Honda Crf 250 M Manual

							Servicing Your Honda77
Brakes
Fluid Level Inspection
Front Brake Fluid Level Check
(1) LOWER level mark
With the motorcycle in an upright position, check
the fluid level.
It should be above the LOWER level mark (1). If
the level is at or below the LOWER level mark,
check the brake pads for wear (page 79).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the brake lever freeplay exceeds 0.8 in 
(20 mm), there is probably air in the brake 
system and it must be bled. Refer to the Honda
Service Manual or see your Honda motorcycle
dealer for brake bleeding.Rear Brake Fluid Level Check
(2) LOWER level mark
With the motorcycle in an upright position, check
the fluid level.
It should be above the LOWER level mark (2). If
the level is at or below the LOWER level mark,
check the brake pads for wear (page 79).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the brake pedal freeplay exceeds 0.8 in 
(20 mm), there is probably air in the brake 
system and it must be bled. Refer to the Honda
Service Manual or see your Honda motorcycle
dealer for brake bleeding.
(1)
(2)
(cont’d) 
						

							78Servicing Your Honda
Brakes
Adding Front Brake Fluid
The recommended brake fluid is Honda DOT 4
brake fluid or an equivalent.
When adding brake fluid be sure the reservoir is
horizontal before the cap is removed or brake
fluid may spill out.
(1) screws
(2) reservoir cap/diaphragm
(3) upper level mark 
1. Remove the screws (1), reservoir cap (2) and
diaphragm.
2. Fill the reservoir with DOT 4 brake fluid to
the upper level mark (3). Do not overfill.
3. Reinstall the diaphragm and reservoir cap.
4. Tighten the screws securely to the specified
torque:
1.1 lbf·ft (1.5 N·m, 0.15 kgf·m)
Adding Rear Brake Fluid
The recommended brake fluid is Honda DOT 4
brake fluid or an equivalent.
When adding brake fluid be sure the reservoir is
horizontal before the cap is removed or brake
fluid may spill out.
(4) bolts
(5) reservoir cap/diaphragm
(6) upper level mark
1. Remove the bolts (4) reservoir cap and
diaphragm (5).
2. Fill the reservoir with DOT 4 brake fluid to
the upper level mark (6). Do not overfill.
3. Reinstall the diaphragm and reservoir cap. 
4. Tighten the bolts to the specified torque:
1.1 lbf·ft (1.5 N·m, 0.15 kgf·m)
Other Inspection
•Make sure there are not fluid leaks.
•Check for deterioration or cracks in the hoses
and fittings.
(1)
(2)
(3)(4)
(5)
(6) 
						

							Servicing Your Honda79
Brakes
Brake Pad Wear
Brake pad wear depends on the severity of usage
and track conditions.  (Generally, the pads will
wear faster on wet and dirty tracks) Inspect the
pads at each regular maintenance interval (page
21).
Front Brake Pads
Inspect the brake pads (2) through the front
wheel to determine the pad wear.  If either pad is
worn anywhere to a thickness of 0.04 in (1 mm),
both pads must be replaced.
(1) brake caliper (3) brake disc
(2) brake pads
Rear Brake Pads
Inspect the brake pads (5) from the rear side of
the caliper to determine the pad wear.  If either
pad is worn anywhere to a thickness of 0.04 in 
(1 mm), both pads must be replaced.
(4) rear brake caliper (6) brake disc
(5) brake pads
Other Inspections
Check that the front lever and rear pedal
assemblies are positioned properly and the
securing bolts are tight.
Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.
minimum thickness
indicator
wear indicator
groovesreplace
replace0.04 in
(1 mm)
0.04 in
(1 mm)
(1)(3)
(2)
(2)
replace0.04 in
(1 mm)
minimum thickness
indicator(5)
(6)
(4)
(5) 
						

