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 Topic: NSR250 MC18 R5K Engine Rebuild 







philup_7@hotmail.com

 
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philup_7@hotmail.com » Sat Apr 11, 2026 10:40 am

Installing Flywheel
Following installation of the Stator assembly, the Flywheel was located on the Woodruff Key and I used a Universal Flywheel Holder with a homemade extender bar wedged on the ground to torque it up. The Pickups were then installed and the cables routed back to their original connectors.
MC28 Neutral Switch/MC 21 GPS Installation
Using HONDA’s:
    • MC28 Neutral Switch wire, this was routed as shown and connected to the existing MC18 R5K (Neutral Light Switch light Green/Red wire) Bullet Connector in the main loom located by the Regulator. The MC28 Neutral Switch wire was just about long enough.
    • MC21 GPS (Gear Position Sensor), the separate light Green/Red wire (Note: PROTECH’s GPS-01 gear position sensor model 11609 in the Picture is White/Green wire, but I think in reality it’s nearer light Green/Pinkish) can be connected directly to the MC18 R5K (Neutral Light Switch light Green/Red wire) Bullet Connector in the main loom located by the Regulator and the Block Connector stowed away & secured, no connection necessary unless you want to install an aftermarket Gear Position Indicator. Not sure whether the length of HONDA’s MC21 GPS/PROTECH’s GPS-01 wire is long enough to connect back to the Bullet connector and may require extending.

The existing MC18 Neutral Light Wire which is located in the same sub loom as the Pick up wires and was left dangling for the time being.
Note: the MC21 GPS Wire will be a lot fatter as it has 7 wires instead of the MC28’s Neutral single wire.




An extra cut out was required in the Flywheel Cover to enable the Neutral/GPS wire to pass thru it. The old MC18 Neutral Wire was clipped out of the way to the Flywheel Cover.

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