Honda 2010 CRF250R Manuals

Honda 2010 CRF250R Manuals

Manuals and User Guides for Honda 2010 CRF250R. We have 1 Honda 2010 CRF250R manual available for free PDF download: Service Manual

Honda 2010 CRF250R Service Manual

Honda 2010 CRF250R Service Manual (447 pages)

Brand: Honda | Category: Motorcycle | Size: 50.4 MB

Table of Contents

A few Words about Safety
2
Service Information
2
Important Safety Precautions
2
Symbols
4
Contents
5
Table of Contents
7
General Information
7
Service Rules
8
- Abbreviation
  8
- Serial Numbers
  9
Model Identification
9
Label
10
General Specifications
11
Lubrication System Specifications
11
Cylinder/Piston Specifications
14
Crankcase/Crankshaft/Transmission/Balancer Specifications
15
Steering Specifications
16
Rear Wheel/Suspension Specifications
17
Hydraulic Brake Specifications
17
Electrical System Specifications
18
Torque Values
18
Lubrication & Seal Points
24
Cable & Harness Routing
27
- Frame/Body Panels/Exhaust System
  39
- Frame/Body Panels/Exhaust System Service Information
  40
- Frame/Body Panels/Exhaust System Torque Values
  40
- Frame/Body Panels/Exhaust System Troubleshooting
  40
- Seat Removal/Installation
  41
- Side Cover Removal/Installation
  41
- Engine Guard Removal/Installation
  42
- Radiator Shroud Removal/Installation
  42
- Front Fender Removal/Installation
  43
- Number Plate Removal/Installation
  43
- Rear Fender Removal/Installation
  44
- Sub-Frame Removal
  44
- Sub-Frame Installation
  46
- Exhaust System
  47
  - Muffler Removal/Installation
    47
  - Glass Wool Replacement
    49
  - Exhaust Pipe Removal
    53
  - Exhaust Pipe Disassembly/Assembly
    54
  - Exhaust Pipe Installation
    54
  - Cylinder Head Exhaust Pipe Stud Bolt Replacement
    55
  - Maintenance
    57
  - Maintenance Service Information
    58
  - Maintenance Specifications
    58
  - Maintenance Tools
    59
  - Maintenance Torque Values
    59
- Maintenance Schedule
  60
- Additional Items Requiring Frequent Replacement
  61
- Fuel Line
  62
  - Fuel Tank Hanging
    62
  - Fuel Tank Inspection
    63
- Throttle Operation
  63
- Air Cleaner
  64
- Crankcase Breather
  66
  - Spark Plug Inspection
    66
  - Spark Plug Removal
    66
- Radiator Coolant
  67
  - Valve Clearance Inspection
    68
  - Engine Oil/Oil Filter
    69
  - Exhaust Side
    69
  - Oil Level Inspection
    69
  - Recommended Engine Oil
    69
  - Engine Oil & Filter Change
    70
  - Engine Oil Capacity
    71
  - Engine Idle Speed
    72
  - Transmission Oil Level Inspection
    72
- Cooling System
  73
- Drive Chain Roller (,10, '11)
  77
- Drive Chain Slider
  77
- DRIVE CHAIN ROLLER (after '11)
  78
- Drive/Driven Sprocket
  78
- Brake Fluid Level Inspection
  79
- Brake Pads Wear
  80
  - Fluid Filling
    80
  - Brake Lever Position
    81
  - Brake Pedal Height
    81
- Brake System
  81
- Clutch System
  81
- Clutch Lever Freeplay
  82
- Control Cables
  83
- Exhaust Pipe/Muffler
  84
  - Exhaust System Inspection
    84
  - Front Suspension Inspection
    84
  - Rear Suspension Inspection
    85
  - Nuts, Bolts, Fasteners
    86
- Swingarm/Shock Linkage
  86
- Wheels/Tires
  86
- Steering Head Bearings
  87
- COMPONENT Locatlon
  98
- PGM-FI System Location
  103
- Pgm-Fi System Diagram ('10 - ·12)
  104
- PGM-FI SYSTEM DIAGRAM (after '12)
  105
- Fuel System (PGM-FI) Connector Location
