Honda Crf250l Service Manual

8-6
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LUBRICATION SYSTEMASSEMBLY
INSTALLATION
Install the dowel pins [1].
Apply engine oil to a new O-ring [2].
Install the O-ring to the oil pump assembly [3].
Install the oil pump assembly  while aligning its slit with
cam chain guide hook and its hole with the pressure
relief valve.
Install and tighten the oil pump mounting bolts [1].
If the oil pump was disasse mbled, tighten the oil pump
assembly bolt [2].
OIL PUMP BODY
INNER ROTOR
OIL PUMP SHAFT
OUTER ROTOR
OIL PUMP COVER
OIL PUMP...

8-7
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LUBRICATION SYSTEM
Apply engine oil to the oil pump driven gear [1] teeth.
Install the oil pump driven gear while aligning the flats of
the oil pump driven gear and oil pump shaft.
Install the right crankcase cover (page 12-8).
PRESSURE RELIEF VALVE
REMOVAL/INSTALLATION
Remove the oil pump (page 8-4).
Remove the oil pressure relief valve [1] and O-rings [2].
Apply engine oil to new O-rings.
Install the O-rings to the oil pressure relief valve
grooves.
Install the oil pressure...

MEMO
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9-1
9
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9. COOLING SYSTEM
SERVICE INFORMATION ·····························9-2
TROUBLESHOOTING···································9-2
SYSTEM FLOW PATTERN ···························9-3
SYSTEM TESTING ········································9-4
COOLANT REPLACEMENT ·························9-5
THERMOSTAT ··············································9-5RADIATOR/COOLING FAN ··················\
········ 9-6
WATER PUMP ·············································· 9-8
RADIATOR RESERVE TANK...

9-2
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COOLING SYSTEM
COOLING SYSTEMSERVICE INFORMATION
GENERAL
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap
water may cause engine damage.
 • Add cooling system at the reserve ta nk. Do not remove the radiator cap except to refill or drain the system.
 • All cooling system services can be do ne with the engine installed in the frame.
 • Avoid spilling coolant on painted surfaces.
 • After servicing the...

9-3
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COOLING SYSTEM
SYSTEM FLOW PATTERN
RADIATOR
SIPHON HOSE
THERMOSTAT
WATER PUMP
RESERVE TANK
WATER HOSE
WATER HOSE
WATER PIPE 

9-4
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COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE 
INSPECTION
Loosen the cap screw [1] and  remove the radiator cap
[2].
Wet the sealing surfaces of  the radiator cap [1], then
install the cap onto the tester [2].
Pressurize the cap using the tester. Replace the
radiator cap if it does not hold pressure, or if relief
pressure is too high or too low. It must hold the
specified pressure for at least 6 seconds.
Pressurize the radiator, engine and hoses using the
tester, and...

9-5
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COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING
Remove the radiator cap (page 9-4).
Remove the drain bolt [1] and sealing washer [2] on the
water pump cover and drain the coolant from the
system.
Install and tighten the drain bolt with a new sealing
washer.
Fill the system with the recommended coolant through
the filler opening.
Bleed air from the system as follows:
1. Shift the transmission into neutral.Start the engine and let it idle for 2 – 3 minutes.
2. Snap the...

9-6
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COOLING SYSTEM
Remove the thermostat [1] from the cylinder head.
Installation is in the reverse order of removal.
 • Install the thermostat with the bleed hole [2] facingup.
 • When installing the thermostat, align the tab of the seal ring [3] with the groove of the thermostat cover.
Fill and bleed the cooling system (page 9-5).
INSPECTION
Visually inspect the thermostat [1] for damage.
Check the seal ring [2] for damage and replace if
necessary.
Wear insulated gloves and
adequate...

9-7
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COOLING SYSTEM
Disconnect the siphon hose [1] from the radiator.
Loosen the water hose band screws [2] and disconnect
the upper and lower water hoses [3].
Remove the radiator guard [4] by releasing the bosses
[5]
Remove the radiator mounting bolts [6] and radiator [7].
Installation is in the reverse order of removal.
Tighten the hose band screw to the specified range.
Fill the system with the recommended coolant (page 9-
5).
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the...