Honda Crf 250 M Manual

Servicing Your Honda67
Piston/Piston Rings/Piston Pin
Piston Installation
1. Place clean shop towels in the crankcase to
keep the piston pin clips from falling into the
crankcase.
2. Apply molybdenum disulfide oil (a mixture of
1/2 engine oil and 1/2  molybdenum disulfide
grease (containing more than 3%
molybdenum disulfide additive)) to the
connecting rod small end.
3. Install the piston (1) with the “IN” mark (2)
and/or the large valve recesses (3) facing the
intake side of the engine. 
4. Apply flesh...

68Servicing Your Honda
Piston/Piston Rings/Piston Pin
5. Apply clean engine oil to the cylinder wall,
piston outer surface and piston rings.
Route the cam chain (3) through the cylinder
(4).
Install the cylinder over the piston rings by
hand while compressing the piston rings (5).
Do not damage the piston rings and cylinder
walls.
NOTICE
(3) cam chain (4) cylinder
(5) piston rings
6. Install the cam chain guide (6) and fit the cam
chain guide tabs (7) in the cylinder cut-outs
(8).
Push the guide until it...

Servicing Your Honda69
Piston/Piston Rings/Piston Pin
2. Route the cam chain through the cylinder
head (3).
Install the cylinder head.
Do not damage mating surfaces when installing
the cylinder head.
3. Apply engine oil to all cylinder head nut
threads.
Install the washers and cylinder head nuts (4).
Tighten the cylinder head nuts to the specified
torque:
29 lbf·ft (39 N·m, 4.0 kgf·m)
Do not let the washers and nuts fall into the
crankcase.
Tighten the cylinder head nuts in a criss-cross
pattern in 2 or...

70Servicing Your Honda
Piston/Piston Rings/Piston Pin
6. Connect the radiator hose (9) to the cylinder
head and tighten the radiator hose clamp (10)
securely.
(9) radiator hose
(10) radiator hose clamp
7. Install the shims and cam shaft (page 60).
8. Install the spark plug (11) (page 54).
(11) spark plug 
9. Install the crankshaft hole cap (page 62).
(12) spark plug cap
11. Install a new exhaust pipe gasket (13),
exhaust pipe (14) and exhaust pipe joint nuts
(15) and tighten to the specified torque:
15...

Servicing Your Honda71
Suspension
Refer to Safety Precautionson page 19
Loose, worn, or damaged suspension components
may adversely affect the handling and stability of
your CRF.  If any suspension components appear
worn or damaged, see your Honda dealer for
further inspection.  Your dealer is qualified to
determine whether or not replacement parts or
repairs are needed.
Front Suspension Inspection
•When your CRF is new, break it in for
approximately one hour to ensure that the
suspension has worked in...

72Servicing Your Honda
Suspension
Rear Suspension Inspection
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.
The shock absorber’s spring preload and
damping adjustments (compression and rebound)
should be adjusted for the rider’s weight and
track conditions (page 111).
Do not attempt to disassemble, service, or
dis
pose of the damper; see your Honda dealer.
The...

Suspension
Servicing Your Honda73
Recommended Fork Oil
Fork Oil Change
Refer tosuspension removal on (page 95).
1. Record the rebound damping adjuster position
and turn the adjuster counterclockwise until it
stops.
2. Hold the outer tube (1), then remove the fork
damper (2) from the outer tube using a lock
nut wrench (3). Gently slide the outer tube
down onto the lower end of the slider (4). 
viscosity (weight) 5 W
suggested oil
Pro Honda HP Fork Oil or
equivalent
(1) outer tube (3) lock nut wrench
(2)...

74Servicing Your Honda
Suspension
5. Pour the recommended fork oil into the outer
tube (1).Fork Oil Capacity:
 
Standard (0.45 kgf/mm) Fork Spring
or
Standard oil
capacity12.5 US oz
(371 cm
3)
Maximum oil
capacity14.1 US oz
(417 cm
3)Slightly stiffer as
it nears full
compression.
Slightly stiffer as
it nears full
compression. Minimum oil
capacity10.9 US oz
(321 cm
3)
Optional Softer (0.43 kgf/mm) Fork Spring
Standard oil
capacity12.4 US oz
(368 cm
3)
Maximum oil
capacity14.0 US oz
(414 cm
3)Slightly...

Suspension
Servicing Your Honda75
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. 
(2) fork damper 
(10) o-ring 
7. Tighten the fork damper using the special
tool, to the specified torque:
25 lb·ft (34 N·m, 3.5 kgf·m)
(10)
(2) 

76Servicing Your Honda
Brakes
Refer to Safety Precautionson page 19.
Both the front and rear brakes are the hydraulic
disc type.  As the brake pads wear, the brake
fluid level will drop.  A leak in the system will
also cause the level to drop.
Frequently inspect the system to ensure there are
no fluid leaks.  Periodically inspect the brake
fluid level and the brake pads for wear.
If the front brake lever or rear brake pedal
freeplay does not feel within the normal range
while riding, check the brake...