Honda CRF250R Owner's Manual & Competition Handbook
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Honda CRF250R Owner's Manual & Competition Handbook

Owner's manual & competition handbook
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CRF250R
© Honda Motor Co., Ltd. 2008
CRF250R_COVER
1
OWNER'S MANUAL & COMPETITION HANDBOOK
MANUEL DU CONDUCTEUR ET DE COMPETITION
FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG
INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK
MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES
MANUALE D'USO E DEGLI ASSETTI DA COMPETIZIONE
16/6/08, 20:40
HONDA O/M CRF250R(Eu) 3RKRN620 00X3R-KRN-6200
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  • Page 1 MANUEL DU CONDUCTEUR ET DE COMPETITION FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE © Honda Motor Co., Ltd. 2008 CRF250R_COVER 16/6/08, 20:40 HONDA O/M CRF250R(Eu) 3RKRN620 00X3R-KRN-6200...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 3 250R_Contents.qxd 2008.07.17 15:39 ページ2 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 250R_Contents.qxd 2008.07.17 15:39 ページ3 Introduction Congratulations on choosing your Honda CRF As you read this manual, you will find motocross motorcycle. information that is preceded by a NOTICE symbol. This information is intended to help you When you own a Honda, you’re part of a avoid damage to your Honda, other property, or worldwide family of satisfied customers-people the environment.
  • Page 5 250R_Contents.qxd 2008.07.17 15:39 ページ4 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 6: Table Of Contents

    250R_Contents.qxd 2008.07.17 15:39 ページ5 Contents MOTORCYCLE SAFETY.......1 Service Procedures TIPS ..............139 Important Safety Information......2 Fluids & Filters Transporting Your Motorcycle ......140 Important Safety Precautions......2 Fuel System............34 Storing Your Honda.........141 Accessories & Modifications ......3 Engine Oil ............36 You & the Environment ........142 Safety Labels............4 Transmission Oil ..........39 Troubleshooting..........143...

  • Page 7: Motorcycle Safety

    250R_001-023.qxd 2008.07.17 15:39 ページ1 Motorcycle Safety This section presents some of the most important Important Safety Information.......2 information and recommendations to help you Important Safety Precautions ......2 ride your CRF safely. Please take a few Accessories & Modifications .......3 moments to read these pages. This section also Safety Labels ............4 includes information about the location of safety labels on your CRF.

  • Page 8: Important Safety Information

    250R_001-023.qxd 2008.07.17 15:39 ページ2 Important Safety Information Don’t Drink and Ride. Important Safety Precautions Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse Your CRF can provide many years of pleasure, if you take responsibility for your own safety and with every additional drink.

  • Page 9: Accessories & Modifications

    250R_001-023.qxd 2008.07.17 15:39 ページ3 Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 10: Safety Labels

    250R_001-023.qxd 2008.07.17 15:39 ページ4 Safety Labels Read this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety...

  • Page 11: Operating Controls

    250R_001-023.qxd 2008.07.17 15:39 ページ5 Operating Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 12: Operation Component Locations

    250R_001-023.qxd 2008.07.17 15:39 ページ6 Operation Component Locations hot start lever clutch lever front brake lever engine stop button throttle grip choke knob kickstarter rear brake pedal fuel valve shift lever Operating Controls...

  • Page 13: Before Riding

    250R_001-023.qxd 2008.07.17 15:39 ページ7 Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection...........9 evaluate your riding readiness, and what items you should check on your CRF.

  • Page 14: Are You Ready To Ride

    250R_001-023.qxd 2008.07.17 15:39 ページ8 Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 15: Is Your Motorcycle Ready To Ride

    250R_001-023.qxd 2008.07.17 15:39 ページ9 Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right): •...
  • Page 16 250R_001-023.qxd 2008.07.17 15:39 ページ10 Before Riding...

  • Page 17: Basic Operating Instructions

    250R_001-023.qxd 2008.07.17 15:39 ページ11 Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions.........12 start and stop your engine as well as break-in Starting & Stopping the Engine ......13 guidelines. Preparation .............13 Starting Procedure..........13 Flooded Engine ..........13 How to Stop the Engine.........14 Break-in Guidelines ...........15 Basic Operating Instructions...

  • Page 18: Safe Riding Precautions

    250R_001-023.qxd 2008.07.17 15:39 ページ12 Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage.

  • Page 19: Starting & Stopping The Engine

    250R_001-023.qxd 2008.07.17 15:39 ページ13 Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below. levels before starting the engine (pages 37, 40, 41). 1. Turn the fuel valve ON. 2.

  • Page 20: How To Stop The Engine

    250R_001-023.qxd 2008.07.17 15:39 ページ14 Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle grip (1) two or three times, and then close it.

  • Page 21: Break-In Guidelines

    250R_001-023.qxd 2008.07.17 15:39 ページ15 Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 25 km (15 miles). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 22 250R_001-023.qxd 2008.07.17 15:39 ページ16 Basic Operating Instructions...

  • Page 23: Servicing Your Honda

    250R_001-023.qxd 2008.07.17 15:39 ページ17 Servicing Your Honda Keeping your CRF well maintained is absolutely Before You Service Your Honda Chassis essential to your safety. It’s also a good way to The Importance of Maintenance ......18 Suspension............72 protect your investment, get maximum Maintenance Safety ..........19 Front Suspension Inspection......72 performance, avoid breakdowns, and have more...

  • Page 24: The Importance Of Maintenance

    250R_001-023.qxd 2008.07.17 15:39 ページ18 The Importance of Maintenance Keeping your CRF well-maintained is absolutely essential to your safety. It’s also a good way to get maximum performance during each moto. Careful pre-ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off-road competition.

  • Page 25: Maintenance Safety

    250R_001-023.qxd 2008.07.17 15:39 ページ19 Maintenance Safety This section includes instructions on how to • Read the instructions before you begin, and perform some important maintenance tasks. make sure you have the tools and skills Some of the most important safety precautions required.

  • Page 26: Maintenance Schedule

    250R_001-023.qxd 2008.07.17 15:39 ページ20 Maintenance Schedule To maintain the safety and reliability of your Perform the pre-ride inspection (page 9) at each CRF, regular inspection and service is required as scheduled maintenance period. shown in the Maintenance Schedule that follows. Summary of Maintenance Schedule Notes and The Maintenance Schedule lists items that can be Procedures:...
  • Page 27 250R_001-023.qxd 2008.07.17 15:39 ページ21 Maintenance Schedule Perform the Pre-ride Inspection at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace. FREQUENCY Each race Every 3 races Every 6 races Every 9 races Every 12 races or about...

