Honda Crf250l Service Manual

2-6
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FRAME/BODY PANELS/EXHAUST SYSTEM
FRAME GUARD
REMOVAL/INSTALLATION
Remove the socket bolts [1] and frame guard [2].
Installation is in the reverse order of removal.
DRIVE SPROCKET COVER
REMOVAL/INSTALLATION
Remove the bolts [1] and drive sprocket cover [2].
Installation is in the reverse order of removal.
DRIVE CHAIN COVER (U TYPE ONLY)
REMOVAL/INSTALLATION
Remove the socket bolts [1] and drive chain cover [2].
Installation is in the reverse order of removal.
[2]
[1]
[2]
[1]
[2]
[1] 

2-7
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FRAME/BODY PANELS/EXHAUST SYSTEM
TOOL BOX
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Left side cover (page 2-3)
Remove the two mounting bolts [1] and tool box [2].
Installation is in the reverse order of removal.
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the tool box as following illustration.
REAR FENDER
REMOVAL/INSTALLATION
Remove the bolts [1] and rear fender [2].
Installation is in the reverse order of removal.
[2][1]
TOOL BOX
SPECIAL WASHER
HINGE
TOOL...

2-8
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FRAME/BODY PANELS/EXHAUST SYSTEMDISASSEMBLY/ASSE MBLY (U TYPE 
ONLY)
Remove the nuts [1], bolts [2], collars [3], license holder
plate [4] and license plate stay [5].
Remove the stopper rubber [6].
Remove the nuts [7] and rear side reflectors [8].
Assembly is in the reverse order of disassembly.
REAR UPPER FENDER
REMOVAL/INSTALLATION
Remove the seat (page 2-3).
Remove the hook bolts [1] and collars [2].
Slightly spread the side covers [3] and release the
bosses [4] and tabs [5]....

2-9
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FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Rear fender (page 2-7)
– Rear turn signal units (page 20-4)
Disassemble and assemble the tail cover/light unit as following illustration.
REAR LOWER FENDER
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Side covers (page 2-3)
– Tail cover/light unit (page 2-8)
Release the wire bands [1].
BRAKE/TAILLIGHT 
MOUNTING SCREWS
4.5 N·m (0.5 kgf·m, 
3.3 lbf·ft)
COLLARS
REAR TURN SIGNAL 
UNIT...

2-10
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FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the rear lower fender mounting bolt [1].
Remove the bolts [1], helmet holder [2] and rear lower
fender [3].
Use a drill or an equivalent tool when removing the
helmet holder mounting bolts.
Installation is in the reverse order of removal.
 • Replace the helmet holder mounting bolts with newones.
[1]
[1]
[2]
[3] 

2-11
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FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST PIPE/MUFFLER
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Right side cover (page 2-3)
Remove the exhaust pipe/muffler as following
illustration.
Installation is in the reverse order of removal.
STUD BOLT REPLACEMENT
Remove the exhaust pipe (page 2-11).
Thread two nuts onto the stud bolt and tighten them
together, and use a wrench on them to turn the stud bolt
out.
Install and tighten new stud bolts to the specified...

2-12
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FRAME/BODY PANELS/EXHAUST SYSTEM
SUB-FRAME
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Side covers (page 2-3)
– Muffler (page 2-11)
– Fuel tank (page 7-8)
– Battery (page 19-4)
Remove the bolt [1] and reservoir [2].
Disconnect the PAIR air suction hose [3] and crankcase
breather hose [4] from the air cleaner housing.
Remove the wire bands [1].
Remove the following from the air cleaner housing.
– Starter relay switch [2]
– Fuse box [3]
– Relay box [4]
– Wire...

2-13
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FRAME/BODY PANELS/EXHAUST SYSTEM
Loosen the air cleaner connecting hose band screw [1].
Remove the sub-frame lower mounting bolts [1].
Remove the sub-frame upper mounting nuts [1] and
bolts [2].
Pull the sub-frame assembly rearward, then disconnect
the air cleaner connecting hose from the throttle body.
Remove the sub-frame.
Install the sub-frame in position, connect the air cleaner
connecting hose to the throttle body.
Tighten the band screw to the specified torque.
Loosely...

2-14
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FRAME/BODY PANELS/EXHAUST SYSTEM
SIDESTAND
REMOVAL/INSTALLATION
Remove the sidestand switch (page 20-14).
Remove the return spring [1] and sub spring [2].
Remove the pivot lock nut [3], pivot bolt [4] and
sidestand [5].
Apply grease to the sidestand pivot bolt sliding surface.
Install the sidestand and pivot bolt, then tighten it to the
specified torque.
Turn the pivot bolt counterclockwise about 45° – 90°.
Install the pivot lock nut and tighten it to the specified
torque while...

3-1
3
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3. MAINTENANCE
SERVICE INFORMATION ·····························3-2
MAINTENANCE SCHEDULE ························3-2
FUEL LINE·····················································3-3
THROTTLE OPERATION······························3-3
AIR CLEANER···············································3-4
CRANKCASE BREATHER ··················\
·········3-4
SPARK PLUG··················\
··················\
············3-5
VALVE CLEARANCE····································3-6
ENGINE OIL...