Honda 2004 CRF250R - Valve Seat Refacing

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A few Words about Safety2
Service Information2
For Your Customer's Safety2
Important Safety Precautions2
Contents3
Symbols4
General Information: Contents5
Service Rules6
Model Identification6
General Specifications8
Lubrication System Specifications10
Fuel System Specifications10
Cooling System Specifications11
Cylinder Head/Valves Specifications11
Cylinder/Piston Specifications12
Clutch/Kickstarter/Gearshift Linkage Specifications12
Crankcase/Crankshaft/Transmission/Balancer Specifications13
Front Wheel/Suspension/Steering Specifications14
Rear Wheel/Suspension Specifications15
Hydraulic Brake Specifications15
Electrical System Specifications16
Standard Torque Values17
Engine and Frame Torque Values17
Insulator Clamp19
Cylinder Stud Bolt19
Frame General Information20
Lubrication and Seal Points23
Frame25
Cable and Harness Routing26
Optional Parts34
Technical Feature40
HPSD (Honda Progressive Steering Damper/After '07)41
HPSD Characteristics42
Turning Handlebar from Neutral Position to Full Angle (Extension)43
Turning Handlebar from Angle to Neutral Position (Compression)44
Frame/Body Panels/Exhaust System: Contents45
Frame/Body Panels/Exhaust System: System Information, Torque Values, Troubleshooting46
Seat Removal/Installation47
Side Cover Removal/Installation47
Radiator Shroud Removal/Installation48
Engine Guard Removal/Installation48
Number Plate Removal/Installation49
Sub-Frame Removal/Installation50
Fuel Tank Removal/Installation51
Fuel Filter Maintenance52
Exhaust System53
Muffler Removal/Installation53
Exhaust Joint Pipe Removal/Installation (after '05)54
Exhaust Pipe Removal55
Exhaust Pipe Installation56
Maintenance: Contents59
Maintenance: Service Information, Specifications60
Torque Values61
Tools61
Maintenance Schedule62
Additional Items Requiring Frequent Replacement63
Throttle Operation64
Hot Start64
Air Cleaner65
Crankcase Breather66
Spark Plug Removal, Inspection67
Radiator Coolant68
Valve Clearance/Decompressor System69
Valve Clearance Inspection69
Valve Clearance Adjustment70
Engine Oil/Oil Filter71
Oil Level Inspection71
Decompressor System71
Engine Oil and Filter Change72
Engine Idle Speed74
Transmission Oil74
Cooling System75
Transmission Oil Change75
Drive Chain Cleaning and Lubrication76
Drive Chain Slack Inspection/Adjustment77
Drive Chain Slider77
Drive Chain Roller78
Drive/Driven Sprocket78
Brake Fluid Level Inspection79
Fluid Filling79
Brake Pad Wear80
Brake System80
Lever Position Inspection80
Clutch System81
Clutch Lever Position81
Clutch Lever Free Play82
Control Cables83
Exhaust Pipe/Muffler83
Exhaust Inspection83
Glass Wool Replacement84
Front/Rear Suspension Inspection86
Swingarm/Shock Linkage87
Nuts, Bolts, Fasteners87
Wheels/Tires88
Steering Head Bearings89
Lubrication System: Contents90
Lubrication System Diagram91
Lubrication System: Service Information, Specifications, Troubleshooting92
Oil Strainer Removal/Inspection/Installation93
Oil Relief Valve Removal/Inspection/Installation94
Oil Jet Removal/Inspection/Installation95
Oil Pump Disassembly/Inspection96
Oil Pump Assembly98
Fuel System: Contents99
Component Location of Fuel System100
Fuel System: Service Information, Specifications101
Fuel System: Torque Values, Tools102
Fuel System Troubleshooting103
Carburetor Adjustment, Minor104
Idle Mixture and Idle Speed104
Carburetor Adjustment, Major: for Temperature and Altitude105
Tuning Information Chart '04, '05108
Tuning Information Chart '06, '07109
Tuning Information Chart '08, after '08110
Tuning for Special Conditions111
Air Cleaner Housing Removal112
Air Cleaner Housing Installation113
Carburetor Removal114
Carburetor Assembly116
Jet Needle/Throttle Valve116
