Honda CRF250R 2012 Owner's Manual
2012
Honda CRF250R
OWNER’S MANUAL & COMPETITION HANDBOOK
Introduction
Introduction
Congratulations on choosing your Honda CRF
motocross motorcycle.
When you own a Honda, you’re part of a
worldwide family of satisfied customers – people
who appreciate Honda’s reputation for building
quality into every product.
Your CRF is a high performance racing
motorcycle that utilizes the latest motocross
technology and is intended for competition use in
sanctioned, closed-course events by experienced
riders only.
Be aware that motocross is a physically
demanding sport that requires more than just a
fine motorcycle. To do well, you must be in
excellent physical condition and be a skillful
rider. For the best results, work diligently on
your physical conditioning and practice
frequently.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your
investment, we urge you to take responsibility for
keeping your CRF well maintained. Scheduled
service is a must, of course. But it’s just as
important to observe the break-in guidelines, and
perform all the pre-ride and other periodic checks
detailed in this manual.
You should also read the owner’s manual before
you ride. It’s full of facts, instructions, safety
information, and helpful tips. To make it easy to
use, the manual contains a table of contents, a
detailed list of topics at the beginning of each
section, and an index at the back of the book.
As you read this manual, you will find
information that is preceded by a
symbol. This information is intended to help you
avoid damage to your CRF, other property, or the
environment.
Unless you are mechanically qualified and have
the proper tools, you should see your dealer for
the service and adjustment procedures discussed
in this manual.
An official Honda Service Manual for your CRF
is available (page 160). It is the same manual
your dealer uses. If you plan to do any service
on your CRF beyond the standard maintenance
procedures in this manual, you will find an
official Honda Service Manual a valuable
reference.
If you have any questions, or if you ever need a
special service or repairs, remember that your
dealer knows your CRF best and is dedicated to
your complete satisfaction.
Please report any change of address or ownership
to your dealer so we will be able to contact you
concerning important product information.
You may also want to visit our website at
USA: www.powersports.honda.com.
Canada: www.honda.ca.
Happy riding!
California Proposition 65
Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
NOTICE
ABBREVIATION
Throughout this manual, the following
abbreviations are used to identify the respective
parts or system.
Abbrev. term
CKP sensor
DTC
ECM
ECT sensor
HPSD
IAT sensor
MAP sensor
MIL
PGM-FI
TDC
TP sensor
Crankshaft Position sensor
Diagnostic Trouble Code
Engine Control Module
Engine Coolant Temperature sensor
Honda Progressive Steering Damper
Intake Air Temperature sensor
Manifold Absolute Pressure sensor
Malfunction Indicator Lamp
Programmed Fuel Injection
Top Dead Center
Throttle Position sensor
Full term
A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
To help you make informed decisions about safety, this manual contains a section devoted to
Motorcycle Safety, as well as a number of Safety Messages
throughout the manual.
Safety Messages are preceded by a safety alert symbol and one of three signal words:
DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgement.
Safety Messages
DANGER
WARNING
CAUTION
Contents
Contents
MOTORCYCLE SAFETY...............................1
Important Safety Information..............................2
Important Safety Precautions..........................2
Accessories & Modifications..............................3
Safety Labels.......................................................4
INSTRUMENTS & CONTROLS....................5
Operation Component Locations ........................6
Indicator ..............................................................7
MIL Blink Pattern...........................................7
Current DTC/Freeze DTC ..............................7
Circuit Inspection............................................8
DTC Index ......................................................9
BEFORE RIDING...........................................11
Are You Ready to Ride? ...................................12
Is Your Motorcycle Ready to Ride?..................13
Pre-ride Inspection........................................13
BASIC OPERATING INSTRUCTIONS ......15
Safe Riding Precautions................................16
Starting & Stopping the Engine........................17
Fast Idle Knob ..............................................17
Preparation....................................................17
Starting Procedure ........................................17
How to Stop the Engine................................18
Break-in Guidelines ..........................................19
SERVICING YOUR HONDA........................21
Before You Service Your Honda
The Importance of Maintenance .......................22
Maintenance Safety...........................................23
Important Safety Precautions........................23
Maintenance Schedule ......................................24
General Competition Maintenance ...................26
Before & After Competition Maintenance........30
Between Motos & Practice Maintenance .....30
After Competition Maintenance ...................30
Service Preparations
Maintenance Component Locations..................32
Seat....................................................................33
Fuel Tank...........................................................34
Subframe ...........................................................36
Service Procedures
Fluids & Filters
Fuel System.......................................................40
Engine Oil .........................................................49
Transmission Oil ...............................................52
Coolant ..............................................................54
Air Cleaner........................................................56
Crankcase Breather ...........................................58
Engine
Throttle..............................................................59
Engine Idle Speed .............................................61
Clutch System ...................................................62
Spark Plug .........................................................67
Valve Clearance.................................................68
Piston/Piston Rings/Piston Pin..........................76
Chassis
Suspension.........................................................85
Brakes................................................................90
Wheels...............................................................94
Tires & Tubes....................................................95
Drive Chain .......................................................97
Exhaust Pipe/Muffler ......................................100
Steering Damper..............................................103
Additional Maintenance Procedures ...............105
Appearance Care .............................................107
Contents
Contents
ADJUSTMENTS FOR COMPETITION ...109
Front Suspension Adjustments........................110
Front Suspension Air Pressure....................110
Front Suspension Damping.........................110
Fork springs.................................................111
Front Suspension Disassembly ...................112
Damper Oil Change ....................................115
Fork Assembly ............................................118
Rear Suspension Adjustments.........................125
Rear Suspension Spring Pre-Load..............125
Rear Suspension Damping..........................126
Rear Suspension Race Sag .........................127
Suspension Adjustments for Track
Conditions .......................................................129
Suspension Adjustment Guidelines.................130
Tuning Tips .....................................................133
Spark Plug Reading ....................................133
Steering Damper Adjustment..........................134
Steering Damper Damping .........................134
Steering Damper Adjustment Guidelines........135
Chassis Adjustments........................................136
Rear End .....................................................136
Fork Height/Angle......................................136
Wheelbase...................................................136
Gearing............................................................137
Tire Selection for Track Conditions................138
Personal Fit Adjustments ................................139
Control Positioning.....................................139
Handlebar Position, Width & Shape...........139
TIPS................................................................141
Transporting Your Motorcycle........................142
Storing Your Honda.........................................143
Preparation for Storage...............................143
Removal from Storage................................143
You & the Environment ..................................144
Troubleshooting...............................................145
TECHNICAL INFORMATION ..................147
Vehicle Identification ......................................148
Serial Numbers ...........................................148
Specifications ..................................................149
Torque Specifications......................................150
Nuts, Bolts, Fasteners .................................150
Oxygenated Fuels............................................153
Competition Logbook .....................................154
Optional Parts List ..........................................156
Spare Parts & Equipment................................157
Spare Parts ..................................................157
General Tools ..............................................157
Honda Special Tools ...................................157
Chemical Products......................................157
Other Products ............................................157
Wiring Diagram...............................................158
CONSUMER INFORMATION...................159
Authorized Manuals........................................160
Contacting Honda............................................161
Your Dealer .....................................................162
The Honda Rider’s Club (USA only) .............163
INDEX............................................................164
QUICK REFERENCE
Motorcycle Safety
Motorcycle Safety 1
This section presents some of the most important
information and recommendations to help you
ride your CRF safely. Please take a few
moments to read these pages. This section also
includes information about the location of safety
labels on your CRF.
Important Safety Information...............................2
Important Safety Precautions..........................2
Accessories & Modifications...............................3
Safety Labels........................................................4
Important Safety Information
2 Motorcycle Safety
Important Safety Precautions
Your CRF can provide many years of pleasure, if
you take responsibility for your own safety and
understand the challenges you can meet in
competitive racing.