  • Page 28: General Competition Maintenance

    250R_001-023.qxd 2008.07.17 15:39 ページ22 General Competition Maintenance Perform maintenance on firm, level ground using the optional workstand, or equivalent support. When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattern.
  • Page 29 250R_001-023.qxd 2008.07.17 15:39 ページ23 General Competition Maintenance Spark Plug Air Cleaner Some non-resistor plugs may cause ignition problems. Refer Clean and oil your air cleaner regularly because the volume to the recommendations elsewhere in this manual for specific of air able to pass through it has a great effect on types so you will be sure to use the proper reach and heat performance.
  • Page 30 250R_024-054.qxd 2008.07.17 15:39 ページ24 General Competition Maintenance Steering Head Bearings Gaskets Fuel Filter Periodically clean, inspect and regrease the steering head Always use new gaskets when reassembling components. Periodically drain the fuel from the fuel tank, remove and bearings — especially if wet, muddy or extremely dusty clean the fuel valve and fuel filter.
  • Page 31 250R_024-054.qxd 2008.07.17 15:39 ページ25 General Competition Maintenance Suspension Linkage Lubrication Brake Fluid Replacement Handgrips Disassemble, clean, inspect and lubricate all suspension Refer to Brake Pad Wear in your Owner’s Manual, page 80. Always use Hand Grip Cement when replacing handgrips. linkage pivot bearings with grease after each 7.5 hours of Brake Caliper Inspection: Be sure both the front and rear running time in order to maintain proper suspension...

  • Page 32: Before & After Competition Maintenance

    250R_024-054.qxd 2008.07.17 15:39 ページ26 Before & After Competition Maintenance Between Motos & Practice Maintenance After Competition Maintenance After practice or between motos you have a It is important to the long-term performance of chance to make additional checks and your CRF to practice a consistent maintenance adjustments.
  • Page 33 250R_024-054.qxd 2008.07.17 15:39 ページ27 Before & After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty, it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags. Take care to prevent catching your fingers between the chain and sprocket.

  • Page 34: Maintenance Component Locations

    250R_024-054.qxd 2008.07.17 15:39 ページ28 Maintenance Component Locations hot start lever front brake fluid reservoir front brake lever clutch lever throttle grip radiator cap fuel fill cap rear suspension high speed front suspension compression damping adjuster air cleaner damping adjuster rear suspension low speed crankcase breather tube rear brake fluid damping adjuster...

  • Page 35: Seat Removal

    250R_024-054.qxd 2008.07.17 15:39 ページ29 Seat Removal Refer to Safety Precautions on page 19. Installation 1. Install the seat while aligning the front prong Removal (3) with the seat bracket (4) and rear prong (5) 1. Remove the seat mounting bolts (1). with the tab (6) of the subframe.

  • Page 36: Fuel Tank Removal

    250R_024-054.qxd 2008.07.17 15:39 ページ30 Fuel Tank Removal Refer to Safety Precautions on page 19. 5. Pull the breather tube (5) out of steering stem 8. Disconnect the fuel line (8) from the fuel nut. valve. The fuel line leading to the Removal 6.
  • Page 37 250R_024-054.qxd 2008.07.17 15:39 ページ31 Fuel Tank Removal Installation 7. Install the shroud tab (7) onto the subframe 1. Install the fuel tank on the frame. (8). 2. Install the fuel valve (1) and tighten the fuel valve bolt (2). 3. Connect the fuel line (3) to the fuel valve. (7) shroud tab (8) subframe 8.

  • Page 38: Subframe Removal

    250R_024-054.qxd 2008.07.17 15:39 ページ32 Subframe Removal Refer to Safety Precautions on page 19. 7. Remove the subframe lower mounting bolts 4. Disconnect the crankcase breather tube (1). 5. Unhook the fuel tank band (2). (5) and subframe upper mounting bolt (6). Removal Then remove the subframe (7) by pulling it 6.
  • Page 39 250R_024-054.qxd 2008.07.17 15:40 ページ33 Subframe Removal 2. Tighten the screw (4) on the air cleaner 5. Install the exhaust joint pipe (page 89) and Installation 1. Loosely attach the upper and lower ends of connecting tube clamp (5). muffler (page 88). 3.

  • Page 40: Fuel System

    250R_024-054.qxd 2008.07.17 15:40 ページ34 Fuel System Refer to Safety Precautions on page 19. Fuel Line Refueling Procedure Fuel Recommendation Fuel Tank Capacity: 7.3R(1.9 US gal, 1.61 Imp gal) Type Unleaded Research Octane Number 95 (or higher) We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components.
  • Page 41 250R_024-054.qxd 2008.07.17 15:40 ページ35 Fuel System 4. Wash the fuel filter (3) in high flash-point Fuel Filter cleaning solvent. 5. Reassemble the fuel filter in the reverse order of removal. Make sure the O-ring (4) is in The fuel filter is mounted on the bottom left side of the fuel tank.

  • Page 42: Engine Oil

    250R_024-054.qxd 2008.07.17 15:40 ページ36 Engine Oil Refer to Safety Precautions on page 19. • Your CRF does not need oil additives. Oil Recommendation Use the recommended oil. Using the proper oil, and regularly checking, • Do not use API SH or higher 4-stroke engine adding, and changing oil will help extend the oils displaying a circular API “energy SG or higher except oils...
  • Page 43 250R_024-054.qxd 2008.07.17 15:40 ページ37 Engine Oil JASO T 903 standard Checking & Adding Oil Changing Engine Oil & Filter The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. 1. Run the engine at idle for 3 minutes, then shut it off. There are two classes: MA and MB.
  • Page 44 250R_024-054.qxd 2008.07.17 15:40 ページ38 Engine Oil 8. It is recommended to replace the oil and filter 12. Check that the oil filter cover O-ring (9) is in 15.Apply engine oil to a new O-ring and install it every 6 races or about every 15.0 hours. good condition.

  • Page 45: Transmission Oil

    250R_024-054.qxd 2008.07.17 15:40 ページ39 Transmission Oil Refer to Safety Precautions on page 19. Oil Recommendation Using the proper oil, and regularly checking, adding, and changing oil will help extend the API classification SG or higher except oils service life of the transmission and clutch. Even (4-stroke engine oil labeled as energy the best oil wears out.
  • Page 46 250R_024-054.qxd 2008.07.17 16:29 ページ40 Transmission Oil Pour the drained oil into a suitable container and Checking & Adding Oil Replacing Transmission Oil dispose of it in an approved manner (page 142). 1. Run the engine at idle for 3 minutes, then shut NOTICE it off.

