Honda Crf250l Service Manual

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MAINTENANCE
MAINTENANCESERVICE INFORMATION
GENERAL
 • Place the motorcycle on level surface before starting any work.
 • Gasoline is extremely flammable and is explosive under certain conditions.
 • Work in a well ventilated area. Smoking or allowing flames or sp arks in the work area or where the gasoline is stored can cause
a fire or explosion.
 • The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate  or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical  knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.
* Should be serviced by a dealer, unless the owner has  proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by a dealer.
Honda recommends that a dealer should road test your mo torcycle after each periodic maintenance is carried out.
NOTES:
1. At higher odometer readings, repeat at  the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Service more frequently when riding OFF-ROAD.
5. Replacement requires mechanical skill. NOTE
FREQUENCY (NOTE 1)
ANNUAL 
CHECK REGULAR 
REPLACE REFER TO 
PAGE
x 1,000 km1 12243648
ITEMS x 1,000 mi 0.6 8 16 24 32
* FUEL LINE I I I I I 3-3
* THROTTLE OPERATION I I I I I 3-3
* AIR CLEANER NOTE 2 R R 3-4 CRANKCASE BREATHER NOTE 3C C C C C 3-4
* SPARK PLUG I R3-5
* VALVE CLEARANCE I I I3-6
ENGINE OIL RRRRR R3-9
ENGINE OIL FILTER RRRRR R3-10
* ENGINE IDLE SPEED I I I I I I3-10
RADIATOR COOLANT NOTE 5I I I I I 3 YEARS 3-11
* COOLING SYSTEM I I I I I3-11
* SECONDARY AIR SUPPLY SYSTEM I I I I I3-11
DRIVE  CHAIN NOTE  4EVERY 1,000 km (600 mi) 
I, L 3-12
DRIVE CHAIN SLIDER NOTE 4I I I I 3-14
BRAKE FLUID NOTE 5I I I I I 2 YEARS 3-15
BRAKE PADS WEAR I I I I I3-16
BRAKE SYSTEM I I I I I I3-17
BRAKE LIGHT SWITCH I I I I I3-17
HEADLIGHT AIM I I I I I3-18
CLUTCH SYSTEM I I I I I I3-18
SIDESTAND I I I I I3-19
* SUSPENSION I I I I I3-19
* NUTS, BOLTS, FASTENERS NOTE 4I I I I I I 3-19
** WHEELS/TIRES
NOTE 4
IEVERY 6,000 km 
(4,000 mi) I I 3-20
** STEERING HEAD BEARINGS I I I I I I3-20 
						

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MAINTENANCE
FUEL LINE
INSPECTION
Remove the right fuel tank shroud (page 2-4).
Check the quick connect fitting [1] for looseness.
Check the fuel feed hose [2] for deterioration, damage
or leakage.
Check the quick connect fitting for dirt, and clean if
necessary.
Replace the fuel pump packing if necessary (page 7-9).
THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cable.
Check the throttle grip for smooth operation.
Check that the throttle opens and automatically closes
in all steering positions.
If the throttle grip does not return properly, overhaul and
lubricate the throttle grip housing.
If the throttle grip still do not return properly, replace the
throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change.
If idle speed increases, check the throttle grip freeplay
and throttle cable connection.
Measure the throttle grip freeplay at the throttle grip
flange.
Throttle grip freeplay can be adjusted at either end of
the throttle cable.
Minor adjustment is made with the upper adjuster [1] at
throttle housing.
Loosen the lock nut [2] and turn the adjuster.
Tighten the lock nut securely  while holding the adjuster.
Recheck the throttle operation.
[2]
[1]
FREEPLAY: 2 – 6 mm (0.08 – 0.24 in)
2 – 6 mm (0.08 – 0.24 in)
[1]
[2] 
						

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MAINTENANCE
Major adjustment is made with the lower adjuster [1] at
the throttle body.
Loosen the lock nut [2] and turn the adjuster.
Tighten the lock nut to the specified torque while
holding the adjuster.
Recheck the throttle operation.
AIR CLEANER
REMOVAL/INSTALLATION
 • The viscous paper element cannot be cleanedbecause the element contains a dust adhesive.
 • If the motorcycle is used in unusually wet or dusty areas, more frequent inspections are required.
Remove the right side cover (page 2-3).
Remove the screws [1] and air cleaner cover [2].
Remove the air cleaner element [3] by releasing its
grooves from the housing.
Inspect the air cleaner element in accordance with the
maintenance schedule (page 3-2) or any time it is
excessively dirt or damaged.
Install the air cleaner element in the reverse order of
removal.
 • After installing air cleaner  element, make sure the air
cleaner element grooves are secure.
 • Check that the condition of the packings, replace them if necessary.
CRANKCASE BREATHER
Service more
frequently when
ridden in rain, at full throttle, or after the
motorcycle iswashed or
overturned.Check the crankcase breather hose [1] for deterioration,
damage or loose connection. Make sure that the hoses
are not kinked, pinched or cracked.
Replace the crankcase breather hose if necessary. TORQUE: 3.0 N·m (0.3  kgf·m, 2.2 lbf·ft)
[1]
[2]
TORQUE:
Air cleaner cover screw:1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)
[2]
[1]
[3]
[1] 
						