  106
- Opens and Shorts
  107
- Fail-Safe Function
  107
- Intermittent Failure
  107
- Pgm -Fi Troubleshooting Information
  107
- Battery Harness Connecting/Operation
  108
- MIL Blink Pattern
  109
- Current Dtc/Freeze DTC
  109
- HDS Pocket Testing Information
  109
- DTC Readout
  109
- Erasing DTC
  110
- Reading DTC with the MIL
  110
- Circuit Inspection
  110
- Inspection at ECM Connector
  110
- DTC Index
  111
- DTC Troubleshooting
  112
- DTC 1-1 (Map Sensor Low Voltage)
  112
- DTC 1-2 (Map Sensor High Voltage)
  113
- DTC 2-1 (Map Sensor)
  114
- DTC 7-1 (ECT Sensor Low Voltage)
  115
- DTC 7-2 (ECT Sensor High Voltage)
  116
- DTC 8-1 (TP Sensor Low Voltage)
  117
- DTC 8-2 (TP Sensor High Voltage)
  119
- DTC 9-1 (IAT Sensor Low Voltage)
  119
- DTC 9-2 (IAT Sensor High Voltage)
  120
- DTC 12-1 (Injector)
  121
- DTC 19-1 (No. 1 CKP Sensor)
  123
MIL Circuit Inspection
125
- Dtc 33-2 (Eeprom)
  125
- When the Engine Starts but the MIL Does Not Come on
  125
- When the Engine Starts but the MIL Does Not Go off Within a few Seconds
  125
- Fuel Line Replacement
  126
  - Fuel Pressure Relieving
    126
  - Fuel Pump Side
    127
  - Quick Connect Fitting Removal
    127
  - Injector Side
    128
  - Quick Connect Fitting Installation
    129
  - Fuel Pressure Increasing
    131
  - Fuel Pressure Test
    132
  - Fuel Flow Inspection
    133
  - Fuel Pump Unit Inspection
    133
  - Fuel Tank Removal/Installation
    141
  - Air Cleaner Housing Removal
    142
  - Air Cleaner Inspection/Installation
    142
  - Air Cleaner Disassembly/Assembly
    143
  - Injector Removal
    143
  - Injector Installation
    144
  - Throttle Body Removal
    145
  - Throttle Body Disassembly/Assembly
    147
  - Throttle Body Installation
    148
  - Fast Idle Knob Inspection
    150
  - Fast Idle Knob Removal
    150
  - Fast Idle Knob Installation
    151
  - Map Sensor Output Voltage Inspection
    151
  - Map Sensor Removal/Installation
    151
  - IAT Sensor Removal/Installation
    152
  - ECT Sensor Inspection
    153
  - ECT Sensor Installation
    153
  - ECT Sensor Removal
    153
  - ECM Power/Ground Line Inspection
    154
  - ECM Removal/Installation
    154
  - Engine Does Not Start (Mil Does Not Blink)
    154
  - Cooling System Flow Pattern
    156
  - Cooling System Service Information
    157
  - Cooling System Tools
    157
  - Cooling System Torque Values
    157
  - Coolant Leak
    158
  - Cooling System Troubleshooting
    158
  - Engine Temperature too High
    158
  - Coolant (Hydrometer Test)
    159
  - Coolant Gravity Chart
    159
  - Cooling System Testing
    159
- Coolant Replacement
  160
  - Radiator Cap/System Pressure Inspection
    160
  - Recommended Antifreeze
    160
  - Recommended Mixture
    160
  - Radiator Removal
    161
  - Replacement/Air Bleeding
    161
  - Radiator Installation
    163
  - Water Pump Mechanical Seal Inspection
    164
  - Water Pump Removal
    164
  - Water Pump Bearing/Mechanical Seal/Oil Seal Replacement
    165
  - Engine Removal/Installation
    169
  - Engine Removal/Installation Component Location
    170
  - Engine Removal/Installation Service Information
    171
  - Engine Removal/Installation Torque Values
    171
  - Engine Removal
    172
  - Engine Installation
    174
  - Cylinder Head/Valves
    177
- Troubleshooting
  177
