Honda CRF250L/LA Rally 2020 Manual
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Honda CRF250L/LA Rally 2020 Manual

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Contents
31KZZC30
2020 CRF250L/LA Rally
MOM 17332 (1909)
P. 2
P. 18
P. 35
P. 87
P. 107
P. 129
P. 133

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Table of Contents
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Summary of Contents for Honda CRF250L/LA Rally 2020

  • Page 1: Table Of Contents

    Contents Vehicle Safety P. 2 Operation Guide P. 18 Maintenance P. 35 Troubleshooting P. 87 Information P. 107 Specifications P. 129 Index P. 133 31KZZC30 2020 CRF250L/LA Rally MOM 17332 (1909)
  • Page 2 Welcome Congratulations on your purchase of a new When service is required, remember that Honda vehicle. Your selection of a Honda your Honda dealer knows your vehicle best. makes you part of a worldwide family of If you have the required mechanical “know- satisfied customers who appreciate Honda's how”...
  • Page 3 A Few Words About Safety DANGER Your safety, and the safety of others, is very important. Operating this vehicle safely is an You WILL be KILLED or SERIOUSLY important responsibility. HURT if you don’t follow instructions. To help you make informed decisions about safety, we have provided operating WARNING procedures and other information on safety...

  • Page 4: Vehicle Safety

    Vehicle Safety This section contains important information for safe riding of your vehicle. Please read this section carefully. Safety Guidelines ..........P. 3 Safety Labels............P. 7 Safety Precautions..........P. 9 Riding Precautions ..........P. 11 Accessories & Modifications......P. 15 Off-Road Safety ..........

  • Page 5: Safety Guidelines

    Safety Guidelines Safety Guidelines Before Riding Make sure that you are physically fit, mentally Follow these guidelines to enhance your safety: focused and free of alcohol and drugs. Check Perform all routine and regular inspections ● that you and your passenger are both wearing specified in this manual.
  • Page 6 Safety Guidelines For information about the MSF training course Make Yourself Easy to See nearest you, call the national toll-free number: Make yourself more visible, especially at night, (800) 446-9227. by wearing bright reflective clothing, positioning yourself so other drivers can see you, signaling Other riding tips can be found in the You before turning or changing lanes, and using and Your Motorcycle Riding Tips booklet that...
  • Page 7 Keep Your Honda in Safe Condition It's important to keep your vehicle properly If you decide to continue riding, first turn the maintained and in safe riding condition.
  • Page 8 Safety Guidelines WARNING Carbon Monoxide Hazard Exhaust contains poisonous carbon monoxide, a Running the engine of your vehicle colorless, odorless gas. Breathing carbon while in an enclosed or even partially monoxide can cause loss of consciousness and enclosed area can cause a rapid build- may lead to death.

  • Page 9: Safety Labels

    Safety Labels Safety Labels serious injury. Read these labels carefully and don't remove them. Safety and information labels on your vehicle If a label comes off or becomes hard to read, provide important safety information and may contact your dealer for a replacement. warn you of potential hazards that could cause Continued...
  • Page 10 Safety Labels...

  • Page 11: Safety Precautions

    Safety Precautions Safety Precautions Helmet Should be safety-standard certified, high- Ride cautiously and keep your hands on the visibility, and correct size for your head ● handlebar and feet on the footpegs. Must fit comfortably but securely, with the ● Keep passenger's hands onto the seat strap chin strap fastened.
  • Page 12 Safety Precautions Gloves Additional Off-road Gear Full-finger leather gloves with high abrasion On-road apparel may also be suitable for casual resistance off-road riding. But if you plan on any serious off-road riding you will need more serious off- road gear. In addition to your helmet and eye Boots or Riding Shoes protection, we recommend off-road motorcycle Sturdy boots with non-slip soles and ankle...

  • Page 13: Riding Precautions

    Riding Precautions Riding Precautions Exercise caution on low traction surfaces. ● The tires slip more easily on such surfaces and braking distances are Break-in Period longer. During the first 300 miles (500 km) of running, Avoid continuous braking. ● follow these guidelines to ensure your vehicle's Repeated braking, such as when future reliability and performance.
  • Page 14 Riding Precautions Anti-lock Brake System (ABS) Engine Braking Engine braking helps slow your vehicle down CRF250RLA This model is equipped with an Anti-lock Brake when you release the throttle. For further System (ABS) designed to help prevent the slowing action, downshift to a lower gear. Use brakes from locking up during hard braking.
  • Page 15 Riding Precautions Parking with the Side Stand Parking Stop the engine. Park on a firm, level surface. ● Push the side stand down. If you must park on a slight incline or loose ● Slowly lean the vehicle to the left until its surface, park so that the vehicle cannot weight rests on the side stand.
  • Page 16 Riding Precautions Refueling and Fuel Guidelines Follow these guidelines to protect the engine, fuel system and catalytic converter: Use only unleaded gasoline. ● Use recommended octane number. Using ● lower octane gasoline will result in decreased engine performance. Do not use fuels containing a high ●...

  • Page 17: Accessories & Modifications

    We strongly advise that you do not add any seriously hurt or killed. accessories that were not specifically designed or approved for your vehicle by Honda or make Follow all instructions in this owner's modifications to your vehicle from its original manual regarding accessories and design.

