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2004 CRF250R
Service manual
Honda 2004 CRF250R Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
A few Words about Safety
Service Information
For Your Customer's Safety
Important Safety Precautions
Contents
Symbols
General Information: Contents
Service Rules
Model Identification
General Specifications
Lubrication System Specifications
Fuel System Specifications
Cooling System Specifications
Cylinder Head/Valves Specifications
Cylinder/Piston Specifications
Clutch/Kickstarter/Gearshift Linkage Specifications
Crankcase/Crankshaft/Transmission/Balancer Specifications
Front Wheel/Suspension/Steering Specifications
Rear Wheel/Suspension Specifications
Hydraulic Brake Specifications
Electrical System Specifications
Standard Torque Values
Engine and Frame Torque Values
Insulator Clamp
Cylinder Stud Bolt
Frame General Information
Lubrication and Seal Points
Frame
Cable and Harness Routing
Optional Parts
Technical Feature
HPSD (Honda Progressive Steering Damper/After '07)
HPSD Characteristics
Turning Handlebar from Neutral Position to Full Angle (Extension)
Turning Handlebar from Angle to Neutral Position (Compression)
Frame/Body Panels/Exhaust System: Contents
Frame/Body Panels/Exhaust System: System Information, Torque Values, Troubleshooting
Seat Removal/Installation
Side Cover Removal/Installation
Radiator Shroud Removal/Installation
Engine Guard Removal/Installation
Number Plate Removal/Installation
Sub-Frame Removal/Installation
Fuel Tank Removal/Installation
Fuel Filter Maintenance
Exhaust System
Muffler Removal/Installation
Exhaust Joint Pipe Removal/Installation (after '05)
Exhaust Pipe Removal
Exhaust Pipe Installation
Maintenance: Contents
Maintenance: Service Information, Specifications
Torque Values
Tools
Maintenance Schedule
Additional Items Requiring Frequent Replacement
Throttle Operation
Hot Start
Air Cleaner
Crankcase Breather
Spark Plug Removal, Inspection
Radiator Coolant
Valve Clearance/Decompressor System
Valve Clearance Inspection
Valve Clearance Adjustment
Engine Oil/Oil Filter
Oil Level Inspection
Decompressor System
Engine Oil and Filter Change
Engine Idle Speed
Transmission Oil
Cooling System
Transmission Oil Change
Drive Chain Cleaning and Lubrication
Drive Chain Slack Inspection/Adjustment
Drive Chain Slider
Drive Chain Roller
Drive/Driven Sprocket
Brake Fluid Level Inspection
Fluid Filling
Brake Pad Wear
Brake System
Lever Position Inspection
Clutch System
Clutch Lever Position
Clutch Lever Free Play
Control Cables
Exhaust Pipe/Muffler
Exhaust Inspection
Glass Wool Replacement
Front/Rear Suspension Inspection
Swingarm/Shock Linkage
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
Lubrication System: Contents
Lubrication System Diagram
Lubrication System: Service Information, Specifications, Troubleshooting
Oil Strainer Removal/Inspection/Installation
Oil Relief Valve Removal/Inspection/Installation
Oil Jet Removal/Inspection/Installation
Oil Pump Disassembly/Inspection
Oil Pump Assembly
Fuel System: Contents
Component Location of Fuel System
Fuel System: Service Information, Specifications
Fuel System: Torque Values, Tools
Fuel System Troubleshooting
Carburetor Adjustment, Minor
Idle Mixture and Idle Speed
Carburetor Adjustment, Major: for Temperature and Altitude
Tuning Information Chart '04, '05
Tuning Information Chart '06, '07
Tuning Information Chart '08, after '08
Tuning for Special Conditions
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Carburetor Removal
Carburetor Assembly
Jet Needle/Throttle Valve
SE Valve/Throttle Position Sensor
Accelerator Pump/Float/Jets
Carburetor Assembly Overview
Carburetor Installation
Throttle Position Sensor Replacement
Pilot Screw Adjustment
Cooling System: Contents
System Flow Pattern
Cooling System: Service Information
Tools for Cooling System, Troubleshooting
Cooling System Testing
Coolant (Hydrometer Test)
Coolant Gravity Chart
Radiator Cap/System Pressure Inspection
Coolant Replacement: Preparation
Coolant Replacement/Air Bleeding
Radiator Removal
Radiator Installation
Water Pump
Water Seal Inspection/Removal
Bearing/Water Seal/Oil Seal Replacement
Bearing/Water Seal/Oil Seal Installation
Engine Removal/Installation: Contents
Engine: Component Location
Engine Service Information, Specification
Engine Removal
Engine Installation
Cylinder Head/Valves: Contents
Cylinder Head/Valves: Component Location
Cylinder Head/Valves: Service Information, Specification
Cylinder Head/Valves: Troubleshooting
Cylinder Compression Test
Cylinder Head Cover Removal
Camshaft/Rocker Arm Removal
Rocker Arm
Rocker Arm Disassembly/Inspection
Cylinder Head Removal
Rocker Arm Assembly
Cam Chain Tensioner/Cam Chain Guide Removal/Inspection
Cylinder Head Disassembly
Cam Chain Tensioner/Cam Chain Guide Installation
