Honda Crf250l Service Manual

							7-6
dummyhead
dummyhead
FUEL SYSTEM
2. Set a new joint rubber [1] to the joint [2] as shown.Press the quick connect fitting [3] onto the pipe until
both retainer pawls lock with a CLICK.
 • Align the quick connect fitting with the joint.
 • If it is hard to connect, put a small amount of engineoil on the joint end.
3. Make sure the connection is secure and that the pawls [1] are firmly locked into place; check visually
and by pulling the connector.
4. Make sure the joint rubber [2] is positioned between the retainer [3] and joint flange [4] as shown.
5. Reposition the fuel tank [1] and tighten the three bolts [2].
FUEL PRESSURE NORMALIZATION
1. Connect the fuel pump 3P (Black) connector [1].
Connect the battery negative (–) cable (page 19-4).
2. Turn the ignition switch ON and engine stop switch .
 • Do not start the engine.
The fuel pump will run for about 2 seconds, and fuel
pressure will rise.
Repeat 2 or 3 times, and  check that there is no
leakage in the fuel supply system.
Turn the ignition switch OFF.
[2]
[1]
[1]
[3]
[1]
[2]
[4][3]
[2]
[1][2]
[1] 
						

							7-7
dummyhead
dummyhead
FUEL SYSTEM
FUEL PRESSURE TEST
Relieve the fuel pressure and disconnect the quick
connect fitting (page 7-4).
Attach the special tools as follows:
Temporarily connect the battery negative (–) cable and
fuel pump 3P (Black) connector.
Start the engine and let it idle.
Read the fuel pressure.
If the fuel pressure is higher  than specified, replace the
fuel pump assembly.
If the fuel pressure is lower than specified, inspect the
following:
– Fuel line leaking
– Pinched or clogged fuel  feed hose or fuel tank
breather hose
– Fuel pump unit (page 7-8)
– Clogged fuel filter
After inspection, relieve the fuel pressure (page 7-4).
Remove the fuel pressure gauge, attachment and
manifold from the fuel pump.
Connect the quick connect fitting (page 7-5).
FUEL FLOW INSPECTION
Relieve the fuel pressure and disconnect the quick
connect fitting (page 7-4).
Connect the special tool to the fuel pump joint.
Place the end of the hose into an approved gasoline
container.
Temporarily connect the battery negative (–) cable and
fuel pump 3P (Black) connector.
Turn the ignition switch ON and engine stop switch  .
Measure the amount of fuel flow.
 • The fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time.
 • Return fuel to the fuel tank when the first fuel is
flowed.
If fuel flow is less than specified, inspect the following:
– Fuel pump unit (page 7-8)
– Clogged fuel filter
Connect the quick connect fitting (page 7-5). TOOLS:
[1] Fuel pressure gauge 07406-0040004
[2] Pressure gauge ma nifold 07ZAJ-S5A0111
[3] Hose attachment, 9 mm/9 mm 07ZAJ-S5A0120
[4] Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100
[5] Attachment joint, 8 mm/9 mm 07ZAJ-S7C0200
STANDARD: 343 kPa (3.5 kgf/cm
2, 50 psi)
[1]
[2]
[4]
[3]
[5]
Wipe off spilled out
gasoline.
TOOL:
[1] Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100
Amount of fuel flow:83 cm
3 (2.81 US oz, 2.92 Imp oz) minimum/
10 seconds at 12 V
[1] 
						

