Honda Crf250l Service Manual

							15-8
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ENGINE REMOVAL/INSTALLATION
Install the rear brake light switch holder [1] while
aligning its tab with the frame hole.
Install and tighten the bolt [2].
Connect the water hoses [1] and tighten the water hose
band screws [2] (page 9-7).
Connect the crankcase breather hose [1].
Route the VS sensor wire through the guide [2]
Install and tighten the starte r motor terminal nut [3] with
starter motor cable terminal [4].
Install the rubber cap [5].
Install and tighten the starter motor mounting bolt [6]
with ground terminal [7].
Connect the clutch cable [1] to the clutch lifter arm [2].
Install clutch cable guide [3] and tighten the bolts [4].[1]
[2]Align
[2][2]
[1][1]
[1]
[6]/[7]
[5]
[2]
[3]/[4]
[3][2]
[4]
[1] 
						

							15-9
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ENGINE REMOVAL/INSTALLATION
Close the harness band [1] and secure the wires.
Connect the VS sensor 3P (Blue) connector [2].
Connect the following:
– Alternator 3P connector [1]
– CKP sensor/neutral switch 3P (Black) connector [2]
Secure the alternator wir e [3] with the clamp [4].
Connect the O
2 sensor cap [1].
 • Take care not to tilt the O2 sensor cap when
connecting the cap to the O
2 sensor.
 • Do not turn the O
2 sensor cap after connecting it.
Connect the ECT sensor 3P connector [2].
Connect the following:
– Spark plug cap [1]
– PAIR air supply hose [2]
Install the following:
– Brake pedal (page 18-12)
– Gearshift pedal (page 12-17)
– Exhaust pipe/muffler (page 2-11)
– Throttle body (page 7-13)
– Skid plate (page 2-5)
– Frame guard (page 2-6)
Inspect the following:
– Drive chain slack (page 3-12)
– Throttle grip freeplay (page 3-3)
– 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).
[1][2]
[3][1]
[2][4]
[1]
[2]
[1]
[2] 
						

							MEMO
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							16-1
16
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16. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION ···························16-2
TROUBLESHOOTING·································16-2
COMPONENT LOCATION ··························16-3
FRONT WHEEL ···········································16-4FORK··························································· 16-6
HANDLEBAR ··················\
··················\
········ 16-16
STEERING STEM ····································· 16-21 
						

							16-2
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FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL/SUSPENSION/STEERINGSERVICE INFORMATION
GENERAL
 • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
 • Raise the front wheel off the ground by  supporting the frame securely when servicing.
 • For hydraulic brake system service (page 18-3).
 • After the front wheel installation, check  the brake operation by applying the brake lever.
TROUBLESHOOTING
Hard steering
 • Steering bearing fork pipe too tight
 • Worn or damaged steering head bearings
 • Worn or damaged steering head bearing races
 • Damaged steering stem
 • Insufficient tire pressure
 • Faulty front tire
Steers to one side or does not track straight
 • Bent fork leg
 • Damaged or loose steering head bearings
 • Worn wheel bearings
 • Bent front axle
 • Wheel installed incorrectly
 • Bent frame
 • Worn swingarm pivot components (page 17-10)
Front wheel wobbles
 • Bent rim
 • Worm or damaged wheel bearings
 • Faulty front tire
 • Low tire pressure
 • Loose or broken spokes
 • Loose front axle fasteners
Wheel turns hard
 • Faulty wheel bearings
 • Bent axle
 • Brake drag (page 18-2)
Soft suspension
 • Weak fork springs
 • Low fluid level in fork
 • Wrong type of fluid in fork
 • Low tire pressure
Stiff suspension
 • Bent fork pipes
 • Fork pipe binds
 • High fluid level in fork
 • Incorrect fluid weight (high viscosity)
 • Clogged fork fluid passage
 • High tire pressure
Front suspension noise
 • Loose fork fasteners
 • Worn slider or fork pipe bushing
 • Low fluid level in fork 
						

							16-3
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FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION
73.5 N·m (7.5 kgf·m, 54 lbf·ft)
20 N·m (2.0 kgf·m, 15 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
10 N·m (1.0 kgf·m, 
7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
103 N·m (10.5 kgf·m, 76 lbf·ft) 
						

