Honda Crf250l Service Manual

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HOW TO USE THIS MANUAL
HOW TO USE THIS MANUALA Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempt ing
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage  the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for per forming service, maintenance and repairs. Some procedures
require the use of specially designed tool s and dedicated equipment. Any person who int ends to use a replacement part, service
procedure or a tool that is  not recommended by Honda, must determine the risks to their personal safety and the safe operation  of
the vehicle.
If you need to replace a part, use Honda Genuine parts with the co rrect part number or an equivalent part. We strongly recommend
that you do not use replacement  parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to  the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operatio n, damage to the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service te chnician, we do not provide warnings about many basic shop safet y
practices (e.g., Hot parts–wear gloves). If you have not receiv ed shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not  attempt to perform the procedures described in this manual.
Some of the most important general service safety precauti ons are given below. However, we cannot warn you of every 
conceivable hazard that can arise in perf orming service and repair procedures. Only  you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any servic e task, be especially careful of the following:
 • Read all of the instructions before you  begin, and make sure you have the tools, t he replacement or repair parts, and the skills
required to perform the tasks safely and completely.
 • Protect your eyes by using proper safety glasses, goggles or  face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is an y doubt, put on eye protection.
 • Use other protective wear when necessary, for example gloves  or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that loo ks like it can hurt you, stop and put on gloves.
 • Protect yourself and others whenever you have the vehicle up in  the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always se curely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedu res, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
 • Carbon monoxide poisoning from engine exhaust. Be sure  there is adequate ventilation whenever you run the engine
 • Burns from hot parts or coolan t. Let the engine and exhaust system cool before working in those areas.
 • Injury from moving parts. If the instruct ion tells you to run the engine, be sure your hands, fingers and clothing are out of  the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To  reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
 • Use only a nonflammable solvent, not gasoline, to clean parts.
 • Never drain or store gasoline in an open container.
 • Keep all cigarettes, sparks and flames away  from the battery and all fuel-related parts.
Improper service or repairs can create an unsafe 
condition that can cause your  customer or others to 
be seriously hurt or killed. 
Follow the procedures and precautions in this 
manual and other service materials carefully.
Failure to properly follow instructions and 
precautions can cause you to be seriously hurt or 
killed.
Follow the procedures and precautions in this 
manual carefully. 
						

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HOW TO USE THIS MANUAL
How To Use This Manual
This manual describes the service procedures for the CRF250L.
Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installa tion of components that may be
required to perform service described in the following sections.
Section 4 through 20 describe parts of the  motorcycle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensu re that the motorcycle is in peak operating condition.
Performing the first scheduled maintenance is very important. It  compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on t he first page of the section.
Most sections start with an assembly or  system illustration, service information and tr oubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting in each section according to the ma lfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.
As you read this manual, you will find info rmation that is preceded by a   symbol. Th e purpose of this message is to help 
prevent damage to your vehicle,  other property, or the environment.
© Honda Motor Co., Ltd.
SERVICE PUBLI CATION OFFICE
Date of Issue: June, 2012 Your safety, and the safety of others, is very important. 
To help you make informed decisions we have provided safety 
messages and other information throughout this manual. Of course,  it is not practical or possible to warn you about all the 
hazards associated  with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
 • Safety Labels – on the vehicle
  • Safety Messages – preceded by a safety alert symbol   an d one of three signal words, DANGER, WARNING, or CAUTION. 
These signal words mean:
 You WILL be KILLED or SERIOUSLY HURT  if you don’t follow instructions.
 You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
 You CAN be HURT if you don’t follow instructions.
 • Instructions – how to service this vehicle correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS  INCLUDED IN THIS PUBLICATION ARE 
BASED ON THE LATEST PRODUCT INFO RMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda 
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHAN GES AT ANY TIME WITHOUT NOTICE AND WITHOUT 
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF  THIS PUBLICATION MAY BE REPRODUCED WITHOUT 
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIR ED BASIC KNOWLEDGE OF 
MAINTENANCE ON Honda MOTORCYC LES, MOTOR SCOOTERS OR ATVS. 
						

