Honda Crf250l Service Manual

15-8
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ENGINE REMOVAL/INSTALLATION
Install the rear brake light switch holder [1] while
aligning its tab with the frame hole.
Install and tighten the bolt [2].
Connect the water hoses [1] and tighten the water hose
band screws [2] (page 9-7).
Connect the crankcase breather hose [1].
Route the VS sensor wire through the guide [2]
Install and tighten the starte r motor terminal nut [3] with
starter motor cable terminal [4].
Install the rubber cap [5].
Install and tighten the starter motor...

15-9
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ENGINE REMOVAL/INSTALLATION
Close the harness band [1] and secure the wires.
Connect the VS sensor 3P (Blue) connector [2].
Connect the following:
– Alternator 3P connector [1]
– CKP sensor/neutral switch 3P (Black) connector [2]
Secure the alternator wir e [3] with the clamp [4].
Connect the O
2 sensor cap [1].
 • Take care not to tilt the O2 sensor cap when
connecting the cap to the O
2 sensor.
 • Do not turn the O
2 sensor cap after connecting it.
Connect the ECT sensor 3P...

MEMO
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16-1
16
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16. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION ···························16-2
TROUBLESHOOTING·································16-2
COMPONENT LOCATION ··························16-3
FRONT WHEEL ···········································16-4FORK··························································· 16-6
HANDLEBAR ··················\
··················\
········ 16-16
STEERING STEM ····································· 16-21 

16-2
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FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL/SUSPENSION/STEERINGSERVICE INFORMATION
GENERAL
 • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
 • Raise the front wheel off the ground by  supporting the frame securely when servicing.
 • For hydraulic brake system service (page 18-3).
 • After the front wheel installation, check  the brake operation by applying the brake...

16-3
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FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
73.5 N·m (7.5 kgf·m, 54 lbf·ft)
20 N·m (2.0 kgf·m, 15 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
10 N·m (1.0 kgf·m, 
7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
103 N·m (10.5 kgf·m, 76 lbf·ft) 

16-4
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FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL
REMOVAL/INSTALLATION
Raise the front wheel off the ground by placing a work
stand or box under the frame.
Loosen the axle pinch bolts [1] on the right fork leg and
remove the front axle [2].
Remove front wheel and side collars [3].
 • Do not operate the brake lever after removing thewheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
Apply thin coat of grease  to the axle outer surface.
Install the...

16-5
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FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front wheel as following illustration.
BEARING REPLACEMENT
Install the remover head [1] into the bearing.
From the opposite side of the wheel, install the remover
shaft [2] and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
Pack new bearing cavities with grease.
Drive in a new left side (brake disc side) bearing [1]
squarely with the sealed side...

16-6
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FRONT WHEEL/SUSPENSION/STEERINGWHEEL CENTER ADJUSTMENT
Adjust the hub position so th at the distance from the left
end surface [1] of the hub center to the side of rim [2] is
within the following specification as shown.
Tighten the spokes in 2 or 3 progressive steps.
FORK
REMOVAL
Remove the front wheel (page 16-4).
Remove the following from the left fork leg:
– Bolts [1]
– Brake hose clamp [2]
– Brake caliper mounting bolts [3]
– Brake caliper [4]
– Socket bolts [1]
– Fork...

16-7
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FRONT WHEEL/SUSPENSION/STEERING
Left side:Remove the bolt [1] and brake hose guide [2].
Loosen the fork top bridge pinch bolts [3].
If you will disassemble the fo rk, loosen the fork cap [4],
but do not remove it.
Loosen the fork bottom pinch bolts [1] while supporting
the fork leg.
Pull the fork leg down and remove it out of the fork
bridges.
INSTALLATION
Install the outer tube into  the bottom and top bridges.
Align the top of the outer tube with the upper surface of
the top...