Index - Honda 2004 CRF250X Service Manual

ADOInONAL ITEMS REQUIRING FREQUENT
REPLACEMENT· ·····························································3-7
AlA CLEANER·······························································3- 10
AlA CLEANER HOUSING ··············································5-7
ALTERNATOR CHARGING CQll········· .. ······ .. ···· ·· · .. ····l&8
BALANCER GEAR/BALANCER ················· ··········· ······· 12· 6
BA TTEAY ...................................................... ················ 16·6
BATTERY/CHARGING SYSTEM SPECIFICATIONS ··· , -, 1
BRAKE FLUiD······························································· 3-26
BRAKE FLUID REPLACEMENT/AIR BLEEDING ......... 15-6
BRAKE PAD WEAR ...................................................... 3-27
BRAKE PADIDISC ...................................................... , 5-10
BRAKE PEDAL···························································· 15-24
BRAKE SYSTEM ...................................................... ····3-27
CABLE
&
HARNESS ROUTING ··································· 1-23
CAM CHAIN TENSIONER/C AM CHAIN GUIDE ·········8-14
CAMSHAFT/ROCKER ARM INSTALLATION··············8-27
CAMSHAFT/ROCKER ARM REMOVAL ························8-7
CARBURETOR ADJUSTMENT ·····································5·6
CARBU RETOR ASSEMBLY ································· .... ····5-18
CARBURETOR DISASSEMBLY·· ·································5-13
CARBURETOR INSTALLATION ,· .... ··· .. ··· .. ······ .. ··········5-24
CARBURETOR REMOVAL ············· .. ·· .. ·· ··· ······ .. ··· .. · .. ···5·1 1
CHARGING SYSTEM INSPECTION ·· .. ···· .. · .. ·· .... ····· .. ··16·6
CLUTCH ...... .. .................................................. ···· .. ···· .. ·· 1 0-7
CLUTCH SWiTCH ······ .. ······• .. ··········· .... · .. ············ .. ········ 19-7
CLUTCH SySTEM ···· .. ·· .. · .... ··· .. ····································3-28
CLUTCH/STARTER CLUTCH/KICKSTARTEA/
GEARSHIFT LINKAGE SPECIFICATIONS .. ········· .. ········1-9
COMPETITlON MAINTENANCE SCHEDULE .. ··· .. · .. ·· .. ·3·6
COMPONENT LOCATION
ALTERNATOR ··················· .. ··· .. · .. ·· .. ···· .... ················11-2
BATIERY/CHARGING SYSTEM···· .. ···· .. ····· .. ··········16-2
CLUTCH/STARTER CLUTCHI
KICKSTARTERIGEARSHIFT LINKAGE ··················· 10-2
CRANKCASE/CRANKSHAFTfTRANSMISSIONI
BALANCER ··········· .. ··· .. ·· .. ·· .. ··· .. · .. ·· .. ···· .... ················ 12-2
CYLINDER HEADNALVES ·· .. ···· .. ··· .. ··· .. ·· .. ·· ········ .. ····8-2
CYlINDERlPISTON ······• .. ···· .. ····· .. ··· .... ·········· .. · .. ·······9·2
ELECTRIC STARTER ··························· .... · .. ··· ...... ·· .. 18-2
ENGINE REMOVAUlNSTALLATION .. ·········· .. ·· .. ······7-2
FRONT WHEEUSUSPENSION/STEERING ···· .. · .. ··· 13-2
FUEL SySTEM···· .. ····· .. ·•· · .. ······· .. ·······························5-2
HYDRAULIC BRAKE ········ .. ··· .. ·· .. ·· .. ·· .... ················ .. · 15-2
IGNITION SYSTEM ······················· .. ··· .. · .. ······· ········· 17-2
LIGHTS/METER/S WITCHES ····· .. ········ .... ··· .. ··· .. ······19-2
REAR WHEEUSUSPENSION··································14-2
CONTROL CABLES .. ····················································3-29
