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2010 CRF250R
Service manual
Honda 2010 CRF250R Service Manual
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Table Of Contents
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447
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
A few Words about Safety
Service Information
Important Safety Precautions
Symbols
Contents
Table of Contents
General Information
Service Rules
Abbreviation
Serial Numbers
Model Identification
Label
General Specifications
Lubrication System Specifications
Fuel System (Pgm -Fi) Specifications
Cooling System Specifications
Cylinder Head/Valves Specifications
Cylinder/Piston Specifications
Crankcase/Crankshaft/Transmission/Balancer Specifications
Steering Specifications
Rear Wheel/Suspension Specifications
Hydraulic Brake Specifications
Electrical System Specifications
Torque Values
Lubrication & Seal Points
Cable & Harness Routing
Frame/Body Panels/Exhaust System
Frame/Body Panels/Exhaust System Service Information
Frame/Body Panels/Exhaust System Torque Values
Frame/Body Panels/Exhaust System Troubleshooting
Seat Removal/Installation
Side Cover Removal/Installation
Engine Guard Removal/Installation
Radiator Shroud Removal/Installation
Front Fender Removal/Installation
Number Plate Removal/Installation
Rear Fender Removal/Installation
Sub-Frame Removal
Sub-Frame Installation
Exhaust System
Muffler Removal/Installation
Glass Wool Replacement
Exhaust Pipe Removal
Exhaust Pipe Disassembly/Assembly
Exhaust Pipe Installation
Cylinder Head Exhaust Pipe Stud Bolt Replacement
Maintenance
Maintenance Service Information
Maintenance Specifications
Maintenance Tools
Maintenance Torque Values
Maintenance Schedule
Additional Items Requiring Frequent Replacement
Fuel Line
Fuel Tank Hanging
Fuel Tank Inspection
Throttle Operation
Air Cleaner
Crankcase Breather
Spark Plug Inspection
Spark Plug Removal
Radiator Coolant
Valve Clearance Inspection
Engine Oil/Oil Filter
Exhaust Side
Oil Level Inspection
Recommended Engine Oil
Engine Oil & Filter Change
Engine Oil Capacity
Engine Idle Speed
Transmission Oil Level Inspection
Cooling System
Transmission Oil Change
Drive Chain Cleaning and Lubrication
Drive Chain Slack Inspection
Drive Chain Roller (,10, '11)
Drive Chain Slider
DRIVE CHAIN ROLLER (after '11)
Drive/Driven Sprocket
Brake Fluid Level Inspection
Brake Pads Wear
Fluid Filling
Brake Lever Position
Brake Pedal Height
Brake System
Clutch System
Clutch Lever Freeplay
Control Cables
Exhaust Pipe/Muffler
Exhaust System Inspection
Front Suspension Inspection
Rear Suspension Inspection
Nuts, Bolts, Fasteners
Swingarm/Shock Linkage
Wheels/Tires
Steering Head Bearings
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System Troubleshooting
Oil Strainer Screen Installation
Oil Strainer Screen Removal/Inspection
Oil Pump Disassembly
Pressure Relief Valve Installation
Pressure Relief Valve Removal/Inspection
Oil Pump Inspection
Oil Pump Assembly
Fuel System (PGM-FI)
COMPONENT Locatlon
Fuel System (PGM-FI) Component Location
Fuel System (PGM-FI) Service Information
Fuel System (PGM-FI) Torque Values
Fuel System (PGM-FI) Tools
Fuel System (PGM-FI) Symptom Troubleshooting
PGM-FI System Location
Pgm-Fi System Diagram ('10 - ·12)
PGM-FI SYSTEM DIAGRAM (after '12)
Fuel System (PGM-FI) Connector Location
Opens and Shorts
Fail-Safe Function
Intermittent Failure
Pgm -Fi Troubleshooting Information
Battery Harness Connecting/Operation
MIL Blink Pattern
Current Dtc/Freeze DTC
HDS Pocket Testing Information
DTC Readout
Erasing DTC
Reading DTC with the MIL
Circuit Inspection
Inspection at ECM Connector
DTC Index
DTC Troubleshooting
DTC 1-1 (Map Sensor Low Voltage)
DTC 1-2 (Map Sensor High Voltage)
DTC 2-1 (Map Sensor)
DTC 7-1 (ECT Sensor Low Voltage)
DTC 7-2 (ECT Sensor High Voltage)
DTC 8-1 (TP Sensor Low Voltage)
DTC 8-2 (TP Sensor High Voltage)
DTC 9-1 (IAT Sensor Low Voltage)
DTC 9-2 (IAT Sensor High Voltage)
DTC 12-1 (Injector)
DTC 19-1 (No. 1 CKP Sensor)
MIL Circuit Inspection
Dtc 33-2 (Eeprom)
When the Engine Starts but the MIL Does Not Come on
When the Engine Starts but the MIL Does Not Go off Within a few Seconds
Fuel Line Replacement
Fuel Pressure Relieving
Fuel Pump Side
Quick Connect Fitting Removal
Injector Side
Quick Connect Fitting Installation
Fuel Pressure Increasing
Fuel Pressure Test
Fuel Flow Inspection
Fuel Pump Unit Inspection
Fuel Tank Removal/Installation
Air Cleaner Housing Removal
Air Cleaner Inspection/Installation
