Honda 2005 CRF250X Manuals

Manuals and User Guides for Honda 2005 CRF250X. We have 1 Honda 2005 CRF250X manual available for free PDF download: Service Manual

Honda 2005 CRF250X Service Manual

Honda 2005 CRF250X Service Manual (419 pages)

Brand: Honda | Category: Motorcycle | Size: 46.37 MB

Table of Contents

A few Words about Safety
2
Important Safety Precautions
2
Contents
3
Symbols
4
General Information
5
Service Rules
6
Model Identification
6
General Specifications
9
Lubrication System Specifications
10
Fuel System Specifications
11
Cooling System Specifications
11
Cylinder/Piston Specifications
12
Cylinder Head/Valves Specifications
12
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications
13
Crankcase/Crankshaft/Transmission/Balancer Specifications
13
Front Wheel/Suspension/Steering Specifications
14
Rear Wheel/Suspension Specifications
14
Hydraulic Brake Specifications
15
Battery/Charging System Specifications
15
Ignition System Specifications
15
Electric Starter Specification
16
Lights/Meter/Switches Specifications
16
Standard Torque Values
17
Engine & Frame Torque Values
17
Lubrication & Seal Points
24
Cable & Harness Routing
27
Secondary Air Supply System
33
Optional Parts
34
Emission Control Systems
37
Source of Emissions
37
Exhaust Emission Control System
37
Crankcase Emission Control System
37
Servicing the Honda
39
Noise Emission Control System
39
Rebuilt Engine
39
Table of Contents
41
Frame/Body Panels/Exhaust System
41
Torque Values
42
Service Information
42
Troubleshooting
42
- Seat Installation
  43
- Seat Removal
  43
- Side Cover Removal/Installation
  43
- Engine Guard Removal/Installation
  44
- Radiator Shroud Removal/Installation
  44
- Front Visor Removal/Installation
  45
- Sub-Frame Removal
  45
- Sub-Frame Installation
  46
- Fuel Tank Removal/Installation
  47
- Exhaust System Muffler Removal/Installation
  48
- Maintenance
  53
- Maintenance Service Information
  54
- Maintenance Specifications
  54
- Tools
  55
- Maintenance Schedule ('04 - '06)
  56
- Competition Maintenance Schedule
  58
- Additional Items Requiring Frequent Replacement
  59
- Fuel Line
  60
- Fuel Strainer Screen
  60
- Throttle Operation
  60
- Hot Start
  61
- Air Cleaner
  62
- Crankcase Breather
  63
  - Spark Plug Removal
    63
  - Spark Plug Inspection
    64
  - Spark Plug Installation
    64
- Cooling System
  65
- Radiator Coolant
  65
- ('04 - '06 California Type, after '06)
  66
- Secondary Air Supply System
  66
- Engine Oil/Oil Filter
  69
  - Oil Level Inspection
    69
  - Engine Idle Speed
    71
- Transmission Oil
  72
  - Transmission Oil Change
    72
  - Drive Chain Adjustment
    73
  - Drive Chain Cleaning and Lubrication
    73
  - Drive Chain Slack Inspection
    73
  - Drive Chain Replacement
    74
  - Drive Chain Slider
    76
- Drive Chain Roller
  77
- Drive/Driven Sprocket
  77
  - Brake Fluid Filling
    78
  - Brake Fluid Level Inspection
    78
- Brake Pad Wear
  79
- Brake System
  79
  - Lever Position Inspection
    79
  - Brake Pedal Height
    80
- Clutch System
  80
- Headlight Aim
  80
- Control Cables
  81
- Exhaust Pipe/Muffler
  81
- Swingarm/Shock Linkage
  84
- Nuts, Bolts, Fasteners
  85
- Wheels/Tires
  85
- Steering Head Bearings
  86
  - Lubrication System
    87
  - Lubrication System Diagram
    88
  - Lubrication System Service Information
    89
  - Lubrication System Torque Values
    89
  - Lubrication System Troubleshooting
    89
  - Oil Strainer Installation
    90
  - Oil Strainer Removal/Inspection
    90
  - Pressure Relief Valve Removal/Installation
    91
  - Pressure Relief Vavle Inspection
    91
  - Oil Jet Installation
    92
  - Oil Jet Removal/Inspection
    92
  - Oil Pump Disassembly
    93
  - Oil Pump Inspection
    93
  - Oil Pump Assembly
    95
  - Fuel System
    97
  - Fuel System Component Location
    98
  - Fuel System Service Information
    99
  - Fuel System Tool
    100
  - Fuel System Torque Values
    100
  - Engine will Not Start
    101
  - Fuel System Troubleshooting
    101
  - Lean Mixture
    101
  - Misfiring During Acceleration
    101
- Carburetor Adjustment
  102
  - Idle Mixture and Idle Speed
    102
  - Air Cleaner Housing Removal
    103
  - Air Cleaner Housing Installation
    105
