Honda Crf250l Service Manual

							2-6
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FRAME/BODY PANELS/EXHAUST SYSTEM
FRAME GUARD
REMOVAL/INSTALLATION
Remove the socket bolts [1] and frame guard [2].
Installation is in the reverse order of removal.
DRIVE SPROCKET COVER
REMOVAL/INSTALLATION
Remove the bolts [1] and drive sprocket cover [2].
Installation is in the reverse order of removal.
DRIVE CHAIN COVER (U TYPE ONLY)
REMOVAL/INSTALLATION
Remove the socket bolts [1] and drive chain cover [2].
Installation is in the reverse order of removal.
[2]
[1]
[2]
[1]
[2]
[1] 
						

							2-7
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FRAME/BODY PANELS/EXHAUST SYSTEM
TOOL BOX
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Left side cover (page 2-3)
Remove the two mounting bolts [1] and tool box [2].
Installation is in the reverse order of removal.
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the tool box as following illustration.
REAR FENDER
REMOVAL/INSTALLATION
Remove the bolts [1] and rear fender [2].
Installation is in the reverse order of removal.
[2][1]
TOOL BOX
SPECIAL WASHER
HINGE
TOOL BOX COVER
LOCK UNIT
LOCK SPRING
[2]
[1] 
						

							2-8
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FRAME/BODY PANELS/EXHAUST SYSTEMDISASSEMBLY/ASSE MBLY (U TYPE 
ONLY)
Remove the nuts [1], bolts [2], collars [3], license holder
plate [4] and license plate stay [5].
Remove the stopper rubber [6].
Remove the nuts [7] and rear side reflectors [8].
Assembly is in the reverse order of disassembly.
REAR UPPER FENDER
REMOVAL/INSTALLATION
Remove the seat (page 2-3).
Remove the hook bolts [1] and collars [2].
Slightly spread the side covers [3] and release the
bosses [4] and tabs [5].
Remove the rear upper fender [6].
Installation is in the reverse order of removal.
TAIL COVER/LIGHT UNIT
REMOVAL/INSTALLATION
Remove the following:
– Rear upper fender (page 2-8)
– Rear fender (page 2-7)
Disconnect the brake/taillight 6P (Black) connector [1].
Remove the bolts A [2], bolts  B [3] and tail cover/light
unit [4].
Installation is in the reverse order of removal. TORQUE:
Rear side reflector mounting nut:1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
[1]/[3]
[2][5]
[4]
[7]
[8]
[6]
TORQUE: Hook bolt: 21 N·m (2.1  kgf·m, 15 lbf·ft)
[2]
[3]
[1]
[5]
[4]
[6]
[2]
[3]
[1]
[4] 
						

							2-9
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FRAME/BODY PANELS/EXHAUST SYSTEM
DISASSEMBLY/ASSEMBLY
Remove the following:
– Rear fender (page 2-7)
– Rear turn signal units (page 20-4)
Disassemble and assemble the tail cover/light unit as following illustration.
REAR LOWER FENDER
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Side covers (page 2-3)
– Tail cover/light unit (page 2-8)
Release the wire bands [1].
BRAKE/TAILLIGHT 
MOUNTING SCREWS
4.5 N·m (0.5 kgf·m, 
3.3 lbf·ft)
COLLARS
REAR TURN SIGNAL 
UNIT STAYBRAKE/TAILLIGHT UNIT
SCREW
LEFT TAIL COVER
REAR REFLECTOR
SOCKET BOLTS
RIGHT TAIL COVER
REFLECTOR 
MOUNTING NUT
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
[1] 
						

							2-10
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FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the rear lower fender mounting bolt [1].
Remove the bolts [1], helmet holder [2] and rear lower
fender [3].
Use a drill or an equivalent tool when removing the
helmet holder mounting bolts.
Installation is in the reverse order of removal.
 • Replace the helmet holder mounting bolts with newones.
[1]
[1]
[2]
[3] 
						

							2-11
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FRAME/BODY PANELS/EXHAUST SYSTEM
EXHAUST PIPE/MUFFLER
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Right side cover (page 2-3)
Remove the exhaust pipe/muffler as following
illustration.
Installation is in the reverse order of removal.
STUD BOLT REPLACEMENT
Remove the exhaust pipe (page 2-11).
Thread two nuts onto the stud bolt and tighten them
together, and use a wrench on them to turn the stud bolt
out.
Install and tighten new stud bolts to the specified
torque.
After installation, check that the length from the bolt
head to the cylinder head surface is within specification.
SOCKET BOLTS
12 N·m (1.2 kgf·m, 9 lbf·ft)18 N·m (1.8 kgf·m, 
13 lbf·ft)
22.5 N·m (2.3 kgf·m, 17 lbf·ft)
32 N·m (3.3 kgf·m, 24 lbf·ft)
MUFFLER
MUFFLER PROTECTOR
SOCKET BOLTS
BOLT
BAND BOLT
MUFFLER FRONT MOUNTING BOLTNUT
GASKET
EXHAUST PIPE
JOINT NUTS
EXHAUST PIPE 
PROTECTOR
GASKET
DAMPER RUBBER
TORQUE: 9.0 N·m (0.9  kgf·m, 6.6 lbf·ft)
22.0 ± 0.5 mm 
(0.87 ± 0.02 in) 
						

