Honda CRF250L/LA Rally 2020, Manual

Page 1: ...Contents Vehicle Safety P 2 Operation Guide P 18 Maintenance P 35 Troubleshooting P 87 Information P 107 Specifications P 129 Index P 133 2020 CRF250L LA Rally 31KZZC30 MOM 17332 1909 ...

Page 2: ...ake responsibility for keeping your vehicle well serviced and maintained Also observe the break in guidelines and always perform the pre ride inspection and other periodic checks in this manual When service is required remember that your Honda dealer knows your vehicle best If you have the required mechanical know how and tools you can purchase an official Honda Service Manual to help you perform ...

Page 3: ... maintaining a vehicle You must use your own good judgment You will find important safety information in a variety of forms including Safety labels on the vehicle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or...

Page 4: ...7 Safety Precautions P 9 Riding Precautions P 11 Accessories Modifications P 15 Off Road Safety P 16 Loading P 17 This section contains important information for safe riding of your vehicle Please read this section carefully Vehicle Safety ...

Page 5: ...t mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved helmet and protective apparel Instruct your passenger on holding onto the seat strap or your waist leaning with you in turns and keeping their feet on the footpegs even when the vehicle is stopped Take Time to Learn Practice Even if you have ridden other vehicles practice riding in a saf...

Page 6: ...ound you and do not assume that other drivers see you Be prepared to stop quickly or perform an evasive maneuver Make Yourself Easy to See Make yourself more visible especially at night by wearing bright reflective clothing positioning yourself so other drivers can see you signaling before turning or changing lanes and using your horn when necessary Be Alert for Off road Hazards The terrain can be...

Page 7: ...make your vehicle unsafe 2 P 15 If You are Involved in a Crash Personal safety is your first priority If you or anyone else has been injured take time to assess the severity of the injuries and whether it is safe to continue riding Call for emergency assistance if needed Also follow applicable laws and regulations if another person or vehicle is involved in the crash If you decide to continue ridi...

Page 8: ...ntain a dangerous amount of carbon monoxide Never run your vehicle inside a garage or other enclosure 3WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsciousness and lead to death Only run your vehicle s engine when it is located in a ...

Page 9: ...mportant safety information and may warn you of potential hazards that could cause serious injury Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for a replacement Safety Labels Vehicle Safety 7 Continued ...

Page 10: ...Safety Labels Vehicle Safety 8 ...

Page 11: ...clothing Ride defensively in response to weather and road conditions Helmet Should be safety standard certified high visibility and correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection USA Look for a DOT Department of Transportation certification label on any helmet you buy 3WARNING ...

Page 12: ...r riding or a protective suit Additional Off road Gear On road apparel may also be suitable for casual off road riding But if you plan on any serious off road riding you will need more serious off road gear In addition to your helmet and eye protection we recommend off road motorcycle boots and gloves riding pants with knee and hip pads a jersey with elbow pads and a chest shoulder protector Safet...

Page 13: ...g can reduce the vehicle s stability u Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tires slip more easily on such surfaces and braking distances are longer Avoid continuous braking u Repeated braking such as when descending long steep slopes can seriously overheat the brakes reducing their effectiveness Use engine brakin...

Page 14: ...ways use the recommended front rear tires and sprockets to ensure correct ABS operation Engine Braking Engine braking helps slow your vehicle down when you release the throttle For further slowing action downshift to a lower gear Use engine braking with intermittent use of the brakes to reduce speed when descending long steep slopes Wet or Rainy Conditions Road surfaces are slippery when wet and w...

Page 15: ...hood of theft always lock the handlebar and remove the key when leaving the vehicle unattended Use of an anti theft device is also recommended Parking with the Side Stand 1 Stop the engine 2 Push the side stand down 3 Slowly lean the vehicle to the left until its weight rests on the side stand 4 Turn the handlebar fully to the left u Turning the handlebar to the right reduces stability and may cau...

Page 16: ... gasoline Use recommended octane number Using lower octane gasoline will result in decreased engine performance Do not use fuels containing a high concentration of alcohol 2 P 122 Do not use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Riding Precautions Vehicle Safety 14 ...

Page 17: ...ate on public roads Before deciding to install accessories on your vehicle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding accessories and modifications Do not pull a trailer with or attach a sidecar to your vehicle Your vehicle was no...

Page 18: ...u can assist each other in case of trouble Familiarity with your vehicle is critically important should a problem occur far from help Never ride beyond your ability and experience or faster than conditions warrant If you are not familiar with the terrain ride cautiously Hidden rocks holes or ravines could spell disaster A muffler is required in most off road areas Don t modify your exhaust system ...

Page 19: ...ot place objects near the lights or the muffler Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability 3WARNING Overloading or improper loading can cause a crash a...

Page 20: ...nt reserve tank P 69 Rear brake fluid reservoir P 71 Engine oil filter P 66 Engine oil fill cap P 64 Engine oil level inspection window P 64 Front brake fluid reservoir P 71 Engine oil drain bolt P 66 Air cleaner P 68 Spark arrester P 62 Right side cover P 57 ...

Page 21: ...el fill cap P 32 Fuse box P 102 Drive chain P 75 Side stand P 74 Shift lever P 31 Battery P 55 Main fuse P 103 Seat P 56 Left side cover P 57 Crankcase breather P 85 Helmet holder P 33 Document bag P 34 Tool box Tool kit P 34 Spark plug P 59 ...

