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Honda 2004 CRF250R Service Manual

Honda 2004 CRF250R
406 pages
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Table of Contents

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Honda 2004 CRF250R Specifications

General IconGeneral
Engine TypeLiquid-cooled single-cylinder four-stroke
Displacement249 cc
Bore x Stroke78.0mm x 52.2mm
Compression Ratio12.5:1
InductionKeihin 37 mm flat-slide carburetor
IgnitionCDI
Transmission5-speed
Front BrakeSingle 240 mm disc with twin-piston caliper
Rear BrakeSingle 240 mm disc
Front Tire80/100-21
Rear Tire100/90-19
Wheelbase58.3 inches
Seat Height37.6 inches
Fuel Capacity1.9 gallons
Valve Trainfour-valve
Final Drive520 chain
Front Suspension47mm inverted Showa cartridge fork with 16-position rebound and 16-position compression damping adjustability; 12.4 inches travel
Rear SuspensionPro-Link Showa single shock with spring preload, 17-position rebound damping adjustability, and compression damping adjustment separated into low-speed (13 positions) and high-speed (3.5 turns); 12.4 inches travel
Curb Weight204 lbs

Summary

A Few Words About Safety

Service Information

General guidance and warnings for servicing the motorcycle safely.

Important Safety Precautions

Crucial safety measures to follow during maintenance and operation.

SYMBOLS

Service Symbol Definitions

Explanation of symbols used in service procedures for clarity.

GENERAL INFORMATION

Service Rules

Essential guidelines for performing service and maintenance on the motorcycle.

General Specifications

Key technical data and dimensions for the motorcycle model.

Standard Torque Values

Specifications for tightening various fasteners to ensure proper assembly.

TECHNICAL FEATURE

HPSD Operation and Servicing

Details on the steering damper's function, characteristics, and maintenance.

FRAME/BODY PANELS/EXHAUST SYSTEM

Frame and Body Panel Service

Procedures for removing and installing seat and side covers.

Fuel Filter Maintenance

Instructions for draining and cleaning the fuel filter.

Exhaust System Removal/Installation

Instructions for servicing the exhaust system components.

MAINTENANCE

Maintenance Schedule

Recommended service intervals and tasks for regular upkeep.

Throttle and Air Cleaner Service

Procedures for checking and adjusting throttle and servicing the air cleaner.

Cooling System Service

Information and procedures for maintaining the cooling system.

LUBRICATION SYSTEM

Lubrication System Diagram and Specs

Visual overview and specifications for the lubrication system.

Oil Strainer and Relief Valve

Procedures for servicing the oil strainer and relief valve.

FUEL SYSTEM

Carburetor Adjustment

Steps for minor and major carburetor adjustments.

Tuning for Special Conditions

Guidance for adjusting the carburetor for atmospheric conditions.

COOLING SYSTEM

Coolant Replacement

Instructions for draining, refilling, and bleeding the cooling system.

Radiator Removal and Installation

Procedures for removing and installing the radiator.

ENGINE REMOVAL/INSTALLATION

Engine Removal Steps

Step-by-step guide for removing the engine from the frame.

Engine Installation Steps

Procedures for correctly installing the engine back into the frame.

CYLINDER HEAD/VALVES

Valve Clearance Inspection and Adjustment

How to check and adjust valve clearance using feeler gauges and shims.

Cylinder Head Disassembly

Procedures for disassembling the cylinder head components.

CYLINDER/PISTON

Cylinder and Piston Removal

Instructions for removing the cylinder and piston from the engine.

Cylinder/Piston Inspection

How to inspect the cylinder bore and piston for wear or damage.

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE

Clutch Service

Detailed procedures for clutch removal, inspection, and installation.

Gearshift Linkage Service

Procedures for inspecting and servicing the gearshift linkage.

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

Crankcase Separation and Assembly

Steps for separating and reassembling the crankcase halves.

Transmission Assembly

Guide for assembling the transmission gears and components.

FRONT WHEEL/SUSPENSION/STEERING

Front Wheel Service

Procedures for removing, inspecting, and installing the front wheel.

Fork Service

Procedures for fork removal, disassembly, and assembly.

Handlebar Removal/Installation

Instructions for removing and installing the handlebar and controls.

REAR WHEEL/SUSPENSION

Rear Wheel Service

Steps for removing, inspecting, and installing the rear wheel.

Shock Absorber Service

Procedures for shock absorber removal, disassembly, and reassembly.

HYDRAULIC BRAKE

Brake Fluid Replacement and Air Bleeding

Instructions for changing brake fluid and bleeding the system.

Brake Pads and Disc Service

Procedures for replacing brake pads and inspecting brake discs.

ELECTRICAL SYSTEM

Ignition System Inspection

Checks for spark plug, ignition coil, and related components.

Throttle Position Sensor Inspection

How to test the throttle position sensor for proper function.

WIRING DIAGRAM

Wiring Diagram Details

Detailed wiring diagrams for different model years.

TROUBLESHOOTING

Engine Start Issues

Diagnostic steps for starting problems and common causes.

Engine Power Loss

Troubleshooting guide for diagnosing and resolving engine power loss.

Handling Problems

Troubleshooting steps for issues related to motorcycle handling.

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