COOLANT REPLACEMENT ··· .. ···· .... ···· .. ·· .. · .. ·· .. ·············6-6
COOLING SYSTEM ················· .. ····· .. ·· .. ··· .. · .... · .... · .. · .. ···3·13
COOLING SYSTEM SPECIFICATIONS .. ····· · .. ··· .. · .. ·······1-7
CRANKCASE ASSEMBLY ··········· .. · .. ·· .. ··· ...... ·· .......... 12-2 1
CRANKCASE BEARING REPLACEMENT ················· 12-13
CRANKCASE BREATHER ····················· .. ·····················3-' 1
CRANKCASE SEPARATION .. ·· .... ····· .. ·· .. ··········· .. · .. ·····12·7
CRANKCASElCRANKSHAFTfTRANSMISSION/
BALANCER SPECIFICATIONS .. ····· .. ···· .. ······ .. ··· ·· ····· ····· 1-9
CRANKSHAFT INSTALLATION ···· .. ··· .. ······ .. ··· ··········12-18
CRANKSHAFT REMOVAL ······ .. ····· .. ··· .. ··· .. ·· ·· ·· .. ·· ···· ·· '2· 12
CYLINDER COMPRESSION TEST· .... ·· .. ·· .. · .. ··· .. ······ .. ···· 8-6
CYLINDER HEAD ASSEMBLY····· .... ···· .. ······················8-23
CYLINDER HEAD COVER INSTALLATION ····· .... ········8-30
CYLINDER HEAD COVER REMOVAL · .. ·········· .... ···· .. ····8-6
CYLINDER HEAD DISASSEMBLY·· .. ··· .... ······· .. · .. · .. ·····8-15
CYLINDER HEAD INSPECTION ········· .. ························8-17
CYLINDER HEAD INSTALLATION ······ .. ··············· .. ·····8-25
CYLINDER HEAD REMOVAL ····················· .. ········ .. ·· .. ··8-'2
CYLINDER HEADNALVES SPECIFICATIONS····· .. ·······'-8
CYLINDER INSTALLATION ··,·· .. ·········· .. ····· ··················· 9-8
22.
INDEX
CYLINDER REMOVAL · .. ··· .. ·· .. · .. ··· .. ···· .. ··· .. ·· .. ·· .. ···· .. ·· .. ·· 9-4
CYLINDERIPISTON INSPECTION ...... ·· .. ······ .. ········ .. ·· .. · 9-5
CYLINDER/PISTON SPECIFICATIONS · .... ·········· .. ··· .. ··· 1-8
DRIVE CHAIN ········································ .. ················ .. ···3·21
DRIVE CHAIN ROLLER ................................................ 3-25
DRIVE CHAIN SLIDER ......................... ......... ............... 3-24
DRIVE SPROCKET ................ .. ... ..... ............................... 7-4
DRIVE/DRIVEN SPROCKET· ······ .. ································ 3·25
ELECTRIC STARTER SPECIFICATIONS··· .. ········ ······" 1-12
EMISSION CONTROL SYSTEMS ···· .. ··· .. ··· ····· ·· ·········· '-33
ENGINE & FRAME TORQUE VALUES·· .. ······ .. ··· .. ··· .. · ' · 13
ENGINE GUARD· .. ·· .. · .. ·· .. ····• .... · .. ··· .... ··· .. ··· .. · .. ···· .. ········ 2-4
ENGINE IDLE SPEED··· .. ·· .. ····· .. · .... ······ .. ·········· .. ·········· 3-19
ENGINE INSTALLATION···············································7-7
ENGINE OIUOIL FILTER ·· .. ····· .. ··· .. ······························ 3-17
ENGINE REMOVAL ....................................................... 7·5
ENGINE STOP BUTION ····················· .. ··· .. ·· .. ·· .. ··· .. ·· .. 19-6
EXHAUST PIPE/MUFFLER .......................... ................ 3-29
EXHAUST SYSTEM ...................................................... 2-8
FLYWHEEL·························· ··········· ··· .. ·························'1-5
FORK··· .. ················ .. ················································ .. ·13-12
FRONT BRAKE CALIPER··········································· 15-18
FRONT MASTER CyLINDER··············· .. ···················· 15-12
FRONT VISOR ............................................................... 2·5
