Honda Crf 250 M Manual
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Servicing Your Honda17 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 152). Before You Service Your Honda The Importance of Maintenance ........................18 Maintenance Safety ............................................19 Important Safety Precautions........................19 Maintenance Schedule .......................................20 General Competition Maintenance ....................22 Before & After Competition Maintenance.........26 Between Motos & Practice Maintenance .....26 After Competition Maintenance ...................26 Service Preparations Component Locations ........................................28 Seat Removal .....................................................29 Fuel Tank Removal ............................................30 Subframe Removal .............................................32 Service Procedures Fluids & Filters Fuel System ........................................................34 Engine Oil ..........................................................36 Transmission Oil ................................................39 Coolant ...............................................................41 Air Cleaner .........................................................43 Crankcase Breather ............................................45 Engine Throttle ...............................................................46 Engine Idle Speed ..............................................48 Clutch System ....................................................49 Hot Start Lever ...................................................53 Spark Plug ..........................................................54 Valve Clearance ..................................................55 Piston/Piston Rings/Piston Pin ...........................63Chassis Suspension..........................................................71 Front Suspension Inspection........................71 Rear Suspension Inspection .........................72 Fork Oil Change ..........................................73 Brakes .................................................................76 Wheels ................................................................80 Tires & Tubes .....................................................81 Drive Chain ........................................................83 Exhaust Pipe/Muffler .........................................86 Additional Maintenance Procedures ..................89 Appearance Care ................................................91
18Servicing Your Honda WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. The Importance of Maintenance Keeping your CRF well-maintained is absolutely essential to your safety. It’s also a good way to get maximum performance during each moto. Careful pre-ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off-road competition. Remember, proper maintenance is your responsibility. Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section.
Servicing Your Honda19 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Important Safety Precautions •Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts.Let the engine and exhaust system cool before touching. Injury from moving parts.Do not run the engine unless instructed to do so. •Read the instructions before you begin, and make sure you have the tools and skills required. •To help prevent the motorcycle from falling over, park it on a firm, level surface, using the optional work stand or a maintenance stand to provide support. •To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene —not gasoline— to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts. WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual.
20Servicing Your Honda Maintenance Schedule To maintain the safety and reliability of your CRF, regular inspection and service is required as shown in the Maintenance Schedule that follows. The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in this schedule are provided in a service manual available for purchase from your dealer (page 154). Service intervals in the maintenance schedule are expressed in terms of races and riding hours. To avoid overlooking required service, we urge you to develop a convenient way to record the number of races and/or hours you ride. If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability. Perform the pre-ride inspection (page 9) at each scheduled maintenance period. Summary of Maintenance Schedule Notes and Procedures: Notes: 1. Clean after every heat for dusty riding conditions. 2. Replace every 2 years. Replacement requires mechanical skill. 3. Replace after the first break-in ride. 4. Inspect after the first break-in ride. 5. Replace the transmission oil, if the clutch discs and plates are replaced. Maintenance Procedures: I: inspect and clean, adjust, lubricate, or replace, if necessary C: clean L: lubricate R: replace
Servicing Your Honda21 Maintenance Schedule ITEMS THROTTLE OPERATION HOT START SYSTEM AIR FILTER CRANKCASE BREATHER SPARK PLUG RADIATOR COOLANT VALVE CLEARANCE / DECOMPRESSOR SYSTEM ENGINE OIL ENGINE OIL FILTER ENGINE IDLE SPEED PISTON AND PISTON RINGS PISTON PIN TRANSMISSION OIL COOLING SYSTEM DRIVE CHAIN DRIVE CHAIN SLIDER DRIVE CHAIN ROLLER DRIVE SPROCKET DRIVEN SPROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE/MUFFLER SUSPENSION SWINGARM/SHOCK LINKAGE FORK OIL NUTS, BOLTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARINGS (NOTE 1) (NOTE 2) (NOTE 4) (NOTE 3) (NOTE 3) (NOTE 5) (NOTE 2) (NOTE 5) (NOTE 3)I I C I I I I I I I I,L I I I I I I I I I,L I I I IR L RI R R R R R46 53 43 45 54 41 55 36 38 48 63 63 39 42 83 83 84 85 85 77 79 76 49 89 86 71 25, 72 73 98 90 80,81 89 R I FORK TUBE/SLIDER DAMPER FREQUENCY NOTERef. Page Each race or about 2.5 hoursEvery 3 races or about 7.5 hoursEvery 6 races or about 15.0 hoursEvery 9 races or about 22.5 hoursEvery 12 races or about 30.0 hours This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every heat for dusty riding conditions. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. 5.Replace the transmission oil, if the clutch discs and plates are replaced. Perform the Pre-ride Inspection at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.