  • Page 47: Coolant

    250R_024-054.qxd 2008.07.17 15:40 ページ41 Coolant Your CRF’s liquid cooling system dissipates Increasing the concentration of antifreeze is not WARNING engine heat through the coolant jacket that recommended because it decreases cooling Removing the radiator cap while the surrounds the cylinder and cylinder head. system performance.
  • Page 48 250R_024-054.qxd 2008.07.17 15:40 ページ42 Coolant Cooling System Inspection Coolant Replacement 1. Check the cooling system for leaks (see the Refer to Safety Precautions on page 19. Honda Shop Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2.

  • Page 49: Air Cleaner

    250R_024-054.qxd 2008.07.17 15:40 ページ43 Air Cleaner Refer to Safety Precautions on page 19. 5. Remove the air cleaner element (5) from the Cleaning air cleaner holder (6). The air cleaner uses polyurethane inner and outer pieces which can’t be separated. 1.
  • Page 50 250R_024-054.qxd 2008.07.17 15:40 ページ44 Air Cleaner 11.Install the air cleaner assembly (3) into the air NOTICE cleaner housing keeping the two access top tabs (2) up. Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and 12.Carefully position the sealing flange of the element to prevent dirt intrusion.

  • Page 51: Crankcase Breather

    250R_024-054.qxd 2008.07.17 15:40 ページ45 Crankcase Breather Refer to Safety Precautions on page 19. Service more frequently if your CRF is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube. Draining 1.

  • Page 52: Throttle

    250R_024-054.qxd 2008.07.17 15:40 ページ46 Throttle Lower Adjustment Refer to Safety Precautions on page 19. 1. Pull the dust cover (2) back. The lower adjuster is used for major freeplay 2. Loosen the lock nut (3). adjustment, such as after replacing the throttle 3.
  • Page 53 250R_024-054.qxd 2008.07.17 15:40 ページ47 Throttle Throttle Inspection (1) throttle 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions.

  • Page 54: Engine Idle Speed

    250R_024-054.qxd 2008.07.17 15:40 ページ48 Engine Idle Speed Refer to Safety Precautions on page 19. Idle Speed Adjustment The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled 1. If the engine is cold, start it and warm it up 3 servicing, including carburetor adjustment.

  • Page 55: Clutch System

    250R_024-054.qxd 2008.07.17 15:40 ページ49 Clutch System Refer to Safety Precautions on page 19. 4. Turn the cable end adjuster (3) in direction (+) Clutch Lever Freeplay until it seats lightly and then turn it out 5 turns. Clutch Lever Adjustment (–) The distance between the tip of the clutch lever and grip may be adjusted.
  • Page 56 250R_024-054.qxd 2008.07.17 15:40 ページ50 Clutch System Cable End Adjustment Integral Cable Adjustment Other Inspections & Lubrication Minor adjustments are generally made with the The integral cable adjuster is used if the cable clutch cable end adjuster. end adjuster is threaded out near its limit — or the correct freeplay cannot be obtained.
  • Page 57 250R_024-054.qxd 2008.07.17 15:40 ページ51 Clutch System 5. Remove the clutch pressure plate (8). Clutch Cover/Disc/Plate Removal Clutch Disc/Plate Inspection 1. Drain the transmission oil (page 40). Replace the clutch discs (1) if they show signs of 2. Remove the rear brake pedal (1) by removing scoring or discolouration.
  • Page 58 250R_024-054.qxd 2008.07.17 15:40 ページ52 Clutch System 2 Install the clutch disc A (larger I.D. disc) (5) 7. Install the clutch pressure plate (8). Clutch Spring Inspection onto the clutch outer. 8. Install the five clutch springs and clutch Stack the seven clutch plates and seven clutch spring bolts (9).
  • Page 59 250R_024-054.qxd 2008.07.17 15:40 ページ53 Clutch System 12.Lubricate the dust seals (12), rear brake pedal (13) pivot and rear brake pedal pivot bolt (14) with Honda Lithium Grease or equivalent. 13.Apply locking agent to the brake pedal pivot bolt threads. 14.Install the dust seals into the rear brake pedal. 15.Install the pivot bolt with the washer (15) and tighten the pivot bolt to the specified torque: 36 N·m (3.7 kgf·m, 27 lbf·ft)

  • Page 60: Hot Start Lever

    250R_024-054.qxd 2008.07.17 15:40 ページ54 Hot Start Lever Refer to Safety Precautions on page 19. Adjustment Adjustments can be made with the cable adjuster. Hot Start Lever Freeplay Loosen the lock nut (3) and turn the adjuster (4). Turning the adjuster clockwise (+) will increase freeplay and turning it counterclockwise (–) will decrease freeplay.

  • Page 61: Spark Plug

    250R_055-073.qxd 2008.07.17 15:40 ページ55 Spark Plug Refer to Safety Precautions on page 19. 7. To obtain accurate spark plug readings, Spark Plug Inspection & Replacement accelerate up to speed on a straightaway. Push the engine stop button and disengage the Spark Plug Recommendation clutch by pulling the lever in.

  • Page 62: Valve Clearance

    250R_055-073.qxd 2008.07.17 15:40 ページ56 Valve Clearance Refer to Safety Precautions on page 19. Cylinder Head Cover Removal Positioning At Top Dead Centre On The Compression Stroke Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance Before inspection, clean the engine thoroughly to will prevent the valve from closing and cause keep dirt from entering the engine.

