2004-2012 CRF250X Service & Repair Manual

HOW TO USE THIS MANUAL Thi8 WI'IIioe manual dHaibes the IJe'VICII prooedures 10< the CRF2S0X fQIow \he Mail'llonanca Schedule (Sec:bon 3) rec:ommendallons to ensurelt\allhe vehICle Is I" peak operatll'lg condrtk>n Alt er '06 mod&I: TllII emlS$lI)r1 1eY&j, .re with'" the standards set by the US EnIIironmental ProIec;l1QIl Agency (EPA) and Ca~lomiil Air Resources BoMIICAAB) f'ertol'/'AlnQ the firsl sdle<\U1II'd IIIIIlnlenanee is V8f)' Important. II eompenaalEls lor the ~I~al wear that occurs during ttle break·ln ,.,.. SaetIona I and 3 apPly 10 the whole 1TIOI00qcIe ~ 2 ~'trales procICIul9S lor ~lallOl't 01 COOTIpOn8ntS that may be f8QUUIG 10 por1om1 S8rv>ee described in the foIoIwlg secbOr'IS See!ion 4 through 20 describe parts 01 the molOrqCl<e, grouped 8CCOI'dIng 10 location Find the sact;on \'OU wall! 001 thiS page then turn 10 the table of oorrtems on me fifSt page olille sectIOn Mo5I .c1ions srart wlln an assemCly or $)'Slem Ilustnl.tlOI'o. MfVIC8 InlonTlabon and troutlleshoobng for me IIeC1IOn The lWb5equenl pagel QMI dalailed procedure M )10\1 dot'I1 know tne lOuree of !hiJ troubje. go to saction 21 TtoubIe5hoo1lng Ybut u!ety. and the salery 01 others. " very important To t>eIp you make Informed deciSIOnS we have provided safety messages and Othllr Inkmnatlon Il'IfQ\.lgho!Jl th" mlillOaL 0 1 eours.e. II I. rIOt pmctk:al or posSible 10 warn you 1100...1 aU the hazards IlSSOClIII&d WIth ~lIlg thIS ~ Ybu musI usa )'0lIl' own goo!! jUClgement You ifni lind IfflpOl18/'11 salery IIlformanon In II variety of 101'rT1:5 ..... '" • Safety ~"~"::"~-~M~~m~.:""'~ d, o Salely '.::!:" _ :: : ~" These mean m141;!mm, You Will be KillED or SERIOUSLY HURT ~ you don't toIow ,"SlrUCbOnl, You CAN be KILLED or SERIOUSLY HURT il yo\J don' lloliow lns trucl loos. Aij,meU. :'~ be HURT it you don't Io»ow • IrI$lrucbO!1s - how to S4lr'VlCe !hIS vehicle correctly arid salely w z (; z w VJ u; VJ " l: U -' " ~ c:: 9 -' w CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVES REAR WHEEUBRAKEISUSPENSION HYDRAULIC BRAKE BATIERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES WIRING DIAGRAM AI you read tms manual, you WIll find mbrmllUon!hat is preceded b)t II L __ I======================== ~- .yrnboI. The purpo&e 01 Itmi rnes.saga Is 10 help prevent darnawa 10 your veIlICIe OIlIer prope"y . or me erMrt)nm8l'1I 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 leXl withoullhe use althe symbols. 111 Replace the pants) with new one(5) before assembly_ -, Use lhe recommended engine oH, unless otherwise specified. 7! Use molybdenum oil solution (mixlUre of the engine oil and molybdenum grease in a ratio of 1:1). • .s;;;u;.. 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: Molykot~ BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M·2 manufactured by Mitsubishl Oil , Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: MoIykoteo1' G·n Paste manufactured by Dow Corning U.S.A. --- Hooda Moly 60 (U.S.A. only) Rocol ASP manufactured by Roeol Umited, U.K. Aocol Paste manufactured by Sumico Lubricant Japan .... -'iiSiII Use silicone grease. '11111 Apply a locking agent. Use a medium strength locking agent unless otherwise specified. . .,(Gll! Apply sealant. - I Use DOT 4 brake fluid . Use the recommended brake fluid unless otherwise specified. - .. Use fork or suspension Huid .

