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Table of Contents
- 2. A Few Words About Safety
- 3. Contents
- 4. Symbols
- 5. General Information
- 6. Service Rules
- 9. General Specifications
- 10. Lubrication System Specifications
- 11. Fuel System Specifications
- 12. Cylinder Head/Valves specifications
- 13. Clutch/Starter clutch/Kickstarter/Gearsh...
- 14. Front Wheel/Suspension/Steering Specific...
- 15. Hydraulic Brake Specifications
- 16. Electric Starter Specification
- 17. Standard Torque Values
- 24. Lubrication & Seal Points
- 27. Cable & Harness Routing
- 33. Secondary Air Supply System
- 34. Optional Parts
- 37. Emission Control Systems
- 39. Servicing the Honda
- 41. Frame/Body Panels/Exhaust system
- 42. Service information
- 43. Seat Removal
- 44. Radiator Shroud Removal/Installation
- 45. Front Visor Removal/Installation
- 46. Sub-Frame Installation
- 47. Fuel Tank Removal/Installation
- 48. Exhaust System Muffler Removal/Installat...
- 53. Maintenance
- 54. Maintenance Service information
- 55. Tools
- 56. MAINTENANCE SCHEDULE ('04 - '06)
- 58. COMPETITION MAINTENANCE SCHEDULE
- 59. Additional Items Requiring Frequent Repl...
- 60. Fuel Line
- 61. Hot Start
- 62. Air Cleaner
- 63. Crankcase Breather
- 64. Spark Plug Inspection
- 65. Radiator Coolant
- 66. Valve Clearance/Decompressor System
- 69. Engine Oil/Oil Filter
- 71. Engine Idle Speed
- 72. Transmission Oil
- 73. Drive Chain Slack Inspection
- 74. Drive chain replacement
- 76. Drive chain Slider
- 77. Drive Chain Roller
- 78. Brake Fluid Level Inspection
- 79. Brake Pad Wear
- 80. Headlight Aim
- 81. Control Cables
- 82. Spark Arrester Removal/Installation
- 83. Side Stand Inspection
- 84. Swingarm/Shock Linkage
- 85. Nuts, Bolts, Fasteners
- 86. Steering Head Bearings
- 87. Lubrication System
- 88. Lubrication System Diagram
- 89. Lubrication System Service information
- 90. Oil Strainer Removal/Inspection
- 91. Pressure Relief Valve removal/installati...
- 92. Oil Jet Removal/Inspection
- 93. Oil Pump Disassembly
- 95. Oil Pump Assembly
- 97. Fuel System
- 98. Fuel System Component Location
- 99. Fuel System Service information
- 100. Fuel System Torque Values
- 101. Fuel System Troubleshooting
- 102. Carburetor Adjustment
- 103. Air Cleaner Housing Removal
- 105. Air Cleaner Housing Installation
- 107. Carburetor Removal
- 109. Carburettor Disassembly
- 110. Choke knob/Throttle Position Sensor
- 111. Accelerator Pump/Float/Jet
- 114. Carburetor Assembly
- 120. Carburetor Installation
- 122. Throttle Position Sensor Replacement
- 123. Pilot Screw Adjustment
- 124. Idle Drop Procedure
- 125. HIGH ALTITUDE ADJUSTMENT (California typ...
- 127. Secondary Air Supply System Inspection
- 128. Pair Check Valve Inspection
- 132. Cooling System Flow Pattern
- 133. Cooling System Service Information
- 134. Cooling System Tools
- 135. Cooling System Testing
- 136. Radiator Cap/System pressure inspection
- 137. Replacement/Air Bleeding
- 138. Radiator Removal
- 139. Radiator Installation
- 140. Water Pump
- 142. Water Pump Bearing/Water Seal/Oil Seal R...
- 143. Water Pump Installation
- 145. Engine Removal/Installation
- 146. Engine Removal/Installation Component Lo...
- 148. Drive Sprocket Removal
- 149. Engine Removal
- 151. Engine Installation
- 155. Cylinder Head/Valves
- 156. Cylinder Head/Valves Component Location
- 157. Cylinder Head/Valves Service Information
- 158. Cylinder Head/Valves Tools
- 159. Cylinder Head/Valves Troubleshooting
- 160. Cylinder Compression Test
- 161. Camshaft/Rocker Arm Removal
- 166. Cylinder Head Removal
- 168. Cam Chain Tensioner/Cam Chain Guide Remo...