SE Valve/Throttle Position Sensor117
Accelerator Pump/Float/Jets118
Carburetor Assembly Overview122
Carburetor Installation128
Throttle Position Sensor Replacement130
Pilot Screw Adjustment131
Cooling System: Contents132
System Flow Pattern133
Cooling System: Service Information134
Tools for Cooling System, Troubleshooting135
Cooling System Testing136
Coolant (Hydrometer Test)136
Coolant Gravity Chart136
Radiator Cap/System Pressure Inspection137
Coolant Replacement: Preparation137
Coolant Replacement/Air Bleeding138
Radiator Removal138
Radiator Installation139
Water Pump140
Water Seal Inspection/Removal140
Bearing/Water Seal/Oil Seal Replacement142
Bearing/Water Seal/Oil Seal Installation144
Engine Removal/Installation: Contents146
Engine: Component Location147
Engine Service Information, Specification148
Engine Removal150
Engine Installation151
Cylinder Head/Valves: Contents154
Cylinder Head/Valves: Component Location155
Cylinder Head/Valves: Service Information, Specification156
Cylinder Head/Valves: Troubleshooting159
Cylinder Compression Test160
Cylinder Head Cover Removal160
Camshaft/Rocker Arm Removal161
Rocker Arm163
Rocker Arm Disassembly/Inspection164
Cylinder Head Removal166
Rocker Arm Assembly166
Cam Chain Tensioner/Cam Chain Guide Removal/Inspection168
Cylinder Head Disassembly169
Cam Chain Tensioner/Cam Chain Guide Installation169
Cylinder Head Inspection170
Valve Spirit/Guide171
Valve Guide Replacement172
Valve Seat Inspection/Refacing173
Valve Seat Refacing174
Cylinder Head Assembly177
Cylinder Head Installation180
Camshaft/Rocker Arm Installation181
Cylinder Head Cover Installation185
Cylinder/Piston187
Cylinder/Piston: Component Location188
Cylinder/Piston: Service Information, Troubleshooting189
Cylinder/Piston Removal190
Cylinder/Piston/Piston Ring Inspection191
Connecting Rod Inspection193
Piston Ring Installation193
Cam Chain Tensioner Lifter Inspection193
Piston, Cylinder Installation194
Clutch/Kickstarter/Gearshift Linkage: Contents196
Clutch/Kickstarter/Gearshift Linkage: Component Location197
Clutch/Kickstarter/Gearshift Linkage: Service Information, Tools198
Clutch/Kickstarter/Gearshift Linkage: Troubleshooting199
Right Crankcase Cover Removal200
Right Crankcase Cover Installation201
Clutch Removal202
Clutch Inspection204
Clutch Plates, Center205
Judder Spring/Spring Seat205
Clutch Lifter/Needle Bearing205
Clutch Lifter Rod/Lever206
Clutch Outer206
Clutch Outer Guide, Bearing206
Clutch Installation207
Kickstarter Removal, Disassembly, Inspection211
Kickstarter Assembly212
Kickstarter Installation213
Gearshift Linkage Removal214
Gearshift Linkage Inspection215
Gearshift Spindle215
Gearshift Linkage Installation216
Ratchet Pawl216
Crankcase/Crankshaft/Transmission/Balancer: Contents218
Crankcase/Crankshaft/Transmission/Balancer: Component Location219
Crankcase/Crankshaft/Transmission/Balancer: Service Information, Specifications220
Crankcase/Crankshaft/Transmission/Balancer: Torque Values, Tools221
Crankcase/Crankshaft/Transmission/Balancer: Troubleshooting223
Balancer Gear/Balancer Removal, Inspection224
Balancer Gear/Balancer Installation225
Crankcase Separation226
Transmission Disassembly229
Transmission Inspection230
Shift Fork Shaft/Shift Drum231
Transmission Bearing231
Crankshaft Removal/Inspection232
Crankcase Bearing Replacement233
Crankcase Bearing/Oil Seal Location233
Transmission/Balancer/Shift Drum Bearings235
Left Crankcase235
Right Crankcase237
Crankcase Installation241
Crankcase Assembly242
Front Wheel/Suspension/Steering: Contents245
Front Wheel/Suspension/Steering: Component Location246
Front Wheel/Suspension/Steering: Service Information249
Front Wheel/Suspension/Steering: Torque Values250
Front Wheel/Suspension/Steering: Tools251
Front Wheel/Suspension/Steering: Troubleshooting253
