2004-2009 Honda CRF250R Service & Repair Manual

HOW TO USE THIS MANUAL n.. 5eI'VII)8 manual descobM It1e servICe procedures lot the CAF250A. Follow the MaIntenance SChedule (Sectlon 4) recommendabOOs to ensure thallhe veh,.;le is. 10 peak operating condition. Pel1o<ming the first SCheduled mallltenance ~ very ,mpottanl II compensates lor \he IIVMI wearlhilt occurs dunng!he break..n penod. SeehG'" 1 and 4 apPly 10 the whole moIOI'cycIe SectiorI 3 ilktstrates procedures lor remova1ronstallatlOl'1 01 components that may be reqUired 10 perform IOervOCEl described in !he IoIloWII'Ig secilO!lS. SectIOn 5 thfough 11 descnbe parts 01 lIle molort:yde. grouped ~,ng 10 IocabOl'l, ~~ the secllOI1 you walll on IIlI$ page, then tum 10 !he table 01 contents on the "<51 page 01 Ihe &eCbOn Most sections star! Wllh an assembly or 5ystam l«uS!l'Ilhon, service lnformatiOf1 and IrOUbleshoobng lor the sectlOt'l The subsequent pages ~ oetadecl procedure " you are not lam ilia, WIth IIlIS ITIQIOrcycle read TectlrllcaJ Feature In 5&Cllo02. II you don' know the source 01 Iha trooble, QO to secttOn 18 TlOUbIeshootlng Your safety. and the safety 01 others. is very important To tl&lp you mai<6 informed deciSIonS we have provided safety massages and other ,nlormaTion throughout Ihls manual. 01 course. II is not practICal or ~ to warn you about all the hazards a!iSOCl8.!ed WJItlsemclng Ihls vehICle You mum use your 0WTl good liJdger'l1el1l You witl find Impoftant safety r1lormatl(lO'1 !f1 a O/8r1ety of /ofnu lnduding; • S8fety Labotls - 01'1 the whde • S8fety Messages - preceded II)' a safety alert symbol i and one of three 191al W!lfd$. OANGER WARNtNG. Of CAU- noo These SIgflal words mean You WILL be KILLED or SERIOUSLY rg'l+}\in,j' HURT If you doll'! follow instructIOns You CAN be KILlED or SERIOUSlY m 'Lh~ i!f' 1tIt! HURT ~ you doll·, IoIIow InllJ\ICIJOnS You CAN 00 HURT I. you don·t ~Iow M'W"fl'li' Instructions • InstrucbOOll - I"IO'N 10 &efVIC8 Itus vehicle COfractty and safety. AS)'OI,I read this manu.al. )'01,1 will 'Ind infollnation that IS preceded by a ..HOTiCEl symbol The purpose of th.s message Is to help pf_nt damage to your vehICle. oCher prOptrty or the elMf'Ol"omanl. w z a z w III iii III .. J: l) CONTENTS GENERAL INFORMATION TECHNICAL FEATURE MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVALJlNSTALLATION CYLINDER HEAONALVES CYLINOERIPISTON REAR WHEELJSUSPENSION HYORAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

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 wilhoul l he use of the symbols. :11 I Replace the part(s) with new one(s) before assembly. 'B Usa the recommended engine oil, unless otherwise specified . 7J Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1). • .s;;:;;.. 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 equ ivalent) . ~ Example: MoIykot~ BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Milsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykot~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 .... -'iSioI Use silicone grease. Dum Apply a locking agent. Use a medium strength locking agent unless othelWise specified . .,( '@llll Apply sealant. - I Use DOT 4 brake fluid. Use the recommended brake nuid unless otherwise specified. .. Use fork or suspension fluid .