							80Servicing Your Honda
Wheels
Refer to Safety Precautionson page 19.
Maintenance of spoke tension and wheel trueness
(roundness) is critical to safe motorcycle
operation. During the first 100 miles (150 km),
spokes will loosen more rapidly due to the initial
seating of the parts.  Excessively loose spokes
may result in instability at high speeds and the
possible loss of control.  It’s also important that
the rim locks are secure to prevent tire slippage.
It is not necessary to remove the wheels to
perform the recommended service in the
Maintenance Schedule (page 21).  However,
information for wheel removal is provided for
emergency situations.
Wheel Rims & Spokes
(1) wheel rim (3) rim lock
(2) spoke
1. Inspect the wheel rims (1) and spokes (2) for
damage.2. Tighten, any loose spokes and rim locks (3) to
the specified torque:
Front Spoke
: 
2.7 lbf·ft (3.68 N·m, 0.38 kgf·m)
Rear Spoke: 
2.7 lbf·ft (3.7 N·m, 0.38 kgf·m)
Rim Lock: 9.4 lbf·ft (13 N·m, 1.3 kgf·m)
3. Check wheel rim runout.  If runout is
noticeable, see the Honda Service Manual for
inspection instructions.
Axles & Wheel Bearings
See the Honda Service Manual for inspection
information:
1. Check the axle shaft for runout.
2. Check the condition of the wheel bearings.
(1)
(3)
(2) 
						

							Servicing Your Honda81
Tires & Tubes
WARNING
Using tires that are excessively worn or
improperly inflated can cause a crash in
which you can be seriously hurt or killed.
Follow all instructions in this owner’s
manual regarding tire inflation and
maintenance.Front 15 psi (100 kPa, 1.0 kgf/cm2)
Rear 15 psi (100 kPa, 1.0 kgf/cm
2)
Refer to Safety Precautionson page 19.
To safely operate your CRF the tires must be the
proper type (off-road) and size, in good condition
with adequate tread, and correctly inflated.
The following pages give detailed information on
how and when to check your air pressure, how to
inspect your tires for wear and damage, and our
recommendations on tire repair and replacement.
Air Pressure
Properly inflated tires provide the best
combination of handling, tread life, and riding
comfort.  Generally, underinflated tires wear
unevenly, adversely affect handling, and are more
likely to fail from being overheated.
Underinflated tires can also cause wheel damage
on hard terrain.  Overinflated tires make your
motorcycle ride more harshly, are more prone to
damage from surface hazards, and wear
unevenly.
Make sure the valve stem caps are secure.  If
necessary, install a new cap.Always check air pressure when your tires are
“cold.”  If you check air pressure when your tires
are “warm” — even if your CRF has only been
ridden for a few miles — the readings will be
higher.  If you let air out of warm tires to match
the recommended cold pressures, the tires will be
underinflated.
The correct “cold” tire pressures are:
If you decide to adjust tire pressures for a
particular riding condition, make changes a little
at a time.
Inspection
Take time to inspect your tires and wheels before
you ride.•Inspect carefully for bumps or bulges in the
side of the tire or the tread.  Replace any tire
that has a bump or bulge.
•Look closely for cuts, slits, or cracks in the
tires.  Replace a tire if you can see fabric or
cord.
•Check for rocks or other objects embedded in
the tire or tread.  Remove any objects.
•Measure tread depth (1).  Replace the tire
before depth at the center reaches 0.12 in (3
mm), or any time you notice a reduction in
traction.
•Check the position of both valve stems.  A
tilted valve stem indicates the tube is slipping
inside the tire or the tire is slipping on the
rim.
Tube Replacement
If a tube is punctured or damaged, you should
replace it as soon as possible.  A repaired tube
may not have the same reliability as a new one,
and it may fail while you are riding.
Use a replacement tube equivalent to the original.
(1)
(1) tire tread depth 
						

							82Servicing Your Honda
Tires & Tubes
Tire Replacement
The tires that came on your CRF were designed
to provide a good combination of 
handling, braking, durability, and comfort across
a broad range of riding conditions.
WARNING
Installing improper tires on your
motorcycle can affect handling and
stability.  This can cause a crash in which
you can be seriously hurt or killed.
Always use the size and type of tires
recommended in this owner’s manual.
Front 80/100-21  51M
Rear 100/90-19  57M
Type bias-ply, tube
•Use a replacement tire equivalent to the
original.
•Replace the tube any time you replace a tire.
The old tube will probably be stretched and, if
installed in a new tire, could fail. 
						

