Honda CRF250X 2004 thru 2013 / Honda CRF250R 2010 thru 2013, repair e-manual

Content

Honda CRF250X 2004 thru 2013

General information

• Service rules
• Model identification
• General specifications
• Standard torque values
• Lubrication and seal points
• Cable and harness routing
• Optional parts
• Emission control systems

Frame / body panels / exhaust system

• Service information
• Troubleshooting
• Seat
• Side cover
• Radiator shroud
• Engine guard
• Front visor
• Sub-frame
• Fuel tank
• Exhaust system

Maintenance

• Service information
• Maintenance schedule
• Competition maintenance schedule

Lubrication system

• Lubrication system diagram
• Pressure relief valve
• Service information
• Oil jet
• Troubleshooting
• Oil pump
• Oil strainer

Fuel system

• Component location
• Carburetor assembly
• Service information
• Carburetor installation
• Troubleshooting
• Throttle position sensor replacement
• Carburetor adjustment
• Pilot screw adjustment
• Air cleaner housing
• High altitude adjustment carburetor removal
• Carburetor disassembly
• Secondary air supply system

Cooling system

• System flow patiern
• Service information
• Troubleshooting
• System testing
• Coolant replacement
• Radiator
• Radiator reserve tank
• Water pump

Engine removal / installation

• Component location
• Engine removal
• Service information
• Engine installation
• Drive sprocket

Clutch / starter clutch / kickstarter / gearshift linkage

• Component location
• Clutch
• Service information
• Kickstarter
• Troubleshooting
• Starter clutch
• Right crankcase cover
• Gearshift linkage

Alternator

• Component location
• Stator
• Service information
• Flywheel
• Left crankcase cover removal
• Left crankcase cover installation

Crankcase / crankshaft / transmission / balancer

• Component location
• Crankshaft removal
• Service information
• Crankcase bearing replacement
• Troubleshooting
• Crankshaft installation
• Balancer gear/balancer
• Transmission assembly
• Crankcase separation
• Crankcase assembly
• Transmission disassembly

Front wheel / suspension / steering

• Component location
• Service information
• Troubleshooting
• Front wheel
• Fork
• Handlebar
• Steering stem

Rear wheel / suspension

• Component location
• Service information
• Troubleshooting
• Rear wheel
• Shock absorber
• Shock linkage
• Swingarm

Hydraulic brake

• Component location
• Front master cylinder
• Service information
• Rear master cylinder
• Troubleshooting
• Front brake caliper
• Brake fluid replacement i rear brake caliper
• Air bleeding
• Brake pedal

Ignition system

• Component location
• Ignition system inspection
• System diagram
• Ignition control module (LCM)
• Service information
• Ignition timing
• Troubleshooting
• Throtile position sensor inspection

Electric starter

• Component location
• Troubleshooting
• System diagram
• Starter motor
• Service information
• Starter relay switch

Lights / meter / switches

• Component location
• Service information
• Headlight
• Tail light
• Engine stop bution
• Clutch switch
• Starter switch
• Tripmeter
• Main relay

Troubleshooting

• Engine does not start or is hard poor performance to start
• Engine lacks power
• Poor performance at low and idle speed
• Poor performance at high speed
• Poor handling

Troubleshooting

Honda CRF250R 2010 thru 2013

General information

• Service rules
• Model identification
• General specifications
• Torque values
• Lubrication and seal points
• Cable and harness routing
• Optional parts

Frame / body panels / exhaust system

• Service information
• Troubleshooting
• Seat
• Side cover
• Radiator shroud
• Engine guard
• Number plate
• Front fender
• Rear fender
• Sub-frame
• Exhaust system

Maintenance

• Service information
• Maintenance schedule·
• Additional items requiring frequent replacement

Lubrication system

• Lubrication system diagram
• Service information
• Troubleshooting
• Oil strainer screen
• Pressure relief valve
• Oil pump

Fuel system (PGM-FI)

• Component locatlon
• Service information
• PGM-FI symptom troubleshooting
• PGM-FI system location
• PGM-FI system diagram
• Connector location
• DTC index
• Mil circuit inspection
• Fuel line replacement
• Fuel pump unit
• Fuel tank
• Air cleaner housing
• Injector
• Throttle body
• Fast idle knob
• MAP sensor
• IAT sensor
• ECT sensor

Cooling system

• System flow pattern
• Service information
• Troubleshooting
• System testing
• Coolant replacement
• Radiator
• Water pump

Engine removal / installation

• Component location
• Service information
• Engine removal
• Engine installatlon
• Cylinder headnalves
• Cylinder / piston

Clutch / kick starter / gearshift linkage

• Component location
• Clutch
• Service information
• Kickstarter
• Troubleshootlng
• Gearshift linkage
• Right crankcase cover

Alternator

• Component location
• Flywheel
• Service information
• Stator / ckp sensor
• Left crankcase cover removal
• Left crankcase cover installation

Crankcase / crankshaft / transmission / balancer

• Component location
• Crankcase
• Service information
• Transmission
• Troubleshooting
• Crankshaft
• Primary drive gear / balancer crankcase bearing drive gear
• Balancer driven gear / oil jet
• Balancer shaft

Front wheel / suspension / steering

• Component location
• Service information
• Troubleshooting
• Front wheel
• Fork
• Handlebar
• Hpsd
• Steering stem
• Clutch lever

Rear wheel / suspension

• Component location
• Service informatlon
• Troubleshooting
• Rear wheel
• Shock absorber
• Shock linkage
• Swingarm

Hydraulic brake

• Component location
• Front master cylinder
• Service information
• Rear master cylinder
• Troubleshooting
• Front brake caliper
• Brake fluid replacement / air rear brake caliper
• Bleeding
• Brake pedal
• Brake pads / disc

Electrical system

• System location
• Service information
• Troubleshootlng
• Ignition system inspection
• Alternator coil
• Regulator/rectifier
• Ignition coil
• Ignition timing
• Engine stop switch inspection
• Condenser

Wiring diagram

Troubleshooting

• Engine does not start or is poor performance at hard to start
• High speed
• Engine lacks power
• Poor handling
• Poor performance at low and idle speed

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