22Servicing Your Honda General Competition Maintenance Perform maintenance on firm, level ground using the optional workstand, or equivalent support. When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattern. Use genuine Honda parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Lubricate any sliding surface, O-rings, and seals before reassembling. Grease parts by coating or filling where specified. After any engine disassembly, always install new gaskets, O-rings, cotter pins, piston pin clips, snap rings, etc. when reassembling. After reassembly, check all parts for proper installation and operation. All Pre-ride Inspection Items Refer to Pre-ride Inspectionpage 9.
Servicing Your Honda23 Spark Plug Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule. (page 20). Engine Oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston, cylinder and crankshaft. Also replace engine oil filter often to ensure the greatest service life. Frequent changes will also assure consistent performance of power and response. (page 37).Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance. Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass. Inspect the cleaner closely each time it’s serviced for evidence of small tears or seam separation. Keep a spare air cleaner oiled and ready to install, sealed in a plastic bag. Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre-serviced air cleaner between motos. Be careful not to over oil the air cleaner. While it is important to oil the air cleaner thoroughly, over oiling will cause an overall rich running condition, probably more noticeable off idle and in low rpm performance. Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium Grease, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 43). Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model. Using the wrong Honda air cleaner or a non-Honda air cleaner which is not of equivalent quality may cause premature engine wear or performance problems. Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch. Frequent changes will also assure consistent performance of both shifting and clutch action (page 39).Airbox Sealing Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity. Use Hondalock or an equivalent on the attaching studs. Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration. General Competition Maintenance
24Servicing Your Honda General Competition Maintenance Handgrips Always use Honda Hand Grip Cement (U.S.A only) or Honda Bond A when replacing handgrips. Throttle Grip Align the index mark on the throttle grip with the edge of the throttle cable guide. Left handlebar grip: Align the “∆” mark on the left handlebar grip with the punch mark on the handlebar. Refer to the Service Manual for installation instructions. For added security, you may choose to safety wire the hand grips to the handlebar and throttle to prevent the possibility of them loosening. Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the grip rubber so they will not snag your glove. Throttle Control Remove the throttle control every few rides, clean the inside of the drum and the handlebar thoroughly, and apply a light coating of silicone lubricant. Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way. Move the handlebar from lock to lock to be sure there is no cable interference. Check to be sure the top of the carburetor is screwed on tight. Make certain the throttle operation is perfect after servicing and inspecting.Gaskets Always use new gaskets when reassembling components. Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals. The tolerances are quite tight, so it’s important to keep these dowels absolutely clean (page 65). Fuel Filter Periodically drain the fuel from the tank, remove and clean the fuel valve/filter. Replace the fuel valve O-ring if there are any signs of damage or deterioration (page 35). Fuel Contamination Refer to Fuel System in your Owner’s Manual, page 34, and, in this supplement, Fuel System, page 34. Check the fuel lines for deterioration, damage, or leakage. Replace the fuel lines, if necessary. Periodically drain the fuel from the tank, remove and clean the fuel valve and fuel strainer screen. Replace the fuel valve O-ring if there are any signs of damage or deterioration (page 35). Loosen the exterior drain screw and examine the fuel that flows out of the float bowl. If you notice anything in the fuel, such as water or dirt, remove the float bowl and inspect its contents (page 117). For maximum efficiency, drain and replace fuel that has remained in your fuel tank for more than a month. Engine Mounting Bolts Make sure the engine mounting bolts are tightened to the proper torque specification. For added peace of mind, remove the nuts, clean the threads, and apply Honda Thread Lock or an equivalent prior to torquing the nuts.Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections, water shorts or corrosion. Additional corrosion protection is offered by using Honda Dielectoric Grease on all electrical connections.
