Honda Crf250l Service Manual

							19-6
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BATTERY/CHARGING SYSTEM
REGULATOR/RECTIFIER
REMOVAL/INSTALLATION
Remove the radiator reserve tank (page 9-12).
Disconnect the regulator/rectifier 5P connector [1].
Remove the bolts [2] and regulator/rectifier [3] from the
reserve tank stay.
Install the regulator/rectifier in the reverse order of
removal.
SYSTEM INSPECTION
Remove the right fuel tank shroud (page 2-4).
Turn the ignition switch OFF.
Disconnect the regulator/rectifier 5P connector [1], and
check it for loose contacts or corroded terminals.
If the charging voltage reading (page 19-5) is out of the
specification, check the following at the wire harness
side connector [1]:
If all components of the charging system are normal
and there are no loose connections at the regulator/
rectifier connector, replace the regulator/rectifier unit.
[1]
[2][3]
[1]
Item Terminal Specification
Battery charging 
line Red/white (+) 
and ground (–)Battery voltage 
should register
Charging coil line Yellow and  Yellow0.1 – 1.0 
Ω at 
(20°C/68°F)
Ground line Green and  groundContinuity should 
exist
[1] 
						

							20-1
20
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20. LIGHTS/METERS/SWITCHES
SERVICE INFORMATION ···························20-2
SYSTEM LOCATION···································20-2
HEADLIGHT ················································20-3
POSITION LIGHT ········································20-3
TURN SIGNAL LIGHT ·································20-4
BRAKE/TAILLIGHT···················\
··················\
20-5
SPEEDOMETER························\
··················\
20-5
VS SENSOR ················································20-8
HIGH COOLANT TEMPERATURE 
INDICATOR ·················································20-9 IGNITION SWITCH ···································· 20-10
HANDLEBAR SWITCH ··················\
··········· 20-11
BRAKE LIGHT SWITCH ··················\
········· 20-12
NEUTRAL SWITCH ·································· 20-12
SIDESTAND SWITCH ······························· 20-13
CLUTCH SWITCH ····································· 20-14
FUEL GAUGE/FUEL LEVEL 
SENSOR···················································· 20-14
HORN ························································ 20-15
TURN SIGNAL RELAY ····························· 20-15 
						

							20-2
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LIGHTS/METERS/SWITCHES
LIGHTS/METERS/SWITCHESSERVICE INFORMATION
GENERAL
 • Note the following when replacing the halogen headlight bulb.– Wear clean gloves while replacing the bulb. Do not put fingerpr ints on the headlight bulb, as they may create hot spots on the
bulb and cause it to fail.
– If you touch the bulb with your bare hands, clean it with a  cloth moistened with alcohol to prevent its early failure.
 • Be sure to install the dust cover after replacing the headlight bulb.
 • A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is turned OFF. Be s ure
to let it cool down before servicing.
 • Check the battery condition before performing an y inspection that requires proper battery voltage.
 • A continuity test can  be made with the switches installed on the motorcycle.
 • The following color codes are used throughout this section.
SYSTEM LOCATION
Bu = Blue G = Green Lb = Light Blue O = Orange R = Red Y = Yellow
Bl = Black Gr = GrayLg = Light Green P = Pink W = White
SPEEDOMETER
FRONT BRAKE LIGHT SWITCH
FUEL LEVEL SENSOR
TURN SIGNAL 
RELAY
NEUTRAL SWITCHREAR BRAKE 
LIGHT SWITCH
IGNITION SWITCH
STARTER SWITCH
CLUTCH SWITCH
HORN
VS SENSOR
ENGINE STOP SWITCH
DIMMER SWITCH
HORN SWITCH
TURN SIGNAL 
SWITCH
SIDESTAND SWITCH 
						

							20-3
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LIGHTS/METERS/SWITCHES
HEADLIGHT
BULB REMOVAL/INSTALLATION
Remove the headlight cowl (page 2-5).
Remove the dust cover [1].
Unhook the bulb retainer [2] and remove the headlight
bulb [3].
Avoid touching halogen headlight bulb. Fingerprints can
create hot spots that cause a bulb to break.
Install the bulb while aligning its tabs with the slots of
the headlight unit.
Hook the bulb retainer into the headlight unit groove.
Install the dust cover tightly against the headlight unit.
Install the headlight cowl (page 2-5).
HEADLIGHT UNIT REMOVAL/
INSTALLATION
Remove the headlight cowl (page 2-5).
Remove the screws [1] and headlight unit [2] from the
headlight cowl.
Installation is in the reverse order of removal.
POSITION LIGHT
BULB REMOVAL/INSTALLATION
Remove the headlight cowl (page 2-5).
Pull out the bulb  socket [1] from the headlight case.
Remove the bulb [2 ] from the socket.
Installation is in the reverse order of removal.
[2]
[3][1]
TORQUE: Headlight unit mounting screw:1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
[1]
[2]
[1]
[2] 
						

