Related Manuals for Honda CRF250X'04
Summary of Contents for Honda CRF250X'04
- Page 1 PARTS CATALOG CRF250X’04 FEBRUARY, 2004 American Honda Motor Co., Inc. 14KSC401M (Fiche Version) 14KSC401P (Paper Version) 2004 American Honda Motor Co., Inc., (Order through Helm)
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Page 3: Table Of Contents
TABLE OF CONTENTS Introduction • HOW TO USE THIS CATALOG ... A2 • LOCATION OF SERIAL NUMBER ... A2 • SERIAL NUMBERS ... A3 • CONSTRUCTION OF VEHICLE IDENTIFICATION NUMBER ... A3 • BULK HOSE PART NUMBER PATTERN... A4 • MASTER INDEX ... -
Page 4: How To Use This Catalog
HOW TO USE THIS CATALOG 2004 American Honda Motor Co., Inc. FEBRUARY, 2004... -
Page 5: Location Of Serial Number
LOCATION OF SERIAL NUMBER FEBRUARY, 2004 2004 American Honda Motor Co., Inc. -
Page 6: Serial Numbers
Models and applicable serial numbers Models and applicable serial numbers given in this parts catalog can be identified as follows. Model CRF250X’04 CRF250X’04 2004 American Honda Motor Co., Inc. SERIAL NUMBERS Engine Area Serial Code ME11E-5000001~ JH2ME110*4K000001~ AC ME11E-5000001~ JH2ME111*4K000001~ FEBRUARY, 2004 Frame Carburetor... -
Page 7: Construction Of Vehicle Identification Number
CONSTRUCTION OF VEHICLE IDENTIFICATION NUMBER FEBRUARY, 2004 2004 American Honda Motor Co., Inc. -
Page 8: Bulk Hose Part Number Pattern
BULK HOSE PART NUMBER PATTERN 2004 American Honda Motor Co., Inc. FEBRUARY, 2004... -
Page 10: Master Index
Title ENGINE SECTION CYLINDER HEAD COVER ..... . 1-C1 CYLINDER HEAD ......1-C1 CAMSHAFT •... -
Page 11: Engine Section
Page Title CYLINDER HEAD COVER ................. . . 1-C1 CYLINDER HEAD . -
Page 12: Cylinder Head Cover
4 =CRF250X’04 Description 1 SEAL, RING ... -------- -------- 2 COVER, CYLINDER HEAD ... -------- -------- 3 PLATE, BREATHER... -------- -------- 4 GASKET, HEAD COVER ... -------- -------- 5 BOLT, HEAD COVER... -------- -------- 6 RUBBER, SETTING ... -------- -------- 7 BOLT, FLANGE (6X12) ... -
Page 13: Cylinder Head
4 =CRF250X’04 Description 1 CYLINDER HEAD ASSY... -------- -------- A CYLINDER HEAD ASSY... -------- -------- AC 2 GUIDE, VALVE (OS) ... -------- -------- 3 GUIDE, EX. VALVE (OS) ... -------- -------- 4 GASKET, CYLINDER HEAD ... -------- -------- 5 INSULATOR, CARBURETOR ... -------- -------- 6 BAND, INSULATOR ... - Page 14 4 =CRF250X’04 Description 15 CAP (14MM)... -------- -------- 16 NUT, CAP (9MM) ... -------- -------- 17 WASHER, PLAIN (9MM) ... -------- -------- 18 WASHER, CAMSHAFT THRUST... -------- -------- 19 WASHER, SEALING (5MM)... -------- -------- AC 20 STRAP, CABLE (118MM) *NH1L* (BLACK) -------- -------- 21 PIN, DOWEL (9X14)...
- Page 15 4 =CRF250X’04 Description 1 SEAL, VALVE STEM (NOK)... -------- -------- 2 CAMSHAFT ... -------- -------- A CAMSHAFT ... -------- -------- AC 3 WEIGHT, DECOMPRESSION ... -------- -------- 4 PLATE, WEIGHT SETTING ... -------- -------- 5 SPRING, DECOMPRESSION ... -------- -------- 6 ARM, EX.
- Page 16 4 =CRF250X’04 Description 16 SHIM, TAPPET (1.250) ... -------- -------- SHIM, TAPPET (1.275) ... -------- -------- SHIM, TAPPET (1.300) ... -------- -------- SHIM, TAPPET (1.325) ... -------- -------- SHIM, TAPPET (1.350) ... -------- -------- SHIM, TAPPET (1.375) ... -------- -------- SHIM, TAPPET (1.400) ...
- Page 17 4 =CRF250X’04 Description 16 SHIM, TAPPET (1.700) ... -------- -------- SHIM, TAPPET (1.725) ... -------- -------- SHIM, TAPPET (1.750) ... -------- -------- SHIM, TAPPET (1.775) ... -------- -------- SHIM, TAPPET (1.800) ... -------- -------- SHIM, TAPPET (1.825) ... -------- -------- SHIM, TAPPET (1.850) ...
- Page 18 4 =CRF250X’04 Description 17 SHIM, TAPPET (1.275) ... -------- -------- SHIM, TAPPET (1.300) ... -------- -------- SHIM, TAPPET (1.325) ... -------- -------- SHIM, TAPPET (1.350) ... -------- -------- SHIM, TAPPET (1.375) ... -------- -------- SHIM, TAPPET (1.400) ... -------- -------- SHIM, TAPPET (1.425) ...
- Page 19 4 =CRF250X’04 Description 17 SHIM, TAPPET (1.725) ... -------- -------- SHIM, TAPPET (1.750) ... -------- -------- SHIM, TAPPET (1.775) ... -------- -------- SHIM, TAPPET (1.800) ... -------- -------- SHIM, TAPPET (1.825) ... -------- -------- SHIM, TAPPET (1.850) ... -------- -------- SHIM, TAPPET (1.875) ...
