADDENDUM
6-24
MAINTENANCE SCHEDULE
• Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
• I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
• The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may
require more technical information and tools. Consult a dealer.
AG, LA type
• * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified.
• ** In the interest of safety, we recommend these items be serviced only by a dealer.
• Honda recommends that a dealer should road test the vehicle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replacement requires mechanical skill.
• Refer to “Basic" Service Manual for each maintenance instruction except the instructions described in this
manual.
ITEMS NOTE
FREQUENCY (NOTE 1)
ANNUAL
CHECK
REGULAR
REPLACE
REFER
TO
PAGE
X1,000 km 1 6 12 18 24 30 36
X1,000 mi0.6 4 8 12162024
* FUEL LINE I I I I
** FUEL FILTER Every 48,000 km (32,000 mi) R 2-5
* THROTTLE
OPERATION
IIII
* AIR CLEANER NOTE2 R R 2-8
CRANKCASE
BREATHER
NOTE3 CCCCCC
SPARK PLUG I R I
* VALVE CLEARANCE I I I 2-17
ENGINE OIL RRRRR 2-13
ENGINE OIL FILTER R R
* ENGINE IDLE SPEED I I I I
DRIVE CHAIN Every 1,000 km (600 mi) I, L
DRIVE CHAIN SLIDER I I I
BRAKE FLUID NOTE4 IIIIII I 2 years
BRAKE PADS WEAR IIIIII I
BRAKE SYSTEM I I I I
BRAKE LIGHT
SWITCH
IIII
HEADLIGHT AIM I I I I 4-51
CLUTCH SYSTEM IIIIII I
SIDESTAND I I I I
* SUSPENSION I I I I
* NUTS, BOLTS,
FASTENERS
IIII
** WHEELS/TIRES I I I I
** STEERING HEAD
BEARINGS
IIII
MC250/A/C/W-K ADDENDUM
6-25
BODY PANELS
REARVIEW MIRROR
FRONT COWL
20 N·m
20 N·m
MC250/A/C/W-K ADDENDUM
6-26
REAR FENDER A
• Headlight 4-47
• Rear center cowl 3-7
MC250/A/C/W-K ADDENDUM
6-27
FRONT BRAKE
BRAKE CALIPER
18 N·m
2.0 N·m
STD, ABS TYPE
(ABS TYPE SHOWN)
MC250/A/C/W-K ADDENDUM
6-28
18 N·m
CBS TYPE
26 N·m
34 N·m
STD, ABS TYPE
(ABS TYPE SHOWN)
(ABS type)
• Brake fluid 3-26
MC250/A/C/W-K ADDENDUM
6-29
26 N·m
CBS TYPE
34 N·m
• Brake fluid 3-26
Silicon grease
5.4 N·m
Silicon grease
(0.4 g minimum)
STD, ABS TYPE
(ABS TYPE SHOWN)
Silicon grease
(0.4 g minimum)
• Brake caliper inspection
MC250/A/C/W-K ADDENDUM
6-30
PCV VALVE (CBS TYPE ONLY)
5.4 N·m
Silicon grease
(0.4 g minimum)
CBS TYPE
Silicon grease
Silicon grease
(0.4 g minimum)
5.4 N·m
• Brake caliper inspection
14 N·m
34 N·m
MC250/A/C/W-K ADDENDUM
6-31
DELAY VALVE (CBS TYPE ONLY)
14 N·m
MC250/A/C/W-K ADDENDUM
6-32
PGM-FI SYSTEM
PGM-FI SYSTEM DIAGRAM
MC250/A/C/W-K ADDENDUM
6-33
DTC TROUBLESHOOTING
DTC 21-1 (O2 SENSOR)
O
2 Sensor Diagram
• Fuel tank 2-7
O2
ECMO2 sensor
Bl
O2 sensor 4P connector
ECM 33P connector
R/Bl
W
Bl
G/W
Gr
W
SG
HTCTRL
Bl
G/W
W
W
G/W
Bl
W
R/Bl
From Battery
1. O2 Sensor System Inspection
• Test-ride the vehicle and check the O
2 sensor with
MCS.
