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Honda CRF250R, CRF250X, CRF450R, CRF450X Repair Manual 2002-2005Click To Enlarge Product Image

Honda CRF250R, CRF250X, CRF450R, CRF450X Repair Manual 2002-2005

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  • Item Description
  • Table of Contents
  • Specifications

The 2002-2005 Honda CRF250, CRF450 repair manual by Haynes covers:

  • Honda CRF250R 2002-2005
  • Honda CRF250X 2002-2005
  • Honda CRF450R 2002-2005
  • Honda CRF450X 2002-2005

Book Excerpt: 2002-2005 Honda CRF250R, CRF250X, CRF450R, CRF450X Repair Manual



If the engine bearings, crankshaft, piston, piston rings or cylinder have been serviced, perform the following break-in procedure.

  1. Observe the following conditions when breaking in the engine:
    1. Operate the motorcycle on flat ground. Do not run in sand, mud or up hills. This will overload and possibly overheat the engine.
    2. Vary the throttle position. Do not keep the throttle in the same position for more than a few seconds.
    3. Check the spark plug frequently. Refer to the Spark plug in this chapter to identify spark plug condition.

  2. Perform the Pre-Ride Inspection in this chapter.
  3. Service the air filter as described in this chapter.
  4. Check the engine and transmission oil levels.
  5. Make sure the cooling system is full.
  6. Start the engine and allow it to warm up. During this time, check for proper idle speed and leaks.
  7. Break-in time consists of the motorcycle's first 15 miles (24km).


Remove the parts from the countershaft in the order below, while noting in Figure 14 that the parts are removed from both sides of the countershaft.

Mark the parts with a grease pencil or metal marking pen so they can be installed facing in their original operating position.

  1. Hold the countershaft to keep the parts from sliding off, then clean in solvent and dry with compressed air.
  2. Remove the following parts from the countershaft's splined end:
    1. Thrust washer.
    2. Second gear bushing and second gear.
    3. Thrust washer.
    4. Fourth gear.

  3. Thrust washer, first gear, first gear bushing and thrust washer.
  4. Fifth gear.
  5. Snap ring and spline washer.
  6. Third gear and third gear bushing.
  7. Thrust washer.
  8. Inspect the countershaft assembly as described under Transmission Inspection in this chapter.

Subject: 2002, 2003, 2004, 2005 Honda CRF250R, CRF250X, CRF450R, CRF450X service, maintenance, repair. ISBN-10: 0892879289 | ISBN-13: 9780892879281 | Clymer M352


  • General Information
  • Troubleshooting
  • Lubrication, Maintenance and Tune-up
  • Engine
  • Clutch and External Gearshift Linkage
  • Transmission and Internal Shift Mechanism
  • Fuel and Emission Systems
  • Exhaust System
  • Electrical System
  • Wheels, Tires and Drivetrain
  • Front Suspension and Steering
  • Rear Suspension
  • Brakes
  • Body and Frame
  • Wiring Diagrams

  • Publisher: Clymer Series / Haynes Manuals
  • Pages: 615 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 7 x 10 inches
  • ISBN: 978-0-89287-928-1
  • Years: 2002 - 2005
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