							2-12
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FRAME/BODY PANELS/EXHAUST SYSTEM
SUB-FRAME
REMOVAL/INSTALLATION
Remove the following:
– Seat (page 2-3)
– Side covers (page 2-3)
– Muffler (page 2-11)
– Fuel tank (page 7-8)
– Battery (page 19-4)
Remove the bolt [1] and reservoir [2].
Disconnect the PAIR air suction hose [3] and crankcase
breather hose [4] from the air cleaner housing.
Remove the wire bands [1].
Remove the following from the air cleaner housing.
– Starter relay switch [2]
– Fuse box [3]
– Relay box [4]
– Wire clips [5]
Open the harness band [1] and release the wires.
Disconnect the battery case drain hose [2].
Release the wire bands [1].
Disconnect the brake/taillight 6P (Black) connector [2].
[2]
[3][1]
[4]
[1]
[2]
[4][5]
[5]
[3]
[2][1]
[1]
[2] 
						

							2-13
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FRAME/BODY PANELS/EXHAUST SYSTEM
Loosen the air cleaner connecting hose band screw [1].
Remove the sub-frame lower mounting bolts [1].
Remove the sub-frame upper mounting nuts [1] and
bolts [2].
Pull the sub-frame assembly rearward, then disconnect
the air cleaner connecting hose from the throttle body.
Remove the sub-frame.
Install the sub-frame in position, connect the air cleaner
connecting hose to the throttle body.
Tighten the band screw to the specified torque.
Loosely install all t he mounting fasteners.
Tighten the upper mounting  nut first, then the lower
bolts to the specified torque.
Install the removed parts in the reverse order of
removal.
[1]
[1]
TORQUE: 1.5 N·m (0.2  kgf·m, 1.1 lbf·ft)
TORQUE: Sub-frame upper mounting nut: 27 N·m (2.8 kg f·m, 20 lbf·ft)
Sub-frame lower mounting bolt:
27 N·m (2.8 kg f·m, 20 lbf·ft)
TORQUE: Rear master cylinder reservoir mounting bolt:10 N·m (1.0 kgf·m, 7 lbf·ft)
[1][2] 
						

							2-14
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FRAME/BODY PANELS/EXHAUST SYSTEM
SIDESTAND
REMOVAL/INSTALLATION
Remove the sidestand switch (page 20-14).
Remove the return spring [1] and sub spring [2].
Remove the pivot lock nut [3], pivot bolt [4] and
sidestand [5].
Apply grease to the sidestand pivot bolt sliding surface.
Install the sidestand and pivot bolt, then tighten it to the
specified torque.
Turn the pivot bolt counterclockwise about 45° – 90°.
Install the pivot lock nut and tighten it to the specified
torque while holding the pivot bolt.
Install the return spring and sub spring as shown.
Install the sidestand  switch (page 20-14).
TORQUE: 10 N·m (1.0
 kgf·m, 7 lbf·ft)
TORQUE: 30 N·m (3.1  kgf·m, 22 lbf·ft)
[1]/[2]
[3][4]
[5]
[1]
[2] 
						

							3-1
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3. MAINTENANCE
SERVICE INFORMATION ·····························3-2
MAINTENANCE SCHEDULE ························3-2
FUEL LINE·····················································3-3
THROTTLE OPERATION······························3-3
AIR CLEANER···············································3-4
CRANKCASE BREATHER ··················\
·········3-4
SPARK PLUG··················\
··················\
············3-5
VALVE CLEARANCE····································3-6
ENGINE OIL ··················································3-9
ENGINE OIL FILTER ···································3-10
ENGINE IDLE SPEED ··················\
···············3-10
RADIATOR COOLANT ·······························3-11
COOLING SYSTEM···················\
··················\
3-11
SECONDARY AIR SUPPLY SYSTEM ········3-11 DRIVE CHAIN ············································· 3-12
DRIVE CHAIN SLIDER ······························· 3-14
BRAKE FLUID ··················\
··················\
········ 3-15
BRAKE PADS WEAR ··················\
··············· 3-16
BRAKE SYSTEM ··················\
··················\
···· 3-17
BRAKE LIGHT SWITCH ··················\
··········· 3-17
HEADLIGHT AIM ········································ 3-18
CLUTCH SYSTEM ······································ 3-18
SIDESTAND ················································ 3-19
SUSPENSION ··················\
··················\
········· 3-19
NUTS, BOLTS, FASTENERS ····················· 3-19
WHEELS/TIRES ·········································· 3-20
STEERING HEAD BEARINGS ··················· 3-20