Honda Crf250l Service Manual

11-6
dummyhead
dummyhead
CYLINDER/PISTON
Install new piston pin clips [1] into the grooves of the
piston pin hole.
 • Always use new piston pin clips. Reinstalling usedpiston pin clips may lead to serious engine damage.
 • Set the piston pin clip in the groove properly.
 • Do not align the clip’s end gap [2] with the piston cut- out [3].
CYLINDER INSTALLATION
Install the dowel pins [1] and a new gasket [2].
Apply engine oil to the cylinder [1] inner surface and
piston [2] sliding surface.
Route the cam...

11-7
dummyhead
dummyhead
CYLINDER/PISTON
CAM CHAIN TENSIONER
REMOVAL/INSTALLATION
Remove the cam chain tensioner lifter plug [1] and O-
ring [2].
Turn the cam chain tensioner lifter shaft fully in
(clockwise) and secure it using the special tool.
Remove the cam chain tensioner lifter mounting bolts
[4].
Remove the cam chain tensioner lifter [5] and gasket
[6].
Install a new gasket [1] on the cam chain tensioner lifter
[2] and install them to the cylinder.
Install and tighten the cam chain tensioner...

MEMO
dummyhead
dummyhead 

12-1
12
dummytext
12. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION ···························12-2
TROUBLESHOOTING·································12-2
COMPONENT LOCATION ··························12-3
RIGHT CRANKCASE COVER ··················\
··12-4CLUTCH ······················································ 12-9
GEARSHIFT LINKAGE ····························· 12-14
PRIMARY DRIVE GEAR ··························· 12-17 

12-2
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGE
CLUTCH/GEARSHIFT LINKAGESERVICE INFORMATION
GENERAL
 • This section covers service of the clutch and gearshift linkage. All services can be done with the engine installed in the frame.
 • Engine oil viscosity and level have an effe ct on clutch disengagement. Oil additives also effect clutch performance and are not
recommended. When the clutch does not disengage or the motorcycle creeps with the clutch lever pulled in, inspect the engine
oil level before...

12-3
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGE
COMPONENT LOCATION
108 N·m (11.0 kgf·m, 80 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
108 N·m (11.0 kgf·m, 80 lbf·ft) 

12-4
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 9-5).
Remove the following:
– Water pipe (page 9-13)
– Frame guard (page 2-6)
– Brake pedal (page 18-12)
Remove the bolts [1] and clutch cable guide [2], then
disconnect the clutch cable [3] from the clutch lifter arm
[4].
Loosen the water hose band screw [1] and disconnect
the water hose [2].
Remove the bolt [3] and rear brake light switch holder
[4].
Loosen the right...

12-5
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGE
Remove the collars [1] and O-rings [2].
DISASSEMBLY
Remove the return spring [1] from the right crankcase
cover.
Remove the clutch lifter arm [1] from the right
crankcase cover.
INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
–Oil seal
– Clutch lifter arm needle bearing
– Clutch lifter arm
– Return spring
– Crankshaft bearing
[1]/[2]
[1]
[1] 

12-6
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGEBEARING REPLACEMENT
CRANKSHAFT BEARING
Remove the crankshaft bearing [1] using the special
tools.
Drive in a new crankshaft bearing [1] into the right
crankcase cover with the ma rked side facing up until it
is fully seated using the special tools.
After installation, apply engine oil to the bearing.
CLUTCH LIFTER ARM NEEDLE BEARING
Remove the oil seal [1] from  the right crankcase cover.
Remove the clutch lifter arm needle bearings [2] using
the special...

12-7
dummyhead
dummyhead
CLUTCH/GEARSHIFT LINKAGE
Install the bearing remover head [1] to the pilot collar [2]
as shown.
Drive in a new clutch lifter arm needle bearings [1] until
the specified depth, using the special tools as shown.
After installation, apply engine oil to the bearing.
Install a new oil seal [1] to the right crankcase cover as
shown.
ASSEMBLY
Apply grease to the clutch lifter arm oil seal lips [1].
Apply molybdenum oil solution to the clutch lifter arm [2]
sliding surface.
Install the...