- Page 20 4 =CRF250X’04 Description 17 SHIM, TAPPET (2.575) ... -------- -------- SHIM, TAPPET (2.600) ... -------- -------- SHIM, TAPPET (2.625) ... -------- -------- SHIM, TAPPET (2.650) ... -------- -------- SHIM, TAPPET (2.675) ... -------- -------- SHIM, TAPPET (2.700) ... -------- -------- SHIM, TAPPET (2.725) ...
- Page 21 4 =CRF250X’04 Description 1 CHAIN, CAM ... -------- -------- 2 TENSIONER, CAM CHAIN... -------- -------- 3 COLLAR, TENSIONER (6X9)... -------- -------- 4 LIFTER ASSY., TENSIONER... -------- -------- 5 GASKET, TENSIONER LIFTER... -------- -------- 6 GUIDE, CAM CHAIN ... -------- -------- 7 BOLT, FLANGE (6X10) (NSHF)...
- Page 22 4 =CRF250X’04 Description 1 COLLAR, WATER PASS (16MM) ... -------- -------- 2 CYLINDER ... -------- -------- 3 GASKET, CYLINDER... -------- -------- 4 PIN A, DOWEL (12X20) ... -------- -------- 5 BOLT, FLANGE (6X28) ... -------- -------- 1-12 2004 American Honda Motor Co., Inc. CYLINDER Engine Serial Number...
- Page 23 4 =CRF250X’04 Description 1 COLLAR, WATER PASS (16MM) ... -------- -------- 2 COVER, R. CRANKCASE ... -------- -------- 3 COVER, CLUTCH ... -------- -------- 4 GASKET, CLUTCH COVER... -------- -------- 5 GASKET, R. COVER ... -------- -------- 6 CAP, OIL FILLER ... -------- -------- 7 CAP (30MM)...
- Page 24 4 =CRF250X’04 Description 1 CLIP, PISTON PIN (10MM) ... -------- -------- 2 CLUTCH OUTER ... -------- -------- 3 CENTER, CLUTCH ... -------- -------- 4 SEAT, JUDDER SPRING... -------- -------- 5 DISK A, CLUTCH FRICTION ... -------- -------- 6 DISK B, CLUTCH FRICTION ... -------- -------- 7 PLATE, CLUTCH ...
- Page 25 4 =CRF250X’04 Description 19 BEARING, NEEDLE (12MM) ... -------- -------- BEARING, NEEDLE (12MM) (TOMUSON) 20 BEARING, NEEDLE (27X31X16.8) ... -------- -------- 21 BOLT-WASHER (6X20) ... -------- -------- CLUTCH Engine Serial Number From AREA Part Number 91001-147-003 -------- -------- 91001-147-006 91012-P68-003 93404-06020-08 FEBRUARY, 2004 1089549...
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Page 26: Oil Pump
4 =CRF250X’04 Description 1 SHAFT, OIL PUMP... -------- -------- 2 GEAR, OIL PUMP DRIVEN (18T) ... -------- -------- 3 ROTOR, OIL PUMP (INNER)... -------- -------- 4 ROTOR, OIL PUMP (OUTER) ... -------- -------- 5 ROLLER (3X17.8) ... -------- -------- 1-16 2004 American Honda Motor Co., Inc. -
Page 27: Water Pump
4 =CRF250X’04 Description 1 IMPELLER, WATER PUMP ... -------- -------- 2 COVER, WATER PUMP... -------- -------- 3 GASKET, WATER PUMP... -------- -------- 4 GEAR, WATER PUMP (22T) ... -------- -------- 5 WASHER, SEALING (7MM)... -------- -------- 6 WASHER, SEALING (6.5MM) ... -------- -------- 7 BEARING, RADIAL BALL (12X28X7) (TOYO)... - Page 28 4 =CRF250X’04 Description 1 COVER, OIL FILTER ... -------- -------- 2 COVER, L. CRANKCASE... -------- -------- 3 GASKET, L. COVER ... -------- -------- 4 VALVE ASSY., RELIEF ... -------- -------- 5 FILTER, ENGINE OIL... -------- -------- 6 SPRING, OIL FILTER... -------- -------- 7 DIPSTICK, OIL ...
- Page 29 4 =CRF250X’04 Description 19 O-RING (39.8X2.2) (ARAI) ... -------- -------- 20 O-RING (13.8X2.5)... -------- -------- 21 O-RING (18X3)... -------- -------- 22 CLIP (6X20) ... -------- -------- 23 PIN A, DOWEL (8X14) ... -------- -------- 24 PIN A, DOWEL (10X16) ... -------- -------- 25 CIRCLIP (INNER) (14MM) ...
- Page 30 4 =CRF250X’04 Description 1 ALTERNATOR ASSY., FLYWHEEL TYPE 2 CLAMP, WIRE ... -------- -------- 3 CLIP, PURSE LOCK... -------- -------- 4 BOLT, FLANGE (5X16) ... -------- -------- 5 SCREW-WASHER (4X24) ... -------- -------- 6 WASHER, PLAIN (12MM) ... -------- -------- 7 NUT, FLANGE (12MM)...