  • Page 63: Valve Clearance Inspection

    250R_055-073.qxd 2008.07.17 15:40 ページ57 Valve Clearance 3. Rotate the crankshaft by turning the primary 2. Measure the exhaust valve clearance by Valve Clearance Inspection drive gear bolt (2) (crankshaft) clockwise until inserting a feeler gauge (1) between the aligning the punch mark (3) on the primary exhaust rocker arm (4) and exhaust valve drive gear with the “...
  • Page 64 250R_055-073.qxd 2008.07.17 15:40 ページ58 Valve Clearance 2. Remove the cam chain tensioner lifter cover Use the tensioner stopper tool. Camshaft Removal bolt (1) and sealing washer (2). • Tensioner stopper 070MG-0010100 3. Turn the tensioner shaft clockwise with the 1. Record the intake valve clearance and exhaust valve clearance (page 57).
  • Page 65 250R_055-073.qxd 2008.07.17 15:40 ページ59 Valve Clearance 4. Remove the camshaft holder bolts (4) and 6. Remove the valve lifters (7). 7. Remove the shims (8). camshaft holders (5). Loosen the camshaft holder bolts in a Position the removed intake valve lifters and crisscross pattern in two or three steps.
  • Page 66 250R_055-073.qxd 2008.07.17 15:40 ページ60 Valve Clearance 3. Calculate the new shim thickness using the Shim Selection equation below. A = (B – C) + D 1. Clean the valve shim contact area in the valve lifter (1) with compressed air. A: New shim thickness B: Recorded valve clearance C: Specified valve clearance...
  • Page 67 250R_055-073.qxd 2008.07.17 15:40 ページ61 Valve Clearance 2. Apply molybdenum disulfide oil (a mixture of 4. Apply molybdenum oil solution to the Camshaft Installation 1/2 engine oil and 1/2 molybdenum disulfide camshaft journals and cam lobes. grease containing more than 3% molybdenum Place the camshaft (7) with the intake cam disulfide additive) to the outer surface of the lobes (8) facing up and align the timing marks...
  • Page 68 250R_055-073.qxd 2008.07.17 15:41 ページ62 Valve Clearance Each camshaft holder has an identification mark 8. Remove the tensioner stopper (18) from the 10.Rotate the camshaft by rotating the crankshaft (15). cam chain tensioner lifter. clockwise several times. (15) 11.Insert the feeler gauge (21) between the intake valve lifter and cam lobe.
  • Page 69 250R_055-073.qxd 2008.07.17 15:41 ページ63 Valve Clearance 12.Install the spark plug (page 55). 2. Inspect the cylinder head cover packing (3) 4. Install the cylinder head cover (4) and tighten 13.Coat a new O-ring (22) with oil and install it for damage or deterioration, replace it if the cylinder head cover bolts (7) to the onto the crankshaft hole cap (23).

  • Page 70: Piston/Piston Rings/Piston Pin

    250R_055-073.qxd 2008.07.17 15:41 ページ64 Piston/Piston Rings/Piston Pin 7. Remove the spark plug (page 55). 11.Remove the engine hanger nuts/bolts (3) and Cylinder Head Removal 8. Remove the cylinder head cover (page 56). engine hanger plates (4). 9. Position the piston at top dead centre on the compression stroke (page 56).
  • Page 71 250R_055-073.qxd 2008.07.17 15:41 ページ65 Piston/Piston Rings/Piston Pin 14.Remove the cylinder head nuts/washers (7) 12.Remove the cylinder head bolts (5). 15.Remove the dowel pins (9), cylinder head and cylinder head (8). 13.Loosen the cylinder bolt (6). gasket (10) and cam chain guide (11). Loosen the nuts in a crisscross pattern in two or three steps.
  • Page 72 250R_055-073.qxd 2008.07.17 15:41 ページ66 Piston/Piston Rings/Piston Pin Piston Removal Piston Ring Removal Cylinder Removal 1. Place clean shop towels in the crankcase to Spread each piston ring (1) and remove by lifting 1. Remove the cylinder bolt (1) and cylinder (2). keep the piston pin clips or other parts from it up at a point just opposite the gap.
  • Page 73 250R_055-073.qxd 2008.07.17 15:41 ページ67 Piston/Piston Rings/Piston Pin Piston/Piston Pin/Piston Ring Piston Ring Installation top ring Inspection 1. Clean the piston ring thoroughly. oil ring We recommend you consult the Shop Manual or 2. Apply engine oil to the piston rings and install your Honda dealer for correct Service Limit them.
  • Page 74 250R_055-073.qxd 2008.07.17 15:41 ページ68 Piston/Piston Rings/Piston Pin Piston Installation Cylinder Installation 1. Place clean shop towels over the crankcase 1. Place clean shop towels over the crankcase opening to keep the piston pin clips from opening to prevent dust or dirt from entering falling into the crankcase.
  • Page 75 250R_055-073.qxd 2008.07.17 15:41 ページ69 Piston/Piston Rings/Piston Pin 6. Apply clean engine oil to the cylinder wall, 7. Install the cam chain guide (6) and fit the cam Cylinder Head Installation piston outer surface and piston rings. chain guide tabs (7) in the cylinder cut-outs Route the cam chain (3) through the cylinder (8).
  • Page 76 250R_055-073.qxd 2008.07.17 15:41 ページ70 Piston/Piston Rings/Piston Pin 2. Route the cam chain through the cylinder 4. Install the cylinder bolt (5) and cylinder head 5. Install the engine hanger plates (7), engine head (3). bolts (6) and tighten them to the specified hanger nuts/bolts of the frame side (8) and Install the cylinder head.
  • Page 77 250R_055-073.qxd 2008.07.17 15:41 ページ71 Piston/Piston Rings/Piston Pin 6. Connect the radiator hose (10) to the cylinder 9. Install the crankshaft hole cap (page 63). 15.Pour a fresh recommended coolant mixture head and tighten the radiator hose clamp (11) 10.Install the cylinder head cover (page 63). (page 41).

  • Page 78: Suspension

    250R_055-073.qxd 2008.07.17 15:41 ページ72 Suspension Refer to Safety Precautions on page 19. • Refer to Suspension Adjustment Guidelines (page 116). Make all rebound and 1.5 mm (0.06 in) compression damping adjustments in one-click Loose, worn, or damaged suspension components may adversely affect the handling and stability of increments.

  • Page 79: Rear Suspension Inspection

    250R_055-073.qxd 2008.07.17 15:41 ページ73 Suspension 1. Bounce the rear of the motorcycle up and down Rear Suspension Inspection and check for smooth suspension action. The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure. The gas pressure in the reservoir is contained within a rubber bladder.

  • Page 80: Recommended Fork Oil

    250R_074-096.qxd 2008.07.17 15:41 ページ74 Suspension 4. Drain the fork oil by turning the outer tube (1) NOTICE Recommended Fork Oil upside down. (About 12 cm (0.4 US oz) of fork oil will be left in the outer tube when it is The outer tube (1) can drop on the slider and left inverted for about 20 minutes at damage the fork dust seal (5) and guide bushing...
  • Page 81 250R_074-096.qxd 2008.07.17 15:41 ページ75 Suspension 5. Pour the recommended fork oil into the outer Fork Oil Capacity Optional Stiffer 4.710 N/mm (26.89 lbf/in) Fork Spring tube (1). Standard 4.510 N/mm (25.75 lbf/in) Fork Spring No mark 3 scribe marks (factory products) 5 scribe marks (aftermarket parts) Standard oil...
  • Page 82 250R_074-096.qxd 2008.07.17 15:41 ページ76 Suspension 6. Check that the O-ring (10) on the fork damper (2) is in good condition. Apply the recommended fork oil to the O-ring. (10) (2) fork damper (10) O-ring 7. Temporarily install the fork damper to the outer tube.

