Honda Crf250l Service Manual

							17-12
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REAR WHEEL/SUSPENSIONBEARING REPLACEMENT
Remove the pivot bearings [1] and dust seals [2] using
the special tool.
Apply grease to the needle rollers of new bearings [1]
and new dust seal [2] lips.
Install the dust seals to the specified depth with the
marked side facing in.
Press the needle bearings to  the specified depth with
the marked side facing up, using the special tools.
DRIVE CHAIN GUIDE
REMOVAL/INSTALLATION
Remove the two nuts [1], screws [2] and chain slider
guide [3].
Remove the bolts [4] and drive chain guide [5].
Installation is in the reverse order of removal.
 • Replace the chain guide mounting bolts with new ones.
TOOLS:
[3] Bearing remover, 20 mm 07936-3710600
[4] Remover weight 07741-0010201
Remover handle 07936-3710100
[3]
[4]
[2]
[1]
TOOLS:
[3] Driver 07949-3710001
[4] Attachment, 24 × 26 mm 07746-0010700
[5] Pilot 20 mm
07746-0040500
[6] Fork seal driver attachment, 
20 mm 07747-0010400
7.0 – 7.5 mm 
(0.28 – 0.30 in)
27.0 – 27.5 mm 
(1.06 – 1.08 in)
[1]
[3]
[2]
[4]/[5]
[6]
[2]
12.0 – 12.5 mm 
(0.47 – 0.49 in)
32.0 – 32.5 mm 
(1.26 – 1.28 in)
Left side:
Right side:
[1]
[2]
[1]
TORQUE:
Chain guide mounting bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Chain slider guide mounting nut: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)
[3][2]
[5][4][1] 
						

							18-1
18
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18. BRAKE SYSTEM
SERVICE INFORMATION ···························18-2
TROUBLESHOOTING·································18-2
COMPONENT LOCATION ··························18-3
BRAKE FLUID REPLACEMENT/
AIR BLEEDING ···········································18-4
BRAKE PAD/DISC··················\
··················\
··18-5 FRONT MASTER CYLINDER ····················· 18-7
REAR MASTER CYLINDER ······················· 18-8
FRONT BRAKE CALIPER ························ 18-10
REAR BRAKE CALIPER ·························· 18-11
BRAKE PEDAL ··················\
··················\
····· 18-12 
						

							18-2
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BRAKE SYSTEM
BRAKE SYSTEMSERVICE INFORMATION
GENERAL
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir  cap; make sure the master cylinder reservoir is horizontal first.
 • A contaminated brake disc or pad reduces stopping power.  Discard contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
 • Always use fresh DOT 3 or DOT 4 brake fl uid from a sealed container when servicing the system. Do not mix different types of
fluid as they may not be compatible.
 • Never allow contaminants (dirt, wate r, etc.) to enter an open reservoir.
 • Once the hydraulic system has been opened, or if  the brake feels spongy, the system must be bled.
 • Always check brake operation before riding the motorcycle.
TROUBLESHOOTING
Brake lever/pedal soft or spongy
 • Air in hydraulic system
 • Leaking hydraulic system
 • Contaminated brake pad/disc
 • Worn caliper piston seal
 • Worn master cylinder piston cups
 • Worn brake pad/disc
 • Contaminated caliper
 • Contaminated master cylinder
 • Caliper not sliding properly
 • Low brake fluid level
 • Clogged fluid passage
 • Warped/deformed brake disc
 • Sticking/worn caliper piston
 • Sticking/worn master cylinder piston
 • Bent brake lever/pedal
Brake lever/pedal hard
 • Clogged/restricted brake system
 • Sticking/worn caliper piston
 • Sticking/worn master cylinder piston
 • Caliper not sliding properly
 • Warped/deformed brake disc
 • Bent brake lever/pedal
Brake drags
 • Contaminated brake pad/disc
 • Misaligned wheel
 • Badly worn brake pad/disc
 • Warped/deformed brake disc
 • Caliper not sliding properly
 • Clogged/restricted fluid passage
 • Sticking caliper piston
Frequent inhalation of brake pad dust, regardless of mate rial composition, could be hazardous to your health.
 • Avoid breathing dust particles.
 • Never use an air hose or brush to clean brake  assemblies. Use an OSHA-approved vacuum cleaner. 
						

