Honda Crf250l Service Manual

							5-2
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IGNITION SYSTEM
IGNITION SYSTEMSERVICE INFORMATION
GENERAL
 • When servicing the ignition system, always follow the steps in the troubleshooting table (page 5-2).
 • A faulty ignition system is often related to poorly connected or corroded connections. Check those connections before
proceeding.
TROUBLESHOOTING
 • Inspect the following before diagnosing the system. – Faulty spark plug
– Loose spark plug cap or spark plug wire connection
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
 • Initial voltage of the ignition primary coil is the battery  voltage with the ignition switch turned ON and engine stop swit ch  
(The engine is not cranked by the starter motor).
Unusual condition Probable cause (Check in numerical order)
Ignition coil 
primary voltage No initial voltage with the ignition 
switch turned ON and engine stop 
switch   (Other electrical 
components are normal). 1. Faulty ignition switch
2. An open circuit in Black/blue wire between the ignition coil 
and engine stop switch
3. An open circuit in Black/green or Black/red wires between 
the engine stop switch and ignition switch
4. Loose or poor connection of the primary terminal, or an  open circuit in the primary coil
5. Faulty ECM (in case when the initial voltage is normal with  the ECM connector disconnected).
6. Faulty engine stop switch
Initial voltage is normal, but it drops by 
2 – 4 V while cranking the engine. 1. Incorrect peak voltage adaptor connections (System is 
normal if measured voltage is  over the specifications with 
reverse connections).
2. Battery is undercharged (Voltage drops largely when the  engine is started).
3. No voltage between the Black/blue (+) wire and body  ground (–) at the ECM connector or poor connection of the 
ECM connector
4. An open circuit or loose connection in Green or Green/ black wire at the ECM
5. An open circuit or loose connection in Green/red wire 
between the ignition coil and ECM
6. Faulty sidestand switch or  neutral switch or related wires
7. Faulty CKP sensor (Measure peak voltage)
8. Faulty ECM (in case when above No. 1 through 7 are 
normal).
Initial voltage is normal but there is no 
peak voltage while cranking the 
engine. 1. Incorrect peak voltage adaptor connections
2. Faulty peak voltage adaptor
3. Faulty CKP sensor
4. Faulty ECM (in case when above No. 1 through 3 are 
normal).
Initial voltage is normal but peak 
voltage is lower than the standard 
value. 1. The multimeter impedance is too low; below 10 M
Ω/DCV.
2. Cranking speed is too slow (Battery is undercharged).
3. The sampling timing of the test er and measured pulse were 
not synchronized (System is normal if measured voltage is 
over the standard voltage at least once).
4. Faulty ECM (in case when above No. 1 through 3 are  normal).
Initial and peak voltages are normal 
but no spark jumps. 1. Faulty spark plug or leaking ignition coil secondary current
2. Faulty ignition coil
CKP sensor Peak voltage is lower than standard  value. 1. The multimeter impedance is too low; below 10 M
Ω/DCV.
2. Cranking speed is too low. (Battery is undercharged.)
3. The sampling timing of the test er and measured pulse were 
not synchronized (System is normal if measured voltage is 
over the standard voltage at least once).
4. Faulty CKP sensor (in case when above No.1 through 3  are normal).
No peak voltage 1. Faulty peak voltage adapter
2. Faulty CKP sensor 
						

							5-3
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IGNITION SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
IGNITION SWITCH
BATTERY
IGNITION COIL
NEUTRAL SWITCH
CKP SENSOR
SPARK PLUG
CLUTCH SWITCH
MAIN FUSE (30 A)
ECM
FI, IGN FUSE (10 A)
BANK ANGLE SENSOR
ENGINE STOP SWITCH
SIDESTAND 
SWITCH
BATTERY
MAIN FUSE (30 A)Bl/R
Bl/Bu
IGNITION SWITCHSIDESTAND 
SWITCH
BANK 
ANGLE 
SENSOR
CKP 
SENSOR
IGNITION 
COIL
SPARK 
PLUG
ECM
R/W
Bl/G
Bl/Bu
R/BuG/OBu/Y
W/Y
G/R
Bl: Black
Bu: Blue
G: Green
Lg: Light green
O: Orange
R: Red
W: White
Y: Yellow
Br: Brown
FI, IGN FUSE (10 A)G/WG NEUTRAL 
DIODENEUTRAL 
SWITCH
G/R
Lg/R
ENGINE STOP 
SWITCH
GG
G/Bl 
						