  • Page 83: Brakes

    250R_074-096.qxd 2008.07.17 15:41 ページ77 Brakes Refer to Safety Precautions on page 19. Front Brake Lever Adjustment Rear Brake Pedal Height Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake The brake pedal height should be approximately fluid level will drop.
  • Page 84 250R_074-096.qxd 2008.07.17 15:41 ページ78 Brakes Rear Brake Fluid Level Check Fluid Level Inspection Front Brake Fluid Level Check (2) LOWER level mark With the motorcycle in an upright position, check the fluid level. (1) LWR mark It should be above the LOWER level mark (2). If the level is at or below the LOWER level mark, With the motorcycle in an upright position, check check the brake pads for wear (page 80).
  • Page 85 250R_074-096.qxd 2008.07.17 15:41 ページ79 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid NOTICE NOTICE Spilled brake fluid will severely damage the Spilled brake fluid will severely damage the painted surfaces. It is also harmful to some painted surfaces. It is also harmful to some rubber parts.
  • Page 86 250R_074-096.qxd 2008.07.17 15:41 ページ80 Brakes Rear Brake Pads Brake Pad Wear Inspect the brake pads (5) from the rear side of the caliper to determine the pad wear. If either pad is worn anywhere to a thickness of 1 mm Brake pad wear depends on the severity of usage and track conditions.

  • Page 87: Wheels

    250R_074-096.qxd 2008.07.17 15:41 ページ81 Wheels Refer to Safety Precautions on page 19. 2. Tighten, any loose spokes and rim locks (3) to the specified torque: Keeping the wheels true (round) and maintaining Front Spoke : correct spoke tension is critical to safe 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) motorcycle operation.

  • Page 88: Tyres & Tubes

    250R_074-096.qxd 2008.07.17 15:41 ページ82 Tyres & Tubes Refer to Safety Precautions on page 19. Always check air pressure when your tyres are Tube Replacement “cold.” If you check air pressure when your To safely operate your CRF the tyres must be the tyres are “warm”...
  • Page 89 250R_074-096.qxd 2008.07.17 15:41 ページ83 Tyres & Tubes U, IIU type: Tyre Replacement 80/100-21 51M Front DUNLOP D742FA The tyres that came on your CRF were designed 100/90-19 57M to provide a good combination of handling, Rear braking, durability, and comfort across a broad DUNLOP D756 range of riding conditions.

  • Page 90: Drive Chain

    250R_074-096.qxd 2008.07.17 15:41 ページ84 Drive Chain Refer to Safety Precautions on page 19. Drive Chain Sliders The service life of the chain depends on proper lubrication and adjustment. Poor maintenance 1. Check the chain slider (1) for wear. can cause premature wear or damage to the drive If the wear is 5 mm (0.2 in) or more, replace chain or sprockets.
  • Page 91 250R_074-096.qxd 2008.07.17 15:41 ページ85 Drive Chain Drive Chain Rollers Adjustment Lubrication 1. Check the upper drive chain roller (1) and 1. Loosen the rear axle nut (1). Commercially prepared drive chain lubricants lower drive chain roller (2) for wear or 2.
  • Page 92 250R_074-096.qxd 2008.07.17 15:41 ページ86 Drive Chain 4. Inspect the sprocket teeth for wear or damage. Service limit: 259.0 mm (10.20 in) Removal, Cleaning & Replacement We recommend replacing the sprocket whenever a new chain is installed. Both chain and sprockets must be in good For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each condition, or the new replacement chain or...

  • Page 93: Exhaust Pipe/Muffler

    250R_074-096.qxd 2008.07.17 15:41 ページ87 Exhaust Pipe/Muffler 2. Loosen the muffler clamp bolts (4). Exhaust Pipe/Muffler Inspection 3. Remove the mufflers (5) by removing the muffler mounting bolts (6) and washers (7). Check the mounting bolts and joint nuts for tightness. Check the exhaust pipe, exhaust joint pipe and mufflers for cracks or deformation.
  • Page 94 250R_074-096.qxd 2008.07.17 15:41 ページ88 Exhaust Pipe/Muffler 5. Install each muffler mounting bolt (7) and 8. Install and tighten the side covers (10) and Muffler Installation washer (8). side cover bolts (11). 6. Tighten each muffler clamp bolt (9) to the 9.
  • Page 95 250R_074-096.qxd 2008.07.17 15:42 ページ89 Exhaust Pipe/Muffler 5. Install the exhaust joint pipe mounting bolt. Exhaust Joint Pipe Removal Exhaust Joint Pipe Installation 6. Install the muffler (page 88), but do not tighten the bolt yet. 7. Tighten the joint pipe clamp bolt to the 1.
  • Page 96 250R_074-096.qxd 2008.07.17 15:42 ページ90 Exhaust Pipe/Muffler Exhaust Pipe Removal Exhaust Pipe Installation 1. Remove the muffler (page 87). 1. Install a new exhaust pipe gasket (1) as 2. Remove the exhaust joint pipe (page 89). shown. 3. Remove the exhaust pipe joint nuts (1), 2.

  • Page 97: Steering Damper

    250R_074-096.qxd 2008.07.17 15:42 ページ91 Steering Damper Refer to Safety Precautions on page 19. 1. Unlock the number plate tab (1) from the 3. Place your CRF on the workstand or handlebar pad. equivalent support with the front wheel off the Loose, worn or damaged steering damper Remove the bolts (2) and number plate (3).
  • Page 98 250R_074-096.qxd 2008.07.17 15:42 ページ92 Steering Damper 2. Check the condition of the spherical bearings Removal (2). Move the spherical bearing with your finger. The spherical bearing should move smoothly 1. Remove the number plate (page 91). 2. Remove the steering damper mounting bolts and quietly.

