Honda Crf 250 M Manual

							Front Suspension Adjustments
Adjustments for Competition97 13.Hold the outer tube (18), then remove the fork
damper (19) from the outer tube using a lock
nut wrench (20). Gently slide the outer tube
down onto the lower end of the slider (21).  10.Clean the fork assembly, especially the sliding
surface of the slider (15) and dust seal (16). 
The outer tube can drop on the slider and
damage the fork dust seal and guide bushing
when the fork damper is removed. To avoid
damage hold both the outer tube and slider when
removing the fork cap. 
NOTICE
(15) slider  (16) dust seal
11. Record the rebound damping adjuster position
and turn the adjuster counterclockwise until it
stops.
12.Measure the length (17) between the axle
holder and outer tube and record it before
disassembling the fork.
(18) outer tube (20) lock nut wrench
(19) fork damper (21) slider, lower end 
14.Pour the fork oil from the outer tube.
Pour the fork oil from the oil hole (22) of the
fork damper.
(22) oil hole 
15.Temporarily install the fork damper to the
outer tube. 
16.Set the lower end (axle holder) (23) of the
slider in a vise with a piece of wood or soft
jaws to avoid to damage. 
Overtightening the vise can damage the axle
holder.
17.Loosen the fork center bolt (24). 
NOTICE
(23) axle holder (24) fork center bolt
18.Push out the fork center bolt from the axle
holder of the slider by pushing the fork
damper.
19.Make the mechanics stopper tool out of a thin
piece of steel (1.0 mm thick) as shown if you
do not have the special tool.
(17) length
(15)
(16)
(17)
(20)(21)(18)
(19)
(22)
(24)
(23)
(cont’d) 
						

							Front Suspension Adjustments
98Adjustments for Competition
20.Apply pressure to the fork damper and insert a
special tool or mechanics stopper tool (25)
(see below) between the axle holder (23) and
lock nut (26). 
21.Hold the lock nut and remove the fork center
bolt (24) from the fork damper. 
Do not remove the lock nut from the fork damper
piston rod. If the lock nut is removed, the piston
rod will fall in the fork damper and you can not
reassemble the fork damper. 
NOTICE
(23) axle holder (25) stopper tool
(24) fork center bolt (26) lock nut 
22.Remove the push rod (27) from the fork
damper. 
23.Remove the special tool or mechanics stopper
tool between the axle holder (23) and lock nut
(26) while applying pressure to the fork cap.
Be careful not to damage the lock nut and fork
center bolt hole.
NOTICE
(23) axle holder (26) lock nut
(25) tool  (27) push rod
24.Remove the fork damper assembly (28) from
the fork assembly (29). 
Remove the fork from the vise. 
Remove the fork spring (30) from the fork.
(28) fork damper assembly (30) fork spring
(29) fork assembly(1) fork cap (3) lock nut wrench 
(2) fork damper 
1. Loosen the fork cap (1) by turning the fork
damper (2) using the lock nut wrench (3).(23)
(25)(26)
(24)
(23)
(25)
(27)(26)
(28)
(30)
(29)
(2)
(1)
(3)
Damper Oil Change 
						

							Front Suspension Adjustments
Adjustments for Competition99
(2) fork damper (4) fork cap assembly
3. Empty the fork oil from the fork damper (2)
by pumping the damper rod several times. 
(2) fork damper  (5) oil hole
4. Clean the fork cap and fork damper threads.
(2) fork damper
6. Pump the fork damper piston rod (6) slowly
several times to bleed the air from the fork
damper (2).
(2) fork damper  (6) piston rod(2) fork damper
8. Apply fork oil to the bushing and new O-ring
on the fork cap assembly (4). 
Extend the fork damper piston rod to
maximum, holding it, install the fork cap
assembly to the fork damper (2).
Be careful not to damage the fork cap bushing.
If it is difficult to install the fork cap assembly,
the fork damper oil level might be higher than
standard oil level. Inspect the fork damper oil
level again. 
(2) fork damper  (4) fork assembly
(4)
(2)
(2)(5)
(2)
(2)
(6)
1.65 – 1.85 in
(42 – 47 mm)
(2)
(2)
(4)
7. Extend the fork damper piston rod to
maximum. Adjust the oil level of the fork
damper (2) as shown.
Oil Level:1.65 – 1.85 in (42 – 47 mm) 5. Extend the fork damper piston rod to maximum.
Pour the recommended fork oil into the fork
damper.
Recommended Oil:
Pro Honda HP Fork Oil 5 W or equivalent
Recommended Amount:
6.0 US oz (178 cc) 2. Remove the fork cap assembly (4) from the
fork damper (2).
Be careful not to damage the fork cap bushing. 
Do not disassemble the fork cap assembly. 
Replace the fork cap as an assembly if it is
damaged.
(cont’d) 
						

