Honda Crf250l Service Manual

							3-12
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MAINTENANCE
Remove the right fuel tank shroud (page 2-4).
Check the PAIR air supply hose [1] between the PAIR
control solenoid valve [2] and cylinder head cover for
deterioration, damage or loose connections. Make sure
that the hoses are not cracked.
Check the air suction hose [3] between the air cleaner
and PAIR control solenoid valve for deterioration,
damage or loose connections.
Make sure that the hoses are not kinked, pinched or
cracked.
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
Never inspect andadjust the drivechain while the
engine is running.Turn the ignition switch OF F, support the motorcycle on
its sidestand and shift the  transmission into neutral.
Check the slack in the drive chain lower run midway
between the sprockets.
Excessive chain slack, 50  mm (2.0 in) or more, may
damage the frame.
ADJUSTMENT
Loosen the rear axle nut [1].
Loosen the lock nuts [2] and turn the adjusters [3] until
the correct drive chain slack is obtained.
If the hoses show
any signs of heatdamage, inspect
the PAIR check
valve in the cylinder head cover for
damage (page 7- 18).[2][1]
[3]
DRIVE CHAIN SLACK: 25 – 35 mm (1.0 – 1.4 in)25 – 35 mm (1.0 – 1.4 in)
[2][1]
[3] 
						

							3-13
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MAINTENANCE
Make sure the same index lines [1] on both adjusting
plates [2] are aligned with punch mark [3] in the
swingarm.
Tighten the axle nut to the specified torque.
Hold the drive chain adjusters [4] and tighten the lock
nuts [5] to the specified torque.
Recheck the drive chain slack and free wheel rotation.
Check the drive chain wear indicator label attached on
the left swingarm.
If the drive chain adjuster cut-out [1] reaches red zone
[2] of the indicator label, replace the drive chain with a
new one.
CLEANING AND LUBRICATION
Clean the drive chain [1] with a chain cleaner designed
specifically for O-ring chains or a neutral detergent. Use
a soft brush if the drive chain is dirty.
Do not use a steam cleaner, high pressure cleaner, wire
brush, volatile solvent such as gasoline and benzene,
abrasive cleaner or a chain cleaner NOT designed
specifically for O-ring chains to clean the drive chain.
Inspect the drive chain for possible damage or wear.
Replace any drive chain that has damaged rollers,
loose fitting links, or otherwise appears unserviceable.
Be sure the drive chain has dried completely before
lubricating.
Lubricate the drive chain with  drive chain lubricant [2]
designed specifically for us e with O-ring chains, #80 –
90 gear oil or equivalent.
Do not use a chain lubricant NOT designed specifically
for use with O-ring chains to lubricate the drive chain.
Wipe off the excess oil or drive chain lubricant. TORQUE: 88 N·m (9.0 kgf·m, 65 lbf·ft)
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
[2]
[1]/[3][5][4]
[2]
[1]
[2]
[1] 
						

							3-14
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MAINTENANCESPROCKET INSPECTION
Remove the drive sprocket cover (page 2-6).
Inspect the drive and driven sprocket teeth for wear or
damage, replace if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or
new replacement chain will wear rapidly.
Check the attaching bolts and nuts on the drive and
driven sprockets.
If any are loose, tighten th em to the specified torque.
Install the drive sprocket cover (page 2-6).
DRIVE CHAIN SLIDER
U type only:Remove the drive chain cover (page 2-6).
Remove the drive sprocket cover (page 2-6).
Check the drive chain slider [1] for wear or damage.
The drive chain slider must be replaced if it is worn to
the wear limit indicator [2] or wear limit line [3].
For drive chain slider replacement (page 17-10). TORQUE: Drive sprocket fixing plate bolt [1]:10 N·m (1.0 kgf·m, 7 lbf·ft)
Driven sprocket nut [2]:
50 N·m (5.1 kgf·m, 37 lbf·ft)
[1]
[2]
[1]
[2]
[3] 
						