							Servicing Your Honda83
Drive Chain
Refer to Safety Precautionson page 19.
The service life of the chain depends on proper
lubrication and adjustment.  Poor maintenance
can cause premature wear or damage to the drive
chain or sprockets.
When the motorcycle is ridden on unusually
dusty or muddy tracks, more frequent
maintenance will be necessary.
Before servicing your drive chain, turn the
engine OFF, raise the rear wheel off the ground
by placing the optional workstand or equivalent
support under the engine and check that your
transmission is in neutral.
It is not necessary to remove or replace the drive
chain to perform the recommended service in the
Maintenance Schedule.
Drive Chain Inspection
1. Turn the engine off, raise the rear wheel off
the ground by placing the optional workstand
or equivalent support under the engine and
shift the transmission into neutral.
2. Check slack (1) in the upper drive chain run
midway between the sprockets (2)(3).  Drive
chain slack should allow the following
vertical movement by hand:
1 – 1 3/8 in (25 – 35 mm)
(1) drive chain slack (3) driven sprocket
(2) drive sprocket
3. Check drive chain slack at several points
along the chain.  The slack should remain
constant.  If it isn’t, some links may be kinked
and binding.  Lubricating the chain will often
eliminate binding and kinking.
Excessive chain slack may allow the drive chain
to damage the engine cases.
4. Inspect the drive chain for:
•damaged rollers
•loose pins
•dry or rusted links
•kinked or binding links
•excessive wear
Replace the drive chain (page 85) if it has
damaged rollers, loose pins, or kinks that cannot
be freed.  Lubricate the drive chain (page 84) if it
appears dry or shows signs of rust.  Lubricate
any kinked or binding links and work them free.
Adjust chain slack if needed.
NOTICE
(4) chain slider
6. Check the chain guide slider (5) for wear.
Replace the chain guide slider if it is worn to
the bottom of the wear limit groove (6).
(5) chain guide slider
(6) wear limit groove
(cont’d)
(2)
(1)
(3)
(4)
(5)(6)
5. Check the chain slider (4) for wear.
If the wear is 3/16 in (5 mm) or more, replace
it. 
						

							84Servicing Your Honda
(6) upper drive chain roller
(7) lower drive chain roller
If the upper drive chain roller was removed,
install the drive chain roller with its “” mark
(8) side facing out.
Install the lower drive chain roller.
Drive Chain
(6) upper drive chain roller (8) “” mark
(7) lower drive chain roller
8. Check the driven sprocket nut torque values
after each race.
24 lbf·ft (32 N·m, 3.3 kgf·m)
(1) rear axle nut (4) index mark
(2) lock nut (5) axle plate
(3) adjusting bolt (6) reference mark
3. Tighten the rear axle nut to the specified
torque:
94 lbf·ft (128 N·m, 13.0 kgf·m)
4. Recheck chain stack and adjust as necessary.
5. Loosen the adjusting bolt counterclockwise
lightly until it touches the axle plate.  Then,
while holding the adjusting bolt with a
wrench, tighten the lock nut to the specified
torque:
20 lbf·ft (27 N·m, 2.8 kgf·m)
(6)
(7)
(8)
(7)
(6)
(6)
(1)(2)
(3)
(5)
(4)
Lubrication
Commercially prepared drive chain lubricants
may be purchased at most motorcycle shops and
should be used in preference to motor oil.  Pro
Honda Chain Lube or an equivalent, or SAE 80
or 90 gear oil is recommended.
Saturate each chain joint so that the lubricant
penetrates the space between adjacent surfaces of
the link plates and rollers.
Adjustment
1. Loosen the rear axle nut (1).
2. Loosen both the lock nuts (2) and turn the
adjusting bolts (3) counterclockwise to
decrease slack or clockwise to increase slack.
Align the index marks (4) of the axle plates
(5) with the same reference marks (6) on both
sides of the swingarm. 7. Check the upper drive chain roller (6) and
lower drive chain roller (7) for wear or
damage.
Replace if necessary.
Upper Roller: 1.5 in (39 mm)
Lower Roller: 1.2 in (31 mm) 
						

