Honda Crf250l Service Manual

							11-6
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CYLINDER/PISTON
Install new piston pin clips [1] into the grooves of the
piston pin hole.
 • Always use new piston pin clips. Reinstalling usedpiston pin clips may lead to serious engine damage.
 • Set the piston pin clip in the groove properly.
 • Do not align the clip’s end gap [2] with the piston cut- out [3].
CYLINDER INSTALLATION
Install the dowel pins [1] and a new gasket [2].
Apply engine oil to the cylinder [1] inner surface and
piston [2] sliding surface.
Route the cam chain [3] through the cylinder and install
the cylinder over the piston while compressing the
piston rings with your fingers.
Install the following:
– Cylinder head (page 10-17)
– Water pipe (page 9-13)
[1]
[3]
[2]
[2][1]
Be careful not to
damage the piston rings and cylinder
wall.
[1]
[2][3] 
						

							11-7
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CYLINDER/PISTON
CAM CHAIN TENSIONER
REMOVAL/INSTALLATION
Remove the cam chain tensioner lifter plug [1] and O-
ring [2].
Turn the cam chain tensioner lifter shaft fully in
(clockwise) and secure it using the special tool.
Remove the cam chain tensioner lifter mounting bolts
[4].
Remove the cam chain tensioner lifter [5] and gasket
[6].
Install a new gasket [1] on the cam chain tensioner lifter
[2] and install them to the cylinder.
Install and tighten the cam chain tensioner lifter
mounting bolts [1].
Remove the tensioner stopper [2] from the cam chain
tensioner lifter.
Apply engine oil to a new O-ring [3] and install it to the
cam chain tensioner lifter.
Install and tighten the cam chain tensioner lifter plug [4]
to the specified torque.
INSPECTION
Check the cam chain tensioner lifter [1] operation:
– The cam chain tensioner lifter shaft should not go
into the cam chain tensioner lifter body when it is
pushed.
– When it is turned clockwise with a tensioner stopper or a screwdriver [2], the cam chain tensioner lifter
shaft should be pulled into the cam chain tensioner
lifter body. The cam chai n tensioner lifter shaft
should spring out of the cam chain tensioner lifter
body as soon as the stopper tool is released.
TOOL:
[3] Tensioner stopper 070MG-0010100
[4][3]
[1]/[2][5][6]
[1]
[2]
TORQUE: 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
[2][4]
[3]
[1]
[1]
[2] 
						

							MEMO
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							12-1
12
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12. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION ···························12-2
TROUBLESHOOTING·································12-2
COMPONENT LOCATION ··························12-3
RIGHT CRANKCASE COVER ··················\
··12-4CLUTCH ······················································ 12-9
GEARSHIFT LINKAGE ····························· 12-14
PRIMARY DRIVE GEAR ··························· 12-17 
						

							12-2
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CLUTCH/GEARSHIFT LINKAGE
CLUTCH/GEARSHIFT LINKAGESERVICE INFORMATION
GENERAL
 • This section covers service of the clutch and gearshift linkage. All services can be done with the engine installed in the frame.
 • Engine oil viscosity and level have an effe ct on clutch disengagement. Oil additives also effect clutch performance and are not
recommended. When the clutch does not disengage or the motorcycle creeps with the clutch lever pulled in, inspect the engine
oil level before servic ing the clutch system.
TROUBLESHOOTING
Faulty clutch operation can usually be  corrected by adjusting the freeplay.
Clutch lever too hard to pull in
 • Damaged, kinked or dirty clutch cable
 • Improperly routed clutch cable
 • Damaged clutch lifter mechanism
 • Faulty clutch lifter plate bearing
Clutch will not disengage or moto rcycle creeps with clutch disengaged
 • Excessive clutch lever freeplay
 • Clutch plate warped
 • Engine oil level too high, improper oil viscosity or additive used
 • Loose clutch center lock nut
Clutch slips
 • Clutch lifter sticking
 • Worn clutch discs
 • Weak clutch springs
 • No clutch lever freeplay
 • Engine oil level too low or oil additive used
Hard to shift
 • Misadjusted clutch cable
 • Damaged or bent shift fork
 • Bent shift fork shaft
 • Incorrect engine oil viscosity
 • Bent or damaged gearshift spindle
 • Damaged shift drum stopper plate
 • Damaged shift drum guide grooves (page 14-11)
Transmission jumps out of gear
 • Worn shift drum stopper arm
 • Worn or broken gearshift spindle return spring
 • Bent shift fork shaft
 • Worn or damaged shift drum stopper plate
 • Damaged shift drum guide grooves (page 14-11)
 • Worn gear dogs or dog holes (page 14-11)
Gearshift pedal will not return
 • Weak or broken gearshift spindle return spring
 • Bent gearshift spindle 
						

