Instruction/ maintenance manual of the product CRF250X (2005) Honda
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HOND A CRF250X O WNER’S MANU AL & COMPETITION HANDBOOK.
IMPORT ANT NOTICES This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing.
2005 Honda CRF250X OWNER’S MANUAL & COMPETITION HANDBOOK.
Intr oduction Congratulations on choosing your Honda off- road motorcycle. When you own a Honda, you’re part of a worldwide family of satisfied customers-people who appreciate Honda’ s reputation for building quality into every product. Y our Honda was designed as a recreational motorcycle for off-road use by one rider only .
A Few W ords About Safety Y our safety , and the safety of others, is very important. And operating this motorcycle safely is an important responsibility . T o help you make informed decisions about safety , we have provided operating procedures and other information on labels and in this manual.
Contents MOTORCYCLE SAFETY...............................1 Important Safety Precautions..... .....................2 Loading..... ......................................................3 Accessories & Modifications ..........................4 Safety Labels .
Motor cycle Safety This section presents some of the most important information and recommendations to help you ride your motorcycle safely . Please take a few moments to read these pages. This section also includes information about the location of safety labels on your motorcycle.
Important Safety Information Important Safety Precautions Y our motorcycle can provide many years of pleasure, if you take responsibility for your own safety and understand the challenges you can meet in competitive racing. There is much that you can do to protect yourself when you ride.
Loading Y our Honda was designed as a rider-only motorcycle. It was not designed to carry a passenger or cargo. A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the motorcycle.
Accessories & Modifications Accessories W e strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non- Honda accessories.
Motorcycle Safety 5 Safety Labels This page shows the locations of safety labels on your motorcycle. Some labels warn you of potential hazards that could cause serious injury . Othere provide important safety information. Read these labels carefully and don ’ t remove them.
6 Motorcycle Safety.
Operating Controls 7 Operating Contr ols Read this section carefully before you ride. It presents the location of the basic controls on your motorcycle.
8 Operating Controls Component Locations clutch le ver hot star t le ver front brak e lev er engine stop button fuel fill cap throttle grip tripmeter star t button choke knob fuel valv e shift le ver .
Before Riding 9 Before each ride, you need to make sure you and your Honda are both ready to ride. T o help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your motorcycle. For information about suspension, carburetion and other adjustment see page 103.
10 Before Riding Ar e Y ou Ready to Ride? Before riding your CRF for the first time, we recommend that you read this owner ’ s manual, make sure you understand the safety messages, and know how to operate the controls. Before each ride, it ’ s also important to make sure you and your motorcycle are both ready to ride.
Before Riding 11 Is Y our Motor cycle Ready to Ride? Competitive riding can be tough on a motorcycle, so it ’ s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the right): Pre-ride Inspection Check the following before each ride: • Engine oil level .
12 Before Riding.
Basic Operating Instructions 13 Basic Operating Instructions 13 Basic Operating Instructions This section gives basic information on how to start and stop your engine as well as break-in guidelines. Safe Riding Precautions ............................
T ripmeter The tripmeter (1) is used to record the distance traveled (USA: miles, Canada: kilometers) per trip or section of route. T o operate, pull the tripmeter reset knob (2) out (OFF) and turn it until the meter shows all zeros (0), then push the knob in (ON).
Starting & Stopping the Engine Always follow the proper starting procedure described below . Y our motorcycle can be kickstarted wirh the transmission in gear by pulling in the clutch lever before operating the kickstarter . Preparation Make sure that the transmission is in neutral.
Starting & Stopping the Engine. Flooded Engine Starting the engine after a stall during riding or after a fall: 1. Shift the transmission into neutral. 2. Pull the hot start lever and start the engine. (Do not open the throttle). 3. As soon as the engine starts, release the hot start lever .
Shifting Gears Remember to close the throttle and pull the clutch lever in completely before shifting. Impr oper shifting may damage the engine, transmission, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high.
Braking T o slow or stop, apply the front brake and rear brake smoothly , while down shifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. T o prevent stalling the engine, pull the clutch lever in before coming to a complete stop.
Parking Lower the side stand to support your motorcycle. If you ’ re through riding for the day , also turn the fuel valve OFF . Always choose a level place to park.
Post-ride Inspection When you return home after riding thoroughly clean your motorcycle and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way . After cleaning, carefully inspect your motorcycle for leaks or damage.
Basic Operating Instructions 21 Br eak-in Guidelines Help assure your CRF ’ s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration.