• Is the DTC 21-1 is indicated?
No
►
• Intermittent failure
• Loose or poor contact at the connector
Yes ▼
2. O
2 Sensor Circuit Inspection
• Check an open or short circuit in Bl and G/W wire.
• Is there open or short circuit?
Yes
►
• Faulty Bl or G/W wire
No ▼
3. O
2 Sensor Inspection
• Replace the O
2 sensor with a new one. 4-21
• Erase the DTC’s.
• Test-ride the vehicle and check the O
2 sensor with
MCS.
• If DTC 21-1 is indicated, replace the ECM with a
new one 4-20, and recheck.
MC250/A/C/W-K ADDENDUM
6-34
ABS
DTC CODE INDEX
DTC Function Failure
Detection
Symptom/Fail-safe function Page
*A *B
–
ABS indicator malfunction
• ABS modulator voltage input line
• Indicator related wires
• Speedometer
• ABS modulator
• ABS fuses
• ABS indicator never come
ON at all
4-36
• ABS indicator stays ON
6-37
1-1
Front wheel speed sensor circuit inspection
• Wheel speed sensor or related wires
• Stops ABS operation
6-38
1-2
Front wheel speed sensor malfunction
• Wheel speed sensor, pulser ring or related
wires
• Electromagnetic interference
• Stops ABS operation
1-3
Rear wheel speed sensor circuit malfunction
• Wheel speed sensor or related wires
• Stops ABS operation
6-39
1-4
Rear wheel speed sensor malfunction
• Wheel speed sensor, pulser ring or related
wires
• Electromagnetic interference
• Stops ABS operation
2-1
Front pulser ring
• Pulser ring or related wires
• Stops ABS operation
6-38
2-3
Rear pulser ring
• Pulser ring or related wires
• Stops ABS operation
6-39
3-1 Solenoid valve malfunction (ABS modulator) • Stops ABS operation
4-41
3-2
3-3
3-4
4-1
Front wheel lock
• Riding condition
• Stops ABS operation
6-38
4-2
Front wheel lock (Wheelie)
• Riding condition
4-3
Rear wheel lock
• Riding condition
• Stops ABS operation
6-39
5-1
Pump motor lock
• Pump motor (ABS modulator) or related
wires
• ABS MOTOR 20 A fuse
• Stops ABS operation
6-405-2
Pump motor stuck off
• Pump motor (ABS modulator) or related
wires
• ABS MOTOR 20 A fuse
• Stops ABS operation
5-3
Pump motor stuck on
• Pump motor (ABS modulator) or related
wires
• ABS MOTOR 20 A fuse
• Stops ABS operation
5-4
Power supply relay malfunction
• Power supply relay (ABS modulator) or re-
lated wires
• ABS MOTOR 20 A fuse
• Stops ABS operation
6-41
MC250/A/C/W-K ADDENDUM
6-35
*A: Pre-start self-diagnosis
*B: Ordinary self-diagnosis: diagnoses while the vehicle is running (after pre-start self-diagnosis)
6-1
Power circuit under voltage
• Input footage (too low)
• ABS MAIN 10 A fuse
• Stops ABS operation
4-43
6-2
Power circuit over voltage
• Input voltage (too high)
• Stops ABS operation
7-1
Tire malfunction
•Tire size
• Stops ABS operation
4-44
8-1
ABS control unit
• ABS control unit malfunction (ABS modula-
tor)
• Stops ABS operation
4-44
DTC Function Failure
Detection
Symptom/Fail-safe function Page
*A *B
MC250/A/C/W-K ADDENDUM
