HRC NSF250R 2012 User manual

Important
This machine is designed and manufactured for competition use only and is sold “as-is” with no warranty. It does not conform to federal motor
vehicle safety standards and operation on public streets, roads, or highways is illegal.
State laws prohibit operation of this vehicle except in an organized racing or competitive event upon a closed course which is conducted under the
auspices of a recognized sanctioning body or permit issued by the local governmental authority having jurisdiction.
First determine that operation is legal.
Operator only, no passengers.
Read this manual carefully.
This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.
Safety Messages
Your safety and the safety of others is very important. We have provided
important safety messages in this manual and on the HRC NSF250R.
Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or
others. Each safety message is preceded by a safety alert symbol and
one of three words, DANGER, WARNING, or CAUTION.
These mean:
You WILL be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
Each message tells you what the hazard is, what can happen and what
you can do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
Your HRC NSF250R or other property can be
damaged if you don’t follow instructions.
The purpose of these messages is to help prevent damage to your HRC
NSF250R, other property, or the environment.

HRC NSF250R
Owner’s Manual/Parts List
All information in this publication is based on the latest product information available at the time of approval for printing.
Honda Racing Corporation reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.
HRC NSF250R
Owner’s Manual/Parts List
All information in this publication is based on the latest product information available at the time of approval for printing.
Honda Racing Corporation reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission.

(1) FRAME SERIAL NUMBER
The frame serial number is attached on the left side
of the main frame as shown.
(1) ENGINE SERIAL NUMBER
The engine serial number is stamped on the left side
of the crankcase.
(1)
(1)

Cleaning 3–24
Storage 3–24
Nuts, Bolts, Fasteners 3–25
4. Engine Servicing
Lubrication Diagram 4–1
Oil Pressure Relief Valve 4–2
Oil Pump 4–4
Fuel Hose Removal/Installation 4–7
Fuel Line Inspection 4–9
Fuel Tank/Fuel Pump 4–10
Throttle Body/Air Box 4–14
Muffler/Exhaust Pipe 4–20
Engine Removal 4–21
Engine Installation 4–21
Radiator Removal/Installation 4–24
Water Seal/Bearing Replacement 4–24
Cylinder Head Cover/Camshaft Removal 4–27
Cylinder Head Removal 4–30
Cylinder Head Disassembly 4–32
Cylinder Head Inspection 4–33
Cylinder Head Assembly 4–36
Cylinder Head Installation 4–37
Camshaft/Cylinder Head Cover Installation 4–38
Cylinder/Piston 4–43
Clutch 4–46
Right Crankcase Cover 4–51
Primary Drive Gear 4–52
Balancer 4–54
Transmission 4–56
Left Crankcase Cover 4–64
Flywheel 4–67
Crankcase Separation/Disassembly 4–68
Crankshaft 4–71
Crankcase Bearing Replacement 4–76
Crankcase Assembly 4–79
5. Frame Servicing
Front Wheel 5–1
Fork 5–4
Handlebar 5–13
Contents
1. Operating Instruction
Fuel 1–1
Coolant 1–1
Basic Operation 1–2
Controls 1–4
2. Service Data
Specifications 2–1
Service Data 2–2
Optional Parts 2–5
Torque Values 2–6
Tools 2–10
Lubrication & Seal Points 2–12
Cable & Harness Routing 2–15
3. Service And Maintenance
Maintenance Schedule 3–1
Pre-ride Inspection 3–1
Warming-up Inspection 3–2
Ride Inspection 3–2
After Ride Inspection 3–2
Replacement Parts 3–2
Fuel Line 3–4
Air Filter 3–4
Spark Plug 3–4
Valve Clearance 3–5
Engine Oil 3–8
Transmission Oil 3–10
Cooling System 3–12
Clutch System 3–13
Exhaust Pipe/Muffler 3–14
Drive Chain 3–15
Drive Chain Slider/Roller 3–16
Drive/Driven Sprocket 3–17
Brake Fluid 3–19
Brake Pad Wear 3–19
Brake System 3–20
Handlebar And Steering Head Bearings 3–20
Wheels/Tires 3–21
Front Suspension 3–21
Fork 3–22
Rear Suspension 3–22
Steering Stem 5–14
Rear Wheel 5–19
Rear Shock Absorber 5–20
Suspension Linkage 5–24
Swingarm 5–25
Brake Pad Replacement 5–32
Front Brake Caliper 5–35
Rear Brake Caliper 5–35
Front Master Cylinder 5–37
Rear Master Cylinder 5–39
6. Electrical Servicing
Charging System Inspection 6–1
Ignition System Inspection 6–2
Condenser Inspection 6–4
Engine Stop Switch Inspection 6–4
Handle Switch Inspection 6–5
PGM-FI System Inspection 6–5
PGM-FI System Self-diagnosis Procedure 6–6
PGM-FI Self-diagnosis Malfunction
Indicator Lamp (MIL) Failure Codes 6–7
Bank Angle Sensor Inspection 6–8
Coolant Temperature Sensor Inspection 6–9
Wiring Diagram 6–10
7. Machine Setting
Optional Transmission Gear 7–1
Suspension Setting 7–7
Suspension Setting Troubleshooting 7–14

