Honda Crf250l Service Manual
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1-16 dummyhead dummyhead GENERAL INFORMATIONFRAME MATERIAL LOCATIONREMARKS Urea based multi-purpose grease with extreme pressure agent (example: Kyodo Yushi, EXCELITE EP2 or equivalent) Steering head bearing inner race and outer race rolling surface 3 – 5 g (0.11 – 0.18 oz) Steering head bearing dust seal lips Multi-purpose grease Sidestand pivot sliding surface Axle outer surface Throttle pipe flange cable groove Shock linkage needle bearing rotating area Shock linkage collar whole surface Swingarm pivot needle bearing rotating area Swingarm pivot collar whole surface Swingarm pivot bolt outer surface Swingarm cap lips Gap between the swingarm caps, pivot collar and bearings Brake pedal pivot sliding area Main step pivot pin sliding area Pillion step pivot pin sliding surface Each dust seal lips Each O-ring Silicone grease Brake pad pin stopper ring surface Brake caliper bracket pin boots 0.4 g (0.01 oz) minimum Brake caliper dust seal whole surface Brake lever contacting area with master piston0.1 g (0.004 oz) Rear master cylinder push r od contacting area with master cylinder piston and boot 0.1 g (0.004 oz) Master cylinder boot 0.1 g (0.004 oz) DOT 3 or DOT 4 brake fluid Brake master piston sliding area and piston cups Rear master cylinder hose joint O-ring Brake caliper piston sliding area and piston seal Fork fluid Fork cap O-ring Fork oil seal lips Fork dust seal lips Fork guide bushing and slider bushing surface Honda Bond A or equivalent Left handlebar a nd throttle pipe outer surface (grip rubber contacting area) Air cleaner connecting hose mating surface with air cleaner housing Swingarm rubber cap mating surface with swingarm
1-17 dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLES RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE CABLESFRONT BRAKE HOSE HANDLEBAR SWITCH WIRE HANDLEBAR WIRE BANDS Front Align the lower end of outer rubber with the lower end of hose clamp.25° – 30°
1-18 dummyhead dummyhead GENERAL INFORMATION SPEEDOMETER 16P CONNECTOR BOOT CLUTCH CABLE LEFT HANDLEBAR SWITCH 14P (GRAY) CONNECTOR THROTTLE CABLES RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH 9P (BLACK) CONNECTOR IGNITION SWITCH WIRE IGNITION SWITCH WIRE HEADLIGHT 3P (BLACK) CONNECTOR WIRE CLAMP WIRE CLAMP IGNITION SWITCH 3P (BROWN) CONNECTOR CONNECTORS: – RIGHT FRONT TURN SIGNAL 2P (LIGHT BLUE) – LEFT FRONT TURN SIGNAL 2P (ORANGE) LEFT FRONT TURN SIGNAL 2P (ORANGE) CONNECTORRIGHT FRONT TURN SIGNAL 2P (LIGHT BLUE) CONNECTOR RIGHT FRONT TURN SIGNAL WIRE LEFT FRONT TURN SIGNAL WIREMETER STAY SPEEDOMETER LEFT FRONT TURN SIGNAL WIRE IGNITION SWITCH WIREMAIN WIRE HARNESS METER STAY Viewed from the front side: Viewed from the upper side:Viewed from the right side: POSITION LIGHT 2P (BLACK) CONNECTOR