1. GENERAL INFORMATION SERVICE RULES .. .. ... .......... .......... ......... .. ... ' ·2 MODEL IDENTIFICATION ··· ·········· ······· ·· · ·· ·· '·2 GENERAL SPECIFICATIONS····· ··· ·········· · ··· '·5 LUBRICATION SYSTEM SPECiFiCATIONS ··········· ····· ····· ··· ··· ·· ······· ···· '·6 FUEL SYSTEM SPECIFICATlONS·············· '·7 COOLING SYSTEM SPECIFICATIONS ······ '·7 CYLINDER HEADIVALVES SPECiFiCATIONS ···· ········ ····· ·· ·· ···· ········ ······· ' ·8 CYLINDER/PISTON SPECIFICATIONS ...... '·8 CLUTCH/STARTER CLUTCH/ KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS ............. .. .. ............. .. ........ '·9 CRANKCASE/CRANKSHAFT/ TRANSMISSION/BALANCER SPECIFICATIONS ........................................ '·9 FRONT WHEEL/SUSPENSION/STEERING SPECiFiCATIONS ·· ····················· ········ ······· , · '0 REAR WHEEL/SUSPENSION SPECIFICATIONS .................. .. .. ... ............ '·'0 HYDRAULIC BRAKE SPECIFICATIONS··· ' ·" BA ITERY /CHARGING SYSTEM SPECIFICATIONS ..... .. . .. .. ..... ..... ..... .......... 1-1, IGNITION SYSTEM SPECiFiCATIONS ···· ' ·" ELECTRIC STARTER SPECiFiCATION····· '·'2 LIGHTS/METER/SWITCHES SPECIFICATIONS ..................................... '· '2 STANDARD TORQUE VALUES···· ··· ·· ··· ··· 1-13 ENGINE & FRAME TORQUE VALUES ···· ' · '3 LUBRICATION & SEAL POINTS ·············· ' ·20 CABLE & HARNESS ROUTING .. ............. ' ·23 OPTIONAL PARTS ···································· ' ·30 EMISSION CONTROL SYSTEMS .... .... .. .. '· 33 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 motorcycte. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metr ic tools when servicing the motorcycle. Metri c bolts, nuts and screws are nol interchangeable with English fastener. 4. Inslall 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 1-23). MODEL IDENTIFICATION 1-2

The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. The engine serial number is stamped on the left side of the l ower crankcase. The carburetor identification number is stamped on the left side of the carburetor body. GENERAL INFORMATION 1-3

GENERAL INFORMATION The name plate (U.S.A.) or Safety Certification Label (Canada) is attached on the left side of the down tube. "- NAME PLATE (U .S .A.) SAFETY CERTIFICATION LABEL (CANADA) The Vehicle Emission Information Label is attached on the rear fender ,----------- ----- -, ('04 - ' 06 California type, After '06 U.S.A.). '04 - '06 California type, After '06 U.S.A. : EMISSION INFORMATION LABEL 1-4

