Honda Crf250l Service Manual

							20-10
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LIGHTS/METERS/SWITCHES
HIGH COOLANT TEMPERATURE 
INDICATOR
SYSTEM INSPECTION
 • Before starting the inspection, check for loose orpoor contact on the spee dometer 16P connector,
ECT sensor 3P connector and ECM 33P (Black)
connector.
Turn the ignition switch ON and engine stop switch  .
Check that the high coolant temperature indicator [1]
comes ON.
If the high coolant temperature indicator blinks, follow
the PGM-FI troubleshootin g for ECT sensor (page 4-
30).
If the high coolant temperature indicator does not come
ON at all or remains  ON, inspect as follows.
Remove the reserve tank cover (page 2-4).
Turn the ignition switch OFF.
Disconnect the ECM 33P (Black) connector [1].
Turn the ignition switch ON and engine stop switch  .
Check that the high coolant temperature indicator
remains OFF.
 • If the indicator comes ON, check for short circuit in the Green/blue wire between the speedometer and
ECM.
 • If the wire is OK, replace the speedometer with a known good one and recheck.
Turn the ignition switch OFF.
Ground the following terminal of the wire harness side
ECM 33P (Black) connector [1] with a jumper wire [2].
Turn the ignition switch ON and engine stop switch  
the high coolant temperature indicator should come on.
 • If the indicator does no t come ON, check for open
circuit in the Green/blue wire between the
speedometer and ECM.
 • If the indicator comes on with the Green/blue wire
grounded but does not come ON with the ECM 33P
(Black) connector connect ed, replace the ECM with
a known good one and recheck.[1]
[1]
CONNECTION: Green/blue – Ground
TOOL:
Test probe 07ZAJ-RDJA110
[1]
G/Bu
[2] 
						

							20-11
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LIGHTS/METERS/SWITCHES
IGNITION SWITCH
INSPECTION
Remove the headlight cowl (page 2-5).
Disconnect the ignition switch 3P (Brown) connector [1].
Check for continuity between the switch side connector
terminals in each switch position according to the chart
(page 21-2).
REMOVAL/INSTALLATION
Remove the top bridge (page 16-21).
Remove the ignition switch mounting bolts [1] and
ignition switch [2].
Use a drill or an equivalent tool when removing the
ignition switch mounting bolts.
Install the ignition swit ch onto the top bridge.
Install and tighten new igniti on switch mounting bolts to
the specified torque.
Install the top bridge (page 16-24).
HANDLEBAR SWITCH
RIGHT HANDLEBAR SWITCH
Remove the headlight cowl (page 2-5).
Disconnect the right handlebar switch 9P (Black)
connector [1].
Check for continuity between the switch side connector
terminals in each switch posi tion according to the chart
(page 21-2).
[1]
TORQUE: 24 N·m (2.4 kgf·m, 18 lbf·ft)
[2]
[1]
[1] 
						

							20-12
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LIGHTS/METERS/SWITCHESLEFT HANDLEBAR SWITCH
Remove the headlight cowl (page 2-5).
Disconnect the left handlebar switch 14P (Gray)
connector [1].
Check for continuity between the switch side connector
terminals in each swit ch position according to the chart
(page 21-2).
BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake light switch connectors and
check for continuity between the switch terminals [1].
There should be continuity with the brake lever
squeezed, and no continuity with the brake lever
released.
REAR 
Remove the left side cover (page 2-3).
Disconnect the rear brake light switch 3P (Black)
connector [1].
Check for continuity between the switch side terminals.
There should be continuity with the brake pedal [2]
depressed, and no contin uity when the brake pedal
released.
[1]
[1]
[2][1] 
						

							20-13
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LIGHTS/METERS/SWITCHES
NEUTRAL SWITCH
REMOVAL/INSTALLATION
Drain the engine oil (page 3-9).
Remove the gearshift pedal (page 12-14).
Disconnect the neutral switch wire connector [1].
Remove the neutral switch [2] and sealing washer [3].
Installation is in the reverse order of removal.
 • Replace the sealing washer with a new one.
Fill the engine with the recommended engine oil (page
3-9).
INSPECTION
Make sure that the neutral indicator come on with the
ignition switch ON and transmission is in neutral.
If the neutral indicator does not come on, inspect as
follows:
Remove the drive sprocket cover (page 2-6).
Disconnect the neutral switch wire connector.
Check for continuity between the switch terminal and
engine ground.
There should be continuity with the transmission is in
neutral, and no continuity when the transmission is into
gear.
If the continuity inspection is normal, check for open
circuit in Light green/red wire between neutral switch
wire connector and neutral indicator.
If the continuity inspection is abnormal, replace the
neutral switch (page 20-13).
SIDESTAND SWITCH
INSPECTION
Remove the left side cover (page 2-3).
Disconnect the sidestand switch 3P (Green) connector
[1].
Check the continuity between  the following terminals of
the switch side connector.
The switch is normal if there is continuity when the
sidestand is retracted, and no continuity when the
sidestand is lowered. TORQUE:
Neutral switch: 12 N·m  (1.2 kgf·m, 9 lbf·ft)
[1][2]
[3]
CONNECTION: Green/white – Green
[1] 
						