Front Wheel Removal254
Front Wheel Inspection255
Axle255
Wheel Bearing255
Front Wheel Disassembly256
Front Wheel Assembly257
Front Wheel Installation260
Fork Removal263
Fork Disassembly264
Fork Damper Disassembly267
Outer Tube and Slider Disassembly267
Fork Damper Inspection268
Fork Cap Assembly268
Fork Center Bolt269
Slider/Outer Tube269
Fork Spring270
Bushing/Back-Up Ring270
Fork Damper270
Fork Assembly271
Outer Tube and Slider Assembly272
Fork Damper Refilling/Assembly273
Fork Damper Operation Inspection276
Fork Damper Installation/Preparation277
Fork Damper Installation278
Oil Capacity Adjustment280
Fork Installation281
Standard Position282
Handlebar Removal283
Handlebar Installation285
HPSD (Honda Progressive Steering Damper) Removal/Installation288
HPSD Inspection289
Spherical Bearing Replacement290
HPSD Disassembly291
HPSD Assembly293
Steering Stem Removal298
Bearing Replacement299
Bearing Installation301
Rear Wheel/Suspension: Contents303
Rear Wheel/Suspension: Component Location304
Rear Wheel/Suspension: Service Information305
Rear Wheel/Suspension: Torque Values306
Rear Wheel/Suspension: Tools307
Rear Wheel/Suspension: Troubleshooting309
Rear Wheel Removal, Inspection310
Rear Wheel Disassembly311
Wheel Rim Runout311
Rear Wheel Assembly312
Rear Wheel Installation315
Shock Absorber Removal, Disassembly316
Bladder Replacement317
Recommended Shock Oil319
Damper Disassembly320
Piston Ring Replacement321
Damper Rod Disassembly322
Rod Guide Case Inspection324
Rebound Spring Inspection324
Damper Rod Inspection324
Damper Assembly325
Damper Installation331
Shock Linkage Removal332
Shock Linkage Inspection333
Shock Arm Needle Bearing334
Shock Link Needle Bearing335
Swingarm Removal338
Swingarm Disassembly339
Swingarm Assembly341
Swingarm Installation343
Hydraulic Brake: Contents345
Hydraulic Brake: Component Location346
Hydraulic Brake: Service Information347
Hydraulic Brake: Torque Values, Tools348
Hydraulic Brake: Troubleshooting349
Brake Fluid Replacement/Air Bleeding350
Brake Fluid Draining350
Brake Fluid Filling/Air Bleeding351
Brake Pads/Disc354
Brake Pads Replacement356
Front Master Cylinder Removal358
Brake Disc Inspection358
Front Master Cylinder Disassembly, Inspection359
Front Master Cylinder Assembly360
Front Master Cylinder Installation361
Hydraulic Brake Assembly364
Hydraulic Brake Installation366
Rear Master Cylinder Removal366
Rear Master Cylinder Disassembly, Inspection367
Rear Master Cylinder Assembly, Installation368
Front Brake Caliper Removal369
Front Brake Caliper Disassembly, Inspection370
Front Brake Caliper Assembly, Installation371
Rear Brake Caliper Removal372
Rear Brake Caliper Disassembly373
Rear Brake Caliper Inspection, Assembly374
Rear Brake Caliper Installation375
Brake Pedal Removal, Installation376
Electrical System: Contents379
Electrical System: Diagram380
Electrical System: Service Information381
Electrical System: Tools382
Electrical System: Troubleshooting383
Ignition System Inspection384
Ignition Coil Primary Peak Voltage384
Direct Ignition Coil Inspection385
Exciter Coil Peak Voltage385
CKP (Crankshaft Position) Sensor Peak Voltage386
Ignition Control Module Removal/Installation387
Flywheel Removal389
Flywheel Installation390
Stator Removal390
Left Crankcase Cover Installation391
Stator Installation391
Ignition Timing392
Engine Stop Button393
Throttle Position Sensor Inspection394
Wiring Diagram: Contents395
Wiring Diagram '04-'07396
Wiring Diagram after '07397
Troubleshooting: Contents398
Engine Does Not Start or Is Hard to Start399
Engine Lacks Power400
Poor Performance at Low and Idle Speed402
Poor Performance at High Speed403
Poor Handling404
Index405

Honda 2004 CRF250R - Valve Seat Refacing

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