							Front Suspension Adjustments
100Adjustments for Competition (2) fork damper (6) piston rod
(2) fork damper  (8) spring chamber
(10) pressure release screw (11) fork cap 
(2)
(6)
(6) piston rod (7) lock nut
Turn the rebound adjuster and compression
adjuster counterclockwise to the softest position. 
Check the fork damper piston rod sliding surface
for damage. 
Apply fork oil to the fork damper piston rod
sliding surface 
Cover the fork piston rod end with soft jaws to
prevent fork damage.
Be careful not to bend or damage the fork
damper piston rod when the piston rod is stroked.
12.Blow the extra oil off to the fork damper (2)
spring chamber (8) by pumping the fork
damper piston rod to full stroke. 
NOTICE
(8) spring chamber  (9) oil hole
14.Blow out the oil from the fork damper spring
chamber using compressed air to the oil hole. 
Wipe the oil completely off the fork damper.
15.If you can not use compressed air, remove the
pressure release screw (10) on the fork cap
(11). 
Hold the fork damper up side down for 10
minutes and drain the oil from the fork
damper spring chamber.
(6)
(7)
(8)
(2)
(8)(9)
(11)
(10)
13.Drain the extra oil from the fork damper
spring chamber (8) oil hole (9).
By doing this procedure, about 17 cm
3of fork
fluid will be drained from the damper spring
chamber through the oil hole and cause 178 cm
3
of fork fluid to be left in the chamber.  11. Screw in the lock nut (7) to the fork damper
piston rod (6) fully. 
(1) fork cap (3) lock nut wrench
(2) fork damper
10.Hold the fork damper (2) in an upright
position and pump the fork piston rod (6) to
3.9 in (100 mm) slowly several times.
(2)
(1)
(3)
9. Tighten the fork cap (1) while holding the cut
out of the fork damper (2) using the lock nut
wrench (3) to the specified torque: 
25 Ibf·ft (34 N·m, 3.5 kgf·m) 
						

							Front Suspension Adjustments
Adjustments for Competition101
Fork Assembly
1. Drain the fork oil from the outer tube/slider
(1) by placing it upside down.
(About 7 cc of fork oil will be left in the outer
tube/slider when it is left inverted for about 20
minutes at 20°C/68°F)
(1) outer tube/slider
2. Tighten the lock nut (2) fully and measure the
thread length (A) as shown.
Standard:0.43 – 0.51 in (11 – 13 mm)
Wipe the oil completely off the fork damper.
(2) lock nut (A) thread length
3. Wipe the oil completely off the fork spring
(3).
Install the fork spring.
Install the fork damper (4) to the outer
tube/slider (1).
(1) outer tube/slider (4) fork damper assembly
(3) fork spring
(1)
Amount of fork oil left in the fork
(without damper and spring) unit: cc
minute
°C/°F
30/86
20/68
10/50
0/32
5
7.1
10.6
11.8
12.910
5.9
8.2
8.3
10.620
4.7
7.1
7.2
9.435
4.2
5.9
6.2
8.255
3.5
5.6
5.8
7.985
3.5
4.7
4.9
7.1145
3.5
4.7
4.8
5.9
(A)
(2)
(4)
(3)
(1)
(cont’d) 
						