FRONT WHEEL· .. · .... · .. ······· .. · .. ·· .. ·· .. ····· .... · .. ·· .. ··· .. ··· .. ··· 13-7
FRONT WHEEUSUSPENSIONI
STEERING SPECIFICATIONS ..................................... 1-10
FUEL LINE ··· .. ·································································3-8
FUEL STRAINER SCREEN ............................................ 3-8
FUEL SYSTEM SPECIFICATIONS · .. ····· .... ········· .. ········· 1·7
FUEL TANK ····· .. ·· .. ······ .. ·············· .. ··· .... ·· .. ··· .. ·················2-7
GEARSHIFT LINKAGE ··············································· 10 -25
GENERAL SPECIFICATIONS ........................................ 1-5
HANDLEBAR··· .. ··············· .. ····································· .. · 13·31
HEADLIGHT ............ , ................................ ................ · .. ·19·4
HEADLIGHT AIM ......................................... ................ 3-28
HIGH AL nTUDE ADJUSTMENT
(California type onIV)··············· .. ··········· .. ··············· .... ·
5-29
HOT START ......................................................... ··········3-9
HYDRAULIC BRAKE SPECIFICAnONS············· .. ······· 1-1 1
IGNITION CONTROL MODULE (ICM) .... ·· .. · .. ·· .. ········· 17-8
IGNITION SYSTEM INSPECTION·· ·· .. ·· · .. ·· .... ········· .. · .. 17-5
IGNITION SYSTEM SPECiFiCATIONS ······················· 1-11
IGNITION TIMING ....................................................... 17-8
KICKSTARTER .. ·········· .. ····················· .. ······················10-15
LEFT CRANKCASE COVER INSTALLATION· ···· .. ······· 11 -7
LEFT CRANKCASE COVER REMOVAL ...................... 11 -4
lIGHTS/METEA/SWITCHES SPECIFICATIONS ········· 1-12
LUBRICATION
&
SEAL POINTS · .. ····· .. ··· .. ··········· .. ·· .. · 1-20
LUBRICATION SYSTEM DIAGRAM ·· .. · .. ··· .. ·· .. ············· 4-2
LUBRICATION SYSTEM SPECIFICATIONS·· .. ············· 1-6
~
MAIN RELAY (,04, '05) ················ .. ························· .... · 19-9
~
MAINTENANCE SCHEDULE
'04 -
'06 ..................................................................... 3-4
After '06· .... ··· .. ·· .. · .. ·,· .. ····· .. ·· .. ··· .. ····· .. ··· .. · .. ·· .. ··· .. ·· .. ···3-5
MODEL IDENTIFICATION .. ··········································· 1-2
NUTS, BOLTS, FASTENERS .. ·································· .. · 3·33
OIL JET .......... ... ........................................ .. . ···· .. ············ 4-6
OIL PUMP ....................................................... ............... 4-7
OIL STRAINER···································· .. ··· .. ····· .. ··,· .. · .. ····4-4
OPTIONAL PARTS .. ····· .. ·· .. ········· .. ······ .. ······················· 1-30
PILOT SCREW ADJUSTMENT ................................... 5-27
PISTON INSTAllATION ····················· .. ··· .. · .. ·· .... · .... ····· 9-8
PISTON REMOVAL······ .. ·· .. ····· .. ·· .... ···· .. ·· .. ····················· 9-4
PRESSURE RELIEF VALVE ····· .. ··························· .. ·· .. ··· 4-5
RADIATOR ........................................... .......................... 6-8
RADIATOR COOLANT· .. ··•······ .. ·· .. ···························•··· 3-13
RADIATOR RESERVE TANK· ································· .. · .... 6·9
RADIATOR SHROUD· ··················· .. ·········· .. · .. ················ 2-4
22-1