1996–2000 Honda Rebel 250 / CMX250C Repair Manual (P/N 61KEN10)

This 273-page PDF reproduces Honda's August 1995 factory service manual for the CMX250C Rebel 250, centered on the 1996-2000 configuration. It covers the 234 cc air-cooled parallel vertical twin, single constant-velocity carburetor, wet multi-plate clutch, five-speed constant-mesh transmission, chain final drive, AC-CDI ignition, and three-phase output alternator. Honda states that the service and repair information is intended for qualified professional technicians and written for people who already have basic knowledge of Honda motorcycle maintenance; several procedures also call for dedicated tools and test equipment.

• Document and model coverage: Identifies the frame serial number, VIN, engine serial number, carburetor ID, and color-code label locations, with separate 49-state, California, and Canadian carburetor configurations. Selected electrical and lighting notes distinguish 1996-2000 machines from later versions.

• Engine service: Covers engine removal and installation, cylinder-compression testing, rocker-arm and camshaft work, cylinder-head disassembly, valve-guide replacement, valve-seat inspection and refacing, cylinder and piston inspection, and oil-pump service.

• Fuel and emissions: Details carburetor removal, disassembly, inspection, assembly, float-level checking, pilot-screw idle-drop adjustment, high-altitude setup, air-cleaner housing work, and California evaporative-emission routing.

• Clutch and transmission repair: Includes clutch inspection and assembly, gearshift-linkage service, primary and oil-pump drive gears, alternator and starter-clutch work, crankcase separation, transmission teardown, crankshaft inspection, bearing replacement, and crankcase assembly.

• Chassis and brakes: Provides front-wheel, fork, steering-stem, and steering-head-bearing procedures; rear-wheel, drum-brake, shock-absorber, swingarm, and brake-pedal service; plus front hydraulic-brake draining, filling, bleeding, pad and disc inspection, and master-cylinder and caliper repair.

• Electrical diagnosis: Supplies battery and charging-system tests, alternator-coil and regulator/rectifier checks, ignition peak-voltage diagnosis, starter-motor and relay testing, switch-continuity charts, side-stand interlock checks, and a full wiring diagram.

• Shop reference data: Includes component torque tables, fluid capacities, wear and service limits, lubrication and seal points, cable and harness routing, connector checks, and an indexed Honda special-tool list with tool numbers.

Coverage Details That Matter

The carburetor tables identify VE35C for 49-state models, VE36B for California models, and VE35D for Canadian models. California coverage includes the EVAP canister, purge-control valve, fuel-tank breather and vacuum-tube routing, and the 1996-2004 vacuum-hose routing label. After-2000 callouts address specific regulator/rectifier test data, headlight equipment, and side-stand-switch circuitry; they are component-specific additions rather than blanket coverage for every later model year.

The manual also makes the repair scope clear before teardown. The camshaft, clutch, gearshift linkage, carburetor, and oil pump can be serviced with the engine in the frame. Cylinder-head and valve work, cylinder and piston service, crankshaft work, and transmission repair require engine removal.

Diagrams, Diagnostics, and Special Tools

Named visual references include the Lubrication System Diagram, California Emission Control System Routing, Battery/Charging System Diagram, Ignition System Diagram, Electric Starter System Diagram, and the complete Wiring Diagram. A separate troubleshooting section follows fault paths for hard starting, loss of power, poor low-speed or idle operation, poor high-speed performance, and handling problems.

Tool references are tied to the procedures rather than presented as generic shop advice. Examples include the flywheel holder 07725-0040000, flywheel puller 07733-0020001, valve spring compressor 07757-0010000, clutch center holder 07GMB-KT70101, steering stem socket 07916-3710101, and peak-voltage adapter 07HGJ-0020100 used with the specified meter requirements.

Repair Cautions and Workshop Safety

The manual warns that driving the countershaft oil seal too deeply can block the shaft's oil passage. It also calls for removing the carburetor diaphragms before compressed-air cleaning and keeping the vacuum-chamber diaphragm clear of the cover so it is not damaged or pinched.

Safety coverage addresses gasoline vapor, carbon monoxide, hot engine and exhaust parts, battery hydrogen and electrolyte, brake dust, and brake-fluid handling. This is factory workshop literature for trained or mechanically experienced users with suitable equipment, not a substitute for basic shop-safety training or an owner's operating manual.