  • Page 18: Off-Road Safety

    Off-Road Safety Off-Road Safety A muffler is required in most off-road areas. ● Don't modify your exhaust system. Learn to ride in an uncongested off-road area Remember that excessive noise bothers free of obstacles before venturing onto everyone and creates a bad image for motorcycling.

  • Page 19: Loading

    Loading Loading Also follow these guidelines when you ride off- road on rough terrain: Carrying extra weight affects your vehicle's Do not carry a passenger. ● ● handling, braking and stability. Keep cargo small and light weight. ● Make sure it cannot easily be caught on Always ride at a safe speed for the load you are carrying.

  • Page 20: Operation Guide

    Parts Location Spark arrester (P.62) Air cleaner (P.68) Throttle grip (P.84) Front brake fluid reservoir (P.71) Right side cover　 (P.57) Coolant reserve tank (P.69) Engine oil fill cap (P.64) Engine oil filter (P.66) Rear brake fluid Engine oil level inspection reservoir (P.71) window...
  • Page 21 Clutch lever Fuel fill cap (P.81) (P.32) Document bag (P.34) Seat (P.56) Helmet holder (P.33) Battery (P.55) Main fuse (P.103) Fuse box (P.102) Tool box/Tool kit (P.34) Crankcase breather (P.85) Left side cover (P.57) Drive chain (P.75) Side stand Spark plug (P.74) Shift lever (P.31)
  • Page 22 Instruments Tachometer Tachometer red zone (excessive engine rpm range) NOTICE Do not operate the engine in the tachometer red zone. Excessive engine speed can adversely affect engine life. button button Display Check When the ignition switch is turned to the ON position, all the mode and digital segments will show.
  • Page 23 Odometer [TOTAL] & Tripmeter[TRIP A/B] button switches between the odometer Speedometer and tripmeters. Odometer: Total distance ridden. ● When “------” is displayed, go to your dealer for service. Tripmeter: Distance ridden since tripmeter ● was reset (press and hold button to reset to 0.0 km/mile at the tripmeter display).
  • Page 24 Instruments (Continued) 1 To set the clock: Press the button. The minute digits start flashing. Turn the ignition switch to the ON position. Press and hold the button and the button until the hour digits start flashing. Press the button until the desired minute is displayed.
  • Page 25 Press the button. The clock is set, and 2 Changing the speed and mileage unit: then the display moves to the changing of Press the button to select either “km/h” the speed and mileage unit. & “km” or “mph” & “mile” for the The adjustment can also be set by speedometer, odometer and tripmeters.
  • Page 26 Indicators If one of these indicators does not come on when it should, have your dealer check for problems. Rear ABS (Anti-lock Brake System) OFF indicator CRF250RLA Comes on briefly when the ignition switch is turned to the ON position. Comes on when the ABS function on the rear wheel is turned off.
  • Page 27 High coolant temperature indicator High beam indicator Comes on briefly when the ignition switch is turned to the ON position with the engine stop switch in the (Run) position. If it comes on while running: (P.89) Left turn signal indicator Right turn signal indicator ABS (Anti-lock Brake System) indicator CRF250RLA...
  • Page 28 Switches Headlight dimmer switch • : High beam • : Low beam Horn button Turn signal switch Pressing the switch turns the turn signal off. Hazard switch Switchable when the ignition switch is turned to the ON position.
  • Page 29 Ignition switch Turns electrical system Switches the electrical system on/off, locks on for starting/riding. the steering. Key can be removed when in the OFF or Turns engine off. LOCK position. LOCK Steering Lock: (P.28) Locks steering. Rear ABS switch CRF250RLA Switches the ABS function on the rear wheel on/off.
  • Page 30 Switches (Continued) Steering Lock Locking Turn the handlebar all the way to the left. Lock the steering when parking to help Push the key down, and turn the ignition prevent theft. switch to the LOCK position. A U-shaped wheel lock or similar device is Jiggle the handlebar if the lock is difficult also recommended.
  • Page 31 ABS function on the rear wheel To turn on the ABS function on both CRF250RLA The ABS function on the rear wheel can be wheels optionally turned off for off-road riding. Stop the vehicle. Press and hold the rear ABS switch until the Each time the ignition switch is turned to the rear ABS OFF indicator is turned off, or turn ON position, the ABS function on both...
  • Page 32 Starting the Engine Start your engine using the following procedure, Make sure the engine stop switch is in the (Run) position. regardless of whether the engine is cold or warm. Turn the ignition switch to the ON position. Shift the transmission to Neutral ( indicator to come on).
  • Page 33 Shifting Gears Your vehicle transmission has 6 forward Recommended Shift Points gears in a one-down, five-up shift pattern. Shifting Up From 1st to 2nd 12 mph (20 km/h) From 2nd to 3rd 19 mph (30 km/h) From 3rd to 4th 25 mph (40 km/h) From 4th to 5th 31 mph (50 km/h)
  • Page 34 Refueling Ignition key Opening the Fuel Fill Cap Lock cover Open the lock cover, insert the ignition key, Level plate and turn it clockwise to open the fuel fill cap. Closing the Fuel Fill Cap After refueling, push the fuel fill cap closed until it locks.
  • Page 35 Storage Equipment Helmet Holder Unlocking The helmet holder is located on the left side Open the lock cover, insert the ignition key of the vehicle. and turn it counterclockwise. When hanging two helmets, use the helmet Locking set wire. Hang your helmet on the holder pin and The helmet set wire is in the tool kit.
  • Page 36 Storage Equipment (Continued) Document Bag Tool Kit The document bag is located under the seat. The tool kit is stored in the tool box located on the left side of the vehicle. Document bag Tool box Ignition Tool kit Removing the Seat (P.56) Insert the ignition key and turn it clockwise to open the tool box.

