Honda Crf250l Service Manual

							14-20
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the balancer driven gear assembly while aligning
the woodruff key on the balancer shaft with balancer
driven gear keyway.
Apply engine oil to the balancer shaft nut [1] threads
and seating surface.
Install the washer [2] and balancer shaft nut.
Apply engine oil to the balancer drive gear [3] teeth and
install it while aligning its wide groove with the punch
mark on the crankshaft.
Install the balancer drive gear with its OUT mark [4]
facing out.
Align the punch marks of the balancer drive gear and
balancer driven gear.
Insert the gear holder [1] between the balancer drive
gear [2] and balancer driven gear [3].
Tighten the balancer shaft nut [4] to the specified
torque.
Remove a 3 mm (0.12 in) O.D. pin [5] from the balancer
driven gear assembly.
Align
[1]/[2]
Align
[3]
[4]
Align
TOOL:
[1] Gear holder, M2.5 07724-0010100
TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)
[3]
[2][1]
[5][4] 
						

							14-21
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CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
Install the timing sprocket while aligning its wide groove
with the punch mark on the crankshaft.
Apply engine oil to the cam chain [1] whole surface.
Install the cam chain through the crankcase.
Install the cam chain over the timing sprocket [2].
Apply locking agent to the cam chain tensioner pivot
bolt [3] threads (page 1-12).
Install the cam chain tensioner [4], collar [5] and cam
chain tensioner pivot bolt.
Tighten the cam chain tensioner pivot bolt to the
specified torque.
Install the removed parts (page 14-2) in the reverse
order of removal.Align
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[4][3]/[5]
[2][1] 
						

							MEMO
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							15-1
15
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15. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION ···························15-2
COMPONENT LOCATION ··························15-3ENGINE REMOVAL ···································· 15-4
ENGINE INSTALLATION ···························· 15-7 
						

							15-2
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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATIONSERVICE INFORMATION
GENERAL
 • When removing/installing the engine, tape the fr ame around the engine beforehand for frame protection.
 • When installing the engine, be sure to tighten the engine moun ting fasteners to the specified torque in the specified sequence. If
you make mistake in torque or sequence, loosen all mounting fa steners, then tighten them again to the specified torque in the
correct sequence.
 • The following components can be servic ed with the engine installed in the frame.
– Oil pump (page 8-4)
– Throttle body (page 7-11)
– Camshaft (page 10-6)
– Water pump (page 9-8)
– Clutch (page 12-9)
– Gearshift linkage (page 12-14)
– Stator/CKP sensor (page 13-4)
– Flywheel (page 13-5)
– Starter motor (page 6-4)
 • The following components require engine removal for service. – Cylinder head/valves (page 10-13)
– Cylinder/piston (page 11-3)
– Crankshaft (page 14-6)
– Transmission (page 14-10)
– Balancer (page 14-14) 
						

							15-3
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ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbf·ft)
55 N·m (5.6 kgf·m, 41 lbf·ft)
55 N·m (5.6 kgf·m, 41 lbf·ft)
45 N·m (4.6 kgf·m, 33 lbf·ft)
27 N·m (2.8 kgf·m, 
20 lbf·ft)
45 N·m (4.6 kgf·m, 33 lbf·ft) 
						

							15-4
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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-9).
Drain the coolant (page 9-5).
Remove the following:
– Frame guard (page 2-6)
– Skid plate (page 2-5)
– Throttle body (page 7-11)
– Exhaust pipe/muffler (page 2-11)
– Gearshift pedal (page 12-14)
– Brake pedal (page 18-12)
Disconnect the following:
– Spark plug cap [1]
– PAIR air supply hose [2]
Disconnect the O
2 sensor cap [1] and ECT sensor 3P
connector [2].
Disconnect the following:
– Alternator 3P connector [1]
– CKP sensor/neutral switch 3P (Black) connector [2]
Release the alternator wire [3] from the clamp [4].
Open the harness band [1] and release the wires.
Disconnect the VS sensor 3P (Blue) connector [2].
[1]
[2]
[1]
[2]
[3][1]
[2][4]
[1][2] 
						

							15-5
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ENGINE REMOVAL/INSTALLATION
Remove the bolts [1] and cl utch cable guide [2], then
disconnect the clutch cable [3 ] from the clutch lifter arm
[4].
Remove the starter motor mounting bolt [1] and ground
terminal [2].
Release the rubber cap [3].
Remove the starter motor terminal nut [4] and starter
motor cable terminal [5].
Disconnect the crankcase breather hose [6].
Release the VS sensor wire from the guide [7]
Loosen the water hose band screws [1] and disconnect
the water hoses [2].
Remove the bolt [1] and rear  brake light switch holder
[2].
[2][4]
[1]
[3]
[6]
[1]/[2]
[3]
[7]
[4]/[5]
[1][1]
[2][2]
[2]
[1] 
						

							15-6
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ENGINE REMOVAL/INSTALLATION
Loosen the rear axle nut [1], lock nuts [2] and drive
chain adjusters [3].
Push the rear wheel forward and make the drive chain
slack fully.
Remove the bolts [1], fixing plate [2] and drive sprocket
[3].
Remove the rear engine hanger upper mounting nut [1]
and bolt [2].
Remove the bolts [3] and engine hanger plate [4].
The jack height
must be continually adjusted to relievestress for ease of
bolt removal.Support the engine using a jack or other adjustable
support to ease of engine hanger bolts removal.
Remove the following:
– Front upper engine mounting nut [1]/washer [2]/twocollars [3]/bolt [4]
– Front lower engine mounting nut [5]/washer/collar/
bolt [6]
– Rear lower engine mounting nut [7]/bolt [8]
From the right side of the vehicle, slightly lift up the
engine and turn its lower rear  side out of the frame, then
remove the engine from the frame.
[1]
[2]
[3]
[1][2]
[3]
[1]/[2] 
[3]
[4]
During engine
removal, hold the
engine securely and
be careful not to
damage the frame and engine.
[1]/[2]/[3]/[4]
[5]/[2]/[3]/[6][7]/[8] 
						

							15-7
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ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
During engine
installation, hold the
engine securely
and be careful not to damage the
frame and engine.Place the engine in the frame, then loosely install all the
bolts [1], collars [2], washers [3] and nuts.
Tighten the rear lower engine mounting nut [4] to the
specified torque.
Tighten the front lower engine mounting nut [5] to the
specified torque.
Tighten the front upper engine mounting nut [6] to the
specified torque.
With the engine hanger plate [1] in position, tighten the
engine hanger plate bolts [2] to the specified torque.
Tighten the rear engine hang er upper mounting nut [3]
to the specified torque.
Install the drive chain [1] over the drive sprocket [2] with
the 14T mark [3] of the sprocket facing out.
Install the drive sprocket to the countershaft.
Install the fixing plate [4].
Rotate the fixing plate and align the holes in the plate
with the bolt holes in the sprocket.
Install and tighten the drive sprocket fixing plate bolts
[5] to the specified torque. TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft)
TORQUE: 55 N·m (5.6 kgf·m, 41 lbf·ft)
TORQUE: 55 N·m (5.6 kgf·m, 41 lbf·ft)
[1]
[2]
[3]
[6]
[5]
[6]
[5][4]
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
TORQUE: 45 N·m (4.6 kgf·m, 33 lbf·ft)
[3] 
[2]
[1]
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[4]
[2][1]
[3][5]