Page 22: ... Do not operate the engine in the tachometer red zone Excessive engine speed can adversely affect engine life Display Check When the ignition switch is turned to the ON position all the mode and digital segments will show If any part of these displays does not come on when it should have your dealer check for problems ...

Page 23: ... TOTAL Tripmeter TRIP A B SEL button switches between the odometer and tripmeters Odometer Total distance ridden Tripmeter Distance ridden since tripmeter was reset press and hold SET button to reset to 0 0 km mile at the tripmeter display Remaining fuel when only 1st E segment starts flashing When is displayed go to your dealer for service When is displayed go to your dealer for service ...

Page 24: ...our digits start flashing c Press the SEL button until the desired hour is displayed u Press and hold to advance the hour fast d Press the SET button The minute digits start flashing e Press the SEL button until the desired minute is displayed u Press and hold to advance the minute fast Operation Guide 22 Instruments Continued ...

Page 25: ...no buttons were pressed for about 30 seconds the display will stop flashing automatically and the adjustment will be cancelled 2 Changing the speed and mileage unit a Press the SEL button to select either km h km or mph mile for the speedometer odometer and tripmeters b Press the SET button The speed and mileage unit is set and then the display will return to the ordinary display Operation Guide 2...

Page 26: ...omes on while engine is running P 90 Neutral indicator PGM FI Programmed Fuel Injection malfunction indicator lamp MIL If one of these indicators does not come on when it should have your dealer check for problems Rear ABS Anti lock Brake System OFF indicator CRF250RLA Comes on briefly when the ignition switch is turned to the ON position Comes on when the ABS function on the rear wheel is turned ...

Page 27: ...fly when the ignition switch is turned to the ON position with the engine stop switch in the Run position If it comes on while running P 89 ABS Anti lock Brake System indicator CRF250RLA Comes on when the ignition switch is turned to the ON position Goes off when your speed reaches approximately 6 mph 10 km h If it comes on while riding P 90 ...

Page 28: ...ation Guide 26 Horn button u Pressing the switch turns the turn signal off Headlight dimmer switch Low beam Turn signal switch High beam Hazard switch Switchable when the ignition switch is turned to the ON position ...

Page 29: ...ring Lock P 28 Engine stop switch Should normally remain in the Run position u In an emergency switch to the Stop position the starter motor will not operate to stop the engine Start button Rear ABS switch CRF250RLA Switches the ABS function on the rear wheel on off P 29 ON Turns electrical system on for starting riding OFF LOCK Turns engine off Locks steering ...

Page 30: ... a Turn the handlebar all the way to the left b Push the key down and turn the ignition switch to the LOCK position u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the key push it in and turn the ignition switch to the OFF position Operation Guide 28 Switches Continued Push Turn Ignition key ...

Page 31: ...or starts flashing then release the switch while the indicator is flashing u The rear ABS OFF indicator is on when the ABS function on the rear wheel is turned off u The ABS function on the rear wheel remains on if the switch is released after indicator stops flashing To turn on the ABS function on both wheels a Stop the vehicle b Press and hold the rear ABS switch until the rear ABS OFF indicator...

Page 32: ...ngine stop switch is in the Run position b Turn the ignition switch to the ON position c Shift the transmission to Neutral N indicator to come on Alternatively pull in the clutch lever to start your vehicle with the transmission in gear so long as the side stand is raised d Press the start button with the throttle completely closed If the engine does not start a Open the throttle fully and press t...

Page 33: ... h From 2nd to 3rd 19 mph 30 km h From 3rd to 4th 25 mph 40 km h From 4th to 5th 31 mph 50 km h From 5th to 6th 37 mph 60 km h Shifting Down From 6th to 5th 28 mph 45 km h From 5th to 4th 22 mph 35 km h From 4th to 3rd 16 mph 25 km h NOTICE Improper shifting can damage the engine transmission and drive train Also coasting or towing the vehicle for long distances with the engine off can damage the ...

Page 34: ...kwise to open the fuel fill cap Closing the Fuel Fill Cap a After refueling push the fuel fill cap closed until it locks b Remove the key and close the lock cover u The key cannot be removed if the fuel fill cap is not locked 3WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel ...

Page 35: ... helmet on the holder pin and push it in to lock b Remove the key and close the lock cover u Use the helmet holder only when parked 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder Operation ...

Page 36: ...ng the Seat P 56 Tool Kit The tool kit is stored in the tool box located on the left side of the vehicle u Insert the ignition key and turn it clockwise to open the tool box Operation Guide 34 Storage Equipment Continued Document bag Tool box Tool kit Ignition key ...

Page 37: ... P 64 Air Cleaner P 68 Coolant P 69 Brakes P 71 Side Stand P 74 Drive Chain P 75 Wheels P 80 Clutch P 81 Throttle P 84 Crankcase Breather P 85 Other Adjustments P 86 Adjusting the Headlight Aim P 86 Please read Importance of Maintenance and Maintenance Fundamentals carefully before attempting any maintenance Refer to Specifications for service data An optional larger tool kit may be available Chec...

Page 38: ... 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 For information about the exhaust emission and noise emission requirements of the U S Environmental Protection Agency EPA the California Air Resources Board CARB and the Environment and Clim...

