Honda 2004 CRF250X - ENGINE REMOVAL;INSTALLATION

Honda 2004 CRF250X

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7.

ENGINE REMOVAL/INSTALLATION

COMPONENT LOCATION .......................... 7-2

ENGINE REMOVAL ..........................

..

........ 7-5

SERVICE INFORMATION ................

..

........ ·7-3

ENGINE INSTALLATION

..........................

..

7-7

DRIVE SPROCKET ......................

..

............

..

7-4

7-1

Table of Contents

A few Words about Safety2
Important Safety Precautions2
Contents3
Symbols4
General Information5
Service Rules6
Model Identification6
General Specifications9
Lubrication System Specifications10
Fuel System Specifications11
Cooling System Specifications11
Cylinder/Piston Specifications12
Cylinder Head/Valves Specifications12
Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Specifications13
Crankcase/Crankshaft/Transmission/Balancer Specifications13
Front Wheel/Suspension/Steering Specifications14
Rear Wheel/Suspension Specifications14
Hydraulic Brake Specifications15
Battery/Charging System Specifications15
Ignition System Specifications15
Electric Starter Specification16
Lights/Meter/Switches Specifications16
Standard Torque Values17
Engine & Frame Torque Values17
Lubrication & Seal Points24
Cable & Harness Routing27
Secondary Air Supply System33
Optional Parts34
Emission Control Systems37
Source of Emissions37
Exhaust Emission Control System37
Crankcase Emission Control System37
Servicing the Honda39
Noise Emission Control System39
Rebuilt Engine39
Table of Contents41
Frame/Body Panels/Exhaust System41
Torque Values42
Service Information42
Troubleshooting42
- Seat Installation43
- Seat Removal43
- Side Cover Removal/Installation43
- Engine Guard Removal/Installation44
- Radiator Shroud Removal/Installation44
- Front Visor Removal/Installation45
- Sub-Frame Removal45
- Sub-Frame Installation46
- Fuel Tank Removal/Installation47
- Exhaust System Muffler Removal/Installation48
- Maintenance53
- Maintenance Service Information54
- Maintenance Specifications54
- Tools55
- Maintenance Schedule ('04 - '06)56
- Competition Maintenance Schedule58
- Additional Items Requiring Frequent Replacement59
- Fuel Line60
- Fuel Strainer Screen60
- Throttle Operation60
- Hot Start61
- Air Cleaner62
- Crankcase Breather63
  - Spark Plug Removal63
  - Spark Plug Inspection64
  - Spark Plug Installation64
- Cooling System65
- Radiator Coolant65
- ('04 - '06 California Type, after '06)66
- Secondary Air Supply System66
  - Valve Clearance/Decompressor System66
  - Decompressor System69
  - Engine Oil & Filter Change69
- Engine Oil/Oil Filter69
  - Oil Level Inspection69
  - Engine Idle Speed71
- Transmission Oil72
  - Transmission Oil Change72
  - Drive Chain Adjustment73
  - Drive Chain Cleaning and Lubrication73
  - Drive Chain Slack Inspection73
  - Drive Chain Replacement74
  - Drive Chain Slider76
- Drive Chain Roller77
- Drive/Driven Sprocket77
  - Brake Fluid Filling78
  - Brake Fluid Level Inspection78
- Brake Pad Wear79
- Brake System79
  - Lever Position Inspection79
  - Brake Pedal Height80
- Clutch System80
- Headlight Aim80
- Control Cables81
- Exhaust Pipe/Muffler81
  - Exhaust System Inspection81
  - Spark Arrester Inspection/Cleaning82
  - Spark Arrester Removal/Installation82
  - Front Suspension Inspection83
  - Side Stand Inspection83
  - Rear Suspension Inspection84
- Swingarm/Shock Linkage84
- Nuts, Bolts, Fasteners85
- Wheels/Tires85
- Steering Head Bearings86
  - Lubrication System87
  - Lubrication System Diagram88
  - Lubrication System Service Information89
  - Lubrication System Torque Values89
  - Lubrication System Troubleshooting89
  - Oil Strainer Installation90
  - Oil Strainer Removal/Inspection90
  - Pressure Relief Valve Removal/Installation91
  - Pressure Relief Vavle Inspection91
  - Oil Jet Installation92
  - Oil Jet Removal/Inspection92
  - Oil Pump Disassembly93
