2012 Onwards Honda CRF250L Service & Repair Manual

0-1 dummyhead dummyhead HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never drain or store gasoline in an open container. • Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully.

0-2 dummyhead dummyhead HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CRF250L. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 20 describe parts of the motorcycle, grouped according to location. Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI section troubleshooting first. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: June, 2012 Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels – on the vehicle • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service this vehicle correctly and safely. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

0-3 dummyhead dummyhead HOW TO USE THIS MANUAL SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommend engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: • Molykote® BR-2 plus manufactured by Dow Corning U.S.A. • Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: • Molykote® G-n Paste manufactured by Dow Corning U.S.A. • Honda Moly 60 (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use fork or suspension fluid.

CONTENTS dummyhead dummyhead GENERAL INFORMATION 1 FRAME/BODY PANELS/EXHAUST SYSTEM 2 MAINTENANCE 3 PGM-FI SYSTEM 4 IGNITION SYSTEM 5 ELECTRIC STARTER SYSTEM 6 FUEL SYSTEM 7 LUBRICATION SYSTEM 8 COOLING SYSTEM 9 CYLINDER HEAD/VALVES 10 CYLINDER/PISTON 11 CLUTCH/GEARSHIFT LINKAGE 12 ALTERNATOR/STARTER CLUTCH 13 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER 14 ENGINE REMOVAL/INSTALLATION 15 FRONT WHEEL/SUSPENSION/STEERING 16 REAR WHEEL/SUSPENSION 17 BRAKE SYSTEM 18 BATTERY/CHARGING SYSTEM 19 LIGHTS/METERS/SWITCHES 20 WIRING DIAGRAM 21 INDEX

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1-1 1 dummytext 1. GENERAL INFORMATION SERVICE RULES ··········································1-2 MODEL IDENTIFICATION ····························1-2 SPECIFICATIONS ·········································1-4 TORQUE VALUES ········································1-9 LUBRICATION & SEAL POINTS ··············· 1-15 CABLE & HARNESS ROUTING················· 1-17 EMISSION CONTROL SYSTEMS ·············· 1-27

1-2 dummyhead dummyhead GENERAL INFORMATION GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-17). 9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. DESTINATION CODE Throughout this manual, the following codes are used to identify individual types for each region. MODEL IDENTIFICATION Abbrev. term Full term CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory IACV Idle Air Control Valve IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MIL Malfunction Indicator Lamp PAIR Pulse Secondary Air Injection PGM-FI Programmed Fuel Injection SCS connector Service Check Short connector TP sensor Throttle Position sensor VS sensor Vehicle Speed sensor DESTINATION CODE REGION E U.K. F France ED European direct sales U Australia, New Zealand

1-3 dummyhead dummyhead GENERAL INFORMATION SERIAL NUMBERS/LABELS The Vehicle Identification Number (V.I.N.) [1] is stamped on the right side of the steering head. The throttle body identification number [1] is stamped on the lower left side of the throttle body. The engine serial number [1] is stamped on the lower left side of the crankcase. The Registered Number Plate (except U type) /Compliance plate (U type) [1] is stamped on the left front side of the steering head. The color label [1] is attached on the frame behind rear brake master cylinder reservoir. When ordering color-coded parts, always specify the designated color code. [1] [1] [1] [1] [1]

1-4 dummyhead dummyhead GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,195 mm (86.4 in) Overall width 815 mm (32.1 in) Overall height 1,195 mm (47.0 in) Wheelbase 1,445 mm (56.9 in) Seat height 875 mm (34.4 in) Footpeg height 365 mm (14.4 in) Ground clearance 255 mm (10.0 in) Curb weight 143 kg (315 lbs) Maximum weight capacity 159 kg (351 lbs) FRAME Frame type Twin tube Front suspension Telescopic fork Front axle travel 222 mm (8.7 in) Rear suspension Swingarm Rear axle travel 240 mm (9.4 in) Tire size Front 3.00-21 51P Rear 120/80-18M/C 62P Tire brand Front GP-21F Z (IRC) Rear GP-22R (IRC) Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 27° 35’ Trail length 113 mm (4.4 in) Fuel tank capacity 7.7 liter (2.03 US gal, 1.69 Imp gal) ENGINE Cylinder arrangement Single cylinder inclined 20° from vertical Bore and stroke 76.0 x 55.0 mm (2.99 x 2.17 in) Displacement 249.6 cm 3 (15.23 cu-in) Compression ratio 10.7:1 Valve train Chain driven DOHC with rocker arm Intake valve opens at 1.0 mm (0.04 in) lift 20° BTDC closes at 1.0 mm (0.04 in) lift 35° ABDC Exhaust valve opens at 1.0 mm (0.04 in) lift 40° BBDC closes at 1.0 mm (0.04 in) lift 0° TDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Viscous paper filter Engine dry weight 34.5 kg (76.1 lbs) FUEL DELIVERY SYSTEM Type PGM-FI Throttle bore 36 mm (1.4 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 6 speeds Primary reduction 2.807 (73/26) Final reduction 2.857 (40/14) Gear ratio 1st 3.333 (40/12) 2nd 2.117 (36/17) 3rd 1.571 (33/21) 4th 1.304 (30/23) 5th 1.115 (29/26) 6th 0.962 (26/27) Gearshift pattern Left foot operated return system 1 - N - 2 - 3 - 4 - 5 - 6 ELECTRICAL Ignition system Computer-controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave rectification Lighting system Battery

1-5 dummyhead dummyhead GENERAL INFORMATION PGM-FI SYSTEM SPECIFICATIONS IGNITION SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATION Unit: mm (in) FUEL SYSTEM SPECIFICATIONS LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM SPECIFICATIONS Fuel injector resistance (20°C/68°F) 11 – 13 Ω ITEM SPECIFICATION Spark plug SIMR8A9 (NGK) Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in) Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0.7 V minimum Ignition timing ("F" mark) 10° BTDC at idle ITEM STANDARD SERVICE LIMIT Starter motor brush length 11.8 – 12.3 (0.46 – 0.48) 6.5 (0.26) ITEM SPECIFICATIONS Throttle body identification number GQ32A Engine idle speed 1,450 ± 100 min -1 (rpm) Throttle grip freeplay 2 – 6 mm (0.08 – 0.24 in) Fuel pressure at idle 343 kPa (3.5 kgf/cm 2 , 50 psi) Fuel pump flow (at 12 V) 83 cm 3 (2.81 US oz, 2.92 Imp oz) minimum/10 seconds PAIR control solenoid valve resistance (20°C/68°F) 20 – 24 Ω ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 1.4 liters (1.5 US qt, 1.2 Imp qt) – At oil filter change 1.5 liters (1.6 US qt, 1.3 Imp qt) – At disassembly 1.8 liters (1.9 US qt, 1.6 Imp qt) – 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 – Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 – 0.22 (0.006 – 0.009) 0.35 (0.014) Side clearance 0.02 – 0.09 (0.001 – 0.004) 0.10 (0.004)

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2012 Onwards Honda CRF250L Service & Repair Manual

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