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HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically  in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based  multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or 
equivalent).
Example:
 • Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
 • Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more  than 40% molybdenum disulfide, NLGI #2 or 
equivalent).
Example:
 • Molykote® G-n Paste manufa ctured by Dow Corning U.S.A.
 • Honda Moly 60 (U.S.A. only)
 • Rocol ASP manufactured by Rocol Limited, U.K.
 • Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 3 or DOT 4 brake fluid. Use the reco mmended brake fluid unless otherwise specified.
Use fork or suspension fluid. 
						

							CONTENTS
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GENERAL INFORMATION1
FRAME/BODY PANELS/EXHAUST SYSTEM
2
MAINTENANCE
3
PGM-FI SYSTEM
4
IGNITION SYSTEM
5
ELECTRIC STARTER SYSTEM
6
FUEL SYSTEM
7
LUBRICATION SYSTEM
8
COOLING SYSTEM
9
CYLINDER HEAD/VALVES
10
CYLINDER/PISTON
11
CLUTCH/GEARSHIFT LINKAGE
12
ALTERNATOR/STARTER CLUTCH
13
CRANKCASE/CRANKSHAFT/TRAN SMISSION/BALANCER
14
ENGINE REMOVAL/INSTALLATION
15
FRONT WHEEL/SUSPENSION/STEERING
16
REAR WHEEL/SUSPENSION
17
BRAKE SYSTEM
18
BATTERY/CHARGING SYSTEM
19
LIGHTS/METERS/SWITCHES
20
WIRING DIAGRAM
21
INDEX 
						

							MEMO
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1
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1. GENERAL INFORMATION
SERVICE RULES ··········································1-2
MODEL IDENTIFICATION ····························1-2
SPECIFICATIONS ·········································1-4
TORQUE VALUES ········································1-9LUBRICATION & SEAL POINTS ··············· 1-15
CABLE & HARNESS ROUTING ················· 1-17
EMISSION CONTROL SYSTEMS ·············· 1-27 
						

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GENERAL INFORMATION
GENERAL INFORMATIONSERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Hondas design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for this prod uct to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metr ic bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pi ns, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diago nally in
incremental steps unless a part icular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly.  Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts fo r proper installation and operation.
8. Route all electrical wires as shown in  the Cable and Harness Routing (page 1-17).
9. Do not bend or twist control cables. Damaged control  cables will not operate smoothly and may stick or bind.
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual types for each region.
MODEL IDENTIFICATION
Abbrev. term Full term
CKP sensor Crankshaft Position sensor
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
EEPROM Electrically Erasable Programmable Read Only Memory
IACV Idle Air Control Valve
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PAIR Pulse Secondary Air Injection
PGM-FI Programmed Fuel Injection
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
VS sensor Vehicle Speed sensor
DESTINATION 
CODE REGION
EU.K.
FF ra nce
ED European direct sales
U Australia, New Zealand 
						

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GENERAL INFORMATION
SERIAL NUMBERS/LABELS
The Vehicle Identification Number (V.I.N.) [1] is stamped on 
the right side of the steering head. The throttle body identification number [1] is stamped on the 
lower left side of the throttle body.
The engine serial number [1] is stamped on the lower left side 
of the crankcase. The Registered Number Plate 
(except U type) /Compliance 
plate (U type) [1] is stamped on the left front side of the 
steering head.
The color label [1] is attached  on the frame behind rear brake 
master cylinder reservoir. When ordering color-coded parts, 
always specify the designated color code.
[1][1]
[1]
[1]
[1] 
						