22 Basic Operating Instructions.
Servicing Y our Honda 23 Servicing Y our Honda Keeping your motorcycle well maintained is absolutely essential to your safety . It ’ s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun.
24 Servicing Y our Honda W ARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner ’ s manual.
Servicing Y our Honda 25 Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow . However , we cannot warn you of every conceivable hazard that can arise in performing maintenance.
26 Servicing Y our Honda Maintenance Schedule T o maintain the safety and reliability of your motorcycle, regular inspection and service is required as shown in the Maintenance Schedules – Regular OFF ROAD (non- competition) Use and Competition Use-that follow .
Maintenance Schedule Summary of Maintenance Schedule Notes and Pr ocedur es; NOTES: 1. Service more frequently when ridden in wet or dusty conditions. 2.
MAINTENANCE SCHEDULE – COMPETITION USE All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not cover ed by the Distributor’ s Limited W arranty on your Honda.
Servicing Y our Honda 29 General Competition Maintenance Perform maintenance on firm, level ground using the side stand, a workstand, or equivalent support. Use genuine Honda parts or their equivalent when servicing your motorcycle. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
30 Servicing Y our Honda Spark Plug Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule (pages 27, 28).
General Competition Maintenance Handgrips Always use Honda Hand Grip Cement (U.S.A only) or Honda Bond A when replacing handgrips. Throttle grip Align the index mark on the throttle grip with the edge of the throttle cable guide. Left handlebar grip: Align the “ ∆ ” mark on the left handlebar grip with the punch mark on the handlebar.
Swingarm Pivot Lubrication Clean, inspect and lubricate when servicing suspension linkage pivots. Be sure all of the suspension pivot seals are in good condition. Use Honda Moly 60 paste (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disulfide additive).
Befor e & After Competition Maintenance Between Motos & Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments. • Clean accumulated dirt from under the fenders and off the wheels, suspension components, hand grips, controls, and footpegs.
Befor e & After Competition Maintenance Routine Cleaning If your motorcycle is only slightly dirty , it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags. T ake care to prevent catching your fingers between the chain and sprocket.
Component Locations choke knob carburetor air cleaner housing cover rear suspension taillight left side cover chain slipper rear wheel axle drive chain chain adjuster fuel tank fuel valve front suspen.
Seat Removal Refer to Safety Pr ecautions on page 2. Removal 1. Remove the seat bolts (1) and collars (2). 2. Slide the seat (3) back. (1) seat bolts (3) seat (2) collars Installation 1.
Fuel T ank Removal Refer to Safety Pr ecautions on page 2. Removal 1. T urn the fuel valve OFF . 2. Remove the seat (page 36). 3. Remove the shroud A bolts/collars (1). 4. Remove the shroud B bolts/collars (2) and shrouds (3). (1) shroud A bolts/collars (2) shroud B bolts/collars (3) shrouds 5.
Fuel T ank Removal (2) (1) (3) (7) (8) (9) (10) Installation 1. Install the fuel tank on the frame. 2. Install the fuel valve (1) and fuel valve bolt (2). 3. Connect the fuel line (3) to the fuel valve. (1) fuel valve (3) fuel line (2) fuel valve bolt 4.
Subframe Upright Position Refer to Safety Pr ecautions on page 2. The subframe may be adjusted to an upright position to permit servicing of the rear suspension. Upright Position 1. Remove the right side cover bolt (1), seat bolt (2), collars (3) and right side cover (4).
Subframe Upright Position 2. T ighten the screw (4) on the air cleaner connecting tube clamp (5). 4. Install the muffler (page 63). 5. Install the seat (9) (page 36). 6. Install the left side cover (10), collars (1 1), seat bolt (12), and left side cover bolt (13).
Fuel System Refer to Safety Pr ecautions on page 2. Fuel Recommendation W e recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components. Y our engine is designed to use any gasoline that has a pump octane number of 91 or higher .
Fuel System Fuel Filter The fuel filter is mounted on the bottom left side of the fuel tank. Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor . T o service the fuel filter: 1. Drain the fuel from the fuel tank into an approved gasoline container .
* Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label. Engine Oil Refer to Safety Pr ecautions on page 2. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the engine ’ s life.
Engine Oil JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB.
Engine Oil 7. Remove the left engine guard bolt (4) and left engine guard (5). 1 1. Apply grease to the seat face of spring (10). 12.Position the spring against the engine crankcase and install a new oil filter with the rubber seal (1 1) facing out, away from the engine.
