Honda Crf250l Service Manual

5-2
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IGNITION SYSTEM
IGNITION SYSTEMSERVICE INFORMATION
GENERAL
 • When servicing the ignition system, always follow the steps in the troubleshooting table (page 5-2).
 • A faulty ignition system is often related to poorly connected or corroded connections. Check those connections before
proceeding.
TROUBLESHOOTING
 • Inspect the following before diagnosing the system. – Faulty spark plug
– Loose spark plug cap or spark plug wire connection
– Water got into the spark plug cap (Leaking...

5-3
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IGNITION SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
IGNITION SWITCH
BATTERY
IGNITION COIL
NEUTRAL SWITCH
CKP SENSOR
SPARK PLUG
CLUTCH SWITCH
MAIN FUSE (30 A)
ECM
FI, IGN FUSE (10 A)
BANK ANGLE SENSOR
ENGINE STOP SWITCH
SIDESTAND 
SWITCH
BATTERY
MAIN FUSE (30 A)Bl/R
Bl/Bu
IGNITION SWITCHSIDESTAND 
SWITCH
BANK 
ANGLE 
SENSOR
CKP 
SENSOR
IGNITION 
COIL
SPARK 
PLUG
ECM
R/W
Bl/G
Bl/Bu
R/BuG/OBu/Y
W/Y
G/R
Bl: Black
Bu: Blue
G: Green
Lg: Light green
O: Orange
R: Red
W: White
Y: Yellow
Br:...

5-4
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IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
 • If there is no spark at the plug, check all connectionsfor loose or poor contact  before measuring the peak
voltage.
 • Use a commercially available digital multimeter with an impedance of 10 M Ω/DCV minimum.
 • The display value differs depending upon the internal impedance of the multimeter.
 • If using the Imrie diagnostic tester (model 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor [1] to the...

5-5
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IGNITION SYSTEM
CKP SENSOR PEAK VOLTAGE
Remove the reserve tank cover (page 2-4).
Disconnect the ECM 33P (Black) connector [1].
Connect the peak voltage tester or adaptor probes to
the ECM 33P (Black) connector [1] terminals of the wire
harness side.
Shift the transmissi on into neutral.
Turn the ignition switch ON and engine stop switch  .
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
If the peak voltage measured at the ECM 33P (Black)
connector...

5-6
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IGNITION SYSTEM
IGNITION TIMING
Warm up the engine.
Stop the engine and remove the timing hole cap using
the special tool.
Connect the timing light [1] to the spark plug wire.
Start the engine and let it idle.
The ignition timing is correct if the F mark [2] on the
flywheel aligns with the index notch [3] on the left
crankcase cover.
Apply engine oil to a new O-ring and install it to the
timing hole cap.
Apply engine oil to the timing hole cap threads.
Install and tighten the...

6-1
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6. ELECTRIC STARTER SYSTEM
SERVICE INFORMATION ·····························6-2
TROUBLESHOOTING···································6-2
SYSTEM LOCATION·····································6-3
SYSTEM DIAGRAM ······································6-3STARTER MOTOR ······································· 6-4
STARTER RELAY SWITCH ························· 6-8
NEUTRAL DIODE ········································· 6-9 

6-2
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ELECTRIC STARTER SYSTEM
ELECTRIC STARTER SYSTEMSERVICE INFORMATION
GENERAL
 • When servicing the starter system, always follow the steps in the troubleshooting flow chart (page 6-2).
 • A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
TROUBLESHOOTING
Unusual conditionProbable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Loose or poor contact on related connectors and terminals
2. Blown...

6-3
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ELECTRIC STARTER SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
STARTER MOTOR
BATTERY
STARTER RELAY 
SWITCH
IGNITION SWITCH
CLUTCH SWITCH
NEUTRAL SWITCH
MAIN FUSE (30 A)
STARTER SWITCHENGINE STOP SWITCH
FI. IGN FUSE (10 A)
SIDESTAND SWITCH
STARTER 
MOTOR
BATTERY
MAIN FUSE 
(30 A)
IGNITION SWITCH
Bl/RR/W
Bl/G
STARTER 
SWITCH
ENGINE STOP 
SWITCH
FI. IGN 
FUSE (10 A)
CLUTCH 
SWITCH
GG/W
Y/R
Bl/Bu
STARTER 
RELAY 
SWITCH
G/R
NEUTRAL DIODE
Lg/Bl
G/R
NEUTRAL 
SWITCH
Lg/R
To NEUTRAL 
INDICATORBl:...

6-4
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ELECTRIC STARTER SYSTEM
STARTER MOTOR
REMOVAL/INSTALLATION
 • Always turn the ignition switch OFF beforeservicing the starter motor. The motor could
suddenly start, causing serious injury.
Remove the cam chain tensioner lifter (page 11-7).
Remove the bolts [1] and clutch cable guide [2].
Disconnect the clutch cable [3] from the clutch lifter arm
[4].
Release the rubber cap [1].
Remove the starter motor terminal nut [2] and starter
motor cable [3].
Remove the stater motor mounting...

6-5
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ELECTRIC STARTER SYSTEM
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the starter motor as
following illustration.
The coil may be damaged if the magnet pulls the armature against the motor case.
Upon assembly, align the index lines on the covers and
motor case.
ARMATURE
TERMINAL BOLT
BRUSH HOLDER
SPRING
NUT
TERMINAL STOPPER
INSULATOR
REAR COVER
WASHER
O-RING
FRONT COVER
SEAL RING
MOTOR CASE
SEAL RING
4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)
3.7 N·m (0.4 kgf·m, 
2.7 lbf·ft)
POSITIVE...