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MAINTENANCE
Service if the
deposits level can
be seen in the air cleaner housing drain plug.Check the air cleaner housing drain plug [1].
If necessary, remove the drain plug from the air cleaner
and drain the deposits into a suitable container.
Reinstall the drain plug securely.
SPARK PLUG
REMOVAL/INSTALLATION
Disconnect the spark plug cap [1].
Clean around the
spark plug base
with compressed air
before removing the
spark plug, and be
sure that no debris
is allowed to enter
into the combustion chamber.Remove the spark plug [1] using a spark plug wrench
[2].
Inspect or replace the spark plug as described in the
maintenance schedule (page 3-2).
Install and hand tighten the spark plug to the cylinder
head, then tighten the spark pl ug to the specified torque
using a spark plug wrench.
Connect the spark plug cap securely.
INSPECTION
Check the following and replace if necessary
(recommended spark plug: page 3-6).
 • Insulator [1] for damage
 • Center electrode [2] and side electrode [3] for wear
 • Burning condition, coloration
If the electrodes are contaminated with accumulated
objects or dirt, replace the spark plug.
[1]
[1]
TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)
[1]
[2]
This motorcycles
spark plug is
equipped with an iridium center
electrode. Replace
the spark plug if the electrodes are
contaminated.
[1]
[2][3] 
						

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MAINTENANCE
Always use
specified spark
plugs on thismotorcycle.Replace the plug if the center electrode [1] is rounded
as shown in the illustration.
To prevent
damaging the iridium center
electrode, use a wire type feeler
gauge to check the
spark plug gap.Check the spark plug gap between the center and side
electrodes with a wire type feeler gauge [1].
Make sure that the  Φ 1.0 mm (0.039 in) plug gauge
does not insert between the gap.
If the gauge can be inserted into the gap, replace the
plug with a new one.
VALVE CLEARANCE
INSPECTION
 • Inspect and adjust the valve clearance while the
engine is cold (below 35°C/95°F).
 • After the valve clearance inspection, check the engine idle speed (page 3-10).
 • Inspection and adjustment can be done with the engine installed in the frame.
Remove the cylinder head cover (page 10-4).
Remove the timing hole cap [1] and crankshaft hole cap
[2].
Rotate the crankshaft counterclockwise and align the
T mark [1] on the flywheel with the index notch [2] on
the left crankcase cover. SPECIFIED SPARK PLUG: NGK: SIMR8A9
[1]
Do not adjust the
spark plug gap. If the gap is out of specification,
replace with a new one.
[1]
TOOL:
Timing cap wrench 07709-0010001
[1]
[2]
[2]
[1]
[2] 
						

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MAINTENANCE
Make sure that the outside index lines (IN [1] and EX
[2] marks) on the cam sprockets are flush with the
cylinder head top surface and facing outward as shown.
If the IN and EX marks are facing inward, turn the
crankshaft counterclockwise one full turn (360°) and
realign the T mark with the index notch.
Check the valve clearance by inserting a feeler gauge
[1] between the rocker arm and shim.
ADJUSTMENT
 • The valve clearances can be adjusted without removing the camshafts.
 • The intake and exhaust valve clearance service procedures are the same.
Remove the bolt, sealing washer and rocker arm shaft
(page 10-11).
Slide the rocker arm [1] and remove the shims [2].
 • Do not allow the shims to fall into the crankcase.
 • Mark all shims to ensure correct reassembly in their original locations.
 • The shims can be easily removed with a tweezers or magnet.
[1]
[2]
VALVE CLEARANCE:
IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in)
EX: 0.27 ± 0.03 mm (0.011 ± 0.001 in)
[1]
[1]
[2] 
						

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MAINTENANCE
Sixty-nine different
thickness shims are
available from the
thinnest 1.200 mm thickness shim to
the thickest 2.900
mm thickness shim in increments of
0.025 mm.Measure the shim [1] th ickness and record it.
Calculate the new shim thickness using the equation
below.
A = (B – C) + D
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
 • Make sure of the correct shim thickness by measuring the shim by micrometer.
 • Inspect the valve seat if  the calculated dimension is
over 2.900 mm.
Install the shims in
their originallocationsInstall the newly selected sh im [1] on the valve spring
retainer.
Install the rocker arm shaft while aligning the hole of the
rocker arm [2] and cylinder head (page 10-11).
Rotate the camshafts by turning the crankshaft
counterclockwise several times.
Recheck the valve clearance.
Install the cylinder head cover (page 10-5).
Apply engine oil to new O-rings [1] and install them to
each hole cap.
Apply engine oil to timing hole cap [2] and crankshaft
hole cap [3] threads.
Install and tighten the ti ming hole cap and crankshaft
hole cap to the specified torque.
[1]
1.80 mm1.825 mm1.85 mm1.875 mm
[2]
[1]
TOOL:
Timing cap wrench 07709-0010001
TORQUE:
Timing hole cap: 6.0 N· m (0.6 kgf·m, 4.4 lbf·ft)
Crankshaft hole cap: 8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)
[1]
[3][2] 
						