  • Page 37: Maintenance

    Please read “Importance of Maintenance” and “Maintenance Fundamentals” carefully before attempting any maintenance. Refer to “Specifications” for service data. An optional larger tool kit may be available. Check with your Honda dealer's parts department. Importance of Maintenance ......P. 36 Brakes..............P. 71 Maintenance Schedule........

  • Page 38: Importance Of Maintenance

    Importance of Maintenance For information about the exhaust emission and Importance of Maintenance noise emission requirements of the U.S. Keeping your vehicle well-maintained is Environmental Protection Agency (EPA), the absolutely essential to your safety and to California Air Resources Board (CARB), and the protect your investment, obtain maximum Environment and Climate Change Canada performance, avoid breakdowns, and reduce air...
  • Page 39 Importance of Maintenance Maintenance Safety Always read the maintenance instructions before you begin each task, and make sure that you have the tools, parts, and skills required. We cannot warn you of every conceivable hazard that can arise in performing maintenance.

  • Page 40: Maintenance Schedule

    Maintenance work should be performed in owner. accordance with Honda's standards and specifications by properly trained and equipped technicians. Your dealer meets all of these requirements. All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer.
  • Page 41 Lubricate mechanically skilled. Replace Procedures are provided in an official Honda Service Clean Manual (2 P. 123). : Technical. In the interest of safety, have your vehicle serviced by your dealer.
  • Page 42 Maintenance Schedule Frequency Regular Refer to Items × 1,000 mi Replace page × 1,000 km 12.8 19.2 25.6 32.0 38.4 Drive Chain Every 600 mi (1,000 km): Drive Chain Slider Brake Fluid 2 Years Brake Pads Wear Brake System Brake light Switch Headlight Aim Clutch System Side Stand...

  • Page 43: Maintenance Record

    Maintenance Record Distance Odometer Date Performed By: Notes 600 miles (1,000 km) 4,000 miles (6,400 km) 8,000 miles (12,800 km) 12,000 miles (19,200 km) 16,000 miles (25,600 km) 20,000 miles (32,000 km) 24,000 miles (38,400 km) 28,000 miles (44,800 km) 32,000 miles (51,200 km) 36,000 miles (57,600 km) 40,000 miles (64,000 km)

  • Page 44: Maintenance Fundamentals

    Maintenance Fundamentals Check the following items if you are carrying a Pre-ride Inspection passenger or cargo: To ensure safety, it is your responsibility to Combined weight is within load limits. ● perform a pre-ride inspection and make sure P. 129 that any problem you find is corrected.
  • Page 45 Maintenance Fundamentals Check the following items at regular intervals: Before riding off-road check all of the preceding Oil level is between the upper and lower plus the following: ● level marks. P. 64 Make sure spokes are tight. Check the rims ●...
  • Page 46 Maintenance Fundamentals Also, check the odometer reading against the Periodic Checks Maintenance Schedule and perform all You should also perform other periodic maintenance that is due. P. 38 maintenance checks at least once a month regardless of how often you ride, or more often if you ride frequently.
  • Page 47 Maintenance Fundamentals Replacing Parts Color label Always use Honda Genuine Parts or their equivalents to ensure reliability and safety. When ordering colored components, specify the model name, color, and code mentioned on the color label. The color label is attached to the left side of the front frame.
  • Page 48 Maintenance Fundamentals Electrolyte splashes onto your skin: Battery ● Remove affected clothing and wash your Your vehicle has a maintenance-free type skin thoroughly using water. battery. You do not have to check the battery Electrolyte splashes into your mouth: ● electrolyte level or add distilled water.
  • Page 49 30 days using a charger designed specifically for If the terminals are heavily corroded, clean your Honda, which can be purchased from your and polish the terminals with a wire brush or dealer. Read the information that came with sandpaper.
  • Page 50 Bump starting is also not recommended. NOTICE Installing non-Honda electrical accessories can NOTICE Replacing a fuse with one that has a higher rating greatly overload the electrical system, discharging the increases the chance of damage to the electrical system.
  • Page 51 Use SG or higher oils, excluding oils marked as “Energy If you use non-Honda engine oil, check the Conserving” or “Resource Conserving” on the label to make sure that the oil satisfies all of the circular API service symbol.
  • Page 52 Recommended brake fluid: Also inspect the drive sprocket and driven Honda DOT 3 or DOT 4 Brake Fluid or sprocket. If either has worn or damaged teeth, equivalent have the sprocket replaced by your dealer.
  • Page 53 Use a soft brush if the chain is dirty. After cleaning, wipe dry and lubricate with the Recommended Coolant recommended lubricant. Pro Honda HP Coolant is a pre-mixed solution Recommended lubricant: of antifreeze and distilled water. Pro Honda HP Chain Lube or equivalent...
  • Page 54 Maintenance Fundamentals only ride on pavement, check the pressure at NOTICE least once a month or any time you think the Using coolant not specified for aluminum engines tires look low. Always check air pressure when or tap/mineral water can cause corrosion. your tires are cold.
  • Page 55 Maintenance Fundamentals Inspecting for Abnormal Wear Inspecting Rims and Valve Stems Inspect the rims for damage and loose spokes. Inspect the tires for Also inspect the valve stems for their positions. signs of abnormal wear A tilted valve stem indicates the tube is slipping on the contact surface.
  • Page 56 Maintenance Fundamentals Have your tires replaced by your dealer. Air Cleaner For recommended tires, air pressure and This vehicle is equipped with a viscous type air minimum tread depth, see “Specifications.” cleaner element which cannot be cleaned with P. 130 compressed air or otherwise without degrading Follow these guidelines whenever you replace its performance.