Page 39: ...an decide whether or not you should perform a given task Follow these guidelines when performing maintenance Stop the engine and remove the key Place your vehicle on a firm level surface using the side stand to provide support Allow the engine muffler brakes and other high temperature parts to cool before servicing as you can get burned Run the engine only when instructed and do so in a well venti...

Page 40: ...cians Your dealer meets all of these requirements All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer Keeping an accurate maintenance record will help ensure your vehicle is properly maintained 2 P 41 Make sure whoever performs the scheduled maintenance completes the maintenance record Retain all service documents If you sell your vehicle...

Page 41: ...ine Idle Speed Radiator Coolant 7 3 Years 69 Cooling System Secondary Air Supply System Evaporative Emission Control System 4 Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures are provided in an official Honda Service Manual 2 P 123 Inspect clean adjust lubricate or replace if necessary ...

Page 42: ...utch System 81 Side Stand 74 Suspension Spark Arrester 6 62 Nuts Bolts Fasteners 5 Wheels Tires 5 52 80 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 4 5 50 STATE meets California Service more frequently when riding OFF ROAD 2 Service more frequently when riding in unusually wet or dusty areas 6 7 USA only Replacement requires mechanica...

Page 43: ...0 km 16 000 miles 25 600 km 20 000 miles 32 000 km 24 000 miles 38 400 km 28 000 miles 44 800 km 32 000 miles 51 200 km 36 000 miles 57 600 km 40 000 miles 64 000 km 44 000 miles 70 400 km 48 000 miles 76 800 km 52 000 miles 83 200 km 56 000 miles 89 600 km 60 000 miles 96 000 km 64 000 miles 102 400 km 68 000 miles 108 800 km Maintenance 41 ...

Page 44: ... or anything that appears unusual Also check the following Tire tread wear and air pressures are within limits 2 P 52 Lights horn and turn signals operate normally Check the condition of the drive chain Adjust slack and lubricate as needed 2 P 50 Check the following items if you are carrying a passenger or cargo Combined weight is within load limits 2 P 129 Cargo is secured properly Check the foll...

Page 45: ...off road check all of the preceding plus the following Make sure spokes are tight Check the rims for any damage 2 P 80 Oil level is between the upper and lower marks 2 P 64 Check the fuel level and refuel when needed 2 P 14 2 P 32 Be sure the fuel fill cap is securely fastened 2 P 32 Clutch lever operates smoothly Adjust freeplay if necessary 2 P 81 Check for loose cables and other parts and anyth...

Page 46: ...cate 2 P 51 as needed Fuses Check that you have a full supply of spare fuses Nuts bolts Check the major nuts and bolts and tighten as needed Crankcase Breather Service the crankcase breather more frequently if your vehicle 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 2 P 85 Periodic Checks You should also ...

Page 47: ... mentioned on the color label The color label is attached to the left side of the front frame 3WARNING Installing non Honda parts may make your vehicle unsafe and cause a crash in which you can be seriously hurt or killed Always use Honda Genuine Parts or equivalents that have been designed and approved for your vehicle Maintenance Fundamentals Maintenance 45 Color label ...

Page 48: ...to your eyes u Wash your eyes repeatedly with cool water for at least 15 minutes Using water under pressure can damage your eyes Electrolyte splashes onto your skin u Remove affected clothing and wash your skin thoroughly using water Electrolyte splashes into your mouth u Rinse mouth thoroughly with water and do not swallow 3WARNING The battery gives off explosive hydrogen gas during normal operat...

Page 49: ...type Charging If you use electrical accessories that drain the battery or you do not ride frequently we recommend that you charge the battery every 30 days using a charger designed specifically for your Honda which can be purchased from your dealer Read the information that came with your battery charger and follow the instructions on the battery Avoid using an automobile type battery charger as t...

Page 50: ...electrical on your vehicle stops working check for and replace any blown fuses 2 P 102 Inspecting and Replacing Fuses Turn the ignition switch to the OFF position to remove and inspect fuses If a fuse is blown replace with a fuse of the same rating For fuse ratings see Specifications 2 P 131 NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the ele...

Page 51: ...he following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the following label shows the MA classification 2 The SAE standard grades oils by their viscosity 3 The API classification specifies the quality and performance ratin...

Page 52: ...Use only DOT 3 or DOT 4 fluid from a sealed container Drive Chain The drive chain must be inspected and lubricated regularly Inspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 75 If the chain does not move smoothly makes strange noises has damaged rollers has loose pins has missing O rings or kinks have the chain inspecte...

Page 53: ...leaner a wire brush volatile solvent such as gasoline and benzene abrasive cleaner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tires Avoid applying excess chain lubricant to prevent spray onto your clothes and the vehicle Recommended Coolant Pro Honda HP Coolant is a pre mixed solution o...

Page 54: ... and use an air pressure gauge to measure the air pressure before each off road ride and whenever you return to pavement after riding off road If you only ride on pavement check the pressure at least once a month or any time you think the tires look low Always check air pressure when your tires are cold If you decide to adjust the tire pressure for a particular off road riding condition make chang...

Page 55: ...s Inspect the rims for damage and loose spokes Also inspect the valve stems for their positions A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim See your dealer 3WARNING Riding on 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 re...

Page 56: ...obably be stretched and it could fail if installed in a new tire 3WARNING Installing improper tires on your vehicle can adversely affect handling and stability and can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual Air Cleaner This vehicle is equipped with a viscous type air cleaner element which cannot be cleaned...