Air Cleaner Disassembly/Assembly
Injector Removal
Injector Installation
Throttle Body Removal
Throttle Body Disassembly/Assembly
Throttle Body Installation
Fast Idle Knob Inspection
Fast Idle Knob Removal
Fast Idle Knob Installation
Map Sensor Output Voltage Inspection
Map Sensor Removal/Installation
IAT Sensor Removal/Installation
ECT Sensor Inspection
ECT Sensor Installation
ECT Sensor Removal
ECM Power/Ground Line Inspection
ECM Removal/Installation
Engine Does Not Start (Mil Does Not Blink)
Cooling System Flow Pattern
Cooling System Service Information
Cooling System Tools
Cooling System Torque Values
Coolant Leak
Cooling System Troubleshooting
Engine Temperature too High
Coolant (Hydrometer Test)
Coolant Gravity Chart
Cooling System Testing
Coolant Replacement
Radiator Cap/System Pressure Inspection
Recommended Antifreeze
Recommended Mixture
Radiator Removal
Replacement/Air Bleeding
Radiator Installation
Water Pump Mechanical Seal Inspection
Water Pump Removal
Water Pump Bearing/Mechanical Seal/Oil Seal Replacement
Engine Removal/Installation
Engine Removal/Installation Component Location
Engine Removal/Installation Service Information
Engine Removal/Installation Torque Values
Engine Removal
Engine Installation
Cylinder Head/Valves
Troubleshooting
Cylinder Head/Valves Component Location
Cylinder Head/Valves Service Information
Cylinder Head/Valves Torque Values
Cylinder Head/Valves Tools
Cylinder Head/Valves Troubleshooting
Cylinder Compression Test
Cylinder Head Cover Removal
Cylinder Head Cover Disassembly/Assembly
Cylinder Head Cover Installation
Camshaft/Rocker Arm Removal
Rocker Arm Inspection
Rocker Arm Shaft
Camshaft Holders
Decompressor System
Decompressor System Assembly
Decompressor System Disassembly
Decompressor System Inspection/Cleaning
Valve Clearance Adjustment
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Lifter
Valve Spring
Valve/Valve Guide
Valve Guide Replacement
Valve Seat Inspection/Refacing
Valve Seat Refacing
Cylinder Head Assembly
Cylinder Head Installation
Camshaft/Rocker Arm Installation
Cam Chain Tensioner
Cam Chain Tensioner Lifter
Cam Chain Tensioner Lifter Inspection
Cam Chain Tensioner Lifter Installation
Cam Chain Tensioner/Cam Chain Guide Inspection
Cam Chain Tensioner/Cam Chain Guide Installation
Cam Chain Tensioner/Cam Chain Guide Removal
Cylinder/Piston
Cylinder/Piston Component Location
Cylinder/Piston Service Information
Cylinder/Piston Troubleshooting
Cylinder Removal
Piston Removal
Cylinder/Piston Inspection
Piston/Piston Pin/Piston Ring
Connecting Rod
Piston Installation
Cylinder Installation
Clutch/Kickstarter/Gearshift Linkage
Clutch/Kickstarter/Gearshift Linkage Component Location
Clutch/Kickstarter/Gearshift Linkage Service Information
Clutch/Kickstarter/Gearshift Linkage Specifications
Clutch/Kickstarter/Gearshift Linkage Tools
Clutch/Kickstarter/Gearshift Linkage Torque Values
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
Right Crankcase Cover Removal
Right Crankcase Cover Installation
Clutch Removal
Clutch Discs
Clutch Inspection
Clutch Plates
Clutch Springs
Clutch Lifter Rod
Clutch Lifter/Needle Bearing
Clutch Outer
Judder Spring/Spring Seat
Clutch Lifter Lever
Clutch Outer Guide
Lifter Lever Bearing Replacement
Needle Bearing
Clutch Installation
Kickstarter Disassembly
Kickstarter Inspection
Kickstarter Removal
Kickstarter Assembly
Kickstarter Installation
Gearshift Linkage Removal
Gearshift Linkage Inspection
Gearshift Spindle
Ratchet Pawl
Gearshift Linkage Installation
Alternator
Alternator Component Location
Alternator Service Information
Alternator Tools
Alternator Torque Values
Left Crankcase Cover Removal
Flywheel Installation
Flywheel Removal
Stator/Ckp Sensor Removal
Stator/Ckp Sensor Installation
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 Values
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
Excessive Noise
Hard to Shift
Transmission Jumps out of Gear
Primary Drive Gear/Balancer Drive Gear Installation
Primary Drive Gear/Balancer Drive Gear Removal
Right Crankcase Cover
Balancer Driven Gear/Balancer Shaft Installation
Balancer Driven Gear/Balancer Shaft Removal
Balancer Bearing Replacement
Right Balancer Bearing
Left Balancer Needle Bearing
Crankcase Separation
Crankcase Assembly
Transmission Disassembly
Gear Inspection
Oil Pump Shaft Needle Bearing
Transmission Inspection
Mainshaft/Countershaft
Shift Fork
Shift Fork Shaft
Gearshift Drum
Transmission Assembly
Transmission Bearing
Transmission Installation