T ype API classification (4-stroke engine oil only) Viscosity (weight) JASO T903 standard others suggested oil * Refer to Safety Pr ecautions on page 2. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch.
JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard has the following classification on the oil container .
Coolant 48 Servicing Y our Honda Y our motorcycle ’ s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head. Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion.
Coolant (4) left side cover (8) collars (5) quick fastener (9) reserve tank cap (6) left side cover bolt (10) air cleaner box cover (7) seat bolt Servicing Y our Honda 49 4. Add coolant to the reserve tank as require to bring the coolant level to the UPPER level mark.
Coolant Replacement Refer to Safety Pr ecautions on page 2. Coolant should be replaced by your Honda dealer , unless you have the proper tools and service data and are mechanically qualified.
Air Cleaner Refer to Safety Pr ecautions on page 2. The air cleaner uses polyurethane inner and outer pieces which can ’ t be separated. A dirty air cleaner will reduce engine power . Proper air cleaner maintenance is very important for off-road vehicles.
Air Cleaner Impr oper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder . NOTICE 7. Apply a thin coat of Honda White Lithium Grease to the sealing surface. 8. Assemble the air cleaner and holder .
Crankcase Br eather Servicing Y our Honda 53 Refer to Safety Pr ecautions on page 2. Crankcase Breather Service more frequently if your motorcycle is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube.
Thr ottle Refer to Safety Pr ecautions on page 2. Throttle Fr eeplay (1) freeplay Inspection Check freeplay (1). Freeplay: 1/8 - 3/16 in (3 - 5 mm) If necessary , adjust to the specified range. Upper Adjustment Minor adjustments are generally made with the upper adjuster .
Thr ottle Throttle Inspection (1) throttle 1. Check that the throttle assembly is positioned properly and the securing screws are tight. 2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer .
Clutch System Refer to Safety Pr ecautions on page 2. Clutch Freeplay Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster . Cable end adjuster: (2) cable end adjuster (+) increase free play ( – ) decrease free play 1.
Clutch System Other Inspections & Lubrication • Check that the clutch lever assembly is positioned properly and the securing bolts are tight. • Check the clutch cable for kinks or signs of wear .
Clutch System Clutch Disc Inspection Replace the clutch discs (1) if they show signs of scoring or discoloration. Measure the thickness of each clutch disc. Service Limit: 0.1 12 in (2.85 mm) Replace the clutch discs and clutch plates as a set. (1) clutch disc Clutch Spring Inspection (1) clutch spring Measure the free length of each spring.
Clutch System 1 1. Lubricate the O-rings (12), rear brake pedal (13) pivot and pivot bolt (14) with Honda Lithium Grease. T ighten the pivot bolt to the specified torque: 19 lbf · ft (26 N · m, 2.7 kgf · m) Connect the brake pedal return spring (15) if it was removed.
Hot Start Lever Refer to Safety Pr ecautions on page 2. Hot Start Lever Fr eeplay left handlebar (1) hot start lever (2) freeplay Inspection Check freeplay: 1/16 – 1/8 in (2 – 3 mm) If necessary , adjust to the specified range. Adjustment Adjustments can be made with the cable end adjuster .
Refer to Safety Pr ecautions on page 2. Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions. Use only the recommended type of spark plugs in the recommended heat range. Using spark plugs with an impr oper heat range or incorr ect r each can cause engine damage.
Exhaust Pipe/Muffler Exhaust Pipe/Muffler Inspection Check the flange bolts for tightness. Check the exhaust pipe and muffler for cracks or deformation. A damaged exhaust pipe and muffler may reduce engine performance. (1) seat bolt (3) side cover bolt (2) collars (4) right side cover 2.
Exhaust Pipe/Muffler Muffler Installation 1. Remove the gasket. 2. Install a new gasket (1) and muffler (2). (1) gasket (2) muf fler 3. T ighten the muf fler B bolt (3) and muffler A bolt (4) to the specified torque: 19 lbf · ft (26 N · m, 2.7 kgf · m) 4.
Exhaust Pipe/Muffler 64 Servicing Y our Honda Exhaust Pipe Installation 1. Install a new exhaust pipe gasket (1), exhaust pipe (2) and exhaust pipe joint nuts (3) and tighten the nuts 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.
Spark Arr ester Servicing Y our Honda 65 Spark Arrester Inspection The spark arrester must be serviced every 100 operating hours to maintain its efficiency . Regular servicing prevents carbon buildup (which can diminish engine performance) and also complies with USDA regulations for regular maintenance to assure proper function.