Page 57: ... the battery 6 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight Make sure the clock information is correct after the battery is reconnected 2 P 22 For proper handling of the battery see Maintenance Fundamentals 2 P 46 Battery Goes Dead 2 P 98...

Page 58: ...ss with the tab and insert the prongs into the front stay and rear stays 2 Install the collars onto the hook bolts Tighten the hook bolts Torque 15 lbf ft 21 N m 2 1 kgf m Removing Installing Body Components u Seat Maintenance 56 Hook bolt Prongs Hook bolt Collar Tab Recess Front stay Seat Rear stays Collar ...

Page 59: ...e prongs from the grommets 4 Remove the side cover Installation Install the parts in the reverse order of removal Removing Installing Body Components u Side Cover Maintenance 57 Right Left Grommets Prongs Tool box Bolt Bolt Left side cover Grommets Bolt Right side cover Prongs Bolt ...

Page 60: ...e bolts and washers on rear under cowl 3 Remove the rear under cowl Installation Install the parts in the reverse order of removal Removing Installing Body Components u Under Cowl Maintenance 58 Front Side Front under cowl Bolts Rear Side Bolts and washers Rear under cowl ...

Page 61: ... Do not clean the spark plug If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one To check the spark plug gap use only a wire type feeler gauge To prevent damaging the iridium coating of the center electrode never use a leaf type feeler gauge Do not adjust the spark plug gap If the gap is out of specification replace the spark plug with a new one 1...

Page 62: ...re type feeler gauge cannot be inserted between the spark plug gap If the gauge fits in the gap replace the plug with a new one 6 Make sure the plug washer is in good condition 7 Install the spark plug With the plug washer attached thread the spark plug in by hand to prevent cross threading Spark Plug u Checking Spark Plug Maintenance 60 Spark plug cap Spark plug gap ...

Page 63: ...lug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 9 Install the parts in the reverse order of removal u When reinstalling the spark plug cap take care to avoid pinching any cables or wires Spark Plug u Checking Spark Plug Maintenan...

Page 64: ...ts random sparks from the combustion process in your engine from reaching the environment 1 Allow the engine and muffler to cool 2 Remove the right side cover 2 P 57 3 Remove the muffler cover bolts and muffler cover from the muffler 4 Remove the tail cap cover bolts and tail cap cover from the muffler Maintenance 62 Spark arrester mounting bolts Spark arrester Gasket Muffler cover bolts Muffler c...

Page 65: ...Check the gasket Replace if necessary 7 Install the gasket and the spark arrester and tighten the spark arrester mounting bolts Torque 6 6 lbf ft 9 0 N m 0 9 kgf m 8 Install the tail cap cover and tighten the tail cap cover bolts Torque 3 9 lbf ft 5 25 N m 0 5 kgf m 9 Install the muffler cover and tighten the muffler cover bolts Torque 1 1 lbf ft 1 5 N m 0 2 kgf m 10 Install the right side cover 2...

Page 66: ...ch to the OFF position and wait for 2 to 3 minutes 3 Place your vehicle in an upright position on a firm level surface 4 Check that the oil level is between the upper level and lower level marks on the oil level inspection window Maintenance 64 Oil fill cap Oil level inspection window Upper level mark Lower level mark ...

Page 67: ...el u Do not overfill above the upper level mark u Make sure no foreign objects enter the oil filler opening u Wipe up any spills immediately 2 Securely reinstall the oil fill cap NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine Do not mix different brands and grades of oil They may affect lubrication and clutch operation For the recommended oil and oil...

Page 68: ...the engine is cold idle the engine for 3 to 5 minutes 3 Turn the ignition switch to the OFF position and wait for 2 to 3 minutes 4 Place your vehicle on a firm level surface 5 Place a drain pan under the drain bolt 6 Remove the oil fill cap drain bolt and sealing washer to drain the oil 7 Remove the oil filter cover oil filter spring and gasket by removing the oil filter cover bolts u Discard the ...

Page 69: ... m 2 4 kgf m 11 Fill the crankcase with the recommended oil 2 P 49 2 P 130 and install the oil fill cap Required oil When changing oil engine oil filter 1 6 US qt 1 5 L When changing oil only 1 5 US qt 1 4 L 12 Check the oil level 2 P 64 13 Check that there are no oil leaks 14 Install the under cowl 2 P 58 NOTICE Improper installation of the oil filter can result in serious damage to the engine En...

Page 70: ...or performance problems 1 Remove the right side cover 2 P 57 2 Remove the air cleaner housing cover by removing the screws 3 Release the tabs and pull out the air cleaner element 4 Install the new air cleaner element u Make sure the air cleaner element is installed securely 5 Install the parts in the reverse order of removal Maintenance 68 Air cleaner element Tabs Screws Air cleaner housing cover ...

Page 71: ...vehicle in an upright position 3 Check that the coolant level is between the UPPER level and LOWER level marks on the reserve tank If the coolant level is dropping noticeably or the reserve tank is empty you likely have a serious leak Have your vehicle inspected by your dealer Maintenance 69 UPPER level mark LOWER level mark Reserve tank Reserve tank cap ...

Page 72: ...u Do not overfill above the UPPER level mark u Make sure no foreign objects enter the reserve tank opening 2 Securely reinstall the reserve tank cap 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out potentially scalding you Always let the engine and radiator cool down before removing the radiator cap Changing Coolant Have your dealer change the coolant u...