Read instructions contained in Owner’s Manual carefully.
Read instructions contained in Shop Manual carefully.
In the interest of safety, take the motorcycle to be serviced
only by a Honda dealer.
DANGER (with RED background)
You WILL be KILLED or SERIOUSLY HURT if you don’t fol-
low instructions.
WARNING (with ORANGE background)
You CAN be KILLED or SERIOUSLY HURT if you don’t fol-
low instructions.
CAUTION (with YELLOW background)
You CAN be HURT if you don’t follow instructions.
Image Labels
The following pages describe the label meanings. Some labels warn you of
potential hazards that could cause serious injury, Others provide important
safety information, Read this information carefully and don’t remove the labels.
If a label comes off or becomes hard to read, contact your HRC dealer for a
replacement.
There is a specific symbol on each label.
The meanings of each symbol and label are as follows.
RADIATOR CAP SEAL
DANGER!
NEVER OPEN WHEN HOT.
Hot coolant will scald you.
Relief pressure valve begins to open at 108
kPa.
CAUTION LABEL
IMPORTANT INFORMATION
• Operator only. No passengers.
• The HRC NSF250R is sold as is without
warranty, and the entire risk as to quali-
ty and performance is with the buyer.
READ OWNER’S MANUAL
• The vehicle is designed and manufac-
tured for competition only.
• Operation on public streets, roads, or
highways is illegal.
• Local laws prohibit operation of this
vehicle expert in an organized racing or
competitive event upon a closed course
which is conducted under the auspices
of a recognized sanctioning body or by
permit issued by the local governmental
authority having jurisdiction.
• First determine that operation is legal.
REAR CUSHION LABEL
GAS FILLED
Do not heat.

Importance Of Proper Preparation
Proper pre-competition preparation and regular
service is essential to rider safety and the reliability
of the motorcycle. Any error or oversight made by
the technician during preparation or servicing can
easily result in faulty operation, damage to the
machine, or injury to the rider.
How To Use This Manual
The purpose of this Owner’s Manual is to help
ensure that you obtain the greatest possible satis-
faction from your new NSF250R roadracer; satisfac-
tion with the performance of the motorcycle, and
through success in competition.
If you plan to do any service on your NSF250R, sec-
tion 3 describes standard maintenance and sections
4 through 6 contain information on repair, disas-
sembly, assembly and special tools.
Follow the Maintenance Schedule recommendation
(page 3-1) to ensure that your NSF250R is always in
peak operating condition.
To The New Owner
By selecting a HRC roadracer NSF250R as your new
machine, you have placed yourself in a distin-
guished family of owners and riders.
The NSF250R is a high performance racing machine
utilizing the latest racing technology. This machine
is intended for competition use by experienced rid-
ers only.
This new racer was designed to be as competitive as
possible. But motorcycle racing is a physically
demanding sport that requires more than just a fine
racing machine. To do well, you must be in excellent
physical condition and be a skillful rider. For the
best possible results, work diligently on your physi-
cal conditioning and practice frequently.
The purpose of this Manual is to help ensure that
you obtain the greatest possible satisfaction from
your new NSF250R roadracer.

