Honda Crf250l Service Manual
Have a look at the manual Honda Crf250l Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 328 Honda manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
![Page 334
20-13
dummyhead
dummyhead
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...](http://img.usermanuals.tech/thumb/34/103137/w64_crf250l-service-manual-1512603421_d-333.png "Page 334
20-13
dummyhead
dummyhead
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...")
![Page 335
20-14
dummyhead
dummyhead
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...](http://img.usermanuals.tech/thumb/34/103137/w64_crf250l-service-manual-1512603421_d-334.png "Page 335
20-14
dummyhead
dummyhead
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...")
![Page 336
20-15
dummyhead
dummyhead
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...](http://img.usermanuals.tech/thumb/34/103137/w64_crf250l-service-manual-1512603421_d-335.png "Page 336
20-15
dummyhead
dummyhead
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...")
![Page 337
20-16
dummyhead
dummyhead
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,...](http://img.usermanuals.tech/thumb/34/103137/w64_crf250l-service-manual-1512603421_d-336.png "Page 337
20-16
dummyhead
dummyhead
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,...")
![Page 338
20-17
dummyhead
dummyhead
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]](http://img.usermanuals.tech/thumb/34/103137/w64_crf250l-service-manual-1512603421_d-337.png "Page 338
20-17
dummyhead
dummyhead
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]")
21-2 dummytext WIRING DIAGRAM WIRING DIAGRAMWIRING DIAGRAM COLORCOLOR COLOR COLOR COLOR COLOR R/W P BI/R Y/R BI/Bu BI/Y Bu/W BI/G BI/Bu Gr Lb Bu/W BuW O Lg BI/O 2P LbLb G Lb G 2P OO G O G 3P BlW Bu G Bu/W BuW Bu/W BuW Bu/W BuW Gr Lb O Gr Lb O Gr Lb O G/OG/R G/OG/R Bl/O Lg Bl/O Lg Bl/O Lg G/O G/R Bl/Bu Bl/Bu Bl/BuBl/W Bl/WBl/G Lg/Bl Lg/R G/R Bl/R Bl/G Bl/O Bl/O Bl/W Bl/W R/WBl/R Bl/Y Bl R Bu Br/R Br Bl/Bu G/WY/R Gr/Bu Lg/Bl Y Bu Y G 33P Bl 4P Bl Bl/Bu G/Bl Bl/W G/W Y Y/R BrG G G/R Bu/Y P Gr/Bu Bu P/W W/R W/Bu Bl/G Br/W Bu/W G/Bu W/Y Y/Bu G/O R/Bu Lg/Bl O/G G/R Y Br/Bl Bu/Bl Br/Bl Br/W Bu/Bl Bu/W Y/BuG/W BI Bl/W G/O Lg/R W/Y Bu/Y Y Y Y Lg/R W/Y Bu/Y Y Y Y Y Y Y G G R/W G Bl/Bu G/R Bl/Bu G/WG P/W G G G G G/Bl Bl/Bu Bl/Bu Bl/Bu 2P Lb 2P O G/YG Bl O G Lb G/Y G Bl O Lb G/Y G Bl O Lb G G G G G G G G G G G G R/W R/W G/RY/R BI R/W Bl/R P G/Y Bl/O BI R/W Bl/R P Y/R Bl/Y Bu/W Bl/Bu Bl/GG/Y Bl/O Y/R Bl/Y Bu/W Bl/Bu Bl/G Bl Bl/O Y/R Bl/Bu Bl/Y Bu/W Bl/Bu Bl/G Bl Bl/O G Bu BI Bu R/Bl Y/R Bl/W Y/W Br/R G Gr G Bl/O O/G Bl/Bu R/Bu Bl/Bu P Bl G W/R Bl/R G/Bl Lb Bu O G/Bu W/Bu Y/W R Bl G/Bl W/R Bl/R Lg/Bl G Lg G BLACK YELLOW BLUE GREEN RED WHITE GRAY PINK LIGHT GREEN LIGHT BLUE ORANGE BROWN W R G Bu Y Bl Gr P Lg Lb O Br COLOR COMB : GROUND/MARKING 16P 3P Bu2P 2P BI 3P BI2P BI9P BI 3P Br 3P BI 4P R 12P 2P Gr 5P 4P R 14P Gr 6P BI 5P 3P 3P G 3P 1P BI 3P BI 3P BI BATTERY HORN HEADLIGHT 12V 60/55W LEFT FRONT TURN SIGNAL LIGHT 12V 21W RIGHT FRONT TURN SIGNAL LIGHT 12V 21W SPEEDOMETER VS SENSORBANK ANGLE SENSOR TURN SIGNAL RELAY PAIR CONTROL SOLENOID VA LV E FUEL PUMP UNITFA N MOTOR ENGINE STOP SWITCH STARTER SWITCH IGNITION SWITCH STARTER MOTOR STARTER RELAY SWITCH REAR BRAKE LIGHT SWITCH FRONT BRAKE LIGHT SWITCH RIGHT HANDLEBAR SWITCH MAIN FUSE (30A) JUNCTION BOX RIGHT REAR TURN SIGNAL LIGHT 12V 21W LEFT REAR TURN SIGNAL LIGHT 12V 21WBRAKE/TAILLIGHT 12V 21/5W REGULATOR/ RECTIFIER ALTERNATOR CKP SENSOR NEUTRAL SWITCH JOINT FRAME GROUND 4 FRAME GROUND 3 FRAME GROUND 2 FRAME GROUND 1 SIDESTAND SWITCH SPARK PLUG INJECTOR ECT SENSOR SENSOR UNIT FUSE BOX TURN SIGNAL SWITCH CLUTCH SWITCH HORN SWITCH DIMMER SWITCH NEUTRAL DIODE TURN SIGNAL SWITCH IGNITION SWITCH DIMMER SWITCH HORN SWITCH ENGINE STOP SWITCH STARTER SWITCH 10A 10A 10A 10A 5A 10A 1 2 3 4 5 6 LEFT HANDLEBAR SWITCH FI,IGN TURN,HORN,STOP METER,TAIL FA N ODO,CLOCK HEAD FA N CONTROL RELAY FUEL PUMP RELAY IACV ECM DLC 123456 GND NEUTRAL VSP SP SIG SP GND IGN(Vcc) BATT FUEL FI TEMP TURN L HIGH BEAM TURN R16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1IGP OUT GND IGN OUTF/PUMP - F/PUMP + SENDER +BAT IG UP DOWNO2 SENSOR IGP LG O2 SG THL VCC FLR PG1 PG2 IGPLS PCP IMOV TA SCS INJ VSP FI-IND FA N C IACV2A IACV1A TW-IND PCMTW SSTAND BA PB EX-AI NLSW K-LINE IACV2B IACV1B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 SG VCC TA PB THL L R W LO HI HL NWR L (N)HL LO HI ON OFF LOCK BAT IG HO BAT FREE PUSH BAT IG IG PUSH FREE ST BAT HL S S IG BATIG STHL BAT HO BAT IGNITION COIL G Bl Bl/G Bu/W G2P Bl POSITION LIGHT 12V 5W