Suspension Linkage Lubrication Disassemble, clean, inspect and lubricate all pivot bearings after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear. Use Honda Moly 60 paste (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disulfide additive). Swingarm Pivot Lubrication Clean, inspect and lubricate when servicing suspension linkage pivots. Be sure all of the suspension pivot seals are in good condition. Use Honda Moly 60 paste (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disulfide additive). Swingarm Do not attempt to weld or otherwise repair a damaged swingarm. Welding will weaken the swingarm. Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file. Be aware that filing them too sharp will reduce boot sole lifespan. Sharpen only the points of the teeth. Filing the grooves deeper will weaken the footpegs. Be sure the pegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition.Brake Fluid Replacement Refer to Brake Pad Wear in your Owner’s Manual, page 79. Brake Caliper Inspection: Be sure both the front and rear calipers are able to move freely on the caliper bracket pins. Check pad thickness periodically and replace when minimum thickness is reached. If the brakes fade when they are hot, inspect the pads for glazing or damage, and replace if necessary. Brake Fluid Replacement: Replace the hydraulic fluid in the brake system every two years. Replace the fluid more frequently if you subject your brakes to severe use. Heavy braking heats the brake fluid and it may deteriorate sooner than expected. Any type of riding, that requires frequent use of the brakes, such as in tight woods, can shorten the service life of brake fluid.Steering Head Bearings Periodically clean, inspect and regrease the steering head bearings — especially if wet, muddy or extremely dusty courses are encountered often. Water Pump Inspection Hole After every race, check the inspection hole, located just below the water pump cover on the right crankcase cover. Clean away any clogged dirt or sand, if necessary. Look for coolant or oil leakage. Leaking coolant indicates a worn or damaged water seal. Leaking oil indicates a bad transmission oil seal. If replacement is necessary, both seals should be replaced.Fork Oil/Performance Disassemble, clean and inspect the fork and replace the oil regularly. Contamination due to the tiny metal particles produced from the normal action of the fork, as well as normal oil breakdown, will deteriorate the performance of the suspension. Refer to the Honda Service Manual. Use only Pro Honda HP Fork Oil 5W (U.S.A. only) or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension. Frame Because your CRF is a high-performance machine, the frame should not be overlooked as part of your overall competition maintenance program. Periodically inspect the frame closely for possible cracking or other damage. It makes good racing sense. Spokes Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact points seat-in, the spokes may need to be retightened. Once past this initial seating-in period, the spokes should hold their tension. Still, be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis (page 80). Nuts, Bolts, Etc Application of a thread locking agent to essential fasteners offers added assurance and security. Remove the nuts, clean the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque. Servicing Your Honda25 General Competition Maintenance
26Servicing Your Honda Before & After Competition Maintenance Between Motos & Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments. •Clean accumulated dirt from under the fenders and off the wheels, suspension components, hand grips, controls, and footpegs. A stiff, nylon parts cleaning brush works well. •Check tire air pressure. • Check spoke tension and rim lock nut security. •Check sprocket bolt and nut security. •Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. •After adjustment, check that the chain adjuster index marks (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. •Suspend the front wheel above te ground and use the pressure release screws (1) to release the built-up pressure (in excess of normal atmospheric pressure: 0 psi) in the fork tubes. This pressure is caused by normal fork action while riding. (If you are riding at altitude, remember that fork pressure of 0 at sea level will increase as elevation increases.) (1) chain adjuster index marks (1) pressure release screws (1) (1) After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program. Right after the event is a good time to begin your next maintenance cycle. After Race Lubrication Apply a light coating of rust-inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away. This will prevent rusting of the exposed metal. Apply rust-inhibiting oil more heavily if the event was particularly wet or muddy. Take care to avoid spraying any oil near the disc brakes or the disc rotors. Remove the drive chain, clean it, and lubricate the chain and sprockets. Be sure the chain is wiped clean and is dry before applying the chain lube. Take care to prevent catching your fingers between the chain and sprocket.