							16-4
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FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL
REMOVAL/INSTALLATION
Raise the front wheel off the ground by placing a work
stand or box under the frame.
Loosen the axle pinch bolts [1] on the right fork leg and
remove the front axle [2].
Remove front wheel and side collars [3].
 • Do not operate the brake lever after removing thewheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
Apply thin coat of grease  to the axle outer surface.
Install the side collars to the both sides of the wheel.
Place the wheel between the fork legs while inserting
the brake disc between the brake pads.
Install the front axle from the right side of the vehicle,
then tighten it to the specified torque.
With the front brake applied, pump the forks up and
down several times to seat  the axle and check the
brake operation.
Tighten the axle pinch bolt s to the specified torque.
INSPECTION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing outer  race fits tightly in the hub.
Replace the bearings if they do not turn smoothly,
quietly, or if they fit loosely in the hub.
Inspect the following parts for damage, abnormal wear,
deformation, looseness or bend.
–Front axle
– Spoke
– Wheel rim
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS (page 1-
8).
Replace any part if it is out of service limit. TORQUE: 73.5 N·m (7.5  kgf·m, 54 lbf·ft)
TORQUE:  20 N·m (2.0 kgf·m, 15 lbf·ft)
[2][3]
[1] 
						

							16-5
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FRONT WHEEL/SUSPENSION/STEERING
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front wheel as following illustration.
BEARING REPLACEMENT
Install the remover head [1] into the bearing.
From the opposite side of the wheel, install the remover
shaft [2] and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.
Pack new bearing cavities with grease.
Drive in a new left side (brake disc side) bearing [1]
squarely with the sealed side facing up until it is fully
seated.
Install the distance collar.
Drive in a new right side bearing with the sealed side
facing up until its inner race is fully seated on the
distance collar.
LEFT WHEEL 
BEARING (6202U)
DISTANCE COLLAR
 LEFT DUST SEALBRAKE DISC
20 N·m (2.0 kgf·m, 15 lbf·ft)
BRAKE DISC BOLTS
RIGHT WHEEL 
BEARING (6202U)
 RIGHT DUST SEAL
TOOLS:
[1] Bearing remover head, 15 mm 07746-0050400
[2] Bearing remover shaft 07746-0050100
[2][1]
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 32 x 35 mm 07746-0010100
[4] Pilot, 15 mm 07746-0040300
[2]
[3]/[4]
[1] 
						

							16-6
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FRONT WHEEL/SUSPENSION/STEERINGWHEEL CENTER ADJUSTMENT
Adjust the hub position so th at the distance from the left
end surface [1] of the hub center to the side of rim [2] is
within the following specification as shown.
Tighten the spokes in 2 or 3 progressive steps.
FORK
REMOVAL
Remove the front wheel (page 16-4).
Remove the following from the left fork leg:
– Bolts [1]
– Brake hose clamp [2]
– Brake caliper mounting bolts [3]
– Brake caliper [4]
– Socket bolts [1]
– Fork protectors [2] WHEEL HUB-TO-RIM DISTANCE: 
23.45 ± 1.0 mm (0.92 ± 0.04 in)
WHEEL RIM RUNOUT: Radial: 2.0 mm (0.08 in) or less
Axial: 2.0 mm (0.08 in) or less
TOOL:
Spoke wrench, 5.8 x 6.1 mm 07701-0020300
TORQUE:  3.7 N·m (0.4  kgf·m, 2.7 lbf·ft)
[2]
[1]
[2]
[3]
[1]
[4]
Left side only:
[2]
[1] 
						

							16-7
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FRONT WHEEL/SUSPENSION/STEERING
Left side:Remove the bolt [1] and brake hose guide [2].
Loosen the fork top bridge pinch bolts [3].
If you will disassemble the fo rk, loosen the fork cap [4],
but do not remove it.
Loosen the fork bottom pinch bolts [1] while supporting
the fork leg.
Pull the fork leg down and remove it out of the fork
bridges.
INSTALLATION
Install the outer tube into  the bottom and top bridges.
Align the top of the outer tube with the upper surface of
the top bridge.
Tighten the bottom bridge pinch bolts [1] to the
specified torque.
Tighten the fork cap [2] to the specified torque if it was
removed.
Tighten the top bridge pinch bolts [3] to the specified
torque.
Install the brake hose guide [4] and tighten the bolt [5]
to the specified torque.
[2][3]
[1][4]
[1]
TORQUE:  32 N·m (3.3 kgf·m, 24 lbf·ft)
TORQUE:  35 N·m (3.6 kgf·m, 26 lbf·ft)
TORQUE:  32 N·m (3.3 kgf·m, 24 lbf·ft)
Left side:
TORQUE:  10 N·m (1.0 kgf·m, 7 lbf·ft)
[4][3]
[5][2]
[1]
Align