- Carburetor Removal
  107
  - Carburettor Disassembly
    109
  - Jet Needle/Throttle Valve
    109
  - Choke Knob/Throttle Position Sensor
    110
  - Accelerator Pump/Float/Jet
    111
- Carburetor Assembly
  114
- Carburetor Installation
  120
  - Throttle Position Sensor Replacement
    122
  - Best Idle
    123
- Pilot Screw Adjustment
  123
- Idle Drop Procedure
  124
- HIGH ALTITUDE ADJUSTMENT (California Type Only)
  125
  - Pair Control Valve Removal/Installation
    127
  - Secondary Air Supply System Inspection
    127
  - Air Supply Pipe Removal/Installation
    128
  - Pair Check Valve Inspection
    128
  - Cooling System Flow Pattern
    132
  - Cooling System Service Information
    133
  - Cooling System Torque Values
    133
  - Coolant Leak
    134
  - Cooling System Tools
    134
  - Cooling System Troubleshooting
    134
  - Engine Temperature too High
    134
  - Coolant (Hydrometer Test)
    135
  - Coolant Gravity Chart
    135
  - Cooling System Testing
    135
  - Coolant Replacement Preparation
    136
  - Radiator Cap Relief Pressure
    136
  - Radiator Cap/System Pressure Inspection
    136
  - Recommended Antifreeze
    136
  - Replacement/Air Bleeding
    137
  - Radiator Removal
    138
  - Radiator Installation
    139
  - Radiator Reserve Tank Removal/Installation
    139
  - Water Pump
    140
  - Water Pump Removal
    140
  - Water Seal Inspection
    140
  - Water Pump Bearing/Water Seal/Oil Seal Replacement
    142
  - Water Pump Installation
    143
  - Engine Removal/Installation
    145
  - Engine Removal/Installation Component Location
    146
  - Drive Sprocket Installation
    148
  - Drive Sprocket Removal
    148
  - Engine Removal
    149
  - Engine Installation
    151
  - Cylinder Head/Valves
    155
  - Cylinder Head/Valves Component Location
    156
- ('04 - '06 California Type, after '06)
  157
  - Cylinder Head/Valves Service Information
    157
  - Cylinder Head/Valves Torque Values
    157
  - Cylinder Head/Valves Tools
    158
  - Compression too High
    159
  - Compression too Low, Hard Starting or Poor Performance at Low Speed
    159
  - Cylinder Head/Valves Troubleshooting
    159
  - Excessive Noise
    159
  - Cylinder Compression Test
    160
  - Cylinder Head Cover Removal
    160
  - Camshaft/Rocker Arm Removal
    161
  - Cylinder Head Removal
    166
  - Cam Chain Tensioner/Cam Chain Guide Inspection
    168
  - Cam Chain Tensioner/Cam Chain Guide Removal
    168
  - Cam Chain Tensioner/Cam Chain Guide Installation
    169
  - Cylinder Head Disassembly
    169
  - Cylinder Head Inspection
    171
  - Valve/Valve Guide
    172
  - Valve Guide Replacement
    173
  - Valve Seat Inspection/Refacing
    173
  - Valve Seat Refacing
    174
  - Exhaust Side
    176
  - Intake Side
    176
  - Cylinder Head Assembly
    177
  - Cylinder Head Installation
    179
  - Camshaft/Rocker Arm Installation
    181
  - Cylinder Head Cover Installation
    184
  - Cylinder/Piston
    187
  - Cylinder/Piston Component Location
    188
  - Cylinder/Piston Service Information
    189
  - Cylinder/Piston Troubleshooting
    189
  - Cylinder Removal
    190
  - Piston Removal
    190
  - Cylinder/Piston Inspection
    191
  - Piston/Piston Ring Inspection
    191
  - Cam Chain Tensioner Lifter Inspection
    193
  - Connecting Rod Inspection
    193
  - Piston Ring Installation
    193
  - Cylinder Installation
    194
  - Piston Installation
    194
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage
    197
- COMPONENT LOCA Non
  198
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information
    199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Tools
    199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Torque Values
    199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Troubleshooting
    200
  - Right Crankcase Cover Removal
    201
  - Right Crankcase Cover Installation
    202
  - Clutch Removal
    203
  - Clutch Discs
    205
  - Clutch Inspection
    205
  - Clutch Spring
    205
  - Clutch Center
    206
  - Clutch Lifter/Needle Bearing
    206
  - Clutch Plates
    206
  - Friction Spring/Spring Seat
    206
  - Clutch Lifter Lever
    207
  - Clutch Lifter Rod
    207
  - Clutch Outer
    207
