1980–1981 Honda FL250 Odyssey UTV Shop Manual (P/N 6295002)

Honda’s shop manual covers the 1980–1981 FL250 Odyssey through the base service chapters and integrated 1980 and 1981 addenda. The cover carries references 6295002 and A25008011.

• Engine repair: Engine removal and installation, cylinder and piston inspection, crankcase separation, crankshaft checks, and selective-fit connecting-rod bearing tables.

• Fuel and intake systems: PW carburetor disassembly, float-height inspection and adjustment, diaphragm fuel-pump service, air-cleaner maintenance, and muffler decarbonizing.

• Converter and reduction unit: Salsbury drive and driven pulley servicing, spider removal and installation, drive-belt inspection, and reduction-case disassembly.

• Steering and suspension: Steering-column inspection, throttle-linkage adjustment, front shock-absorber disassembly, steering-knuckle service, tie-rod installation, and toe-in adjustment.

• Brakes, wheels, and axle: Disc-caliper servicing, pad and disc inspection, parking-brake adjustment, rear brake-drum inspection, wheel disassembly, and rear-axle removal.

• Electrical diagnosis: Contact-breaker and CDI ignition coverage, generator and coil checks, electrical diagrams, switch-contact tables, and harness-routing illustrations.

This manual suits mechanically proficient owners and technicians with the specified tools; it assumes familiarity with standard workshop procedures.

Engine Inspection and Fuel-System Service

The engine chapters distinguish standard dimensions from service limits for the cylinder, piston, rings, wrist pin, and crankshaft. Fastener-specific torque tables distinguish cylinder-head flanged nuts from special nuts and cover the engine, reduction unit, and chassis.

Color-coded bearing-selection tables match wrist-pin and connecting-rod combinations, along with crank-pin and connecting-rod combinations. These tables help identify the specified needle bearing before replacement parts are ordered.

The cylinder-head and exhaust-port cleaning notes warn against scoring or scratching the surfaces during carbon removal. Recoil-starter disassembly and reassembly illustrations show the return spring, pulley, and ratchet arrangement, with warnings about sudden spring release.

The Carburetor Disassembly/Reassembly and Float Height Adjustment illustrations accompany the jet, needle, and starter-valve details. A diagnostic note explains why carburetor adjustment should not be used to compensate for ignition or compression faults.

Salsbury Converter and Reduction Unit

The converter chapter documents pulley dismounting, roller-arm servicing, spider installation, and spring-loaded driven-pulley assembly. Illustrated tool references include the Salsbury #602090 clutch puller and #602112 spanner.

The Driven Pulley Disassembly/Reassembly illustrations identify the cam, key, spring, and retaining components. The chapter refers to Salsbury’s separate shop manual for more detailed converter instructions; that separate publication is not included in this PDF.

Reduction-unit views identify the primary shaft, drive chain, sprockets, bearings, and thrust washers. Inspection notes cover bearing play and sprocket wear, with assembly-orientation details and oil-capacity data.

Steering, Suspension, and Brake Inspection

The Front Suspension Removal/Installation drawings cover the front arms, steering knuckle, king-pin, tie-rod ball joints, and front hub. Related illustrations show shock-absorber compression tooling and hub bearing and oil-seal installation.

Brake coverage extends to the caliper’s adjusting ratchet, pad replacement, disc runout and thickness checks, parking-brake operation, and drum and lining inspection. Rear-axle and split-rim wheel procedures are also included.

Contact-Breaker and CDI Ignition Systems

The base chapters cover flywheel-magneto servicing, contact-breaker inspection, ignition-coil continuity and performance tests, and static timing adjustment. The 1981 addendum documents the CDI system and its exciter, pulse, and lighting coils.

CDI ignition timing is not adjustable. The revised June 1982 page provides a tester-specific CDI test matrix for the Sanwa tester P/N 7308-0020000 and Kowa TH-5H. Its notes explain that an unsuitable tester can produce misleading readings.

Separate electrical diagrams cover the base and addendum circuits, including the Canada-only taillight circuit in the 1980 addendum. The 1981 Harness Routing illustration identifies the ignition, lighting, and stop-switch components.

A Sample of Cylinder and Ignition-Coil Inspection Data

These examples represent a small selection of the manual’s inspection specifications. The FL250E cylinder data list a standard bore of 70.0–70.01 mm and a 70.1 mm service limit. Standard end gap for both piston rings is 0.2–0.4 mm.

For the 1981 CDI-equipped model, ignition-coil checks specify primary resistance of 0.2–0.8 Ω and secondary resistance of 8–15 kΩ.

PDF Reading Features and Included Addenda

Search, bookmarks, and wiring detail: PDF text search and embedded bookmarks are not available. Wiring labels, wire-color codes, and switch-contact tables are readable, with enlargement helpful for the smallest details.

Delivered as one printable, 118-page PDF: 92 pages of base manual and front matter, two pages comprising the addendum posting sheet and its blank reverse, 10 pages for the 1980 addendum, and 14 pages for the 1981 addendum. The cover, eight blank pages, and June 1982 replacement page are already included in that total.