Honda Crf250l Service Manual

							12-8
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CLUTCH/GEARSHIFT LINKAGE
Install the return spring [1] to the right crankcase cover
by aligning the spring short end with the hole of the
clutch lifter arm and long end with the groove of the
right crankcase cover.
INSTALLATION
Be careful not to
damage the mating surfaces.Clean any gasket material from the mating surfaces of
the right crankcase and cover.
Apply engine oil to new O-rings [1].
Install the collars [2] and O-rings.
Install the dowel pin A [1], dowel pin B [2] and a new
gasket [3].
Be careful not to let
the return spring fall into the crankcase.Install the right crankcase cover [1] while turning the
clutch lifter arm [2] clockwise to engage the lifter arm
spindle groove with the lifter piece flange.
Install and tighten  the bolts [3] in a crisscross pattern in
2 or 3 steps.
[1]Align
Align
/[2][1]
[3]
[2][1]
[1][3]
[2] 
						

							12-9
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CLUTCH/GEARSHIFT LINKAGE
Connect the water hose [1] and tighten the water hose
band screw [2] (page 9-7).
Install the rear brake light switch holder [3] and tighten
the bolt [4].
Connect the clutch cable [1] to the clutch lifter arm [2].
Install the clutch cable guide [3] and bolts [4].
Tighten the bolts securely.
Install the following:
– Brake pedal (page 18-12)
– Frame guard (page 2-6)
– Water pipe (page 9-13)
Adjust the clutch lever freeplay (page 3-18).
Fill the engine with the recommended engine oil (page
3-9).
Fill the recommended coolant and bleed the air (page
9-5).
CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-4).
Loosen the clutch lifter plate bolts [1] in a crisscross
pattern in 2 or 3 steps.
Remove the clutch lifter pl ate bolts and clutch springs
[2].
Remove the clutch lifter plate [3].
Remove the clutch discs [4] and plates [5].
Remove the clutch lifter piece [1], judder spring [2] and
spring seat [3].
[4]
[1]
[2]
[3]
[2][3]
[4]
[1]
[4]/[5]
[3]
[1]/[2]
[1]
[2]/[3] 
						

							12-10
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CLUTCH/GEARSHIFT LINKAGE
Unstake the clutch center lock nut [1].
Hold the clutch center [1 ] with the special tool and
loosen the clutch center lock nut [2].
Remove the clutch center  lock nut and washer [4].
Remove the washer [1] and clutch outer [2].
Remove the needle bearing [1], clutch outer guide [2]
and washer [3] from the mainshaft.
Unstake
[1]
TOOL:
[3] Clutch center holder 07724-0050002
[3][2]/[4]
[1]
[2][1]
[1][3]
[2] 
						

							12-11
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CLUTCH/GEARSHIFT LINKAGE
INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
– Clutch lifter bearing
– Clutch springs
– Clutch center
– Clutch discs/plates
– Clutch outer
– Clutch outer guide/needle bearing
– Mainshaft
Measure each part according to CLUTCH/GEARSHIFT
LINKAGE SPECIFICATIONS (page 1-7).
Replace any part if it is out of service limit.
 • Replace the clutch springs as a set.
 • Replace the clutch discs and plates as a set.
CLUTCH LIFTER BEARING REPLACEMENT
Drive out the old bearing from  the clutch lifter plate [1].
Drive in a new bearing [2] squarely with its marked side
facing up.
After installation, apply engine oil to the bearing.
INSTALLATION
TOOLS:
[3] Driver 07749-0010000
[4] Attachment, 28 x 30 mm 07946-1870100
[5] Pilot, 12 mm 07746-0040200
[3]
[2]
[4]/[5]
[1]
BEARING
CLUTCH SPRING
CLUTCH PLATE A
WASHER
CLUTCH OUTER GUIDE
CLUTCH OUTER
108 N·m (11.0 kgf·m, 80 lbf·ft)
WASHER
NEEDLE BEARING
CLUTCH 
DISC A
12 N·m (1.2 kgf·m, 9 lbf·ft)
CLUTCH LIFTER PLATE
CLUTCH LIFTER PIECE
CLUTCH CENTERWASHER
JUDDER SPRING
SPRING SEAT
LOCK NUT
CLUTCH PLATE 
B (White paint)CLUTCH DISC 
B (Larger I.D.) 
						

							12-12
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CLUTCH/GEARSHIFT LINKAGE
Install the washer [1] to the mainshaft.
Apply molybdenum oil solution to the clutch outer guide
[2] whole surface and install it to the mainshaft.
Apply engine oil to the needle bearing [3] rotating area
and install it to the clutch outer guide.
Install the clutch outer [1] and washer [2].
Apply engine oil to a new clutch center lock nut [1]
threads and seating surface.
Install the clutch center [2 ], washer [3] and lock nut.
Hold the clutch center [1] with the special tool and
tighten the lock nut [2] to the specified torque.[1][3]
[2]
[1][2]
[3]
[2]
[1]
TOOL:
[3] Clutch center holder 07724-0050002
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)
[1]
[3]
[2] 
						