							Front Suspension Adjustments
102Adjustments for Competition
4. Set the lower end (axle holder) of the slider in
a vise with a piece of wood or soft jaws to
avoid to damage. 
Do not overtighten the axle holder. 
5. Temporarily install the fork damper to the
fork. 
Push out the fork damper piston rod from the
axle holder of the slider by pushing the fork
damper.
Apply pressure to the fork damper and insert
the special tool or mechanics stopper tool (5)
between the axle holder and lock nut (2). 
Measure the thread length again.
Standard:0.43 – 0.51 in (11 – 13 mm) 
6. Install the push rod (6) into the piston rod
until it stops. 
Check the push rod installation by turning the
push rod right and left.
7. Install a new O-ring (7) to the fork center bolt
(8).
Install the fork center bolt to the fork damper
piston rod aligning the center bolt adjusting
rod (9) with the push rod. Tighten the center
bolt fully by hand. 
NOTICE
(2) lock nut (7) O-ring
(5) stopper tool (8) fork center bolt
(6) push rod (9) adjusting rod
8. Measure the length of the lock nut (2) and
center bolt (8) clearance. 
Standard: 0.06 – 0.08 in (1.5 – 2.0 mm)
If the clearance is out of specification, check the
lock nut and center bolt installation. 
(2) lock nut (8) center bolt
9. Tighten the lock nut (2) to the fork center bolt
(8) closely by hand. Tighten the lock nut to
the specified torque: 
16 Ibf·ft (22 N·m, 2.2 kgf·m) 
(2) lock nut
(8) fork center bolt
10.Apply fork oil to the fork center bolt (8) O-
ring.
Remove the special tool or mechanics stopper
tool while applying pressure to the fork
damper. 
Install the center bolt to the axle holder and
tighten it to the specified torque: 
51 Ibf·ft (69 N·m, 7.0 kgf·m)
(8) fork center bolt 
11. Measure the length between the axle holder
and outer tube. 
Standard:317 ± 2 mm 
12.Compare the length (10) at assembly and at
disassembly. They should be the same length. 
If the length at assembly is longer than at
disassembly, check the center bolt and lock nut
installation. 
(10) length
(8)
(7)
(9)
(5)
(2)
(6)
(2)
(8)
(8)
(2)
(8)
(10) 
						

							Front Suspension Adjustments
Adjustments for Competition103 13.Pour the recommended fork oil (11) into the
outer tube/slider (1).
Recommended Oil: 
Pro Honda HP Fork Oil 5 W or equivalent.
(1) outer tube/slider (11) fork oil
(1)
(11)
()
Fork Oil Capacity: 
Standard (0.45 kgf/mm) Fork Spring
Standard oil
capacity12.5 US oz
(371 cm
3)
Maximum oil
capacity14.1 US oz
(417 cm
3)Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression. Minimum oil
capacity10.9 US oz
(321 cm
3)
()
Optional Softer (0.43 kgf/mm) Fork Spring
Standard oil
capacity12.4 US oz
(368 cm
3)
Maximum oil
capacity14.0 US oz
(414 cm
3)Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression. Minimum oil
capacity10.8 US oz
(318 cm
3)
No mark
(factory products)
1 scribe mark
1 scribe mark
(aftermarket parts)or()
Optional Stiffer (0.47 kgf/mm) Fork Spring
Standard oil
capacity12.6 US oz
(374 cm
3)
Maximum oil
capacity14.2 US oz
(420 cm
3)Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression. Minimum oil
capacity11.0 US oz
(324 cm
3)
1 scribe mark and
3 scribe mark 75 degrees apart
Be sure the oil capacity is the same in both fork
legs.
14.Install the fork damper as described in
Damper Oil Change (page 104-106).
(cont’d) 
						