  • Page 57: Removing & Installing Body Components

    Removing & Installing Body Components Battery Remove the bolts. Remove the battery holder. Disconnect the negative - terminal from Negative terminal Positive terminal the battery. Disconnect the positive + terminal from the battery. Remove the battery taking care not to drop the terminal nuts.

  • Page 58: Seat

    Removing & Installing Body Components Seat Seat Removal Remove the hook bolts and collars. Prongs Pull the seat back and up. Collar Installation Hook bolt Align the recess with the tab and insert Recess the prongs into the front stay and rear stays.

  • Page 59: Side Cover

    Removing & Installing Body Components Side Cover Side Cover Installation Install the parts in the reverse order of Removal removal. Open the tool box. P. 34 Left Remove the bolts. Remove the prongs from the grommets. Remove the side cover. Grommets Right side cover Grommets...

  • Page 60: Under Cowl

    Removing & Installing Body Components Under Cowl Under Cowl Rear Side Removal Front Side Rear under cowl Bolts and washers Remove the bolts and washers on rear under cowl. Bolts Front under cowl Remove the rear under cowl. Installation Remove the bolts and front under cowl. Install the parts in the reverse order of removal.

  • Page 61: Spark Plug

    Spark Plug Checking Spark Plug Do not clean the spark plug. If an ● electrode is contaminated with accumulated objects or dirt, replace the For the recommended spark plug, see spark plug with a new one. “Specifications.” P. 130 To check the spark plug gap, use only a ●...
  • Page 62 Spark Plug Checking Spark Plug Spark plug cap Spark plug gap Make sure the plug washer is in good condition. Inspect the electrodes and center Install the spark plug. With the plug porcelain for deposits, erosion or carbon washer attached, thread the spark plug in fouling.
  • Page 63 Spark Plug Checking Spark Plug Tighten the spark plug: If the old plug is good: ● 1/8 turn after it seats. If installing a new plug, tighten it twice ● to prevent loosening: a) First, tighten the plug: 1/2 turn after it seats. b) Then loosen the plug.

  • Page 64: Spark Arrester

    Spark Arrester Cleaning the Spark Arrester Spark arrester mounting bolts Spark arrester Regular servicing prevents carbon buildup Gasket (which can diminish engine performance) and also complies with USDA regulations for Muffler cover bolts regular maintenance to assure proper function. The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment.
  • Page 65 Spark Arrester Cleaning the Spark Arrester Remove the spark arrester mounting Install the gasket and the spark arrester, bolts, spark arrester and gasket from the and tighten the spark arrester mounting muffler. bolts. Use a brush to remove carbon deposits Torque: 6.6 lbf·ft (9.0 N·m, 0.9 kgf·m) from the spark arrester screen.

  • Page 66: Engine Oil

    Engine Oil Checking the Engine Oil Oil level inspection If the engine is cold, idle the engine for 3 window to 5 minutes. Upper level Turn the ignition switch to the OFF mark position and wait for 2 to 3 minutes. Place your vehicle in an upright position on a firm, level surface.
  • Page 67 Engine Oil Adding Engine Oil Adding Engine Oil NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine. Do not mix If the engine oil is below or near the lower different brands and grades of oil. They may level mark, add the recommended engine oil.
  • Page 68 Changing the oil and filter requires special tools. We recommend that you have your Sealing washer vehicle serviced by your dealer. Use a new Honda Genuine oil filter or equivalent specified for your model. NOTICE Using the wrong oil filter can result in serious damage to the engine.
  • Page 69 Engine Oil Changing Engine Oil & Filter Install a new sealing washer onto the drain bolt. Tighten the drain bolt. Torque: 18 lbf·ft (24 N·m, 2.4 kgf·m) Spring Fill the crankcase with the recommended Oil filter cover oil ( P. 49, P.

  • Page 70: Air Cleaner

    Air Cleaner Changing Air Cleaner Element Air cleaner element Use a new Honda Genuine air cleaner element or an equivalent specified for your vehicle. NOTICE Using the wrong air cleaner element may cause Tabs premature engine wear or performance problems.