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GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEMSPECIFICATION
DIMENSIONS Overall length 2,195 mm (86.4 in)
Overall width 815 mm (32.1 in)
Overall height 1,195 mm (47.0 in)
Wheelbase 1,445 mm (56.9 in)
Seat height 875 mm (34.4 in)
Footpeg height 365 mm (14.4 in)
Ground clearance 255 mm (10.0 in)
Curb weight 143 kg (315 lbs)
Maximum weight capaci ty 159 kg (351 lbs)
FRAME Frame type Twin tube
Front suspension Telescopic fork
Front axle travel 222 mm (8.7 in)
Rear suspension Swingarm
Rear axle travel 240 mm (9.4 in)
Tire size Front3.00-21 51P
Rear 120/80-18M/C 62P
Tire brand FrontGP-21F Z (IRC)
Rear GP-22R (IRC)
Front brake Hydraulic single disc
Rear brake Hydraulic single disc
Caster angle 27° 35’
Trail length 113 mm (4.4 in)
Fuel tank capacity 7.7 liter (2.03 US gal, 1.69 Imp gal)
ENGINE Cylinder arrangement Single cylinder inclined 20° from vertical
Bore and stroke 76.0 x 55.0 mm (2.99 x 2.17 in)
Displacement 249.6 cm
3 (15.23 cu-in)
Compression ratio 10.7:1
Valve train Chain driven DOHC with rocker arm
Intake valve opens at 1.0 mm (0.04 in) lift 20° BTDC
closes at 1.0 mm (0.04 in) lift 35° ABDC
Exhaust valve opens at 1.0 mm (0.04 in) lift 40° BBDC closes at 1.0 mm (0.04 in) lift 0° TDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper filter
Engine dry weight 34.5 kg (76.1 lbs)
FUEL DELIVERY 
SYSTEM Type
PGM-FI
Throttle bore 36 mm (1.4 in)
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation syst em Cable operating
Transmission Constant mesh, 6 speeds
Primary reduction 2.807 (73/26)
Final reduction 2.857 (40/14)
Gear ratio 1st3.333 (40/12)
2nd 2.117 (36/17)
3rd 1.571 (33/21)
4th 1.304 (30/23)
5th 1.115 (29/26)
6th 0.962 (26/27)
Gearshift pattern Left foot operated return system
1 - N - 2 - 3 - 4 - 5 - 6
ELECTRICAL Ignition system Computer-controlled digital transistorized 
with electric advance
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full-wave 
rectification
Lighting system Battery 
						

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GENERAL INFORMATION
PGM-FI SYSTEM SPECIFICATIONS
IGNITION SYSTEM SPECIFICATIONS
ELECTRIC STARTER SPECIFICATION
Unit: mm (in)
FUEL SYSTEM S PECIFICATIONS
LUBRICATION SYSTEM SPECIFICATIONS
Unit: mm (in)
ITEM SPECIFICATIONS
Fuel injector resistance (20°C/68°F) 11 – 13  Ω
ITEMSPECIFICATION
Spark plug SIMR8A9 (NGK)
Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing (F mark) 10° BTDC at idle
ITEMSTANDARDSERVICE LIMIT
Starter motor brush length 11.8 – 12.3 (0.46 – 0.48)6.5 (0.26)
ITEM SPECIFICATIONS
Throttle body identification number GQ32A
Engine idle speed 1,450 ± 100 min
-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.08 – 0.24 in)
Fuel pressure at idle 343 kPa (3.5 kgf/cm
2, 50 psi)
Fuel pump flow (at 12 V) 83 cm3 (2.81 US oz, 2.92 Imp oz) minimum/10 seconds
PAIR control solenoid valve resistance (20°C/68°F) 20 – 24  Ω
ITEMSTANDARDSERVICE LIMIT
Engine oil capacity At draining1.4 liters (1.5 US qt, 1.2 Imp qt) –
At oil filter change 1.5 liters (1.6 US qt, 1.3 Imp qt) –
At disassembly 1.8 liters (1.9 US qt, 1.6 Imp qt) –
Recommended engine oil Honda 4-stroke motorcycle oil or an 
equivalent
API classification: SG or higher (except 
oils labeled as energy conserving on the 
circular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA –
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.22 (0.006 – 0.009) 0.35 (0.014)
Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.10 (0.004)