Page 73: ...nd that the fluid level is between the LOWER level and UPPER level marks If the brake fluid level in either reservoir is below the LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your vehicle inspected by your dealer Maintenance 71 Front brake fluid reservoir LOWER level mark UP...

Page 74: ... the brake pads from below the brake caliper 2 Rear Inspect the brake pads from the rear right of the vehicle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time Brakes u Inspecting the Brake Pads Maintenance 72 Front Rear Pads Wear indicator Disc Pads Wear indicator Disc Wear indicator Wear indicator ...

Page 75: ...switch Hold the brake light switch and turn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon Brakes u Adjusting the Brake Light Switch Maintenance 73 Brake light switch Adjusting nut B A ...

Page 76: ...ck the spring for damage or loss of tension 3 Sit on the vehicle shift the transmission to Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into gear 5 Lower the side stand all the way The engine should stop as you lower the side stand If the engine doesn t stop have your vehicle inspected by your dealer Maintenance 74 Side stand spring ...

Page 77: ...ransmission to Neutral Stop the engine 2 Place your vehicle on its side stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack 1 6 2 0 in 40 50 mm u Do not ride your vehicle if the slack exceeds 2 4 in 60 mm 4 Roll the vehicle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 50 6 Clean and lubri...

Page 78: ...ser ring 1 Shift the transmission to Neutral Stop the engine 2 Place your vehicle on its side stand on a firm level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both adjusting bolts Drive Chain u Adjusting the Drive Chain Slack Maintenance 76 Adjusting plate Adjusting bolt Lock nut Rear axle nut Pulser ring Wheel speed sensor CRF250RLA CRF250RLA Adjusting bolt Lock nut Reference ma...

Page 79: ...chain adjusting plate aligns with the reference mark on both sides of the swingarm Both marks should correspond If the axle is misaligned turn the right or left adjusting bolt until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut Torque 65 lbf ft 88 N m 9 0 kgf m 8 Hold the adjusting bolts and tighten the lock nuts Torque 20 lbf ft 27 N m 2 8 kgf m 9 Recheck drive chain s...

Page 80: ... chain adjuster plate enters the red zone on the label after the chain has been adjusted to the proper slack the chain is excessively worn and must be replaced Chain DID 520VF If necessary have the drive chain replaced by your dealer Drive Chain u Adjusting the Drive Chain Slack Maintenance 78 Indicator groove Red zone ...

Page 81: ...is worn to the wear limit indicator or wear limit line To inspect the wear limit line remove the drive sprocket cover by removing the bolts If necessary have the drive chain slider replaced by your dealer Drive Chain u Checking the Drive Chain Slider Maintenance 79 Wear limit indicator Drive chain slider Wear limit line Bolts Drive sprocket cover ...

Page 82: ...cessary to remove the wheels to perform the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 2 P 92 1 Inspect the wheel rims and spokes for damage 2 Tighten any loose spokes 3 Rotate the wheel slowly to see if it appears to wobble If it does the rim is out of round or not true If the wobble is noticeable see your dealer for ...

Page 83: ...0 8 in 10 20 mm Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTICE Improper freeplay adjustment can cause premature clutch wear Maintenance 81 Clutch lever Freeplay ...

Page 84: ...bber dust cover 2 Loosen the minor lock nut 3 Turn the minor clutch cable adjuster until the freeplay is 0 4 0 8 in 10 20 mm 4 Tighten the minor lock nut and check the freeplay again 5 Install the rubber dust cover Clutch u Adjusting the Clutch Lever Freeplay Maintenance 82 Rubber dust cover Minor lock nut Minor clutch cable adjuster ...

Page 85: ...k nut 3 Turn the major clutch cable adjuster until the clutch lever freeplay is 0 4 0 8 in 10 20 mm 4 Tighten the major lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the vehicle does not creep Gradually release the clutch lever and open the throttle Your vehicle should move smoothly and accelerat...

Page 86: ...es not move smoothly close automatically or if the cable is damaged have the vehicle inspected by your dealer Freeplay at the throttle grip flange 0 1 0 2 in 2 6 mm Adjusting the Throttle Freeplay 1 Loosen the lock nut 2 Turn the adjuster until the freeplay is 0 1 0 2 in 2 6 mm 3 Tighten the lock nut and inspect the throttle action again Maintenance 84 Freeplay Flange Throttle grip Adjuster Lock n...

Page 87: ...g the Crankcase Breather 1 Place a suitable container to receive deposits 2 Remove the crankcase breather tube and drain deposits into the container 3 Reinstall the crankcase breather tube Maintenance 85 Crankcase breather tube ...

Page 88: ...sting the Headlight Aim You can adjust vertical aim of the headlight for proper alignment Turn the pinion using a Phillips screwdriver in or out as necessary Obey local laws and regulations Maintenance 86 Lower Raise Pinion ...

Page 89: ...ed Fuel Injection Malfunction Indicator Lamp MIL P 90 ABS Anti lock Brake System Indicator P 90 Other Warning Indications P 91 Fuel Gauge Failure Indication P 91 Tire Puncture P 92 Electrical Trouble P 98 Battery Goes Dead P 98 Burned out Light Bulb P 98 Blown Fuse P 102 Unstable Engine Operation Occurs Intermittently P 106 Troubleshooting ...