Cylinder Head Inspection
Valve Spirit/Guide
Valve Guide Replacement
Valve Seat Inspection/Refacing
Valve Seat Refacing
Cylinder Head Assembly
Cylinder Head Installation
Camshaft/Rocker Arm Installation
Cylinder Head Cover Installation
Cylinder/Piston
Cylinder/Piston: Component Location
Cylinder/Piston: Service Information, Troubleshooting
Cylinder/Piston Removal
Cylinder/Piston/Piston Ring Inspection
Connecting Rod Inspection
Piston Ring Installation
Cam Chain Tensioner Lifter Inspection
Piston, Cylinder Installation
Clutch/Kickstarter/Gearshift Linkage: Contents
Clutch/Kickstarter/Gearshift Linkage: Component Location
Clutch/Kickstarter/Gearshift Linkage: Service Information, Tools
Clutch/Kickstarter/Gearshift Linkage: Troubleshooting
Right Crankcase Cover Removal
Right Crankcase Cover Installation
Clutch Removal
Clutch Inspection
Clutch Plates, Center
Judder Spring/Spring Seat
Clutch Lifter/Needle Bearing
Clutch Lifter Rod/Lever
Clutch Outer
Clutch Outer Guide, Bearing
Clutch Installation
Kickstarter Removal, Disassembly, Inspection
Kickstarter Assembly
Kickstarter Installation
Gearshift Linkage Removal
Gearshift Linkage Inspection
Gearshift Spindle
Gearshift Linkage Installation
Ratchet Pawl
Crankcase/Crankshaft/Transmission/Balancer: Contents
Crankcase/Crankshaft/Transmission/Balancer: Component Location
Crankcase/Crankshaft/Transmission/Balancer: Service Information, Specifications
Crankcase/Crankshaft/Transmission/Balancer: Torque Values, Tools
Crankcase/Crankshaft/Transmission/Balancer: Troubleshooting
Balancer Gear/Balancer Removal, Inspection
Balancer Gear/Balancer Installation
Crankcase Separation
Transmission Disassembly
Transmission Inspection
Shift Fork Shaft/Shift Drum
Transmission Bearing
Crankshaft Removal/Inspection
Crankcase Bearing Replacement
Crankcase Bearing/Oil Seal Location
Transmission/Balancer/Shift Drum Bearings
Left Crankcase
Right Crankcase
Crankcase Installation
Crankcase Assembly
Front Wheel/Suspension/Steering: Contents
Front Wheel/Suspension/Steering: Component Location
Front Wheel/Suspension/Steering: Service Information
Front Wheel/Suspension/Steering: Torque Values
Front Wheel/Suspension/Steering: Tools
Front Wheel/Suspension/Steering: Troubleshooting
Front Wheel Removal
Front Wheel Inspection
Axle
Wheel Bearing
Front Wheel Disassembly
Front Wheel Assembly
Front Wheel Installation
Fork Removal
Fork Disassembly
Fork Damper Disassembly
Outer Tube and Slider Disassembly
Fork Damper Inspection
Fork Cap Assembly
Fork Center Bolt
Slider/Outer Tube
Fork Spring
Bushing/Back-Up Ring
Fork Damper
Fork Assembly
Outer Tube and Slider Assembly
Fork Damper Refilling/Assembly
Fork Damper Operation Inspection
Fork Damper Installation/Preparation
Fork Damper Installation
Oil Capacity Adjustment
Fork Installation
Standard Position
Handlebar Removal
Handlebar Installation
HPSD (Honda Progressive Steering Damper) Removal/Installation
HPSD Inspection
Spherical Bearing Replacement
HPSD Disassembly
HPSD Assembly
Steering Stem Removal
Bearing Replacement
Bearing Installation
Rear Wheel/Suspension: Contents
Rear Wheel/Suspension: Component Location
Rear Wheel/Suspension: Service Information
Rear Wheel/Suspension: Torque Values
Rear Wheel/Suspension: Tools
Rear Wheel/Suspension: Troubleshooting
Rear Wheel Removal, Inspection
Rear Wheel Disassembly
Wheel Rim Runout
Rear Wheel Assembly
Rear Wheel Installation
Shock Absorber Removal, Disassembly
Bladder Replacement
Recommended Shock Oil
Damper Disassembly
Piston Ring Replacement
Damper Rod Disassembly
Rod Guide Case Inspection
Rebound Spring Inspection
Damper Rod Inspection
Damper Assembly
Damper Installation
Shock Linkage Removal
Shock Linkage Inspection
Shock Arm Needle Bearing
Shock Link Needle Bearing
Swingarm Removal
Swingarm Disassembly
Swingarm Assembly
Swingarm Installation
Hydraulic Brake: Contents
Hydraulic Brake: Component Location
Hydraulic Brake: Service Information
Hydraulic Brake: Torque Values, Tools
Hydraulic Brake: Troubleshooting
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Table of
Contents
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System: System Information, Torque Values, Troubleshooting
46
Lubrication System: Service Information, Specifications, Troubleshooting
92
Fuel System Troubleshooting
103
Tools For Cooling System, Troubleshooting
135
Cylinder Head/Valves: Troubleshooting
159
Cylinder/Piston: Service Information, Troubleshooting
189
Clutch/Kickstarter/Gearshift Linkage: Troubleshooting
199
Crankcase/Crankshaft/Transmission/Balancer: Troubleshooting
223
Front Wheel/Suspension/Steering: Troubleshooting
253
Rear Wheel/Suspension: Troubleshooting
309
Hydraulic Brake: Troubleshooting
349
Electrical System: Troubleshooting
383
Troubleshooting: Contents
398
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