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Page 31: Starting Motor
4 =CRF250X’04 Description 1 RECEIVER, CLUTCH CABLE ... -------- -------- 2 MOTOR ASSY., STARTER ... -------- -------- 3 TERMINAL SET, BRUSH... -------- -------- 4 SPRING, CARBON BRUSH... -------- -------- 5 BOLT, SETTING... -------- -------- 6 HOLDER SET, BRUSH ... -------- -------- 7 RING... - Page 32 4 =CRF250X’04 Description 1 GEAR, BALANCER DRIVE (32T)... -------- -------- 2 GEAR, PRIMARY DRIVE (18T) ... -------- -------- 3 GEAR, STARTING DRIVEN (38T) ... -------- -------- 4 CLUTCH OUTER, STARTING ... -------- -------- 5 HOLDER, STARTER GEAR... -------- -------- 6 CLUTCH, ONE-WAY ... -------- -------- 7 RING, FRICTION ...
- Page 33 4 =CRF250X’04 Description 1 CRANKCASE, R..-------- -------- 2 TUBE A, BREATHER ... -------- -------- 3 TUBE B, BREATHER ... -------- -------- 4 TUBE C, BREATHER... -------- -------- 5 GASKET, CRANKCASE... -------- -------- 6 CRANKCASE, L..-------- -------- 7 PLATE, CAM CHAIN GUIDE ...
- Page 34 4 =CRF250X’04 Description 19 JET, OIL (#100) ... -------- -------- 20 BEARING, RADIAL BALL (30X72X16)... -------- -------- 21 BEARING, SPECIAL ROLLER... -------- -------- 22 BEARING, SHELL (33X38X8) (TOYO) ... -------- -------- 23 OIL SEAL (35X52X7) (ARAI) ... -------- -------- 24 OIL SEAL (39X56X7) (ARAI) ... -------- -------- 25 OIL SEAL (14X22X5) (NOK) ...
- Page 35 4 =CRF250X’04 Description 36 BOLT, FLANGE (8X25) ... -------- -------- 37 BOLT, FLANGE (8X70) ... -------- -------- CRANKCASE E-14 Engine Serial Number From AREA Part Number 96300-08025-00 96300-08070-00 FEBRUARY, 2004 1829969 7607583 2004 American Honda Motor Co., Inc. 1-25...
- Page 36 4 =CRF250X’04 Description 1 CRANKSHAFT ... -------- -------- 2 RING SET, PISTON (STD)... -------- -------- 3 PISTON ... -------- -------- 4 PIN, PISTON ... -------- -------- 5 CLIP, PISTON PIN ... -------- -------- 6 KEY, WOODRUFF SPECIAL (25X1) ... -------- -------- 1-26 2004 American Honda Motor Co., Inc.
- Page 37 4 =CRF250X’04 Description 1 SHAFT, BALANCER... -------- -------- 2 GEAR, BALANCER DRIVEN (32T) ... -------- -------- 3 GEAR, WATER PUMP DRIVE (19T) ... -------- -------- 4 COLLAR, WATER PUMP GEAR ... -------- -------- 5 BOLT, HEX. (6X16) ... -------- -------- 6 NUT, HEX.
- Page 38 4 =CRF250X’04 Description 1 SHAFT, MAIN... -------- -------- 2 COUNTERSHAFT ... -------- -------- 3 COLLAR, COUNTERSHAFT ... -------- -------- 4 GEAR, COUNTERSHAFT LOW (31T) ... -------- -------- 5 COLLAR (17MM) ... -------- -------- 6 GEAR, MAINSHAFT SECOND (16T)... -------- -------- 7 GEAR, COUNTERSHAFT SECOND (28T) 8 COLLAR (24MM) ...
- Page 39 4 =CRF250X’04 Description 19 COLLAR, DRIVE SPROCKET ... -------- -------- 20 BOLT, FLANGE SOCKET (6X14) ... -------- -------- 21 BOLT, UBS (8X33)... -------- -------- 22 WASHER, THRUST INVOLUTE (22X21X1) -------- -------- 23 PLATE, BEARING HOLDER ... -------- -------- 24 WASHER, THRUST (17.2MM)... -------- -------- 25 WASHER (24X32X1) ...
- Page 40 4 =CRF250X’04 Description 1 FORK, R. GEARSHIFT... -------- -------- 2 FORK, L. GEARSHIFT ... -------- -------- 3 FORK C, GEARSHIFT ... -------- -------- 4 SHAFT A, SHIFT FORK ... -------- -------- 5 SHAFT B, SHIFT FORK ... -------- -------- 6 DRUM, GEARSHIFT ... -------- -------- 7 CENTER, SHIFT DRUM...
- Page 41 4 =CRF250X’04 Description 19 SPRING, GEARSHIFT RETURN ... -------- -------- 20 PIN, GEARSHIFT RETURN SPRING ... -------- -------- 21 PIVOT, SHIFT DRUM STOPPER ARM ... -------- -------- 22 BOLT, FLANGE SOCKET (6X14) ... -------- -------- 23 WASHER (6.1MM) ... -------- -------- 24 PLATE, BEARING HOLDER ...
- Page 42 4 =CRF250X’04 Description 1 PLATE, OIL GUIDE ... -------- -------- 2 PINION, KICK STARTER (32T) ... -------- -------- 3 GEAR, STARTER IDLE (30T) ... -------- -------- 4 RATCHET, STARTER ... -------- -------- 5 SPRING, RATCHET... -------- -------- 6 SPINDLE, KICK STARTER ... -------- -------- 7 SPRING, STARTER RETURN ...
- Page 43 4 =CRF250X’04 Description 1 GASKET SET... -------- -------- 2 VALVE SET, FLOAT... -------- -------- 3 FLOAT SET ... -------- -------- 4 TOP SET ... -------- -------- 5 CHAMBER SET, FLOAT ... -------- -------- 6 SCREW SET A... -------- -------- 7 ARM SET, LINK ... -------- -------- 8 START SET, HOT ...
