Honda Crf250l Service Manual

7-6
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FUEL SYSTEM
2. Set a new joint rubber [1] to the joint [2] as shown.Press the quick connect fitting [3] onto the pipe until
both retainer pawls lock with a CLICK.
 • Align the quick connect fitting with the joint.
 • If it is hard to connect, put a small amount of engineoil on the joint end.
3. Make sure the connection is secure and that the pawls [1] are firmly locked into place; check visually
and by pulling the connector.
4. Make sure the joint rubber [2] is positioned between...

7-7
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FUEL SYSTEM
FUEL PRESSURE TEST
Relieve the fuel pressure and disconnect the quick
connect fitting (page 7-4).
Attach the special tools as follows:
Temporarily connect the battery negative (–) cable and
fuel pump 3P (Black) connector.
Start the engine and let it idle.
Read the fuel pressure.
If the fuel pressure is higher  than specified, replace the
fuel pump assembly.
If the fuel pressure is lower than specified, inspect the
following:
– Fuel line leaking
– Pinched or clogged...

7-8
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FUEL SYSTEM
FUEL TANK
REMOVAL/INSTALLATION
Relieve the fuel pressure and disconnect the quick
connect fitting (page 7-4).
Lift up the fuel tank [1] and release the fuel feed hose
[2] from the hose clamps [3].
Disconnect the fuel tank breather hose [4] and remove
the fuel tank.
Install the fuel tank in t he reverse order of removal.
Connect the quick connect fitting (page 7-5).
FUEL PUMP UNIT
SYSTEM INSPECTION
Turn the ignition switch ON and engine stop switch  
and confirm that...

7-9
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FUEL SYSTEM
REMOVAL/INSTALLATION
Do not disassemble the fuel pump.
Remove the fuel tank (page 7-8).
Clean around the fuel pump.
Loosen the fuel pump mounting nuts [1] in a crisscross
pattern in 2 or 3 steps and remove the nuts.
Remove the fuel pump unit [2] from the fuel tank, being
careful not to damage the fu el level sensor float arm.
Remove the packing [1] from the fuel pump unit [2].
Install a new packing onto the fuel pump unit.
 • Always replace the packing with a new one....

7-10
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FUEL SYSTEM
FUEL PUMP RELAY
INSPECTION
Remove the left side cover (page 2-3).
Remove the dust cover [1]
Remove the fuel pump relay [2].
Connect a ohmmeter to the fuel pump relay [1]
terminals.
Connect a 12 V battery to the fuel pump relay terminals
as shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity when the 12 V battery is
connected, replace the fuel pump relay.
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the sub-frame (page...

7-11
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FUEL SYSTEM
THROTTLE BODY
REMOVAL
Remove the fuel tank (page 7-8).
Disconnect the sensor unit 5P connector [1].
Disconnect the IACV 4P (Black) connector [1] and
injector 2P (Gray) connector [2].
Release the wire band [3] from the clamp stay.
Loosen the throttle cable A adjuster lock nut [1] and
adjuster [2] then disconnect the throttle cable A [3] from
the throttle drum and cable stay.
Loosen the throttle cable B nut [4] then disconnect the
throttle cable B [5] from the throttle...

7-12
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FUEL SYSTEMDISASSEMBLY/ASSEMBLY
 • Do not remove the sensor unit unless it is replaced.
 • The throttle body/sensor unit is factory pre-set. Donot disassemble in a way other than shown in this
manual.
 • Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It
may cause incorrect idle operation.
 • Do not damage the throttle body. It may cause incorrect throttle valve operation.
 • Do not loosen or tighten  the white painted nut...

7-13
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FUEL SYSTEM
Install the throttle body insulator [1] to the throttle body
by aligning the tab of the thro ttle body with the groove of
the throttle body insulator.
 • Install the throttle body  insulator with KZZ mark [2]
facing the cylinder head.
 • Align the insulator band hole with the insulator boss.
INSTALLATION
Install the throttle body a ssembly [1] to the cylinder
head by aligning the tab of  the cylinder head with the
groove of the throttle body insulator.
Tighten the...

7-14
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FUEL SYSTEM
Connect the sensor unit 5P connector [1].
Install the fuel tank (page 7-8).
Adjust the throttle grip freeplay (page 3-3).
If the sensor unit is removed, perform the TP sensor
reset procedure (page 4-45).
INJECTOR
REMOVAL
Remove the fuel tank (page 7-8).
Disconnect the injector 2P (Gray) connector [1].
Remove the bolts [2] and injector assembly [3] from the
throttle body.
Remove the injector joint [1],  O-ring [2], cushion ring [3]
and seal ring [4] from the injector...

7-15
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FUEL SYSTEM
Install the injector [1] into the injector joint [2], being
careful not to damage the O-ring.
Align the injector body with the injector joint tab [3] as
shown.
Be careful not to
damage the seal ring.Install the injector assemb ly [1] to the throttle body.
Install and tighten the injector joint mounting bolts [2]
alternately to the specified torque.
Connect the injector 2P (Gray) connector [3] while
aligning its groove with the ta b of the injector joint.
Install the...