Memo

1-1
1. Operating Instruction
(1) FUEL FILL CAP
Fuel
Gasoline is highly flammable and is explosive.
You can be burned or seriously injured.
When refueling:
• Stop engine and keep heat, sparks, and flame
away.
• Refuel only outdoors.
• Wipe up spills immediately.
Open the tank cap by turning it counterclockwise.
Fill the fuel tank with recommended fuel.
Fuel tank capacity: 11.0 liter (2.90 US gal, 2.42 Imp gal)
Gasoline: Premium unleaded gasoline (commercially
available unleaded; research octane number
100 or higher)
Install the fuel fill cap by turning it clockwise.
Install the three buffle sponge into the fuel tank.
(1) RADIATOR CAP
Coolant
The engine of the NSF250R is a water-cooled type.
In order to provide adequate cooling, it is essential
that the radiator be filled with coolant up to the
proper level.
Coolant:
Water only. Use clean tap water or distilled
water.
Removing the radiator cap while the engine is hot
will allow the coolant to spray out, seriously scald-
ing you.
Always let the engine and radiator cool down before
removing the radiator cap.
Failure to bleed the air completely may cause over-
heating and damage the engine
(1) FILLER NECK
When filling the cooling system, be sure to bleed air
completely so that the system can be sufficiently
filled.
Bleed the air thoroughly using the following proce-
dure:
Raise the front end of the machine and put a stand
beneath engine.
1. Fill the coolant up to the filler neck.
2. Rock the machine from left to right 2 – 3 times
holding the handlebars.
3. Repeat 1 to 2 until the water level does not go
down.
4. Reinstall the radiator cap securely.
If the radiator cap is not installed properly, it will
cause excessive coolant loss and may result in over-
heating and engine damage.
5. After starting the engine, check the coolant level.
The coolant level is correct when it is at the bot-
tom of the radiator filler neck.
Add coolant up to the filler neck if the level is low.
(1)
(1) (1)

1-2
Operating Instruction
(1) OVERFLOW CATCH TANK
Before running, drain the coolant from the overflow
catch tank.
After running, check the radiator and coolant pas-
sages for rusting or clogging. Since the cooling sys-
tem uses water only, it should be drained complete-
ly at the end of each race day to prevent corrosion
damage.
(1) ENGINE STOP SWITCH
Basic Operation
Starting The Engine
Your NSF250R exhaust contains poisonous carbon
monoxide gas. High levels of carbon monoxide can
collect rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door closed.
Even with the door open, run the engine only long
enough to move your NSF out of the garage.
Cold Engine Starting
1. Turn the engine stop switch to RUN.
2. Shift the transmission into second gear.
3. With the throttle closed, start the engine by push-
ing the machine.
4. After the engine starts, shift the transmission into
neutral, and run it for a few minutes, "blipping"
the throttle, until it warms up enough.
(1)
(1)

1-3
Operating Instruction
(1) ENGINE STOP SWITCH
Warm Engine Starting
Follow the cold engine starting procedure.
Stopping The Engine
1. Shift the transmission into neutral.
2. Lightly open the throttle 2 – 3 times, and then
close it.
3. Turn the engine stop switch OFF until the engine
stops completely.
(1) TACHOMETER
(2) WATER TEMPERATURE METER
Warming-up The Engine
• Do not rev the engine more than necessary or
engine damage may result.
• Do not race the engine for an extended period of
time during the warm-up while the machine is sta-
tionary.
1. Vary the engine speed up to a maximum of 9,000
min-1 (rpm) until the water temperature meter indi-
cates 50˚C (122˚F).
2. When the temperature meter indicates more than
50˚C (122˚F), vary the engine speed to a maximum
of 10,000 min-1 (rpm) to warm-up the engine.
3. Warm-up the engine for a few minutes until it is
heated to the operating temperature [60˚C
(140˚F)].
Break-In Procedure
New Machine
• Use Ultra G1 engine oil for break-in. Using other
engine oil, correct break-in effect is not obtained.
• Before running, check that the engine oil is in
proper level through the sight glass.
Following proper break-in procedure helps ensure
that the most important and expensive components
on your new machine will provide maximum per-
formance and service life. (Also follow proper break-
in procedure for a newly rebuilt engine.)
When riding a new machine, keep engine speed
constantly, and shifting gears within the specified
range. Use 5th or 6th gear at circuit straight and
always check machine condition:
Below 6,000 min-1 (rpm)......... About 50 km (30 mi)
(About 30 minutes)
Below 8,000 min-1 (rpm)......... About 15 km (9 mi)
Below 10,000 min-1 (rpm)....... About 15 km (9 mi)
Above 10,000 min-1 (rpm)....... About 15 km (9 mi)
(About 30 minutes)
Total: About 95 km (57 mi; about one hour)
• After break-in, check contamination of engine oil
and oil consumption, the change engine oil.
• After break-in, check valve clearance.
(1) (1)
(2)