V alve Clearance Cylinder Head Cover Removal Before inspection, clean the engine thoroughly to keep dirt from entering the engine. 1. Remove the seat (page 36). 2. Remove the fuel tank (page 37). 3. Disconnect the breather tube (1) and spark plug cap (2).
V alve Clearance V alve Clearance Inspection 1. Measure the intake valve clearance by inserting a feeler gauge (1) between the valve lifters (2) and intake cam lobe (3). 2. Measure the exhaust valve clearance by inserting a feeler gauge (1) between the exhaust rocker arm (4) and shim (5).
V alve Clearance CamShaft Removal 1. Record the intake valve clearance and exhaust valve clearance. 2. Remove the cam chain tensioner lifter cover bolt (1) and sealing washer (2). (1) cam chain tensioner lifter cover bolt (2) sealing washer Use the tensioner stopper tool.
V alve Clearance 4. Remove the camshaft holder bolts (4) and camshaft holders (5). Loosen the camshaft holder bolts in a criss-cross pattern in 2 or 3 steps. 5. Remove the camshaft (6), and then attach a piece of wire to the cam chain to prevent it from falling into the crankcase.
V alve Clearance Shim Selection 1. Clean the valve shim contact area in the valve lifter (1) with compressed air . 2. Measure the shim thickness and record it. T wenty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.
V alve Clearance Camshaft Installation 1. Install the newly selected shims (1) on the valve retainers (2). Do not let the shims fall into the crankcase.
V alve Clearance 72 Servicing Y our Honda 6. Insert the feeler gauge between the intake valve lifter and cam lobe. If the feeler gauge (13) cannot be inserted, the shim is caught between the valve lifter and the valve retainer . Remove the camshaft holders to place the shim correctly , and reinstall the camshaft holders.
V alve Clearance Cylinder Head Cover Installation 1. Remove the spark plug hole packing (1) from the cylinder head cover . Install the spark plug hole packing to the spark plug hole (2). (1) spark plug hole packing (2) spark plug hole 2. Install the cylinder head cover packing (3) into the groove of the cylinder head cover (4).
Piston/Piston Rings/Piston Pin Cylinder Head Removal 1. Clean the area above the engine before disassembly to prevent dirt falling into the engine. 2. Drain the engine oil (page 44). 3. Drain the radiator coolant after cooling the motorcycle (page 139).
Piston/Piston Rings/Piston Pin 14. Remove the engine hanger nuts (8) and engine hanger plates (9). (8) engine hanger nuts (9) engine hanger plates 15. Remove the cylinder head bolts (10). 16.Loosen the cylinder bolt (1 1). (10) cylinder head bolts (1 1) cylinder bolt 17.
Piston/Piston Rings/Piston Pin Cylinder Removal 1. Remove the cylinder bolt (1) and cylinder (2). Do not let the cam chain fall into the crankcase. Do not pry on or strike the cylinder . NOTICE (1) cylinder bolt (2) cylinder 2. Remove the dowel pins (3) and cylinder gasket (4).
Piston/Piston Rings/Piston Pin Piston Ring Installation 1. Clean the piston ring groove 2. Apply engine oil to the piston rings and install them. Do not damage the piston ring by spr eading the ends too far . Do not damage the piston during piston ring installation.
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.
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).
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).
Piston/Piston Rings/Piston Pin 6. Connect the radiator hose (10) to the cylinder head and tighten the radiator hose clamp (1 1) securely . (10) radiator hose (1 1) radiator hose clamp 7. Install the shims and cam shaft (page 71). 8. Install the spark plug (page 61).
Suspension Refer to Safety Pr ecautions on page 2 Loose, worn, or damaged suspension components may adversely affect the handling and stability of your motorcycle. If any suspension components appear worn or damaged, see your Honda dealer for further inspection.
Suspension Rear Suspension Inspection The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure.
Suspension 84 Servicing Y our Honda Recommended Fork Oil Fork Oil Change Refer to Suspension Removal on page 105. 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 the lock nut wrench (3).
Servicing Y our Honda 85 Suspension 5. Pour the recommended fork oil (page 84) into the outer tube. Fork Oil Capacity: Standard (0.42 kgf/mm) Fork Spring or Standard oil capacity 1 1.7 US oz (345 cm 3 ) Maximum oil capacity 13.5 US oz (399 cm 3 ) Slightly stiffer as it nears full compression.
86 Servicing Y our Honda Brakes Refer to Safety Pr ecautions on page 2. 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.