  - Oil Pump Inspection93
  - Oil Pump Assembly95
  - Fuel System97
  - Fuel System Component Location98
  - Fuel System Service Information99
  - Fuel System Tool100
  - Fuel System Torque Values100
  - Engine will Not Start101
  - Fuel System Troubleshooting101
  - Lean Mixture101
  - Misfiring During Acceleration101
- Carburetor Adjustment102
  - Idle Mixture and Idle Speed102
  - Air Cleaner Housing Removal103
  - Air Cleaner Housing Installation105
- Carburetor Removal107
  - Carburettor Disassembly109
  - Jet Needle/Throttle Valve109
  - Choke Knob/Throttle Position Sensor110
  - Accelerator Pump/Float/Jet111
- Carburetor Assembly114
- Carburetor Installation120
  - Throttle Position Sensor Replacement122
  - Best Idle123
- Pilot Screw Adjustment123
- Idle Drop Procedure124
- HIGH ALTITUDE ADJUSTMENT (California Type Only)125
  - Pair Control Valve Removal/Installation127
  - Secondary Air Supply System Inspection127
  - Air Supply Pipe Removal/Installation128
  - Pair Check Valve Inspection128
  - Cooling System Flow Pattern132
  - Cooling System Service Information133
  - Cooling System Torque Values133
  - Coolant Leak134
  - Cooling System Tools134
  - Cooling System Troubleshooting134
  - Engine Temperature too High134
  - Coolant (Hydrometer Test)135
  - Coolant Gravity Chart135
  - Cooling System Testing135
  - Coolant Replacement Preparation136
  - Radiator Cap Relief Pressure136
  - Radiator Cap/System Pressure Inspection136
  - Recommended Antifreeze136
  - Replacement/Air Bleeding137
  - Radiator Removal138
  - Radiator Installation139
  - Radiator Reserve Tank Removal/Installation139
  - Water Pump140
  - Water Pump Removal140
  - Water Seal Inspection140
  - Water Pump Bearing/Water Seal/Oil Seal Replacement142
  - Water Pump Installation143
  - Engine Removal/Installation145
  - Engine Removal/Installation Component Location146
  - Drive Sprocket Installation148
  - Drive Sprocket Removal148
  - Engine Removal149
  - Engine Installation151
  - Cylinder Head/Valves155
  - Cylinder Head/Valves Component Location156
- ('04 - '06 California Type, after '06)157
  - Cylinder Head/Valves Service Information157
  - Cylinder Head/Valves Torque Values157
  - Cylinder Head/Valves Tools158
  - Compression too High159
  - Compression too Low, Hard Starting or Poor Performance at Low Speed159
  - Cylinder Head/Valves Troubleshooting159
  - Excessive Noise159
  - Cylinder Compression Test160
  - Cylinder Head Cover Removal160
  - Camshaft/Rocker Arm Removal161
  - Cylinder Head Removal166
  - Cam Chain Tensioner/Cam Chain Guide Inspection168
  - Cam Chain Tensioner/Cam Chain Guide Removal168
  - Cam Chain Tensioner/Cam Chain Guide Installation169
  - Cylinder Head Disassembly169
  - Cylinder Head Inspection171
  - Valve/Valve Guide172
  - Valve Guide Replacement173
  - Valve Seat Inspection/Refacing173
  - Valve Seat Refacing174
  - Exhaust Side176
  - Intake Side176
  - Cylinder Head Assembly177
  - Cylinder Head Installation179
  - Camshaft/Rocker Arm Installation181
  - Cylinder Head Cover Installation184
  - Cylinder/Piston187
  - Cylinder/Piston Component Location188
  - Cylinder/Piston Service Information189
  - Cylinder/Piston Troubleshooting189
  - Cylinder Removal190
  - Piston Removal190
  - Cylinder/Piston Inspection191
  - Piston/Piston Ring Inspection191
  - Cam Chain Tensioner Lifter Inspection193
  - Connecting Rod Inspection193
  - Piston Ring Installation193
  - Cylinder Installation194
  - Piston Installation194
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage197
- COMPONENT LOCA Non198
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Service Information199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Tools199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Torque Values199
  - Clutch/Starter Clutch/Kickstarter/Gearshift Linkage Troubleshooting200
  - Right Crankcase Cover Removal201
