Honda Crf250l Service Manual

							17-2
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REAR WHEEL/SUSPENSION
REAR WHEEL/SUSPENSIONSERVICE INFORMATION
GENERAL
 • Raise the rear wheel off the ground by supporting the frame securely when servicing. A box or work stand is required to suppo rt
the motorcycle.
 • The shock absorber contains nitrogen under high pressu re. Do not allow fire or heat near the shock absorber.
 • Before disposal of the shock absorber, release the nitrogen (page 17-7).
 • A contaminated brake disc or pad reduces stopping power.  Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
 • Use only Honda Genuine replacement bolts and nuts for all  suspension linkage and swingarm pivot mounting points; ordinary
bolts lack adequate strength for these applicatio ns. Also take note of the installation direction of these bolts since they mus t be
installed correctly.
 • For hydraulic brake system service (page 18-3).
 • After the rear wheel installation, check the brake operation by applying the brake pedal.
 • For drive chain information (page 3-12).
TROUBLESHOOTING
Soft suspension
 • Incorrect suspension adjustment
 • Weak shock absorber spring
 • Oil leakage from damper unit
 • Low tire pressure
Stiff suspension
 • Incorrect suspension adjustment
 • Bent shock absorber damper rod
 • Damaged suspension or swingarm pivot bearings
 • Bent swingarm pivot or frame
 • High tire pressure
Steers to one side or does not track straight
 • Drive chain adjusters not adjusted equally
 • Bent axle
 • Bent frame
 • Worn swingarm pivot components
Rear suspension noise
 • Loose suspension fasteners
 • Worn or damaged suspension pivot bearings
 • Faulty shock absorber
Rear wheel wobbles
 • Bent rim
 • Worn or damaged rear wheel bearings
 • Faulty rear tire
 • Low tire pressure
 • Loose or broken spokes
 • Worn or damaged swingarm bearings
 • Bent frame or swingarm
 • Axle fastener not tightened properly
Wheel turns hard
 • Faulty wheel bearings
 • Bent axle
 • Drive chain too tight (page 3-12)
 • Brake drag (page 18-2) 
						

							17-3
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REAR WHEEL/SUSPENSION
COMPONENT LOCATION
88 N·m (9.0 kgf·m, 65 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
74 N·m (7.5 kgf·m, 
55 lbf·ft)
54 N·m (5.5 kgf·m, 40 lbf·ft)
2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
44 N·m (4.5 kgf·m, 32 lbf·ft)
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
88 N·m (9.0 kgf·m, 65 lbf·ft)
44 N·m (4.5 kgf·m, 32 lbf·ft) 
						

							17-4
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REAR WHEEL/SUSPENSION
REAR WHEEL
REMOVAL/INSTALLATION
Loosen the axle nut [1].
Raise the rear wheel off the ground by placing a work
stand or box under the frame.
Loosen the lock nuts [2] and turn in the drive chain
adjusters [3] completely.
Remove the axle nut and right drive chain adjuster plate
[4].
Push the wheel forward and derail the drive chain [1]
from the driven sprocket.
Remove the following:
–Axle [2]
– Left chain adjuster plate [3]
– Rear wheel
– Side collars [4]
 • Do not operate the brake pedal after removing the wheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
Remove the rear brake cali per bracket [1] from the
guide rail [2] of the swingarm.
Install the rear wheel in the reverse order or removal.
 • Apply thin coat of grease to the axle outer surface.
Adjust the drive chain slack (page 3-12).
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.
– Rear axle
– Spoke
– Wheel rim
Measure each part according to REAR WHEEL/
SUSPENSION SPECIFICATIONS (page 1-8).
Replace any part if it is out of service limit.
[2][3]
[1]
[4]
Support the caliper
so it does not hang
from the brake
hose. Do not twist the brake hose.
[2][3]
[1][4]
[2][1] 
						

							17-5
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REAR WHEEL/SUSPENSION
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear wheel as following illustration.
BEARING REPLACEMENT
Install the remover head [1] into the bearing.
From the opposite side of the wheel, install the bearing
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 right 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 left side bearing with the sealed side
facing up until its inner race is fully seated on the
distance collar.
DUST SEAL
DRIVEN SPROCKET
BEARING (6303U)
BRAKE DISC
DUST SEAL
DISTANCE COLLARDRIVEN SPROCKET 
BOLTS
DRIVEN SPROCKET NUTS
50 N·m (5.1 kgf·m, 37 lbf·ft)
WASHERS
BRAKE DISC BOLTS
42 N·m (4.3 kgf·m, 31 lbf·ft)
BEARING (6303U)
TOOLS:
[1] Bearing remover head, 17 mm 07746-0050500
[2] Bearing remover shaft 07746-0050100
[2][1]
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 42 x 47 mm 07746-0010300
[4] Pilot, 17 mm 07746-0040400
[2]
[3]/[4]
[1] 
						