  • Page 99: Additional Maintenance Procedures

    250R_074-096.qxd 2008.07.17 15:42 ページ93 Additional Maintenance Procedures Refer to Safety Precautions on page 19. Handlebar Inspection Steering Head Bearings Inspection 1. Remove the handlebar pad. 2. Check the handlebar (1) for bends or cracks. 1. With your CRF on a box or workstand (front 3.
  • Page 100 250R_074-096.qxd 2008.07.17 15:42 ページ94 Additional Maintenance Procedures LEFT SIDE RIGHT SIDE Nuts, Bolts, Fasteners (11) Check and tighten nuts, bolts, and fasteners before every outing. Torque Item N•m kgf•m lbf•ft ENGINE Cylinder head cover bolts Exhaust pipe joint nuts Water pump cover bolts Crankshaft hole cap Transmission oil check (10)

  • Page 101: Appearance Care

    250R_074-096.qxd 2008.07.17 15:42 ページ95 Appearance Care Refer to Safety Precautions on page 19. If you use a high pressure washer, avoid spraying Washing Your Motorcycle with a Mild the following areas: Detergent Frequent cleaning and polishing will keep your wheel hubs Honda looking newer longer.
  • Page 102 250R_074-096.qxd 2008.07.17 15:42 ページ96 Appearance Care Condensation Control Aluminum Frame Maintenance Exhaust Pipe Maintenance Some condensation can form within the Aluminum corrodes when it comes in contact The exhaust pipe and exhaust joint pipe are transmission cavity as well. This is natural and with dust, mud and road salt.

  • Page 103: Adjustments For Competition

    250R_097-119.qxd 2008.07.17 15:42 ページ97 Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......98 for maximum competition performance. Rear Suspension Adjustments ......111 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ............115 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....116 break-in time.

  • Page 104: Front Suspension Adjustments

    250R_097-119.qxd 2008.07.17 15:42 ページ98 Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).
  • Page 105 250R_097-119.qxd 2008.07.17 15:42 ページ99 Front Suspension Adjustments Both compression and rebound damping can be Fork Springs Front Suspension Disassembly increased by turning the adjuster clockwise. The fork springs in CRF’s are about right for • If your CRF is brand-new, put enough part- NOTICE riders weighing between 68 and 73 kg (150 and throttle break-in time (about one hour) on it to...
  • Page 106 250R_097-119.qxd 2008.07.17 15:42 ページ100 Front Suspension Adjustments 3. Remove the front axle nut (2) and loosen the Do not hang the brake caliper by the brake hose. 9. Loosen the upper pinch bolts (14). 10.Loosen the fork dampers (15) using a lock nut front axle pinch bolts (3) on both forks.
  • Page 107 250R_097-119.qxd 2008.07.17 15:42 ページ101 Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (18) and dust seal (19). outer tube. 13.Record the rebound damping adjuster position 18.Set the axle holder (22) in a vise with a piece of The outer tube can drop on the slider and and turn the adjuster counterclockwise until it damage the fork dust seal (19) and guide bushing...
  • Page 108 250R_097-119.qxd 2008.07.17 15:42 ページ102 Front Suspension Adjustments 21.Push out the fork center bolt (25) from the Damper Oil Change axle holder (22) of the slider by pushing the fork damper. While the fork center bolt is pushed out, install the piston base (26) or a (28) 1.
  • Page 109 250R_097-119.qxd 2008.07.17 15:42 ページ103 Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the 6. Extend the fork damper piston rod to maximum. 8. Extend the fork damper piston rod to Pour the recommended fork oil into the fork fork damper (1).
  • Page 110 250R_097-119.qxd 2008.07.17 15:42 ページ104 Front Suspension Adjustments 10.Tighten the fork cap assembly (2) while 12.Screw in the lock nut (7) to the fork damper 14.Drain the extra oil from the oil hole (9). piston rod (5) fully. holding the fork damper (1) using the lock nut wrench (3) to the specified torque: By doing this procedure, about 17 cm (0.6...
  • Page 111 250R_097-119.qxd 2008.07.17 15:42 ページ105 Front Suspension Adjustments 16.If you can not use compressed air, remove the Fork Assembly pressure release screw (10) on the fork cap. Hold the fork damper up side down for 10 minutes and drain the oil from the fork 1.
  • Page 112 250R_097-119.qxd 2008.07.17 15:42 ページ106 Front Suspension Adjustments 4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the centre bolt O-ring (7). wood or soft jaws to avoid to damage. centre bolt (8) clearance.
  • Page 113 250R_097-119.qxd 2008.07.17 15:42 ページ107 Front Suspension Adjustments 13.Remove the fork damper from the fork. Fork Oil Capacity Optional Stiffer 4.710 N/mm (26.89 lbf/in) Fork Spring 14.Pour the recommended fork oil (11) into the Standard 4.510 N/mm (25.75 lbf/in) Fork Spring fork assembly (1).
  • Page 114 250R_097-119.qxd 2008.07.17 15:42 ページ108 Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench (15) recommended fork oil to the O-ring.
  • Page 115 250R_097-119.qxd 2008.07.17 15:42 ページ109 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle 26.Tighten the front axle nut (25) to the specified (18) and axle holder thoroughly. clamps contact each other. torque: Apply locking agent to the bolt threads.
  • Page 116 250R_097-119.qxd 2008.07.17 15:42 ページ110 Front Suspension Adjustments 27.Install the handlebar (27), mounting rubbers 30.While keeping the forks parallel, alternately (28), washers and handlebar holder nuts (29) tighten the right axle pinch bolts (30) to the and tighten the handlebar holder nuts to the specified torque: specified torque: 20 N·m (2.0 kgf·m, 15 Ibf·ft)

  • Page 117: Rear Suspension Adjustments

    250R_097-119.qxd 2008.07.17 16:31 ページ111 Rear Suspension Adjustments The rear suspension can be adjusted for the 3. Check that the spring pre-load is adjusted to Pin spanners should be used for turning the lock rider’s weight and riding conditions by changing the standard length.
  • Page 118 250R_097-119.qxd 2008.07.17 15:42 ページ112 Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping Compression damping may be adjusted in two The high speed damping adjuster has 3 1/2 turn or more.
  • Page 119 250R_097-119.qxd 2008.07.17 15:42 ページ113 Rear Suspension Adjustments 4. Calculate the race sag dimension. Rear Suspension Race Sag REAR FENDER MOUNTING BOLT To do this, subtract the loaded with rider dimension (step 3) from the unloaded UNLOADED MEASUREMENT dimension (step 2). Setting the proper race sag (ride height) is very (without rider) EXAMPLE: 600 mm (23.6 in)
  • Page 120 250R_097-119.qxd 2008.07.17 15:42 ページ114 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 121: Suspension Adjustments For Track Conditions