6-36
ABS DIAGRAM
1
10 11 12 13 14 15 16 17 18
2345678 9
Gr/W
Bl/R
Bl/R
Bl
Bl
R/W
R/Bu
Bl
Bl
G/Y G
Bl Bl
Bl
Bl/Br
G
R
W
Bu
W
Bu
G
G
G
Y
Bu
G
G/Y
Bl
Gr/W
R/W
R/W
W/Bl
W/R
(1-4, 4-3)
(1-2, 4-1, 4-2)
(3-1, 3-2, 3-3,
3-4)
RR VSP (-)
RR VSP (+)
(1-3, 1-4)
BLS
(7-1)
FR VSP (-)
FR VSP (+)
IG
(6-1, 6-2)
(1-1, 1-2)
DIAG
GND
4
5
SCS 14
9
15
6
17
8
7
9
(5-1,5-2,5-3)
(8-1)
(2-1)
(2-3)
( ) =
BATTERY
FUSE BOX
IGNITION
SWITCH
ABS MOTOR
20 A
ABS SUB
20 A
STOP,HORN,
TAIL,WINKER,
METER
10 A
ABS MAIN
10 A
MAIN FUSE 20 A
FRONT BRAKE
LIGHT SWITCH
REAR BRAKE
LIGHT SWITCH
FRONT WHEEL
SPEED SENSOR
REAR WHEEL
SPEED SENSOR
FRONT PULSER RING
REAR PULSER RING
DTC
DLC
ABS MODULATOR
PUMP MOTOR
SOLENOID VALVE
TIRE SIZE
ABS
INDICATOR
COMBINATION METER
BRAKE/TAIL
LIGHT
(6-1, 6-2)
(5-4)
ABS MODULATOR 18P (Black) CONNECTOR (MODULATOR SIDE)
MR+B
IND 13
VSP 3
MR GND 1
GND 10
FSR+B18
MC250/A/C/W-K ADDENDUM
6-37
DTC TROUBLESHOOTING
ABS INDICATION MALFUNCTION
ABS indicator stays ON (Indicator does not go off when the motorcycle is running, but DTC is not stored)
DLC
ABS
Bu
W/Bl
G
IG
SCS
METER
ABS MODULATOR
ABS modulator 18P connector
IND
GND
R/Bu
W/Bl
G
R/Bu
Bu
From Battery
1. Service Check Line Inspection
• Check a short circuit in Bu wire.
• Is there short circuit?
No
►
• Faulty Bu wire
Yes ▼
2. ABS Indicator Line Inspection
• Install a jumper wire between the terminal and
ground.
Jumper terminal: W/Bl
• Does the ABS indicator go off?
No
►
• Faulty W/Bl wire
• If wire is ok, faulty meter.
Yes ▼
3. ABS Modulator Ground Line Inspection
• Check an open circuit in G wire.
• Is there no open circuit?
No
►
• Faulty G wire
Yes ▼
4. ABS Modulator Power Line Inspection
• Connection: R/Bu (+) – Ground (–)
• Does the battery voltage exist?
No
►
• Faulty R/Bu wire
Yes ▼
• Faulty ABS modulator
MC250/A/C/W-K ADDENDUM
6-38
DTC 1-1, 1-2, 2-1, 4-1, 4-2
(Front wheel speed sensor circuit / Front wheel speed sensor / Front pulser ring / Front wheel lock)
W
FRONT WHEEL
SPEED SENSOR
ABS MODULATOR
Front wheel speed
sensor 2P connector
ABS modulator 18P connector
Bu
FR VSP (–)
FR VSP (+)
W
Bu
W
Bu
Bu
W
1. Air Gap Inspection
• Measure the air gap.
• Is the air gap correct?
No
►
• Check each part for deformation, looseness and
correct accordingly. Recheck the air gap.
Yes ▼
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.
• Are the sensor and pulser ring in good condition
and proper installed?
No
►
• Remove any deposits.
• Install properly or replace faulty part.
Yes ▼
3. Speed Sensor Line Inspection
• Install a jumper wire between the terminals.
Jumper terminal: W and Bu
• Check the continuity between the above wires.
• Is there continuity?
No
►
• Faulty W and Bu wire
Yes ▼
4. Failure Reproduction
• Replace the speed sensor with a new one. 4-54
• Erase the DTC and test-ride the vehicle above 30
km/h, then recheck the DTC.