- 169. Cylinder Head Disassembly
- 171. Cylinder head inspection
- 172. Valve/Valve Guide
- 173. Valve Guide Replacement
- 174. Valve seat refacing
- 176. Intake Side
- 177. Cylinder Head Assembly
- 179. Cylinder Head Installation
- 181. Camshaft/Rocker Arm Installation
- 184. Cylinder Head Cover Installation
- 187. Cylinder/Piston
- 188. Cylinder/Piston component location
- 189. Cylinder/Piston Service information
- 190. Cylinder Removal
- 191. Cylinder/Piston Inspection
- 193. Connecting Rod Inspection
- 194. Piston Installation
- 197. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 198. COMPONENT LOCA nON
- 199. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 200. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 201. Right Crankcase Cover Removal
- 202. Right Crankcase Cover Installation
- 203. Clutch Removal
- 205. Clutch Inspection
- 206. Clutch Plates
- 207. Clutch Lifter Rod
- 211. Kickstarter removal
- 212. Kickstarter disassembly/inspection
- 213. Kickstarter assembly
- 214. Kickstarter installation
- 215. Starter clutch removal
- 216. Starter clutch disassembly/inspection
- 218. Starter clutch assembly
- 219. Starter clutch installation
- 221. Gearshift Linkage Removal
- 222. Gearshift Linkage Inspection
- 225. Alternator
- 226. Alternator Component Location
- 227. Alternator Service Information
- 228. Left Crankcase Cover Removal
- 229. Stator Removal
- 231. Left Crankcase Cover Installation
- 233. Crankcase/Crankshaft/Transmission/Balanc...
- 234. Crankcase/Crankshaft/Transmission/Balanc...
- 235. Crankcase/Crankshaft/Transmission/Balanc...
- 236. Crankcase/Crankshaft/Transmission/Balanc...
- 237. Crankcase/Crankshaft/Transmission/Balanc...
- 238. Balancer Gear/Balancer Removal
- 239. Crankcase Separation
- 241. Transmission Disassembly
- 242. Transmission Inspection
- 243. Shift fork
- 244. Crankshaft Removal
- 245. Crankcase Bearing Replacement
- 247. Transmission/Balancer/Shift Drum bearing...
- 250. Crankshaft Installation
- 251. Transmission Assembly
- 253. Crankcase Assembly
- 255. Front Wheel/Suspension/Steering
- 256. Front Wheel/Suspension/Steering Componen...
- 257. Front Wheel/Suspension/Steering Service ...
- 258. Front Wheel/Suspension/Steering Torque V...
- 260. Front Wheel/Suspension/Steering Troubles...
- 261. Front Wheel Removal
- 262. Front Wheel Disassembly
- 263. Front Wheel Assembly
- 265. Front Wheel Installation
- 266. Fork Removal
- 268. Fork Disassembly
- 270. Outer Tube and Slider Disassembly
- 271. Fork Damper Disassembly
- 272. Fork Damper Inspection
- 273. Fork Spring
- 274. Outer Tube and Slider Assembly
- 275. Fork Damper Refilling/Assembly
- 278. Fork Damper Operation Inspection
- 279. Fork Damper Installation/Preparation
- 280. Fork Damper Installation
- 282. Oil Capacity Adjustment
- 283. Standard Position
- 285. Handlebar Removal
- 287. Handlebar Installation
- 291. Steering Stem Removal
- 292. Steering Stem Bearing Replacement
- 294. Steering Stem Installation
- 297. Rear Wheel/Suspension
- 298. Rear Wheel/Suspension Component Location
- 299. Rear Wheel/Suspension Service informatio...
- 300. Rear Wheel/Suspension Torque Values
- 302. Rear Wheel/Suspension Troubleshooting
- 303. Rear Wheel Removal
- 304. Rear Wheel Disassembly
- 305. Rear Wheel Assembly
- 308. Rear Wheel Installation
- 309. Shock Absorber Removal
- 310. Shock Absorber Disassembly
- 313. Damper Disassembly
- 315. Piston Ring Replacement
- 317. Rod Guide Case Inspection
- 318. Damper Assembly
- 323. Spherical Bearing Replacement
- 325. Shock Linkage Removal
- 327. Shock Linkage Inspection
- 328. Shock Link Needle Bearing
- 331. Swingarm Removal
- 333. Swingarm Disassembly
- 334. Swingarm Bearing Replacement
- 336. Swingarm Installation
- 339. Hydraulic Brake
- 340. Hydraulic Brake Component Location
- 341. Hydraulic Brake Service Information
- 342. Hydraulic Brake Torque Values
- 343. Hydraulic Brake Troubleshooting
- 344. Brake Fluid Replacement/Air Bleeding
- 345. Brake Fluid Filling/Air Bleeding
- 348. Brake Pad/Disc
- 350. Front Master Cylinder Removal
- 353. Rear Master Cylinder Removal
- 354. Rear Master Cylinder inspection
- 355. Rear Master Cylinder Installation
- 356. Front Brake Caliper Removal
- 357. Front Brake Caliper inspection
- 358. Front Brake Caliper Installation
- 365. Battery/Charging System
- 366. Battery/Charging System Component Locati...