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MAINTENANCE
ENGINE OIL
OIL LEVEL INSPECTION
Hold the motorcycle in an upright position.
Start the engine and let it idle for 3 – 5 minutes.
Stop the engine and wait 2 – 3 minutes.
Check the oil level through the inspection window.
If the level is below the lower level line [1], remove the
oil filler cap [2] and fill the crankcase with the
recommended oil up to the upper level line [3].
Check that the O-ring [4] is in good condition, replace it
if necessary.
Apply engine oil to the O-ring.
Install the oil filler cap.
ENGINE OIL CHANGE
Warm up the engine.
Stop the engine and remove the oil filler cap [1].
Place an oil pan under the engine to catch the engine
oil, then remove the engine oil drain bolt [1]/sealing
washer [2].
Drain the engine oil completely.
Install a new sealing washer onto the drain bolt.
Install and tighten the drain  bolt to the specified torque.
Fill the engine with the recommended engine oil (page
3-9).
Install the oil filler cap.
Check the oil level (page 3-9).
Make sure there are no oil leaks. RECOMMENDED ENGINE OIL: Honda 4-stroke motorcycle oil or an equivalent
API classification: SG or higher (except oils 
labeled as energy conserving on the circular API 
service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
[1]
[4]
[2]
[3]
[1]
TORQUE: 24 N·m (2.4 kgf·m, 18 lbf·ft)
ENGINE OIL CAPACITY:1.4 liters (1.5 US qt, 1.2 Imp qt) at draining
1.5 liters (1.6 US qt, 1.3  Imp qt) at oil filter change
1.8 liters (1.9 US qt, 1.6 Imp qt) at disassembly
[1]
[2] 
						

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MAINTENANCE
ENGINE OIL FILTER
REPLACEMENT
Drain the engine oil (page 3-9).
Remove the following:
– Bolts [1]
– Oil filter cover [2]
– Gasket [3]
–Spring [4]
Remove the oil filter [1].
Install a new oil filter with the OUT-SIDE mark [2]
facing out.
Installing the oil filter backwards will result in severe
engine damage.
Install the oil filter spring [3 ] into the oil filter cover [4].
Install a new gasket [5] and oil filter cover.
Install the cover bolts and tighten them.
Fill the engine with the recommended engine oil (page
3-9).
Make sure there are no oil leaks.
ENGINE IDLE SPEED
 • Inspect the idle speed after all other engine maintenance items have been performed and are
within specifications.
 • Before checking the idle speed, inspect the following items.
– No MIL blinking
– Spark plug condition (page 3-5)
– Secondary air supply system condition (page 3-
11)
– Crankcase breather syst em condition (page 3-4)
– Air cleaner element condition (page 3-4)
 • The engine must be warm for accurate idle speed
inspection.
 • This system eliminates the need for manual idle speed adjustment compared  to previous designs.
Start the engine and let it idle.
Check the idle speed.
If the idle speed is out of  the specification, check the
following:
– Intake air leak or engine top-end problem (page 10- 2)
– Throttle operation and freeplay (page 3-3)
– IACV operation (page 7-16)
[2]/[3][4]
[1]
[1]
[2][5][4]
[3]
IDLE SPEED: 1,450 ± 100 min-1 (rpm) 
						

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MAINTENANCE
RADIATOR COOLANT
Check the coolant level of the reserve tank with the
engine running at normal operating temperature.
The level should be between the UPPER [1] and
LOWER [2] leve l lines with the motorcycle in an
upright position.
If the level is low, remove  the reserve tank cap [3] and
fill the tank to the UPPER level line with a 1:1 mixture
of distilled water and antifreeze.
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely empty, there is
a possibility of air getti ng into the cooling system.
Be sure to remove any air from the cooling system
(page 9-5).
COOLING SYSTEM
Check the radiator air passages for clogging or
damage.
Straighten bent fins, and remove insects, mud or other
obstructions with compressed air or low water pressure.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
Inspect the water hoses for  cracks or deterioration, and
replace them if necessary.
Check the tightness of all water hose band screws
(page 9-7).
SECONDARY AIR SUPPLY SYSTEM
 • This model is equipped with a built-in secondary air supply system. The pulse secondary air supply
system is located on the cylinder head cover [1].
 • The secondary air supply  system introduces filtered
air into exhaust gases in the exhaust port [2].
The secondary air is drawn into the exhaust port
whenever there is negative pressure pulse in the
exhaust system. This c harged secondary air
promotes burning of th e unburned exhaust gases
and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively
harmless carbon dioxide and water.
RECOMMENDED ANTIFREEZE:
High quality ethylene glycol antifreeze containing 
silicate-free corro sion inhibitors
[1]
[3]
[2]
[1]
[2]