22-1 22 dummytext INDEX AAIR CLEANER ································································ 3-4 AIR CLEANER HOUSING ············································ 7-10 ALTERNATOR CHARGING COIL ································ 19-5 BBALANCER ································································· 14-14 BANK ANGLE SENSOR ··············································· 4-48 BATTERY······································································ 19-4 BRAKE FLUID················································ ··············· 3-15 BRAKE FLUID REPLACEMENT/AI R BLEEDING ········ 18-4 BRAKE LIGHT SWITCH LIGHTS/METERS/SWITCHES······························· 20-12 MAINTENANCE ······················································· 3-17 BRAKE PAD/DISC ··········· ·········································· ··· 18-5 BRAKE PADS WEAR ········ ··········································· 3-16 BRAKE PEDAL ······· ···················································· 18-12 BRAKE SYSTEM ······· ···································· ··············· 3-17 BRAKE/TAILLIGHT ·········· ·········································· ··· 20-5 CCABLE & HARNESS ROUTING ······ ····························· 1-17 CAM CHAIN TENSIONER ············································ 11-7 CAMSHAFT ·································································· 10-6 CHARGING SYSTEM INSPECTION · ··························· 19-4 CLUTCH········································································ 12-9 CLUTCH SWITCH ······················································ 20-14 CLUTCH SYSTEM ····· ···································· ··············· 3-18 COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH ························ 13-2 BRAKE SYSTEM········· ·········································· ··· 18-3 CLUTCH/GEARSHIFT LI NKAGE ····························· 12-3 CRANKCASE/CRANKSHA FT/TRANSMISSION/ BALANCER ······························································ 14-3 CYLINDER HEAD/VALVES ····································· 10-3 CYLINDER/PISTON ················································· 11-2 ENGINE REMOVAL/INSTALLATION······················· 15-3 FRONT WHEEL/SUSPENSION/STEERING ····· ······ 16-3 FUEL SYSTEM······ ···································· ················· 7-3 REAR WHEEL/SUSPENSION ································· 17-3 COOLANT REPLACEMENT ············ ······························· 9-5 COOLING SYSTEM ··· ···································· ··············· 3-11 CRANKCASE ASSEMBLY ··· ······················· ··············· 14-18 CRANKCASE BEARING REPLACEM ENT················· 14-15 CRANKCASE BREATHER ··· ·········································· 3-4 CRANKCASE SEPARATION··· ····································· 14-4 CRANKSHAFT ······························································ 14-6 CYLINDER COMPRESSI ON ········································ 10-4 CYLINDER HEAD ······················································· 10-13 CYLINDER HEAD COVER ··········································· 10-4 CYLINDER/PISTON······················································ 11-3 DDRIVE CHAIN ······························································· 3-12 DRIVE CHAIN GUIDE················································· 17-12 DRIVE CHAIN SLIDER ················································· 3-14 DRIVE SPROCKET COVER··········································· 2-6 DTC INDEX ····································································· 4-7 DTC TROUBLESHOOTING·········································· 4-10 EECM ·············································································· 4-49 ECT SENSOR ······························································· 4-46 EMISSION CONTROL SYSTEMS ································ 1-27 ENGINE IDLE SPEED ······· ··········································· 3-10 ENGINE INSTALLATION ·············································· 15-7 ENGINE OIL···································································· 3-9 ENGINE OIL FILTER ···················································· 3-10 ENGINE OIL STRAINER SCREEN · ······························· 8-4 ENGINE REMOVAL ······················································ 15-4 EXHAUST PIPE/MUFFLER ·········································· 2-11 FFAN CONTROL RELAY················································ 9-12 FLYWHEEL ··································································· 13-5 FORK ············································································ 16-6 FRAME GUARD······························································ 2-6 FRONT BRAKE CALIPER · ········································· 18-10 FRONT FENDER ···························································· 2-5 FRONT MASTER CYLINDER······································· 18-7 FRONT WHEEL···························································· 16-4 FUEL GAUGE/FUEL LEVEL SENSOR ······················ 20-15 FUEL LINE ····································································· 3-3 FUEL LINE INSPECTION··············································· 