- Page 44 4 =CRF250X’04 Description 19 BOLT, STOPPER... -------- -------- 20 SCREW, PAN... -------- -------- 21 CARBURETOR ASSY. (FCR02A A) ... -------- -------- A CARBURETOR ASSY. (FCR03A A) ... -------- -------- AC 22 VALVE, THROTTLE ... -------- -------- 23 COVER, THROTTLE ... -------- -------- 24 GASKET, FLOAT CHAMBER...
- Page 45 4 =CRF250X’04 Description 34 TUBE, AIR VENT ... -------- -------- 35 TUBE, AIR VENT ... -------- -------- 36 NEEDLE SET, JET (NCYU) ... -------- -------- AC NEEDLE SET, JET (NCVT) ... -------- -------- A 37 SCREW-WASHER (4X8) ... -------- -------- SCREW-WASHER (4X8) ...
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Page 47: Frame Section
Page Title HEADLIGHT ....................1-E1 METER . -
Page 48: Headlight
4 =CRF250X’04 Description 1 RUBBER, PROTECTOR GASKET... -------- -------- 2 SCREW, PAN (4X55) ... -------- -------- 3 SPRING, BEAM ADJUSTING ... -------- -------- 4 PIPE, CP ... -------- -------- 5 NUT, BEAM ADJUSTING... -------- -------- 6 SOCKET, HEADLIGHT ... -------- -------- 7 HEADLIGHT UNIT ... -
Page 49: Meter
4 =CRF250X’04 Description 1 METER ASSY., TRIP (MPH) ... -------- -------- 2 RUBBER, METER SETTING ... -------- -------- 3 CABLE ASSY., SPEEDOMETER... -------- -------- 4 CABLE (INNER) ... -------- -------- 5 STAY, CONNECTOR ... -------- -------- 6 NUT, CAP (5MM) ... -------- -------- METER Frame Serial Number... -
Page 50: Handle Lever • Switch • Cable
HANDLE LEVER • SWITCH • CABLE 4 =CRF250X’04 Description 1 CABLE A, THROTTLE ... -------- -------- 2 COVER, THROTTLE CABLE ... -------- -------- 3 CABLE B, THROTTLE ... -------- -------- 4 CABLE, HOT STARTER... -------- -------- 5 CABLE, CLUTCH ... -------- -------- A CABLE, CLUTCH ... - Page 51 HANDLE LEVER • SWITCH • CABLE 4 =CRF250X’04 Description 18 HOLDER, L. LEVER BRACKET... -------- -------- 19 COVER, L. HANDLE LEVER ... -------- -------- 20 LEVER, L. HANDLEBAR ... -------- -------- 21 DIAL, CLUTCH CABLE ADJUSTING... -------- -------- 22 LEVER, HOT STARTER... -------- -------- 23 BOLT, WIRE ADJUSTING ...
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Page 52: Fr. Brake Master Cylinder
FR. BRAKE MASTER CYLINDER 4 =CRF250X’04 Description 1 HOSE, FR. BRAKE... -------- -------- 2 BOOT ... -------- -------- 3 MASTER CYLINDER SUB-ASSY., FR. BRAKE (NISSIN) ... -------- -------- 4 CAP, MASTER CYLINDER ... -------- -------- 5 HOLDER, MASTER CYLINDER... -------- -------- 6 SEPARATOR ... - Page 53 FR. BRAKE MASTER CYLINDER 4 =CRF250X’04 Description 18 CIRCLIP ... -------- -------- 19 SCREW, FLAT (4X12) ... -------- -------- SCREW, FLAT (4X12) ... -------- -------- 20 NUT, FLANGE (6MM)... -------- -------- 21 BOLT, FLANGE (6X22) ... -------- -------- Frame Serial Number From AREA Part Number...
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Page 54: Handle Bar • Top Bridge
4 =CRF250X’04 Description 3 GUIDE, FR. BRAKE HOSE ... -------- -------- 4 HANDLEBAR ... -------- -------- 5 PROTECTOR, HANDLE... -------- -------- 6 HOLDER, HANDLE (LOWER) ... -------- -------- HOLDER, HANDLE (LOWER) ... -------- -------- 7 RUBBER, HANDLEBAR... -------- -------- 8 BRIDGE, FORK TOP ... -------- -------- 9 EMBLEM, PRODUCT... -
Page 55: Steering Stem
4 =CRF250X’04 Description 1 GUIDE, SPEEDOMETER CABLE ... -------- -------- 2 GUIDE, FR. BRAKE HOSE ... -------- -------- 3 DUST SEAL, STEERING HEAD ... -------- -------- 4 DUST SEAL, STEERING HEAD (ARAI)... -------- -------- 5 STEM SUB-ASSY., STEERING ... -------- -------- 6 THREAD, STEERING HEAD TOP ... -
Page 56: Front Fender
4 =CRF250X’04 Description 1 FENDER SUB-ASSY., FR... -------- -------- 2 WASHER, FENDER SETTING... -------- -------- 3 COLLAR, FR. FENDER ... -------- -------- 4 BOLT, FLANGE (6X16) ... -------- -------- 2-10 2004 American Honda Motor Co., Inc. FRONT FENDER Frame Serial Number From AREA Part Number... -
Page 57: Front Shock Absorber
4 =CRF250X’04 Description 1 CLAMP A, FR. BRAKE HOSE ... -------- -------- 2 CLAMP B, FR. BRAKE HOSE ... -------- -------- 3 WIRE, SPEEDOMETER CABLE GUIDE ... -------- -------- 4 SPRING, FR. FORK (4.12N/MM,0.42KGF/ MM) (SHOWA) ... -------- -------- 5 TUBE (OUTER) ... -------- -------- 6 RING, BACK-UP... - Page 58 4 =CRF250X’04 Description 18 BOLT, PLUG ... -------- -------- 19 RING, STOPPER ... -------- -------- 20 FORK SUB-ASSY., R. FR..-------- -------- 21 SEAL SET, FR. FORK ... -------- -------- 22 PIPE, L. SLIDE... -------- -------- 23 FORK SUB-ASSY., L. FR..-------- -------- 24 PROTECTOR, L.