• Is the DTC 1-1, 1-2, 2-1, 4-1, 4-2 indicated?
No
►
• Faulty original speed sensor
Yes ▼
• Faulty ABS modulator
MC250/A/C/W-K ADDENDUM
6-39
DTC 1-3, 1-4, 2-3, 4-3
(Rear wheel speed sensor circuit / Rear wheel speed sensor / Rear pulser ring / Rear wheel lock)
• Drive chain case 3-12
Bu
REAR WHEEL
SPEED SENSOR
ABS MODULATOR
Rear wheel speed sensor
2P connector
ABS modulator 18P connector
W
RR VSP (–)
RR VSP (+)
Bu
W
W
W
Bu
Bu
1. Air Gap Inspection
• Measure the air gap.
• Is the air gap correct?
No
►
• Check each part for deformation, looseness and
correct accordingly. Recheck the air gap.
Yes ▼
2. Speed Sensor and Pulser Ring Inspection
• Check the speed sensor and pulser ring.
• Are the sensor and pulser ring in good condition
and proper installed?
No
►
• Remove any deposits.
• Install properly or replace faulty part.
Yes ▼
3. Speed Sensor Line Inspection
• Install a jumper wire between the terminals.
Jumper terminal: W and Bu
• Check the continuity between the above wires.
• Is there continuity?
No
►
• Faulty W and Bu wire
Yes ▼
4. Failure Reproduction
• Replace the speed sensor with a new one. 4-54
• Erase the DTC and test-ride the vehicle above 30
km/h, then recheck the DTC.
• Is the DTC 1-3, 1-4, 2-3, 4-3 indicated?
No
►
• Faulty original speed sensor
Yes ▼
• Faulty ABS modulator
MC250/A/C/W-K ADDENDUM
6-40
DTC 5-1, 5-2 or 5-3
(Pump motor lock/Pump motor stuck off/Pump motor stuck on)
R
MR+B
PUMP
MOTOR
From Battery
ABS MOTOR
20 A
ABS MODULATOR
ABS modulator 18P connector
R
1. ABS Modulator Power Line Inspection
• Connection: R (+) – Ground
• Does the battery voltage exist?
No
►
• Faulty R wire
Yes ▼
2. Failure Reproduction
• Erase the DTC and test-ride the vehicle above 30
km/h, then recheck the DTC.
• Is the DTC 5-1, 5-2 or 5-3 indicated?
No
►
• Intermittent failure
Yes ▼
• Faulty ABS modulator
MC250/A/C/W-K ADDENDUM
6-41
DTC 5-4
(Power supply relay)
R/W
FSR+B
PUMP
MOTOR
From Battery
ABS SUB
20 A
ABS MODULATOR
ABS modulator 18P connector
R/W
1. ABS Modulator Power Line Inspection
• Connection: R/W (+) – Ground
• Does the battery voltage exist?
No
►
• Faulty R/W wire
Yes ▼
2. Failure Reproduction
• Erase the DTC and test-ride the vehicle above 30
km/h, then recheck the DTC.
• Is the DTC 5-4 indicated?
No
►
• Intermittent failure
Yes ▼
• Faulty ABS modulator
MC250/A/C/W-K ADDENDUM
6-42
WHEEL SPEED SENSOR
ABS MODULATOR
• Drive chain case 3-12
• Wheel speed sensor inspection
34 N·m
14 N·m
• Rear suspension 3-25
• Battery box 3-14
MC250/A/C/W-K ADDENDUM
6-43
LIGHTING SYSTEM
• Front cowl 3-3
• Rear fender A 3-8
MC250/A/C/W-K ADDENDUM
6-44
ELECTRICAL COMPONENT
IGNITION SWITCH
Ignition switch circuit
• Front cowl 6-25
P
Ignition switch 3P connector
R/W
Check for continuity the ignition switch connector of the ignition switch side.
• Connection: R/W (+) – P (–) and R/W (–) – P (+)
It is normal if there is continuity in one direction.