7-4 FUEL PUMP RELAY ···················································· 7-10 FUEL PUMP UNIT ·························································· 7-8 FUEL TANK ···································································· 7-8 FUEL TANK SHROUD ··················································· 2-4 GGEARSHIFT LINKAGE··············································· 12-14HHANDLEBAR ············ ··············································· ··· 16-16 HANDLEBAR SWITCH····· ·········································· 20-11 HEADLIGHT ································································· 20-3 HEADLIGHT AIM ·························································· 3-18 HEADLIGHT COWL ······················································· 2-5 HIGH COOLANT TEMPERATURE INDICATOR ······· 20-10 HORN ········································································· 20-15 IIACV ············································································· 7-15 IGNITION COIL ······························································ 5-6 IGNITION SWITCH····················································· 20-11 IGNITION SYSTEM INSPECTION · ································ 5-4 IGNITION TIMING ·························································· 5-6 INJECTOR ···································································· 7-14 LLEFT CRANKCASE COVER ·········· ······························ 13-3 LUBRICATION & SEAL POINTS···· ······························ 1-15 LUBRICATION SYSTEM DIAGRAM · ····························· 8-3 MMAIN JOURNAL BEARIN G ·········································· 14-7 MAINTENANCE SCHEDULE ········································· 3-2 MIL CIRCUIT TROUBLESHOOTING ··························· 4-43 MIL TROUBLESHOOTING··········································· 4-29 MODEL IDENTIFICATION ············································· 1-2 NNEUTRAL DIODE··························································· 6-9 NEUTRAL SWITCH ···················································· 20-13 NUTS, BOLTS, FASTENERS······································· 3-19 OO2 SENSOR································································· 4-47 OIL PUMP ······································································ 8-4 PPGM-FI SYMPTOM TROUBLESHOOTING ··················· 4-6 PGM-FI SYSTEM DIAGRAM·········································· 4-3 PGM-FI SYSTEM LOCATION ········································ 4-2 PGM-FI TROUBLESHOOTING INFORMATION ············ 4-4 POSITION LIGHT ························································· 20-3 PRESSURE RELIEF VALVE ·········································· 8-7 PRIMARY DRIVE GEAR ············································ 12-17 RRADIATOR COOLANT ················································· 3-11 RADIATOR RESERVE TANK ········ ······························ 9-12 RADIATOR/COOLING FAN ··········································· 9-6 REAR BRAKE CALIPER ·· ·········································· 18-11 REAR FENDER ······························································ 2-7 REAR LOWER FENDER ················································ 2-9 REAR MASTER CYLINDER········································· 18-8 REAR UPPER FENDER················································· 2-8 REAR WHEEL ······························································ 17-4 REGULATOR/RECTIFIER ··········································· 19-6 RESERVE TANK COVER ·············································· 2-4 RIGHT CRANKCASE COVER ····································· 12-4 ROCKER ARM ··························································· 10-11 SSEAT ·············································································· 2-3 SECONDARY AIR SUPPLY SYSTEM FUEL SYSTEM ···· ···················································· 7-17 MAINTENANCE ······················································· 3-11 SENSOR UNIT ····························································· 4-44 SENSOR UNIT POWER LINE INSPECTION················· 4-8 SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH························ 13-2 BATTERY/CHARGING SYSTEM ···· ························ 19-2 BRAKE SYSTEM ········· ······································· ····· 18-2 CLUTCH/GEARSHIFT LINKAGE ···························· 12-2 COOLING SYSTEM ········ ··········································· 9-2 CRANKCASE/CRANKSHAF T/TRANSMISSION/ BALANCER ······························································ 14-2 INDEX