    250R_097-119.qxd 2008.07.17 15:42 ページ115 Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 122: Suspension Adjustment Guidelines

    250R_097-119.qxd 2008.07.17 15:42 ページ116 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 98 – 115. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 123 250R_097-119.qxd 2008.07.17 15:42 ページ117 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 124 250R_097-119.qxd 2008.07.17 15:42 ページ118 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 125: Carburetor Adjustments & Tuning Tips

    250R_097-119.qxd 2008.07.17 15:42 ページ119 Carburetor Adjustments & Tuning Tips The carburetor used on your CRF should perform Hot Start Circuit Carburetor Components suitably with the standard recommended settings A lean mixture must be delivered to the cylinder under average load, climatic, and barometric when a hot engine is being started.
  • Page 126 250R_120-139.qxd 2008.07.17 15:43 ページ120 Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.
  • Page 127 250R_120-139.qxd 2008.07.17 15:43 ページ121 Carburetor Adjustments & Tuning Tips Jet Needle Leak Jet Carburetor Circuit Functions The jet needle controls fuel/air mixture over fully The smaller the number, the smaller the jet bore closed to 3/4 throttle. The straight section (1) diameter.
  • Page 128 250R_120-139.qxd 2008.07.17 15:43 ページ122 Carburetor Adjustments & Tuning Tips Drain the carburetor into an approved petrol 7. Remove the wire band (4). Carburetor Removal container and dispose of it in an approved manner (page 142). 1. Turn the fuel valve OFF. 2.
  • Page 129 250R_120-139.qxd 2008.07.17 15:43 ページ123 Carburetor Adjustments & Tuning Tips 9. Release the throttle position sensor wire from 11.Loosen the insulator band screw (7). 14.Remove the throttle drum cover bolt (9) and the wire clips (6). throttle drum cover (10). (10) (7) insulator band screw (9) throttle drum cover bolt (6) wire clips...
  • Page 130 250R_120-139.qxd 2008.07.17 15:43 ページ124 Carburetor Adjustments & Tuning Tips 3. Remove the link arm torx screw (6). When installing the floating valve (9) onto the Carburetor Disassembly/Assembly When installing the link arm torx screw, apply throttle valve (7) make sure the floating valve’s a locking agent to the link arm torx screw flat side faces out and the hole (10) faces down.
  • Page 131 250R_120-139.qxd 2008.07.17 15:43 ページ125 Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (18), throttle stop 9. Measure the float level (25) with the float (11) and accelerator pump cover (12). screw holder (19), float bowl screws (20), level gauge (26) while the float tab is just tube guides (21) and float bowl (17).
  • Page 132 250R_120-139.qxd 2008.07.17 15:43 ページ126 Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. • Route the throttle cables (1), hot start cable (2) To install the carburetor, reverse the removal and throttle sensor wire correctly. procedures. • After installing the carburetor, adjust the throttle grip freeplay and hot start lever Tighten the following parts to the specified freeplay.
  • Page 133 250R_120-139.qxd 2008.07.17 15:43 ページ127 Carburetor Adjustments & Tuning Tips All jetting is based on Standard Tuning Recommendations • Standard jetting • Unmodified Engine For the following recommendations to be accurate, you must use the standard settings as a Temperature CENT. -30°~ -17°...
  • Page 134 250R_120-139.qxd 2008.07.17 15:43 ページ128 Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the situations that may require additional atmospheric conditions or race day situations that...
  • Page 135 250R_120-139.qxd 2008.07.17 15:43 ページ129 Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments Petrol is highly flammable and explosive. The standard carburetor settings are ideal for the You can be burned or seriously injured following conditions: sea level altitude, and 20°C when handling fuel.
  • Page 136 250R_120-139.qxd 2008.07.17 15:43 ページ130 Carburetor Adjustments & Tuning Tips 11.Loosen the connecting and insulator band If you’ve determined that the jet needle or clip screws. Rotate the carburetor. position of jet needle must be changed, you must 12.Remove the float bowl plug (4). remove the carburetor top.
  • Page 137 250R_120-139.qxd 2008.07.17 15:43 ページ131 Carburetor Adjustments & Tuning Tips 22.Tighten the connecting and insulator band NOTICE Spark Plug Reading screws. 23.Install the fuel tank (page 31). An improperly tightened spark plug can damage 24.Start the engine. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 55.

  • Page 138: Steering Damper Adjustment

    250R_120-139.qxd 2008.07.17 15:43 ページ132 Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Adjustment conditions by using following method: • Damping — Turning the steering damper adjuster adjusts how quickly the steering Damping Adjustment damper extends and retracts. The steering damper adjuster (1) has 13 positions or more.

  • Page 139: Steering Damper Adjustment Guidelines

    250R_120-139.qxd 2008.07.17 15:43 ページ133 Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on this page. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment.

  • Page 140: Chassis Adjustments

    250R_120-139.qxd 2008.07.17 15:43 ページ134 Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle not adjustable.

  • Page 141: Gearing

    250R_120-139.qxd 2008.07.17 15:43 ページ135 Gearing You can “adjust” the power delivery of the Lower Gearing (more driven sprocket teeth) A gearing change may help for riding in sand, standard engine to suit track conditions by • decrease top speed in each gear where you want to keep the front end light so it changing gearing.

  • Page 142: Tyre Selection For Track Conditions

    250R_120-139.qxd 2008.07.17 15:43 ページ136 Tyre Selection for Track Conditions Choosing the correct tyre tread pattern and If you choose a tyre with a sticky compound for rubber compound can affect your placing in added traction, remember that it may transfer competition.

  • Page 143: Personal Fit Adjustments

    250R_120-139.qxd 2008.07.17 15:43 ページ137 Personal Fit Adjustments The following suggestions may make your ride • Position the shift lever and brake pedal so • Handlebar width can be trimmed with a both more comfortable and more responsive to they are close to your boot for rapid access, hacksaw to better suit your particular shoulder your control input.
  • Page 144 250R_120-139.qxd 2008.07.17 15:43 ページ138 Adjustments for Competition...

  • Page 145: Tips

    250R_120-139.qxd 2008.07.17 15:43 ページ139 Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......140 Storing Your Honda..........141 You & the Environment ........142 Troubleshooting..........143 Tips...

