Honda Crf250l Service Manual

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GENERAL INFORMATIONCOOLING SYSTEM SPECIFICATIONS
CYLINDER HEAD/VAL VES SPECIFICATIONS
Unit: mm (in)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.02  liters (1.08 US qt, 0.90 Imp qt)
At draining 0.74 liter (0 .78 US qt, 0.65 Imp qt)
Reserve tank 0.16 liter (0 .17 US qt, 0.14 Imp qt)
Radiator cap relief pressure 93.2 – 122.6 kPa (0.95 – 1.25 kgf/cm
2, 13.5 – 17.8 psi)
Thermostat Begin to open 81 – 84°C (178 – 183°F)
Fully...

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GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
ALTERNATOR/STARTER CL UTCH SPECIFICATIONS
Unit: mm (in)
CRANKCASE/CRANKSHAFT/TR ANSMISSION/BALANCER SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 41.5 (1.63) 37.5 (1.48)
Disc thickness Disc A/B 2.30 – 2.50 (0.091 – 0.098) 2.27 (0.089)
Plate warpage Plate A/B –0.30 (0.012)
Clutch outer guide I.D. 20.000 – 20.021 (0.7874 – 0.7882)...

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GENERAL INFORMATIONFRONT WHEEL/SUSPENSION/S TEERING SPECIFICATIONS
Unit: mm (in)
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Minimum tire thre ad depth – 3.0 (0.12)
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm
2, 22 psi) –
Driver and passenger 150 kPa (1.50 kgf/cm2, 22 psi)–
Axle runout –0.2 (0.01)
Wheel rim runout Radial –2.0 (0.08)
Axial –2.0 (0.08)
Wheel hub-to-rim distance 23.45 ± 1.0 (0.92 ±...

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GENERAL INFORMATION
BATTERY/CHARGING SYST EM SPECIFICATIONS
LIGHTS/METERS/SWITCHES SPECIFICATIONS
TORQUE VALUES
STANDARD TORQUE VALUES
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V - 6 Ah (10 HR)
Current leakage 0.34 mA max.
Voltage 
(20°C/68°F) Fully charged
13.0 – 13.2 V
Needs 
charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3 A/1 h
Alternator Capacity  0.34 kW/5,000 min
-1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω
ITEMSPECIFICATION...

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GENERAL INFORMATIONENGINE & FRAME TORQUE VALUES
 • Torque specifications listed below are for important fasteners.
 • Others should be tightened to st andard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM ITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Hook bolt 4 8 21 (2.1, 15)
Left side cover assembly  screw 2 4 0.9 (0.1, 0.7)
Right fuel tank shroud assembly screw 4 4 0.9 (0.1, 0.7)
Left fuel tank shroud assembly screw 2 4...

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GENERAL INFORMATION
IGNITION SYSTEM
ELECTRIC STARTER
FUEL SYSTEM
COOLING SYSTEM
CYLINDER HEAD/VALVES
CYLINDER/PISTONITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply engine oil to the  threads.
ITEMQTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Negative brush screw 15 3.7 (0.4, 2.7)
Starter motor assembly bolt 25 4.9 (0.5, 3.6)
ITEM QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Fuel pump mounting nut 66 12...

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GENERAL INFORMATION
CLUTCH/GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH
CRANKCASE/CRANKSHAFT/T RANSMISSION/BALANCER
ENGINE REMOVAL/INSTALLATION ITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Clutch center lock nut 1 16 108 (11.0, 80) Lock nut; replace with a new  one and stake.
Apply engine oil to the threads 
and seating surface.
Clutch lifter plate bolt 5 6 12 (1.2, 9)
Shift drum stopper plate bolt 1 6 10 (1.0, 7) Apply locking agent to the  threads.
Shift drum...

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GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSIONITEM QTY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Front axle bolt 1 14 73.5 (7.5, 54)
Front axle pinch bolt 2 8 20 (2.0, 15)
Front brake disc bolt 6 6 20 (2.0, 15) ALOC bolt; replace with a new  one.
Front spoke 36 BC 3.2 3.7 (0.4, 2.7)
Top bridge pinch bolt 48 32 (3.3, 24)
Bottom bridge pinch bolt 48 32 (3.3, 24)
Front brake hose guide bolt 26 10 (1.0, 7)
Front brake hose clamp bolt 26 10 (1.0,...

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GENERAL INFORMATION
BRAKE SYSTEM
BATTERY/CHARGING SYSTEM
LIGHTS/METERS/SWITCHESITEM
QTYTHREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Brake caliper bleed valve 28 5.4 (0.6, 4.0)
Master cylinder reservoir cover screw 4 41.5 (0.2, 1.1)
Rear master cylinder reservoir mounting 
bolt 1
6 10 (1.0, 7)
Front brake pad pin 1 1017.2 (1.8, 13)
Rear brake pad pin 1 1017.2 (1.8, 13)
Brake hose oil bolt 4 1034 (3.5, 25)
Front master cylinder holder bolt 26 9.8 (1.0, 7.2)
Front brake light...

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GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIALLOCATIONREMARKS
Liquid sealant (Three bond 
1207B, 1215 or equivalent) Left crankcase mating surface
See page 14-18
Alternator/CKP sensor wire grommet sealing surface
Liquid sealant (Three bond 
5211C, 1207B, 1215, SS 
KE45 or equivalent) Cylinder head semi-circular cut-out
Engine oil Oil pump rotor entire surface
Oil pump shaft outer surface
Water pump shaft outer surface
Cam chain whole surface
Cylinder inner surface...