22-2 dummytext INDEX CYLINDER HEAD/VALVES ····································· 10-2 CYLINDER/PISTON ················································ 11-2 ELECTRIC STARTER SYSTEM································ 6-2 ENGINE REMOVAL/INSTALLATION ······················ 15-2 FRAME/BODY PANELS/EXH AUST SYSTEM·········· 2-2 FRONT WHEEL/SUSPENSION/STEERING ··· ········ 16-2 FUEL SYSTEM ·························································· 7-2 IGNITION SYSTEM ··················································· 5-2 LIGHTS/METERS/SWITCHES ································ 20-2 LUBRICATION SYSTEM ·· ·································· ······· 8-2 MAINTENANCE ························································· 3-2 PGM-FI SYSTEM········· ······································· ······· 4-2 REAR WHEEL/SUSPENSION······ ··························· 17-2 SERVICE RULES ··························································· 1-2 SHOCK ABSORBER ········ ············································ 17-6 SHOCK LINKAGE ························································ 17-7 SIDE COVER ································································· 2-3 SIDESTAND FRAME/BODY PANELS/EXH AUST SYSTEM ········ 2-14 MAINTENANCE ······················································· 3-19 SIDESTAND SWITCH ················································ 20-13 SKID PLATE ··································································· 2-5 SPARK PLUG·········· ················································ ······· 3-5 SPECIFICATIONS··· ················································ ······· 1-4 SPEEDOMETER ·················································· ········ 20-5 STARTER CLUTCH ····················································· 13-7 STARTER MOTOR ························································ 6-4 STARTER RELAY SWITCH ··········································· 6-8 STATOR/CKP SENSOR ·············································· 13-4 STEERING HEAD BEAR INGS································ ····· 3-20 STEERING STEM ······················································ 16-21 SUB-FRAME ································································ 2-12 SUSPENSION ········· ················································ ····· 3-19 SWINGARM ······························································· 17-10 SYSTEM DIAGRAM BATTERY/CHARGING SYSTEM ···························· 19-3 ELECTRIC STARTER SYSTEM··· ····························· 6-3 IGNITION SYSTEM ··················································· 5-3 SYSTEM FLOW PATTERN············ ································ 9-3SYSTEM LOCATION BATTERY/CHARGING SYSTEM ····· ························ 19-3 ELECTRIC STARTER SYSTEM ································ 6-3 IGNITION SYSTEM ······ ·············································· 5-3 LIGHTS/METERS/SWITCHES ································ 20-2 SYSTEM TESTING········ ··········································· ······ 9-4 TTAIL COVER/LIGHT UNIT·············································· 2-8 THERMOSTAT ······························································· 9-5 THROTTLE BODY ························································ 7-11 THROTTLE OPERATION ··············································· 3-3 TOOL BOX······································································ 2-7 TORQUE VALUES ························································· 1-9 TRANSMISSION························································· 14-10 TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH ························ 13-2 BATTERY/CHARGING SYSTEM ····· ························ 19-2 BRAKE SYSTEM ······ ··········································· ···· 18-2 CLUTCH/GEARSHIFT LINKAGE ····························· 12-2 COOLING SYSTEM ········ ··········································· 9-2 CRANKCASE/CRANKSHA FT/TRANSMISSION/ BALANCER ······························································ 14-2 CYLINDER HEAD/VALVES ····································· 10-2 CYLINDER/PISTON ················································· 11-2 ELECTRIC STARTER SYSTEM ································ 6-2 FRAME/BODY PANELS/EXHAU ST SYSTEM ··········· 2-2 FRONT WHEEL/SUSPENSION/STEERING ··········· 16-2 FUEL SYSTEM ···· ···································· ·················· 7-2 IGNITION SYSTEM ······ ·············································· 5-2 LUBRICATION SYSTEM ··· ········································ 8-2 REAR WHEEL/SUSPENSION ································· 17-2 TURN SIGNAL LIGHT ··· ··········································· ···· 20-4 TURN SIGNAL RELAY ·············· ································· 20-16 VVALVE CLEARANCE ····················································· 3-6 VS SENSOR ································································· 20-8 WWATER PIPE ································································ 9-13 WATER PUMP································································ 9-8 WHEELS/TIRES ··························································· 3-20 WIRING DIAGRAM ······················································· 21-2