Honda Crf250l Service Manual

							16-8
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FRONT WHEEL/SUSPENSION/STEERING
Install the fork protectors [1].
Install and tighten the new socket bolts [2] to the
specified torque.
Install the brake hose clamp [1] to the left fork leg and
tighten the bolts [2] to the specified torque.
Install the brake caliper [3 ] with new mounting bolts [4]
and tighten them to  the specified torque.
Install the front wheel (page 16-4).
Inspect the wear rings [1] for wear or damage.
Replace the wear ring, if it is 1.5 mm (0.06 in) or flat
with the outer tube.
DISASSEMBLY
 • Clean the fork assembly, the sliding surface of the fork pipe and bottom of the slider around the center
bolt before disassembling the fork.
Left side:Hold the fork pipe in a vise with soft jaws or shop
towels.
Loosen the fork center bolt [1], but do not remove it yet. TORQUE:  7.0 N·m (0.7  kgf·m, 5.2 lbf·ft)
[1]
[2]
TORQUE:  10 N·m (1.0 kgf·m, 7 lbf·ft)
TORQUE:  30 N·m (3.1 kgf·m, 22 lbf·ft)
[1]
[4]
[2]
[3]
Left side only:
[1]
[1]
Left side only: 
						

							16-9
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FRONT WHEEL/SUSPENSION/STEERING
Right side fork cap
bolt is under spring
pressure; use care when loosening it.Completely loosen the fork cap bolt [1] and lower the
outer tube [2].
Pour out the fork fluid by pumping the fork pipe up and
down several times.
Right side:Push the fork cap [1] down and compress the fork
spring, then remove the stopper ring [2] from the groove
in the fork pipe.
Remove the fork rod assembly [3].
Right side:Loosen the lock nut [1] while holding the fork cap [2]
with a wrench, then remove the fork cap.
Remove the O-ring [3] from the fork cap groove.
Remove the spring seat [4] and rebound spring [5].
[2]
[1]
[2]
[1]
[3]
Right side only:
[2]
[3]
[1]
[5]
[4]
Right side only: 
						

							16-10
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FRONT WHEEL/SUSPENSION/STEERING
Right side:Remove the fork spring [1].
Left side:Loosen the lock nut [1] while holding the fork cap [2]
with a wrench, then remove the fork cap.
Remove the O-ring [3] from the fork cap groove.
Left side:Remove the following:
– Fork center bolt [1]
– Sealing washer [2]
Left side:– Inner damper [1]
[1]Right side only:
[2]
[3]
[1]
Left side only:
[2]
[1]
Left side only:
[1]
Left side only: 
						

							16-11
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FRONT WHEEL/SUSPENSION/STEERING
Be careful not toscratch the fork
pipe sliding surface.– Dust seal [1]
– Stopper ring [2]
Check that the fork pipe [3] moves smoothly in the outer
tube [4].
If the movement is not smooth, check the fork pipe for
bend or bushing for wear or damage.
If they are normal, inspect the outer tube.
Using quick successive moti ons, pull the fork pipe [1]
out of the outer tube [2].
The guide bushing will be forced out by the fork pipe
bushing.
Do not damage the
slider bushing,
especially the
sliding surface. To prevent loss of
tension, do not
open the slider
bushing more than
necessary.Carefully remove the slider bushing [1] by prying the
slot with a screwdriver until the slider bushing can be
pulled off by hand.
Remove the following:
– Guide bushing [2]
– Back-up ring [3]
– Oil seal [4]
– Stopper ring [5]
– Dust seal [6]
INSPECTION
Inspect the following parts for damage, abnormal wear,
bend, deformation, scoring and teflon coating wear
– Fork pipes
– Outer tubes
– Fork spring
– Slider bushings
– Guide bushings
– Back-up rings
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS (page 1-
8).
Replace any part if it is out of service limit.
[2]
[3][1]
[4]
[2]
[1]
[2][3][1]
[5]
[4]
[6] 
						

							16-12
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FRONT WHEEL/SUSPENSION/STEERINGASSEMBLY
Before assembly, wash all parts with a high flash point
or non-flammable solvent and wipe them off completely.
RIGHT SIDE
LEFT SIDE
35 N·m (3.6 kgf·m, 26 lbf·ft)20 N·m (2.0 kgf·m, 15 lbf·ft)
FORK SPRING
OIL SEAL
WEAR RING
OUTER TUBE
STOPPER RING
FORK CAP
BACK-UP RING
SLIDER BUSHING
GUIDE BUSHING
DUST SEAL
O-RING
FORK PIPESTOPPER RING
SPRING SEAT
REBOUND SPRING
LOCK NUT
FORK ROD
35 N·m (3.6 kgf·m, 26 lbf·ft)20 N·m (2.0 kgf·m, 15 lbf·ft)
20 N·m (2.0 kgf·m, 15 lbf·ft)
SEALING WASHER
FORK CENTER BOLT
OIL SEAL
WEAR RING
OUTER TUBE
STOPPER RING
FORK CAP
BACK-UP RING
SLIDER BUSHING
GUIDE BUSHING
DUST SEAL
O-RING
FORK PIPE
LOCK NUT
INNER DAMPER 
						

