Honda Crf250l Service Manual
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Page 251
![Page 251
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the balancer driven gear assembly while aligning
the woodruff key on the balancer shaft with balancer
driven gear keyway.
Apply engine oil to the balancer shaft nut [1] threads
and seating surface.
Install the washer [2] and balancer shaft nut.
Apply engine oil to the balancer drive gear [3] teeth and
install it while aligning its wide groove with the punch
mark on the crankshaft.
Install the balancer drive gear with its OUT...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-250.png "Page 251
14-20
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the balancer driven gear assembly while aligning
the woodruff key on the balancer shaft with balancer
driven gear keyway.
Apply engine oil to the balancer shaft nut [1] threads
and seating surface.
Install the washer [2] and balancer shaft nut.
Apply engine oil to the balancer drive gear [3] teeth and
install it while aligning its wide groove with the punch
mark on the crankshaft.
Install the balancer drive gear with its OUT...")
14-20 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the balancer driven gear assembly while aligning the woodruff key on the balancer shaft with balancer driven gear keyway. Apply engine oil to the balancer shaft nut [1] threads and seating surface. Install the washer [2] and balancer shaft nut. Apply engine oil to the balancer drive gear [3] teeth and install it while aligning its wide groove with the punch mark on the crankshaft. Install the balancer drive gear with its OUT...
Page 252
![Page 252
14-21
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the timing sprocket while aligning its wide groove
with the punch mark on the crankshaft.
Apply engine oil to the cam chain [1] whole surface.
Install the cam chain through the crankcase.
Install the cam chain over the timing sprocket [2].
Apply locking agent to the cam chain tensioner pivot
bolt [3] threads (page 1-12).
Install the cam chain tensioner [4], collar [5] and cam
chain tensioner pivot bolt.
Tighten the cam chain...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-251.png "Page 252
14-21
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the timing sprocket while aligning its wide groove
with the punch mark on the crankshaft.
Apply engine oil to the cam chain [1] whole surface.
Install the cam chain through the crankcase.
Install the cam chain over the timing sprocket [2].
Apply locking agent to the cam chain tensioner pivot
bolt [3] threads (page 1-12).
Install the cam chain tensioner [4], collar [5] and cam
chain tensioner pivot bolt.
Tighten the cam chain...")
14-21 dummyhead dummyhead CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the timing sprocket while aligning its wide groove with the punch mark on the crankshaft. Apply engine oil to the cam chain [1] whole surface. Install the cam chain through the crankcase. Install the cam chain over the timing sprocket [2]. Apply locking agent to the cam chain tensioner pivot bolt [3] threads (page 1-12). Install the cam chain tensioner [4], collar [5] and cam chain tensioner pivot bolt. Tighten the cam chain...
Page 253
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Page 254
15-1 15 dummytext 15. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ···························15-2 COMPONENT LOCATION ··························15-3ENGINE REMOVAL ···································· 15-4 ENGINE INSTALLATION ···························· 15-7
Page 255
15-2 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATIONSERVICE INFORMATION GENERAL • When removing/installing the engine, tape the fr ame around the engine beforehand for frame protection. • When installing the engine, be sure to tighten the engine moun ting fasteners to the specified torque in the specified sequence. If you make mistake in torque or sequence, loosen all mounting fa steners, then tighten them again to the specified torque in the correct sequence. • The...
Page 256
15-3 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 55 N·m (5.6 kgf·m, 41 lbf·ft) 55 N·m (5.6 kgf·m, 41 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft)
Page 257
![Page 257
15-4
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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 9-5).
Remove the following:
– Frame guard (page 2-6)
– Skid plate (page 2-5)
– Throttle body (page 7-11)
– Exhaust pipe/muffler (page 2-11)
– Gearshift pedal (page 12-14)
– Brake pedal (page 18-12)
Disconnect the following:
– Spark plug cap [1]
– PAIR air supply hose [2]
Disconnect the O
2 sensor cap [1] and ECT sensor 3P
connector [2].
Disconnect the following:
– Alternator 3P...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-256.png "Page 257
15-4
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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 9-5).
Remove the following:
– Frame guard (page 2-6)
– Skid plate (page 2-5)
– Throttle body (page 7-11)
– Exhaust pipe/muffler (page 2-11)
– Gearshift pedal (page 12-14)
– Brake pedal (page 18-12)
Disconnect the following:
– Spark plug cap [1]
– PAIR air supply hose [2]
Disconnect the O
2 sensor cap [1] and ECT sensor 3P
connector [2].
Disconnect the following:
– Alternator 3P...")