							17-6
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REAR WHEEL/SUSPENSIONWHEEL CENTER ADJUSTMENT
Adjust the hub position so t hat the distance from the
right 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.
SHOCK ABSORBER
REMOVAL/INSTALLATION
Raise the rear wheel off the ground by placing a work
stand or box under the frame.
Remove the sub-frame (page 2-12).
Remove the upper mounting nut [1] and bolt [2].
Remove the lower mounting nut [3], bolt [4] and shock
absorber [5].
Installation is in the reverse order of removal.
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, oil leakage or bend.
– Damper rod
– Damper unit
– Bushing
If the shock absorber is replaced, refer to shock
absorber disposal procedure (page 17-7). WHEEL HUB-TO-RIM DISTANCE: 
26.9 ± 1.0 mm (1.06 ± 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]
TORQUE: 
Shock absorber upper mounting nut:54 N·m (5.5 kgf·m, 40 lbf·ft)
Shock absorber lower mounting nut: 44 N·m (4.5 kgf·m, 32 lbf·ft)
[5]
[1]/[2]
[3]/[4] 
						

							17-7
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REAR WHEEL/SUSPENSION
SHOCK ABSORB ER DISPOSAL 
PROCEDURE
Center punch the damper case to mark the drilling point
as shown.
Wrap the shock absorber [1] inside a plastic bag.
Support the shock absorber upright in a vise as shown.
Through the open end of the  bag, insert a hand drill
with a sharp 3 mm drill bit.
 • Point the drill hole away  from you to prevent debris
getting in your eyes.
Hold the bag around the hand drill and briefly run it
inside the bag; this will inflate the bag with air from the
motor and help keep the bag from getting caught in the
bit when you start.
Drill into the shock absorber at the center punch mark
to purge the nitrogen gas.
Once all the nitrogen gas has been purged from the
shock absorber and it is no longer under pressure, the
item can be disposed of.
SHOCK LINKAGE
REMOVAL/INSTALLATION
Raise the rear wheel off the ground by placing a work
stand or box under the frame and support the
swingarm.
Remove the rear brake pedal return spring [1].
Remove the following:
– Shock absorber lower mounting nut/bolt [1]
– Shock link-to-shock arm nut/bolt/washer [2]
– Shock arm-to-swingarm nut/bolt/washer [3]
– Shock arm [4]
– Shock link-to-frame nut/bolt [5]
– Shock link [6]
Installation is in the reverse order of removal.
 • Apply engine oil to the shock arm-to-swingarm nut threads.
 • Before tightening the nuts to the specified torque, install all the nuts, bolts and washers.
[1]
[1]
TORQUE:
Shock link-to-frame nut:
44 N·m (4.5 kgf·m, 32 lbf·ft)
Shock arm-to-swingarm nut: 74 N·m (7.5 kgf·m, 55 lbf·ft) 
Shock link-to-shock arm nut: 44 N·m (4.5 kgf·m, 32 lbf·ft)
Shock absorber lower mounting nut:
44 N·m (4.5 kgf·m, 32 lbf·ft)[2]
[3][1]
[5][4][6] 
						

							17-8
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REAR WHEEL/SUSPENSIONDISASSEMBLY/ASSEMBLY
Disassemble and assemble the shock linkage as
following illustration.
 • Install the swingarm side  shock arm dust seals to the
specified depth.
 • Install other dust seals until they  are fully seated on the bearings.
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation or crack.
–Collars
– Shock arm
– Needle bearings
– Shock link
BEARING REPLACEMENT
SHOCK ARM
Press the shock absorber and shock link side needle
bearings [1] out of the shock arm using the special tool.
NEEDLE BEARING 
(20 X 26 X 20)
DUST SEAL 
(20 X 26 X 4.5)
NEEDLE BEARING 
(17 X 24 X 17)
COLLAR (SWING 
ARM SIDE)
DUST SEAL 
(17 X 24 X 5)
DUST SEAL 
(17 X 24 X 5)DUST SEAL 
(17 X 24 X 5)
NEEDLE BEARING 
(17 X 24 X 25)
NEEDLE BEARING 
(17 X 24 X 25)
SHOCK LINK COLLAR
SHOCK LINK
COLLAR (SHOCK 
LINK SIDE)COLLAR (SHOCK 
ABSORBER SIDE)
SHOCK ARM
0.8 – 1.2 mm (0.03 – 0.05 in)
DUST SEAL 
(20 X 26 X 4.5)
0.8 – 1.2 mm (0.03 – 0.05 in)
TOOLS:
Shock link and shock absorber side:
[2] Driver 07949-3710001
[3] Attachment, 22 × 24 mm 07746-0010800
[4] Pilot 17 mm 07746-0040400
[5] Fork seal driver attachment,
27.2 mm07746-0010300
[2]
[1]
[5]
SHOCK ABSORBER/
SHOCK LINK SIDE
[3]/[4] 
						