							3-15
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MAINTENANCE
BRAKE FLUID
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
 • Do not mix different types of fluid, as they are notcompatible with each other.
 • Do not allow foreign ma terial to enter the system
when filling the reservoir.
 • When the fluid level is low, check the brake pads for wear (page 3-16).
 • A low fluid level may be due to wear of the brake pads. If the brake pads are worn and caliper pistons
are pushed out, this accounts for a low fluid level. If
the brake pads are not worn and fluid level is low,
check the entire system for leaks (page 3-17).
FRONT BRAKE
Turn the handlebar to the left so that the reservoir is
level and check the front brake fluid level through the
sight glass.
If the level is near the LOWER level line [1], fill the
recommended brake fluid.
Remove the following:
– Screws [2]
– Reservoir cover [3]
– Set plate [4]
– Diaphragm [5]
Add DOT 3 or DOT 4 brake fluid from a sealed
container to the casting ledge [1].
Install the diaphragm, set plate and reservoir cover.
Install and tighten the cover screws to the specified
torque.[3][2]
[1][4]/[5]
TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
[1] 
						

							3-16
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MAINTENANCEREAR BRAKE
Support the motorcycle on a level surface, and check
the rear brake fluid level.
Check the brake fluid level.
If the level is near the LOWER level line [1], fill the
recommended brake fluid.
Remove the bolt [2] and reservoir [3].
Remove the cover screws [4],  reservoir cover [5], set
plate [6] and diaphragm [7].
Add DOT 3 or DOT 4 brake fluid from a sealed
container to the UPPER level line [8].
Install the diaphragm, set plate and reservoir cover.
Install and tighten the cover screws to the specified
torque.
Install the reservoir and tighten the bolt to the specified
torque while pushing the reservoir against the stopper
[9].
BRAKE PADS WEAR
FRONT BRAKE PADS
Check the front brake pads for wear.
Replace the front brake pads if either pad is worn to the
wear limit groove [1].
For front brake pad replacement (page 18-5).
REAR BRAKE PADS
Check the rear brake pads for wear.
Replace the rear brake pads if either pad is worn to the
wear limit groove [1].
For rear brake pad replacement (page 18-6). TORQUE: 1.5 N·m (0.2  kgf·m, 1.1 lbf·ft)
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[4]
[3]
[2]
[8][5]/[6]/[7][1]
[9]
Always replace the
brake pads as a set to assure even disc
pressure.
[1]
Always replace the
brake pads as a set
to assure even disc pressure.
[1] 
						

							3-17
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MAINTENANCE
BRAKE SYSTEM
INSPECTION
Firmly apply the brake lever or pedal, and check that no
air has entered the system.
If the lever or pedal feels soft or spongy when operated,
bleed the air from the system.
For brake air bleeding (page 18-4).
Inspect the brake hose [1] a nd fittings for deterioration,
cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.
BRAKE PEDAL HEIGHT ADJUSTMENT
Loosen the lock nut [1] and turn the push rod [2] until
the correct pedal height is obtained.
For standard push rod length (page 18-9).
After adjustment, tighten th e push rod lock nut to the
specified torque.
BRAKE LIGHT SWITCH
The front brake light
switch does not
require adjustment.Adjust the brake light switch [1] so that the brake light
comes on just prior to the brake actually being
engaged.
If the light fails to come on,  adjust the switch so that the
light comes on at the proper time.
Hold the switch body and turn the adjuster [2]. Do not
turn the switch body.
[1]
TORQUE: 17.2 N·m (1.8  kgf·m, 13 lbf·ft)
[2]
[1]
[1]
[2] 
						

							3-18
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MAINTENANCE
HEADLIGHT AIM
Support the motorcycle in an upright position.
Adjust the headlight aim horizontally by turning the
horizontal beam adjuster [1].
Adjust the headlight aim vertically by turning the vertical
beam adjuster [2].
CLUTCH SYSTEM
Measure the clutch lever fr eeplay at the end of the
clutch lever.
The adjuster may
be damaged if it is positioned too far
out, leaving minimal thread
engagement.Minor adjustment is made with the minor adjuster [1] at
the clutch lever.
Loosen the lock nut [2] and turn the adjuster.
Tighten the lock nut while holding the adjuster.
Recheck the clutch lever freeplay.
If the adjuster is threaded out near its limit and the
correct freeplay cannot be obtained, turn the adjuster all
the way in and back out one turn, then perform the
adjustment at major adjuster as follows.
Major adjustment is made wi th the major adjuster [1] on
the clutch cable.
Loosen the lock nut [2] and turn the adjuster to adjust
the freeplay.
Tighten the lock nut while holding the adjuster.
If proper freeplay cannot be  obtained, or the clutch slips
during test ride, disassemble and inspect the clutch
(page 12-9).
Adjust the headlight
aim as specified by local laws and
regulations.
[1][2]
FREEPLAY:10 – 20 mm (0.4 – 0.8 in)
10 – 20 mm (0.4 – 0.8 in)
[2]
[1]
[1]
[2] 
						

