2000 2001 Honda CR250R Service Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures fo r the CR250R. Follow the M~ i nleM nce Schedule recommendations (page 3-31 to enSU re that the mOlorcycl " is II l w~y s in pea k operating condition. Sect i ons 1 and 3 app ly to the who le motorcycle. S~ion 2 descr ibes procedures for remova l/inSTallati on 01 components thai may be required \0 perform service described in the following sections. Section' through 15 desc ribe parts of the motorcycl e. grouped according to location. Find Ihe secti,1n you want o n Ihis page, lhen Wrn 10 Ihe lable of contents on the fi rst page of the sect io n. Mos! sect i ons start with an asse mb ly Or system ill ustratio n, service information iUld t rou bleshooting for Ihe sed lan. The s ub S<'!quenl pages gille detailed procedure. If yo u a re not fllm il iar with this motorc ycle, read the Technical F eat urM in ~ion 16 . If you don't kn ow the SOurCe of th e troub le, goto section 17 Tr oub leshoot ing. z g w ~ C C ~ w Z (; Z w '" iii '" '" :J: " CONTENTS GENERAL INFORMATION MAINTENANCE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/ INSTALLATION CYLINDER HEAD/ CYLINDER/ PISTON COMPOSITE RACING VALVE (CRVI REAR WHEELfSUSPENSION HYDRAULIC BRAKE IGNITION SYSTEMfALTERNATOR WIRING DIAGRAM TECHNICAL FEATURES TROUBLESHOOTING INDEX

SYMBOLS The symbo ls used t hrougllo ul this m8~ u a' sh ow s peci f ic se rvice procedures. If supplementa'v informat ion is requ ired pe"" ,ning te these symbo ls, ~ wou ld be e ~plained specifically in the text without the use of Ih e symbols . . ~ "" Replace Ihe pa" (5) with new enelsl before assembly. .,. Use rec ommended engi ne oil. unless ot herwise specified. -, Use mo lybdenum oi l sol ut ion (mi xtI,J '" of the e ngine o il a nd molybde nu m g re ase jr) a ralio o f 1 : H. • ,.;;;;;., Use multi-purpose grea se lli t hi um based mu lti-pu rposo grease NLGI 1I2 or equivalenU. Use m o lybdenum disulfide grease Icontaining more than 3 % mo lybdenum di sulfide. NlG I 1I2 or ~ equiva le nt). EKampl e: Mo lykote S BR·2 plus manufactured by Dow Cor ni n... USA Multi-purpose M· 2 manufactured by Mit subishl Oi l Japan Use mo lybde num disulfide grease leomaini nG morl! than 3 % mo lybdenum disulfide, NLGI 1I2 or equivalent) . ~ Ex ample: M olykot eO BR·2 plus manufactule d by Dow Com ing, U.S.A. Honda Moly 60 (U.S.A on lYI Rocol ASP manufactured by Rocol Limi ted, U,K . Rocol Paste manufactuled by Sumico Lubr icant, Japan --6 Use si licone 91ease. em Apply a locking agent. Use a midd le strength locking agent unless othelwistl spe.;ified. ",.roll Apply sealant. I Use brake fluid, DOT .t. U se the reeom mertded brake flu id, unless olherwise specified, .. Use Fork or Suspensi on Fl ui d. .'

1. GENERAL INFORMATION GENERAL SAFETY S ERVICE RUl~S MODEl IDENTIFICATION S PE CIFICATIONS TORQUE VALUE S GENERAL SAFETY CARBON MONOXIDE 1-1 1-2 1-3 1-' 1-12 If the engi,.,e must be funning 10 do some wor k, ma ke su re the area is well ventilated. Neve r 'U" the ~ ngjne in an endosed area. Tht! ">rhaustCl)ntains pOis onous carbon monoxide gas that c..n c4us" lou of consclousne" and m.9y lead!O death . Run t he ""gi ne in an open area Or with an e~ haust ..vacuation system in an enclosed area_ GASOLINE Work in II well vem ilated area_Keep cigarettes, flames or sparks away from the wc. ,~ area or where gasoline is stored . Ei.% ;,lIliM GnoHne is eX/Fern .. '" IJamm" bJe lind is eJlpl,uj"" under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS tl i0 i.\iii I[d Eng in .. . lJ nd .. xlulUS! "'vst~m parU becom .. verr hot and , .. mlJin hot for some l ime lJlt..r th l! I!ngine is ,un. W .. ", insul;nttl glov..J or wlti, !JnfillhtJ engi".. IIncJ " ", hausl s)'Stem hlJve tooled belo,e hlJndling thes e parts. TOOLS LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING OPTIONAL PARTS USEO ENGINE Oil M'hI, iiild ' -15 1-17 ' -19 1-24 Used " ngine oil m'y tltusa skin ClJncer if repeatedl y le ft in contllct with the skin for prolonglJd p .. ,iods. Although this is unlikely unles5 you handle used oil on It daily basis, it is still lJdvisllble /0 tho,oughly WlJs/' you' hlJnds wil l, soap and wale, lJS 500n as possibl .. a ft er handling usttl 0/1. KEEP OUT OF REACH OF CHILDREN. BRA KE DUST Neller use Itn ~ ; r hose or dry brUsh to clean the bra ke assemblies . Use OS HA·approved vacuum cleaner or alternate me l hod app r oved by OSHA, designed 10 minimi, .. the hala,d ceused ny Itirborne aSbestos fibe,s . /nhe/ttl asbeSTOS fibers hlJve b"" lound to calISe respiratory diselJse and clt nt er. BRAKE FlUID CA UTION Spillingl/uid on pai nted, plastit Of" rubber pJlrtJ will tMmagfl Ihem. Pla tl! It clean shop 'owel OV" , Ihl!s l! f1lJrfS whl!nl!v..r Ihlt s)'Slem is sl!rvkl!d KEEP OUT OF REACH OF CHILOREN. 1-1