Servicing Y our Honda 87 Brakes Fluid Level Inspection Front Brake Fluid Level Check (1) LOWER level mark W ith the motorcycle in an upright position, check the fluid level. It should be above the LOWER level mark (1). If the level is at or below the LOWER level mark, check the brake pads for wear (page 89).
88 Servicing Y our Honda Brakes Adding Front Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent. When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out. (1) screws (2) reservoir cap (3) upper level mark 1.
Servicing Y our Honda 89 Brakes Brake Pad W ear Brake pad wear depends on the severity of usage and track conditions. (Generally , the pads will wear faster on wet and dirty tracks) Inspect the pads at each regular maintenance interval (pages 27 and 28).
90 Servicing Y our Honda Wheels Refer to Safety Pr ecautions on page 2. Maintenance of spoke tension and wheel trueness (roundness) is critical to safe motorcycle operation. During the first 100 miles (150 km), spokes will loosen more rapidly due to the initial seating of the parts.
Servicing Y our Honda 91 T ir es & T ubes W ARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner ’ s manual regarding tire inflation and maintenance.
92 Servicing Y our Honda T ir es & T ubes Tir e Replacement The tires that came on your motorcycle were designed to provide a good combination of handling, braking, durability , and comfort across a broad range of riding conditions. W ARNING Installing improper tires on your motorcycle can affect handling and stability .
Side Stand Servicing Y our Honda 93 Refer to Safety Pr ecautions on page 2. 1. Check the side stand spring (1) for damage and loss of tension. 2. Check the side stand assembly for freedom of movement. (1) side stand spring If the side stand is stiff or squeaky , clean the pivot area and lubricate the pivot bolt with clean engine oil.
94 Servicing Y our Honda Drive Chain Refer to Safety Pr ecautions on page 2. An endless (riveted master link) chain connects the countershaft and rear wheel sprockets. The O- ring chain uses rubber between the side plates of the pin and roller links to seal in the manufacturer-installed lubricating grease and keep out moisture and dirt.
Servicing Y our Honda 95 Drive Chain Removal, Cleaning & Replacement For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing. Y our motorcycle has an endless (riveted master link) type chain. It should only be removed or replaced by your Honda dealer .
96 Servicing Y our Honda Drive Chain Drive Chain Sliders 1. Check the chain slider (1) for wear . If the wear is 3/16 in (5 mm) or more, replace it. Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil.
Servicing Y our Honda 97 Additional Maintenance Pr ocedur es Refer to Safety Pr ecautions on page 2. Steering Stem Inspection 1. W ith 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.
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Battery Servicing Y our Honda 99 Refer to Safety Pr ecautions on page 2 Y our motorcycle has a maintenance-free type battery . Y ou do not have to check the battery electrolyte level or add distilled water as you would with a conventional-type battery .
Headlight & T aillight 100 Servicing Y our Honda Refer to Safety Pr ecaution on page 2. Headlight Bulb 1. Remove the two front visor bolts (1) and pull out the front visor (2). (1) front visor bolts (2) front visor 2. Disconnect the headlight connector (3).
Servicing Y our Honda 101 Appearance Car e Refer to Safety Pr ecautions on page 2. 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.
102 Servicing Y our Honda Appearance Car e 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.
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.
104 Adjustments for Competition Fr ont 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 ef fects of higher or lower fork oil level are only felt during the final 3.
Adjustments for Competition 105 Fr ont Suspension Adjustments Both compression and rebound damping can be increased by turning the adjuster clockwise. Always start with full har d when adjusting damping. Do not turn the adjuster scr ew mor e than the given positions or the adjuster may be damaged.
Fr ont Suspension Adjustments 106 Adjustments for Competition (3) headlight connector 4. Remove the handlebar pad. Remove the handlebar holder nuts (4), washers, mounting rubbers and handlebar (5). Keep the master cylinder upright to pr event air fr om entering system.
Fr ont Suspension Adjustments Adjustments for Competition 107 (20) lower pinch bolts 15. Hold the outer tube (23), then remove the fork damper (24) from the outer tube using the lock nut wrench (25). Gently slide the outer tube down onto the lower end of the slider (26).
Fr ont Suspension Adjustments 108 Adjustments for Competition 22. Apply pressure to the fork damper and insert a special tool or mechanic's stopper tool (30) (see below) between the axle holder (28) and lock nut (31). 23. Hold the lock nut and remove the fork center bolt (29) from the fork damper .