  • Page 71: Coolant

    Coolant Checking the Coolant Reserve tank cap UPPER level mark Check the coolant level in the reserve tank while the engine is cold. Place your vehicle on a firm, level surface. Hold your vehicle in an upright position. Check that the coolant level is between the UPPER level and LOWER level marks on the reserve tank.
  • Page 72 Coolant Adding Coolant Adding Coolant WARNING Removing the radiator cap while the If the coolant level is below the LOWER level engine is hot can cause the coolant to mark, add the recommended coolant spray out, potentially scalding you. P. 51) until the level reaches the UPPER level mark.

  • Page 73: Brakes

    Brakes Checking Brake Fluid If the brake fluid level in either reservoir is below the LOWER level mark or the brake lever and pedal freeplay becomes excessive, Place your vehicle in an upright position inspect the brake pads for wear. on a firm, level surface.
  • Page 74 Brakes Inspecting the Brake Pads Inspecting the Brake Pads Inspect the brake pads from below Front the brake caliper. Inspect the brake pads from the rear Check the condition of the brake pad wear Rear right of the vehicle. indicators. If necessary have the pads replaced by your The pads need to be replaced if a brake pad dealer.
  • Page 75 Brakes Adjusting the Brake Light Switch Adjusting the Brake Light Switch Check the operation of the brake light switch. Hold the brake light switch and turn the adjusting nut in the direction A if the switch operates too late, or turn the nut in the direction B if the switch operates too soon.

  • Page 76: Side Stand

    Side Stand Checking the Side Stand Start the engine, pull the clutch lever in, and shift the transmission into gear. Lower the side stand all the way. The engine should stop as you lower the side stand. If the engine doesn't stop, have your vehicle inspected by your dealer.

  • Page 77: Drive Chain

    Drive Chain Inspecting the Drive Chain Drive chain slack: 1.6 - 2.0 in (40 - 50 mm) Slack Do not ride your vehicle if the slack Check the drive chain slack at several points exceeds 2.4 in (60 mm). along the chain. If the slack is not constant at all points, some links may be kinked and binding.
  • Page 78 Drive Chain Adjusting the Drive Chain Slack Adjusting the Drive Chain Adjusting plate CRF250RLA Slack Wheel speed sensor Adjusting the chain requires special tools. Lock nut Have the drive chain slack adjusted by your dealer. Adjusting bolt CRF250RLA When adjusting the drive chain slack, be CRF250RLA careful not to damage the wheel speed Pulser ring...
  • Page 79 Drive Chain Adjusting the Drive Chain Slack Turn both adjusting bolts an equal Tighten the rear axle nut. number of turns until the correct drive Torque: 65 lbf·ft (88 N·m, 9.0 kgf·m) chain slack is obtained. Turn the adjusting bolts counterclockwise to tighten the Hold the adjusting bolts and tighten the chain.
  • Page 80 Drive Chain Adjusting the Drive Chain Slack Checking the Drive Chain Wear Indicator groove Check the chain wear label when adjusting the drive chain. If the indicator groove on the Red zone chain adjuster plate enters the red zone on the label after the chain has been adjusted to the proper slack, the chain is excessively worn and must be replaced.
  • Page 81 Drive Chain Checking the Drive Chain Slider Checking the Drive Chain Slider Drive chain slider Check the condition of the drive chain slider. The drive chain slider will need to be Wear limit replaced if the chain slider is worn to the indicator wear limit indicator or wear limit line.

  • Page 82: Wheels

    Wheels Wheels Rims & Spokes Rotate the wheel slowly to see if it appears to “wobble.” If it does, the rim is out of round or not “true.” If the wobble is Keeping the wheels true (round) and noticeable, see your dealer for inspection. maintaining correct spoke tension is critical to safe vehicle operation.

  • Page 83: Clutch

    Clutch Checking the Clutch Check the clutch cable for kinks or signs of wear. If necessary have it replaced by your Checking the Clutch Lever Freeplay dealer. Lubricate the clutch cable with a Check the clutch lever freeplay. commercially available cable lubricant to Freeplay at the clutch lever: prevent premature wear and corrosion.
  • Page 84 Clutch Adjusting the Clutch Lever Freeplay Adjusting the Clutch Lever Minor lock nut Freeplay Minor clutch cable adjuster Minor Adjustment Attempt adjustment with the minor clutch – cable adjuster first. Rubber dust cover Pull back the rubber dust cover. Loosen the minor lock nut. Turn the minor clutch cable adjuster until the freeplay is 0.4 - 0.8 in (10 - 20 mm).
  • Page 85 Clutch Adjusting the Clutch Lever Freeplay Major Adjustment creep. Gradually release the clutch lever and open the throttle. Your vehicle should If the minor clutch cable adjuster is threaded move smoothly and accelerate gradually. out near its limit, or the correct freeplay cannot be obtained, attempt adjustment with Major clutch cable adjuster the major clutch cable adjuster.

  • Page 86: Throttle

    Throttle Checking the Throttle Adjusting the Throttle Freeplay With the engine off, check that the throttle Loosen the lock nut. rotates smoothly from fully closed to fully Turn the adjuster until the freeplay is open in all steering positions and throttle 0.1 - 0.2 in (2 - 6 mm).

  • Page 87: Crankcase Breather

    Crankcase Breather Cleaning the Crankcase Place a suitable container to receive deposits. Breather Remove the crankcase breather tube and drain deposits into the container. Reinstall the crankcase breather tube. Crankcase breather tube...