15-4 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-9). Drain the coolant (page 9-5). Remove the following: – Frame guard (page 2-6) – Skid plate (page 2-5) – Throttle body (page 7-11) – Exhaust pipe/muffler (page 2-11) – Gearshift pedal (page 12-14) – Brake pedal (page 18-12) Disconnect the following: – Spark plug cap [1] – PAIR air supply hose [2] Disconnect the O 2 sensor cap [1] and ECT sensor 3P connector [2]. Disconnect the following: – Alternator 3P...
Page 258
![Page 258
15-5
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ENGINE REMOVAL/INSTALLATION
Remove the bolts [1] and cl utch cable guide [2], then
disconnect the clutch cable [3 ] from the clutch lifter arm
[4].
Remove the starter motor mounting bolt [1] and ground
terminal [2].
Release the rubber cap [3].
Remove the starter motor terminal nut [4] and starter
motor cable terminal [5].
Disconnect the crankcase breather hose [6].
Release the VS sensor wire from the guide [7]
Loosen the water hose band screws [1] and disconnect
the water hoses...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-257.png "Page 258
15-5
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ENGINE REMOVAL/INSTALLATION
Remove the bolts [1] and cl utch cable guide [2], then
disconnect the clutch cable [3 ] from the clutch lifter arm
[4].
Remove the starter motor mounting bolt [1] and ground
terminal [2].
Release the rubber cap [3].
Remove the starter motor terminal nut [4] and starter
motor cable terminal [5].
Disconnect the crankcase breather hose [6].
Release the VS sensor wire from the guide [7]
Loosen the water hose band screws [1] and disconnect
the water hoses...")
15-5 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the bolts [1] and cl utch cable guide [2], then disconnect the clutch cable [3 ] from the clutch lifter arm [4]. Remove the starter motor mounting bolt [1] and ground terminal [2]. Release the rubber cap [3]. Remove the starter motor terminal nut [4] and starter motor cable terminal [5]. Disconnect the crankcase breather hose [6]. Release the VS sensor wire from the guide [7] Loosen the water hose band screws [1] and disconnect the water hoses...
Page 259
![Page 259
15-6
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ENGINE REMOVAL/INSTALLATION
Loosen the rear axle nut [1], lock nuts [2] and drive
chain adjusters [3].
Push the rear wheel forward and make the drive chain
slack fully.
Remove the bolts [1], fixing plate [2] and drive sprocket
[3].
Remove the rear engine hanger upper mounting nut [1]
and bolt [2].
Remove the bolts [3] and engine hanger plate [4].
The jack height
must be continually adjusted to relievestress for ease of
bolt removal.Support the engine using a jack or other...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-258.png "Page 259
15-6
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ENGINE REMOVAL/INSTALLATION
Loosen the rear axle nut [1], lock nuts [2] and drive
chain adjusters [3].
Push the rear wheel forward and make the drive chain
slack fully.
Remove the bolts [1], fixing plate [2] and drive sprocket
[3].
Remove the rear engine hanger upper mounting nut [1]
and bolt [2].
Remove the bolts [3] and engine hanger plate [4].
The jack height
must be continually adjusted to relievestress for ease of
bolt removal.Support the engine using a jack or other...")
15-6 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Loosen the rear axle nut [1], lock nuts [2] and drive chain adjusters [3]. Push the rear wheel forward and make the drive chain slack fully. Remove the bolts [1], fixing plate [2] and drive sprocket [3]. Remove the rear engine hanger upper mounting nut [1] and bolt [2]. Remove the bolts [3] and engine hanger plate [4]. The jack height must be continually adjusted to relievestress for ease of bolt removal.Support the engine using a jack or other...
Page 260
![Page 260
15-7
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ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
During engine
installation, hold the
engine securely
and be careful not to damage the
frame and engine.Place the engine in the frame, then loosely install all the
bolts [1], collars [2], washers [3] and nuts.
Tighten the rear lower engine mounting nut [4] to the
specified torque.
Tighten the front lower engine mounting nut [5] to the
specified torque.
Tighten the front upper engine mounting nut [6] to the
specified torque.
With the...](http://img.usermanuals.tech/thumb/34/103137/w300_crf250l-service-manual-1512603421_d-259.png "Page 260
15-7
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ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
During engine
installation, hold the
engine securely
and be careful not to damage the
frame and engine.Place the engine in the frame, then loosely install all the
bolts [1], collars [2], washers [3] and nuts.
Tighten the rear lower engine mounting nut [4] to the
specified torque.
Tighten the front lower engine mounting nut [5] to the
specified torque.
Tighten the front upper engine mounting nut [6] to the
specified torque.
With the...")
15-7 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION During engine installation, hold the engine securely and be careful not to damage the frame and engine.Place the engine in the frame, then loosely install all the bolts [1], collars [2], washers [3] and nuts. Tighten the rear lower engine mounting nut [4] to the specified torque. Tighten the front lower engine mounting nut [5] to the specified torque. Tighten the front upper engine mounting nut [6] to the specified torque. With the...