1. GENERAL INFORMATION SERVICE RULES ··················· .. · .. ···· ............ · 1-2 MODEL IDENTIFICATION····················· ··· ·· · 1-2 GENERAL SPECIFICATIONS······················ 1-4 LUBRICATION SYSTEM SPECIFICATIONS ········································ 1-6 FUEL SYSTEM SPECIFICATIONS ·· ············ 1-6 COOLING SYSTEM SPECIFICATIONS ····· ·1-7 CYLINDER HEADIVALVES SPECiFiCATIONS······································ ·· 1-7 CYLINDER/ PISTON SPECIFICATIONS ······ 1-8 CLUTCH/ KICKSTARTER/ GEARSHIFT LINKAGE SPECIFICATIONS ·· ····· ·· ·········· ··· ·1-8 CRANKCASE/CRANKSHAFT /TRANSM IS- SION/BALANCER SPECIFICATIONS ········· 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ······· ·· ··· ·· ················· ·· · .. ·1 -10 REAR WHEEL/SUSPENSION SPECIFICATIONS ..................................... 1- 11 HYDRAULIC BRAKE SPECIFICATIONS··· 1-11 ELECTRICAL SYSTEM SPECIFICATIONS ································ .. · .. 1-12 STANDARD TORQUE VALUES ··············· 1-13 ENGINE & FRAME TORQUE VALUES ·· ·· 1-13 LUBRICATION & SEAL POINTS·············· 1-19 CABLE & HARNESS ROUTING ............... 1-22 OPTIONAL PARTS ···································· 1-30 1-1

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 moto rcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembl y. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and sc rews are not interchangeable with English fastener. 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 increment al 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 1-22). MODEL IDENTIFICATION ' 04 mod el shown : After ' 08 : 1-2

The Vehicle Identification Number (V1N ) is stamped on the right side of the steering head. The engine serial number is stamped on the left side of the lower crankcase. The ca r buretor identification number is stamped on the left side of the carburetor body. GENERAL INFORMATION ENGINE SERIAL NUMBER • 1-3

GENERAL INFORMATION GENERAL SPECIFICATIONS DIMENSIONS FRAME 1-4 Overall length Overall width Overall height Wheelbase Seat height F ootpeg height Ground clearance Frame type Front suspension ITEM Front suspension axle travel Front suspension cushion stroke Rear suspension Rear wheel travel Rear damper Fr ont tire size Rear tire size Tire brand (Dunlop) Front brake Front brake swept area Rear brake Rear brake swept area Caster angle Trail length Fuel tank capacity 1'04 - '07) (After '07) 1'04) (After '04) 1'04 - '07) (After '07) 1'04) (After '04) 1'04) (After '04) 1'04) ('05 - '07) (After '07) 1'04) tAtter '04) 1'04) (Afte r '04) 1'04 - '06) (After '06) 1'04) (Afte r '04) 1'04) 1'05 - '07) (After '07) SPECIFICATION 2,172 mm (85.5 in) 2,170 mm (85.4 in) 827 mm (32.6 in) 1,263 mm (49.7 in) 1,277 mm (50.3 in) 1,479 mm (58.2 in) 1,477 mm (58. 1 in) 957 mm (37.7 in) 965 mm (38.0 in) 434 mm (17.1 in) 446 mm (17.6 in) 349 mm (13.7 in) 361 mm (14.2 in) 362 mm (14.3 in) Twin tube Telescopic fork 280 mm (11.0 in) 279 mm (11 .0 in) 315 mm ( 12.4 in) Pro-link 312 mm (12.3 in) 313 mm (12.3 in) Decarbon type with nitrogen gas filled damper 80/1 00-21 51M 100 190-1957M Front: 0742F/Rear: 0756 Front: 0742FAlRear: 0756 Hydraulic single disc 334.5 cm l (5 1.8 in 2 ) Hydraulic single disc 391. 1 cm? (60.6 in') 27°44' 27"50' 112 mm (4.4 in) 123 mm (4.8 in) 125 mm (4.9 in) 7.3 liter (1.93 US gal, 1.61 Imp gal)