1-19 dummyhead dummyhead GENERAL INFORMATION CLUTCH CABLE THROTTLE CABLES RADIATOR SIPHON HOSE RESERVE TANK OVERFLOW HOSE WATER HOSE BAND Front 0°± 30°
1-20 dummyhead dummyhead GENERAL INFORMATION ECM 33P (BLACK) CONNECTORGROUND POINT BANK ANGLE SENSOR 2P CONNECTOR PAIR CONTROL SOLENOID VALVE 2P (BLACK) CONNECTOR TURN SIGNAL RELAY 3P (BLACK) CONNECTOR JUNCTION BOX REGULATOR/RECTIFIER 5P CONNECTOR FUEL HOSE FUEL PUMP 3P (BLACK) CONNECTOR RADIATOR SIPHON HOSE
1-21 dummyhead dummyhead GENERAL INFORMATION GROUND POINT PAIR AIR SUCTION HOSE PAIR AIR SUCTION HOSE PAIR AIR SUCTION HOSE RESERVE TANK OVERFLOW HOSE CRANKCASE BREATHER HOSE CLUTCH CABLE RESERVE TANK OVERFLOW HOSE WIRE BAND GUIDE WIRE BAND Viewed from the front side: Viewed from the front side:VS SENSOR CRANKCASE BREATHER HOSE HOSE CLAMPS REAR BRAKE LIGHT SWITCH WIRE VS SENSOR 3P (BLUE) CONNECTOR PAIR AIR SUPPLY HOSE
1-22 dummyhead dummyhead GENERAL INFORMATION CLUTCH CABLE THROTTLE CABLES RADIATOR SIPHON HOSE RESERVE TANK OVERFLOW HOSE PAIR AIR SUCTION HOSE PAIR AIR SUPPLY HOSE FUEL PUMP 3P (BLACK) CONNECTOR IACV 4P (BLACK) CONNECTOR FUEL INJECTOR 2P (GRAY) CONNECTOR SPARK PLUG WIRE FUEL TANK BREATHER HOSE (To FUEL TANK) FUEL TANK BREATHER HOSE FUEL TANK BREATHER HOSESUB-FRAME Right HOSE BAND
1-23 dummyhead dummyhead GENERAL INFORMATION PAIR AIR SUCTION HOSE PAIR AIR SUPPLY HOSE Viewed from the rear side: RADIATOR SIPHON HOSE FUEL PUMP 3P (BLACK) CONNECTOR SPARK PLUG WIRE PAIR AIR SUCTION HOSE PAIR AIR SUPPLY HOSE DLC PAIR CONTROL SOLENOID VALVE FAN MOTOR 2P (BLACK) CONNECTOR WATER HOSE BAND Front WATER HOSE BAND Front WATER HOSE BAND O2 SENSOR 1P (BLACK) CONNECTOR ECT SENSOR 3P CONNECTOR SENSOR UNIT 5P CONNECTOR Left 90°± 30° 55°± 30° 20°± 30°
1-24 dummyhead dummyhead GENERAL INFORMATION FUEL TANK BREATHER HOSE BATTERY CASE DRAIN HOSE SIDESTAND SWITCH WIRE CONNECTORS: – ALTERNATOR 3P – REAR BRAKE LIGHT SWITCH 3P (BLACK) – SIDESTAND SWITCH 3P (GREEN) – CKP SENSOR/NEUTRAL SWITCH 3P (BLACK) ECT SENSOR 3P CONNECTOR VS SENSOR 3P (BLUE) CONNECTOR WIRE CLAMP STARTER MOTOR CABLE BATTERY NEGATIVE (-) CABLE NEUTRAL SWITCH CRANKCASE BREATHER HOSE SIDESTAND SWITCH WIRE BATTERY CASE DRAIN HOSE SIDESTAND SWITCH WIRE BATTERY NEGATIVE (-) CABLE NEUTRAL SWITCH WIRE DRIVE SPROCKET COVER LEFT CRANKCASE COVER Viewed from the upper side: Viewed from the lower side: ALTERNATOR WIRE FUEL TANK BREATHER HOSE RESERVE TANK OVERFLOW HOSE
1-25 dummyhead dummyhead GENERAL INFORMATION BATTERY NEGATIVE (-) CABLE Viewed from the front side: BATTERY POSITIVE (+) CABLE STARTER RELAY SWITCH 4P (RED) CONNECTOR FAN CONTROL RELAY FUEL PUMP RELAY STARTER MOTOR CABLE WIRE BANDS STARTER MOTOR CABLE SUB-FRAME MAIN WIRE HARNESS REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE