Table Of Contents - Honda 2004 CRF250X Service Manual

Table of Contents

A Few Words About Safety2
Important Safety Precautions2
Contents3
Symbols4
General Information5
Service Rules6
Model Identification6
General Specifications9
Lubrication System Specifications10
Fuel System Specifications11
Cooling System Specifications11
Cylinder Head/Valves Specifications12
Cylinder/Piston Specifications12
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications13
Crankcase/Crankshaft/Transmission/Balancer Specifications13
Front Wheel/Suspension/Steering Specifications14
Rear Wheel/Suspension Specifications14
Hydraulic Brake Specifications15
Battery/Charging System Specifications15
Ignition System Specifications15
Electric Starter Specification16
Lights/Meter/Switches Specifications16
Standard Torque Values17
Engine & Frame Torque Values17
Lubrication & Seal Points24
Cable & Harness Routing27
Secondary Air Supply System33
Optional Parts34
Emission Control Systems37
Source Of Emissions37
Exhaust Emission Control System37
Crankcase Emission Control System37
Servicing The Honda39
Noise Emission Control System39
Rebuilt Engine39
Frame/Body Panels/Exhaust System41
Table Of Contents41
Service Information42
Troubleshooting42
Torque Values42
Seat Removal43
Seat Installation43
Side Cover Removal/Installation43
Radiator Shroud Removal/Installation44
Engine Guard Removal/Installation44
Front Visor Removal/Installation45
Sub-Frame Removal45
Sub-Frame Installation46
Fuel Tank Removal/Installation47
Exhaust System Muffler Removal/Installation48
Maintenance53
Maintenance Service Information54
Maintenance Specifications54
Tools55
Maintenance Schedule ('04 - '06)56
Competition Maintenance Schedule58
Additional Items Requiring Frequent Replacement59
Fuel Line60
Fuel Strainer Screen60
Throttle Operation60
Hot Start61
Air Cleaner62
Crankcase Breather63
Spark Plug Removal63
Spark Plug Inspection64
Spark Plug Installation64
Radiator Coolant65
Cooling System65
Valve Clearance/Decompressor System66
('04 - '06 California Type, After '06)66
Engine Oil/Oil Filter69
Oil Level Inspection69
Decompressor System69
Engine Oil & Filter Change69
Engine Idle Speed71
Transmission Oil72
Transmission Oil Change72
Drive Chain Slack Inspection73
Drive Chain Adjustment73
Drive Chain Cleaning And Lubrication73
Drive Chain Replacement74
Drive Chain Slider76
Drive Chain Roller77
Drive/Driven Sprocket77
Brake Fluid Level Inspection78
Brake Fluid Filling78
Brake Pad Wear79
Brake System79
Lever Position Inspection79
Headlight Aim80
Clutch System80
Brake Pedal Height80
Control Cables81
Exhaust Pipe/Muffler81
Exhaust System Inspection81
Spark Arrester Removal/Installation82
Spark Arrester Inspection/Cleaning82
Side Stand Inspection83
Front Suspension Inspection83
Swingarm/Shock Linkage84
Rear Suspension Inspection84
Nuts, Bolts, Fasteners85
Wheels/Tires85
Steering Head Bearings86
Lubrication System87
Lubrication System Diagram88
Lubrication System Service Information89
Lubrication System Troubleshooting89
Lubrication System Torque Values89
Oil Strainer Removal/Inspection90
Oil Strainer Installation90
Pressure Relief Valve Removal/Installation91
Pressure Relief Vavle Inspection91
Oil Jet Removal/Inspection92
Oil Jet Installation92
Oil Pump Disassembly93
Oil Pump Inspection93
Oil Pump Assembly95
Fuel System97
Fuel System Component Location98
Fuel System Service Information99
Fuel System Torque Values100
Fuel System Tool100
Fuel System Troubleshooting101
Engine Will Not Start101
Lean Mixture101
Misfiring During Acceleration101
Carburetor Adjustment102
Idle Mixture And Idle Speed102
Air Cleaner Housing Removal103
Air Cleaner Housing Installation105
Carburetor Removal107
Carburettor Disassembly109
Jet Needle/Throttle Valve109
Choke Knob/Throttle Position Sensor110
Accelerator Pump/Float/Jet111
Carburetor Assembly114
Carburetor Installation120
Throttle Position Sensor Replacement122
Pilot Screw Adjustment123
Best Idle123
Idle Drop Procedure124
High Altitude Adjustment (California Type Only)125
Secondary Air Supply System Inspection127
Pair Control Valve Removal/Installation127
Pair Check Valve Inspection128
Air Supply Pipe Removal/Installation128
Cooling System Flow Pattern132
Cooling System Service Information133
Cooling System Torque Values133
Cooling System Tools134
Cooling System Troubleshooting134
Engine Temperature Too High134
Coolant Leak134
Cooling System Testing135
Coolant (Hydrometer Test)135
Coolant Gravity Chart135
Radiator Cap/System Pressure Inspection136
Coolant Replacement Preparation136