• It is faulty of the ignition switch if there is continuity in both directions.
M
BATTERY
IG
VSP
MOTOR GND
FSR+B
BLS
DIAG
SCS
RRVSP(-)
RRVSP(+)
FRVSP(-)
FRVSP(+)
BAT
IND
GND
DUMMY
TAIL
STOP
EARTH
UP DOWN
OUT
GND
VCC
IGP
LG
O2
SG
THL
VCC
TACHO
FLR
PG1
PG2
IGPLS
PCP
IMOV
TA
SCS
INJ
/
FIIND
FLCNT
IACV2A
IACV1A
HTCTRL
PCM
TO
SSTAND
BA
PB
ALC
NLSW
K-LINE
IACV2B
IACV1B
/
SG
VCC
TA
PB
TPS
20A
10A
10A
10A
10A
20A
3.1W×2
+
(12.8V)
TURN-R
HIGH-BEAM
SP SENS IGN
SP SENS GND
GND
/
/
/
TURN-L
ENGINE
NEUTRAL
ALC/ILLUMI
SPEED
TACHO
FLCNT
FUEL
BAT1
VO1
IMOV
VCC
OUT
GND
ABS (ABS)
(CBS,ABS)
(STD,CBS)
(STD,CBS)
/
BATTERY
IGNITION
ST
IG
HL
BAT2
IG
BAT1
F/P
20A
V-
V+
V+
V-
IACV
HL
LO
HI
HI
BAT
HO
BAT
R
W
L
LO
ON
BAT IG
S
OFF
LOCK
OFF
BAT1 IG
RUN
FREE
IG ST
BAT2 HL
PUSH
LO
HL LO HI
(N)
HI
R
W R L
N
L
FREE
BAT HO
PUSH
FREE
BAT HI
PUSH
10A
(CBS,ABS)
Lb
Bu
W/Bl
R
Bl
R/Bl
G/Bl
G
O
W/Bu
Lg/Bl
P/Y
W/R
Bu/R
Bu/Y
Y/Bl
R/Bl
R/Bl
R/Bl
R/Bl
R/Bl
R/Bl
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/R
Bl/Br
Bl
Bl/R
Y/R
Bu/W
G
G Bl
R/WR/W
Bl
R/W
Bl
Bl
Bl
Bl
G
Y/Bl
Br/Y
Y/R
Y/R
G/R
R/W
R/W
G/R
G/R
Y/R
R/Bu
R/Bu
Bl/R
W/R
G
R/W
G/Y
Y
Bu
W
W
Bu
Bu
W
Bu
Bu
W
G/Y
G/Y
G/Y
Bl
Bl
Bl
Bl/Br
G/Y
W
G
Bu
Bu
W
R
W/Bl
G
R/Bl
R/Bl
R/W
Bl/R
R/W
Bl/R
PP
R/W
Bl/R
P
Bl/Br
Bl
Bl/W
Y/R
Bu/W
R/Bl
Bl/R
Bl/Br
Bl
Y/Bl
G
G
Br/Y
Bl/W
Bl/W
Y/R
Bu/W
Bl/R
R/Bl
W/R
G/Bl
Br/Y
R/Bl
Br
R/Bl
G
Bl/R
Y
Bu
Lb
O
G
G
G
G
Bl
Bl
G/Y
G
Bl
G/Y
G
G
Lb
G
O
G
Bl
P/Bl
G
R/W
Y
Y
Y
Y
Y
Y
W/Y
Bu/Y
Lg/R
G
G/Y
Y
Y
Y
W/Y
Bu/Y
Lg/R
Lg/RG
R/Bl
P/Bu
Bl/R
R/Bl
W
G/W
Bl
W
W
Gr
Bl
G/W
Y/Bu
G
G/W
Y/R
Gr/Bu
Lg/R
Y
Lg/Bl
Bl/G
Lg
G/R
R/Bl
R/Bl
R/W
Bl/R
Bl
R/Bl
R/Bl
R/W
R
Bl/R
R
Lg/R
R/W
Bl
Gr
G
Bl
O
Lb
R/Bl
W
Bu/W
Bu
G/R
G/Y
Lg
Gr
Bl
Bl
O
Lb
R/Bl
Bu
Bu/W
W
Bu
Bl/Br
Lg
Gr
G
G
G
G
G