  • Page 88: Other Adjustments

    Other Adjustments Adjusting the Headlight Aim You can adjust vertical aim of the headlight for proper alignment. Turn the pinion using a Phillips screwdriver in or out as necessary. Obey local laws and regulations. Pinion Lower Raise...

  • Page 89: Troubleshooting

    Troubleshooting Engine Will Not Start........P. 88 Unstable Engine Operation Occurs Overheating (High coolant temperature Intermittently ..........P. 106 indicator is on) ..........P. 89 Warning Indicators On or Flashing....P. 90 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)....P. 90 ABS (Anti-lock Brake System) Indicator ..

  • Page 90: Engine Will Not Start

    Engine Will Not Start Starter Motor Operates But Starter Motor Does Not Engine Does Not Start Operate Check the following items: Check the following items: Check the correct engine starting Check the correct engine starting ● ● sequence. P. 30 sequence.

  • Page 91: Overheating

    Overheating (High coolant temperature indicator is on) The engine is overheating when the following If the fan is not operating: occurs: Suspect a fault. Do not start the engine. High coolant temperature indicator Transport your vehicle to your dealer. ● comes on.

  • Page 92: Warning Indicators On Or Flashing

    Warning Indicators On or Flashing PGM-FI (Programmed Fuel Indicator comes on or starts flashing while ● riding. Injection) Malfunction Indicator does not come on when the ● Indicator Lamp (MIL) ignition switch is in the ON position. Indicator does not go off at speeds above ●...

  • Page 93: Other Warning Indications

    Other Warning Indications Fuel Gauge Failure Indication If the fuel system has an error, the fuel gauge indicators will be displayed as shown in the illustration. If this occurs, see your dealer as soon as possible.

  • Page 94: Tire Puncture

    Tire Puncture Repairing a puncture or removing a wheel WARNING requires special tools and technical expertise. Riding your vehicle with a temporary We recommend you have this type of service tire or tube repair can be risky. If the performed by your dealer. temporary repair fails, you can crash After an emergency repair, always have the and be seriously injured or killed.
  • Page 95 Tire Puncture Removing Wheels CRF250RLA Axle pinch bolts When removing and installing the wheel, be careful not to damage the wheel speed sensor and pulser ring. Front Wheel Removal Place your vehicle on a firm, level surface. Loosen the axle pinch bolts. Loosen the front axle shaft.
  • Page 96 Tire Puncture Removing Wheels Installation Tighten the axle pinch bolt. Attach the side collars to the wheel. Torque: 16 lbf·ft (22 N·m, 2.2 kgf·m) On the right side, place the wheel between the fork legs and insert the front Raise the front wheel off the ground axle shaft, through the right fork leg and again, and check that the wheel rotates wheel hub.
  • Page 97 Tire Puncture Removing Wheels Rear Wheel Adjusting plate CRF250RLA Removal Wheel speed Place your vehicle on a firm, level surface. sensor Support your vehicle securely and raise Lock nut the rear wheel off the ground using a hoist. Adjusting bolt Loosen the rear axle nut and lock nuts, and turn the adjusting bolts so the rear CRF250RLA...
  • Page 98 Tire Puncture Removing Wheels Remove the brake caliper bracket, rear Make sure that the slot on the brake wheel and side collars. caliper bracket is positioned in the lug on Support the brake caliper assembly so the swingarm. that it doesn't hang from the brake Brake caliper bracket hose.
  • Page 99 Tire Puncture Removing Wheels Adjust the drive chain. P. 76 If a torque wrench was not used for Install and tighten the rear axle nut. installation, see your dealer as soon as possible to verify proper assembly. Torque: 65 lbf·ft (88 N·m, 9.0 kgf·m) Improper assembly may lead to loss of braking capacity.

  • Page 100: Electrical Trouble

    Electrical Trouble Battery Goes Dead Burned-out Light Bulb Charge the battery using a motorcycle Follow the procedure below to replace a battery charger. burned-out light bulb. Remove the battery from the vehicle before Turn the ignition switch to the OFF or LOCK charging.
  • Page 101 Electrical Trouble Burned-out Light Bulb Headlight Brake light/Taillight Bulb Remove the seat. P. 56 Headlights Remove the hook bolts and collars. Remove the prongs from the grommets. Remove the rear fender. Collar Rear fender Hook bolt The headlights use several LEDs. Collar If there is an LED which is not turned on, see Hook bolt...
  • Page 102 Electrical Trouble Burned-out Light Bulb Front/Rear Turn Signal Bulb Turn the socket counterclockwise, and remove it. Remove the screw. Slightly press the bulb and turn it Remove the turn signal lens. counterclockwise. Slightly press the bulb and turn it Install a new bulb and parts in the reverse counterclockwise.
  • Page 103 Electrical Trouble Burned-out Light Bulb License Plate Light License plate light The license plate light uses an LED. If the LED is not turned on, see your dealer for servicing.