1-4
Operating Instruction
Reconditioned Machine
• After replacing the cylinder and crankshaft, oper-
ate the machine for the first 95 km (57 mi; about
one hour) observing the same cautions as for a
new machine.
• Use same break-in procedure and after break-in
check:
Below 6,000 min-1 (rpm)......... About 20 km (15 mi)
(About 15 minutes)
Below 8,000 min-1 (rpm)......... About 10 km (6 mi)
Below 10,000 min-1 (rpm)....... About 10 km (6 mi)
Above 10,000 min-1 (rpm)....... About 10 km (6 mi)
Total: About 50 km (30 mi; about 30 minutes)
(1) CLUTCH LEVER
Controls
Clutch
1. The normal clutch lever free play is 10 – 20 mm
(0.4 – 0.8 in) measured at the tip of the lever.
(1) LOCK NUT (2) ADJUSTER
(A) INCREASE (B) DECREASE
2. Minor adjustments can be made with the cable
end adjuster.
Loosen the lock nut and turn the adjuster. Turning
the adjuster in direction A will increase free play,
turning the adjuster direction B will decrease free
play. After adjustment, tighten the lock nut.
If the adjuster is threaded out near its limit or the
correct free play cannot be reached, turn the
adjuster all the way in and back out one turn.
Tighten the lock nut and make the adjustment
with the integral cable adjuster.
(1) (2)
(B)
(A)
(1)

1-5
Operating Instruction
(1) LOCK NUT (2) ADJUSTER
(C) INCREASE (D) DECREASE
3. Major adjustments can be made at the integral
cable adjuster.
Loosen the lock nut and turn the adjuster.
Turning the adjuster in direction C will increase
free play and turning it in direction D will decrease
free play. Tighten the lock nut after adjusting.
4. Test ride to be sure the clutch operates properly
without slipping or dragging.
(1) THROTTLE GRIP
Throttle Grip
Throttle Grip Free Play
Measure the throttle grip free play at the grip rota-
tion.
Free play: 2 – 6 mm (0.08 – 0.24 in)
(1) LOCK NUT (2) ADJUSTER
(A) DECREASE (B) INCREASE
Adjustment is made with the upper adjuster.
Loosen the lock nut.
Turning the adjuster in direction A will decrease free
play, turning it in direction B will increase free play.
Tighten the lock nut and reinstall the dust cover after
adjustment.
Operate the throttle grip to ensure that it functions
smoothly and returns completely in all steering
position.
(2)
(1)
(D)
(C)
(1) (2)
(1)
(B)
(A)

1-6
Operating Instruction
(1) ARROW (2) INDEX MARK (3) ADJUSTER
Front Brake Lever
The distance between the tip of the brake lever and
the grip can be adjusted by turning the adjuster.
Align the allow on the brake lever with index mark
on the adjuster.
(1) LOCK NUT (2) ADJUSTING BOLT
(A) RAISE THE PEDAL HEIGHT
(B) LOWER THE PEDAL HEIGHT
Brake Pedal Height
The brake pedal height can be adjusted to the rider's
preference.
To adjust the rear brake pedal height:
1. Loosen the lock nut and turn the adjusting bolt in
direction A to raise the pedal, or in direction B to
lower it.
2. Tighten the lock nut at the desired pedal height.
(1) LOCK NUTS (2) CHANGE ROD
Gearshift Pedal Height
The gearshift pedal height can be adjusted to the
rider's preference.
The gearshift pedal height can be adjusted by
changing the length of the change rod on its thread-
ed ends.
To adjust the gearshift pedal height:
1. Loosen the lock nuts (one lock nut has reverse
threads) on both ends of the change rod, and turn
the rod as required.
2. Tighten the lock nuts at the desired pedal height.
The change arm should be installed so that it has
at a right angle to the gearshift pedal lever.
Shifting pattern: 1-UP and 5-DOWN
(1)
(2)
(B)
(A)
(1)
(3)
(2) (2)
(1)

1-7
Operating Instruction
1-DOWN AND 5-UP
To change the pattern to "1-DOWN and 5-UP", rein-
stall the change arm upside down (rod connecting
end facing down).
Before running, apply grease to the change pedal
pivot surface.
(1) STEERING DAMPER (2) ADJUSTER
(A) HARD (B) SOFT
Steering Damper
Turn the adjuster clockwise to increase damping,
counterclockwise to decrease damping. There are
12 – 17 notches between minimum and maximum.
Do not force the adjuster to pass its limit.
Standard setting: Full soft position
Improper handling or failure to install the damper
properly may damage the steering damper.
(1) THICK WASHER (2) SPHERICAL BEARING
• When installing the damper on the frame, pay
careful attention to prevent the piston rod from
being applied with excessive bending force
beyond the allowable rotation angle of the spher-
ical bearing.
• Handle carefully to avoid scratching, damaging or
leaving foreign substances on the rod.
• Do not try to disassemble the steering damper.
• The steering damper must first be set at the stan-
dard (full soft) position, than adjust as required.
• At steering damper installation, set the thick
washer (2.3 mm) between the spherical bearing
and frame, and the spherical bearing and bottom
bridge.
1-UP AND 5-DOWN
(1) CHANGE ARM (2) CHANGE ROD
(3) GEARSHIFT PEDAL
(1) CHANGE ARM (2) CHANGE ROD
(3) GEARSHIFT PEDAL
(1)
(2)
(B)
(A) (1)
(1)
(2)
(2)
(1)
(2)
(3)
(1)
(2)
(3)

