Honda Crf250l Service Manual

							16-18
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FRONT WHEEL/SUSPENSION/STEERING
– Screws [1]
– Right handlebar switch [2]
– Screws [1]
– Throttle housing cover [2]
– Bolts [1]
– Handlebar upper holders [2]
– Handlebar [3]
Pull out the handlebar [1] from the throttle pipe [2].
Remove the following:
– Throttle cables [3]
– Throttle pipe
– Throttle housing [4] 
[2][1]
[2]
[1]
[2]
[3][1]
[2]
[3]
[1]
[4] 
						

							16-19
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FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Apply grease to the cable rolling area of the throttle pipe
[1] flange.
Connect the throttle cables [2] to the throttle pipe.
Insert the handlebar [3] into the throttle pipe.
Align the punch mark on the
handlebar with the top edge of the
lower holder.Install the handlebar and upper holders [1] with the
punch marks [2] facing forward.
Install the bolts [3], tighten the front bolts first, then
tighten the rear bolts securely.
Install the throttle housing cover [1] by aligning its boss
with the hole of the handlebar.
Install the screws [2], tighte n the upper screw first, then
tighten the lower screw.
Check the throttle grip for smooth operation.
Install the right handlebar switch cover [1] by aligning its
boss with the hole of the handlebar.
[1]
[2]
[3]
Align
[2]
[3]
[1]
Align
[2][1]
Align
[1] 
						

							16-20
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FRONT WHEEL/SUSPENSION/STEERING
Install and tighten the upper screw [1] first, then tighten
the lower screw [2] to the specified torque.
If the left handlebar grip [1] was removed, apply Honda
Bond A or equivalent to the inside surface of the grip
and to the clean surface of the handlebar.
Wait 3 – 5 minutes and install the grip. Rotate the grip
for even application of the adhesive.
Position the handlebar grip so that the projection [2] of
the grip is aligned with  the punch mark [3] of the
handlebar.
Install the left handlebar switch cover [1] by aligning its
boss with the hole of the handlebar.
Install and tighten the upper  screw [1] first, then tighten
the lower screw [2] to the specified torque. TORQUE:  2.5 N·m (0.3  kgf·m, 1.8 lbf·ft)[1]
[2]
Allow the adhesive
to dry for 1 hour
before using.
[2][3]
[1]
Align[1]
TORQUE:  2.5 N·m (0.3  kgf·m, 1.8 lbf·ft)
[2]
[1] 
						

							16-21
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FRONT WHEEL/SUSPENSION/STEERING
Align the edge of
the master cylinder
with the punchmark on thehandlebar.Install the brake master cy linder [1] and holder [2] with
the UP mark [3] facing up.
Install the bolts [4] and tighten the upper bolt first, then
tighten the lower bolt to the specified torque.
Connect the brake light switch connectors [5]. 
Align the edge of
the bracket with the punch mark on the handlebar.Install the clutch lever bracket [1] and holder [2].
Install the bolts [3] and tighten the upper bolt first, then
tighten the lower bolt.
Connect the clutch switch wire connectors [4]
Secure the wires with the wire bands [1].
Install each rearview mirror [2] and tighten the lock nut.
Check the throttle grip freeplay (page 3-3).
STEERING STEM
REMOVAL
Remove the following:
– Front fender (page 2-5)
– Headlight cowl (page 2-5)
– Handlebar (page 16-16)
– Front wheel (page 16-4)
Disconnect the ignition switch 3P (Brown) connector [1].
Release the ignition switch wire from the harness bands
[2].
Remove the bolts [3] and meter stay [4]. TORQUE:  9.8 N·m (1.0  kgf·m, 7.2 lbf·ft)
Align[2]
[3]
[1]
[5][4]
[2]
[1]
[3]
[4]
Align
[2]
[1]
[2]
[3]
[1][4] 
						

							16-22
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FRONT WHEEL/SUSPENSION/STEERING
Remove the bolt [1] and brake hose guide [2].
Remove the steering stem cap [1].
Loosen the steering stem nut [2].
Remove the fork legs (page 16-6).
Remove the stem nut, washer [3] and top bridge [4].
Loosen the steering stem adjusting nut [1] using the
special tool.
While holding the steering stem, remove the adjusting
nut.
Remove the following:
– Upper dust seal [1]
– Upper steering bearing [2]
– Steering stem [3]
Inspect the bearings and outer races for wear or
damage.
If necessary, replace them as a set (page 16-23).
[2]
[1]
[2][3]
[1][4]
TOOL:
[2] Stem socket wrench 07916-KA50100
[2]
[1]
[2]
[3]
[1] 
						

