1978-2004 Honda Twinstar, Rebel 250 & Nighthawk 250 Service Manual

Complete repair and maintenance guide covering the Honda Twinstar, Rebel 250, and Nighthawk 250 models from 1978-2003. Includes hundreds of photos and diagrams. PN C324-5

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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 Build 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.)
Technical Specifications
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Document Number / Seller:
28324 / Andrew Crawford
File Size:
173.67 MB
File Type:
PDF
Language:
English
Pages:
307
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Feb 13, 2025

Honda Manual Features & Content Preview

Honda Twinstar, Rebel 250, and Nighthawk 250 Service Documentation

  • Covers 1978–2003 Honda Twinstar, Rebel 250, and Nighthawk 250 motorcycles, including CMX250C and CMX250CD variants
  • Official Clymer publication M324-5, fifth edition published April 2004
  • Features 120 technical figures, including exploded-view diagrams, ignition circuit wiring schematics, and multi-stage cylinder head torque tables
  • Accessible immediately as a high-resolution digital download
  • Indexed PDF search covers every chapter and appendix
  • Re-download the file any time, no expiration
  • Page spreads stay legible when printed at original size
  • This 307-page Clymer factory-style reference remains the standard for maintaining all Honda 250 air-cooled twin-cylinder series engines

Technical Scope and Structure

This publication provides detailed servicing information for the Honda Twinstar and the associated 250cc series models. Chapters are logically arranged to assist with general maintenance, lubrication, and tune-up intervals. The document includes technical descriptions for engine, clutch, transmission, fuel and exhaust, and electrical systems. It provides comprehensive diagrams and text-based explanations for front suspension, rear suspension, and frame repainting procedures.

Specification Highlights

Cylinder head bolt torque for the Honda Rebel 250 is documented at 10–14 N-m (7–10 ft-lb). The Honda Twinstar compression pressure at sea level is specified at 12 +/- 2 kg/cm2 in the quick reference data. Maintenance schedules for the Honda Nighthawk 250 list oil filter screen cleaning intervals and periodic lubrication points for the control cables. All technical data provided follows the International Modernized Metric System. An authoritative 307-page Clymer OEM-style manual for the 1978–2003 Honda Twinstar, Rebel 250, and Nighthawk 250, documenting chassis, engine, and electrical specifications for the entire production series.

Manual FAQ, Purchase & Download Details

Does this manual include exploded views or parts illustrations for major components? keyboard_arrow_down

Document contains hundreds of photos and drawings that show component assemblies and parts layouts.

What kind of specification tables can I expect to find in the document? keyboard_arrow_down

Manual features Quick Reference Data pages that list various technical values such as engine torque specifications and fluid capacities. These tables provide categorized information to support the referenced models.

Which specific motorcycle series and year ranges are addressed in this edition? keyboard_arrow_down

Publication covers the Honda Twinstar from 1978 to 1983, the Rebel 250 from 1985-1987 and 1996-2003, and the Nighthawk 250 from 1991-2002. It consists of 307 pages and represents the fifth edition updated through 2004.

Can I see which systems are covered by the chapter structure? keyboard_arrow_down

Chapter breakdown includes dedicated sections for the engine, clutch, transmission, fuel, exhaust, electrical system, and both front and rear suspension.

Is there a reference chart for electrical values such as charging voltage or bulb specifications? keyboard_arrow_down

Quick Reference Data sections contain tables for replacement bulbs and other electrical specifications. These charts are organized by model year to help locate the relevant system data.

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