							5-4
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IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
 • If there is no spark at the plug, check all connectionsfor loose or poor contact  before measuring the peak
voltage.
 • Use a commercially available digital multimeter with an impedance of 10 M Ω/DCV minimum.
 • The display value differs depending upon the internal impedance of the multimeter.
 • If using the Imrie diagnostic tester (model 625),
follow the manufacturer’s instructions.
Connect the peak voltage adaptor [1] to the digital
multimeter [2], or use th e Imrie diagnostic tester.
IGNITION COIL PRIMARY PEAK 
VOLTAGE
Shift the transmission into neutral and disconnect the
spark plug cap (page 3-5).
Connect a known good spark plug [1] to the spark plug
cap [2] and ground it to the cylinder head as done in a
spark test.
With the ignition coil primar y wire connected, connect
the peak voltage adaptor or Imrie tester to the ignition
coil primary terminal [1] and ground.
Shift the transmissi on into neutral.
Turn the ignition switch ON and engine stop switch  .
Crank the engine with the starter motor with the throttle
grip fully opened and read ignition coil primary peak
voltage.
If the peak voltage is abnormal, follow the checks
described in the troubleshooting table (page 5-2). TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100 
with commercially availa ble digital multimeter 
(impedance 10 M Ω/DCV minimum)
[2]
[1]
[1]
[2]
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100 
with commercially availa ble digital multimeter 
(impedance 10 M Ω/DCV minimum)
CONNECTION: Green/red (+) – Ground (–)
Avoid touching the spark plug and
tester probes to prevent electric
shock.
PEAK VOLTAGE: 100 V minimum
[1] 
						

							5-5
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IGNITION SYSTEM
CKP SENSOR PEAK VOLTAGE
Remove the reserve tank cover (page 2-4).
Disconnect the ECM 33P (Black) connector [1].
Connect the peak voltage tester or adaptor probes to
the ECM 33P (Black) connector [1] terminals of the wire
harness side.
Shift the transmissi on into neutral.
Turn the ignition switch ON and engine stop switch  .
Crank the engine with the starter motor and measure
the CKP sensor peak voltage.
If the peak voltage measured at the ECM 33P (Black)
connector is abnormal, measure the peak voltage at the
CKP sensor connector.
Turn the ignition switch OFF.
Remove the left side cover (page 2-3).
Disconnect the CKP sensor/neutral switch 3P (Black)
connector [1] and connect the tester probes to the
connector terminals of the CKP sensor side.
In the same manner as at the ECM 33P (Black)
connector, measure the peak voltage and compare it to
the voltage measured at the ECM 33P (Black)
connector.
 • If the peak voltage measured at the ECM is abnormal and the one meas ured at the CKP sensor
is normal, the wire harness has an open or short
circuit or loose connection.
 • If the peak voltage of the CKP sensor side is lower than standard value, follow the checks described in
the troubleshooting table (page 5-2).
For CKP sensor replacement (page 13-4).
Install the removed parts in the reverse order of
removal.
[1]
TOOLS:
Imrie diagnostic te ster (model 625) or
Peak voltage adaptor [2] 07HGJ-0020100 
with commercially available digital multimeter 
(impedance 10 M Ω/DCV minimum)
Test probe 07ZAJ-RDJA110 
CONNECTION: Blue/yellow (+) – White/yellow (–)
PEAK VOLTAGE: 0.7 V minimum
Bu/Y W/Y
[1]
[2]
CONNECTION: Blue/yellow (+) – White/yellow (–)
[1] 
						

							5-6
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IGNITION SYSTEM
IGNITION TIMING
Warm up the engine.
Stop the engine and remove the timing hole cap using
the special tool.
Connect the timing light [1] to the spark plug wire.
Start the engine and let it idle.
The ignition timing is correct if the F mark [2] on the
flywheel aligns with the index notch [3] on the left
crankcase cover.
Apply engine oil to a new O-ring and install it to the
timing hole cap.
Apply engine oil to the timing hole cap threads.
Install and tighten the timing hole cap to the specified
torque.
IGNITION COIL
REMOVAL/INSTALLATION
Disconnect the spark plug cap [1].
Disconnect the primary wire connectors [2] from the
ignition coil.
Release the spark plug wire [3] from the guides [4] on
the fan motor shroud.
Remove the bolts [5], spacer s [6] and ignition coil [7].
Installation is in the reverse order of removal. TOOL:
Timing cap wrench 07709-0010001
IDLE SPEED: 1,450 ± 100 min
-1 (rpm)
TORQUE: 6.0 N·m (0.6  kgf·m, 4.4 lbf·ft)
[2]
[1]
[3]
[2]
[1]
[5]/[6]
[7]
[3]
[4] 
						

							6-1
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6. ELECTRIC STARTER SYSTEM
SERVICE INFORMATION ·····························6-2
TROUBLESHOOTING···································6-2
SYSTEM LOCATION·····································6-3
SYSTEM DIAGRAM ······································6-3STARTER MOTOR ······································· 6-4
STARTER RELAY SWITCH ························· 6-8
NEUTRAL DIODE ········································· 6-9 
						

