Honda Twinstar Rebel 250 Nighthawk 250 1978-2003 Service Manual (P/N M324-5, fifth edition)
Honda Models Covered & Key Technical Specifications
Models: Honda Twinstar (1978–1983), Honda Rebel 250 (1985–1987, 1996–2003), Honda Nighthawk 250 (1991–2002)
Sub-models / Variants: CM185T, CM200T, CM250C, CMX250C, CMX250CD (Limited)
Trade Names: Twinstar, Rebel 250, Nighthawk 250
Model Years: 1978–2003
Serial Numbers: M324-5
Technical Data:
- Cylinder head bolt torque (Rebel 250/Nighthawk 250): 10–14 N-m (7–10 ft-lb)
- Cylinder head nut torque (Rebel 250/Nighthawk 250): 21–25 N-m (15–18 ft-lb)
- Compression pressure (Rebel 250/Nighthawk 250): 14 +/- 2 kg/cm2 (199 +/- 28 psi)
- Compression pressure (all other models): 12 +/- 2 kg/cm2 (170 +/- 28 psi)
- Engine oil capacity (250 cc): 1.5 liters (1.6 U.S. qt.)
- Fork oil capacity (250 cc, 1985-on): 238 cc (8.1 oz.)
- Valve clearance (intake and exhaust): 0.05 mm (0.002 in.)
Honda Manual Features & Content Preview
- Covers 1978–2003 Honda Twinstar, Rebel 250, and Nighthawk 250 motorcycles, including CMX250C and CMX250CD variants
- Official 307-page Clymer publication (M324-5, fifth edition, April 2004)
- Features 120 technical figures, including exploded-view diagrams, ignition circuit wiring schematics, and multi-stage cylinder head torque tables
- Serves as a factory-style reference for maintaining Honda 250 air-cooled twin-cylinder series engines
Technical Structure
This publication breaks down the 250cc series chassis, engine, and electrical systems into logical, easy-to-navigate chapters. Mechanics and DIYers will find comprehensive diagrams alongside text-based breakdowns for front and rear suspension setups, as well as detailed frame repainting procedures. When working on fuel, exhaust, or electrical systems, safety is critical. Always properly secure the motorcycle on a stable stand and disconnect the battery before diving into the ignition circuits. The manual clearly outlines routine maintenance intervals, including oil filter screen cleaning and periodic lubrication points for control cables.
Specification Highlights
Precision matters when maintaining these air-cooled twins. The reference data documents cylinder head bolt torque for the Rebel 250 at 10–14 N-m (7–10 ft-lb). For the Twinstar, baseline compression pressure at sea level is specified at 12 +/- 2 kg/cm2. All technical measurements follow the International Modernized Metric System to ensure accurate adjustments across the entire production run. This comprehensive OEM-style documentation provides the exact chassis, engine, and electrical specifications needed to evaluate clutch wear, service transmissions, and rebuild top ends without guesswork.
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