							Front Suspension Adjustments
104Adjustments for Competition
15.Check that the O-ring (12) on the fork damper
assembly (4) is in good condition. Apply the
recommended fork oil to the O-ring. 
(1) outer tube/slider (12) O-ring 
(4) fork damper assembly 
16.Temporarily thread the fork damper (4) into
the outer tube (1). Insert both fork legs into
the fork clamps. Align the groove in the outer
tube with the top surface of the upper fork
clamp. 
If installing the optional 20 inch wheel, align
the top of the outer tube (not the top of the
fork cap) with the top surface of the upper
fork clamp. 
Temporarily tighten the fork lower pinch bolts
(13) and then tighten the fork damper (4) to
the specified torque using a special tool: 
25 Ibf·ft (34 N·m, 3.5 kgf·m) 
For ease of releasing air pressure after the forks
are installed, loosen the lower pinch bolts and
position the  outer tubes so that the pressure
release screws are in front of the rebound
damping adjusters. 17.Tighten the fork lower pinch bolts (13) to the
specified torque:
14 Ibf·ft (20 N·m, 2.0 kgf·m)
18.Tighten the fork upper pinch bolts (14) to the
specified torque:
16 Ibf·ft (22 N·m, 2.2 kgf·m) 
Over-tightening the pinch bolts can deform the
outer tubes. Deformed outer tubes must be
replaced. 
NOTICE
(4) fork damper (14) upper pinch bolts
(13) lower pinch bolts
(4)(12)
(1)
(13)(4)
(14) 
						

							Front Suspension Adjustments
Adjustments for Competition105 19.Clean the threads of the fork protector (15)
bolts and axle holder thoroughly. 
Apply locking agent to the bolt threads. 
Install the fork protector and tighten the bolts
to the specified torque:
5.1 Ibf·ft (7 N·m, 0.7 kgf·m)
(15)  fork protector 
20.Clean the surfaces where the axle and axle
clamps contact each other. 
Install the left and right side collars into the
wheel hub. Insert the front axle shaft through
the wheel hub from the right side. Make sure
the front axle shaft is seated firmly onto the
left fork leg clamp inner surface. Tighten the
axle nut (16) to the specified torque: 
65 Ibf·ft (88 N·m, 9.0 kgf·m)
(16) axle nut
21.Align the brake caliper (17) and hose with the
left fork leg, making sure that the brake hose
is not twisted.
22.Clean the threads of the caliper mounting
bolts (18) and brake caliper thoroughly.
Apply locking agent to the bolt threads.
Install the brake caliper on the slider and
tighten the caliper mounting bolts to the
specified torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m) 
WARNING
An improperly routed brake hose may
rupture and cause a loss of braking
efficiency. Route the hose carefully
Fit the brake caliper over the disc, taking care
not to damage the brake pads.
NOTICE
(17) caliper 
(18) caliper mounting bolts 
(15)
(16)
(18)
(17)
(cont’d) 
						

							Front Suspension Adjustments
106Adjustments for Competition
23.Install the handlebar (19), mounting rubbers
(20), washers and handlebar holder nuts (21)
and tighten the handlebar holder nuts to the
specified torque:
33 Ibf·ft (44 N·m, 4.5 kgf·m)
(19) handlebar
(20) mounting rubbers
(21) washers/handlebar holder nuts
24.Install the number plate (22) by aligning its
hole with the tab (23) on the steering stem.
(22) number plate (23) tab
25.Install and tighten the number plate bolt (24).
Install the handlebar pad (25).
(24) number plate bolt
(25) handlebar pad
26.With the front brake applied, pump the fork
up and down several times to seat the axle and
check front brake operation.
27.Tighten the left axle pinch bolts (26)
alternately first. 
While keeping the forks parallel, alternately
tighten the right axle pinch bolts to the
specified torque:
14 Ibf·ft (20 N·m, 2.0 kgf·m) 
(26) axle pinch bolts 
To avoid damage when torquing the axle pinch
bolts, be sure the axle is seated firmly onto the
left fork leg clamp inner surface.
28.Clean the threads of the disk cover bolts and
axle holder thoroughly. Apply locking agent
to the disc cover bolts threads. 
Install the disc cover (27) and tighten the disc
cover bolts (28) to the specified torque:
9 Ibf·ft (13 N·m, 1.3 kgf·m)
NOTICE
(27) disc cover (28) disc cover bolts 
29.Turn the rebound damping adjusters back to
their original settings. 
(19)(21)
(20)
(22)(23)
(25)
(24)
(26)(26)
(27)
(28)