GENERAL INFORMATION ITEM SPE CIFICATION ENGINE Bore and stroke 78.0 x 52.2 mm (3.07 x 2.06 in) Displacement 249.4 em 3 (15.2 1 cu-in) Compression ratio ('04 - '07) 12.9 : 1 1'081 13.1 : 1 (Afte r '08) 13.0 : 1 Valve train Chain drive and OHC with rocker arm Intake opens r04 - '07) at 1 mm (0.04 in) lift 15" BTDC valve (Afte r '07) at 1 mm (0.04 in) lift 20" BTDC closes at 1 mm (0.04 in) lift 50" ABDC Exhaust opens at , mm (0.04 in) lift 50" BBDC valve closes ('04 and at 1 mm (0.04 in) l ift 20" ATDC After '07) ('05 - '07) at 1 mm (0.04 in) lift 15" ATDe lubricati on system Forced pressure and wet sump Oil pump type Trochoid Cooling syst em Liquid cooled Air filt r ation Oiled polyurethane foam Crankshaft t ype Assemb led type Engine dry weight (,04, '05) 23 . 90 kg (52 . 68 Ibsl 1'061 24.05 kg (53.02 Ibs) 1'071 24.08 kg (53.09 Ibs) (After '07) 24.10 kg (53. 13Ibs) j Cylin der arrangement Single cy linder, inc l ined 10' from vertical CARBURETOR Carburetor type Pist on valve type Venturi diameter 1'04, 'OS) 37 mm (1.5 in) (Afte r '05) 40 mm (1.6 in) DRIVE TRAIN Clutch system Multi -plate, wet Clutch operation system Cable operated Transmission Constant mesh, 5-speed Primary reduct ion 3.166 (57/18) Final reduction 3.923 (51113) Gear ratio ,,, 2.142 (30/ 14 ) 'o d 1.750 (28116) 3,d 1.450 (29/20) 4,h 1.227 (27122) 51h 1.041 (25124) Gearshift pattern Left foot operated return system, 1 - N - 2 - 3 - 4 - 5 ELE CTRI CAL Ignition system leM (Ign iti on Control Module ) 1-5

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Engine oil capacity oil capacity AI i and Canada) or equivalent molor oil API service classification: SG or higher JASO T 903 standard: MA Recommended transmission oil ____ ~,v~ ;s ~'~ O~S~ity;SAE'~OVV .~.3~°fecifnTSJC__1---------- Pro Honda GN4 4 Oil pump rotor FUEL SYSTEM SPECIFICATIONS IT EM Fuel tank capacity Carburetor identification number '04 h 05 ro 06 h a7 ' 08 After 'OS Main jet '04 j 5" 06 '07 After '07 After '08 Slow jet ' 04 and '06 : ' 05 and After '06 Jet needle '04 '05 ' 06 ' 07 r- '08 After '08 Jet needle dip position '04 (Standard) After '04 Pilot screw initial opening '04 and '07 r. 05 and '06 ro 08 ~er'08 Fl oat level '04 - '05 After '05 , Idle speed Throttle grip freeplay HOI starter lever freeplay 1-6 and Canada) or equivalent moto r oil API service classification: SG or higher JASO T 903 standard: MA Viscosity: SAE lOW-30 0. 15 (0.006) SPECIFICATI ONS 7.3 liter (1.93 US gal. 1. Sl lmp gal) FCR01A FeROlB FeAOle FCR01D FeR01E FCR01F "60 #172 :!:= ::~ - NeYR NeYQ NH FS NK8T NMGU NNSU 4th from the top 3rd from the top 2-1/4 turns out 1-314 turns out 1-7/8 turns out ' -' /4 turns out 8_0 mm (0.3 1 in) 6 .0 mm (0.24 in) 1,700 ± 100 rpm 3 5 mm ( 1/8 3/16 in) 2 3 mm (1116 1/8 in ) < < I 1 1

2004-2009 Honda CRF250R Service & Repair Manual

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