Crankshaft Inspection
Crankshaft Removal
Crankshaft Installation
Crankcase Bearing Replacement
Crankcase Bearing/Oil Seal Location
Crankshaft Bearing
Oil Jet
Right Crankcase
Front Wheel/Suspension/Steering
Front Wheel/Suspension/Steering Component Location
Front Wheel/Suspension/Steering Service Information
Front Wheel/Suspension/Steering Specifications
Front Wheel/Suspension/Steering Tools
Front Wheel/Suspension/Steering Torque Values
Front Wheel/Suspension/Steering Troubleshooting
Front Wheel Removal
Axle Shaft Runout
Front Wheel Disassembly
Front Wheel Inspection
Wheel Bearing
Front Wheel Assembly
Front Wheel Installation
Fork Removal
Fork Disassembly
Outer Tube and Fork Slider Disassembly
Fork Damper Disassembly
Fork Inspection
Spring Seat Collar
Fork Cap Assembly
Fork Center Bolt
Push Rod
Fork Slider/Outer Tube
Fork Spring
Slider Bushing/Guide Bushing/Back-Up Ring
Fork Assembly
Fork Damper
Outer Tube and Slider Assembly
Fork Damper Refilling/Assembly
Recommended Fork Oil
Standard Oil Capacity
Fork Damper Installation/Preparation
Fork Damper Operation Inspection
Fork Damper Installation
Fork Oil Capacity Adjustment
Standard Fork Oil Capacity
Fork Installation
Standard Position
Handlebar Removal
Handlebar Installation
HPSD Removal/Installation
HPSD Inspection
Spherical Bearing Replacement
HPSD Disassembly
HPSD Assembly
Steering Stem Removal
Steering Stem Bearing Replacement
Steering Stem Installation
Clutch Lever Removal/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 Wobbling
Rear Wheel/Suspension Troubleshooting
Soft Suspension
Stiff Suspension
Rear Wheel Inspection
Rear Wheel Removal
Rear Wheel Disassembly
Wheel Rim Runout
Rear Wheel Assembly
Rear Wheel Installation
Shock Absorber Disassembly
Shock Absorber Removal
Shock Absorber Bladder Replacement
Damper Disassembly
Piston Ring Replacement
Damper Rod Disassembly
Compression Adjuster Inspection
Damper Rod Inspection
Rebound Spring Inspection
Rod Guide Case Inspection
Damper Assembly
Recommended Shock Oil
Standard Spring Length
Installation
Shock Linkage Disassembly
Shock Linkage Removal
Shock Linkage Inspection
Shock Arm Needle Bearing
Shock Linkage Bearing Replacement
Shock Link Needle Bearing
Shock Linkage Bearing Assembly
Shock Linkage Installation
Swingarm Removal
Swingarm Disassembly
Swingarm Bearing Replacement
Swingarm Assembly
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 Pads/Disc
Front Brake Pads Replacement
Rear Brake Pads Replacement
Front Master Cylinder Removal
Brake Disc Inspection
Front Master Cylinder Disassembly
Front Master Cylinder Inspection
Front Master Cylinder Assembly
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Disassembly
Rear Master Cylinder Inspection
Rear Master Cylinder Assembly
Rear Master Cylinder Installation
Front Brake Caliper Removal
Front Brake Caliper Disassembly
Rear Brake Caliper Removal
Rear Brake Caliper Disassembly
Rear Brake Caliper Inspection
Rear Brake Caliper Assembly
Rear Brake Caliper Installation
Brake Pedal Removal
Brake Pedal Installation
Electrical System
Electrical System Location
Electrical System Tools
Electrical System Torque Value
Electrical System Service Information
Electrical System Troubleshooting
No Spark at Plug
Ignition System Inspection
Ignition Coil Primary Peak Voltage
CKP Sensor Peak Voltage
Alternator Coil Inspection
Regulator/Rectifier Removal/Installation
Regulator/Rectifier Inspection
Power Output Line
Ground Line
Alternator Coil Line
Ignition Coil Removal/Installation
Ignition Coil Inspection
Ignition Timing
Engine Stop Switch Inspection
Switch Inspection
Switch Line Inspection
Condenser Removal/Installation
Condenser Inspection
Wiring Diagram
Troubleshooting
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
Index
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust system Service Information
40
Lubrication system service information
91
Fuel System (PGM-FI) Symptom Troubleshooting
102
Pgm -fi troubleshooting information
107
DTC Troubleshooting
112
Cooling System Troubleshooting
158
Cylinder Head/Valves
177
Cylinder Head/Valves Troubleshooting
182
Cylinder/Piston Service Information
217
Clutch/Kickstarter/Gearshift Linkage Troubleshooting
226
Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
260
Front Wheel/Suspension/Steering Troubleshooting
292
Rear Wheel/Suspension Troubleshooting
350
Hydraulic Brake Troubleshooting
392
Electrical system Troubleshooting
420
Troubleshooting
437
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