GENERAL INFORMATION COOLANT Under somocondilions, Ihe ethylene gl ycot in engi ne coolant i$ combusti b le and its Ilame is nol visiblQ. IIlhe et hylene glycol does ignit e, yo" will not see any Hem". but y ou can be b"rned . Avoid spilling Itngin~ cooilln! on tllll exllllust s~tero 0' engine p"rtS. Tillty roilY bll 1I0t en ough 10 cau SII tile coolllnt to ignite and burn without a visibllt flame. Co o/eM (erhvlene glvco /) can caUse some skin irriration end is poi~onous if swallow&d. KEEP OUT OF REACH OF CHILDREN. Do not remove rhe radilltO' CliP when the e ngine is 1I0t. Til e cool"M is unde, pressu,e "nd could scald yal/. K eep h"nds lind clothingllway from th e cooling (en. u it st"rts automatically. CAUTION Using coolant wit ll silicate corrosion inlribitors m"y clluSe premllture wellr of war .... pump SiMls o,blocka ge of radia tor passegu. Us ing rap w llter mlly t.1UH enginlt damaglt. If rl contacts your skin, wash t ho affected areas imm edial el y wi th soap and water . II it contacts you, eyes. flush them t horoug hly with fresh waler and gel j mme rli ~te medical ~t1e ntion . II il is swallowed. Ihe victim m ust be forced to "om it t hen rinse mou th end t hroat with fresh waler bef ore obtaining medical 1I110ntion. Because of t hese da ngers, always stOfe cool1lnt in ~ safe place. always away from the reach 01 chi ld,,,n. Ruycle USQd coolanl In an eco logicall y correct m~nnor. SERVICE RULES NITROGEN PRESSURE For shock absorber with II gas_tilled reservoir. Us e onl v nit'ogen ro p'essurl~e rh a shoc k " bsorber. Th e usa of an unstable glls c"n caus e /I fire 0' explosi on resulting in serious injury. The slrock abso,b ar conUins nitrogen unde, Irigh p'ft5sure. Allowi ng fi'e or Irltat ne a, r he slrock sbsorber could le ad to sn a" plo,ion th ll f could result in serious injury. Failurlt to rltlasss tire pre ssurlt f,om a shock abso rber before disposing of it mav lead to a po ssible explosion and sa,ious injury if if is h e. ted or p; erted, To pre"ent the po ssib ili ty of an " "p l osion, rele~se t he nitroge n by pressing the valvo COf O. Then remove tha valve stem ftom the s hoc~ absorber ,eservoir. Dispose of the oil in a m anner acce pt ab le to the Environmental Protection Agency (EPA). Befor e disposal of the shoc~ absorber, release the nitrogen by pressing the valve Core. Than remove the valv e stem f,om the shock abso,ber . 1. Use genuine HONDA or HONDA-recommended parts and lubroc8nts o' t he ir eQuivalents. Part s th at don 't meel HONDA's design specifications may cause damage to th e motorcycle_ 2. Use the special tools d eSIgned for this produCl to avoid damage and incorr ect assembly _ 3. Use on ly m et ric tools wh~n servicing the motorcycle . Metric bo lts. nuts and screw.; are nOl i"terchang ea ble with English fast~ ners. 4. Install new gaskets. O·rings. cotter pins. and lock plates w hen reassembling. 5. W hen tig hte ning bolts or r.uts, begin wi th the la'gQr diamet er or inner boll firs\. Then ti ghten to th e spec ilied torque diagonally in in c'emental steps unlass II particular sequence is specified. 6. Clean pans In cleaning solvent upon disassembly. Lubricate any s li dir.g surfaces befo'" reasse mbly_ 7_ After reassembly. check al l parts lor prope r installation ar.d o pe ration_ S. Route all electrocal wires as show on pages 1· 1gt hr ough 1·23, Ca b le and Harness Routing_ 1-2 ( -~