							16-13
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FRONT WHEEL/SUSPENSION/STEERING
Wrap the end of the fork pipe with tape [1].
Coat new fork oil seal [2] and dust seal [3] lips with
recommended fork oil.
Install the dust seal and stopper ring [4] onto the fork
pipe.
Install the oil seal onto the fork pipe with its marked side
facing the dust seal.
Remove the tape from the end of the fork pipe.
Install the back-up ring [1], guide bushing [2] and slider
bushing [3].
 • Be careful not to damage the slider bushing coating.Do not open the slider bushing more than
necessary.
 • Install the back-up ring with its flange side facing toward the guide bushing.
 • Remove the burrs from the bushing mating surface, being careful not to peel off the coating.
Coat the guide bushing and slider bushing with
recommended fork oil, and install the fork pipe [1] into
the outer tube [2].
Drive in the oil seal [1] into the outer tube using the
special tool.
[2]
[3]
[1][4]
[2]
[3]
[1]
[2]
[1]
TOOL:
[2] Fork seal driver, 43.2 mm 07YMD-MCF0100
[2]
[1] 
						

							16-14
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FRONT WHEEL/SUSPENSION/STEERING
Install the stopper ring [1] into the groove in the outer
tube [2], being careful not to scratch the fork pipe [3].
Install the dust seal [4] into the outer tube.
Left side:Install the inner damper [1] into the fork pipe.
Left side:Apply looking agent to the fork center bolt [1] threads
and install it with a new sealing washer [2]. 
Left side:Hold the left fork pipe in a vise with soft jaws or shop
towels.
Tighten the fork center bolt  [1] to the specified torque.
[1]
[3][4]
[2]
[1]
Left side only:
[2]
[1]
Left side only:
TORQUE:  20 N·m (2.0 kgf·m, 15 lbf·ft)
[1]
Left side only: 
						

							16-15
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FRONT WHEEL/SUSPENSION/STEERING
Pour the specified amount of recommended fork fluid
into the fork pipe.
Slowly pump the fork pipe several times to remove the
trapped air from the lower portion of the fork pipe.
Compress the fork pipe fully and leave it for 5 minutes
to remove air bubbles from the fluid.
Measure the oil level from the top of the fork pipe by
supporting the fork leg vertically.
Right side:Install the fork spring [1] with the tapered side facing up.
Right side:Loosen the lock nut [1] until it stops.
Install the rebound spring [2] to the fork rod.
Install the spring seat [3] in the shown direction.
Apply recommended fork oil to a new O-ring [4], and
install it to the fork cap [5].
Install the fork cap to the fo rk rod and tighten it until it
stops.
Hold the fork cap with a wrench, then tighten the lock
nut to the specified torque. RECOMMENDED FORK FLUID:
Honda ULTRA CUSHION OIL (10W) or equivalent
FORK FLUID CAPACITY:
Right side:
658 ± 2.5 cm
3 (22.3 ± 0.08 US oz, 23.2 ± 0.09 Imp oz)
Left side:
683 ± 2.5 cm
3 (23.1 ± 0.08 US oz, 24.0 ± 0.09 Imp oz)
FORK OIL LEVEL:  Right side: 122 mm (4.8 in)
Left side: 38 mm (1.5 in)
[1]Right side only:
TORQUE:  20 N·m (2.0 kgf·m, 15 lbf·ft)
[2]
[3]
[1]
[5][4]
[1]
[3]Right side only:
UP 
						

							16-16
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FRONT WHEEL/SUSPENSION/STEERING
Right side:Push the fork cap [1] down and compress the fork
spring, then install the stopper ring [2] into the groove in
the fork pipe.
Left side:Loosen the lock nut [1] until it stops.
Apply recommended fork oil to a new O-ring [2], and
install it to the fork cap [3].
Install the fork cap to the inner damper and tighten it
until it stops.
Hold the fork cap with a wrench, then tighten the lock
nut to the specified torque.
Completely extend the outer tube [1].
Install and tighten the fork cap [2] into the outer tube.
Tighten the fork cap to the specified torque after
installing the fork leg into the steering stem (page 16-7).
HANDLEBAR
REMOVAL
Remove the following:
– Wire bands [1]
– Rearview mirrors [2]
[2]
[1]
Right side only:
TORQUE:  20 N·m (2.0 kgf·m, 15 lbf·ft)
[2]
[1]
[1]
[3]Left side only:
[1]
[2]
[2]
[1] 
						

							16-17
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FRONT WHEEL/SUSPENSION/STEERING
– Bolts [1]
– Bracket holder [2]
– Clutch lever bracket [3]
– Clutch switch connectors [4]
– Screws [1]
– Left handlebar switch housing [2]
– Left handlebar grip [1]
Keep the reservoirupright to prevent air from entering the hydraulic
system.– Brake light switch connectors [1]
– Bolts [2]
– Master cylinder holder [3]
– Brake master cylinder [4]
[2]
[3]
[1]
[4]
[2][1]
[1]
[2]
[3]
[1]
[4]