Page 90: ...icator lamp is on contact your dealer as soon as possible Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 30 Make sure engine stop switch is in the Run position 2 P 27 Check for a blown fuse 2 P 102 Check for a loose battery connection 2 P 55 or battery terminal corrosion 2 P 46 Check the condition of the battery 2 P 98 If the problem continu...

Page 91: ...ition switch to the ON position 2 Check that the radiator fan is operating and then turn the ignition switch to the OFF position If the fan is not operating Suspect a fault Do not start the engine Transport your vehicle to your dealer If the fan is operating Allow the engine to cool with the ignition switch in the OFF position 3 After the engine has cooled inspect the radiator hose and check if th...

Page 92: ...our vehicle inspected by your dealer as soon as possible Indicator comes on or starts flashing while riding Indicator does not come on when the ignition switch is in the ON position Indicator does not go off at speeds above 6 mph 10 km h If the ABS indicator stays on your brakes will continue to work as a conventional system but without the anti locking function The ABS indicator may flash if you ...

Page 93: ...Indications Fuel Gauge Failure Indication If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustration If this occurs see your dealer as soon as possible Troubleshooting 91 ...

Page 94: ...you need to make a temporary repair by patching a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is replaced the tire should be carefully inspected as described 3WARNING Riding your vehicle with a temporary tire or tube repair can be risky If the temporary repair fails you can crash and be seriously injured or kille...

Page 95: ...oosen the front axle shaft 4 Support your vehicle securely and raise the front wheel off the ground using a maintenance stand or a hoist 5 Remove the front axle shaft side collars and wheel u Avoid getting grease oil or dirt on the disc or pad surfaces u Do not pull the brake lever while the brake caliper is removed Tire Puncture u Removing Wheels Troubleshooting 93 Continued Axle pinch bolts Fron...

Page 96: ...Tighten the axle shaft Torque 51 lbf ft 69 N m 7 0 kgf m 4 Lower the front wheel on the ground 5 Apply the brake lever several times Then pump the fork several times 6 Tighten the axle pinch bolt Torque 16 lbf ft 22 N m 2 2 kgf m 7 Raise the front wheel off the ground again and check that the wheel rotates freely after you release the brake 8 Lower the front wheel on the ground again If a torque w...

Page 97: ...oved all the way forward for maximum drive chain slack 4 Remove the rear axle nut 5 Remove the drive chain from the driven sprocket by pushing the rear wheel forward 6 Remove the rear axle shaft and adjusting plates Tire Puncture u Removing Wheels Troubleshooting 95 Continued Adjusting plate Adjusting bolt Lock nut Rear axle nut Pulser ring Wheel speed sensor CRF250RLA CRF250RLA Lock nut Adjusting...

Page 98: ...emoved Installation 1 To install the rear wheel reverse the removal procedure u Take care to prevent the brake caliper from scratching the wheel during installation NOTICE When installing a wheel or caliper into original position carefully fit the brake disc between the pads to avoid scratching them 2 Make sure that the slot on the brake caliper bracket is positioned in the lug on the swingarm Tir...

Page 99: ... pedal several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity Tire Puncture u Removing Wheels Troubleshooting 97 ...

Page 100: ... dealer NOTICE Jump starting using an automobile battery can damage your vehicle s electrical system and is not recommended Bump starting is also not recommended Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the OFF or LOCK position Allow the bulb to cool before replacing it Do not use bulbs other than those specified Check the repl...

Page 101: ...his servicing Brake light Taillight Bulb 1 Remove the seat 2 P 56 2 Remove the hook bolts and collars 3 Remove the prongs from the grommets 4 Remove the rear fender Electrical Trouble u Burned out Light Bulb Troubleshooting 99 Continued Headlights Collar Collar Hook bolt Hook bolt Prong Grommet Rear fender ...

Page 102: ...rts in the reverse order of removal Front Rear Turn Signal Bulb 1 Remove the screw 2 Remove the turn signal lens 3 Slightly press the bulb and turn it counterclockwise 4 Install a new bulb and parts in the reverse order of removal Electrical Trouble u Burned out Light Bulb Troubleshooting 100 Bulb Socket Turn signal lens Screw Bulb ...

Page 103: ... License Plate Light The license plate light uses an LED If the LED is not turned on see your dealer for servicing Electrical Trouble u Burned out Light Bulb Troubleshooting 101 License plate light ...

Page 104: ...P 57 2 Open the fuse box cover 3 Pull the fuses out with the fuse puller in the tool kit one by one check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating 4 Close the fuse box cover 5 Install the left side cover Electrical Trouble u Blown Fuse Troubleshooting 102 Fuse box cover Spare fuses ...

Page 105: ... out with the fuse puller in the tool kit and check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating u Spare main fuse is provided in the starter magnetic switch 5 Reinstall parts in the reverse order of removal Electrical Trouble u Blown Fuse Troubleshooting 103 Continued Starter magnetic switch Main fuse Spare main fuse Wire connector ...

Page 106: ...with the fuse puller in the tool kit and check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating u Spare ABS main fuse is provided in the fuse box 2 P 102 4 Close the fuse box cover 5 Reinstall the left side cover Electrical Trouble u Blown Fuse Troubleshooting 104 ABS main fuse Fuse box cover ...

