Honda CMX 250 / CMX 250C Rebel 1996–2009 Service Manual (P/N C4256-90954)

• 270-page PDF of Honda Motor Co., Ltd.’s August 1995 CMX250C factory service manual, organized into 21 numbered sections with troubleshooting, wiring, and a final index.
• Coverage separates 49-state, California, and Canadian carburetor configurations and identifies differences between 1996–2000 and later machines, including California emissions-routing information through 2004.
• Covers engine removal and internal repair, cylinder-head and valve service, cylinder and piston inspection, clutch and gearshift linkage repair, starter-clutch work, crankcase separation, and transmission and crankshaft service.
• Details carburetor removal and overhaul, starting-enrichment and accelerator-pump components, float-level and pilot-screw procedures, high-altitude adjustment, oil-pump service, valve-clearance maintenance, and drive-chain adjustment and master-link riveting.
• Provides frame, body, and exhaust removal; front and rear wheel service; fork, steering-head, and swingarm repair; rear drum-brake work; and front hydraulic-brake bleeding, master-cylinder, caliper, pad, and disc procedures.
• Supports electrical diagnosis with battery and charging tests, ignition peak-voltage checks, starter-motor and safety-interlock troubleshooting, switch continuity tests, system diagrams, fault charts, and the two-page wiring diagram.

Model Coverage and Configuration Differences

Written specifically for the CMX250C, this manual covers the air-cooled 234 cc vertical parallel twin with a single constant-velocity carburetor. Its model-identification page shows 1996–2000 machines and states that models after 2000 are similar. Coverage is organized as a core manual with embedded later-model notes rather than separate year-by-year chapters.

Fuel-system specifications distinguish the VE35C 49-state carburetor, VE36B California carburetor, and VE35D Canadian carburetor. Separate notes identify post-2000 charging-system and headlamp changes, while the California vacuum-hose routing label is listed for 1996–2004 California-type machines. Those distinctions help a shop select the correct components and test data before repair work begins.

Internal Engine, Fuel, and Drivetrain Repair

The engine chapters cover scheduled service and internal repair. Procedures address compression testing; rocker-arm and camshaft service; cylinder-head removal, disassembly, inspection, and installation; valve-guide replacement and valve-seat refacing; cam-chain and timing-mark alignment; and cylinder, piston, ring, pin, and connecting-rod inspection.

Clutch and gearshift linkage work is documented as an in-frame repair. Rocker-arm and camshaft service can also be performed with the engine installed. Full crankshaft and transmission repair proceeds through engine removal, crankcase separation, shaft and gear inspection, shift-fork and drum checks, bearing replacement, and crankcase reassembly. The crankcase chapter warns that driving the countershaft oil seal too deep can block the shaft’s oil passage.

The fuel-system section follows the carburetor from removal through disassembly and final adjustment. It covers the starting-enrichment valve, diaphragm and vacuum piston, accelerator pump, float and jets, float-level inspection, pilot-screw idle-drop adjustment, and high-altitude setting and update labeling. It also warns that forcing the pilot screw against its seat can damage the seat.

Chassis, Hydraulic Brake, and Electrical Diagnosis

Frame and body pages cover the fuel tank, seat, side covers, rear fender, and exhaust system. Front-end repair includes the handlebar, front wheel and hub bearings, spokes, fork removal and internal service, oil-seal and bushing replacement, and steering-stem bearing and race work. At the rear, the manual covers the wheel, driven-flange bearings, internal-expanding drum brake, brake pedal, swingarm pivots, bushings, and chain slider. The rear shock is covered for removal and installation, but is treated as a replace-if-damaged assembly rather than an internal rebuild.

The hydraulic front-brake chapter includes fluid replacement and air bleeding, pad and disc inspection, and master-cylinder and caliper disassembly, inspection, assembly, and installation. Electrical repair sections provide battery inspection and load testing, charging-current and leakage checks, and alternator-coil and regulator/rectifier diagnosis. They also cover ignition primary, exciter-coil, and pulse-generator peak-voltage testing; starter-motor disassembly and inspection; relay and diode checks; and neutral, clutch, and side-stand interlock diagnosis. Ignition timing is inspection-only because the ICM is factory preset.

Factory Tooling, Diagrams, and Fault Isolation

Visual references include cable and harness routing illustrations, a lubrication-system diagram, carburetor exploded views, and valvetrain and cam-timing views. Additional drawings map the crankshaft and transmission assemblies and bearing locations, while charging, ignition, and starter system diagrams lead into the two-page wiring diagram.

The manual supplies component-specific torque tables, fluid-capacity data, wear and service limits, clearance and adjustment specifications, lubrication and seal-point charts, and a two-page factory tool list. Named tools include the 07401-0010000 carburetor float-level gauge, 07733-0020001 flywheel puller, 07GMB-KT70101 clutch-center holder, 07HGJ-0020100 peak-voltage adapter, and 07HMH-MR10103 drive-chain tool set.

Section 20 closes with troubleshooting paths for no-start or hard-start complaints, lack of power, poor low-speed and idle operation, poor high-speed performance, and poor handling. Because the work covers gasoline, hot engine parts, hydraulic brake service, electrical testing, and rotating components, follow the manual’s safety notes and assembly specifications throughout diagnosis and repair.