MODEL IDENTIFICATION 2000 Shown, After 2000 similar: (11 The frame seri ~ 1 n umber is stamped on the right s,do of the steering head (3) The c8rburelo r identif ication nu mbors are stamped on the left side of tho carburet or body as shown. (2000) GENERAL INFORMATION (2) The engine seri~ ' number is stamped on the lo wer left si de of the crankcase. 14) Th e c arbu retor Ident ificat ion n umbers are SlamlX'd on the fron t sid ~ of the carbu retor tx..dy as shown. ( After 2000) 1·3

GENERAL INFORMATION SPECIFICATIONS GENERAL '''M S!'ECI FI CA nONS DI MENSIONS Overall length 2,189 mm 186.2 inl Overall width 823 (rim (32.4 inl Ove r~ 1 1 heighl 1.263 mm 149.7 in) Whef!lbase 1.487 mm (58.5 in) Seal height 933 mm 136.7 in) Foolpeg heighl 412mm(16.2in) Ground clearance 331 (rim 03.0 in) Dry weight 97.0 kg (214 Ibs) FRAME Frame type Twin lUbe Fronl suspension Telescopic fork Front suspensipn axl e I rave l 275.5 mm (10.8 in) FlOnl suspensiOn cushIon stroke 315 mm (124 in) Rear $u$pensipn Swinga'm/F'ro-Link Rear wheel I "lvel 318mm( 12.5 in) Rear damper Deca,bon type w ilh nilrogen gas filled damper Front tire Si18 801100-21S1M Rear tire size 11 0/90-1962M Tire brand Dunlop Front K490G/Rear: '695 Fronl brake Hydraulic single ,disc Fronl brake swepl area 33 45 em' 15 1.8 in') Rear br ake Hydraulic single disc Ra ar bfa ~e swept area 334. 1) em' \5 1.8 in') Caster angle 27· 44 ' Tr ai l length 113.8 mm (4.5 in) Fuel tank capacily 7.5l i ler 12.0 US gal, 1.6 1mp gal) ENGINE Bore and stroke 66.' X no mm 12.S1 X 2.83 in) Oisplace melll 249.3 cm' 05.2 cu -i n) Compression ratio 8.7 : 1 Lubrication syslem FueVoi l mi M Cooling syste m liquid cooled Air fiUration Oiled polyurethane foam Crankshaft type Assembfy-typo Engine dry wei ght 23.3 kg (51.4 lbs) Cylinder arrangement Single cyl ill d er, inclined S' from ven ical CARBURETOR Carburetor type PiSIOn valve tvpe VenlUri diameler 38.3 mm (1.50 in) 1-4

GENERAL INFORMATION GENERAL (Cont'd) ITE M SPECIFICATI ON S DRIVE TRAIN Clutch system Multi-plate, wet Clutch opera ti on system Cllble opa ral l!d Transmi5Si(>n Consu mt mes n, 5-3paoo Primary re duction 3_000 (S3R1) Final reduction 3.1046(50/13) Gear ,alio ,,, 1.1000 (2711!i) 2" 1.470 (25/11) 3" 1_ 210123/19) "" 1.000(2 1/ 21 ) "" 0.869 (20123) GearShift P ~tt8rn Lett foot op.er~led return system, 1- N - 2 - 3 - 4 - 5 ELECTRICAL Ignition system CD' 1-5

