Honda Crf 250 M Manual

							Servicing Your Honda87
Exhaust Pipe/Muffler
Muffler Installation
1. Install the muffler clamp (1) by aligning the
tab (2) of the muffler clamp with the cut-out
(3) of the muffler (4).
(1) muffler clamp (3) cut-out
(2) tab (4) muffler
2. Remove the old gasket.
3. Install the new gasket (5).
(5) gasket
4. Install the muffler.5. Tighten the muffler A bolt (6) and muffler B
bolt/washer (7) to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
6. Tighten the muffler clamp bolt (8) to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
(4) muffler (7) muffler B bolt/washer
(6) muffler A bolt (8) muffler clamp bolt(9) right side cover (11) side cover bolt
(10) collars (12) seat bolt
(3)
(4)(1)
(2)
(5)
(4)(6)
(8)
(7)
(10)
(12)
(9)
(11)
(10)
7. Install the right side cover (9), collar (10) and
side cover bolt (11).
8. Install the collar (10) and seat bolt (12) and
tighten the bolt to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m) 
						

							88Servicing Your Honda
Exhaust Pipe/Muffler
Exhaust Pipe Installation
1.  Install a new exhaust pipe gasket (1), exhaust
pipe (2) and exhaust pipe joint nuts (3) and
tighten to the specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
(1) exhaust pipe gasket
(2) exhaust pipe
(3) exhaust pipe joint nuts 
2. Install the muffler (page 87).
Exhaust Pipe Removal
1.  Remove the muffler (page 86).
2.  Remove the exhaust pipe joint nuts (1),
exhaust pipe (2) and exhaust pipe gasket (3).
(1) exhaust pipe joint nuts
(2) exhaust pipe
(3) exhaust pipe gasket
(2)
(1)
(3)
(1)(2)
(3) 
						

							Servicing Your Honda89
Additional Maintenance Procedures
Refer toSafety Precautionson page 19.
Steering Head Bearings Inspection
1. With your CRF on a box or workstand (front
wheel elevated), turn the handlebar to the
right and left to check for roughness in the
steering head bearings.
2. Stand in front of your CRF, grab the fork (at
the axle), look at the steering head, and push
the fork in and out (toward the engine) to
check for play in the steering head bearings.
If any roughness or play is felt, but you do
not see any movement in the steering head,
the fork bushings may be worn.  Refer to the
Honda Service Manual for replacement or
adjustment procedures, or see your Honda
dealer.
Handlebar Inspection
1. Remove the handlebar pad.
2. Check the handlebar (1) for bends or cracks.
3. Check that the handlebar has not moved from
its proper position (by inspecting the punch
mark).
4. Tighten the front bolts first.
5. Check the torque of the upper holder (2) bolts:
16 lbf·ft (22 N·m, 2.2 kgf·m)
(1) handlebar             (2) handlebar upper holders
Control Cables
Periodically, disconnect the throttle, clutch and
hot start cables at their upper ends.  Thoroughly
lubricate the cable pivot points with a
commercially-available cable lubricant.  Be
certain that the throttle cables have no kinks or
other damage.
(2)
(1) 
						

							90Servicing Your Honda
Additional Maintenance Procedures
Nuts, Bolts, Fasteners
Check and tighten nuts, bolts, and fasteners
before every outing.
Item 
1
2
3
4
5
6
7
8
9
10ENGINE
Cylinder head cover
Exhaust pipe joint nut
Water pump cover
Crankshaft hole cap
Transmission oil check 
bolt
Clutch cover
Cylinder bolt
Oil filter cover
Cylinder head bolt
Drive sprocket
Torque
lbf
•ft N
•m kgf
•m
7
15
7
11
7
7
7
9
7
2310
21
10
15
10
10
10
12
10
311.0
2.1
1.0
1.5
1.0
1.0
1.0
1.2
1.0
3.2
(1) cylinder head cover
(2) exhaust pipe joint nuts
(3) water pump cover
(4) crankshaft hole cap
(5) transmission oil check bolt
(6) clutch cover(7) cylinder bolts
(8) oil filter cover
(9) cylinder head bolt
(10) drive sproket
(6)
(1)
(2)
(3)
(5)(4)
(9)
(7)
(8)
(10)
RIGHT SIDELEFT SIDE 
						

							Servicing Your Honda91
Appearance Care
Refer to Safety Precautionson page 19.
Frequent cleaning and polishing will keep your
Honda looking newer longer.  Frequent cleaning
also identifies you as an owner who values his
motorcycle.  A clean CRF is also easier to inspect
and service.
While you’re cleaning, be sure to look for 
damage, wear, and gasoline or oil leaks.
General Recommendations
•To clean your CRF you may use:
– water
– a mild, neutral detergent and water
– a mild spray and wipe cleaner/polisher
– a mild spray and rinse cleaner/degreaser and
water
•Avoid products that contain harsh detergents
or chemical solvents that could damage the
metal, paint, and plastic on your CRF or 
discolor the seat and decals.
•If your CRF is still warm from recent
operation, give the engine and exhaust system
time to cool off.
•We recommend the use of a garden hose to
wash your CRF.  High pressure washers, (like
those at coin-operated car washes) can
damage certain parts of your CRF.  The force
of water under extreme pressure can penetrate
the dust seals of the suspension pivot points
and steering head bearings-driving dirt inside
and needed lubrication out.  If you use a high pressure washer, avoid spraying
the following areas:
wheel hubs
muffler outlet
under seat
engine stop button
brake master cylinders
under fuel tank
drive chain
carburetor
steering head bearings
suspension pivot points
(1) steering head bearings
(2) suspension pivot points
High pressure water (or air) can damage 
certain parts of your CRF.
You may use Pro Honda Hondabrite, a 
multi-surface cleaner/degreaser, to remove both
dirt and petroleum-based grime from paint, alloy,
plastic, and rubber surfaces.  Wet any heavy
deposits with water first.  Then spray on the
Hondabrite and rinse with a garden hose at full
pressure.  Stubborn deposits may require a quick
wipe with a sponge.
NOTICE
Washing Your Motorcycle with a Mild
Detergent
1. Rinse your CRF thoroughly with cool water to
remove loose dirt.
2. Fill a bucket with cool water.  Mix in a mild,
neutral detergent, such as dish washing 
liquid or a product made especially for 
washing motorcycles or automobiles.
3. Wash your CRF with a sponge or a 
soft towel.  As you wash, check for heavy
grime.  If necessary, use a mild
cleaner/degreaser to remove the grime.
Do not use steel wool to clean the frame as it
could damage or discolor the frame surface.
Muffler stain remover is for removing stains on
the non-coated aluminum frame only.
4. After washing, rinse your CRF thoroughly
with plenty of clean water to remove any
residue.
5. Dry your CRF with a chamois or a 
soft towel.
6. Lubricate the drive chain to prevent rusting.
7. Start the engine and let it idle for several 
minutes.  The engine heat will help dry moist
areas.
8. As a precaution, ride at a slow speed and
apply the brakes several times.  This will help
dry the brakes and restore normal braking
performance.
(2)
(1) 
						

							92Servicing Your Honda
Appearance Care
Condensation Control
Some condensation can form within the
transmission cavity as well.  This is natural and
just one more reason you should change the
engine and transmission oil often.
After Cleaning Lubrication
There are some things you should do just after
washing your CRF to help prevent rust and
corrosion.
Once your CRF is clean and dry, you should
protect any bare steel from rusting by applying a
light coating of a rust-inhibitor.  Lubricate the
drive chain and drive sprocket after removing
and thoroughly cleaning in solvent.  Be sure the
chain is wiped clean and is dry before applying
the chain lube.
Follow the suggestions given in the pages of this
manual for lubricating items such as the brake
and clutch lever pivot points and footpeg pivot
pins.
Aluminum Frame Maintenance
Aluminum corrodes when it comes in contact
with dust, mud and road salt.
To remove stains, use Scotch Brite Hand Pad
#7447 (maroon) or an equivalent.
Wet the pad and polish the surface using strokes
parallel to the length of the frame.
Clean the frame using a wet sponge and a mild
detergent, then rinse well with clean water. Dry
the frame with a soft clean cloth, using strokes
parallel to the length of the frame.
Do not use steel wool to clean the frame as it
could damage or discolor the frame surface.
Muffler stain remover (Scotch Brite Hand Pad
#7447-maroon) is for removing stains on the
non-coated aluminum frame only.
NOTICE
Exhaust Pipe Maintenance
The exhaust pipe is stainless steel, but may
became stained by oil or mud.
Remove heat stains with a liquid kitchen
abrasive. 
						

							This section tells you how to fine tune your CRF
for maximum competition performance.
Initial suspension adjustments should be
performed after a minimum of two hours of easy
break-in time.
Optional front and rear suspension springs are
available in both firmer and softer than standard
rates, in order to tailor your CRF specifically for
your weight, riding style and course conditions.
Follow the instructions given in the rear
suspension sag setting section of Rear
Suspension Adjustmentsto determine if your
combined rider and sprung machine weight (rider
fully dressed for competition and machine
coolant, oil and fuel levels ready for competition)
requires an optional firmer or softer rear spring.
The need for either optional rear spring may need
to be balanced by installing the optional fork
springs of a similar rate.Front Suspension Adjustments ...........................94 
Rear Suspension Adjustments ..........................107
Suspension Adjustments  for Track 
Conditions ...................................................111
Suspension Adjustment  Guidelines ..................112
Carburetor Adjustments & Tuning Tips ...........115
Chassis Adjustments.........................................127
Gearing .............................................................128
Tire Selection for Track Conditions .................129
Personal Fit Adjustments .................................130
Adjustments for Competition93
Adjustments for Competition 
						

							94Adjustments for Competition
Front Suspension Adjustments
The front suspension can be adjusted for the
rider’s weight and riding conditions by using one
or more of the following methods:
•Oil volume— The effects of higher or lower
fork oil level are only felt during the final 3.9
in (100 mm) of fork travel.
•Compression damping— Turning the
compression damping screw adjusts how
quickly the fork compresses.
•Rebound damping— Turning the rebound
damping screw adjusts how quickly the fork
extends.
•Fork springs— Optional springs are
available in softer and stiffer types than the
standard rate. (page 147)
The inverted fork on your CRF features sealed
damper cartridges with dual (separate air and oil)
chambers to prevent aeration. The design also
isolates the oil in each fork tube/slider, which
may contain air bubbles and/or metal particles,
from the sealed cartridge to provide more
consistent damping. 
(1) compression damping adjuster
(2) rebound damping adjuster
(1)
(2)
Front Suspension Air Pressure
Air is an unstable gas which builds up pressure
as it is worked (such as in a fork).  Air pressure
acts as a progressive spring and affects the entire
range of fork travel.  This means the fork action
on your CRF will get stiffer during a race.  For
this reason, release built-up air pressure in the
fork legs between motos.  Be sure the fork is
fully extended with the front tire off the ground
when you release the pressure.
The standard air pressure is 0 psi (0 kPa, 0
kgf/cm
2).  You may relieve accumulated air
pressure in the fork legs by using the pressure
release screws.  The front wheel should be off the
ground before you release the pressure.The air
pressure should be adjusted according to the
altitude and outside temperature.
1. Place an optional workstand under the engine,
so that the front wheel is off the ground.
Do not adjust air pressure with the front wheel
on the ground as this will give false pressure
readings.
2. Remove the pressure release screw (1).
3. Check that the O-ring (2) is in good condition.
4. Install the pressure release screw to the
specified torque:
0.9 lbf·ft (1.2 N·m, 0.12 kgf·m)
(1) pressure release screws      (2) O-ring
(2)(1)
Front Suspension Damping
Rebound Damping Adjustment
The fork rebound damping adjuster screw (1) has
16 positions or more. Turning the adjuster screw
one full turn clockwise advances the adjuster four
positions. To adjust the rebound damping to the
standard setting, proceed as follows: 
Turn the adjuster clockwise until it will no longer
turn (lightly seats). This is the full hard position. 
The adjuster is set in the standard position when
the adjuster is turned counterclockwise 8 clicks. 
Make sure that both fork legs are adjusted to the
same position. 
Compression Damping 
Adjustment
This adjustment affects how quickly the fork
compresses. The fork compression damping
adjuster screw (2) has 16 positions or more.
Turning the adjuster screw one full turn changes
the adjuster four positions. To adjust the adjuster
to the standard position, proceed as follows: 
Turn the adjuster clockwise until it will no longer
turn (lightly seats). This is the full hard position.
The adjuster is set in the standard position when
the adjuster is turned counterclockwise 10 clicks.
Make sure that both fork legs are adjusted to the
same position.  
						

							Adjustments for Competition95
Front Suspension Adjustments
Both compression and rebound damping can be
increased by turning the adjuster clockwise. 
Always start with full hard when adjusting
damping. 
Do not turn the adjuster screw more than the
given positions or the adjuster may be damaged. 
Be sure that the rebound and compression
adjusters are firmly located in a detent, and not
between positions. 
NOTICE
Front Suspension Disassembly
• If your CRF is brand-new, put enough part-
throttle break-in time (about one hour) on it to
ensure that the suspension has worked in.
• For optimum performance, and extended fork
life, the fork should be completely
disassembled and cleaned after the first three
hours of riding.  See the Service Manual or
your authorized Honda dealer for this service.
1. Place your CRF on the optional workstand or
equivalent support with the front wheel off the
ground.
2. Remove the number plate bolt (1) and number
plate (2).
Fork Springs
The fork springs in CRF’s are about right for
riders weighing between 150 and 160 lbs (less
riding gear). So if youre a heavier rider, you
have to go up on the oil level or get a stiffer
spring. Do not use less oil than the minimum
specified for each spring or there will be a loss of
rebound damping control near full extension. If
the fork is too hard on big bumps, turn the
damping adjuster counterclockwise 1-turn and
lower the oil level in increments of 0.2 oz (5 cc)
in both fork legs until the desired performance is
obtained. Do not, however, lower the oil level
below the minimum oil level. 
Minimum oil capacity:
Standard spring:10.9 US oz (321 cm
3)
Softer spring:10.8 US oz (318 cm3) 
Stiffer spring:11.0 US oz (324 cm3)
When adjusting oil levels, bear in mind that the
air in the fork will increase in pressure while
riding; therefore, the higher the oil level, the
higher the eventual pressure of any air in the
fork.
(1) rebound damping (2) compression
adjuster screw damping
adjuster screw
(1)
(2)
Force (N)
Stroke (mm)
Oil capacity 14.1 US oz (417 cm3)
(MAX)
Oil capacity 12.5 US oz (371 cm
3)
(STANDARD)
Oil capacity 10.9 US oz (321 cm
3)
(MIN)
(2)(1)
(1) number plate bolt
(2) number plate
(cont’d) 
						

							Front Suspension Adjustments
96Adjustments for Competition
3. Remove the handlebar pad.
Remove the washers/handlebar holder nuts (3),
mounting rubbers and handlebar (4).
Keep the master cylinder upright to prevent air
from entering system.
NOTICE
(4)(3)
(3) washers/houndlebar holder nuts
(4) handlebar
4. Loosen the upper pinch bolts (5). 
5. Loosen the fork damper (6), but do not
remove them yet.
Do not use an adjustable wrench to loosen the
fork damper: it may damage them.
Loosen the upper pinch bolts before loosening
the fork damper to avoid damaging the fork cap. 
NOTICE
(5) upper pinch bolts  (6) fork damper
6. Remove the disc cover (7) by removing the
disc cover bolts (8). 
(7) disc cover  (8) disc cover bolts 
7. Remove the front axle nut (9) and loosen the
front axle pinch bolts (10) on both forks. 
Pull the front axle shaft (11) out of the wheel
hub and remove the front wheel. 
(9) axle nut (11) front axle shaft 
(10) axle pinch bolts
8. Remove the fork protector (12) and brake
caliper (13). 
Do not support the brake caliper by the brake
hose. Do not operate the brake lever after the
front wheel is removed. To do so will cause
difficulty in fitting the brake disc between the
brake pads.
NOTICE
(12) fork protector  (13) brake caliper
9. Loosen the fork leg lower pinch bolts (14),
then pull the fork legs down and out.  
(14) lower pinch bolts
(6)(5)
(7)
(8)
(11)
(10)(10)
(9)
(12)
(13)
(14)