							Servicing Your Honda85
Drive Chain
4. Inspect the sprocket teeth for wear or damage.
We recommend replacing the sprocket
whenever a new chain is installed.
Both chain and sprockets must be in good
condition, or the new replacement chain or
sprocket(s) will wear rapidly.
Excessively worn sprocket teeth have a
hooked, worn appearance.  Replace any
sprocket which is damaged or excessively
worn.
Use of a new chain with worn sprockets will
cause rapid chain wear.
5. Measure a section of the drive chain to
determine whether the chain is worn beyond
its service limit.  Put the transmission in gear,
and then turn the rear wheel forward until the
lower section of the chain is pulled taut.  With
the chain held taut and any kinked joints
straightened, measure the distance between a
span of 17 pins, from pin center to pin center.
If the measurement exceeds the service limit,
replace the chain.  After the chain is
measured, shift the transmission into neutral
again before proceeding with inspection and
service.
NOTICE
MEASURE A SPAN OF 17 PINS (16 PITCHES)
6. Lubricate the drive chain.
7. Pass the chain over the sprockets and join the
ends of the chain with the master link.  For
ease of assembly, hold the chain ends against
adjacent rear sprocket teeth while inserting
the master link.  Install the master link
retaining clip so that the closed end of the clip
will face the direction of forward wheel
rotation.
8. Recheck chain slack and adjust as necessary.
More About Drive Chain
•The master link is the most critical element of
drive chain security.  Master links are
reusable, as long as they remain in excellent
condition.  We recommend installing a new
master link retaining clip when the drive
chain is reassembled.
•You may find it easier to install a new chain
by connecting it to the old chain with a
master link and pulling the old chain to
position the new chain on the sprockets.
Removal, Cleaning & Replacement
For maximum service life, the drive chain should
be cleaned, lubricated, and adjusted before each
outing.
1. Remove the master link retaining clip (1) with
pliers.  Do not bend or twist the clip.
Remove the master link (2).  Remove the
drive chain.
(1) retaining clip (2) master link
2. Clean the drive chain in high flash-point
solvent and allow it to dry.
3. Inspect the drive chain for possible wear or
damage.  Replace the drive chain if it has
damaged rollers, loose fitting links, or
otherwise appears unserviceable.
Replacement chain:
D.I.D.520DMA2
(1)
(2)
Service limit:10.20 in (259.0 mm) 
						

							86Servicing Your Honda
Exhaust Pipe/Muffler
Exhaust Pipe/Muffler Inspection
1. Check the flange bolts for tightness.
2. Check the exhaust pipe and muffler for cracks
or deformation.
A damaged exhaust pipe and muffler may
reduce engine performance.
Muffler Removal
1. Remove the seat bolt (1), collars (2), side
cover bolt (3) and right side cover (4).
(1) seat bolt (3) side cover bolt
(2) collars (4) right side cover
2. Loosen the muffler clamp bolt (5).
3. Remove the muffler A bolt (6), muffler B
bolt/washer (7) and muffler (8).
(5) muffler clamp bolt (7) muffler B bolt/washer
(6) muffler A bolt (8) muffler(2)
(1)
(4)
(3)(2)
(7)
(8)(6)
(5)