							12-3
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CLUTCH/GEARSHIFT LINKAGE
COMPONENT LOCATION
108 N·m (11.0 kgf·m, 80 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
108 N·m (11.0 kgf·m, 80 lbf·ft) 
						

							12-4
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CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 9-5).
Remove the following:
– Water pipe (page 9-13)
– Frame guard (page 2-6)
– Brake pedal (page 18-12)
Remove the bolts [1] and clutch cable guide [2], then
disconnect the clutch cable [3] from the clutch lifter arm
[4].
Loosen the water hose band screw [1] and disconnect
the water hose [2].
Remove the bolt [3] and rear brake light switch holder
[4].
Loosen the right crankcase cover bolts [1] in a
crisscross pattern in 2 or 3  steps and remove the bolts.
Remove the right crankcase cover [2] while turning the
clutch lifter arm [3] counter clockwise to disengage the
lifter arm spindle from the lifter piece.
Remove the dowel pin A [1], dowel pin B [2] and gasket
[3].[4][2]
[1]
[3]
[3]
[2]
[1]
[4]
Be careful not to let
the return spring fall into the crankcase.
[2][1]
[3]
[3]
[2][1] 
						

							12-5
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CLUTCH/GEARSHIFT LINKAGE
Remove the collars [1] and O-rings [2].
DISASSEMBLY
Remove the return spring [1] from the right crankcase
cover.
Remove the clutch lifter arm [1] from the right
crankcase cover.
INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
–Oil seal
– Clutch lifter arm needle bearing
– Clutch lifter arm
– Return spring
– Crankshaft bearing
[1]/[2]
[1]
[1] 
						

							12-6
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CLUTCH/GEARSHIFT LINKAGEBEARING REPLACEMENT
CRANKSHAFT BEARING
Remove the crankshaft bearing [1] using the special
tools.
Drive in a new crankshaft bearing [1] into the right
crankcase cover with the ma rked side facing up until it
is fully seated using the special tools.
After installation, apply engine oil to the bearing.
CLUTCH LIFTER ARM NEEDLE BEARING
Remove the oil seal [1] from  the right crankcase cover.
Remove the clutch lifter arm needle bearings [2] using
the special tools. TOOLS:
[2] Remover weight 07741-0010201
[3] Bearing remover set, 12 mm 07936-1660101
[1]
[2][3]
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 28 x 30 mm 07946-1870100
[4] Pilot, 12 mm 07746-0040200
[2]
[3]/[4]
[1]
TOOLS:
[3] Bearing remover set, 12 mm 07936-1660101
[4] Remover weight 07741-0010201
[2][3]
[4]
[1][2] 
						

							12-7
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CLUTCH/GEARSHIFT LINKAGE
Install the bearing remover head [1] to the pilot collar [2]
as shown.
Drive in a new clutch lifter arm needle bearings [1] until
the specified depth, using the special tools as shown.
After installation, apply engine oil to the bearing.
Install a new oil seal [1] to the right crankcase cover as
shown.
ASSEMBLY
Apply grease to the clutch lifter arm oil seal lips [1].
Apply molybdenum oil solution to the clutch lifter arm [2]
sliding surface.
Install the clutch lifter arm to the right crankcase cover.
TOOLS:
[1] Bearing remover head, 10 mm 07746-0050200
[2] Pilot collar, 16 mm 07PAF-0010620
[2]
[1]
TOOLS:
[2] Bearing remover head, 10 mm 07746-0050200
[3] Pilot collar, 16 mm 07PAF-0010620
[1]
[3][2]
6.5 – 7.5 mm 
(0.26 – 0.30 in)
49.0 – 
50.0 mm 
(1.93 – 
1.97 in)
0.5 – 1.0 mm 
(0.02 – 0.04 in)
[1]
[1][2]