Page 107: ... by one check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating 4 Close the fuse box cover 5 Reinstall the seat NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your vehicle inspected by your dealer Electrical Trouble u Blown Fuse Troubleshooting 105 Spare fuse Fuse box cover ...

Page 108: ...nstable engine operation will occur intermittently while riding Even if this symptom occurs you can continue to ride your vehicle If unstable engine operation occurs even if sufficient fuel is available have your vehicle inspected by your dealer as soon as possible Troubleshooting 106 ...

Page 109: ... 113 Transporting Your Vehicle P 114 You the Environment P 115 Vehicle Identification Number P 116 Emission Control Systems P 117 Catalytic Converter P 121 Oxygenated Fuels P 122 Authorized Manuals P 123 Warranty Coverage and Service P 124 Honda Contacts P 126 USA Reporting Safety Defects P 128 Information ...

Page 110: ...ocation To make a duplicate take the spare key or the key number to your dealer If you lose all ignition keys and the key number the ignition switch assembly will probably have to be removed by your dealer to determine the key number A metal key holder may cause damage to the area surrounding the ignition switch Keys Information 108 ...

Page 111: ...on Failing to do so will drain the battery Odometer The display locks at 999 999 when the read out exceeds 999 999 Tripmeter The tripmeters return to 0 0 when each read out exceeds 9 999 9 Document Bag The owner s manual registration and insurance information can be stored in the plastic document bag located under the seat Ignition Cut off System A banking lean angle sensor automatically stops the...

Page 112: ...them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your vehicle with plenty of clean water and dry with a soft clean cloth 4 After the vehicle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tires Brake discs pads drum or shoes contaminated with oil will suffer greatly reduced braking effectiveness and can lead t...

Page 113: ...er u Water in the air cleaner can prevent the engine from starting Do not direct water near the headlight u The headlight s inside lens may fog temporarily after washing or while riding in the rain This does not impact the headlight function However if you see a large amount of water or ice accumulated inside the lens es have your vehicle inspected by your dealer Do not use wax or polishing compou...

Page 114: ...ts or any kind of chemical cleaner on the windscreen Dry with a soft clean cloth NOTICE To avoid possible scratching or other damage use only water and a soft cloth or sponge to clean the windscreen For a dirtier windscreen use a diluted neutral detergent with a sponge and plenty of water Make sure to wash off all the detergent Detergent residue may cause windscreen cracks Replace the windscreen i...

Page 115: ...riding for an extended period follow these guidelines Wash your vehicle and wax all painted surfaces except matte painted surfaces Coat chrome pieces with rust inhibiting oil Lubricate the drive chain 2 P 50 Place your vehicle on a maintenance stand and position a block so that both tires are off the ground After rain remove the body cover and allow the vehicle to dry Remove the battery 2 P 55 to ...

Page 116: ...a ca and look up Storage Tips under the Honda Warranty in the Warranty tab for your Model Transporting Your Vehicle If your vehicle needs to be transported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your vehicle with a wheel or wheels on the ground NOTICE Towing your vehicle ...

Page 117: ...Put oil and other toxic wastes in approved containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and to get instructions on how to dispose of non recyclable wastes Do not place used engine oil in the trash or pour it down a drain or on the ground Used oil gasoline coolant and cleaning solvent...

Page 118: ...iquely identify your vehicle and are required in order to register your vehicle They may also be required when ordering replacement parts You should record these numbers and keep them in a safe place Vehicle Identification Number Information 116 VIN VIN Engine number ...

Page 119: ...on emission standards during its useful life when operated and maintained according to the instructions provided CARB also requires that your vehicle comply with applicable evaporative emission requirements during its useful life when operated and maintained according to the instructions provided USA Compliance with the terms of the Distributor s Warranties for Honda Motorcycle Emission Control Sy...

Page 120: ...ection and is comprised of air intake engine control fuel control and exhaust control subsystems The engine control module ECM uses sensors to determine how much air enters the engine and then controls how much fuel to inject Ignition Timing Control System The ignition timing control system adjusts the ignition timing to reduce the amount of HC CO and NOx produced Secondary Air Injection System Th...

Page 121: ...chnologies to prevent fuel vapor emissions Tampering with these components to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED U S federal law prohibits and Canadian provincial laws may prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by a...

Page 122: ...nance Removing or disabling any emissions compliance component or replacing any compliance component with a noncompliant component Problems Affecting Vehicle Exhaust Emissions Have your vehicle inspected and repaired by your dealer if you experience any of the following symptoms Hard starting or stalling after starting Rough idling Misfiring or backfiring during acceleration Poor engine performanc...

Page 123: ...engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your vehicle s catalytic converters Always use unleaded gasoline Leaded gasoline will damage the catalytic converters Keep the engine in good running condition A poorly running engine can cause the catalytic converter to overheat causing damage to the converter or the vehicle If ...

Page 124: ...olvents and corrosion inhibitors to protect the fuel system Never use a blend containing more than 5 If you accidentally fill your fuel tank with an oxygenated fuel containing higher percentages you may experience performance problems To resolve the problem have your dealer drain the fuel tank and replace with the correct fuel Fuel system or performance problems resulting from the use of an oxygen...

Page 125: ...ce information for various systems on Honda motorcycles scooters and ATV USA The Winter Storage Guide in conjunction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician However if you possess the proper tools observe the safety standards and are mechanically capa...