G
G
G
G/W
W/Y
Bu/Y
G/W
Y/R
R/Bu
Bu/Bl
Bu/W
Br/W
Bl/R
G
Bl
G/W
Y
Y/R
Bu/R
Br
G
G
P/Bu
Bu/Y
Gr/Bu
P
Bu
P/Bl
W/Bu
Bu/Y
Br/W
Bu/W
W
W/Y
Y/Bu
G/Y
R/Bu
Lg/R
P/Y
G/R
Y
Br/Bl
Bu/Bl
Br/Bl
G
Bu
W
G
O
Lb
G
Bu
W
G
O
Lb
G
Bu
W
O
Lb
G
G
O
Lb
FUEL
PUMP
DIODE
FUEL
LEVEL
SENSOR
FRONT
BRAKE LIGHT
SWITCH
STARTER
SWITCH
ENGINE
STOP
SWITCH
IGNITION
SWITCH
STARTER
MOTOR
GROUND
GROUND
STARTER
RELAY
SWITCH
ABS MODULATOR
(ABS)
(ABS)
ABS MAIN
FRONT
WHEEL
SPEED
SENSOR
REAR
WHEEL
SPEED
SENSOR
JOINT
REAR BRAKE
LIGHT SWITCH
4P
R
2P
3P6P
5P
18P
Bl
2P
Bl
2P
Bl
3P
1P
FUEL
PUMP
RELAY
REAR RIGHT TURN
SIGNAL LIGHT
REAR LEFT TURN
SIGNAL LIGHT
LICENCE LIGHT
12V 5W
REGULATOR/
RECTIFIER
ALTERNATOR
CKP SENSOR
NEUTRAL SWITCH
SIDE
STAND
SWITCH
IGNITION
COIL
INJECTOR
TAILLIGHT
4P
4P
R
2P
3P
Bl
5P
3P
3P3P
G
2P
Bl
2P
Bl
5P
Bl
2P
9P
Bl
3P
Bl
3P
Bl
4P
Bl
33P
Bl
4P
Bl
O2 SENSOR
BANK
ANGLE
SENSOR
IACV
ECM
EOT
SENSOR
GROUND
SENSOR
UNIT
CLUTCH
SWITCH
DIMMER
SWITCH
PASSING
SWITCH
TURN
SIGNAL
SWITCH
HORN
SWITCH
TURN
SIGNAL
RELAY
HORN
(ABS)
(ABS)
H/L (BAT3)
METER
CLOCK/ODO
FI
IGN, START, INJ, ECU
AI SOL, O2 SENSOR
FUEL RELAY, FUEL PUMP
SIG
STOP, HORN, TAIL
WINKER, METER
ABS SUB
ABS MOTOR
DIODE
DIODE
HEADLIGHT
12V 60/55W
FRONT LEFT
TURN SIGNAL
LIGHT
FRONT RIGHT
TURN SIGNAL
LIGHT
8P
Bl
3P
Bl
METER
VS
SENSOR
JOINT JOINT
3P
Bl
20P
Gr
IGNITION SWITCH
ENGINE
STOP SWITCHSTARTER SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH PASSING SWITCH
SWITCH CONTINUITY
Black
Yellow
Blue
Green
Red
White
Bl
Y
Bu
G
R
W
TWO COLORED WIRE
(
EXAMPLE:YELLOW/RED
)
Br
O
Lb
Lg
P
Gr
Brown
Orange
Light Blue
Light Green
Pink
Gray
MC250/A/C/W-K (AG,LA,BR)
GROUND
© Honda Motor Co.,Ltd. 2018
Published by Honda Motor Co.,Ltd.
Printed in Japan
Book#: 62K31B0Y
B.2018.09.K