							18-3
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BRAKE SYSTEM
COMPONENT LOCATION
FRONT:
REAR:
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf·ft) 
						

							18-4
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BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR 
BLEEDING
BRAKE FLUID DRAINING
For front brake:Turn the handlebar until the master cylinder reservoir is
level before removing the reservoir cap.
Remove the screws [1], reservoir cap [2], set plate [3],
and diaphragm [4].
For rear brake:Remove the bolt [1] and reservoir [2].
Remove the cover screws [3],  reservoir cover [4], set
plate [5] and diaphragm [6].
Connect a bleed hose [1] to the bleed valve [2].
Loosen the bleed valve and pump the brake lever or
pedal until no more fluid flows out of the bleed valve.
Tighten the bleed valve.
BRAKE FLUID FILLI NG/AIR BLEEDING
Close the bleed valve.
Fill the reservoir to the upper  level line [1] with DOT 3 or
DOT 4 brake fluid from a sealed container.
Connect a commercially available brake bleeder to the
bleed valve.
Operate the brake bleeder a nd loosen the bleed valve.
If an automatic ref ill system is not us ed, add fluid when
the fluid level in the reservoir is low.
Perform the bleeding proc edure until the system is
completely flushed/bled.
Close the bleed valve and operate the brake lever or
pedal. If it still  feels spongy, bleed the system again.
[2][3][1]
[4]
[3]
[2]
[1]
[4]/[5]/[6]
TORQUE:  5.4 N·m (0.6  kgf·m, 4.0 lbf·ft)
[2]
[1]
Check the fluid level
often while bleeding
the brake to prevent air from being
pumped into the system.
[1][1]
FRONT:REAR: 
						

							18-5
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BRAKE SYSTEM
If a brake bleeder is not available, use the following
procedure:
Connect a bleed hose to the bleed valve.
Pressurize the system with the brake lever or pedal until
lever or pedal resistance is felt.
1. Squeeze the brake lever or depress the brake pedal,open the bleed valve 1/4 turn and then close it.
2. Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel.
3. Repeat the steps 1 and  2 until there are no air
bubbles in the bleed hose.
After bleeding the system co mpletely, tighten the bleed
valve to the specified torque.
Fill the reservoir to the u pper level line with DOT 3 or
DOT 4 brake fluid.
Install the diaphragm, set plate and reservoir cover and
tighten the screws to the specified torque.
For rear brake:Install the reservoir and bolt, then tighten it to the
specified torque while pushing the reservoir against the
stopper.
BRAKE PAD/DISC
FRONT BRAKE PAD REMOVAL/
INSTALLATION
Remove the pad pin [1].
Pull the pad pin out of the caliper body while pushing in
the pads against the pad spring.
Remove the brake pads [1].
Install the brake pads into the caliper so their ends rest
into the pad retainer on  the bracket properly.
Do not release the
lever or pedal until
the bleed valve has been closed.
TORQUE:  5.4 N·m (0.6  kgf·m, 4.0 lbf·ft)
TORQUE:  1.5 N·m (0.2  kgf·m, 1.1 lbf·ft)
TORQUE:  10 N·m (1.0 kgf·m, 7 lbf·ft)
[1]
[1]
AlignAlign 
						

							18-6
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BRAKE SYSTEM
Apply silicone grease to a new stopper ring [1] and
install it into the pad pin [2] groove.
Install the pad pin by pushing in the pads against the
pad spring to align the pad pin holes in the pads and
caliper body.
Tighten the pad pin to the specified torque.
Operate the brake lever to seat the caliper pistons
against the pads.
REAR BRAKE PAD REMOVAL/
INSTALLATION
Remove the pad pin plug [1] and pad pin [2].
Remove the brake pads [3].
Apply silicone grease to a new stopper ring [1] and
install it into the pad pin [2] groove.
Install the brake pads [3] into the caliper.
Install the pad pin by pushing in the pads against the
pad spring to align the pad pin holes in the pads and
caliper body.
Tighten the pad pin to the specified torque.
Install the pad pin plug [4].
Operate the brake pedal to seat the caliper pistons
against the pads.
BRAKE DISC INSPECTION
Visually inspect the brake  disc for damage or cracks.
Measure the brake disc according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
Make sure the pad spring is installed
correctly.
Always replace the
brake pads in pairs
to ensure even disc pressure.
TORQUE: 17.2 N·m (1.8  kgf·m, 13 lbf·ft)[1]
[2]
[2]
[3][1]
Make sure the pad
spring is installed correctly.
Always replace the
brake pads in pairs
to ensure even disc
pressure.
TORQUE: 17.2 N·m (1.8  kgf·m, 13 lbf·ft)
[2]
[3]
[1]
[4] 
						