Fr ont Suspension Adjustments Adjustments for Competition 109 (1) fork cap (3) lock nut wrench (2) fork damper 1. Loosen the fork cap (1) by turning the fork damper (2) using the lock nut wrench (3). (2) fork damper (4) fork cap assembly 3. Empty the fork oil from the fork damper (2) by pumping the damper rod several times.
Fr ont Suspension Adjustments 110 Adjustments for Competition (2) fork damper (6) piston rod (2) (6) (6) piston rod (7) lock nut T urn the rebound adjuster and compression adjuster counterclockwise to the softest position. Check the fork damper piston rod sliding surface for damage.
Fr ont Suspension Adjustments Adjustments for Competition 111 (2) fork damper (8) spring chamber (10) pressure release screw (1 1) fork cap (8) spring chamber (9) oil hole (8) (2) (8) (9) (10) (11) 13. Drain the extra oil from the fork damper spring chamber (8) oil hole (9).
Fr ont Suspension Adjustments 112 Adjustments for Competition Fork Assembly 1. Drain the fork oil from the outer tube/slider by placing it upside down. (About 7 cc of fork oil will be left in the outer tube/slider when it is left inverted for about 20 minutes at 20°C) (1) outer tube/slider 2.
Adjustments for Competition 113 Fr ont Suspension Adjustments 4. Set the lower end (axle holder) of the slider in a vise with a piece of wood or soft jaws to avoid to damage. Overtightening the vise can damage the axle holder . 5. T emporarily install the fork damper to the fork.
114 Adjustments for Competition Fr ont Suspension Adjustments 13. Pour the recommended fork oil (1 1) into the outer tube/slider (1). Recommended Oil: Pro Honda HP Fork Oil 5 W or equivalent. (1) outer tube (1 1) fork oil (1) (11) () Fork Oil Capacity: Standard (0.
Adjustments for Competition 115 Fr ont Suspension Adjustments 15. Check that the O-ring (12) on the fork damper assembly (4) is in good condition. Apply the recommended fork oil to the O-ring. (1) outer tube/slider (12) O-ring (4) fork damper assembly 16.
116 Adjustments for Competition Fr ont Suspension Adjustments 19. Clean the threads of the fork protector bolts (15) and axle holder thoroughly . Apply locking agent to the bolt threads. Install the fork protectors (16), fork protector bolts, brake hose clamp bolts (17) and tripmeter cable clamp bolt (18).
Adjustments for Competition 117 Fr ont Suspension Adjustments 23. Install the handlebar (22), mounting rubbers (23), washers and handlebar holder nuts (24) and tighten the handlebar holder nuts to the specified torque: 33 Ibf · ft (44 N · m, 4.5 kgf · m) (22) handlebar (23) mounting rubbers (24) washers/handlebar holder nuts 24.
118 Adjustments for Competition Rear Suspension Adjustments Pin spanners should be used for turning the lock nut and adjusting nut. See page 159 for optional pin spanners. Spring pre-load length (Standard spring) Standard: 10.02 in (254.4 mm) Min. : 9.
Adjustments for Competition 119 Rear Suspension Adjustments (3) rebound damping adjuster T o adjust to the standard position: 1. T urn the adjuster clockwise until it will no longer turn (lightly seat).
120 Adjustments for Competition Rear Suspension Adjustments 4. Calculate the race sag dimension. T o do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Standard Race Sag: 3.9 in (100 mm) Adjust spring pre-load as necessary to obtain the desired handling results.
Adjustments for Competition 121 Rear Suspension Adjustments Because of the great absorption quality of the shock bumper rubber , it may be dif ficult for you to notice when your motorcycle ’ s suspension is bottoming. Some riders may think the damping or perhaps the leverage ratio is too harsh.
122 Adjustments for Competition Suspension Adjustments for T rack Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear . Sand often requires a bit more rebound damping to minimize rear end kick.
Adjustments for Competition 123 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF , using the methods described on pages 104 - 1 19. Remember to make all adjustments in one-click increments. T est ride after each adjustment.
124 Adjustments for Competition Suspension Adjustment Guidelines Stiff suspension Symptom Initial travel too stiff: • Stiff on small bumps while riding at full throttle in a straight line. • Stif f on small cornering bumps. • Front end wanders while riding at full throttle in a straight line.
Adjustments for Competition 125 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for T ype of T rack Symptoms and Adjustment • Always begin with the standard settings. • T urn the low speed compression and rebound adjusters in one-click increments, and the high speed compression adjuster in 1/6 turn increments at a time.
