Honda Crf250l Service Manual

18-10
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BRAKE SYSTEMINSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Master cylinder
– Master piston
– Piston cups
–Spring
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
FRONT BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from  the front brake hydraulic
system (page 18-4).
Remove the following:
– Oil bolt [1]
– Sealing washers [2]
– Brake hose [3]
– Brake caliper mounting bolts [4]
– Brake...

18-11
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BRAKE SYSTEM
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Caliper cylinders
– Caliper pistons
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
REAR BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 18-4).
Remove the oil bolt [1], s ealing washers [2], and brake
hose [3].
Remove the rear wheel (page 17-4).
Remove the rear brake caliper  [1]...

18-12
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BRAKE SYSTEMDISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake caliper as following illustration.
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Caliper cylinder
– Caliper piston
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the following:
– Brake light switch  return spring [1]
– Brake pedal return spring [2]
DUST SEAL
CALIPER PISTON
PAD...

18-13
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BRAKE SYSTEM
– Cotter pin [1]
– Joint pin [2]
– Brake rod joint [3]
– Stopper pin [4]
–Washer [5]
– Brake pedal [1]
– Dust seals [2]
Installation is in the reverse order of removal.
 • Replace the dust seals and cotter pin with new ones.
 • Install the dust seals in shown direction.
 • Apply grease to the brake pedal pivot sliding surfaceand dust seal lips.
[2]
[3]
[1][5][4]
[2]
[1]
[1]
[2] 

MEMO
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19-1
19
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19. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION ···························19-2
TROUBLESHOOTING·································19-2
SYSTEM LOCATION···································19-3
SYSTEM DIAGRAM ····································19-3BATTERY ···················································· 19-4
CHARGING SYSTEM INSPECTION ·········· 19-4
ALTERNATOR CHARGING COIL ·············· 19-5
REGULATOR/RECTIFIER ·························· 19-6 

19-2
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BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEMSERVICE INFORMATION
GENERAL
 • Always turn OFF the ignition switch before disconnecting any electrical component.
 • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
 • For extended storage, remove the battery,  give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every 2...

19-3
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BATTERY/CHARGING SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
BATTERY
ALTERNATOR
REGULATOR/RECTIFIER 
MAIN FUSE (30 A) 
BATTERYREGULATOR/RECTIFIER
MAIN FUSE (30 A)
ALTERNATOR
GR/WYYY
Y: Yellow
G: Green
R: Red
W: White 

19-4
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BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/INSTALLATION
Remove the left side cover (page 2-3).
Turn the ignition switch OFF.
Disconnect the negative (–) cable [1] first and then the
positive (+) cable [2].
Remove the bolt [3], battery holder plate [4] and battery
[5].
Install the battery in the reverse order of removal.
 • Install the battery holder plate by aligning its hook
with the slit of the battery case.
 • For digital clock setting procedure (page 20-7).
VOLTAGE INSPECTION...

19-5
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BATTERY/CHARGING SYSTEM
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
Remove the left side cover (page 2-3).
Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
terminal [1] and negative (–) terminal [2].
 • To...