Manual de Taller HONDA MC250 MANUAL TALLER 2019

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

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.

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

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

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

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

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.

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.

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.

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.

WHITE PAINT

ABS TYPE

TAPE

MC250/A/C/W-K ADDENDUM

6-14

Contact.

CBS BRAKE HOSE

FRONT BRAKE HOSE

Contact.

CBS TYPE

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