126 Adjustments for Competition Carbur etor Adjustments & T uning Tips The carburetor used on your CRF will seldom experience trouble with the standard settings under average load, and average climatic and barometric conditions.
Carbur etor Adjustments & T uning Tips Adjustments for Competition 127 Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened.
Carbur etor Adjustments & T uning Tips Carburetor Removal 1. T urn the fuel valve OFF . 2. Drain the remaining fuel in the float bowl by removing the float bowl plug (1). W ARNING Gasoline is highly flammable and explosive. Y ou can be burmed or seriously injured when handing fuel.
Carbur etor Adjustments & T uning Tips Adjustments for Competition 129 Carburetor Disassembly 1. Pull up the cable clamp (1) and remove the carburetor top bolts (2). Then remove the carburetor top (3). (1) cable clamp (2) carburetor top bolts (3) carburetor top 2.
Carbur etor Adjustments & T uning Tips When installing the floating valve (10) onto the throttle valve (8) make sure the floating valve’ s flat side faces out and the hole (11) faces down. (8) throttle valve (10) floating valve (1 1) hole (11) (8) (10) 130 Adjustments for Competition 5.
Carbur etor Adjustments & T uning Tips (26) float level (27) float level gauge (28) carburetor intake 10. Remove the leak jet (29) from the float bowl (18). Clean the leak jet. 9. Measure the float level (26) with the float level gauge (27) during float tab just contacting the float valve and the carburetor intake (28) facing up.
Carbur etor Adjustments & T uning Tips Pre-Adjustment Checks Before adjusting carburetor settings, check the following: • air cleaner • air leaks • float level • clogged carburetor jets .
Chassis Adjustments Adjustments for Competition 133 The following suggestions may improve a specific concern. Subtle changes in overall handling may also be noted. Rear End If you have a problem with rear wheel traction, raise the rear end of your motorcycle by increasing the rear spring pre-load.
Gearing 134 Adjustments for Competition Y ou can “adjust” the power delivery of the standard engine to suit track conditions by changing gearing. This allows you to utilize a different portion of the engine’ s power range at a given throttle setting.
T ir e Selection for T rack Conditions Adjustments for Competition 135 Choosing the correct tire tread pattern and rubber compound can affect your placing in competition. The tires on your motorcycle offer a “happy medium” for the variety of soil conditions the majority of riders are likely to encounter .
Personal Fit Adjustments 136 Adjustments for Competition The following suggestions may make your ride both more comfortable and more responsive to your control input. Control Positioning • Position the control levers so that you can use them comfortably when seated and standing.
T ips Tips 137 Here’ s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. T ransporting Y our Motorcycle .........................138 Storing Y our Motorcycle ..................................139 Y ou & the Environment .
T ransporting Y our Motor cycle 138 Tips If you use a truck or motorcycle trailer to transport your Honda, we recommend that you follow these guidelines: • Use a loading ramp. • Make sure the fuel valve is off. • Secure the motorcycle in an upright position, using motorcycle tie-down straps.
Storing Y our Honda Tips 139 W ARNING Gasoline is highly flammable and explosive. Y ou can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks and flame away . • Handle fuel only outdoors. • Wipe up spills immediately .
Storing Y our Honda 140 Tips Removal from Storage 1. Uncover and clean your CRF . Change the engine and transmission oil if more than 4 months have passed since the start of storage. 2. Uncover the end of the muffler and remove the rag from the muffler outlet.
Tips 141 Y ou & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport of off-road riding. Following are tips on how you can be an environmentally-responsible motorcycle owner .
142 Tips T r oubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis. The items that require use of the Honda Service Manual are followed by an asterisk. POOR PERFORMANCE A T LO W AND UNST ABLE IDLE SPEED CHECK POSSIBLE CA USES 1.
T aking Care of the Unexpected T aking Care of the Unexpected 143 This section gives practical advice to help you problems. If a Fuse Blows ...........
144 T aking Care of the Unexpected If a Fuse Blows All of the electrical circuits on your motorcycle have a fuse to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your motorcycle stops working, the first thing you should check for is a blown fuse.
If Y our Battery is Low (or Dead) Jump-starting is not recommended, especially if you use an automobile battery . The greater amperage of an automobile battery when the car engine is running can damage your motorcycle’ s electrical system. Bump starting is also not recommended.
146 T aking Care of Unexpected.
T echnical Information 147 T echnical Information This section contains dimensions, capacities, and other technical data. V ehicle Identification .......................................148 Specifications ...............................................