GENERAL INFORMATION LUBRICATION SYSTEM Unit mm lin) ITEM S PE CIFICATIO NS Racommendod eng ine oil PRO HO NDA HP2 2-Slroke oi l Or e Cj uivale nt mo t or oil FU/:IVoil mixing rat io 32:1 Trll ns m issio n oil capacity At draining 0.75 lit er (O. W US ql, 0. 661mp qU At disa s sembl y 0.85 li te r (0 .90 US qt, 0.75 1 mp qlf Recomme nded transmi ssion o il PRO HONDA HP Trans oi l, P RO HO NDA G N4 ( ·stro~e o il or equi va le nt motor oil API service c la ss ific" ti on SF or SG Vise,»il y: SAl: 10W_40 r FUEL SYSTEM ITE M S PE CIFI CATIONS Carbureto r id,, " ti{i cat Klrl nu moor """ PWKOOB - After 2000 TM X l 1A Mai n )01 2000 # 180 After 2000 1 420 Slow jet 2000 "8 After 2000 '" Jet needle 2000 A71S/289 R/A3 27 fA 487 Aft er 2000 6BE HI -73 Jet need le dip pos i ti on ISt andftrd) 3" Pi l ot serew in itIa l ope ning 2000 1'1/2 tur ns Out Afte r WOO 1-3{4 (urns out Fl'Ht ~"el 2 000 1 £0 mm \0.£3 if'll Afte r 2000 15.0 mm lO.S9 in) Throttle grip free pl ay 3 S mm 11 18- 1/4 in) COOLING SYSTEM '''M SPECI FICATIONS Cool~nt capacity at chenge I_ U liler (1.29 US 'It, 1.07 Imp qt) al disassembl y 1.35 liter 11. 43 US Qt. 1_19 Imp 'lit Ra diator cap relief P1"essure "" 137 kPa (1.1 1. 4 ~gffcm', 16 - 20 psi) Recommend ed a nt if r eele PRO HONDA HP Co ol a nt or an equivalent high qu a li ly ethylene g lyco l antif r eele containing s il ieate free corrosion inllibilors. St8!1da,d coolftnt cono:e!l\' e\ iQ(', 50% mllm "e with soft w~te' \ 1-6 ,

- GENERAL INFORMATION CYLINDER HEAD/ CYLINDER/ PISTON Unit· mrn (Inl nEM ST ANDARD SERVI CE LIMIT Cylinder head warpage -- 0.0510.002) Cylinder 1.0. A 66.398 - 66.405 /2.61 41 2.(144) 66.430/2.615) B 66.390 - 66.398 (2 .6138 2. 61(1) 66.428 (26 15) Out of round 0.05/0.002) Taper 0.05 (0.002) Warpage 0.05 (0.0021 Piston. pis t on Piston mark directi on " IN " mark facing towa rd t he int ake side rings Piston 00. A 66.330 - 66.338 (2 .6114 - 2.( 117) 66.28 12.609) B 56323 - 66330 126111 - 2.(11 4) 66.273 (2.6091 Piston 0.0. me asur e ment point 15·25mm (0.59-0.98in) from bottom of sk,rt Pis ton pi rl borel.O. 18.007 - 18.013 (0 . 7Q.89 - 0.10921 18.Q2 (0.709) Piston pirl 0.0. 17 .994 - 18.000 1O.7Q.8 4 - 0.70871 17.98 (0.707) Piston· to·pis ton pin cl ear a nce 0.007 - 0.019 (0.0003 - 0.(007) 0.0 4 (0.0016) Piston ring-to· ring 'o p 0.045 0.07510.002 0.0031 0.095 (0.0031i groove clea rance Second 0.025 - 0.055 (0.001 - 0.0021 0.075 ((W029) Pi ston ring end ga p 0.40 - 0.55 (0.016 - 0.022) 0. 65 (0.026) Cylinde r- la-pi ston ciearano::e 0.050 - 0.075 10.0024 - 0.0029) 0.0910.0041 Connecting rod s mall end 1.0. 21.997 - 22.009 (0.8660 - 0.98651 22.a2 la.8611 CRV ________________ -, ______________ -r-'u""" ;'C'cmcm~nC")l I TEM Ex haust valve shaft 0.0. STANDARD 4.988 _ 5.000 (0.1964 - O. 1 9691 ClUTCH / KICKSTARTER/ GEARSHIFT LINKAGE "'M S TANDARD Clutch lever fr ee pl ay 1 0-20(318-3/41 Clutch sp ring free l englh 45.711.83) ClUtc h OUter guide 0.0. 27.981 _ 28.000 (1. 10 18 - 1.1024) ClutCh dis<: thi ckness 2.92 _ 3.08 (0.114 _ 0. 12 11 Clutch plate w arpage Kickst arte r pinion gea r 1 .0. 22.007 - 22.028 (0.8664 - 0.88721 Kicksl arte r spin d l" 0.0. 21.959 - 21 .980 (0.8645 - 0.8(5 4) Kic kstarte r I rl le gea r 1.0. 20.0 20 - 20.0 41 10.7882 - 0.789() K Ic kstarter id le gear be>shing 1.0. 17.000 -17.018 (0.6693 - 0.67001 0.0. 19.979 - 20.000 (0.7866 - 0.7874) CO ll nlershaft 0 .0 . al klckstarter idlll gllar 16.966 - 16.984 (0.6680 _ 0.6687) SERVI CE LIMIT 4.968 (0.1 961 Uni/" mm li n) SE RVI CE LIMIT 44.1 (1.76) 27.9711.1011 2.85 (0.112) 0.20/0 .008) 21. 0510.868) 21.95 (0.864) 20m (0.7901 17.04 (0.67 11 19.96 (0.1861 16.95 (0.0671 '·7

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2000 2001 Honda CR250R Service Manual

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