							7-8
dummyhead
dummyhead
FUEL SYSTEM
FUEL TANK
REMOVAL/INSTALLATION
Relieve the fuel pressure and disconnect the quick
connect fitting (page 7-4).
Lift up the fuel tank [1] and release the fuel feed hose
[2] from the hose clamps [3].
Disconnect the fuel tank breather hose [4] and remove
the fuel tank.
Install the fuel tank in t he reverse order of removal.
Connect the quick connect fitting (page 7-5).
FUEL PUMP UNIT
SYSTEM INSPECTION
Turn the ignition switch ON and engine stop switch  
and confirm that the fuel  pump operates for 2 seconds.
If the fuel pump does not operate, inspect as follows:
Turn the ignition switch OFF.
Disconnect the fuel pump 3P (Black) connector [1].
Turn the ignition switch ON and engine stop switch  .
Measure the voltage at the fuel pump 3P (Black)
connector terminals of the wire side.
There should be standard voltage for a few seconds.
If there is standard voltage, replace the fuel pump unit.
If there is no standard vo ltage, inspect the following:
– Main fuse (30 A)
– FI, IGN fuse (10 A)
– Ignition switch (page 20-11)
– Engine stop switch (page 20-11)
– Fuel pump relay (page 7-10)
– Open circuit in Brown/red or Green wire
[1]
[3]
[4]
[2][3]
CONNECTION: Brown/re d (+) – Green (–)
STANDARD: Battery voltage
[1] 
						

							7-9
dummyhead
dummyhead
FUEL SYSTEM
REMOVAL/INSTALLATION
Do not disassemble the fuel pump.
Remove the fuel tank (page 7-8).
Clean around the fuel pump.
Loosen the fuel pump mounting nuts [1] in a crisscross
pattern in 2 or 3 steps and remove the nuts.
Remove the fuel pump unit [2] from the fuel tank, being
careful not to damage the fu el level sensor float arm.
Remove the packing [1] from the fuel pump unit [2].
Install a new packing onto the fuel pump unit.
 • Always replace the packing with a new one.
 • Be careful not to pinch the dirt and debris between the fuel pump unit and packing.
Install the fuel pump [1] into the fuel tank.
Install and tighten the fuel  pump mounting nuts [2] to
the specified torque in the sequence as shown.
Install the fuel tank (page 7-8).
INSPECTION
Check the fuel pump unit [1] for wear or damage,
replace it if necessary.
[1][2]
[1]
[2]
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[2][1]
5
2
1
3
6
4
[1] 
						

							7-10
dummyhead
dummyhead
FUEL SYSTEM
FUEL PUMP RELAY
INSPECTION
Remove the left side cover (page 2-3).
Remove the dust cover [1]
Remove the fuel pump relay [2].
Connect a ohmmeter to the fuel pump relay [1]
terminals.
Connect a 12 V battery to the fuel pump relay terminals
as shown.
There should be continuity only when 12 V battery is
connected.
If there is no continuity when the 12 V battery is
connected, replace the fuel pump relay.
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the sub-frame (page 2-12).
Remove the bolts [1] and air cleaner housing.
Installation is in the reverse order of removal.
[2]
[1]
[1]
TORQUE:Air cleaner housing mounting bolt:  7.0 N·m (0.7 kgf· m, 5.2 lbf·ft)
[2]
[1] 
						

							7-11
dummyhead
dummyhead
FUEL SYSTEM
THROTTLE BODY
REMOVAL
Remove the fuel tank (page 7-8).
Disconnect the sensor unit 5P connector [1].
Disconnect the IACV 4P (Black) connector [1] and
injector 2P (Gray) connector [2].
Release the wire band [3] from the clamp stay.
Loosen the throttle cable A adjuster lock nut [1] and
adjuster [2] then disconnect the throttle cable A [3] from
the throttle drum and cable stay.
Loosen the throttle cable B nut [4] then disconnect the
throttle cable B [5] from the throttle drum and cable
stay.
Loosen the connecting hose band screw [1] and
insulator band screws [2], then remove the throttle body
assembly [3].
[1]
[1]
[3]
[2]
[1][3][2]
[5]
[4]
[3][1]
[2] 
						

