Honda Crf250l Service Manual

							6-6
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ELECTRIC STARTER SYSTEMINSPECTION
Check the oil seal [1] of the front cover for deterioration
or damage.
Check the bearing [2] and needle bearing [3] for wear or
damage.
Replace the starter motor as an assembly if necessary.
Do not use emeryor sand paper on the commutator.Clean the metallic debris  off between commutator bars
[1].
Check the commutator bars of the armature for
discoloration, wear or damage.
Replace the starter motor as an assembly if necessary.
Check for continuity between pair of commutator bars
[1].
There should be continuity.
Check for continuity between each individual
commutator bar [1] and the armature shaft [2].
There should be no continuity.
[3]
[1]
[2]
[1]
CONTINUITY:[1]
NO CONTINUITY:[1][2] 
						

							6-7
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ELECTRIC STARTER SYSTEM
Check for continuity between the positive brushes [1]
and cable terminal [2].
There should be continuity.
Check for continuity between the positive brushes [1]
and rear cover [2].
There should be no continuity.
Check for continuity between the positive and negative
brushes [3].
There should be no continuity.
Measure the brush length.
Check the bushing [1] of the rear cover for wear or
damage.
Replace the starter motor as an assembly if necessary.CONTINUITY:
[2][1]
NO CONTINUITY:
[1]
[2][3]
SERVICE LIMIT: 6.5 mm (0.26 in)
[1] 
						

							6-8
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ELECTRIC STARTER SYSTEM
STARTER RELAY SWITCH
INSPECTION
Remove the left side cover (page 2-3).
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch  .
Push the starter switch.
The coil is normal if the st arter relay switch [1] clicks.
If you dont hear the star ter relay switch CLICK,
inspect the starter relay switch using a procedure
below.
GROUND LINE
Disconnect the starter relay switch 4P (Red) connector
[1].
Check for continuity between the following terminal of
the wire harness side and ground when the starter
switch is pushed.
If there is continuity under following conditions, the
ground circuit is normal.
– When the transmission is in  neutral (In neutral, there
is a slight resistance due to the diode.)
– When the transmission is in gear with the clutch
lever pulled in and sidestand retracted
STARTER RELAY INPUT VOLTAGE
Connect the starter relay switch 4P (Red) connector [1].
Turn the ignition switch ON and engine stop switch  .
Measure the voltage between the following terminal at
the starter relay switch 4P (Red) connector and ground.
If the battery voltage appears only when the starter
switch is pushed with the ignition switch ON and engine
stop switch  , the starter re lay input voltage is normal.
[1]
CONNECTION: Green/red – Ground
[1]
CONNECTION: Yellow/red (+) – Ground (–)
STANDARD: Battery voltage
[1] 
						

							6-9
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ELECTRIC STARTER SYSTEM
OPERATION CHECK
Remove the starter relay switch (page 6-9).
Connect a fully charged 12 V battery to the starter relay
switch as shown.
There should be continuity between the cable terminals
when the battery is connected, and no continuity when
the battery is disconnected.
REMOVAL/INSTALLATION
Remove the left side cover (page 2-3).
Disconnect the battery negative (-) terminal (page 19-
4).
Disconnect the starter relay switch 4P (Red) connector
[1].
Release the starter relay switch [2] from the air cleaner
housing.
Pull back the rubber cover [3].
Remove the bolts [4] and cables [5].
Remove the starter relay switch from the stays with the
shock rubber.
Remove the starter relay s witch from the shock rubber.
Installation is in the reverse order of removal.
NEUTRAL DIODE
INSPECTION
Remove the left side cover (page 2-3).
Open the fuse box cover and remove the neutral diode
[1].
Check for continuity between the neutral diode
terminals.
When there is continuity, a small resistance value will
register.
If there is continuity, in direction shown by the arrow,
the neutral diode is normal.
[4]/[5][1]
[2]
[3]
[1]
CB
A
A
B
C 
						

							MEMO
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							7-1
7
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7. FUEL SYSTEM
SERVICE INFORMATION ·····························7-2
TROUBLESHOOTING···································7-2
COMPONENT LOCATION ····························7-3
FUEL LINE INSPECTION··················\
············7-4
FUEL TANK ···················································7-8
FUEL PUMP UNIT ·········································7-8 FUEL PUMP RELAY ··································· 7-10
AIR CLEANER HOUSING ·························· 7-10
THROTTLE BODY ······································ 7-11
INJECTOR··················································· 7-14
IACV ···························································· 7-15
SECONDARY AIR SUPPLY SYSTEM ······· 7-17 
						

