Honda 2004 CRF250R Manuals

Manuals and User Guides for Honda 2004 CRF250R. We have 1 Honda 2004 CRF250R manual available for free PDF download: Service Manual

Honda 2004 CRF250R Service Manual (407 pages)

Brand: Honda | Category: Motorcycle | Size: 50.24 MB

A few Words about Safety
2
Service Information
2
For Your Customer's Safety
2
Important Safety Precautions
2
Contents
3
Symbols
4
General Information: Contents
5
Service Rules
6
Model Identification
6
General Specifications
8
Lubrication System Specifications
10
Fuel System Specifications
10
Cooling System Specifications
11
Cylinder Head/Valves Specifications
11
Cylinder/Piston Specifications
12
Clutch/Kickstarter/Gearshift Linkage Specifications
12
Crankcase/Crankshaft/Transmission/Balancer Specifications
13
Front Wheel/Suspension/Steering Specifications
14
Rear Wheel/Suspension Specifications
15
Hydraulic Brake Specifications
15
Electrical System Specifications
16
Standard Torque Values
17
Engine and Frame Torque Values
17
Insulator Clamp
19
Cylinder Stud Bolt
19
Frame General Information
20
Lubrication and Seal Points
23
Frame
25
Cable and Harness Routing
26
Optional Parts
34
Technical Feature
40
HPSD (Honda Progressive Steering Damper/After '07)
41
HPSD Characteristics
42
Turning Handlebar from Neutral Position to Full Angle (Extension)
43
Turning Handlebar from Angle to Neutral Position (Compression)
44
Frame/Body Panels/Exhaust System: Contents
45
Frame/Body Panels/Exhaust System: System Information, Torque Values, Troubleshooting
46
Seat Removal/Installation
47
Side Cover Removal/Installation
47
Radiator Shroud Removal/Installation
48
Engine Guard Removal/Installation
48
Number Plate Removal/Installation
49
Sub-Frame Removal/Installation
50
Fuel Tank Removal/Installation
51
Fuel Filter Maintenance
52
Exhaust System
53
Muffler Removal/Installation
53
Exhaust Joint Pipe Removal/Installation (after '05)
54
Exhaust Pipe Removal
55
Exhaust Pipe Installation
56
Maintenance: Contents
59
Maintenance: Service Information, Specifications
60
Torque Values
61
Tools
61
Maintenance Schedule
62
Additional Items Requiring Frequent Replacement
63
Throttle Operation
64
Hot Start
64
Air Cleaner
65
Crankcase Breather
66
Spark Plug Removal, Inspection
67
Radiator Coolant
68
Valve Clearance/Decompressor System
69
Valve Clearance Inspection
69
Valve Clearance Adjustment
70
Engine Oil/Oil Filter
71
Oil Level Inspection
71
Decompressor System
71
Engine Oil and Filter Change
72
Engine Idle Speed
74
Transmission Oil
74
Cooling System
75
Transmission Oil Change
75
Drive Chain Cleaning and Lubrication
76
Drive Chain Slack Inspection/Adjustment
77
Drive Chain Slider
77
Drive Chain Roller
78
Drive/Driven Sprocket
78
Brake Fluid Level Inspection
79
Fluid Filling
79
Brake Pad Wear
80
Brake System
80
Lever Position Inspection
80
Clutch System
81
Clutch Lever Position
81
Clutch Lever Free Play
82
Control Cables
83
Exhaust Pipe/Muffler
83
Exhaust Inspection
83
Glass Wool Replacement
84
Front/Rear Suspension Inspection
86
Swingarm/Shock Linkage
87
Nuts, Bolts, Fasteners
87
Wheels/Tires
88
Steering Head Bearings
89
Lubrication System: Contents
90
Lubrication System Diagram
91
Lubrication System: Service Information, Specifications, Troubleshooting
92
Oil Strainer Removal/Inspection/Installation
93
Oil Relief Valve Removal/Inspection/Installation
94
Oil Jet Removal/Inspection/Installation
95
Oil Pump Disassembly/Inspection
96
Oil Pump Assembly
98
Fuel System: Contents
99
Component Location of Fuel System
100
Fuel System: Service Information, Specifications
101
Fuel System: Torque Values, Tools
102
Fuel System Troubleshooting
103
Carburetor Adjustment, Minor
104
Idle Mixture and Idle Speed
104
Carburetor Adjustment, Major: for Temperature and Altitude
105
Tuning Information Chart '04, '05
108
Tuning Information Chart '06, '07
109
Tuning Information Chart '08, after '08
110
Tuning for Special Conditions
111
Air Cleaner Housing Removal
112
Air Cleaner Housing Installation
113
Carburetor Removal