							18-7
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BRAKE SYSTEM
FRONT MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the front brake hydraulic
system (page 18-4).
Remove the following:
– Right rearview mirror [1]
– Oil bolt [2]
– Sealing washers [3]
– Brake hose [4]
– Brake light switch connectors [5]
– Bolts [1]
– Master cylinder holder [2]
– Master cylinder [3]
Installation is in the reverse order of removal.
 • Replace the sealing washers with new ones.
 • Align the edge of the master cylinder with the punch mark on the handlebar.
 • Install the master cylinder and holder with its UP mark [4] facing up.
 • Tighten the upper bolt first, then tighten the lower
bolt.
Fill and bleed the hydraulic system (page 18-4).
When removing the oil bolt, cover the
end of the hose to prevent
contamination.
[2][3]
[1]
[5]
[4]
TORQUE:  Front master cylinder holder bolt:
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
Oil bolt: 34 N·m (3.5 kgf· m, 25 lbf·ft)
[2][3]
[1]
Align
[4] 
						

							18-8
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BRAKE SYSTEMDISASSEMBLY/ASSEMBLY
Disassemble and assemble the front brake master
cylinder as following illustration.
 • Replace the master piston, spring, piston cups andsnap ring as a set.
 • Do not allow the piston cup lips to turn inside out.
 • Be certain the snap ring is firmly seated in the groove.
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Master cylinder
– Master piston
– Piston cups
–Spring
– Boot
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
REAR MASTER CYLINDER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 18-4).
Release the reservoir hose [1] from the clamp [2].
Remove the following:
– Oil bolt [3]
– Sealing washers [4]
– Brake hose
PIVOT BOLT
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
5.9 N·m (0.6 kgf·m, 
4.4 lbf·ft)1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
BOOT
SNAP RINGSPRING
BRAKE LIGHT SWITCH
DUST COVERSCREWPIVOT NUT
BRAKE LEVER
MASTER CYLINDER
PISTON 
CUPS
MASTER 
PISTONSEPARATOR
STOPPER RING
Align
When removing the
oil bolt, cover the
end of the hose to prevent
contamination.
[2][3]
[4]
[1] 
						

							18-9
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BRAKE SYSTEM
– Cotter pin [1]
– Joint pin [2]
– Master cylinder mounting bolts [3]
– Snap ring [1]
– Hose joint [2]
– O-ring [3]
– Rear master cylinder [4]
Installation is in the reverse order of removal.
 • Replace the O-ring, master cylinder mounting bolts,cotter pin and sealing washers with new ones.
 • Apply brake fluid to the joint O-ring.
Fill and bleed the hydraulic system (page 18-4).
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake master
cylinder as following illustration.
 • Replace the master piston, spring, piston cups and snap ring as a set.
 • Do not allow the piston cup lips to turn inside out.
 • Be certain the snap ring is firmly seated in the groove.
[2]
[3][1]
TORQUE: 
Rear master cylinder mounting bolt: 14 N·m (1.4 kgf·m, 10 lbf·ft)
Oil bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
[2]
[3][1][4]
SPRING
PUSH ROD ASSEMBLY
PISTON CUPS
SNAP RING
BOOT
64 - 65 mm 
(2.52 - 2.56 in)
BRAKE ROD JOINT
MASTER PISTON
MASTER CYLINDER
17.2 N·m (1.8 kgf·m, 13 lbf·ft)
PUSH ROD LOCK NUT
Standard push rod length: