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2004 CRF250X
Service manual
Honda 2004 CRF250X Service Manual
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Also See for 2004 CRF250X
:
Parts catalog
(118 pages)
,
Owner's manual
(119 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
A few Words about Safety
Important Safety Precautions
Contents
Symbols
General Information
Service Rules
Model Identification
General Specifications
Lubrication System Specifications
Fuel System Specifications
Cooling System Specifications
Cylinder/Piston Specifications
Cylinder Head/Valves Specifications
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications
Crankcase/Crankshaft/Transmission/Balancer Specifications
Front Wheel/Suspension/Steering Specifications
Rear Wheel/Suspension Specifications
Hydraulic Brake Specifications
Battery/Charging System Specifications
Ignition System Specifications
Electric Starter Specification
Lights/Meter/Switches Specifications
Standard Torque Values
Engine & Frame Torque Values
Lubrication & Seal Points
Cable & Harness Routing
Secondary Air Supply System
Optional Parts
Emission Control Systems
Source of Emissions
Exhaust Emission Control System
Crankcase Emission Control System
Servicing the Honda
Noise Emission Control System
Rebuilt Engine
Table of Contents
Frame/Body Panels/Exhaust System
Torque Values
Service Information
Troubleshooting
Seat Installation
Seat Removal
Side Cover Removal/Installation
Engine Guard Removal/Installation
Radiator Shroud Removal/Installation
Front Visor Removal/Installation
Sub-Frame Removal
Sub-Frame Installation
Fuel Tank Removal/Installation
Exhaust System Muffler Removal/Installation
Maintenance
Maintenance Service Information
Maintenance Specifications
Tools
Maintenance Schedule ('04 - '06)
Competition Maintenance Schedule
Additional Items Requiring Frequent Replacement
Fuel Line
Fuel Strainer Screen
Throttle Operation
Hot Start
Air Cleaner
Crankcase Breather
Spark Plug Removal
Spark Plug Inspection
Spark Plug Installation
Cooling System
Radiator Coolant
('04 - '06 California Type, after '06)
Secondary Air Supply System
Valve Clearance/Decompressor System
Decompressor System
Engine Oil & Filter Change
Engine Oil/Oil Filter
Oil Level Inspection
Engine Idle Speed
Transmission Oil
Transmission Oil Change
Drive Chain Adjustment
Drive Chain Cleaning and Lubrication
Drive Chain Slack Inspection
Drive Chain Replacement
Drive Chain Slider
Drive Chain Roller
Drive/Driven Sprocket
Brake Fluid Filling
Brake Fluid Level Inspection
Brake Pad Wear
Brake System
Lever Position Inspection
Brake Pedal Height
Clutch System
Headlight Aim
Control Cables
Exhaust Pipe/Muffler
Exhaust System Inspection
Spark Arrester Inspection/Cleaning
Spark Arrester Removal/Installation
Front Suspension Inspection
Side Stand Inspection
Rear Suspension Inspection
Swingarm/Shock Linkage
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System Torque Values
Lubrication System Troubleshooting
Oil Strainer Installation
Oil Strainer Removal/Inspection
Pressure Relief Valve Removal/Installation
Pressure Relief Vavle Inspection
Oil Jet Installation
Oil Jet Removal/Inspection
Oil Pump Disassembly
Oil Pump Inspection
Oil Pump Assembly
Fuel System
Fuel System Component Location
Fuel System Service Information
Fuel System Tool
Fuel System Torque Values
Engine will Not Start
Fuel System Troubleshooting
Lean Mixture
Misfiring During Acceleration
Carburetor Adjustment
Idle Mixture and Idle Speed
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Carburetor Removal
Carburettor Disassembly
Jet Needle/Throttle Valve
Choke Knob/Throttle Position Sensor
Accelerator Pump/Float/Jet
Carburetor Assembly
Carburetor Installation
Throttle Position Sensor Replacement
Best Idle
Pilot Screw Adjustment
Idle Drop Procedure
HIGH ALTITUDE ADJUSTMENT (California Type Only)
Pair Control Valve Removal/Installation
Secondary Air Supply System Inspection
Air Supply Pipe Removal/Installation
Pair Check Valve Inspection
Cooling System Flow Pattern
Cooling System Service Information
Cooling System Torque Values
Coolant Leak
Cooling System Tools
Cooling System Troubleshooting
Engine Temperature too High
Coolant (Hydrometer Test)
Coolant Gravity Chart
Cooling System Testing
Coolant Replacement Preparation
Radiator Cap Relief Pressure
Radiator Cap/System Pressure Inspection
Recommended Antifreeze
Replacement/Air Bleeding
Radiator Removal
Radiator Installation
Radiator Reserve Tank Removal/Installation
Water Pump
Water Pump Removal
Water Seal Inspection
Water Pump Bearing/Water Seal/Oil Seal Replacement
Water Pump Installation
Engine Removal/Installation
Engine Removal/Installation Component Location
Drive Sprocket Installation
Drive Sprocket Removal
Engine Removal
Engine Installation
Cylinder Head/Valves
Cylinder Head/Valves Component Location
('04 - '06 California Type, after '06)
Cylinder Head/Valves Service Information
Cylinder Head/Valves Torque Values
Cylinder Head/Valves Tools
Compression too High
Compression too Low, Hard Starting or Poor Performance at Low Speed
Cylinder Head/Valves Troubleshooting
Excessive Noise
Cylinder Compression Test
Cylinder Head Cover Removal
Camshaft/Rocker Arm Removal
Cylinder Head Removal
Cam Chain Tensioner/Cam Chain Guide Inspection
Cam Chain Tensioner/Cam Chain Guide Removal
Cam Chain Tensioner/Cam Chain Guide Installation
Cylinder Head Disassembly
Cylinder Head Inspection
Valve/Valve Guide
Valve Guide Replacement
Valve Seat Inspection/Refacing
Valve Seat Refacing
Exhaust Side
Intake Side
Cylinder Head Assembly
Cylinder Head Installation
Camshaft/Rocker Arm Installation
Cylinder Head Cover Installation
Cylinder/Piston
Cylinder/Piston Component Location
Cylinder/Piston Service Information
Cylinder/Piston Troubleshooting
Cylinder Removal
Piston Removal
Cylinder/Piston Inspection
Piston/Piston Ring Inspection
Cam Chain Tensioner Lifter Inspection
Connecting Rod Inspection
Piston Ring Installation
Cylinder Installation
Piston Installation
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage
COMPONENT LOCA Non
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Tools
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Torque Values
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Troubleshooting
Right Crankcase Cover Removal
Right Crankcase Cover Installation
Clutch Removal
Clutch Discs
Clutch Inspection
Clutch Spring
Clutch Center
Clutch Lifter/Needle Bearing
Clutch Plates
Friction Spring/Spring Seat
Clutch Lifter Lever
Clutch Lifter Rod
Clutch Outer
Needle Bearing/Clutch Outer Guide
Kickstarter Removal
Kickstarter Disassembly/Inspection
Kickstarter Assembly
Kickstarter Installation
Right Crankcase Cover
Starter Clutch Removal
Starter Clutch Disassembly/Inspection
Starter Clutch Assembly
Starter Clutch Installation
Gearshift Linkage Removal
Gearshift Linkage Inspection
Gearshift Linkage Installation
Gearshift Spindle
Ratchet Pawl
Alternator
Alternator Component Location
Alternator Service Information
Alternator Tools
Alternator Torque Values
Left Crankcase Cover Removal
Flywheel Removal
Stator Installation
Stator Removal
Left Crankcase Cover Installation
Crankcase/Crankshaft/Transmission/Balancer
Crankcase/Crankshaft/Transmission/Balancer Component Location
Crankcase/Crankshaft/Transmission/Balancer Service Information
Crankcase/Crankshaft/Transmission/Balancer Tools
Crankcase/Crankshaft/Transmission/Balancer Torque Value
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
Balancer Gear/Balancer Inspection
Balancer Gear/Balancer Installation
Balancer Gear/Balancer Removal
Crankcase Separation
Transmission Disassembly
Bushing
Gear
Mainshaft/Countershaft
Transmission Inspection
Shift Drum
Shift Fork
Shift Fork Shaft
Transmission Bearing
Crankshaft Inspection
Crankshaft Removal
Crankcase Bearing Replacement
Crankcase Bearing/Oil Seal Location
Crankshaft Bearing
Left Crankcase
Transmission/Balancer/Shift Drum Bearings
Crankshaft Installation
Countershaft
Mainshaft
Transmission Assembly
Crankcase Assembly
Front Wheel/Suspension/Steering
Front Wheel/Suspension/Steering Component Location
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Tools
Front Wheel/Suspension/Steering Torque Values
Front Wheel/Suspension/Steering Troubleshooting
Front Wheel Inspection
Front Wheel Removal
Front Wheel Disassembly
Wheel Bearing
Wheel Rim
Front Wheel Assembly
Front Wheel Installation
Fork Removal
Fork Disassembly
Outer Tube and Slider Disassembly
Fork Damper Disassembly
Fork Cap
Fork Centre Bolt
Fork Damper Inspection
Slider/Outer Tube
Bushing/Back-Up Ring
Fork Damper
Fork Spring
Outer Tube and Slider Assembly
Fork Damper Refilling/Assembly
Fork Damper Operation Inspection
Fork Damper Installation/Preparation
Fork Damper Installation
Oil Capacity Adjustment
Standard Oil Capacity
Standard Position
Handlebar Removal
Handlebar Installation
Steering Stem Removal
Steering Stem Bearing Replacement
Steering Stem Installation
Rear Wheel/Suspension
Rear Wheel/Suspension Component Location
Rear Wheel/Suspension Service Information
Rear Wheel/Suspension Tools
Rear Wheel/Suspension Torque Values
Rear Wheel/Suspension Troubleshooting
Rear Wheel Inspection
Rear Wheel Removal
Rear Wheel Disassembly
Wheel Rim Runout
Rear Wheel Assembly
Rear Wheel Installation
Shock Absorber Removal
Shock Absorber Bladder Replacement
Shock Absorber Disassembly
Damper Disassembly
Recommended Shock Oil
Damper Rod Disassembly
Piston Ring Replacement
Damper Rod Inspection
Rod Guide Case Inspection
Damper Assembly
Spherical Bearing Replacement
Shock Linkage Removal
Bearing Replacement
Shock Arm Needle Bearing
Shock Linkage Inspection
Shock Link Needle Bearing
Swingarm Removal
Swingarm Disassembly
Swingarm Assembly
Swingarm Bearing Replacement
Swingarm Installation
Hydraulic Brake
Hydraulic Brake Component Location
Hydraulic Brake Service Information
Hydraulic Brake Tool
Hydraulic Brake Torque Values
Brake Drags
Brake Lever/Pedal Hard
Brake Lever/Pedal Soft or Spongy
Hydraulic Brake Troubleshooting
Brake Fluid Draining
Brake Fluid Replacement/Air Bleeding
Brake Fluid Filling/Air Bleeding
Brake Pad Replacement
Brake Pad/Disc
Front Master Cylinder Disassembly
Front Master Cylinder Removal
Rear Master Cylinder Disassembly
Rear Master Cylinder Removal
Rear Master Cylinder Assembly
Rear Master Cylinder Inspection
Rear Master Cylinder Installation
Front Brake Caliper Disassembly
Front Brake Caliper Removal
Front Brake Caliper Assembly
Front Brake Caliper Inspection
Front Brake Caliper Installation
Rear Brake Caliper Removal
Battery/Charging System
Battery/Charging System Component Location
Battery/Charging System System Diagram
Battery Charging
Battery Testing
Battery/Charging System Service Information
Battery/Charging System Tools
Battery/Charging System Troubleshooting
Battery Removal/Installation
Battery Voltage Inspection
Charging System Inspection
Current Leakage Inspection
Charging Voltage Inspection
Regulator/Rectifier Removal/Installation
Regulator/Rectifier System Inspection
Alternator Charging Coil Inspection
Ignition System
Ignition System Component Location
Ignition System Diagram
Ignition System Service Information
Ignition System Specification
Ignition System Tools
Ignition System Torque Values
Ignition System Troubleshooting
Ignition Coil Primary Peak Voltage
Ignition System Inspection
Direct Ignition Coil Inspection
Exciter Coil Peak Voltage
Ignition Pulse Generator Peak Voltage
Ignition Control Module (ICM) Removal/Installation
Ignition Timing
Throttle Position Sensor Inspection
Electric Starter
Electric Starter Component Location
Electric Starter System Diagram
Electric Starter Service Information
Electric Starter Troubleshooting
Starter Disassembly/Inspection
Starter Motor Removal
Starter Motor Assembly
Starter Motor Installation
Starter Relay Switch Ground Line
Starter Relay Switch Operation Inspection
Starter Relay Switch Function Inspection
Starter Relay Switch Power Input Line
Lights/Meter/Switches
Lights/Meter/Switches Component Location
Lights/Meter/Switches Service Information
Lights/Meter/Switches Torque Values
Headlight Bulb Replacement
Headlight Removal/Installation
Tail Light Inspection
Engine Stop Button
Tail Light Removal/Installation
Clutch Switch Inspection
Starter Switch
Tripmeter Removal/Installation
Main Relay Inspection
Wiring Diagram
Engine Does Not Start or Is Hard to Start
Engine Lacks Power
Poor Performance at Low and Idle Speed
Poor Performance at High Speed
Poor Handling
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Owner's Manual
Table of
Contents
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Table of Contents
Troubleshooting
Service information
42
Lubrication System Service information
89
Fuel System Troubleshooting
101
Cooling System Tools
134
Cylinder Head/Valves Troubleshooting
159
Cylinder/Piston Service information
189
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage troubleshooting
200
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
237
Front Wheel/Suspension/Steering Troubleshooting
260
Rear Wheel/Suspension Troubleshooting
302
Hydraulic Brake Troubleshooting
343
Battery/Charging System Troubleshooting
369
Ignition System Troubleshooting
376
Electric Starter Troubleshooting
386
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