  - Right Crankcase Cover Installation202
  - Clutch Removal203
  - Clutch Discs205
  - Clutch Inspection205
  - Clutch Spring205
  - Clutch Center206
  - Clutch Lifter/Needle Bearing206
  - Clutch Plates206
  - Friction Spring/Spring Seat206
  - Clutch Lifter Lever207
  - Clutch Lifter Rod207
  - Clutch Outer207
  - Needle Bearing/Clutch Outer Guide207
  - Kickstarter Removal211
  - Kickstarter Disassembly/Inspection212
  - Kickstarter Assembly213
  - Kickstarter Installation214
- Right Crankcase Cover215
  - Starter Clutch Removal215
  - Starter Clutch Disassembly/Inspection216
  - Starter Clutch Assembly218
  - Starter Clutch Installation219
  - Gearshift Linkage Removal221
  - Gearshift Linkage Inspection222
  - Gearshift Linkage Installation222
  - Gearshift Spindle222
  - Ratchet Pawl222
  - Alternator225
  - Alternator Component Location226
  - Alternator Service Information227
  - Alternator Tools227
  - Alternator Torque Values227
  - Left Crankcase Cover Removal228
  - Flywheel Removal229
  - Stator Installation229
  - Stator Removal229
  - Left Crankcase Cover Installation231
  - Crankcase/Crankshaft/Transmission/Balancer233
  - Crankcase/Crankshaft/Transmission/Balancer Component Location234
  - Crankcase/Crankshaft/Transmission/Balancer Service Information235
  - Crankcase/Crankshaft/Transmission/Balancer Tools236
  - Crankcase/Crankshaft/Transmission/Balancer Torque Value236
  - Crankcase/Crankshaft/Transmission/Balancer Troubleshooting237
  - Balancer Gear/Balancer Inspection238
  - Balancer Gear/Balancer Installation238
  - Balancer Gear/Balancer Removal238
- Crankcase Separation239
- Transmission Disassembly241
  - Bushing242
  - Gear242
  - Mainshaft/Countershaft242
  - Transmission Inspection242
  - Shift Drum243
  - Shift Fork243
  - Shift Fork Shaft243
  - Transmission Bearing243
  - Crankshaft Inspection244
- Crankshaft Removal244
  - Crankcase Bearing Replacement245
  - Crankcase Bearing/Oil Seal Location245
  - Crankshaft Bearing245
  - Left Crankcase247
  - Transmission/Balancer/Shift Drum Bearings247
- Crankshaft Installation250
  - Countershaft251
  - Mainshaft251
- Transmission Assembly251
- Crankcase Assembly253
  - Front Wheel/Suspension/Steering255
  - Front Wheel/Suspension/Steering Component Location256
  - Front Wheel/Suspension/Steering Service Information257
  - Front Wheel/Suspension/Steering Tools258
  - Front Wheel/Suspension/Steering Torque Values258
  - Front Wheel/Suspension/Steering Troubleshooting260
  - Front Wheel Inspection261
  - Front Wheel Removal261
  - Front Wheel Disassembly262
  - Wheel Bearing262
  - Wheel Rim262
  - Front Wheel Assembly263
  - Front Wheel Installation265
  - Fork Removal266
  - Fork Disassembly268
  - Outer Tube and Slider Disassembly270
  - Fork Damper Disassembly271
  - Fork Cap272
  - Fork Centre Bolt272
  - Fork Damper Inspection272
  - Slider/Outer Tube272
  - Bushing/Back-Up Ring273
  - Fork Damper273
  - Fork Spring273
  - Outer Tube and Slider Assembly274
  - Fork Damper Refilling/Assembly275
  - Fork Damper Operation Inspection278
  - Fork Damper Installation/Preparation279
  - Fork Damper Installation280
  - Oil Capacity Adjustment282
  - Standard Oil Capacity282
  - Standard Position283
  - Handlebar Removal285
  - Handlebar Installation287
  - Steering Stem Removal291
  - Steering Stem Bearing Replacement292
  - Steering Stem Installation294
  - Rear Wheel/Suspension297
  - Rear Wheel/Suspension Component Location298
  - Rear Wheel/Suspension Service Information299
  - Rear Wheel/Suspension Tools300
  - Rear Wheel/Suspension Torque Values300
  - Rear Wheel/Suspension Troubleshooting302
  - Rear Wheel Inspection303
  - Rear Wheel Removal303
  - Rear Wheel Disassembly304
  - Wheel Rim Runout304
  - Rear Wheel Assembly305
  - Rear Wheel Installation308
  - Shock Absorber Removal309
  - Shock Absorber Bladder Replacement310
  - Shock Absorber Disassembly310