Radiator Cap Relief Pressure136
Recommended Antifreeze136
Replacement/Air Bleeding137
Radiator Removal138
Radiator Installation139
Radiator Reserve Tank Removal/Installation139
Water Pump140
Water Seal Inspection140
Water Pump Removal140
Water Pump Bearing/Water Seal/Oil Seal Replacement142
Water Pump Installation143
Engine Removal/Installation145
Engine Removal/Installation Component Location146
Drive Sprocket Removal148
Drive Sprocket Installation148
Engine Removal149
Engine Installation151
Cylinder Head/Valves155
Cylinder Head/Valves Component Location156
Cylinder Head/Valves Service Information157
Cylinder Head/Valves Torque Values157
Cylinder Head/Valves Tools158
Cylinder Head/Valves Troubleshooting159
Compression Too Low, Hard Starting Or Poor Performance At Low Speed159
Compression Too High159
Excessive Noise159
Cylinder Compression Test160
Cylinder Head Cover Removal160
Camshaft/Rocker Arm Removal161
Cylinder Head Removal166
Cam Chain Tensioner/Cam Chain Guide Removal168
Cam Chain Tensioner/Cam Chain Guide Inspection168
Cylinder Head Disassembly169
Cam Chain Tensioner/Cam Chain Guide Installation169
Cylinder Head Inspection171
Valve/Valve Guide172
Valve Guide Replacement173
Valve Seat Inspection/Refacing173
Valve Seat Refacing174
Intake Side176
Exhaust Side176
Cylinder Head Assembly177
Cylinder Head Installation179
Camshaft/Rocker Arm Installation181
Cylinder Head Cover Installation184
Cylinder/Piston187
Cylinder/Piston Component Location188
Cylinder/Piston Service Information189
Cylinder/Piston Troubleshooting189
Cylinder Removal190
Piston Removal190
Cylinder/Piston Inspection191
Piston/Piston Ring Inspection191
Connecting Rod Inspection193
Piston Ring Installation193
Cam Chain Tensioner Lifter Inspection193
Piston Installation194
Cylinder Installation194
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage197
Component Loca Non198
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information199
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Torque Values199
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Tools199
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Troubleshooting200
Right Crankcase Cover Removal201
Right Crankcase Cover Installation202
Clutch Removal203
Clutch Inspection205
Clutch Spring205
Clutch Discs205
Clutch Plates206
Friction Spring/Spring Seat206
Clutch Center206
Clutch Lifter/Needle Bearing206
Clutch Lifter Rod207
Clutch Outer207
Needle Bearing/Clutch Outer Guide207
Clutch Lifter Lever207
Kickstarter Removal211
Kickstarter Disassembly/Inspection212
Kickstarter Assembly213
Kickstarter Installation214
Starter Clutch Removal215
Right Crankcase Cover215
Starter Clutch Disassembly/Inspection216
Starter Clutch Assembly218
Starter Clutch Installation219
Gearshift Linkage Removal221
Gearshift Linkage Inspection222
Gearshift Spindle222
Ratchet Pawl222
Gearshift Linkage Installation222
Alternator225
Alternator Component Location226
Alternator Service Information227
Alternator Torque Values227
Alternator Tools227
Left Crankcase Cover Removal228
Stator Removal229
Stator Installation229
Flywheel Removal229
Left Crankcase Cover Installation231
Crankcase/Crankshaft/Transmission/Balancer233
Crankcase/Crankshaft/Transmission/Balancer Component Location234
Crankcase/Crankshaft/Transmission/Balancer Service Information235
Crankcase/Crankshaft/Transmission/Balancer Torque Value236
Crankcase/Crankshaft/Transmission/Balancer Tools236
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting237
Balancer Gear/Balancer Removal238
Balancer Gear/Balancer Inspection238
Balancer Gear/Balancer Installation238
Crankcase Separation239
Transmission Disassembly241
Transmission Inspection242
Gear242
Bushing242
Mainshaft/Countershaft242
Shift Fork243
Shift Fork Shaft243
Shift Drum243
Transmission Bearing243
Crankshaft Removal244
Crankshaft Inspection244
Crankcase Bearing Replacement245
Crankcase Bearing/Oil Seal Location245
Crankshaft Bearing245
Transmission/Balancer/Shift Drum Bearings247
Left Crankcase247
Crankshaft Installation250
Transmission Assembly251
Mainshaft251
Countershaft251
Crankcase Assembly253
Front Wheel/Suspension/Steering255
Front Wheel/Suspension/Steering Component Location256
Front Wheel/Suspension/Steering Service Information257
Front Wheel/Suspension/Steering Torque Values258
Front Wheel/Suspension/Steering Tools258
Front Wheel/Suspension/Steering Troubleshooting260
Front Wheel Removal261
Front Wheel Inspection261
Front Wheel Disassembly262
Wheel Bearing262
Wheel Rim262
Front Wheel Assembly263
Front Wheel Installation265
