Honda Crf250l Service Manual

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GENERAL INFORMATION
BRAKE/TAILLIGHT 6P 
(BLACK) CONNECTOR
LEFT REAR TURN SIGNAL 
2P (ORANGE) CONNECTORRIGHT REAR TURN 
SIGNAL 2P (LIGHT BLUE) 
CONNECTOR
MAIN WIRE HARNESS 

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GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOX) and hydrocarbons (HC). Control of oxides of
nitrogen and hydrocarbons is very important  because, under certain conditions, they react to form photochemical smog when
subject to sunlight. Carbon monoxide does not  react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes various systems (page 1-28) to  reduce carbon monoxide,...

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GENERAL INFORMATIONEXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of a pulse seco ndary air supply system, three-way catalytic converter and PGM-
FI system.
SECONDARY AIR SUPPLY SYSTEM
The pulse secondary air supply system introduc es filtered air into the exhaust gases in the exhaust port. Fresh air is drawn in to the
exhaust port by the functi on of the PAIR control valve.
This charge of fresh air promotes burning  of the unburned exhaust gases...

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GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONT ROL SYSTEM IS PROHIBITED: Local law may proh ibit the following acts or the causing
there of: (1) The removal or rendering inope rative by any person, other than for purposes of maintenance, repair or replacement, of
any device or element of design incorporated into any vehicle fo r the purpose of noise control prior to its sale or delivery to the
ultimate customer or while it is in use;  (2) the use...

MEMO
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2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION ·····························2-2
TROUBLESHOOTING···································2-2
SEAT······························································2-3
SIDE COVER ·················································2-3
RESERVE TANK COVER ···················\
··········2-4
FUEL TANK SHROUD ··································2-4
SKID PLATE ··················································2-5
HEADLIGHT COWL...

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FRAME/BODY PANELS/EXHAUST SYSTEM
FRAME/BODY PANELS/EXHAUST SYSTEMSERVICE INFORMATION
GENERAL
 • This section covers removal and installation of the body panels, sub-frame and exhaust system.
 • Always replace the gaskets wh en removing the exhaust system.
 • Always inspect the exhaust system  for leaks after installation.
TROUBLESHOOTING
Excessive exhaust noise
 • Broken exhaust system
 • Exhaust gas leak
Poor performance
 • Deformed exhaust system
 • Exhaust gas leak
 • Clogged...

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FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL/INSTALLATION
Remove the hook bolts [1] and collars [2].
Remove the seat [3] by pulling it rearward and releasing
the hooks.
Installation is in the reverse order of removal.
SIDE COVER
REMOVAL/INSTALLATION
Right side:Remove the socket bolt [1] and collar [2].
Remove the socket bolt [1].
Release the boss [3] from the frame grommet, then
remove the side cover [4] by pulling it rearward.
Installation is in the reverse order of removal.
 •...

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FRAME/BODY PANELS/EXHAUST SYSTEM
RESERVE TANK COVER
REMOVAL/INSTALLATION
Remove the trim clips [1], socket bolt [2] and reserve
tank cover [3].
Installation is in the reverse order of removal.
 • Align the cover boss [4] with the hole [5] of the stay.
FUEL TANK SHROUD
REMOVAL/INSTALLATION
Right side only:Remove the reserve tank cover (page 2-4).
Remove the side cover (page 2-3).
Remove the socket bolt A [1], socket bolts B [2] and fuel
tank shroud [3].
Installation is in the...

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FRAME/BODY PANELS/EXHAUST SYSTEM
SKID PLATE
REMOVAL/INSTALLATION
Remove the two bolts [1] and skid plate [2].
Installation is in the reverse order of removal.
 • Align the rear side of the skid plate with the frameslot [3].
HEADLIGHT COWL
REMOVAL/INSTALLATION
Remove the four bolt/was hers [1] and headlight cowl
[2].
Disconnect the headlight 3P (Black) connector [3] and
position light 2P (Black) connector [4].
Installation is in the reverse order of removal.
FRONT FENDER...