- Page 59 4 =CRF250X’04 Description 34 O-RING (44.7X2.4)... -------- -------- 35 O-RING (37.2X2.4) (SHOWA) ... -------- -------- 36 BOLT, FLANGE (6X12) ... -------- -------- FRONT SHOCK ABSORBER Frame Serial Number From AREA Part Number 91356-KZ3-003 91356-MW0-003 96001-06012-00 FEBRUARY, 2004 3010865 4046785 2105930 2004 American Honda Motor Co., Inc.
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Page 60: Front Brake Caliper
4 =CRF250X’04 Description 1 SEAL SET, PISTON... -------- -------- 2 SCREW, BLEEDER ... -------- -------- 3 CAP, BLEEDER ... -------- -------- 4 PAD SET, FR... -------- -------- 5 PISTON ... -------- -------- 6 SPRING, PAD... -------- -------- 7 RETAINER ... -------- -------- 8 BOLT A, BOLT ... -
Page 61: Front Wheel
4 =CRF250X’04 Description 1 SPOKE SET, FR. (240MM) ... -------- -------- 2 CAP, VALVE... -------- -------- 3 AXLE, FR. WHEEL... -------- -------- 4 COLLAR, L. FR. WHEEL ... -------- -------- 5 COLLAR, FR. DISTANCE ... -------- -------- 6 HUB SUB-ASSY., FR..-------- -------- 7 WHEEL SUB-ASSY., FR... - Page 62 4 =CRF250X’04 Description 10 TUBE, TIRE (2.75/3.00-21) (INOUE) ... -------- -------- 11 FLAP, TIRE (DUNLOP) ... -------- -------- 12 STOPPER, BEAD (1.60) ... -------- -------- 13 BOX ASSY., SPEEDOMETER GEAR ... -------- -------- 14 DISK, FR. BRAKE ... -------- -------- 15 COVER, FR.
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Page 63: Rear Brake Caliper
4 =CRF250X’04 Description 1 PAD SET, RR..-------- -------- 2 SEAL SET, PISTON... -------- -------- 3 SPRING, PAD... -------- -------- 4 RETAINER, BRACKET... -------- -------- 5 BOLT, PIN ... -------- -------- 6 CALIPER SUB-ASSY., RR. BRAKE (NISSIN) ... -------- -------- 7 BRACKET SUB-ASSY., RR. - Page 64 REAR BRAKE CALIPER KSC4F1100 4 =CRF250X’04 F-11 Frame Serial Number Description From AREA Part Number 17 BOLT, FLANGE (6X10) (NSHF)... -------- -------- 90004-GHB-600 4938304 2-18 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E9...
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Page 65: Rr. Brake Master Cylinder
RR. BRAKE MASTER CYLINDER 4 =CRF250X’04 Description 1 HOSE, RR. BRAKE ... -------- -------- 2 MASTER CYLINDER ASSY., RR. BRAKE (NISSIN) ... -------- -------- 3 BOOT ... -------- -------- 4 CAP, MASTER CYLINDER ... -------- -------- 5 PISTON SET, MASTER CYLINDER ... -------- -------- 6 PLATE, DIAPHRAGM... -
Page 66: Rear Wheel
4 =CRF250X’04 Description 1 SPOKE SET, RR. INSIDE ... -------- -------- 2 SPOKE SET, RR. (OUTER) ... -------- -------- 3 SPROCKET, FINAL DRIVEN (54T) ... -------- -------- SPROCKET, FINAL DRIVEN (52T) ... -------- -------- SPROCKET, FINAL DRIVEN (53T) ... -------- -------- 4 RETAINER, RR. - Page 67 4 =CRF250X’04 Description 16 CAP, RIM HOLE... -------- -------- 17 DISK, RR. BRAKE ... -------- -------- 18 TUBE, TIRE (3.25/3.50-19) (DUNLOP) (NOT AVAILABLE) ... -------- -------- 19 FLAP, TIRE (1.85-19) (DUNLOP)... -------- -------- 20 BOLT, DISK (6X19) ... -------- -------- 21 SCREW, FLAT (8X31) ...
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Page 68: Fuel Tank
4 =CRF250X’04 Description 1 PETCOCK ASSY... -------- -------- 2 SCREEN SET, FUEL STRAINER ... -------- -------- 3 JOINT ASSY., FUEL... -------- -------- 4 O-RING (11.8X3.55)... -------- -------- 5 COLLAR, TANK SET (6.3X10.5X17.5)... -------- -------- 6 TANK, FUEL... -------- -------- 7 RUBBER, FUEL TANK MOUNTING ... -------- -------- 8 STAY, FR. - Page 69 4 =CRF250X’04 Description 18 SHROUD SET, R. RADIATOR (TYPE1) (WL) ... -------- -------- 19 SHROUD SET, L. RADIATOR (TYPE1) (WL) ... -------- -------- 20 COLLAR ... -------- -------- 21 BOLT, FLANGE (5X12) ... -------- -------- 22 SCREW, PAN (5X13) ... -------- -------- 23 COLLAR A ...