							7-2
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FUEL SYSTEM
FUEL SYSTEMSERVICE INFORMATION
GENERAL
 • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
 • Do not snap the throttle valve from full open to full close af ter the throttle cable has been removed. It may cause incorrect  idle
operation.
 • Bending or twisting the control cables will impair smooth oper ation and could cause the cables to stick or bind, resulting in loss
of vehicle control.
 • Do not damage the throttle body. It may  cause incorrect throttle valve operation.
 • Seal the intake ports with tape or a clean cloth to keep dirt  and debris from entering the engine after the throttle body has been
removed.
 • Prevent dirt and debris from entering the throttle bore and ai r passages after the throttle body has been removed. Clean them
using a compressed  air if necessary.
 • Do not loosen or tighten the white paint ed nut and screw of the throttle body. Loos ening or tightening them can cause throttle
valve and idle control failure.
 • For fuel level sensor inspection (page 20-15).
 • Before disconnecting the fuel feed hose, relieve fuel pressure  from the system by disconnecting the quick connect fitting from
the system (page 7-4).
TROUBLESHOOTING
Engine won’t start
 • Deteriorated fuel
 • Bent or kinked fuel hose/fuel tank breather hose
 • Clogged fuel filter
 • Faulty fuel pump or its drive circuit
 • Intake air leak
 • Faulty injector
 • Faulty IACV
 • Faulty ignition system
 • Faulty ECM
 • Faulty bank angle sensor or its related circuit
 • Faulty fuel pump relay or its related circuit
 • Faulty engine stop switch or its related circuit
 • Blown FI, IGN fuse (10 A)
Engine stall, hard to start, rough idling
 • Deteriorated fuel
 • Bent or kinked fuel hose/fuel tank breather hose
 • Faulty IACV
 • Intake air leak
 • Faulty ignition system
 • Faulty MAP sensor
 • Faulty charging system
Backfiring or misfiring during acceleration
 • Faulty ignition system
Engine lacks power
 • Bent or kinked fuel hose/fuel tank breather hose
 • Clogged fuel filter
 • Faulty fuel pump or its drive circuit
 • Faulty injector
 • Faulty ignition system
 • Clogged air cleaner element 
						

							7-3
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FUEL SYSTEM
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbf·ft)
27 N·m (2.8 kgf·m, 
20 lbf·ft)
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
3.0 N·m (0.3 kgf·m, 
2.2 lbf·ft)
3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
7.0 N·m (0.7 kgf·m, 
5.2 lbf·ft)
27 N·m (2.8 kgf·m, 20 lbf·ft) 
						

							7-4
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FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING
Before disconnecting fuel feed hose, relieve pressure
from the system as follows.
1. Turn the ignition switch OFF.
2. Disconnect the fuel pump 3P (Black) connector [1].
3. Start the engine, and let it idle until the engine stalls.
4. Turn the ignition switch OFF.
5. Disconnect the battery negative (–) cable (page 19-
4).
QUICK CONNECT FITTING REMOVAL
Do not bend or twist fuel feed hose.
1. Relieve the fuel pressure (page 7-4).
2. Remove the three bolts [1] and lift up the fuel tank [2] from the frame.
3. Check the fuel quick connect fitting [1] for dirt, and clean if necessary.
Place a shop towel [2] over the quick connect fitting.
[1]
[1]
[2][1]
[1]
[2] 
						

							7-5
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FUEL SYSTEM
4. Pull and release the joint rubber [1] from theretainer.
5. Hold the connector with one hand and squeeze the retainer tabs [2] with the other hand to release the
locking pawls [3].
Pull the connector off and remove the retainer.
 • Absorb the remaining fuel in the fuel feed hose fromflowing out with a shop towel.
 • Be careful not to damage the hose or other parts.
 • Do not use tools.
 • If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push
the connector until it comes off easily.
6. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with
the plastic bags [1].
QUICK CONNECT FITTING 
INSTALLATION
 • Always replace the retainer and joint rubber of thequick connect fitting when the fuel feed hose is
disconnected.
 • Replace the retainer and joint rubber with the same manufacturer’s item  that was removed.
 • Do not bent or twist fuel feed hose.
1. Insert a new retainer [1] into the connector [2].
 • Align new retainer locking pawls with the connector grooves.
[3]
[2]
[1]
[1]
Align
[1]
[2]