GENERAL INFORMATION GENERAL SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase ITEM Seat height Footpeg height ('04, ' 05 ) ( Aher '05) r04, ' 05) (Aher '05) SPE CIACATION 2,174 mm ( 85-:-6 in) 2,172 mm (85.5 in) 827 mm (32.6 in) 1,261 mm (49.6 in) 1,483 mm (58.4 in) 1,481 mm (58.3 in) 958 mm (37.7 in) 432 mm (17 .0 in) FRAME __ --,-_Ground clearance Frame type _ _ --j~ 34,,6 'i;; mm (13.6 in) Twin tube ( ENGINE CARBORETOR Front suspension Front suspension axle travel Front suspension cushion stroke Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Ti re brand (Dunlop) Front brake Front brake swept area Rear brake Rear brake swept area Caster angle Trail length Fuel tank capacity Fuel tank reserve ca acity Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve lubrication system Oil pump type Cooling system Air filtration Crankshaft type (49 State and Canada type) opens at 1 mm (0.04 in) lift doses at 1 mm (0.04 in) lift (California type) opens at 1 mm (0.04 in) lift doses at 1 mm (0.04 in) lift (49 State and Canada type) opens at 1 mm (0.04 in) lift doses at 1 mm (0.04 in) lift (California type) opens at 1 mm (0 .04 in ) lift doses at 1 mm (0 .04 in ) lift Engine dry weight ('04 - '06) (After '06) Telescopic fork 280 mm (11.0 in ) 315 mm (12.4 in) Pro-link 312 mm (12.3 in) Decarbon type with nitrogen gas filled damper 80/ 100- 21 51M , 80/100-21 M/C 51M 100/100- 18 S9M, 1001100- 18 M/C S9M Front: D742F/Aear: 0756 Hydraulic single disc 334.5 cm 1 (51 .8 in 2 ) Hydraulic single disc 391 .1 cm 1 (60.6 in 2 ) 27 °54 ' 118 mm (4.6 in) 8.3 liter (2 .20 US gal, 1.83 Imp gal) 1.5 liter lOAO US gal, 0.33 Imp gal) 78 .0 x 52 .2 mm (3 .07 x 2.06 in) 249.4 cm J (15.21 cu-in ) 12.9 : 1 Chain drive and OHC with rocker arm 10° BTOC 40° ABOC A .. BTOC 45° ABDC 40" BBOC 10° ATOC 45 ° BBOC 0° ATOC Forced pressure and wet sump Trochoid liquid cooled Oiled polyurethane foam Assembled type 26.6 kg (58.6 Ibs) 26.9 kg (59 .3 Ibs) Cylinder arrangement Carburetor type ______ _ -I-i S~;~ n~g~ le ~c~ y ~ ';~ n~ d~e~ ',c=_ inciined 10" from vertical Piston valve type L ____ _ __ ~ V~ e~ nt ~ u ~ '~ ; d"iamel~ e~ , ___ ___ _ ___ --'---' 3 ,, ' --' m "" m, ( 1046 in ")_ _______ ~ 1-5

GENERAL INFORMATION t DRIVE TRAIN ElECTRICAL ITEM Crutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift paHern Ignition system Starting system Charging system Reg ur ato r/rectifie r ,,, "d 3,d 4th 5th SPECIACATlQN Multi-plate. wei Cable operated Const ant mesh, 5-speed 3.61 1 (65/18) 3.786 (53114) 2.384 (31 /13) 1.750 (28116) 1.333 (28/21 ) 1.041 (25124) 0.814 (22127) Left foot operated return system, l-N-2 -3-4-5 reM (Ignition Control Modu le) Electric starter motor and kickstarter Single phase output alternator Lighting system _________ _ ~ SCR shorted/Single phase, half wave rectification Battery and alte ~, ~ ,~.~to~, ,---_______ ~ LUBRICATION SYSTEM SPECIFICATIONS ITEM Engine oil capacity Transmission oil capacity Recommended engine oil Recommended transmission oil Oil pump rotor 1-6 raining iJter change Atd At! Atd Atd isassembly raining Atd isassembly Tip clearance Y clearance Bod Side clearance STANDARD , 0.66 liter (0.70 US qt , 0.58 Imp qt f 0.69 liter (0.73 US qt , 0.61 Imp qt) 0.85 l iter (0.90 US qt, 0.75 Imp qt ) 0.67 liter (0.71 US qt, 0.59 Imp qt) 0.75 l iter (0.79 US qt. 0.66 Ime gt) Pro Honda GN44-stroke oil (U.S.A. and Canada) or equivalent motor oi l API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W·30 I Pro Honda HP Trans Oil, Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or equivalent motor oil API service classification: SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W-30 0.15 (0.006) 0.' 5 - 0.20 (0 .006 0.008) 0.05 - 0.12 (0 .002 0.005) Unit ' mm (in) SERVICE LIMIT - , - - - 0.20 (0.008) - -

2004-2012 CRF250X Service & Repair Manual

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