Page 126: ...fer to the Warranty Booklet posted on our website at www honda ca It is important to realize that your warranty applies only to defects in material or workmanship of your Honda Your warranty coverage does not apply to the normal wear and deterioration associated with use of the vehicle Your warranty coverage is not voided if you perform your own maintenance However failures that occur due directly...

Page 127: ...ion If a problem exists and is covered under warranty your dealer will perform the warranty repairs If you have any questions about your warranty coverage or the nature of the repair talk to the Service Manager of your Honda dealer If a misunderstanding occurs and you aren t satisfied with your dealer s handling of the situation we suggest you discuss your problem with the appropriate member of th...

Page 128: ...lstop 100 4C 7B Telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Department 180 Honda Boulevard Markham Ontario L6C 0H9 Telephone 888 946 6329 Fax 877 939 0909 E mail honda_cr ch honda com Please include the following information in your letter Name address and telephone number Product model year and VIN Date of purchase Dealer name and address We will likely ask your Honda dealer...

Page 129: ...tment offers Honda Genuine Parts Pro Honda products Honda Genuine Accessories USA only and Honda accessories and products Canada only that provide the same quality that went into your vehicle USA The sales department offers the Honda Protection Plan to extend almost all of your warranty coverage Your Honda dealer can also supply information about riding events and information about safety training...

Page 130: ...ds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or American Honda Motor Co Inc To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 1200 New Jersey Avenue SE...

Page 131: ...pacity 1 320 lb 145 kg Passenger capacity Rider and 1 passenger Minimum turning radius 7 5 ft 2 29 m Displacement 15 3 cu in 250 cm3 Bore x stroke 2 99 x 2 17 in 76 0 x 55 0 mm Compression ratio 10 7 1 Fuel Unleaded gasoline Recommended 86 PON or higher Tank capacity 2 67 US gal 10 1 L Battery YTZ8V 12 V 7 0 Ah 10 HR Gear ratio 1st 3 333 2nd 2 117 3rd 1 571 4th 1 304 5th 1 103 6th 0 967 Reduction ...

Page 132: ...100 rpm Recommended engine oil Honda 4 stroke motorcycle oil API Service Classification SG or higher excluding oils marked as Energy Conserving or Resource Conserving SAE 10W 30 JASO T 903 standard MA Engine oil capacity After draining 1 5 US qt 1 4 L After draining filter change 1 6 US qt 1 5 L After disassembly 1 9 US qt 1 8 L Recommended brake fluid Honda DOT 3 or DOT 4 Brake Fluid Cooling syst...

Page 133: ...m 2 1 kgf m Engine oil drain bolt 18 lbf ft 24 N m 2 4 kgf m Oil filter cover bolt 7 lbf ft 10 N m 1 0 kgf m Front axle shaft 51 lbf ft 69 N m 7 0 kgf m Front wheel axle pinch bolt 16 lbf ft 22 N m 2 2 kgf m Rear axle nut 65 lbf ft 88 N m 9 0 kgf m Drive chain adjusting lock nut 20 lbf ft 27 N m 2 8 kgf m Tail cap cover bolt 3 9 lbf ft 5 25 N m 0 5 kgf m Spark arrester mounting bolt 6 6 lbf ft 9 0...

Page 134: ...Information Record VIN Engine No Color Label Code Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Manager 132 ...

Page 135: ...ttery 46 55 129 Brake Light Switch 73 Brakes Fluid 50 71 130 Pad Wear 72 Braking 11 Bulb Brake light Taillight 99 Headlight 99 License Plate Light 101 Turn Signal 100 C Clock 21 22 Clutch Adjusting 82 Freeplay 81 Color Label 45 Coolant 69 Crankcase Breather 85 Crash 5 D Drive Chain 50 75 Drive Chain Slider 79 E Electrical Trouble 98 Emission Control Systems 117 Index 133 ...

Page 136: ...Fuses 48 102 G Gasohol 122 Gasoline 32 H Hazard Switch 26 Headlight Aim 86 Headlight Dimmer Switch 26 Helmet Holder 33 High Beam Indicator 25 High Coolant Temperature Indicator 25 89 Honda Contacts 126 Horn Button 26 I Ignition Cut off System Banking Sensor 109 Ignition Key 108 Ignition Switch 27 109 Indicators 24 Information Record 132 Instruments Controls Other Features 109 K Keys 108 Index 134 ...

Page 137: ...e 49 64 Overheating 89 Oxygenated Fuels 122 P Parking 13 Parts Location 18 PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL 24 90 Protective Apparel 9 R Rear ABS Anti lock Brake System OFF Indicator 24 Rear ABS switch 27 29 Recommended Coolant 51 Engine Oil 49 130 Fuel 32 Oil 49 Refueling 32 Removal Battery 55 Seat 56 Side Cover 57 Under Cowl 58 Reporting Safety Defects 128 Riding P...

Page 138: ...e 109 Storage Equipment 33 Owner s Manual 34 Tool Kit 34 Storing 113 Switches 26 T Tachometer 20 Throttle 84 Tires Air Pressure 52 Puncture 92 Replacing 52 92 Transporting 114 Tripmeter 21 109 Troubleshooting 87 Turn Signal Indicators 25 Turn Signal Switch 26 V Vehicle Identification Number 116 W Warranty Coverage and Service 124 Washing 110 Weight Limit 17 129 Wheels Front Removal 93 Rear Removal...

Page 139: ...hthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...