DIY Thread for Honda Hornet 250

[S750WP]

Starting a Thread for fellow riders riding Hornet250 whom like to hands on. The Honda Hornet 250 belong to my colleague.

 

Carburetor Synchronization

 

The Hornet 250 vacuum ports is situated in very odd places and I follow the advice from http://www.hondahornet.co.uk to find it as there is no workshop manual available for download, I am also using Honda CBR250R as a reference as both has the same engine and carburetor.

 

Sitting on the bike from left to right, port #1 to 4

 

Vacuum Port#1 and #4 is plugged by a hex bolt at the engine

http://i1318.photobucket.com/albums/t653/J_Herrera_Fermin/vacuumport1_zps221d0863.jpg

 

Vacuum Port #2 is connected to a hose which leads to the vacumm switch and tee off to pet cock

http://i1318.photobucket.com/albums/t653/J_Herrera_Fermin/carb3_zpscd3a4d45.jpg

 

Vacuum port#3 is under carb#3 and capped by a plug impossible to reach without removing the air box.

 

 

Procedure

 

1. Remove seat, side panels, fuel tank

 

2. Remove battery and airbox

 

3. Remove the cap at port #3 and connect a 4mm ID silicone hose permanently and attach this hose to the fuel pet cock directly (easier to connect the carb syn tool hose next time).

 

4. Remove the original hose at port #2 with a tee joint to the fuel petcock and connect a new 4mm ID silicone hose directly to the vacuum switch (since port#3 will be used to connect to fuel pet cock)

 

5. Connect up the carbtune tool to the respective hose (#1 and #4 need to use a adapter). The adjustment screw is very difficult to access except for the left one, and I have to use a very long phillip screw driver to tune. I use a syringe to pump petrol to the carburetor to keep it running.

 

6. Match the vacuum of carb #3 and #4, then carb#1 and Carb#2, finally carb#1&2 to carb#3 and 4.

 

Here is the picture of the result

 

http://i184.photobucket.com/albums/x97/S750WP/20131222_121911.jpg

 

http://i184.photobucket.com/albums/x97/S750WP/20131222_121921.jpg

 

http://i184.photobucket.com/albums/x97/S750WP/20131222_150652.jpg

 

http://i184.photobucket.com/albums/x97/S750WP/20131222_160106.jpg

 

The little hornet is much difficult to work with compare to my Z750 as the space is really cramp.

Edited December 25, 2013 by S750WP

[S750WP]

Change Coolant for Honda Hornet 250

 

You drain the coolant out from this bolt on the water pump, circled in red in this picture below (left side of the bike). Once drained out, replace the bolt and washer and fill it up with distilled water, NOT tap water. You'll then want to run the bike for a little while until its up to temperature. Keep an eye on it, once done you drain that water out and replace it with fresh coolant.

 

http://i.imgur.com/bA0igUR.jpg

[S750WP]

Problem on my colleague Hornet 250

 

1. Difficult to start when its cold

2. Temperature of one of the header is colder than the rest.

3. Power loss

 

Took out the power booster modification (some crap installed by previous owner) connected to the coil and revert it back to stock condition as follow all the problem gone.

 

http://i1186.photobucket.com/albums/z370/kanez1/spark.jpg

Ignition Coil Wiring

 

Ignition Coil No. 1

Top Wire: Yellow with Blue Stripe

Bottom Wire: Black with White Stripe

 

Ignition Coil No.2

Top Wire: Blue with Yellow Stripe

Bottom Wire: Black with Yellow Stripe

[S750WP]

http://i85.photobucket.com/albums/k67/370steve/carb2_zpsf60d486c.jpg

 

The green marking is the adjustment screw for carburetor synchronization.

 

The red marking is for the air/fuel mixture screw, standard setting is 2.5 turns out. Fuel setting increase by turning out the screw and in to decrease the fuel setting.

[altya]

Upz for ur DIY thread!! Awesome skill and knowledge!

[S750WP]

Upz for ur DIY thread!! Awesome skill and knowledge!

 

Thanks for the compliment.

[S750WP]

Rebuilt the front brake pump.

 

Procedure

 

1. Drain the old brake fluid, I connect a length of tubing to the front brake caliper nipple and loosen the brake nipple with a 8mm wrench and drain to a empty container.

 

2. Loosen the banjo nut on the brake pump and disconnect the brake line, discard the old crush washer. Disconnect the wires on the brake switch

 

3. Remove the 2 bolts that is holding the bake pump and removed the brake pump assembly

http://i184.photobucket.com/albums/x97/S750WP/20131222_211310.jpg

 

4. Remove the brake lever and pull off the rubber cap, you will see a circlip.

 

5. Remove the circlip with a circlip plier, the brake pump piston will pop out. Discard all the old parts and clean the brake reservoir with carb cleaner.

 

6. Assemble the new brake pump piston and lubricate with brake fluid, put in the new spring and reinstall the brake pump assembly. (See below for Honda part number for the rebuilt kit)

http://i184.photobucket.com/albums/x97/S750WP/20131222_211337.jpg

 

7. Reinstall everything back together, and use brand new crush washer to prevent brake fluid leaks

 

8. Feed the brake reservoir with fresh brake fluid and bleed the air from the line.

 

9. Finally test the brake is working.

[yinghai]

Admire your work bro.. im a freelance mechanic.. maybe we can exchange knowledge.. this is the recent work i did on a hornet... clutch overhauling..

 

http://i11.photobucket.com/albums/a169/malex_sky/20131006_163959_zpsc42e58da.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131116_222211_zps60ffd9c6.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131116_230352_zpsaac83c14.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131116_230356_zpsc5501b64.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131116_230400_zpsd9ff1b79.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131116_230407_zps86885560.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131205_170410_zpsc8074e76.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20131003_174711_zps3d228518.jpg

 

Valve clearence

 

http://i11.photobucket.com/albums/a169/malex_sky/20130428_215606_zpsbc67eb43.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20130428_215524_zpsd2bf871d.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20130428_213443_zpsa1165be5.jpg

http://i11.photobucket.com/albums/a169/malex_sky/20130428_213606_zpse08c3ee1.jpg

Edited December 27, 2013 by yinghai

[S750WP]

Admire your work bro.. im a freelance mechanic.. maybe we can exchange knowledge.. this is the recent work i did on a hornet... clutch overhauling..

 

Good Job, did you refurbish the clutch housing using files to remove the burs on it? saw alot of files in one of your background picture.

 

What is the mileage of your ride, was any of the valve clearance out of spec?

[yinghai]

Replaced the whole clutch assembly except for the center hub as i bought the wrong year parts..will be getting it after new year... mileage wise, the original meter stopped working at 70k, im on digital now.. valve clearence all still in spec..

 

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