148 T echnical Information V ehicle Identification Serial Numbers The VIN frame and engine serial numbers are required when you register your motorcycle. They may also be required when ordering replacement parts. Y ou may record these numbers in the Quick Reference section at the rear of the manual.
T echnical Information 149 Specifications Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Dry weight Item English 85.6 in 32.6 in 49.6 in 58.4 in 37.7 in 17.0 in 13.6 in 236 Ibs Metric T ype Dimension Frame Fork oil capacity (except fork damper per leg) F .
Specifications 150 T echnical Information 27 54 Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Dry weight Item English 85.6 in 32.6 in 49.6 in 58.4 in 37.7 in 17.0 in 13.6 in 236 Ibs Metric T ype Dimension Frame Fork oil capacity (except fork damper per leg) F .
T echnical Information 151 T orque Specifications Nuts, Bolts, Fasteners Check and tighten nuts, bolts, and fasteners before every outing. Engine Item 1 2 3 4 5 6 7 8 9 10 ENGINE Cylinder head cov er .
152 T echnical Information T orque Specifications Frame Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FRAME Steering stem nut Fork bridge upper pinch bolts Fork bridge lower pinch bolts Hand.
T echnical Information 153 T orque Specifications Item 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 FRAME Front brake master cylinder holder bolts Brake hose bolts Caliper mounting b.
When operating this motorcycle at high altitude, the air-fuel mixture becomes overly rich. Above 6,500 feet (2,000 m), driveability and performance may be reduced and fuel consumption increased. The carburetor can be modified to compensate for this high altitude richness.
Emission Contr ol Systems Exhaust Emission Requirements The California Air Resources Board (CARB) requires that your motorcycle comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided.
156 T echnical Information Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. T o meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.
Consumer Information 157 Competition Logbook Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events. The best way to or ganize the many bits of information is to record them in a logbook. Y our logbook can include such information as suspension adjustments, gearing, and tire selection.
158 Consumer Information Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future us.
T echnical Information 159 Optional Parts List FRAME Remarks Shock spring Standard Stiffer Optional Softer Stiffer Fork spring Standard Optional Softer The standard fork spring and shock spring mounted on the motorcycle when it lea ves the factory are not marked.
160 T echnical Information Spar e Parts & Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding.
T echnical Information 161 W iring Diagram.
162 T echnical Information.
Consumer Information 163 Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual. Authorized Manuals .........................................164 Contacting Honda...................
Publication Item Description Qty . Price T otal Item No. Each * Price Sub T otal Mich. Purchasers Add 6% Sales T ax Handling $4.00 Charge Grand T otal 164 Consumer Information The Service Manual used by your authorized Honda dealer is available from Helm, Inc.
Consumer Information 165 Y our owner ’ s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner ’ s manual can be answered by your Honda dealer . If he doesn ’ t have the answer right away , he will get it for you.
166 Consumer Information Y our Honda Dealer Once you purchase your new Honda, get familiar with the organization of your Honda dealer so you can utilize the full range of services available. The service department is there to perform regular maintenance and unexpected repairs.
Consumer Information 167 The Honda Rider ’ s Club (USA only) One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider ’ s Club of America. Y our purchase of a new motorcycle, scooter , A TV or PWC from a participating U.
T able of Contents The following presents the contents of each section of your owner ’ s manual. MOTORCYCLE SAFETY...............................1 Important Safety Precautions..... .........................2 Loading..................................
T able of Contents TECHNICAL INFORMA TION ..................147 V ehicle Identification ......................................148 Specifications ..................................................149 T orque Specifications .............................
170 Index accessories ...........................................................4 adjustments, altitude and temperature .............................154 carburetor ....................................................132 chassis ......................
Index 171 Index gap, spark plug ...................................................61 gasohol ...............................................................41 gasoline ..............................................................41 gearing .........
172 Index Index suspension, front ..............................................................82 rear ................................................................83 suspension adjustment, front ...................................................
Memo 173.
An important point after buying a device Honda CRF250X (2005) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Honda CRF250X (2005) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Honda CRF250X (2005) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Honda CRF250X (2005) you will learn all the available features of the product, as well as information on its operation. The information that you get Honda CRF250X (2005) will certainly help you make a decision on the purchase.
If you already are a holder of Honda CRF250X (2005), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Honda CRF250X (2005).
However, one of the most important roles played by the user manual is to help in solving problems with Honda CRF250X (2005). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Honda CRF250X (2005) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