							6-2
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ELECTRIC STARTER SYSTEM
ELECTRIC STARTER SYSTEMSERVICE INFORMATION
GENERAL
 • When servicing the starter system, always follow the steps in the troubleshooting flow chart (page 6-2).
 • A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
TROUBLESHOOTING
Unusual conditionProbable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Loose or poor contact on related connectors and terminals
2. Blown fuse
3. Weak battery
4. Faulty starter relay switch
5. Faulty starter motor
6. Faulty engine stop switch
7. Loose connection, open or short circuit in starter motor  cable
8. Faulty starter switch
9. Open circuit in starter relay switch ground circuit
10.Open or short circuit in star ter relay switch power circuit
11.Loose contact or open circuit in related wires
Starter motor turns only when the 
transmission is in neutral (Starter 
motor does not tu rn when the 
transmission is in any gear with the 
sidestand retracted and clutch lever 
pulled in) 1. Loose or poor contact on related connectors and terminals
2. Faulty clutch switch
3. Faulty sidestand switch
4. Loose contact or open circuit in related wires
Starter motor turns only when the 
transmission is in any gear with the 
sidestand retracted and clutch lever 
pulled in (Starter motor does not turn 
when the transmission is in neutral with 
the sidestand lowered and clutch lever 
released) 1. Loose or poor contact on related connectors and terminals
2. Faulty neutral diode
3. Faulty neutral switch
4. Loose contact or open circuit in related wires
Starter motor turns slo wly1. Low battery voltage
2. Poorly connected battery terminal cable
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery ground cable
Starter motor turns, but engine does 
not turn 1. Starter motor is running backwards
– Case assembled improperly
– Terminals connected improperly
2. Faulty starter clutch
3. Damaged or faulty starter idle gear and/or reduction gear
Starter relay switch Clicks, but 
engine does not turn over 1. Crankshaft does not turn due to engine problems 
						

							6-3
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ELECTRIC STARTER SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
STARTER MOTOR
BATTERY
STARTER RELAY 
SWITCH
IGNITION SWITCH
CLUTCH SWITCH
NEUTRAL SWITCH
MAIN FUSE (30 A)
STARTER SWITCHENGINE STOP SWITCH
FI. IGN FUSE (10 A)
SIDESTAND SWITCH
STARTER 
MOTOR
BATTERY
MAIN FUSE 
(30 A)
IGNITION SWITCH
Bl/RR/W
Bl/G
STARTER 
SWITCH
ENGINE STOP 
SWITCH
FI. IGN 
FUSE (10 A)
CLUTCH 
SWITCH
GG/W
Y/R
Bl/Bu
STARTER 
RELAY 
SWITCH
G/R
NEUTRAL DIODE
Lg/Bl
G/R
NEUTRAL 
SWITCH
Lg/R
To NEUTRAL 
INDICATORBl: Black
Bu: Blue
G: Green
Lg: Light green
R: Red
Y: Yellow
W: White
O: Orange
G/O
SIDESTAND 
SWITCH
G/R 
						

							6-4
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ELECTRIC STARTER SYSTEM
STARTER MOTOR
REMOVAL/INSTALLATION
 • Always turn the ignition switch OFF beforeservicing the starter motor. The motor could
suddenly start, causing serious injury.
Remove the cam chain tensioner lifter (page 11-7).
Remove the bolts [1] and clutch cable guide [2].
Disconnect the clutch cable [3] from the clutch lifter arm
[4].
Release the rubber cap [1].
Remove the starter motor terminal nut [2] and starter
motor cable [3].
Remove the stater motor mounting bolts [4] and ground
terminal [5].
Remove the starter motor [6].
Remove the O-ring [1].
Installation is in the reverse order or removal.
 • Apply engine oil to a new O-ring.
[3]
[4][2]
[1]
[5]
[6][2]/[3][1]
[4]
[1] 
						

							6-5
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ELECTRIC STARTER SYSTEM
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the starter motor as
following illustration.
The coil may be damaged if the magnet pulls the armature against the motor case.
Upon assembly, align the index lines on the covers and
motor case.
ARMATURE
TERMINAL BOLT
BRUSH HOLDER
SPRING
NUT
TERMINAL STOPPER
INSULATOR
REAR COVER
WASHER
O-RING
FRONT COVER
SEAL RING
MOTOR CASE
SEAL RING
4.9 N·m (0.5 kgf·m, 3.6 lbf·ft)
3.7 N·m (0.4 kgf·m, 
2.7 lbf·ft)
POSITIVE BRUSHES
NEGATIVE BRUSH
Align