- 367. Battery/Charging System Service informat...
- 368. Battery/Charging System Tools
- 369. Battery/Charging System Troubleshooting
- 370. Battery Removal/Installation
- 371. Regulator/Rectifier System Inspection
- 372. Alternator Charging Coil inspection
- 373. Ignition System
- 374. Ignition System Component Location
- 375. Ignition System Service Information
- 376. Ignition System Troubleshooting
- 377. Ignition System Inspection
- 378. Direct Ignition Coil Inspection
- 379. Ignition Pulse Generator Peak Voltage
- 380. Ignition Control Module (ICM) Removal/In...
- 381. Throttle Position Sensor Inspection
- 383. Electric Starter
- 384. Electric Starter Component Location
- 385. Electric Starter Service Information
- 386. Electric Starter Troubleshooting
- 388. Starter Motor Removal
- 391. Starter Motor Assembly
- 393. Starter Motor Installation
- 394. Starter Relay Switch Power Input Line
- 395. Lights/Meter/Switches
- 396. Lights/Meter/Switches Component Location
- 397. Lights/Meter/Switches Service Informatio...
- 398. Headlight Bulb Replacement
- 399. Headlight Removal/Installation
- 400. Engine Stop Button
- 401. Clutch Switch Inspection
- 402. Starter Switch
- 403. Main Relay Inspection
- 406. Wiring Diagram
- 410. Engine Does Not Start Or Is Hard To Star...
- 411. Engine Lacks Power
- 413. Poor Performance At Low And Idle Speed
- 414. Poor Performance At High Speed
- 415. Poor Handling
- 417. Index
Page 1 of 418
Table of Contents
- 2. A Few Words About Safety
- 3. Contents
- 4. Symbols
- 5. General Information
- 6. Service Rules
- 9. General Specifications
- 10. Lubrication System Specifications
- 11. Fuel System Specifications
- 12. Cylinder Head/Valves specifications
- 13. Clutch/Starter clutch/Kickstarter/Gearsh...
- 14. Front Wheel/Suspension/Steering Specific...
- 15. Hydraulic Brake Specifications
- 16. Electric Starter Specification
- 17. Standard Torque Values
- 24. Lubrication & Seal Points
- 27. Cable & Harness Routing
- 33. Secondary Air Supply System
- 34. Optional Parts
- 37. Emission Control Systems
- 39. Servicing the Honda
- 41. Frame/Body Panels/Exhaust system
- 42. Service information
- 43. Seat Removal
- 44. Radiator Shroud Removal/Installation
- 45. Front Visor Removal/Installation
- 46. Sub-Frame Installation
- 47. Fuel Tank Removal/Installation
- 48. Exhaust System Muffler Removal/Installat...
- 53. Maintenance
- 54. Maintenance Service information
- 55. Tools
- 56. MAINTENANCE SCHEDULE ('04 - '06)
- 58. COMPETITION MAINTENANCE SCHEDULE
- 59. Additional Items Requiring Frequent Repl...
- 60. Fuel Line
- 61. Hot Start
- 62. Air Cleaner
- 63. Crankcase Breather
- 64. Spark Plug Inspection
- 65. Radiator Coolant
- 66. Valve Clearance/Decompressor System
- 69. Engine Oil/Oil Filter
- 71. Engine Idle Speed
- 72. Transmission Oil
- 73. Drive Chain Slack Inspection
- 74. Drive chain replacement
- 76. Drive chain Slider
- 77. Drive Chain Roller
- 78. Brake Fluid Level Inspection
- 79. Brake Pad Wear
- 80. Headlight Aim
- 81. Control Cables
- 82. Spark Arrester Removal/Installation
- 83. Side Stand Inspection
- 84. Swingarm/Shock Linkage
- 85. Nuts, Bolts, Fasteners
- 86. Steering Head Bearings
- 87. Lubrication System
- 88. Lubrication System Diagram
- 89. Lubrication System Service information
- 90. Oil Strainer Removal/Inspection
- 91. Pressure Relief Valve removal/installati...