Fork Removal266
Fork Disassembly268
Outer Tube And Slider Disassembly270
Fork Damper Disassembly271
Fork Damper Inspection272
Fork Cap272
Fork Centre Bolt272
Slider/Outer Tube272
Fork Spring273
Bushing/Back-Up Ring273
Fork Damper273
Outer Tube And Slider Assembly274
Fork Damper Refilling/Assembly275
Fork Damper Operation Inspection278
Fork Damper Installation/Preparation279
Fork Damper Installation280
Oil Capacity Adjustment282
Standard Oil Capacity282
Standard Position283
Handlebar Removal285
Handlebar Installation287
Steering Stem Removal291
Steering Stem Bearing Replacement292
Steering Stem Installation294
Rear Wheel/Suspension297
Rear Wheel/Suspension Component Location298
Rear Wheel/Suspension Service Information299
Rear Wheel/Suspension Torque Values300
Rear Wheel/Suspension Tools300
Rear Wheel/Suspension Troubleshooting302
Rear Wheel Removal303
Rear Wheel Inspection303
Rear Wheel Disassembly304
Wheel Rim Runout304
Rear Wheel Assembly305
Rear Wheel Installation308
Shock Absorber Removal309
Shock Absorber Disassembly310
Shock Absorber Bladder Replacement310
Damper Disassembly313
Recommended Shock Oil313
Piston Ring Replacement315
Damper Rod Disassembly315
Rod Guide Case Inspection317
Damper Rod Inspection317
Damper Assembly318
Spherical Bearing Replacement323
Shock Linkage Removal325
Shock Linkage Inspection327
Bearing Replacement327
Shock Arm Needle Bearing327
Shock Link Needle Bearing328
Swingarm Removal331
Swingarm Disassembly333
Swingarm Bearing Replacement334
Swingarm Assembly334
Swingarm Installation336
Hydraulic Brake339
Hydraulic Brake Component Location340
Hydraulic Brake Service Information341
Hydraulic Brake Torque Values342
Hydraulic Brake Tool342
Hydraulic Brake Troubleshooting343
Brake Lever/Pedal Soft Or Spongy343
Brake Lever/Pedal Hard343
Brake Drags343
Brake Fluid Replacement/Air Bleeding344
Brake Fluid Draining344
Brake Fluid Filling/Air Bleeding345
Brake Pad/Disc348
Brake Pad Replacement348
Front Master Cylinder Removal350
Front Master Cylinder Disassembly350
Rear Master Cylinder Removal353
Rear Master Cylinder Disassembly353
Rear Master Cylinder Inspection354
Rear Master Cylinder Assembly354
Rear Master Cylinder Installation355
Front Brake Caliper Removal356
Front Brake Caliper Disassembly356
Front Brake Caliper Inspection357
Front Brake Caliper Assembly357
Front Brake Caliper Installation358
Rear Brake Caliper Removal358
Battery/Charging System365
Battery/Charging System Component Location366
Battery/Charging System System Diagram366
Battery/Charging System Service Information367
Battery Charging367
Battery Testing367
Battery/Charging System Tools368
Battery/Charging System Troubleshooting369
Battery Removal/Installation370
Battery Voltage Inspection370
Charging System Inspection370
Current Leakage Inspection370
Regulator/Rectifier System Inspection371
Charging Voltage Inspection371
Regulator/Rectifier Removal/Installation371
Alternator Charging Coil Inspection372
Ignition System373
Ignition System Component Location374
Ignition System Diagram374
Ignition System Service Information375
Ignition System Specification375
Ignition System Torque Values375
Ignition System Tools375
Ignition System Troubleshooting376
Ignition System Inspection377
Ignition Coil Primary Peak Voltage377
Direct Ignition Coil Inspection378
Exciter Coil Peak Voltage378
Ignition Pulse Generator Peak Voltage379
Ignition Control Module (Icm) Removal/Installation380
Ignition Timing380
Throttle Position Sensor Inspection381
Electric Starter383
Electric Starter Component Location384
Electric Starter System Diagram384
Electric Starter Service Information385
Electric Starter Troubleshooting386
Starter Motor Removal388
Starter Disassembly/Inspection388
Starter Motor Assembly391
Starter Motor Installation393
Starter Relay Switch Operation Inspection393
Starter Relay Switch Ground Line393
Starter Relay Switch Power Input Line394
Starter Relay Switch Function Inspection394
Lights/Meter/Switches395
Lights/Meter/Switches Component Location396
Lights/Meter/Switches Service Information397
Lights/Meter/Switches Torque Values397
Headlight Bulb Replacement398
Headlight Removal/Installation399
Tail Light Inspection399
Engine Stop Button400
Tail Light Removal/Installation400
Clutch Switch Inspection401
Starter Switch402
Tripmeter Removal/Installation402
Main Relay Inspection403
Wiring Diagram406
Engine Does Not Start Or Is Hard To Start410
Engine Lacks Power411
Poor Performance At Low And Idle Speed413
Poor Performance At High Speed414
Poor Handling415
Index417