Honda Crf250l Service Manual

							18-10
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BRAKE SYSTEMINSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Master cylinder
– Master piston
– Piston cups
–Spring
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
FRONT BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from  the front brake hydraulic
system (page 18-4).
Remove the following:
– Oil bolt [1]
– Sealing washers [2]
– Brake hose [3]
– Brake caliper mounting bolts [4]
– Brake caliper [5]
Installation is in the reverse order of removal.
 • Replace the brake caliper mounting bolts and sealing washers with new ones.
Fill and bleed the hydraulic system (page 18-4).
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the front brake caliper as following illustration.
When removing the oil bolt, cover the
end of the hose to prevent
contamination.
TORQUE:  Brake caliper mounting bolt:
30 N·m (3.1 kgf· m, 22 lbf·ft)
Oil bolt: 34 N·m (3.5 kgf· m, 25 lbf·ft)[2]
[3]
[1][5]
[4]
DUST SEALS
CALIPER PISTONS
PAD PIN
BRACKET PIN BOOT
CALIPER BRACKET
PAD SPRING
PISTON SEALS
BRAKE PADS
BLEED VALVE 
5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
BRACKET PIN
17.2 N·m (1.8 kgf·m, 13 lbf·ft)
CALIPER BODY
BRACKET PIN BOOT
17.2 N·m (1.8 kgf·m, 13 lbf·ft)
STOPPER RING 
						

							18-11
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BRAKE SYSTEM
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Caliper cylinders
– Caliper pistons
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
REAR BRAKE CALIPER
REMOVAL/INSTALLATION
Drain the brake fluid from the rear brake hydraulic
system (page 18-4).
Remove the oil bolt [1], s ealing washers [2], and brake
hose [3].
Remove the rear wheel (page 17-4).
Remove the rear brake caliper  [1] from the slide rail [2]
of swingarm.
Installation is in the reverse order of removal.
 • Replace the sealing washers with new ones.
Fill and bleed the hydraulic system (page 18-4).
When removing the
oil bolt, cover the
end of the hose to prevent
contamination.
[2][1]
[3]
TORQUE:  Oil bolt: 34 N·m (3.5 kgf·m, 25 lbf·ft)
[2][1] 
						

							18-12
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BRAKE SYSTEMDISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear brake caliper as following illustration.
INSPECTION
Check the following parts for scoring, scratches,
deterioration or damage.
– Caliper cylinder
– Caliper piston
Measure the parts according to BRAKE SYSTEM
SPECIFICATIONS (page 1-8) and replace if necessary.
BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the following:
– Brake light switch  return spring [1]
– Brake pedal return spring [2]
DUST SEAL
CALIPER PISTON
PAD PIN
BRACKET PIN 
BOOT
RETAINER
CALIPER BRACKET
PAD SPRING
PISTON SEAL
BRAKE PADS
CALIPER BODY
BRACKET 
PIN BOOT
BLEED VALVE 
5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
17.2 N·m (1.8 kgf·m, 
13 lbf·ft)
STOPPER RING
PAD PIN PLUG
[2][1] 
						

							18-13
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BRAKE SYSTEM
– Cotter pin [1]
– Joint pin [2]
– Brake rod joint [3]
– Stopper pin [4]
–Washer [5]
– Brake pedal [1]
– Dust seals [2]
Installation is in the reverse order of removal.
 • Replace the dust seals and cotter pin with new ones.
 • Install the dust seals in shown direction.
 • Apply grease to the brake pedal pivot sliding surfaceand dust seal lips.
[2]
[3]
[1][5][4]
[2]
[1]
[1]
[2] 
						

							MEMO
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							19-1
19
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19. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION ···························19-2
TROUBLESHOOTING·································19-2
SYSTEM LOCATION···································19-3
SYSTEM DIAGRAM ····································19-3BATTERY ···················································· 19-4
CHARGING SYSTEM INSPECTION ·········· 19-4
ALTERNATOR CHARGING COIL ·············· 19-5
REGULATOR/RECTIFIER ·························· 19-6 
						