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Page 70: Seat • Side Cover
4 =CRF250X’04 Description 1 SEAT ... -------- -------- 2 LEATHER, SEAT (NO LETTERS PRINTED)... -------- -------- 3 COLLAR, TOOL BOX SETTING ... -------- -------- 4 COVER, R. SIDE *R292R* (EXTREME RED)... -------- -------- 5 PLATE *NH1* (BLACK) ... -------- -------- 6 HEAT GUARD ... -
Page 71: Air Cleaner
4 =CRF250X’04 Description 1 CLIP, OIL DRAIN ... -------- -------- A CLIP, BREATHER TUBE ... -------- -------- AC 2 CLIP, OIL DRAIN TUBE ... -------- -------- 3 CLIP, BREATHER TUBE ... -------- -------- AC CLIP, TUBE (B12) ... -------- -------- A 4 JOINT, FUEL TUBE ... - Page 72 4 =CRF250X’04 Description 15 WASHER, AIR CLEANER COVER SETTING ... -------- -------- 16 STUD (6X21) ... -------- -------- 17 HOUSING, AIR CLEANER... -------- -------- 18 TUBE, AIR CLEANER CONNECTING... -------- -------- A TUBE, AIR CLEANER CONNECTING... -------- -------- AC 19 BOLT, ELEMENT SETTING... -------- -------- 20 CLIP A, BREATHER TUBE ...
- Page 73 4 =CRF250X’04 Description 27 TUBE C, BREATHER... -------- -------- 28 PIPE, BREATHER ... -------- -------- AC 29 CLAMP, MASTER CYLINDER OIL HOSE .. -------- -------- 30 PIN, BRAKE LOCK LEVER PIVOT ... -------- -------- 31 PIN, VISOR HINGE ... -------- -------- 32 PLATE, SPRING...
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Page 74: Air Suction Valve
4 =CRF250X’04 Description 1 CLIP, BREATHER TUBE ... -------- -------- AC 2 CLIP, THROTTLE WIRE ... -------- -------- AC 3 VALVE ASSY., AIR SUCTION ... -------- -------- AC 4 STAY, AIR SUCTION VALVE... -------- -------- AC 5 TUBE A, AIR SUCTION VALVE... -------- -------- AC 6 TUBE B, AIR SUCTION VALVE... - Page 75 4 =CRF250X’04 Description 17 BULK HOSE, VACUUM (3.5X1000) (3.5X270) ... -------- -------- AC 18 BOLT, FLANGE (6X16) ... -------- -------- AC AIR SUCTION VALVE F-16-1 Frame Serial Number From AREA Part Number 95005-35001-20M 96001-06016-00 FEBRUARY, 2004 5137153 2105955 2004 American Honda Motor Co., Inc. 2-29...
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Page 76: Muffler
4 =CRF250X’04 Description 1 GASKET, EX. MUFFLER ... -------- -------- 2 GASKET, EX. PIPE ... -------- -------- 3 MUFFLER... -------- -------- 4 PIPE, EX..-------- -------- 5 PROTECTOR, EX. PIPE ... -------- -------- 6 PROTECTOR, MUFFLER ... -------- -------- 7 ARRESTER ASSY... - Page 77 4 =CRF250X’04 Description 18 NUT, FLANGE (8MM)... -------- -------- 19 WASHER, PLAIN (8MM) ... -------- -------- 20 WASHER, PLAIN (8MM) ... -------- -------- MUFFLER F-17 Frame Serial Number From AREA Part Number 94050-08000 94101-08000 94102-08800 FEBRUARY, 2004 0481143 0059097 0562215 2004 American Honda Motor Co., Inc.
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Page 78: Pedal • Kick Starter Arm
4 =CRF250X’04 Description 1 PEDAL, CHANGE... -------- -------- 2 ARM ASSY., KICK STARTER ... -------- -------- 3 JOINT, KICK ARM ... -------- -------- 4 BOLT, KICK JOINT... -------- -------- 5 SPRING, KICK STARTER ... -------- -------- 6 PEDAL, RR. BRAKE... -------- -------- 7 SPRING ASSY., RR. -
Page 79: Step
4 =CRF250X’04 Description 1 PIN, STEP JOINT... -------- -------- 2 BRACKET, R. STEP... -------- -------- 3 BRACKET, L. STEP ... -------- -------- 4 ARM, R. STEP ... -------- -------- 5 SPRING, R. STEP RETURN ... -------- -------- 6 SPRING, L. STEP RETURN... -------- -------- 7 ARM, L. -
Page 80: Stand
4 =CRF250X’04 Description 1 BRACKET, SIDE STAND ... -------- -------- 2 WORKSTAND (17") ... -------- -------- 3 BAR, SIDE STAND... -------- -------- 4 SPRING ASSY., SIDE STAND... -------- -------- 5 BOLT, SIDE STAND PIVOT... -------- -------- 6 BOLT (10X24) (SH) ... -------- -------- 7 BOLT, FLANGE (8X25) ... -
Page 81: Swingarm
4 =CRF250X’04 Description 1 CHAIN, DRIVE (DID520MXV-120ZB) (DAIDO) ... -------- -------- 2 MASTER LINK ... -------- -------- 3 GUIDE, RR. BRAKE HOSE ... -------- -------- 4 SHAFT, SWINGARM PIVOT ... -------- -------- 5 COLLAR, SWINGARM (49MM) ... -------- -------- 6 COLLAR, SWINGARM PIVOT (59MM) ... -------- -------- 7 WASHER, SWINGARM SIDE ... - Page 82 4 =CRF250X’04 Description 18 BOLT, HEX. (8X47.5)... -------- -------- 19 SCREW, PAN (5X8) ... -------- -------- 20 BOLT, FLANGE (8X32) ... -------- -------- 21 NUT, U (6MM) ... -------- -------- 22 NUT, HEX. U (14MM)... -------- -------- 23 NUT, U (8MM) ... -------- -------- 24 NUT, HEX.