							20-4
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LIGHTS/METERS/SWITCHES
TURN SIGNAL LIGHT
BULB REMOVAL/INSTALLATION
Remove the screw [1] and turn signal light lens [2] by
releasing its tab [3].
While pushing in the bulb [4], turn it counterclockwise to
remove it.
Installation is in the reverse order of removal.
Check that the packing is installed in position and is in
good condition, replace it with a new one if necessary.
FRONT TURN SIGNAL UNIT 
REMOVAL/INSTALLATION
Remove the headlight cowl (page 2-5).
Disconnect the front turn signal 2P connector [1].
– Right side: Light blue
– Left side: Orange
Release the wire from the wire band [2].
Release the wire from the wire band [3].
Remove the nut [4] and front turn signal unit [5].
Installation is in the reverse order of removal.
Align the flats of the turn  signal unit and speedometer
stay.
REAR TURN SIGNAL UNIT REMOVAL/
INSTALLATION
Remove the rear fender (page 2-7).
Disconnect the rear turn signal 2P connector [1].
– Right side: Light blue
– Left side: Orange
Remove the nut [2] and rear turn signal unit [3].
Installation is in the reverse order of removal.
Align the flats of the turn signal unit and turn signal unit
stay.
[1]
[2]
[4]
[3]
Left side only:
TORQUE:
Turn signal unit mounting nut:
21 N·m (2.1 kgf·m, 15 lbf·ft)[2]
[3] (Left 
side only)[1]
[4][5][5]
Align
TORQUE: Turn signal unit mounting nut:21 N·m (2.1 kgf·m, 15 lbf·ft)
[2]
[3]
Align
[1] 
						

							20-5
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LIGHTS/METERS/SWITCHES
BRAKE/TAILLIGHT
For brake/taillight removal/installation (page 2-8).
BULB REMOVAL/INSTALLATION
Remove the rear fender (page 2-7).
Remove the brake/taillight mounting screws [1] and
collars [2].
Remove the hook bolts [3] and collars [4].
Pull the tail cover/light unit [5] rearward while pulling up
the rear upper fender [6].
Turn the bulb socket [1] counterclockwise and remove
it.
While pushing in the bulb [2], turn it counterclockwise to
remove it.
Installation is in the reverse order of removal.
SPEEDOMETER
REMOVAL/INSTALLATION
Remove the headlight cowl (page 2-5).
Release the wire bands [1] from the meter stay.
Remove the screws [2], washers [3] and speedometer
[4] by disconnecting the speedometer 16P connector
[5].
Remove the mounting rubbers [6].
Installation is in the reverse order of removal.
[2]
[1]
[5]
[3]
[6]
[4]
TORQUE:
Hook bolt:21 N·m (2.1 kgf·m, 15 lbf·ft)
Brake/taillight mounting screw:
4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
[2]
[1]
TORQUE: Speedometer mounting screw:
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
[2]
[3][1]
[5][4][6] 
						

							20-6
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LIGHTS/METERS/SWITCHESSYSTEM INSPECTION
Check for loose or poor contact terminals at the
speedometer 16P connector.
When the ignition switch is turned ON, check that the
meter segments turn on.
If the speedometer does not show the initial function,
perform the power and ground line inspection of the
speedometer (page 20-6).
If the speedometer shows the initial function but
speedometer does not move when running, check the
speedometer/VS sensor system  inspection (page 20-8).
POWER/GROUND LINES INSPECTION
Remove the speedometer (page 20-5).
 • Do not disconnect the speedometer 16P connector
[1] during inspection.
 • After inspection, reposition the dust cover [2] securely.
Remove the dust cover.
With the speedometer 16P co nnector connected, check
the following at the wire harness side connector.
POWER INPUT LINE
Measure the voltage betwe en the speedometer 16P
connector [1] and ground.
There should be battery voltage with the ignition switch
turned ON.
If there is no battery vo ltage, check the following:
– Open circuit in the Black wire
– Open circuit in Black/red wire between the fuse box and ignition switch
– Blown METER, TAIL fuse (10 A)
[2][1]
CONNECTION: Black (+) – Ground (–)
Bl
[1] 
						