  • Page 104: Blown Fuse

    Electrical Trouble Blown Fuse Blown Fuse Before handling fuses, see “Inspecting and Replacing Fuses.” P. 48 Fuse Box Fuses Remove the left side cover. P. 57 Open the fuse box cover. Pull the fuses out with the fuse puller in Spare fuses the tool kit one by one check for a blown Fuse box cover...
  • Page 105 Electrical Trouble Blown Fuse Main Fuse Remove the left side cover. P. 57 Pull the starter magnetic switch out. Wire connector Main fuse Disconnect the wire connector of the starter magnetic switch. Pull the main fuse out with the fuse puller in the tool kit and check for a blown fuse.
  • Page 106 Electrical Trouble Blown Fuse ABS Fuse Remove the left side cover. P. 57 Open the fuse box cover. CRF250RLA Pull the ABS main fuse out with the fuse ABS Main fuse puller in the tool kit and check for a blown fuse.
  • Page 107 Electrical Trouble Blown Fuse Remove the seat. P. 56 CRF250RLA Other fuses Open the fuse box cover. Pull the fuses out with the fuse puller in Fuse box cover the tool kit one by one check for a blown fuse. Always replace a blown fuse with a spare fuse of the same rating.
  • Page 108 Unstable Engine Operation Occurs Intermittently If the fuel pump filter is clogged, unstable engine operation will occur intermittently while riding. Even if this symptom occurs, you can continue to ride your vehicle. If unstable engine operation occurs even if sufficient fuel is available, have your vehicle inspected by your dealer as soon as possible.

  • Page 109: Information

    Vehicle Identification Number..... P. 116 Emission Control Systems ......P. 117 Catalytic Converter ......... P. 121 Oxygenated Fuels..........P. 122 Authorized Manuals ........P. 123 Warranty Coverage and Service ....P. 124 Honda Contacts ..........P. 126 Reporting Safety Defects ..... P. 128...

  • Page 110: Keys

    Keys Keys Ignition Key Be sure to record the key number provided with the key number plate. Store the spare key and key number in a safe location. To make a duplicate, take the spare key or the key number to your dealer. If you lose all ignition keys and the key number, the ignition switch assembly will probably have to be removed by your dealer to determine the...

  • Page 111: Instruments, Controls, & Other Features

    Instruments, Controls, & Other Features Instruments, Controls, & Tripmeter Other Features The tripmeters return to 0.0 when each read- out exceeds 9,999.9. Ignition Switch Document Bag Leaving the ignition switch in the ON position The owner's manual, registration, and insurance with the engine stopped will drain the battery.

  • Page 112: Caring For Your Vehicle

    Frequent cleaning and polishing is important to After the vehicle dries, lubricate any moving ensure the life of your Honda. A clean vehicle parts. makes it easier to spot potential problems.
  • Page 113 Caring for Your Vehicle Do not use high-pressure washers: Do not direct water near the headlight: ● ● High-pressure water cleaners can The headlight's inside lens may fog damage moving parts and electrical temporarily after washing or while riding parts, rendering them inoperable. in the rain.
  • Page 114 Caring for Your Vehicle Avoid riding over or scraping against curbs. ● NOTICE To avoid possible scratching or other damage, Panels use only water and a soft cloth or sponge to Follow these guidelines to prevent scratches clean the windscreen. and blemishes: For a dirtier windscreen, use a diluted neutral Wash gently using a soft sponge and plenty...

  • Page 115: Storing Your Vehicle

    Storing Your Vehicle Storing Your Vehicle Exhaust Pipe and Muffler When the exhaust pipe and muffler are painted, If you store your vehicle outdoors, you should do not use a commercially available abrasive consider using a full-body cover. kitchen cleaning compound. Use a neutral If you won't be riding for an extended period, detergent to clean the painted surface on the follow these guidelines:...

  • Page 116: Transporting Your Vehicle

    For more information about storage, Canada NOTICE visit our website at www.honda.ca and look up Towing your vehicle can cause serious damage “Storage Tips” under the “Honda Warranty” in to the transmission. the Warranty tab for your Model.

  • Page 117: You & The Environment

    You & the Environment You & the Environment Recycle Wastes Put oil and other toxic wastes in approved Owning and riding a vehicle can be enjoyable, containers and take them to a recycling center. but you must do your part to protect the Call your local or state office of public works or environment.

  • Page 118: Vehicle Identification Number

    Vehicle Identification Number Vehicle Identification Number The VIN and engine serial number uniquely identify your vehicle and are required in order to register your vehicle. They may also be required when ordering replacement parts. You should record these numbers and keep them in a safe place.

  • Page 119: Emission Control Systems

    Your vehicle engine emits combustion Compliance with the terms of the byproducts, including carbon monoxide (CO), Distributor's Warranties for Honda Motorcycle oxides of nitrogen (NOx), and hydrocarbons Emission Control Systems is necessary in order (HC). Gasoline evaporation also emits to maintain a valid emissions system warranty.
  • Page 120 Emission Control Systems Ignition Timing Control System Noise Emission Requirements The ignition timing control system adjusts the The EPA requires that vehicles built after ignition timing to reduce the amount of HC, January 1, 1983 comply with applicable noise CO, and NOx produced. emission standards for one year or 3,730 miles (6,000 km) after the time of purchase when Secondary Air Injection System...
  • Page 121 Emission Control Systems effectiveness of the fuel permeation Evaporative Emission Control System technologies is prohibited. 50 STATE (meets California) An evaporative emissions control system uses a Noise Emission Control System canister filled with charcoal to adsorb fuel vapor TAMPERING WITH THE NOISE CONTROL from the fuel tank while the engine is off.
  • Page 122 Emission Control Systems AMONG THOSE ACTS PRESUMED TO Problems Affecting Vehicle Exhaust CONSTITUTE TAMPERING ARE THE Emissions FOLLOWING ACTS: Have your vehicle inspected and repaired by Removal of, or puncturing the muffler, ● your dealer if you experience any of the baffles, header pipes or any other following symptoms: component which conducts exhaust gases.