- Page 83 4 =CRF250X’04 Description 34 BOLT, FLANGE (6X12) ... -------- -------- 35 BOLT, FLANGE (6X50) ... -------- -------- SWINGARM F-21 Frame Serial Number From AREA Part Number 96001-06012-00 96001-06050-00 FEBRUARY, 2004 2105930 2106052 2004 American Honda Motor Co., Inc. 2-37...
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Page 84: Rr Cushion
4 =CRF250X’04 Description 1 CUSHION ASSY., RR..-------- -------- 2 SPRING, RR. SHOCK ABSORBER (47.1N/ MM,4.8KGF/MM) (SHOWA)... -------- -------- SPRING, RR. SHOCK ABSORBER (48N/ MM,4.9KGF/MM) (SHOWA)... -------- -------- SPRING, RR. SHOCK ABSORBER (4.55).. -------- -------- SPRING, RR. SHOCK ABSORBER (50N/ MM,5.1KGF/MM) (SHOWA)... - Page 85 4 =CRF250X’04 Description 14 RING, PISTON ... -------- -------- 15 O-RING (3.5X43.7)... -------- -------- 16 O-RING (42.5X2.0)... -------- -------- 17 RING, STOPPER ... -------- -------- 18 OIL SEAL SET ... -------- -------- 19 NUT, HEX. (12MM)... -------- -------- 20 ADJUSTER, COMPRESSION DAMPING FORCE...
- Page 86 4 =CRF250X’04 Description 48 BEARING, NEEDLE (19X26X15)... -------- -------- 49 BEARING, SPHERICAL (10) ... -------- -------- 50 O-RING (21.5X1.5)... -------- -------- 51 O-RING (26.2X1.9)... -------- -------- 52 DUST SEAL (25X32X4) ... -------- -------- 53 DUST SEAL, SHOCK... -------- -------- 54 DUST SEAL (17X26X3) ... -------- -------- 55 DUST SEAL, SHOCK (16X26X3)...
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Page 87: Rear Fender
4 =CRF250X’04 Description 4 CUSHION, OIL TANK... -------- -------- 5 NUT, SPECIAL (6X7) ... -------- -------- 6 WASHER, SEAT SETTING ... -------- -------- 7 FENDER SET, RR. *R292R* (WL) (EXTREME RED) ... -------- -------- 8 COLLAR, RR. FENDER ... -------- -------- 12 WASHER, PLAIN (6MM) ... -
Page 88: Taillight
4 =CRF250X’04 Description 1 TAILLIGHT UNIT ... -------- -------- 2 CLAMP ... -------- -------- 3 STAY, TAILLIGHT ... -------- -------- 4 GROMMET, SIDE COVER... -------- -------- 5 SCREW, TAPPING (4X8) (PO) ... -------- -------- 6 SCREW, SPECIAL (5MM) ... -------- -------- 2-42 2004 American Honda Motor Co., Inc. -
Page 89: Battery
4 =CRF250X’04 Description 1 BATTERY (YTH5L-BS) (YUASA)... -------- -------- 2 COVER, BATTERY TERMINAL ... -------- -------- 3 CABLE, STARTER MAGNETIC BATTERY -------- -------- 4 CABLE, STARTER MOTOR... -------- -------- 5 COVER, STARTER MOTOR TERMINAL... -------- -------- COVER, STARTER MOTOR TERMINAL... -------- -------- 6 COVER, BATTERY TERMINAL ... -
Page 90: Wire Harness
4 =CRF250X’04 Description 1 CUSHION, IGNITION CONTROL MODULE (CDI)... -------- -------- 2 MODULE, IGNITION CONTROL (CDI) ... -------- -------- 3 CAP ASSY., NOISE SUPPRESSOR ... -------- -------- 4 RECTIFIER, REGULATOR ... -------- -------- 5 WIRE HARNESS ... -------- -------- 6 RELAY, STARTER ... -------- -------- 7 SUSPENSION, STARTER RELAY... -
Page 91: Radiator
4 =CRF250X’04 Description 1 BOLT, SEALING (16MM) ... -------- -------- 2 RADIATOR, R..-------- -------- 3 RADIATOR, L..-------- -------- 4 GRILLE, RADIATOR ... -------- -------- 5 CAP, RADIATOR ... -------- -------- 6 RUBBER, RADIATOR MOUNTING ... -------- -------- 7 COLLAR, RADIATOR MOUNTING ... - Page 92 4 =CRF250X’04 Description 19 GUIDE, MAIN HARNESS... -------- -------- 20 BOLT, FLANGE (6X23.5) ... -------- -------- 21 NUT, CLIP (6MM)... -------- -------- 22 WASHER, RADIATOR MOUNTING... -------- -------- 23 COLLAR, GEARSHIFT LEVER SETTING .. -------- -------- 24 CLIP, GRILLE... -------- -------- 25 O-RING (13.5X1.4)...
- Page 93 4 =CRF250X’04 Description 1 FRAME SET... -------- -------- 2 STAY, CONNECTOR ... -------- -------- A 3 CLIP, FUEL TUBE ... -------- -------- 4 FRAME, RR... -------- -------- 5 RUBBER, BATTERY ... -------- -------- 6 RUBBER, SEAT RAIL ... -------- -------- 7 GUARD, L.
- Page 94 4 =CRF250X’04 Description 19 BOLT, FLANGE (10X26) ... -------- -------- 20 NUT, U FLANGE (10MM)... -------- -------- 21 WASHER (10MM)... -------- -------- 22 WASHER, HEAD HANGER PLATE ... -------- -------- 23 BAND, WIRE ... -------- -------- 24 BAND, WIRE ... -------- -------- 25 BOLT-WASHER (6X14) ...