Memo

2-1
2. Service Data
Item Specification
Dimensions
Overall length 1,809 mm (71.2 in)
Overall width 560 mm (22.0 in)
Overall height 1,037 mm (40.8 in)
Wheelbase 1,219 mm (48.0 in)
Ground clearance 107 mm (4.2 in)
Seat height 729 mm (28.7 in)
Dry weight 84 kg (185 lbs)
Frame
Type Aluminium, twin tube
Front suspension Telescopic, inverted type
Rear suspension Swinger, Pro-link
Front tire size 90/580 R17
Rear tire size 120/600 R17
Front brake Single disc 296 mm, with 4-piston caliper
Rear brake Single disc 186 mm, with single piston caliper
Fuel capacity 11.0 liter (2.91 US gal, 2.42 Imp. gal)
Caster angle 22˚ 36’
Trail length 84 mm (3.3 in)
Engine
Type Liquid cooled 4-stroke engine
Cylinder arrangement Single cylinder, inclined 15˚ from vertical
Bore and stroke 78.0 x 52.2 mm (3.07 x 2.06 in)
Displacement 249.3 cm3(15.21 cu-in)
Compression ratio 12.3: 1
Valve train Chain driven, DOHC
Valve timing
Intake opens 25˚ BTDC (at 1.0 mm lift)
Intake closes 50˚ ABDC
Exhaust opens 50˚ BBDC
Exhaust closes 20˚ ATDC
Lubrication system Semi-dry sump, forced pressure and wet sump
Oil pump type Trochoid
Specifications
Item Specification
Fuel System
Throttle body type GQD1A
Throttle bore 50 mm (2.0 in)
Drive Train
Clutch operating system Cable operated
Clutch type Wet, multi-plate
Transmission 6 speeds constant mesh
Primary reduction 2.952 (21/62T)
Gear ratio (STD) 1st 1.875 (16/30T)
2nd 1.523 (21/32T)
3rd 1.304 (23/30T)
4th 1.166 (24/28T)
5th 1.076 (26/28T)
6th 1.000 (24/24T)
Final reduction 2.333 (15/35T)
Gearshift pattern 1 – N – 2 – 3 – 4 – 5 – 6 (1 up and 5 down)
Electrical
Fuel Delivery System PGM-FI
Ignition system Full Transistor

2-2
Service Data
Service Data
Item Standard Service Limit
Lubrication System
Suggested engine oil Honda 4-stroke motorcycle oil –
or equivalent
Oil recommendation API service classification: SG or
higher (except oils labeled as
energy conserving on the circular
API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
Engine oil capacity
lower level 1.16 liter (1.23 US qt, 1.02 Imp qt) –
upper level 1.37 liter (1.45 US qt, 1.21 Imp qt) –
at oil change 1.17 liter (1.24 US qt, 1.03 Imp qt) –
at filter replacement 1.20 liter (1.27 US qt, 1.06 Imp qt) –
Suggested engine oil Honda 4-stroke motorcycle oil –
or equivalent
Oil recommendation API service classification: SG or
higher (except oils labeled as
energy conserving on the circular
API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
Transmission oil capacity
at disassembly 0.55 liter (0.58 US qt, 0.48 Imp qt)
–
at oil change 0.49 liter (0.52 US qt, 0.43 Imp qt) –
Oil pump tip clearance 0.15 (0.006) max –
body clearance 0.15 – 0.21 (0.006 – 0.008) –
side clearance 0.02 – 0.08 (0.001 – 0.003) –
Fuel System
Throttle grip free play 2 – 6 (0.08 – 0.24) –
Throttle body identification No. GQD1A –
Engine idle speed 3,000 ± 300 min-1 (rpm) –
Unit: mm (in) Unit: mm (in)
Item Standard Service Limit
Cylinder Head/Valves
Valve clearance IN 0.2 ± 0.02 (0.008 ± 0.001) –
EX 0.3 ± 0.02 (0.012 ± 0.001) –
Valve lift IN 9.0 (0.35) –
EX 8.0 (0.31) –
Valve seat width IN/EX 1.0 (0.04) –
Clutch/Gearshift Linkage
Clutch lever free play 10 – 20 (0.4 – 0.8) –
Clutch plate warpage – 0.16 (0.006)
Clutch spring free length 38.8 (1.53) –
Crankshaft/Transmission
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) –