- 92. Oil Jet Removal/Inspection
- 93. Oil Pump Disassembly
- 95. Oil Pump Assembly
- 97. Fuel System
- 98. Fuel System Component Location
- 99. Fuel System Service information
- 100. Fuel System Torque Values
- 101. Fuel System Troubleshooting
- 102. Carburetor Adjustment
- 103. Air Cleaner Housing Removal
- 105. Air Cleaner Housing Installation
- 107. Carburetor Removal
- 109. Carburettor Disassembly
- 110. Choke knob/Throttle Position Sensor
- 111. Accelerator Pump/Float/Jet
- 114. Carburetor Assembly
- 120. Carburetor Installation
- 122. Throttle Position Sensor Replacement
- 123. Pilot Screw Adjustment
- 124. Idle Drop Procedure
- 125. HIGH ALTITUDE ADJUSTMENT (California typ...
- 127. Secondary Air Supply System Inspection
- 128. Pair Check Valve Inspection
- 132. Cooling System Flow Pattern
- 133. Cooling System Service Information
- 134. Cooling System Tools
- 135. Cooling System Testing
- 136. Radiator Cap/System pressure inspection
- 137. Replacement/Air Bleeding
- 138. Radiator Removal
- 139. Radiator Installation
- 140. Water Pump
- 142. Water Pump Bearing/Water Seal/Oil Seal R...
- 143. Water Pump Installation
- 145. Engine Removal/Installation
- 146. Engine Removal/Installation Component Lo...
- 148. Drive Sprocket Removal
- 149. Engine Removal
- 151. Engine Installation
- 155. Cylinder Head/Valves
- 156. Cylinder Head/Valves Component Location
- 157. Cylinder Head/Valves Service Information
- 158. Cylinder Head/Valves Tools
- 159. Cylinder Head/Valves Troubleshooting
- 160. Cylinder Compression Test
- 161. Camshaft/Rocker Arm Removal
- 166. Cylinder Head Removal
- 168. Cam Chain Tensioner/Cam Chain Guide Remo...
- 169. Cylinder Head Disassembly
- 171. Cylinder head inspection
- 172. Valve/Valve Guide
- 173. Valve Guide Replacement
- 174. Valve seat refacing
- 176. Intake Side
- 177. Cylinder Head Assembly
- 179. Cylinder Head Installation
- 181. Camshaft/Rocker Arm Installation
- 184. Cylinder Head Cover Installation
- 187. Cylinder/Piston
- 188. Cylinder/Piston component location
- 189. Cylinder/Piston Service information
- 190. Cylinder Removal
- 191. Cylinder/Piston Inspection
- 193. Connecting Rod Inspection
- 194. Piston Installation
- 197. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 198. COMPONENT LOCA nON
- 199. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 200. Clutch/Starter Clutch/Kickstarter/Gearsh...
- 201. Right Crankcase Cover Removal
- 202. Right Crankcase Cover Installation
- 203. Clutch Removal
- 205. Clutch Inspection
- 206. Clutch Plates
- 207. Clutch Lifter Rod
- 211. Kickstarter removal
- 212. Kickstarter disassembly/inspection
- 213. Kickstarter assembly
- 214. Kickstarter installation
- 215. Starter clutch removal
- 216. Starter clutch disassembly/inspection
- 218. Starter clutch assembly
- 219. Starter clutch installation
- 221. Gearshift Linkage Removal
- 222. Gearshift Linkage Inspection
- 225. Alternator
- 226. Alternator Component Location
- 227. Alternator Service Information
- 228. Left Crankcase Cover Removal
- 229. Stator Removal
- 231. Left Crankcase Cover Installation
- 233. Crankcase/Crankshaft/Transmission/Balanc...
- 234. Crankcase/Crankshaft/Transmission/Balanc...
- 235. Crankcase/Crankshaft/Transmission/Balanc...
- 236. Crankcase/Crankshaft/Transmission/Balanc...
- 237. Crankcase/Crankshaft/Transmission/Balanc...
- 238. Balancer Gear/Balancer Removal
- 239. Crankcase Separation
- 241. Transmission Disassembly
- 242. Transmission Inspection
- 243. Shift fork
- 244. Crankshaft Removal
- 245. Crankcase Bearing Replacement
- 247. Transmission/Balancer/Shift Drum bearing...
- 250. Crankshaft Installation
- 251. Transmission Assembly
- 253. Crankcase Assembly
- 255. Front Wheel/Suspension/Steering
- 256. Front Wheel/Suspension/Steering Componen...