- Page 95 4 =CRF250X’04 Description 1 SPANNER, PIN (A)... -------- -------- 2 WRENCH, NIPPLE... -------- -------- 3 WRENCH, PLUG (16MM) ... -------- -------- 4 TOOL, CARBURETOR MAINTENANCE ... -------- -------- 5 GAUGE, AIR PRESSURE ... -------- -------- TOOLS F-29 Frame Serial Number From AREA Part Number...
- Page 96 4 =CRF250X’04 Description 2 DIAGRAM, VACUUM HOSE ROUTING... -------- -------- AC 3 LABEL, DRIVE CHAIN ... -------- -------- 4 MARK, CAUTION ... -------- -------- 5 LABEL, TRANSMISSION DRAIN... -------- -------- 2-50 2004 American Honda Motor Co., Inc. CAUTION LABEL F-30 Frame Serial Number From...
- Page 97 4 =CRF250X’04 Description 1 MARK, R. RADIATOR SHROUD (TYPE1).. -------- -------- 2 MARK, L. RADIATOR SHROUD (TYPE1) .. -------- -------- 3 MARK (TYPE1) (HONDA) ... -------- -------- MARKS F-31 Frame Serial Number From AREA Part Number 87126-KSC-000ZA 87127-KSC-000ZA 87130-GEL-A00ZA FEBRUARY, 2004 KSC4F3100 7660145 7660152...
- Page 98 4 =CRF250X’04 Description 1 FAN SET, COOLING ... -------- -------- 2 FAN, COOLING ... -------- -------- 3 NUT, SET ... -------- -------- 4 SHROUD, FAN... -------- -------- 5 MOTOR, COOLING FAN ... -------- -------- 6 SWITCH ASSY., THERMOSTAT ... -------- -------- 7 NUT, TOOTHED (3MM) ...
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Page 99: Part Number Index
Part Number Index FEBRUARY, 2004 2004 American Honda Motor Co., Inc. -
Page 100: Part Number Index
Part Number Grid Page 06420-KSC-000 ... . . 1-E10 2-20 06421-KSC-000 ... . . 1-E10 2-20 06431-MA3-405 ... . . 1-E7 2-14 06435-KZ4-J41 . - Page 101 Part Number Grid Page 14947-KT7-013 ....1-C4 14948-KT7-013 ....1-C3 1-C4 14949-KT7-013 ....1-C3 1-C4 14950-KT7-013 .
- Page 102 Part Number Grid Page 19052-MAC-680 ... . . 1-F6 2-45 19055-KRN-003 ... . . 1-F6 2-45 19061-KRN-000 ... . . 1-F6 2-45 19062-KRN-000 .
- Page 103 Part Number Grid Page 42701-KSC-003 ... . . 1-E10 2-20 42711-KSC-004 ... . . 1-E10 2-20 42714-KA3-710 ... . . 1-E7 2-15 1-E10 2-20...
- Page 104 Part Number Grid Page 52429-KSC-003 ... . . 1-F3 2-38 52431-KZ3-J31 ....1-F3 2-39 52434-KZ3-J21 ....1-F3 2-39 52434-KZ3-J31 .
- Page 105 Part Number Grid Page 90125-KA4-000 ... . . 1-E10 2-21 90130-KZ4-J20 ....1-F3 2-39 90130-KZ4-J40 ....1-F3 2-39 90131-KZ4-J40 .
- Page 106 Part Number Grid Page 91302-PA9-003 ... . . 1-C9 1-19 91303-377-000 ....1-C2 1-C9 1-19 91304-MJ0-003 ... . . 1-C6 1-13 91305-KF0-003 .
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Page 107: Description Index
Description Index FEBRUARY, 2004 2004 American Honda Motor Co., Inc. - Page 108 Description ADJUSTER, COMPRESSION DAMPING FORCE ADJUSTER, SPRING ......1-F3 ALTERNATOR ASSY., FLYWHEEL TYPE .
- Page 109 Description BOLT, FLANGE (6X25) ......1-C5 BOLT, FLANGE (6X28) ......1-C2 BOLT, FLANGE (6X30) .
- Page 110 Description CABLE, STARTER MAGNETIC BATTERY ... 1-F5 CABLE, STARTER MOTOR ..... . . 1-F5 CALIPER SUB-ASSY., L.
- Page 111 Description COLLAR, REBOUND NEEDLE ....1-E5 COLLAR, RR. FENDER ......1-F4 COLLAR, RR.
- Page 112 Description GASKET, FLOAT CHAMBER ..... 1-D1 GASKET, FUEL CAP ......1-E11 GASKET, HEAD COVER .
- Page 113 Description LEVER, HOT STARTER ......1-E2 LEVER, L. HANDLEBAR ......1-E2 LEVER SET, PUMP .
- Page 114 Description O-RING (37.2X2.4) (SHOWA) ..... 1-E6 O-RING (39.8X2.2) (ARAI) ......1-C9 O-RING (42.5X2.0) .
- Page 115 Description ROD, CLUTCH LIFTER ......1-C7 ROD, PISTON ....... . . 1-F3 ROD, PUSH .
- Page 116 Description SHIM, TAPPET (1.525) ......1-C3 SHIM, TAPPET (1.550) ......1-C3 SHIM, TAPPET (1.575) .
- Page 117 Description SPRING ASSY., SIDE STAND ..... 1-F1 SPRING, BEAM ADJUSTING ..... 1-E1 SPRING, BRAKE LEVER .
- Page 118 Description VALVE, THROTTLE ......1-D1 VISOR SET, FR. *NH196* (WL) (ROSS WHITE) WASHER (10MM) .