							20-14
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LIGHTS/METERS/SWITCHESREMOVAL/INSTALLATION
Remove the sub-frame (page 2-12).
Disconnect the sidestand switch 3P (Green) connector
[1].
Release the wire from the clamps [2].
Remove the two bolts [1] and switch cover [2].
Remove the mounting bolt [1] and sidestand switch [2].
Installation is in the reverse order of removal.
 • Replace the sidestand swit ch mounting bolt with a
new one.
 • Align the switch groove with the spring pin of the
frame.
CLUTCH SWITCH
Disconnect the clutch switch wire connectors and check
for continuity between the switch terminals [1].
There should be continuity with the clutch lever
squeezed and no continuity with the clutch lever
released.
[1][2]
[1]
[2]
TORQUE:
Sidestand switch mounting bolt:10 N·m (1.0 kgf·m, 7 lbf·ft)
[1]
[2]
Align
[1] 
						

							20-15
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LIGHTS/METERS/SWITCHES
FUEL GAUGE/FUEL LEVEL SENSOR
FUEL GAUGE INSPECTION
If the fuel gauge [1] is indicated as shown, check for an
open circuit in wire harness and the fuel level sensor.
If the wire harness and fuel level sensor are good,
replace the speedometer assembly (page 20-5).
FUEL LEVEL SENSOR INSPECTION
Remove the fuel pump unit (page 7-9).
Connect the ohmmeter to the following terminals of fuel
pump 3P connector.
Inspect the resistance of the  float at the full and empty
positions.
Replace the fuel pump unit if fuel level sensor is out of
specification.
Install the fuel pump unit (page 7-9).
HORN
INSPECTION
Remove the reserve tank cover (page 2-4).
Disconnect the connectors from the horn.
Connect a 12 V battery to the horn terminals.
The horn is normal if it sounds when the 12 V battery is
connected across the horn terminals.
[1]
CONNECTION: Red/black  – Black/white
Float position FULL EMPTY Resistance 9 – 11 Ω 213 – 219 Ω
FULL
EMPTY
BATTERY 
						

							20-16
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LIGHTS/METERS/SWITCHESREMOVAL/INSTALLATION
Remove the reserve tank cover (page 2-4).
Disconnect the wire connectors [1] from the horn [2].
Remove the bolt [3] and horn.
Installation is in the reverse order of removal.
TURN SIGNAL RELAY
INSPECTION
STANDARD INSPECTION
Check the following:
– Battery condition
– Burned out bulb or non-specified wattage
– Blown TURN, HORN, STOP fuse (10 A)
– Ignition switch and turn signal switch function
– Loose connector
If above items are normal, remove the reserve tank
cover (page 2-4).
INPUT VOLTAGE INSPECTION
Disconnect the turn signal relay 3P (Black) connector
[1] from the relay.
Turn the ignition switch ON and check the voltage
between the following terminals of the wire harness
side connector.
If there is no battery vo ltage, inspect the following:
– Open circuit in Green wire
– Open circuit in Black/orange wire between the turn signal relay 3P (Black) connector and fuse box
SIGNAL LINE INSPECTION
Short the following terminals of the turn signal relay 3P
(Black) connector with a jumper wire.
Turn the ignition switch and turn signal switch ON.
Check that the turn signal lights come ON.
– If the turn signal lights  do not come ON, check for
open circuit in Gray wire.
– If the turn signal lights come ON, replace the turn signal relay with a known-good one and recheck.
[1]
[3][2]
CONNECTION: Black/orange  (+) – Green (–)
STANDARD: Battery voltage
CONNECTION: Black/orange – Gray
[1] 
						

							20-17
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LIGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
Remove the reserve tank cover (page 2-4).
Disconnect the turn signal relay 3P (Black) connector
[1] from the turn  signal relay [2].
Remove the turn signal relay from the frame.
Installation is in the reverse order of removal.
[1]
[2] 
						

							MEMO
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							21-1
21
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21. WIRING DIAGRAM
WIRING DIAGRAM······································21-2