As an experienced rider, you know there is much
you can do to protect yourself when you ride.
The following are a few precautions we consider
to be most important.
Never Carry a Passenger.
Your CRF is designed for one operator only.
Carrying a passenger can cause a crash in which
you and others can be hurt.
Wear Protective Gear.
Whether you’re practicing to improve your skills,
or riding in competition, always wear an
approved helmet, eye protection, and proper
protective gear.
Take Time to Get to Know Your CRF.
Because every motorcycle is unique, take time to
become thoroughly familiar with how this one
operates and responds to your commands before
placing your machine, and yourself, in
competition.
Learn and Respect Your Limits.
Never ride beyond your personal abilites or faster
than conditions warrant. Remember that alcohol,
drugs, illness and fatigue can reduce your ability
to perform well and ride safely.
Don’t Drink and Ride.
Alcohol and riding don’t mix. Even one drink
can reduce your ability to respond to changing
conditions, and your reaction time gets worse
with every additional drink. So don’t drink and
ride, and don’t let your friends drink and ride
either.
Keep your Honda in Safe Condition.
Maintaining your CRF properly is critical to your
safety. A loose bolt, for example, can cause a
breakdown in which you can be seriously
injured.
Accessories & Modifications
Motorcycle Safety 3
Accessories & Modifications
Installing non-Honda accessories, removing
original equipment, or modifying your CRF in
any way that would change its design or
operation, could seriously impair your CRF’s
handling, stability, and braking, making it unsafe
to ride.
WARNING
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 modifications and
accessories.
4 Motorcycle Safety
Safety Labels
Read these labels carefully and don’t remove them.
If the label comes off or becomes hard to read, contact your dealer for replacement.
(For Canada)
Instruments & Controls 5
Instruments & Controls
Read this section carefully before you ride. It
presents the location of the basic controls on your
CRF.
Operation Component Locations .........................6
Indicator ...............................................................7
MIL Blink Pattern............................................7
Current DTC/Freeze DTC ...............................7
Circuit Inspection.............................................8
DTC Index .......................................................9
6 Instruments & Controls
Operation Component Locations
clutch lever
MIL
front brake lever
engine stop button
throttle grip
fast idle knob
(engine idle speed)
shift lever
kickstarter
rear brake pedal
Instruments & Controls 7
Indicator
The MIL on your CRF keeps you informed,
alerts you to possible problems, and makes your
riding safer and more enjoyable. Refer to the
MIL frequently.
(1)
(1) MIL
The MIL flashes when there is any abnormality
in the PGM-FI system. It should also light for a
few seconds and then go off when the engine is
started.
If the MIL comes on at any other time, reduce
speed and refer to an official Honda Service
Manual available for purchase from your dealer
(page 160).
If the MIL does not come on when it should,
have your dealer check it for problems.
MIL Blink Pattern
The MIL will blink the appropriate DTC number
if the ECM detects an active problem while the
engine is running at less than 5,500 rpm.
The MIL will stay ON when the engine speed is
over 5,500 rpm.
The MIL has two types of blinks: a long blink
and short blink. The long blinking lasts for 1.2
seconds, the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short
blinks. For example, when one long blink is
followed by two short blinks, the MIL is 12 (one
long blink = 10 blinks, plus two short blinks).
When the ECM stores more than one DTC, the
MIL will indicate them by blinking in the order
from the lowest number to highest number.
Current DTC/Freeze DTC
The DTC is indicated in two ways according to
the failure status.
– In the case that the ECM detects an active
problem, the MIL will come on and will start to
blink the DTC when the engine is started.
– In the case that the ECM does not detect an
active problem but has recorded a previous
problem in its memory, the MIL will not come
on. If it is necessary to retrieve any past
problems stored in the memory, refer to an
official Honda Service Manual.
8 Instruments & Controls
Indicator
Circuit Inspection
Always clean around the ECM and keep debris
away from the connectors before disconnecting
them.
A faulty PGM-FI system is often related to
poorly connected or corroded connections. Check
the following connections.