  - Damper Disassembly313
  - Recommended Shock Oil313
  - Damper Rod Disassembly315
  - Piston Ring Replacement315
  - Damper Rod Inspection317
  - Rod Guide Case Inspection317
  - Damper Assembly318
  - Spherical Bearing Replacement323
  - Shock Linkage Removal325
  - Bearing Replacement327
  - Shock Arm Needle Bearing327
  - Shock Linkage Inspection327
  - Shock Link Needle Bearing328
  - Swingarm Removal331
  - Swingarm Disassembly333
  - Swingarm Assembly334
  - Swingarm Bearing Replacement334
  - Swingarm Installation336
  - Hydraulic Brake339
  - Hydraulic Brake Component Location340
  - Hydraulic Brake Service Information341
  - Hydraulic Brake Tool342
  - Hydraulic Brake Torque Values342
  - Brake Drags343
  - Brake Lever/Pedal Hard343
  - Brake Lever/Pedal Soft or Spongy343
  - Hydraulic Brake Troubleshooting343
  - Brake Fluid Draining344
  - Brake Fluid Replacement/Air Bleeding344
  - Brake Fluid Filling/Air Bleeding345
  - Brake Pad Replacement348
  - Brake Pad/Disc348
  - Front Master Cylinder Disassembly350
  - Front Master Cylinder Removal350
  - Rear Master Cylinder Disassembly353
  - Rear Master Cylinder Removal353
  - Rear Master Cylinder Assembly354
  - Rear Master Cylinder Inspection354
  - Rear Master Cylinder Installation355
  - Front Brake Caliper Disassembly356
  - Front Brake Caliper Removal356
  - Front Brake Caliper Assembly357
  - Front Brake Caliper Inspection357
  - Front Brake Caliper Installation358
  - Rear Brake Caliper Removal358
  - Battery/Charging System365
  - Battery/Charging System Component Location366
  - Battery/Charging System System Diagram366
  - Battery Charging367
  - Battery Testing367
  - Battery/Charging System Service Information367
  - Battery/Charging System Tools368
  - Battery/Charging System Troubleshooting369
  - Battery Removal/Installation370
  - Battery Voltage Inspection370
  - Charging System Inspection370
  - Current Leakage Inspection370
  - Charging Voltage Inspection371
  - Regulator/Rectifier Removal/Installation371
  - Regulator/Rectifier System Inspection371
  - Alternator Charging Coil Inspection372
  - Ignition System373
  - Ignition System Component Location374
  - Ignition System Diagram374
  - Ignition System Service Information375
  - Ignition System Specification375
  - Ignition System Tools375
  - Ignition System Torque Values375
  - Ignition System Troubleshooting376
  - Ignition Coil Primary Peak Voltage377
  - Ignition System Inspection377
  - Direct Ignition Coil Inspection378
  - Exciter Coil Peak Voltage378
  - Ignition Pulse Generator Peak Voltage379
  - Ignition Control Module (ICM) Removal/Installation380
  - Ignition Timing380
  - Throttle Position Sensor Inspection381
  - Electric Starter383
  - Electric Starter Component Location384
  - Electric Starter System Diagram384
  - Electric Starter Service Information385
  - Electric Starter Troubleshooting386
  - Starter Disassembly/Inspection388
  - Starter Motor Removal388
  - Starter Motor Assembly391
  - Starter Motor Installation393
  - Starter Relay Switch Ground Line393
  - Starter Relay Switch Operation Inspection393
  - Starter Relay Switch Function Inspection394
  - Starter Relay Switch Power Input Line394
  - Lights/Meter/Switches395
  - Lights/Meter/Switches Component Location396
  - Lights/Meter/Switches Service Information397
  - Lights/Meter/Switches Torque Values397
  - Headlight Bulb Replacement398
  - Headlight Removal/Installation399
  - Tail Light Inspection399
  - Engine Stop Button400
  - Tail Light Removal/Installation400
  - Clutch Switch Inspection401
  - Starter Switch402
  - Tripmeter Removal/Installation402
  - Main Relay Inspection403
  - Wiring Diagram406
- Engine Does Not Start or Is Hard to Start410
- Engine Lacks Power411
- Poor Performance at Low and Idle Speed413
- Poor Performance at High Speed414
- Poor Handling415
Index417

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