							20-7
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LIGHTS/METERS/SWITCHES
GROUND LINE
Check for continuity between the speedometer 16P
connector [1] and ground.
There should be continuity at all times.
If there is no continuity, check for an open circuit in the
Green wire.
BACK-UP VOLTAGE LINE
Measure the voltage between the speedometer 16P
connector [1] and ground.
There should be battery voltage at all times.
If there is no battery vo ltage, check the following:
– Open circuit in the Red wire
– Blown ODO, CLOCK fuse (5 A)
– Blown main fuse (30 A)
– Open circuit in Red/white wire between the fuse box and starter relay switch
SPEEDOMETER DIGITAL CLOCK SET 
PROCEDURE
E TYPE:
Turn the ignition switch ON and engine stop switch  .
Push and hold both the A button [1] and B button [2]
until the speed and mileage units [3] start blinking.
Push the B button to select either mph & mile, or
km/h & km for the speedometer, odometer and trip
meter.
Push the A button to confirm the unit setting, and then
the display moves to the clock setting.
The hour digits [4] will star t blinking. Push the B button
until the desired hour is displayed.
Push and hold to advance the hour fast.
Push the A button, then t he minute digits [5] start
blinking.
Push the B button until the des ired minute is displayed.
Push and hold to advance the minute fast.
Push both the A button and B button to complete the
setting.
The time can also be set by turning the ignition switch
OFF. CONNECTION: Green – Ground
G
[1]
CONNECTION: Red (+) – Ground (–)
R
[1]
[2][1]
[4][5]
[3] 
						

							20-8
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LIGHTS/METERS/SWITCHES
EXCEPT E TYPE:
Turn the ignition switch ON and engine stop switch  .
Push and hold both the A button [1] and B button [2]
until the hour digits [3] start blinking.
Push the B button until the desired hour is displayed.
Push and hold to advance the hour fast.
Push the A button, then the minute digits [4] start
blinking.
Push the B button until the des ired minute is displayed.
Push and hold to advance the minute fast.
Push both the A button and B button to complete the
setting.
The time can also be set by turning the ignition switch
OFF.
VS SENSOR
SYSTEM INSPECTION
 • Before starting this inspection, check for
speedometer system inspection (page 20-5).
 • Do not disconnect the speedometer 16P connector during inspection.
 • After inspection, repositio n the dust cover securely.
Shift the transmissi on into neutral.
Turn the ignition switch ON and engine stop switch  .
With the speedometer 16P connector [1] connected,
measure the voltage betwe en the speedometer 16P
connector terminals.
Slowly turn the rear wheel by hand.
There should be 0 V to 5 V pulse voltage.
If pulse voltage appears, replace the speedometer
(page 20-5).
If pulse voltage does not appear, check the following:
– White/red wire for open or short circuit
– Green/black wire for open circuit
– If the wires are OK, check the VS sensor (page 20-
9).
[2][1]
[3][4]
CONNECTION: White/red (+) – Green/black (–)W/R
[1]
G/Bl 
						

							20-9
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LIGHTS/METERS/SWITCHES
VS SENSOR INSPECTION
Remove the left side cover (page 2-3).
Check for loose or poor contact of the VS sensor 3P
(Blue) connector [1].
Disconnect the VS sensor 3P (Blue) connector.
Turn the ignition switch ON and engine stop switch  .
Measure the voltage between the VS sensor 3P (Blue)
connector terminals at the wire side.
If battery voltage appears, replace the VS sensor.
If there is no voltage, check the following:
– Black/red wire for open circuit
– Green/black wire for open circuit
– Speedometer (page 20-5)
REMOVAL/INSTALLATION
Remove the left side cover (page 2-3).
Disconnect the VS sensor 3P (Blue) connector [1].
Remove the VS sensor wire from the guide [1].
Remove the bolt [2], VS sensor [3] and O-ring [4].
Installation is in the reverse order of removal.
 • Replace the O-ring with a new one.
 • Apply engine oil to a new O-ring. CONNECTION: Black/red (+) – Green/black (–)
STANDARD: Battery voltage
[1]
[1]
[2]
[3]
[1]
[4]