  - Needle Bearing/Clutch Outer Guide
    207
  - Kickstarter Removal
    211
  - Kickstarter Disassembly/Inspection
    212
  - Kickstarter Assembly
    213
  - Kickstarter Installation
    214
- Right Crankcase Cover
  215
  - Starter Clutch Removal
    215
  - Starter Clutch Disassembly/Inspection
    216
  - Starter Clutch Assembly
    218
  - Starter Clutch Installation
    219
  - Gearshift Linkage Removal
    221
  - Gearshift Linkage Inspection
    222
  - Gearshift Linkage Installation
    222
  - Gearshift Spindle
    222
  - Ratchet Pawl
    222
  - Alternator
    225
  - Alternator Component Location
    226
  - Alternator Service Information
    227
  - Alternator Tools
    227
  - Alternator Torque Values
    227
  - Left Crankcase Cover Removal
    228
  - Flywheel Removal
    229
  - Stator Installation
    229
  - Stator Removal
    229
  - Left Crankcase Cover Installation
    231
  - Crankcase/Crankshaft/Transmission/Balancer
    233
  - Crankcase/Crankshaft/Transmission/Balancer Component Location
    234
  - Crankcase/Crankshaft/Transmission/Balancer Service Information
    235
  - Crankcase/Crankshaft/Transmission/Balancer Tools
    236
  - Crankcase/Crankshaft/Transmission/Balancer Torque Value
    236
  - Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
    237
  - Balancer Gear/Balancer Inspection
    238
  - Balancer Gear/Balancer Installation
    238
  - Balancer Gear/Balancer Removal
    238
- Crankcase Separation
  239
- Transmission Disassembly
  241
  - Bushing
    242
  - Gear
    242
  - Mainshaft/Countershaft
    242
  - Transmission Inspection
    242
  - Shift Drum
    243
  - Shift Fork
    243
  - Shift Fork Shaft
    243
  - Transmission Bearing
    243
  - Crankshaft Inspection
    244
- Crankshaft Removal
  244
  - Crankcase Bearing Replacement
    245
  - Crankcase Bearing/Oil Seal Location
    245
  - Crankshaft Bearing
    245
  - Left Crankcase
    247
  - Transmission/Balancer/Shift Drum Bearings
    247
- Crankshaft Installation
  250
  - Countershaft
    251
  - Mainshaft
    251
- Transmission Assembly
  251
- Crankcase Assembly
  253
  - Front Wheel/Suspension/Steering
    255
  - Front Wheel/Suspension/Steering Component Location
    256
  - Front Wheel/Suspension/Steering Service Information
    257
  - Front Wheel/Suspension/Steering Tools
    258
  - Front Wheel/Suspension/Steering Torque Values
    258
  - Front Wheel/Suspension/Steering Troubleshooting
    260
  - Front Wheel Inspection
    261
  - Front Wheel Removal
    261
  - Front Wheel Disassembly
    262
  - Wheel Bearing
    262
  - Wheel Rim
    262
  - Front Wheel Assembly
    263
  - Front Wheel Installation
    265
  - Fork Removal
    266
  - Fork Disassembly
    268
  - Outer Tube and Slider Disassembly
    270
  - Fork Damper Disassembly
    271
  - Fork Cap
    272
  - Fork Centre Bolt
    272
  - Fork Damper Inspection
    272
  - Slider/Outer Tube
    272
  - Bushing/Back-Up Ring
    273
  - Fork Damper
    273
  - Fork Spring
    273
  - Outer Tube and Slider Assembly
    274
  - Fork Damper Refilling/Assembly
    275
  - Fork Damper Operation Inspection
    278
  - Fork Damper Installation/Preparation
    279
  - Fork Damper Installation
    280
  - Oil Capacity Adjustment
    282
  - Standard Oil Capacity
    282
  - Standard Position
    283
  - Handlebar Removal
    285
  - Handlebar Installation
    287
  - Steering Stem Removal
    291
  - Steering Stem Bearing Replacement
    292
  - Steering Stem Installation
    294
  - Rear Wheel/Suspension
    297
  - Rear Wheel/Suspension Component Location
    298
  - Rear Wheel/Suspension Service Information
    299
  - Rear Wheel/Suspension Tools
    300
  - Rear Wheel/Suspension Torque Values
    300
  - Rear Wheel/Suspension Troubleshooting
    302
  - Rear Wheel Inspection
    303
  - Rear Wheel Removal
    303
  - Rear Wheel Disassembly
    304
  - Wheel Rim Runout
    304
  - Rear Wheel Assembly
    305
  - Rear Wheel Installation
    308
  - Shock Absorber Removal
    309
  - Shock Absorber Bladder Replacement
    310
  - Shock Absorber Disassembly
    310
  - Damper Disassembly
    313
  - Recommended Shock Oil
    313
  - Damper Rod Disassembly
    315
  - Piston Ring Replacement
    315
  - Damper Rod Inspection
    317