							3-19
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MAINTENANCE
SIDESTAND
INSPECTION
Support the motorcycle using a safety stand or hoist.
Check the sidestand spring [1] for damage or loss of
tension.
Check the sidestand [2] for movement and lubricate the
sidestand pivot if necessary.
Check the sidestand ignition cut-off system:
– Sit astride the motorcycle  and retract the sidestand.
– Start the engine.
– Shift the transmission in gear and lower the
sidestand.
– The engine should stop as the sidestand is lowered.
If there is a problem with the system, check the
sidestand switch (page 20-13).
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the front
brake and compressing the front suspension several
times.
Check the entire assembly for signs of leaks, damage
or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For fork service (page 16-6).
REAR SUSPENSION INSPECTION
Check the action of the rear shock absorber by
compressing the rear end several times.
Check the entire shock absorber assembly for leaks,
damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
For shock absorber service (page 17-6).
Support the motorcycle using  a safety stand or hoist,
raise the rear wheel off the ground.
Check for worn swingarm bearings by grabbing the
swingarm ends and attempting to move it side to side.
Replace the bearings if any looseness to noted.
For swingarm service (page 17-10).
NUTS, BOLTS, FASTENERS
Check that all chassis nuts, screws and bolts are
tightened to their correct torque values (page 1-9).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place and properly secured.
[1]
[2]
Loose, worn or
damaged
suspension parts
impair motorcycle
stability and control.
Loose, worn or damaged
suspension parts
impair motorcycle
stability and control. 
						

							3-20
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MAINTENANCE
WHEELS/TIRES
Support the motorcycle using a safety stand or hoist,
raise the front wheel off the ground.
Hold the front fork leg and move the front wheel
sideways with force to see if the wheel bearings are
worn.
For front wheel service (page 16-4).
Support the motorcycle using  a safety stand or hoist,
raise the rear wheel off the ground.
Hold the swingarm and move the rear wheel sideways
with force to see if the wheel bearings are worn.
For rear wheel service (page 17-4).
Check the tire pressure with a tire pressure gauge when
the tires are cold.
– Front tire (page 1-8)
– Rear tire (page 1-8)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
service limits.
– Front tire (page 1-8)
– Rear tire (page 1-8)
Inspect the wheel rims and spokes for damage.
Tighten any loose spokes to the specified torque using
the special tool.
STEERING HEAD BEARINGS
Support the motorcycle using  a safety stand or hoist,
raise the front wheel off the ground.
Check that the handlebar moves freely from side to
side. Make sure the control cables do not interfere with
the handlebar rotation.
Check for steering stem bearings by grabbing the fork
legs and attempting to move the front fork forward to
backward.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page
16-21). TOOL: Spoke wrench 5.8 x 6.1 mm 07701-0020300
TORQUE: 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) 
						

							4-1
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4. PGM-FI SYSTEM
SERVICE INFORMATION ·····························4-2
PGM-FI SYSTEM LOCATION ·······················4-2
PGM-FI SYSTEM DIAGRAM·························4-3
PGM-FI TROUBLESHOOTING 
INFORMATION ··············································4-4
PGM-FI SYMPTOM 
TROUBLESHOOTING···································4-6
DTC INDEX ····················································4-7
SENSOR UNIT POWER LINE 
INSPECTION ·················································4-8DTC TROUBLESHOOTING ························ 4-10
MIL TROUBLESHOOTING ························· 4-29
MIL CIRCUIT TROUBLESHOOTING ········· 4-43
SENSOR UNIT ············································ 4-44
ECT SENSOR ············································· 4-46
O
2 SENSOR················································· 4-47
BANK ANGLE SENSOR ···················\
·········· 4-48
ECM ····························································· 4-49