  • Page 146: Transporting Your Motorcycle

    250R_140-162.qxd 2008.07.17 15:43 ページ140 Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 147: Storing Your Honda

    250R_140-162.qxd 2008.07.17 15:43 ページ141 Storing Your Honda If you won’t be riding for an extended period, 5. Remove the radiator cap and coolant drain Removal from Storage such as during the winter, thoroughly inspect bolt/sealing washer (1) at the water pump (2) to your Honda and correct any problem before drain coolant.

  • Page 148: You & The Environment

    250R_140-162.qxd 2008.07.17 15:43 ページ142 You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment.

  • Page 149: Troubleshooting

    250R_140-162.qxd 2008.07.17 15:43 ページ143 Troubleshooting The items that are serviceable using this Manual POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT LOW AND UNSTABLE are followed by the page number reference in IDLE SPEED CHECK POSSIBLE CAUSES parenthesis. The items that require use of the 1.
  • Page 150 250R_140-162.qxd 2008.07.17 15:43 ページ144 Tips...

  • Page 151: Technical Information

    250R_140-162.qxd 2008.07.17 15:43 ページ145 Technical Information This section contains dimensions, capacities, and Vehicle Identification ........146 other technical data. Specifications ...........147 Torque Specifications........148 Petrol Containing Alcohol........151 Competition Logbook ........152 Optional Parts List ...........154 Spare Parts & Equipment.........155 Wiring Diagram..........156 Technical Information...

  • Page 152: Vehicle Identification

    250R_140-162.qxd 2008.07.17 15:43 ページ146 Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts.

  • Page 153: Specifications

    250R_140-162.qxd 2008.07.17 15:43 ページ147 Specifications Item Item Metric English Metric English Item Metric English Dimension Engine Drive train Overall length 2,170 mm 85.4 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall width 827 mm 32.6 in Single 10˚ inclined from Transmission 5-speed, constant mesh Cylinder arrangement...

  • Page 154: Torque Specifications

    250R_140-162.qxd 2008.07.17 15:43 ページ148 Torque Specifications Nuts, Bolts, Fasteners Torque Remarks Item N•m kgf•m lbf•ft Check and tighten nuts, bolts, and fasteners before every outing. ENGINE Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Water pump cover bolts Crankshaft hole cap NOTE 1 Transmission oil check...
  • Page 155 250R_140-162.qxd 2008.07.17 15:43 ページ149 Torque Specifications Frame Torque Item Remarks N•m kgf•m lbf•ft FRAME Steering stem nut 11.0 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...
  • Page 156 250R_140-162.qxd 2008.07.17 15:43 ページ150 Torque Specifications Frame Torque Remarks Item N•m kgf•m lbf•ft FRAME (42) (34) (38) Caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 (28) Rear brake disc nuts NOTE 1 Brake pedal pivot bolt NOTE 5 Spoke (front) (49)

  • Page 157: Petrol Containing Alcohol

    250R_140-162.qxd 2008.07.17 15:43 ページ151 Petrol Containing Alcohol If you decide to use a petrol containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended above. There are two types of gasohol: One contains ethanol, and the other contains methanol. Do not use gasohol that contains more than 10% ethanol.

  • Page 158: Competition Logbook

    250R_140-162.qxd 2008.07.17 15:43 ページ152 Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events.
  • Page 159 250R_140-162.qxd 2008.07.17 15:43 ページ153 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 160: Optional Parts List

    250R_140-162.qxd 2008.07.17 15:43 ページ154 Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 52.00 N/mm (296.9 lbf/in) Standard 51 Teeth, Aluminum. Standard CARBURETOR Remarks...

  • Page 161: Spare Parts & Equipment

    250R_140-162.qxd 2008.07.17 15:43 ページ155 Spare Parts & Equipment There are numerous spare parts you can take to ignition components Chemical Products an event to help ensure you get in a full day of top end-complete riding. In addition to the usual nuts and bolts, radiator hoses consider the following: radiator shrouds (L &...

  • Page 162: Wiring Diagram

    250R_140-162.qxd 2008.07.17 15:43 ページ156 Wiring Diagram Technical Information...
  • Page 163 250R_140-162.qxd 2008.07.17 15:43 ページ157 Technical Information...

  • Page 164: Service Preparations Maintenance Component Locations

    250R_140-162.qxd 2008.07.17 15:43 ページ158 Table of Contents The following presents the contents of each Service Preparations ADJUSTMENTS FOR COMPETITION ..97 section of your owner’s manual. Maintenance Component Locations....28 Front Suspension Adjustments......98 Seat Removal ............29 Rear Suspension Adjustments ......111 MOTORCYCLE SAFETY.......1 Fuel Tank Removal ...........30 Suspension Adjustments for Track Important Safety Information......2...

  • Page 165: Index

    250R_140-162.qxd 2008.07.17 15:43 ページ159 Index accessories............3 capacity, fuel .............34 engine, adjustments, carburetor, flooded ............13 altitude and temperature......127 adjustment ..........119 idle speed............48 carburetor ...........119 circuit functions..........121 number ............146 chassis ............134 components..........119 oil ..............36 control freeplay......46, 49, 54, 77 disassembly/assembly ........124 pinging ............34 engine idle speed..........48 idle speed............48 starting............13...
  • Page 166 250R_140-162.qxd 2008.07.17 15:43 ページ160 Index gap, spark plug ..........55 oil, safety, gasohol ............151 engine ............36 a few words about ....Safety Messages gearing.............135 fork ...............74 important information ........2 guidelines, transmission ..........39 important precautions........2 suspension adjustment........116 operating, labels ..............4 steering damper adjustment .......133 controls............5 maintenance..........19 instructions ...........11...
  • Page 167 250R_140-162.qxd 2008.07.17 15:43 ページ161 Index transmission oil ..........39 tuning tips ............119 throttle, freeplay............46 inspection .............47 tyres, air pressure ...........82 flat ..............82 selection............83 tools ...............155 torque specifications ......148 – 150 transporting............140 troubleshooting..........143 tubes, replacing ..........82 valve, fuel............13 vehicle identification no. (VIN) ......146 washing your motorcycle ........95 wheels..............81 wiring diagram ..........156...

  • Page 168: Manufacturer And Authorised Representative For Eu Market

    250R_140-162.qxd 2008.07.18 14:32 ページ162 Manufacturer and Authorised Representative for EU Market Manufacturer Authorised Representatove for EU Market Honda Motor Co., Ltd. Honda Motor Europe Ltd. No. 1-1, 2-chome, Minami-Aoyama Aalst Office Minato-ku, Wijngaardveld 1 (Noord V), Tokyo 107-8556, Japan B-9300 Aalst Belgium...

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