114
Carburetor Assembly
116
Jet Needle/Throttle Valve
116
SE Valve/Throttle Position Sensor
117
Accelerator Pump/Float/Jets
118
Carburetor Assembly Overview
122
Carburetor Installation
128
Throttle Position Sensor Replacement
130
Pilot Screw Adjustment
131
Cooling System: Contents
132
System Flow Pattern
133
Cooling System: Service Information
134
Tools for Cooling System, Troubleshooting
135
Cooling System Testing
136
Coolant (Hydrometer Test)
136
Coolant Gravity Chart
136
Radiator Cap/System Pressure Inspection
137
Coolant Replacement: Preparation
137
Coolant Replacement/Air Bleeding
138
Radiator Removal
138
Radiator Installation
139
Water Pump
140
Water Seal Inspection/Removal
140
Bearing/Water Seal/Oil Seal Replacement
142
Bearing/Water Seal/Oil Seal Installation
144
Engine Removal/Installation: Contents
146
Engine: Component Location
147
Engine Service Information, Specification
148
Engine Removal
150
Engine Installation
151
Cylinder Head/Valves: Contents
154
Cylinder Head/Valves: Component Location
155
Cylinder Head/Valves: Service Information, Specification
156
Cylinder Head/Valves: Troubleshooting
159
Cylinder Compression Test
160
Cylinder Head Cover Removal
160
Camshaft/Rocker Arm Removal
161
Rocker Arm
163
Rocker Arm Disassembly/Inspection
164
Cylinder Head Removal
166
Rocker Arm Assembly
166
Cam Chain Tensioner/Cam Chain Guide Removal/Inspection
168
Cylinder Head Disassembly
169
Cam Chain Tensioner/Cam Chain Guide Installation
169
Cylinder Head Inspection
170
Valve Spirit/Guide
171
Valve Guide Replacement
172
Valve Seat Inspection/Refacing
173
Valve Seat Refacing
174
Cylinder Head Assembly
177
Cylinder Head Installation
180
Camshaft/Rocker Arm Installation
181
Cylinder Head Cover Installation
185
Cylinder/Piston
187
Cylinder/Piston: Component Location
188
Cylinder/Piston: Service Information, Troubleshooting
189
Cylinder/Piston Removal
190
Cylinder/Piston/Piston Ring Inspection
191
Connecting Rod Inspection
193
Piston Ring Installation
193
Cam Chain Tensioner Lifter Inspection
193
Piston, Cylinder Installation
194
Clutch/Kickstarter/Gearshift Linkage: Contents
196
Clutch/Kickstarter/Gearshift Linkage: Component Location
197
Clutch/Kickstarter/Gearshift Linkage: Service Information, Tools
198
Clutch/Kickstarter/Gearshift Linkage: Troubleshooting
199
Right Crankcase Cover Removal
200
Right Crankcase Cover Installation
201
Clutch Removal
202
Clutch Inspection
204
Clutch Plates, Center
205
Judder Spring/Spring Seat
205
Clutch Lifter/Needle Bearing
205
Clutch Lifter Rod/Lever
206
Clutch Outer
206
Clutch Outer Guide, Bearing
206
Clutch Installation
207
Kickstarter Removal, Disassembly, Inspection
211
Kickstarter Assembly
212
Kickstarter Installation
213
Gearshift Linkage Removal
214
Gearshift Linkage Inspection
215
Gearshift Spindle
215
Gearshift Linkage Installation
216
Ratchet Pawl
216
Crankcase/Crankshaft/Transmission/Balancer: Contents
218
Crankcase/Crankshaft/Transmission/Balancer: Component Location
219
Crankcase/Crankshaft/Transmission/Balancer: Service Information, Specifications
220
Crankcase/Crankshaft/Transmission/Balancer: Torque Values, Tools
221
Crankcase/Crankshaft/Transmission/Balancer: Troubleshooting
223
Balancer Gear/Balancer Removal, Inspection
224
Balancer Gear/Balancer Installation
225
Crankcase Separation
226
Transmission Disassembly
229
Transmission Inspection
230
Shift Fork Shaft/Shift Drum
231
Transmission Bearing
231
Crankshaft Removal/Inspection
232
Crankcase Bearing Replacement
233
Crankcase Bearing/Oil Seal Location
233
Transmission/Balancer/Shift Drum Bearings
235
Left Crankcase
235
Right Crankcase
237
Crankcase Installation
241
Crankcase Assembly
242
Front Wheel/Suspension/Steering: Contents
245
Front Wheel/Suspension/Steering: Component Location
246
Front Wheel/Suspension/Steering: Service Information
249
Front Wheel/Suspension/Steering: Torque Values
250
Front Wheel/Suspension/Steering: Tools
251
Front Wheel/Suspension/Steering: Troubleshooting
253
Front Wheel Removal
254