							16-23
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FRONT WHEEL/SUSPENSION/STEERING
BEARING REPLACEMENT
Always replace the
bearings and races
as a set.Remove the upper and lower bearing outer races [1]
using the special tools.
Install the stem nut [1] ont o the stem to prevent the
threads from being damaged when removing the lower
bearing [2].
Remove the lower bearing and lower dust seal [3] with
a chisel or equivalent tool, being careful not to damage
the stem.
Apply specified grease (page 16-24) to a new lower
dust seal [1] lip and install it over the steering stem.
Press a new lower bearing [2] using a special tool.
Drive in new upper and lower bearing outer races [1]
into the steering head pipe. TOOLS:
[2] Ball race remover 07948-4630100
[3] Remover shaft 07953-KA50000[2]
[3]
[1]
[3]
[2]
[1]
[2][3]
[1]
TOOL:
[3] Driver, 28 mm 07946-4300101
[2]
[3]
[1]
TOOLS:
[2] Driver 07749-0010000
[3] Driver attachment, 42 x 47 mm 07746-0010300[2]
[3][2]
[3]
[1]
[1] 
						

							16-24
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FRONT WHEEL/SUSPENSION/STEERINGINSTALLATION
Apply 3 - 5 g (0.11 - 0.18 oz) of specified grease (Urea
based multi-purpose grease with extreme pressure
agent (example: Kyodo  Yushi, EXCELITE EP2 or
equivalent) to each new bearing and fill it up.
Apply specified grease to a new upper dust seal [1] lip.
Insert the steering stem [2] into the steering head pipe,
and install the following while holding the stem.
– upper steering bearing [3]
– upper dust seal
Apply engine oil to the stee ring stem adjusting nut [1]
threads.
Install and tighten the adjusting nut to the initial torque
using the special tool.
LOWER STEERING 
BEARING
LOWER OUTER RACE
ADJUSTING NUT
UPPER STEERING 
BEARING
UPPER DUST SEAL
STEM CAP
WASHER
TOP BRIDGE
STEERING STEM
HOSE GUIDE
LOWER DUST SEAL
UPPER OUTER RACE
HOSE GUIDE
10 N·m (1.0 kgf·m, 7 lbf·ft)
STEM NUT
10 N·m (1.0 kgf·m, 7 lbf·ft)
METER STAY
103 N·m (10.5 kgf·m, 76 lbf·ft)
[2]
[3]
[1]
TOOL:
[2] Stem socket wrench 07916-KA50100
TORQUE: 29.5 N·m (3.0  kgf·m, 22 lbf·ft)
[2]
[1] 
						

							16-25
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FRONT WHEEL/SUSPENSION/STEERING
Turn the steering stem [1] right and left, lock-to-lock
several times to seat the bearings.
Completely loosen the adjusting nut [2].
Retighten the adjusting nut [1] to the specified torque
using the special tool.
Install the top bridge [1], washer [2] and stem nut [3].
Temporarily install the outer tube into the bottom and
top bridges.
Tighten the stem nut to the specified torque.
Make sure the steering st em moves smoothly without
play or binding.
Install the steering stem cap [1].[2]
[1]
TOOL:
[2] Stem socket wrench 07916-KA50100
TORQUE:  6.5 N·m (0.7  kgf·m, 4.8 lbf·ft)
[2]
[1]
TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft)
[1]
[2]/[3]
[1] 
						

							16-26
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FRONT WHEEL/SUSPENSION/STEERING
Install brake hose guide [1] and tighten the bolt [2] to
the specified torque.
Install the meter stay [1] and tighten the bolts [2].
Secure the ignition switch wire with the harness bands
[3].
Connect the ignition switch 3P (Brown) connector [4].
Install the following:
– Front wheel (page 16-4)
– Handlebar (page 16-19)
– Headlight cowl (page 2-5)
– Front fender (page 2-5)
STEERING BEARING PRE-LOAD
Raise the front wheel off the ground by placing a work
stand or box under the frame.
Position the steering stem straight ahead.
Hook a spring scale to the outer tube between the fork
top and bottom bridges.
Make sure there is no cable, wire harness or hose
interference.
Pull the spring scale keeping it at a right angle to the
steering stem.
Read the scale at the point where the steering stem just
starts to move.
If the readings do not fall within the limits, readjust the
steering bearing. TORQUE:  10 N·m (1.0 kgf·m, 7 lbf·ft)
[1]
[2]
[3]
[2]
[4][1]
STEERING BEARING PRE-LOAD:10.6 – 21.2 N (1.08 – 2. 16 kgf, 2.38 – 4.77 lbf)
90° 
						

							17-1
17
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17. REAR WHEEL/SUSPENSION
SERVICE INFORMATION ···························17-2
TROUBLESHOOTING·································17-2
COMPONENT LOCATION ··························17-3
REAR WHEEL ·············································17-4SHOCK ABSORBER ·································· 17-6
SHOCK LINKAGE····················\
··················\
· 17-7
SWINGARM ·············································· 17-10
DRIVE CHAIN GUIDE ······························· 17-12