- Cylinder Compression Test
  183
- Camshaft/Rocker Arm Removal
  186
  - Rocker Arm Inspection
    188
  - Rocker Arm Shaft
    188
  - Camshaft Holders
    189
  - Decompressor System
    189
  - Decompressor System Assembly
    190
  - Decompressor System Disassembly
    190
  - Decompressor System Inspection/Cleaning
    190
- Valve Clearance Adjustment
  191
- Cylinder Head Removal
  193
- Cylinder Head Disassembly
  195
- Cylinder Head Inspection
  196
  - Valve Lifter
    197
  - Valve Spring
    197
  - Valve/Valve Guide
    197
- Valve Guide Replacement
  198
- Valve Seat Inspection/Refacing
  199
- Valve Seat Refacing
  200
- Cylinder Head Assembly
  202
- Cylinder Head Installation
  206
- Camshaft/Rocker Arm Installation
  208
- Cam Chain Tensioner
  211
- Cylinder Removal
  218
- Piston Removal
  218
- Cylinder/Piston Inspection
  219
  - Piston/Piston Pin/Piston Ring
    219
  - Connecting Rod
    221
- Piston Installation
  221
- Cylinder Installation
  222
  - Clutch/Kickstarter/Gearshift Linkage
    223
  - Clutch/Kickstarter/Gearshift Linkage Component Location
    224
  - Clutch/Kickstarter/Gearshift Linkage Service Information
    225
  - Clutch/Kickstarter/Gearshift Linkage Specifications
    225
  - Clutch/Kickstarter/Gearshift Linkage Tools
    225
  - Clutch/Kickstarter/Gearshift Linkage Torque Values
    225
  - Clutch/Kickstarter/Gearshift Linkage Troubleshooting
    226
  - Right Crankcase Cover Removal
    227
  - Right Crankcase Cover Installation
    228
  - Clutch Removal
    229
  - Clutch Discs
    231
  - Clutch Inspection
    231
  - Clutch Plates
    231
  - Clutch Springs
    231
  - Clutch Lifter Rod
    232
  - Clutch Lifter/Needle Bearing
    232
  - Clutch Outer
    232
  - Judder Spring/Spring Seat
    232
  - Clutch Lifter Lever
    233
  - Clutch Outer Guide
    233
  - Lifter Lever Bearing Replacement
    233
  - Needle Bearing
    233
  - Clutch Installation
    234
  - Kickstarter Disassembly
    238
  - Kickstarter Inspection
    238
  - Kickstarter Removal
    238
  - Kickstarter Assembly
    240
  - Kickstarter Installation
    241
  - Gearshift Linkage Removal
    242
  - Gearshift Linkage Inspection
    244
  - Gearshift Spindle
    244
  - Ratchet Pawl
    244
  - Gearshift Linkage Installation
    245
  - Alternator
    247
  - Alternator Component Location
    248
  - Alternator Service Information
    249
  - Alternator Tools
    249
  - Alternator Torque Values
    249
  - Left Crankcase Cover Removal
    250
  - Flywheel Installation
    251
  - Flywheel Removal
    251
  - Stator/Ckp Sensor Removal
    252
  - Stator/Ckp Sensor Installation
    253
  - Left Crankcase Cover Installation
    254
  - Crankcase/Crankshaft/Transmission/Balancer
    255
  - Crankcase/Crankshaft/Transmission/Balancer Component Location
    256
  - Crankcase/Crankshaft/Transmission/Balancer Service Information
    257
  - Crankcase/Crankshaft/Transmission/Balancer Tools
    258
  - Crankcase/Crankshaft/Transmission/Balancer Torque Values
    258
  - Crankcase/Crankshaft/Transmission/Balancer Troubleshooting
    260
  - Excessive Noise
    260
  - Hard to Shift
    260
  - Transmission Jumps out of Gear
    260
  - Primary Drive Gear/Balancer Drive Gear Installation
    261
  - Primary Drive Gear/Balancer Drive Gear Removal
    261
- Right Crankcase Cover
  261
  - Balancer Driven Gear/Balancer Shaft Installation