  - Rod Guide Case Inspection
    317
  - Damper Assembly
    318
  - Spherical Bearing Replacement
    323
  - Shock Linkage Removal
    325
  - Bearing Replacement
    327
  - Shock Arm Needle Bearing
    327
  - Shock Linkage Inspection
    327
  - Shock Link Needle Bearing
    328
  - Swingarm Removal
    331
  - Swingarm Disassembly
    333
  - Swingarm Assembly
    334
  - Swingarm Bearing Replacement
    334
  - Swingarm Installation
    336
  - Hydraulic Brake
    339
  - Hydraulic Brake Component Location
    340
  - Hydraulic Brake Service Information
    341
  - Hydraulic Brake Tool
    342
  - Hydraulic Brake Torque Values
    342
  - Brake Drags
    343
  - Brake Lever/Pedal Hard
    343
  - Brake Lever/Pedal Soft or Spongy
    343
  - Hydraulic Brake Troubleshooting
    343
  - Brake Fluid Draining
    344
  - Brake Fluid Replacement/Air Bleeding
    344
  - Brake Fluid Filling/Air Bleeding
    345
  - Brake Pad Replacement
    348
  - Brake Pad/Disc
    348
  - Front Master Cylinder Disassembly
    350
  - Front Master Cylinder Removal
    350
  - Rear Master Cylinder Disassembly
    353
  - Rear Master Cylinder Removal
    353
  - Rear Master Cylinder Assembly
    354
  - Rear Master Cylinder Inspection
    354
  - Rear Master Cylinder Installation
    355
  - Front Brake Caliper Disassembly
    356
  - Front Brake Caliper Removal
    356
  - Front Brake Caliper Assembly
    357
  - Front Brake Caliper Inspection
    357
  - Front Brake Caliper Installation
    358
  - Rear Brake Caliper Removal
    358
  - Battery/Charging System
    365
  - Battery/Charging System Component Location
    366
  - Battery/Charging System System Diagram
    366
  - Battery Charging
    367
  - Battery Testing
    367
  - Battery/Charging System Service Information
    367
  - Battery/Charging System Tools
    368
  - Battery/Charging System Troubleshooting
    369
  - Battery Removal/Installation
    370
  - Battery Voltage Inspection
    370
  - Charging System Inspection
    370
  - Current Leakage Inspection
    370
  - Charging Voltage Inspection
    371
  - Regulator/Rectifier Removal/Installation
    371
  - Regulator/Rectifier System Inspection
    371
  - Alternator Charging Coil Inspection
    372
  - Ignition System
    373
  - Ignition System Component Location
    374
  - Ignition System Diagram
    374
  - Ignition System Service Information
    375
  - Ignition System Specification
    375
  - Ignition System Tools
    375
  - Ignition System Torque Values
    375
  - Ignition System Troubleshooting
    376
  - Ignition Coil Primary Peak Voltage
    377
  - Ignition System Inspection
    377
  - Direct Ignition Coil Inspection
    378
  - Exciter Coil Peak Voltage
    378
  - Ignition Pulse Generator Peak Voltage
    379
  - Ignition Control Module (ICM) Removal/Installation
    380
  - Ignition Timing
    380
  - Throttle Position Sensor Inspection
    381
  - Electric Starter
    383
  - Electric Starter Component Location
    384
  - Electric Starter System Diagram
    384
  - Electric Starter Service Information
    385
  - Electric Starter Troubleshooting
    386
  - Starter Disassembly/Inspection
    388
  - Starter Motor Removal
    388
  - Starter Motor Assembly
    391
  - Starter Motor Installation
    393
  - Starter Relay Switch Ground Line
    393
  - Starter Relay Switch Operation Inspection
    393
  - Starter Relay Switch Function Inspection
    394
  - Starter Relay Switch Power Input Line
    394
  - Lights/Meter/Switches
    395
  - Lights/Meter/Switches Component Location
    396
  - Lights/Meter/Switches Service Information
    397
  - Lights/Meter/Switches Torque Values
    397
  - Headlight Bulb Replacement
    398
  - Headlight Removal/Installation
    399
  - Tail Light Inspection
    399
  - Engine Stop Button
    400
  - Tail Light Removal/Installation
    400
  - Clutch Switch Inspection
    401
  - Starter Switch
    402
  - Tripmeter Removal/Installation
    402
  - Main Relay Inspection
    403
  - Wiring Diagram
    406
- Engine Does Not Start or Is Hard to Start
  410
- Engine Lacks Power
  411
- Poor Performance at Low and Idle Speed
  413
- Poor Performance at High Speed
  414
- Poor Handling
  415
Index
417

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