Front Wheel Inspection
255
Axle
255
Wheel Bearing
255
Front Wheel Disassembly
256
Front Wheel Assembly
257
Front Wheel Installation
260
Fork Removal
263
Fork Disassembly
264
Fork Damper Disassembly
267
Outer Tube and Slider Disassembly
267
Fork Damper Inspection
268
Fork Cap Assembly
268
Fork Center Bolt
269
Slider/Outer Tube
269
Fork Spring
270
Bushing/Back-Up Ring
270
Fork Damper
270
Fork Assembly
271
Outer Tube and Slider Assembly
272
Fork Damper Refilling/Assembly
273
Fork Damper Operation Inspection
276
Fork Damper Installation/Preparation
277
Fork Damper Installation
278
Oil Capacity Adjustment
280
Fork Installation
281
Standard Position
282
Handlebar Removal
283
Handlebar Installation
285
HPSD (Honda Progressive Steering Damper) Removal/Installation
288
HPSD Inspection
289
Spherical Bearing Replacement
290
HPSD Disassembly
291
HPSD Assembly
293
Steering Stem Removal
298
Bearing Replacement
299
Bearing Installation
301
Rear Wheel/Suspension: Contents
303
Rear Wheel/Suspension: Component Location
304
Rear Wheel/Suspension: Service Information
305
Rear Wheel/Suspension: Torque Values
306
Rear Wheel/Suspension: Tools
307
Rear Wheel/Suspension: Troubleshooting
309
Rear Wheel Removal, Inspection
310
Rear Wheel Disassembly
311
Wheel Rim Runout
311
Rear Wheel Assembly
312
Rear Wheel Installation
315
Shock Absorber Removal, Disassembly
316
Bladder Replacement
317
Recommended Shock Oil
319
Damper Disassembly
320
Piston Ring Replacement
321
Damper Rod Disassembly
322
Rod Guide Case Inspection
324
Rebound Spring Inspection
324
Damper Rod Inspection
324
Damper Assembly
325
Damper Installation
331
Shock Linkage Removal
332
Shock Linkage Inspection
333
Shock Arm Needle Bearing
334
Shock Link Needle Bearing
335
Swingarm Removal
338
Swingarm Disassembly
339
Swingarm Assembly
341
Swingarm Installation
343
Hydraulic Brake: Contents
345
Hydraulic Brake: Component Location
346
Hydraulic Brake: Service Information
347
Hydraulic Brake: Torque Values, Tools
348
Hydraulic Brake: Troubleshooting
349
Brake Fluid Replacement/Air Bleeding
350
Brake Fluid Draining
350
Brake Fluid Filling/Air Bleeding
351
Brake Pads/Disc
354
Brake Pads Replacement
356
Front Master Cylinder Removal
358
Brake Disc Inspection
358
Front Master Cylinder Disassembly, Inspection
359
Front Master Cylinder Assembly
360
Front Master Cylinder Installation
361
Hydraulic Brake Assembly
364
Hydraulic Brake Installation
366
Rear Master Cylinder Removal
366
Rear Master Cylinder Disassembly, Inspection
367
Rear Master Cylinder Assembly, Installation
368
Front Brake Caliper Removal
369
Front Brake Caliper Disassembly, Inspection
370
Front Brake Caliper Assembly, Installation
371
Rear Brake Caliper Removal
372
Rear Brake Caliper Disassembly
373
Rear Brake Caliper Inspection, Assembly
374
Rear Brake Caliper Installation
375
Brake Pedal Removal, Installation
376
Electrical System: Contents
379
Electrical System: Diagram
380
Electrical System: Service Information
381
Electrical System: Tools
382
Electrical System: Troubleshooting
383
Ignition System Inspection
384
Ignition Coil Primary Peak Voltage
384
Direct Ignition Coil Inspection
385
Exciter Coil Peak Voltage
385
CKP (Crankshaft Position) Sensor Peak Voltage
386
Ignition Control Module Removal/Installation
387
Flywheel Removal
389
Flywheel Installation
390
Stator Removal
390
Left Crankcase Cover Installation
391
Stator Installation
391
Ignition Timing
392
Engine Stop Button
393
Throttle Position Sensor Inspection
394
Wiring Diagram: Contents
395
Wiring Diagram '04-'07
396
Wiring Diagram after '07
397
Troubleshooting: Contents
398
Engine Does Not Start or Is Hard to Start
399
Engine Lacks Power
400
Poor Performance at Low and Idle Speed
402
Poor Performance at High Speed
403
Poor Handling
404
Index
405

Honda Categories

Motorcycle Automobile

Lawn Mower Offroad Vehicle Engine

More Honda Manuals

Honda 2004 CRF250R Manuals

Honda 2004 CRF250R Service Manual (407 pages)

Table of Contents

Related Products

Honda Categories