- 257. Front Wheel/Suspension/Steering Service ...
- 258. Front Wheel/Suspension/Steering Torque V...
- 260. Front Wheel/Suspension/Steering Troubles...
- 261. Front Wheel Removal
- 262. Front Wheel Disassembly
- 263. Front Wheel Assembly
- 265. Front Wheel Installation
- 266. Fork Removal
- 268. Fork Disassembly
- 270. Outer Tube and Slider Disassembly
- 271. Fork Damper Disassembly
- 272. Fork Damper Inspection
- 273. Fork Spring
- 274. Outer Tube and Slider Assembly
- 275. Fork Damper Refilling/Assembly
- 278. Fork Damper Operation Inspection
- 279. Fork Damper Installation/Preparation
- 280. Fork Damper Installation
- 282. Oil Capacity Adjustment
- 283. Standard Position
- 285. Handlebar Removal
- 287. Handlebar Installation
- 291. Steering Stem Removal
- 292. Steering Stem Bearing Replacement
- 294. Steering Stem Installation
- 297. Rear Wheel/Suspension
- 298. Rear Wheel/Suspension Component Location
- 299. Rear Wheel/Suspension Service informatio...
- 300. Rear Wheel/Suspension Torque Values
- 302. Rear Wheel/Suspension Troubleshooting
- 303. Rear Wheel Removal
- 304. Rear Wheel Disassembly
- 305. Rear Wheel Assembly
- 308. Rear Wheel Installation
- 309. Shock Absorber Removal
- 310. Shock Absorber Disassembly
- 313. Damper Disassembly
- 315. Piston Ring Replacement
- 317. Rod Guide Case Inspection
- 318. Damper Assembly
- 323. Spherical Bearing Replacement
- 325. Shock Linkage Removal
- 327. Shock Linkage Inspection
- 328. Shock Link Needle Bearing
- 331. Swingarm Removal
- 333. Swingarm Disassembly
- 334. Swingarm Bearing Replacement
- 336. Swingarm Installation
- 339. Hydraulic Brake
- 340. Hydraulic Brake Component Location
- 341. Hydraulic Brake Service Information
- 342. Hydraulic Brake Torque Values
- 343. Hydraulic Brake Troubleshooting
- 344. Brake Fluid Replacement/Air Bleeding
- 345. Brake Fluid Filling/Air Bleeding
- 348. Brake Pad/Disc
- 350. Front Master Cylinder Removal
- 353. Rear Master Cylinder Removal
- 354. Rear Master Cylinder inspection
- 355. Rear Master Cylinder Installation
- 356. Front Brake Caliper Removal
- 357. Front Brake Caliper inspection
- 358. Front Brake Caliper Installation
- 365. Battery/Charging System
- 366. Battery/Charging System Component Locati...
- 367. Battery/Charging System Service informat...
- 368. Battery/Charging System Tools
- 369. Battery/Charging System Troubleshooting
- 370. Battery Removal/Installation
- 371. Regulator/Rectifier System Inspection
- 372. Alternator Charging Coil inspection
- 373. Ignition System
- 374. Ignition System Component Location
- 375. Ignition System Service Information
- 376. Ignition System Troubleshooting
- 377. Ignition System Inspection
- 378. Direct Ignition Coil Inspection
- 379. Ignition Pulse Generator Peak Voltage
- 380. Ignition Control Module (ICM) Removal/In...
- 381. Throttle Position Sensor Inspection
- 383. Electric Starter
- 384. Electric Starter Component Location
- 385. Electric Starter Service Information
- 386. Electric Starter Troubleshooting
- 388. Starter Motor Removal
- 391. Starter Motor Assembly
- 393. Starter Motor Installation
- 394. Starter Relay Switch Power Input Line
- 395. Lights/Meter/Switches
- 396. Lights/Meter/Switches Component Location
- 397. Lights/Meter/Switches Service Informatio...
- 398. Headlight Bulb Replacement
- 399. Headlight Removal/Installation
- 400. Engine Stop Button
- 401. Clutch Switch Inspection
- 402. Starter Switch
- 403. Main Relay Inspection
- 406. Wiring Diagram
- 410. Engine Does Not Start Or Is Hard To Star...
- 411. Engine Lacks Power
- 413. Poor Performance At Low And Idle Speed
- 414. Poor Performance At High Speed
- 415. Poor Handling
- 417. Index
Also for: 2005 CRF250X
File size: 44.22 MB
Created: March 07, 2023
Last updated: March 26, 2023
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