1986–1995 Honda NSR250R / NSR250R SP Service & Repair Manual (P/N 60KV300)

This 369-page PDF reproduces the English-language technical content of Honda's NSR250R / NSR250R SP factory service publication; the cover and closing publication pages retain Japanese text. Organized into 22 numbered sections, it combines repair information for the MC16 chassis and liquid-cooled MC16E two-stroke V2 with dedicated change sections for MC18 configurations, and it carries the printed Honda code 60KV300Y. The material is suited to experienced motorcycle mechanics and restorers who can work from factory inspection limits, special-tool callouts, exploded drawings, and electrical test charts rather than beginner-level explanations.

• Exact model and serial coverage: NSR250R G / MC16 from frame MC16-1000001 onward and engine MC16E-1000001 onward; NSR250R(J) / MC18 from frame MC18-1000020 onward and engine MC16E-1031032 onward; and NSR250R(K) / MC18 from frame MC18-1100001 onward and engine MC16E-1130001 onward. An SP-specific special-features sheet is also included.
• Engine and fuel-system repair: Covers engine removal and installation, cylinder head and top-end disassembly, cylinder/piston selection and inspection, RC valve service, oil-pump and strainer work, radiator/thermostat/water-pump service, carburetor disassembly, float-level checks, air-screw adjustment, synchronization, and reed-valve inspection.
• Clutch and transmission work: Details clutch and kickstarter removal, primary-drive gear service, gear-shift linkage inspection, cassette-transmission removal and replacement, gear and shift-fork checks, bearing replacement, crankcase separation, crankshaft inspection, and AC/pulse-generator service.
• Chassis and brake procedures: Includes front and rear wheel service, wheel balancing, fork and steering-stem overhaul, rear-cushion and suspension-linkage work, swingarm bearing repair, drive-chain adjustment, disc and pad inspection, brake-fluid replacement and bleeding, plus master-cylinder and caliper disassembly and reassembly.
• Electrical diagnosis: Provides charging-system, regulator/rectifier, CDI/PGM ignition, pulse-generator, lighting, meter, switch, RC valve servo, throttle-sensor, oil-pump-solenoid, and carburetor air-jet control tests, with fault trees for no-spark, poor charging, low power, and incorrect RC valve operation.
• Diagrams and assembly views: The visual references include the full vehicle wiring diagram, model-specific wiring-location maps, PGM-2 control block diagrams, RC valve cable-routing views, cassette-transmission exploded views, and brake-caliper/master-cylinder assembly drawings.

How the J, SP, and K Sections Differ

The main sections cover maintenance, lubrication, fuel and cooling systems, engine and drivetrain repair, suspension, disc brakes, bodywork, and electrical systems. The NSR250R(J) section then documents the MC18 changes, including the TA20 carburetor arrangement, cassette transmission, short-body spark plugs, PGM ignition/carburetion control, revised cable routing, and its own maintenance data and troubleshooting.

The NSR250R(K) section is a separate 49-page change section built around the TA21 carburetor and PGM-2 engine-control system. It explains the front- and rear-cylinder ignition control, twin carburetor air-jet solenoids, throttle-sensor input, PGM-RC valve strategy, and oil-pump-solenoid control. Its repair coverage includes model-specific wiring locations, diagnostic flowcharts, RC valve cable adjustment, carburetor-solenoid vacuum and resistance tests, peak-voltage ignition checks, and engine-control-unit output tests.

Section 21 is not a second full SP workshop manual. It is a one-page NSR250R SP supplement covering wheel-bearing position and balance-weight selection; shared SP repair procedures remain in the main chapters.

Factory Data, Tool Numbers, and Repair Cautions

Component-specific torque tables, fluid and lubricant data, cylinder and piston selection marks, wear limits, clearances, brake specifications, suspension data, charging output, resistance checks, peak-voltage tests, and maintenance schedules are placed with the related assemblies. Special-tool references include the 07HMB-KV30100 gear holder, 07HMC-KV30100 rotor-puller attachment, and 07HGJ-0020100 peak-voltage adapter, along with bearing drivers, steering tools, fork-seal tools, and a rear-cushion compressor.

The manual flags two easy-to-miss repair hazards. The primary-drive gear retaining bolt uses a left-hand thread, so treating it like a conventional fastener can damage the fastener or drive assembly. It also warns that an incorrect regulator/rectifier can damage the CDI and that control-unit couplers must be handled with the main switch off to avoid internal electrical damage.

Wheel chapters cover removal, bearing service, runout inspection, and balancing, but the actual tubeless-tire removal method is referred to the separate Honda Motorcycle Tubeless Tire Service Manual No. 6041551. Brake-fluid contamination, caliper support, and stable lifting are specifically addressed in the relevant wheel and brake sections.