							19-2
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BATTERY/CHARGING SYSTEM
BATTERY/CHARGING SYSTEMSERVICE INFORMATION
GENERAL
 • Always turn OFF the ignition switch before disconnecting any electrical component.
 • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
 • For extended storage, remove the battery,  give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every 2 weeks.
 • For a battery remaining in a stored motorcycle, disco nnect the negative battery cable from the battery terminal.
 • The maintenance free battery must be replac ed when it reaches the end of its service life.
 • The battery can be damaged if overcharg ed or undercharged, or if left to discharge for a long period. These same conditions
contribute to shortening  the life span of the battery. Ev en under normal use, the performanc e of the battery deteriorates after 2
– 3 years.
 • Battery voltage may recover after battery charging, but under  heavy load, battery voltage will drop quickly and eventually die out.
For this reason, the charging system is of ten suspected as the problem. Battery over charge often results from problems in the
battery itself, which may appear to be an  overcharging symptom. If one of the battery cells is shorted and battery voltage does
not increase, the regulator/rectifier suppli es excess voltage to the battery. Under these conditions, the electrolyte level goe s
down quickly.
 • Before troubleshooting the charging system, check for proper us e and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and ta illight ON for long periods of time without riding the motorcyc le.
 • The battery will self-discharge when the motorcycle is not in  use. For this reason, charge the battery every 2 weeks to preve nt
sulfation from occurring.
 • For alternator removal (page 13-4).
BATTERY CHARGING
 • Turn power ON/OFF at the charge r, not at the battery terminal.
 • For battery charging, do not exceed the charging current and  time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
 • Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction of the Operation  Manual for the recommended battery tester for details about battery testing. The
recommended battery tester puts a load on the battery  so the actual battery condition can be measured.
TROUBLESHOOTING
 • The battery gives off explosive gases; keep sparks, fl ames and cigarettes away. Provide adequate ventilation when 
charging.
 • The battery contains sulfuric acid (electrolyte). Contact with  skin or eyes may cause severe burns. Wear protective clothing 
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water  for at least 15 minutes and call a physician immediately.
 • Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and ca ll your local Poison Control Center or a physician immediately.
RECOMMENDED BATTERY TESTER:  BM-210 or BATTERY MATE or equivalent
Unusual condition Probable cause (Check in numerical order)
Battery Battery is damaged or weak 1. Faulty battery 2. Current leakage higher than specified value
– Faulty ignition switch
– Shorted wire harness
3. Faulty alternator charging coil
4. Faulty regulator/rectifier
5. Open circuit or loose connection in the wire harness 
						

							19-3
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BATTERY/CHARGING SYSTEM
SYSTEM LOCATION
SYSTEM DIAGRAM
BATTERY
ALTERNATOR
REGULATOR/RECTIFIER 
MAIN FUSE (30 A) 
BATTERYREGULATOR/RECTIFIER
MAIN FUSE (30 A)
ALTERNATOR
GR/WYYY
Y: Yellow
G: Green
R: Red
W: White 
						

							19-4
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BATTERY/CHARGING SYSTEM
BATTERY
REMOVAL/INSTALLATION
Remove the left side cover (page 2-3).
Turn the ignition switch OFF.
Disconnect the negative (–) cable [1] first and then the
positive (+) cable [2].
Remove the bolt [3], battery holder plate [4] and battery
[5].
Install the battery in the reverse order of removal.
 • Install the battery holder plate by aligning its hook
with the slit of the battery case.
 • For digital clock setting procedure (page 20-7).
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital multimeter.
If the battery voltage is below 12.3 V, charge the
battery.
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
CHARGING SYSTEM INSPECTION
CURRENT LEA KAGE INSPECTION
Remove the left side cover (page 2-3).
With the ignition switch turned OFF, disconnect the
negative (–) cable [1].
Connect the ammeter (+) probe to the wire harness
negative (–) cable and ammeter (–) probe to the battery
negative (–) terminal [2].
With the ignition switch turned OFF, check for current
leakage.
 • When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester.
 • While measuring current, do not turn the ignition switch ON and engine stop switch to  . A sudden
surge of current may blow  the fuse in the tester.
Connect the
positive cable first
and then the
negative cable.
TORQUE: Battery holder plate bolt:  7.0 N·m (0.7 kgf· m, 5.2 lbf·ft)
[2]
[3]
[1]
[5]
[4]
Align
VOLTAGE (20°C/68°F):
Fully charged: 13.0 – 13.2 V
Under charged: Below 12.3 V
TOOL:
Battery tester BM-210 or  BATTERY MATE 
or equivalent
SPECIFIED CURRENT LEAKAGE: 0.34 mA max.
[1]
+–
[2] 
						

							19-5
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BATTERY/CHARGING SYSTEM
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
Remove the left side cover (page 2-3).
Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+)
terminal [1] and negative (–) terminal [2].
 • To prevent a short, make absolutely certain whichare the positive (+) and negative (–) terminal or
cable.
 • Do not disconnect the battery or any cable in the charging system without first turning the ignition
switch OFF. Failure to follow this precaution can
damage the tester or electrical components.
With the headlight high beam, measure the voltage on
the multimeter when the engine runs at 5,000 min
-1
(rpm).
ALTERNATOR CHARGING COIL
INSPECTION
Remove the left side cover (page 2-3).
Disconnect the alternator 3P connector [1].
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
Check for continuity between each wire terminal of the
alternator/stator side connector and ground.
There should be no continuity.
Replace the alternator  stator if the resistance is out of
specification, or if any wire has continuity to ground.
For stator replacement (page 13-4). STANDARD:
Measured BV < Measured CV < 15.5 V
 • BV = Battery Voltage
 • CV = Charging Voltage
[2][1]
+
–
STANDARD: 0.1 – 1.0  Ω (20°C/68°F)
[1]