Honda Crf250l Service Manual

17-12
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REAR WHEEL/SUSPENSIONBEARING REPLACEMENT
Remove the pivot bearings [1] and dust seals [2] using
the special tool.
Apply grease to the needle rollers of new bearings [1]
and new dust seal [2] lips.
Install the dust seals to the specified depth with the
marked side facing in.
Press the needle bearings to  the specified depth with
the marked side facing up, using the special tools.
DRIVE CHAIN GUIDE
REMOVAL/INSTALLATION
Remove the two nuts [1], screws [2] and chain slider
guide...

18-1
18
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18. BRAKE SYSTEM
SERVICE INFORMATION ···························18-2
TROUBLESHOOTING·································18-2
COMPONENT LOCATION ··························18-3
BRAKE FLUID REPLACEMENT/
AIR BLEEDING ···········································18-4
BRAKE PAD/DISC··················\
··················\
··18-5 FRONT MASTER CYLINDER ····················· 18-7
REAR MASTER CYLINDER ······················· 18-8
FRONT BRAKE CALIPER ························ 18-10
REAR BRAKE CALIPER...

18-2
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BRAKE SYSTEM
BRAKE SYSTEMSERVICE INFORMATION
GENERAL
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir  cap; make sure the master cylinder reservoir is horizontal first.
 • A contaminated brake disc or pad reduces stopping power.  Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
 • Always use fresh DOT 3 or DOT 4...

18-3
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BRAKE SYSTEM
COMPONENT LOCATION
FRONT:
REAR:
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf·ft) 

18-4
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BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR 
BLEEDING
BRAKE FLUID DRAINING
For front brake:Turn the handlebar until the master cylinder reservoir is
level before removing the reservoir cap.
Remove the screws [1], reservoir cap [2], set plate [3],
and diaphragm [4].
For rear brake:Remove the bolt [1] and reservoir [2].
Remove the cover screws [3],  reservoir cover [4], set
plate [5] and diaphragm [6].
Connect a bleed hose [1] to the bleed valve [2].
Loosen the bleed valve and pump...

18-5
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BRAKE SYSTEM
If a brake bleeder is not available, use the following
procedure:
Connect a bleed hose to the bleed valve.
Pressurize the system with the brake lever or pedal until
lever or pedal resistance is felt.
1. Squeeze the brake lever or depress the brake pedal,open the bleed valve 1/4 turn and then close it.
2. Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel.
3. Repeat the steps 1 and  2 until there are no air
bubbles...

18-6
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BRAKE SYSTEM
Apply silicone grease to a new stopper ring [1] and
install it into the pad pin [2] groove.
Install the pad pin by pushing in the pads against the
pad spring to align the pad pin holes in the pads and
caliper body.
Tighten the pad pin to the specified torque.
Operate the brake lever to seat the caliper pistons
against the pads.
REAR BRAKE PAD REMOVAL/
INSTALLATION
Remove the pad pin plug [1] and pad pin [2].
Remove the brake pads [3].
Apply silicone grease to a new...

18-7
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BRAKE SYSTEM
FRONT MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic
system (page 18-4).
Remove the following:
– Right rearview mirror [1]
– Oil bolt [2]
– Sealing washers [3]
– Brake hose [4]
– Brake light switch connectors [5]
– Bolts [1]
– Master cylinder holder [2]
– Master cylinder [3]
Installation is in the reverse order of removal.
 • Replace the sealing washers with new ones.
 • Align the edge of the master cylinder with the punch...

18-8
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BRAKE SYSTEMDISASSEMBLY/ASSEMBLY
Disassemble and assemble the front brake master
cylinder as following illustration.
 • Replace the master piston, spring, piston cups andsnap ring as a set.
 • Do not allow the piston cup lips to turn inside out.
 • Be certain the snap ring is firmly seated in the groove.
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Master cylinder
– Master piston
– Piston cups
–Spring
– Boot
Measure the parts according...

18-9
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BRAKE SYSTEM
– Cotter pin [1]
– Joint pin [2]
– Master cylinder mounting bolts [3]
– Snap ring [1]
– Hose joint [2]
– O-ring [3]
– Rear master cylinder [4]
Installation is in the reverse order of removal.
 • Replace the O-ring, master cylinder mounting bolts,cotter pin and sealing washers with new ones.
 • Apply brake fluid to the joint O-ring.
Fill and bleed the hydraulic system (page 18-4).
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake master
cylinder as...