							12-13
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CLUTCH/GEARSHIFT LINKAGE
Be careful not todamage the
mainshaft threads.Stake the lock nut [1] into the mainshaft groove.
Install the clutch lifter piece [1].
Install the spring seat [2] and judder spring [3] in the
direction as shown.
Apply engine oil to the entire surface of clutch discs.
Install the clutch disc B [4] and clutch plate B [5].
 • Clutch disc B: larger I.D.
 • Clutch plate B: white paint on outer circumference
Install the clutch discs A [6]  and plates A [7] alternately,
starting with the clutch disc.
Install the clutch lifter plate [1].
Install the clutch springs [2] and bolts [3].
Tighten the clutch lifter pl ate bolts to the specified
torque in a crisscross pattern in 2 or 3 steps.
Install the right crankcase cover (page 12-8).
[1]
Stake
[1]
[7]
[2]/[3]
[6]
[2]
[3]
OUTSIDE[4] (larger I.D.)[5]
(white paint)
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
[1]
[2]/[3] 
						

							12-14
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CLUTCH/GEARSHIFT LINKAGE
GEARSHIFT LINKAGE
REMOVAL
Remove the following:
– Drive sprocket cover (page 2-6)
– Clutch assembly (page 12-9)
Remove the pinch bolt [1] and gearshift pedal [2].
Clean off any dirt from the gearshift spindle serration.
Pull out the gearshift spindle assembly [1] and washer
[2] from the crankcase.
Remove the gearshift spindle oil seal [1].
Be careful not to letthe removed parts
fall into the
crankcase.Remove the shift drum stopper plate bolt [1].
[1]
[2]
[1][2]
[1]
[1] 
						

							12-15
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CLUTCH/GEARSHIFT LINKAGE
Be careful not to letthe removed parts
fall into the
crankcase.Remove the following:
– Shift drum stopper plate [1]
– Dowel pins [2]
– Shift drum stopper arm bolt [3]
– Shift drum stopper arm [4]
–Washer [5]
– Return spring [6]
INSPECTION
Check the return spring [1] and spindle arm spring [2]
for fatigue or damage replace them if necessary.
Check the gearshift spindle [3] for wear or bend.
Check the spindle arm [4] for wear, damage or
deformation.
Replace the gearshift spindle as an assembly if
necessary.
Inspect the gearshift spindle needle bearing and
replace if necessary.
GEARSHIFT SPINDLE NEEDLE 
BEARING REPLACEMENT
Remove the gearshift spindle needle bearing [1] using
the special tools.
Drive in a new gearshift spindle needle bearing [1] into
the left crankcase with the mark ed side facing up until it
is fully seated using the special tools.
After installation, apply engine oil to the bearing.
[1]
[2]
[4][3]
[5]/[6]
[3]
[2]
[4]
[1]
TOOLS:
[2] Remover weight 07741-0010201
[3] Bearing remover shaft, 15 mm 07936-KC10100
[4] Bearing remover head, 14 mm 07WMC-KFG0100
[3]
[2]
[4][1]
TOOLS:
[2] Driver 07749-0010000
[3] Pilot, 20 mm 07746-0040500
[1][3]
[2] 
						

							12-16
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CLUTCH/GEARSHIFT LINKAGEINSTALLATION
Apply locking agent to the shift drum stopper arm bolt
[1] threads.
Install the return spring [2], washer [3] and stopper arm
[4] while hooking the return spring at the stopper arm
groove.
Install and tighten the bolt to the specified torque.
Check the stopper arm for proper operation.
Move the stopper arm [1] out of the way using a
screwdriver.
Install the dowel pins [2] into the shift drum holes.
Install the shift drum stopper plate [3] while aligning its
pin holes [4] with the dowel pins.
Apply locking agent to the shift drum stopper plate bolt
[1] threads.
Install and tighten the shift  drum stopper plate bolt to
the specified torque.
Apply grease to a new gearshift spindle oil seal lip [1].
Install the gearshift spindle oil seal to the specified
depth as shown. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)[2]
[1]
[3][4]
Hook
[3][2][1]
[4]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[1]
[1]
0.5 – 1.0 mm 
(0.02 – 0.04 in) 
						

							12-17
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CLUTCH/GEARSHIFT LINKAGE
Apply engine oil to the gearshift spindle shaft [1] outer
surface.
Install the gearshift spindle assembly and washer [2] to
the crankcase by aligning the return spring ends with
the spring pin.
Install the gearshift pedal [1] onto the gearshift spindle
while aligning the punch marks.
Install and tighten the pinch bolt [2] securely.
Install the following:
– Clutch assembly (page 12-11)
– Drive sprocket cover (page 2-6)
PRIMARY DRIVE GEAR
REMOVAL
Remove the clutch assembly (page 12-9).
Temporarily install the washer [1], clutch outer guide
[2], needle bearing [3] and clutch outer [4].
Insert the gear holder [5] between the primary drive and
driven gears.
Loosen the primary drive gear lock nut [6].
Remove the clutch outer, needle bearing, clutch outer
guide and washer.
Remove the lock nut and washer [7].
Remove the primary drive gear [1].
[2]
Align[1]
[2]
[1]
Align
TOOL:
Gear holder, M1.507724-0010200
[5]
[1]/[2]/[3]/[4]
[6]/[7]
[1]