							7-12
dummyhead
dummyhead
FUEL SYSTEMDISASSEMBLY/ASSEMBLY
 • Do not remove the sensor unit unless it is replaced.
 • The throttle body/sensor unit is factory pre-set. Donot disassemble in a way other than shown in this
manual.
 • Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It
may cause incorrect idle operation.
 • Do not damage the throttle body. It may cause incorrect throttle valve operation.
 • Do not loosen or tighten  the white painted nut and
screw [1] of the throttle body. Loosening or
tightening it can cause throttle valve and idle control
failure.
 • Always clean around the throttle body before each sensor removal to prevent dirt and debris from
entering the air passage.
Remove the following
– Sensor unit (page 4-44)
– Injector (page 7-14)
– IACV (page 7-15)
Clean the air passage of the throttle body using
compressed air.
 • Cleaning the air passages and sensor hole with a piece of wire will damage the throttle body.
Check the air passage for clogs.
Disassemble and assemble the throttle body as following illustration.
[1]
3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
SENSOR UNIT
O-RING
THROTTLE BODY
THROTTLE CABLE STAYINJECTOR
INJECTOR JOINT
SETTING PLATE
IACV
O-RING
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
5.1 N·m (0.5 kgf·m, 
3.8 lbf·ft)
3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
CLAMP STAY
SEAL RINGO-RING
CUSHION RING
THROTTLE BODY INSULATOR
3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) 
						

							7-13
dummyhead
dummyhead
FUEL SYSTEM
Install the throttle body insulator [1] to the throttle body
by aligning the tab of the thro ttle body with the groove of
the throttle body insulator.
 • Install the throttle body  insulator with KZZ mark [2]
facing the cylinder head.
 • Align the insulator band hole with the insulator boss.
INSTALLATION
Install the throttle body a ssembly [1] to the cylinder
head by aligning the tab of  the cylinder head with the
groove of the throttle body insulator.
Tighten the insulator band screws [2] to the specified
torque.
After tightening the insulator band screws, check that
the band ends are seated with each other.
Tighten the air cleaner connecting hose band screw [3]
to the specified torque.
Connect the throttle cables [1] to the throttle drum and
throttle cable stay.
Tighten the throttle cable B nut [2] to the specified
torque.
Connect the IACV 4P (Black) connector [1] and injector
2P (Gray) connector [2].
Install the wire band [3] to the clamp stay.
[1]
Align
Align
[2]
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Align
[1][3]
[2]
TORQUE: 3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)
[1]
[1]
[2]
[1]
[3]
[2] 
						

							7-14
dummyhead
dummyhead
FUEL SYSTEM
Connect the sensor unit 5P connector [1].
Install the fuel tank (page 7-8).
Adjust the throttle grip freeplay (page 3-3).
If the sensor unit is removed, perform the TP sensor
reset procedure (page 4-45).
INJECTOR
REMOVAL
Remove the fuel tank (page 7-8).
Disconnect the injector 2P (Gray) connector [1].
Remove the bolts [2] and injector assembly [3] from the
throttle body.
Remove the injector joint [1],  O-ring [2], cushion ring [3]
and seal ring [4] from the injector [5].
Check the removed parts for wear or damage and
replace them if necessary.
INSTALLATION
Apply engine oil to a new O-ring [1] and a new seal ring
[2].
Install a new cushion ring [3] and seal ring to the
injector [4], being careful not to damage them.
Install the O-ring to the injector.
[1]
[1]
[3]
[2]
[4]
[2]
[3]
[5]
[1]
[2]
[1]
[3]
[4] 
						

							7-15
dummyhead
dummyhead
FUEL SYSTEM
Install the injector [1] into the injector joint [2], being
careful not to damage the O-ring.
Align the injector body with the injector joint tab [3] as
shown.
Be careful not to
damage the seal ring.Install the injector assemb ly [1] to the throttle body.
Install and tighten the injector joint mounting bolts [2]
alternately to the specified torque.
Connect the injector 2P (Gray) connector [3] while
aligning its groove with the ta b of the injector joint.
Install the fuel tank (page 7-8).
IACV
REMOVAL
Remove the fuel tank (page 7-8).
Disconnect the IACV 4P (Black) connector [1].
Remove the IACV torx screws [2], set plate [3] and
IACV [4].
Remove the O-ring [5] from the IACV.
INSTALLATION
Turn the slide valve [1] clockwise until lightly seated on
IACV.
[1]
[2][3]
TORQUE: 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft)[3]
[1]
[2]
Align
[1]
[4]
[2]
[3]
[5]
[1]