This repair and service manual covers Honda CRF250R, CRF250X, CRF450R, and CRF450X, 2002-2005.
Table of Contents
QUICK REFERENCE DATA
CHAPTER ONE | GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications
CHAPTER TWO | TROUBLESHOOTING
Engine principles and operating requirements | Starting the engine | Engine will not start | Poor engine performance | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Electrical testing | Front suspension and steering | Rear suspension | Brake system
CHAPTER THREE | LUBRICATION, MAINTENANCE and TUNE-UP
Maintenance intervals | Air filter | Crankcase breather inspection engine oil and filter | Engine oil strainer | Transmission oil | Engine compression check | Piston and piston ring replacement | Piston pin replacement | Spark plug | Valve clearance and decompressor system inspection | Carburetor | Secondary air supply system | Exhaust system | Cooling system | Control cable inspection and lubrication | Throttle cable adjustment | Hot start cable adjustment | Clutch lever adjustment | Brakes | Drive chain and sprockets | Tires and wheels | Wheel bearing inspection | Steering | Front fork | Rear shock absorber inspection | Rear swing arm and linkage | Headlight adjustment | Sidestand inspection | Fasteners inspection | Engine break-in | Specifications
CHAPTER FOUR | ENGINE (CRF250R and CRF250X)
Servicing engine in frame | Engine | Exhaust system | Cylinder head cover | Camshaft and rocker arm | Cam chain tensioner, guides and cam chain | Cylinder head | Valves | Cylinder | Piston and piston rings | Countershaft seal replacement | Shift shaft seal replacement | Lubrication system | Crankcase | Crankcase seal and bearing replacement | Oil pump and one-way valve | Crankshaft | Specifications
CHAPTER FIVE | ENGINE (CRF450R and CRF450X)
Servicing engine in frame | Engine | Exhaust system | Cylinder head cover | Camshaft holder | Camshaft holder service | Cam chain tensioner, guides and cam chain | Cylinder head | Valves | Cylinder | Piston and piston rings | Countershaft seal replacement | Shift shaft seal replacement | Oil relief valve, oil pump drive gear and oil strainer | Crankcase | Crankcase seal and bearing replacement | Oil pump and one-way valve | Crankshaft | Specifications
CHAPTER SIX | CLUTCH, PRIMARY DRIVE, STARTER CLUTCH, KICKSTARTER and EXTERNAL SHIFT MECHANISM (CRF250R and CRF250X)
Right crankcase cover | Clutch cover | Clutch | Clutch release lever | Balancer shaft and primary drive gear assembly | Starter clutch, balancer shaft and primary drive gear assembly | Kickstarter and kick idle gear | External shift mechanism | Clutch cable replacement | Specifications
CHAPTER SEVEN | CLUTCH, PRIMARY DRIVE, KICKSTARTER and EXTERNAL SHIFT MECHANISM (CRF450R and CRF450X)
Right crankcase cover | Clutch cover | Clutch | Clutch release lever | Balancer shaft and primary drive gear assembly | Starter clutch, balancer shaft and primary drive gear assembly | Kickstarter and kick idle gear | External shift mechanism | Clutch cable replacement | Specifications
CHAPTER NINE | FUEL and EMISSION CONTROL SYSTEMS
Fuel system safety | Fuel tank | Fuel shutoff valve and fuel filter | Air box | Carburetor | Carburetor service | Float height adjustment | Carburetor adjustment and rejetting | Throttle position sensor | Throttle cable replacement | Hot start cable replacement | Emission control labels | Crankcase breather system | Pulse secondary air injection system | Specifications
CHAPTER TEN | ELECTRICAL SYSTEM
Electrical connectors | Left crankcase cover | Stator and ignition pulse generator | Flywheel | Ignition coil | Ignition control module (ICM) | Ignition system testing | Ignition timing | Battery | Charging system | Starting system testing | Starter | Starter relay switch | Lighting system | Switches | Main relay | Fuse | Wiring diagrams | Specifications
CHAPTER ELEVEN | COOLING SYSTEM
Cooling system safety precautions | Cooling system inspection | Water pump seal inspection | Cooling system pressure test | Radiators | Coolant reserve tank | Water pump | Cooling fan | Specifications
CHAPTER TWELVE | WHEELS, TIRES and DRIVE CHAIN
Front wheel | Rear wheel | Front and rear hubs | Wheel service | Drive chain | Sprocket replacement | Tire changing | Specifications
CHAPTER THIRTEEN | FRONT SUSPENSION and STEERING
Handlebar | Handlebar grip replacement | Steering head | Steering play check and adjustment | Steering head bearing races | Front fork | Fork service | Front fork adjustment | Specifications
CHAPTER SIXTEEN | BODY and SUBFRAME
Seat | Side covers | Radiator shrouds | Engine guard | Center engine guard | Number plate | Front visor | Tripmeter and cable | Footpeg and mounting bracket | Sidestand | Subframe | Specifications
COLOR WIRING DIAGRAMS
Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job, from basic maintenance and troubleshooting, to complete teardown and rebuild.
PRODUCT DETAILS:
Publisher: Clymer Manuals - 2005
Author: Clymer Staff
Binding: Paperback - 7 x 10 inches
Pages: 615 - Hundreds of b&w photos and illustrations
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