  • Page 123: Catalytic Converter

    A defective catalytic converter contributes to air or otherwise not running properly, stop pollution and can impair your engine's riding and turn off the engine. Have your performance. A replacement unit must be an vehicle serviced as soon as possible. original Honda part or equivalent.

  • Page 124: Oxygenated Fuels

    Oxygenated Fuels Oxygenated Fuels If you accidentally fill your fuel tank with an oxygenated fuel containing higher percentages, Some conventional fuels blended with alcohol you may experience performance problems. To or an ether compound are available in some resolve the problem, have your dealer drain the locales to help reduce emissions to meet clean fuel tank and replace with the correct fuel.

  • Page 125: Authorized Manuals

    Authorized Manuals Authorized Manuals These Honda manuals are written for the professional technician. However, if you possess The Service Manual used by your the proper tools, observe the safety standards, authorized dealer is available from your Honda and are mechanically capable, you should find dealer or Helm, Inc.

  • Page 126: Warranty Coverage And Service

    Service vehicle. Coverage Your warranty coverage is not voided if you Your new Honda is covered by the following perform your own maintenance. However, warranties: failures that occur due directly to improper Vehicle Limited Warranty ●...
  • Page 127 If you believe you have a problem with your dealership or their designated representative. vehicle, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. You will be asked to authorize that inspection, and your dealer will return the results of the inspection.

  • Page 128: Honda Contacts

    Name, address, and telephone number ● Mailstop: 100-4C-7B, Product model, year, and VIN ● Telephone: (866) 784-1870. Date of purchase ● Dealer name and address ● We will likely ask your Honda dealer to respond, or possibly acknowledge your comments directly.
  • Page 129 Honda Contacts Your Honda Dealer The service department of your Honda dealer offers trained personnel to perform regular maintenance and most repairs. It has the latest available service information from Honda and also handles warranty inspections and repairs. The parts department offers Honda Genuine...

  • Page 130: Usa

    However, NHTSA cannot become involved in individual problems between you, your dealer, or American Honda Motor Co., Inc.

  • Page 131: Specifications

    Specifications Main Components ■ 3.333 Overall length 87.0 in (2,210 mm) 2.117 Overall width 35.4 in (900 mm) 1.571 Gear ratio Overall height 56.1 in (1,425 mm) 1.304 Wheelbase 57.3 in (1,455 mm) 1.103 Minimum ground 0.967 10.6 in (270 mm) clearance Reduction ratio 2.807 / 2.857...
  • Page 132 1.9 US qt (1.8 L) Tire air pressure disassembly (Driver only) Rear 22 psi (150 kPa, 1.50 kgf/cm Recommended Honda DOT 3 or DOT 4 Brake Fluid Tire air pressure Front 22 psi (150 kPa, 1.50 kgf/cm brake fluid (Driver and Cooling system Rear 25 psi (175 kPa, 1.75 kgf/cm...
  • Page 133 Specifications Bulbs ■ Headlight Brake light / Taillight 12 V-21 / 5 W Front turn signal light / 12 V-21 / 5 W x 2 Position light Rear turn signal light 12 V-21 W x 2 License plate light Fuses ■...
  • Page 134 Information Record Engine No. Color Label & Code Owner's Name Address City/State Phone Dealer's Name Address City/State Phone Service Manager...

  • Page 135: Index

    Index Clutch ABS (Anti-lock Brake System)....... 12 Adjusting .............. 82 ABS (Anti-lock Brake System) Freeplay..............81 Indicator ............ 25, 90 Color Label ............45 ABS function on the rear wheel ....29 Coolant............... 69 Accessories ............15 Crankcase Breather ......... 85 Air Cleaner............
  • Page 136 Overheats............. 89 High Beam Indicator........25 Starting ..............30 High Coolant Temperature Indicator ... 25, 89 Stop Switch..........27, 109 Honda Contacts ..........126 Stopping ............109 Horn Button ............26 Will Not Start............88 Ignition Cut-off System Flooded Engine ..........30 Banking Sensor..........
  • Page 137 Labels..............7 Parking ............... 13 Load Limits ............17 Parts Location........... 18 Loading Guidelines.......... 17 PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)..24, 90 Protective Apparel..........9 Maintenance Fundamentals ............. 42 Importance ............36 Rear ABS (Anti-lock Brake System) OFF Record ..............
  • Page 138 Tires Safety Guidelines ..........3 Air Pressure ............52 Safety Labels ............7 Puncture ............... 92 Safety Precautions ..........9 Replacing............52, 92 Shifting Gears ........... 31 Transporting ........... 114 Side Stand............74 Tripmeter........... 21, 109 Spark Arrester........... 62 Troubleshooting ..........87 Spark Plug ............
  • Page 139 California Proposition 65 Warning WARNING: Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

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