    263
  - Balancer Driven Gear/Balancer Shaft Removal
    263
  - Balancer Bearing Replacement
    264
  - Right Balancer Bearing
    264
  - Left Balancer Needle Bearing
    266
  - Crankcase Separation
    267
  - Crankcase Assembly
    269
  - Transmission Disassembly
    272
  - Gear Inspection
    273
  - Oil Pump Shaft Needle Bearing
    273
  - Transmission Inspection
    273
  - Mainshaft/Countershaft
    274
  - Shift Fork
    274
  - Shift Fork Shaft
    274
  - Gearshift Drum
    275
  - Transmission Assembly
    275
  - Transmission Bearing
    275
  - Transmission Installation
    277
  - Crankshaft Inspection
    278
  - Crankshaft Removal
    278
  - Crankshaft Installation
    279
  - Crankcase Bearing Replacement
    280
  - Crankcase Bearing/Oil Seal Location
    280
  - Crankshaft Bearing
    280
  - Oil Jet
    285
  - Right Crankcase
    285
  - Front Wheel/Suspension/Steering
    287
  - Front Wheel/Suspension/Steering Component Location
    288
  - Front Wheel/Suspension/Steering Service Information
    289
  - Front Wheel/Suspension/Steering Specifications
    289
  - Front Wheel/Suspension/Steering Tools
    290
  - Front Wheel/Suspension/Steering Torque Values
    290
  - Front Wheel/Suspension/Steering Troubleshooting
    292
  - Front Wheel Removal
    293
  - Axle Shaft Runout
    294
  - Front Wheel Disassembly
    294
  - Front Wheel Inspection
    294
  - Wheel Bearing
    294
  - Front Wheel Assembly
    296
  - Front Wheel Installation
    298
  - Fork Removal
    300
  - Fork Disassembly
    301
  - Outer Tube and Fork Slider Disassembly
    304
  - Fork Damper Disassembly
    305
  - Fork Inspection
    306
  - Spring Seat Collar
    306
  - Fork Cap Assembly
    307
  - Fork Center Bolt
    307
  - Push Rod
    307
  - Fork Slider/Outer Tube
    308
  - Fork Spring
    308
  - Slider Bushing/Guide Bushing/Back-Up Ring
    308
  - Fork Assembly
    309
  - Fork Damper
    309
  - Outer Tube and Slider Assembly
    310
  - Fork Damper Refilling/Assembly
    312
  - Recommended Fork Oil
    312
  - Standard Oil Capacity
    312
  - Fork Damper Installation/Preparation
    315
  - Fork Damper Operation Inspection
    315
  - Fork Damper Installation
    317
  - Fork Oil Capacity Adjustment
    319
  - Standard Fork Oil Capacity
    319
  - Fork Installation
    320
  - Standard Position
    321
  - Handlebar Removal
    322
  - Handlebar Installation
    324
  - HPSD Removal/Installation
    327
  - HPSD Inspection
    328
  - Spherical Bearing Replacement
    329
  - HPSD Disassembly
    330
  - HPSD Assembly
    333
  - Steering Stem Removal
    338
  - Steering Stem Bearing Replacement
    339
  - Steering Stem Installation
    341
  - Clutch Lever Removal/Installation
    342
  - Rear Wheel/Suspension
    345
  - Rear Wheel/Suspension Component Location
    346
  - Rear Wheel/Suspension Service Information
    347
  - Rear Wheel/Suspension Tools
    348
  - Rear Wheel/Suspension Torque Values
    348
  - Rear Wheel Wobbling
    350
  - Rear Wheel/Suspension Troubleshooting
    350
  - Soft Suspension
    350
  - Stiff Suspension
    350
  - Rear Wheel Inspection
    351
  - Rear Wheel Removal
    351
  - Rear Wheel Disassembly
    352
  - Wheel Rim Runout
    352
  - Rear Wheel Assembly
    354
  - Rear Wheel Installation
    356
  - Shock Absorber Disassembly