							17-9
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REAR WHEEL/SUSPENSION
Press the swingarm side needle bearings [1] out of the
shock arm using the special tool.
Apply grease to the needle rollers of new bearings [1].
Carefully press each needle bearing in the pivot until
the depth from the arm outer surface is 5.8 – 6.2 mm
(0.23 – 0.24 in).
Apply grease to the needle rollers of new bearings [1].
Carefully press each needle bearing in the pivot until
the depth from the arm outer surface is 8.8 – 9.2 mm
(0.35 – 0.36 in).
SHOCK LINK
Remove the needle bearing [1] from the shock link
using the special tools. TOOLS:
Swingarm side:
[2] Driver 07949-3710001
[3] Attachment, 24 × 26 mm 07746-0010700
[4] Pilot, 20 mm 07746-0040500
[5] Fork seal driver attachment,
27.2 mm07746-0010300
[2]
[1]
[5]
SWINGARM SIDE
[3]/[4]
Press in the bearing
with the markedside facing up.
TOOLS: Shock Link and Shock Absorber side:[2] Driver 07749-0010000
[3] Attachment, 22 x 24 mm 07746-0010800
[4] Pilot, 17 mm 07746-0040400
[5] Fork seal driver attachment, 
27.2 mm 07746-0010300
5.8 – 6.2 mm 
(0.23 – 0.24 in)
[2]
[3]/[4][1]
SHOCK ABSORBER/
SHOCK LINK SIDE
[1]
[5]
Press in the bearing
with the markedside facing up.
TOOLS: Swingarm side:
[2] Driver 07749-0010000
[3] Attachment, 24 x 26 mm 07746-0010700
[4] Pilot, 20 mm 07746-0040500
[5] Fork seal dr iver attachment, 
27.2 mm 07746-0010300
8.8 – 9.2 mm 
(0.35 – 0.36 in)
[2]
[1]
SWINGARM SIDE
[1]
[3]/[4]
[5]
TOOLS:
[2] Bearing remover, 17 mm 07936-3710300
[3] Remover weight 07741-0010201
Remover handle 07936-3710100
[2]
[3]
[1] 
						

							17-10
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REAR WHEEL/SUSPENSION
Apply grease to the needle rollers of new bearings.
Carefully press the needle bearing in the pivot until the
depth from the link outer surface is 5.8 – 6.2 mm (0.23 –
0.24 in).
SWINGARM
REMOVAL/INSTALLATION
Remove the following:
– Rear wheel (page 17-4)
– Drive chain guide (page 17-12)
Remove the shock arm-to-swi ngarm nut [1], washer [2]
and bolt [3].
Remove the screws [1] and brake hose guides [2].
Remove the bolts [1] and drive chain case [2].
Press in the bearing
with the markedside facing up.
TOOLS:
[2] Driver 07749-0010000
[3] Attachment, 22 x 24 mm 07746-0010800
[4] Pilot, 17 mm 07746-0040400
5.8 – 6.2 mm 
(0.23 – 0.24 in)
[2]
[1]
[1]
[3]/[4]
5.8 – 6.2 mm 
(0.23 – 0.24 in)
[1]
[2]
[3]
[2]
[1]
[2]
[1] 
						

							17-11
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REAR WHEEL/SUSPENSION
Remove the swingarm pivot nut [1].
Remove the swingarm pivot bolt [2], then remove the
swingarm from the frame.
Remove the swingarm dust seal caps [1].
Installation is in the reverse order of removal.
 • Apply thin coat of grease to the pivot bolt outersurface.
 • Apply grease to the dust seal cap lips and fill the gap between the caps, collar and needle bearings with
grease.
 • Align the drive chain case slot with the swingarm hook.
 • Apply engine oil to t he threads of shock arm-to-
swingarm nut.
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the swingarm as following
illustration.
 • Apply Honda Bond A or equivalent to the sw ingarm rubber cap mating surface with swingarm.
[2]
[1]
TORQUE:
Swingarm pivot nut:88 N·m (9.0 kgf·m, 65 lbf·ft)
Shock arm-to-swingarm nut:  74 N·m (7.5 kgf·m, 55 lbf·ft)
Rear brake hose guide mounting screw:
1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
[1]
 DUST SEALS
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
CHAIN SLIDER
SCREWS
SWINGARM 
RUBBER CAPS
NEEDLE BEARINGS
COLLAR
SWINGARM
CHAIN CASE STAY
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
SCREW