    357
  - Shock Absorber Removal
    357
  - Shock Absorber Bladder Replacement
    358
  - Damper Disassembly
    362
  - Piston Ring Replacement
    363
  - Damper Rod Disassembly
    364
  - Compression Adjuster Inspection
    366
  - Damper Rod Inspection
    366
  - Rebound Spring Inspection
    366
  - Rod Guide Case Inspection
    366
  - Damper Assembly
    367
  - Recommended Shock Oil
    370
  - Standard Spring Length
    372
  - Installation
    374
  - Shock Linkage Disassembly
    375
  - Shock Linkage Removal
    375
  - Shock Linkage Inspection
    376
  - Shock Arm Needle Bearing
    377
  - Shock Linkage Bearing Replacement
    377
  - Shock Link Needle Bearing
    378
  - Shock Linkage Bearing Assembly
    378
  - Shock Linkage Installation
    379
  - Swingarm Removal
    380
  - Swingarm Disassembly
    381
  - Swingarm Bearing Replacement
    382
  - Swingarm Assembly
    383
  - Swingarm Installation
    384
  - Hydraulic Brake
    387
  - Hydraulic Brake Component Location
    388
  - Hydraulic Brake Service Information
    390
  - Hydraulic Brake Tool
    391
  - Hydraulic Brake Torque Values
    391
  - Brake Drags
    392
  - Brake Lever/Pedal Hard
    392
  - Brake Lever/Pedal Soft or Spongy
    392
  - Hydraulic Brake Troubleshooting
    392
  - Brake Fluid Draining
    393
- Brake Fluid Replacement/Air Bleeding
  393
- Brake Fluid Filling/Air Bleeding
  394
- Brake Pads/Disc
  397
- Front Brake Pads Replacement
  397
- Rear Brake Pads Replacement
  399
- Front Master Cylinder Removal
  400
- Brake Disc Inspection
  400
- Front Master Cylinder Disassembly
  401
- Front Master Cylinder Inspection
  402
- Front Master Cylinder Assembly
  403
- Front Master Cylinder Installation
  405
- Rear Master Cylinder Removal
  405
- Rear Master Cylinder Disassembly
  406
- Rear Master Cylinder Inspection
  406
- Rear Master Cylinder Assembly
  407
- Rear Master Cylinder Installation
  408
- Front Brake Caliper Removal
  408
- Front Brake Caliper Disassembly
  408
- Rear Brake Caliper Removal
  411
- Rear Brake Caliper Disassembly
  412
- Rear Brake Caliper Inspection
  413
- Rear Brake Caliper Assembly
  413
- Rear Brake Caliper Installation
  414
- Brake Pedal Removal
  415
- Brake Pedal Installation
  415
- Electrical System
  417
- Electrical System Location
  418
- Electrical System Tools
  419
- Electrical System Torque Value
  419
- Electrical System Service Information
  419
- Electrical System Troubleshooting
  420
- No Spark at Plug
  420
- Ignition System Inspection
  421
- Ignition Coil Primary Peak Voltage
  421
- CKP Sensor Peak Voltage
  422
- Alternator Coil Inspection
  425
- Regulator/Rectifier Removal/Installation
  426
- Regulator/Rectifier Inspection
  427
- Power Output Line
  428
- Ground Line
  428
- Alternator Coil Line
  429
- Ignition Coil Removal/Installation
  429
- Ignition Coil Inspection
  429
- Ignition Timing
  430
- Engine Stop Switch Inspection
  431
- Switch Inspection
  431
- Switch Line Inspection
  431
- Condenser Removal/Installation
  432
- Condenser Inspection
  432
- Wiring Diagram
  433
- Troubleshooting
  437
- Engine Does Not Start or Is Hard to Start
  438
- Engine Lacks Power
  439
- Poor Performance at Low and Idle Speed
  441
- Poor Performance at High Speed
  442
- Poor Handling
  443
- Index
  445

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