(1) MAP sensor connector
(2) ECT sensor connector
(3) TP sensor connector
(4) IAT sensor connector
(5) Injector connector
(6) No.1/No.2 CKP sensor connector
(7) ECM connector
Remember, circuit inspection is not a “cure-all”
for other problems in your engine’s PGM-FI
system.
(1)(2)
(5)
(7)
(6) (3) (4)
Instruments & Controls 9
Indicator
DTC Index
MIL blinks
1
2
7
8
9
MAP sensor circuit malfunction
MAP sensor performance problem
ECT sensor circuit malfunction
TP sensor circuit malfunction
IAT sensor circuit malfunction
12 Injector circuit malfunction
19 No.1 CKP sensor circuit malfunction
69 No.2 CKP sensor circuit malfunction
Engine operates normally
Engine operates normally
Hard start at a low temperature
Poor engine acceleration
Engine operates normally
• Engine does not start
• Injector, fuel pump and ignition shut down
• Engine does not start
• Injector, fuel pump and ignition shut down
• Engine does not start
• Injector, fuel pump and ignition shut down
Function Failure Symptom/Fail-safe Function
Should be serviced by your dealer, unless the owner has proper tools and is technically qualified.
The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started.
If the engine does not start, check all connector connections and/or refer to an official Honda Service
Manual (page 160) for troubleshooting of the PGM-FI symptom.
Refer to MIL Blink Pattern on page 7.
10 Instruments & Controls
Before Riding 11
Before each ride, you need to make sure you and
your Honda are both ready to ride. To help get
you prepared, this section discusses how to
evaluate your riding readiness, and what items
you should check on your CRF.
For information about suspension, steering
damper, and other adjustments, see page 109.
Before Riding
Are You Ready to Ride?.....................................12
Is Your Motorcycle Ready to Ride?...................13
Pre-ride Inspection........................................13
12 Before Riding
Are You Ready to Ride?
Before riding your CRF for the first time, we
strongly recommend that you read this owner’s
manual, make sure you understand the safety
messages, and know how to operate the controls.
Before each ride, it’s also important to make sure
you and your CRF are both ready to ride.
For information about suspension, steering
damper, and other adjustments, see page 109.
Whether you’re preparing for competition or for
practice, always make sure you are:
• In good physical and mental condition
• Free of alcohol and drugs
• Wearing an approved helmet, eye protection,
and other appropriate riding gear
Although complete protection is not possible,
wearing the proper gear can reduce the chance or
severity of injury when you ride.
WARNING
Not wearing a helmet increases the
chance of serious injury or death in a
crash.
Be sure you always wear a helmet, eye
protection and other protective apparel
when you ride.
Before Riding 13
Is Your Motorcycle Ready to Ride?
Competitive riding can be tough on a motorcycle,
so it’s important to inspect your CRF and correct
any problems you find before each ride. Check
the following items (page numbers are at the
right):
Pre-ride Inspection
Check the following before each ride:
• Engine oil level.............................................50
• Transmission oil level...................................53
• Fuel line for condition ..................................40
• Coolant for proper level............................... 54
• Cooling system and hoses for condition.......55
• Spark plug for proper heat range, carbon
fouling and spark plug wire terminal for
looseness .......................................................67
• Air cleaner for condition and
contamination................................................56
• Clutch lever adjustment and freeplay...........62
• Breather drain for cleaning...........................58
• Steering head bearing and related parts
for condition................................................105
• Steering damper operation..........................103
• Throttle operation .........................................59
• Tires for damage or improper inflation
pressure ........................................................95
• Spokes for looseness.....................................94
• Rim locks for looseness................................94
• Front and rear suspension for proper
operation .................................................85, 86
• Front and rear brakes, check operation ........90
• Drive chain for correct slack and adequate
lubrication................................................97-98
• Drive chain sliders and drive chain rollers
for damage or wear.................................97, 98
• Exhaust pipe/Muffler for looseness............100
• Every possible part for looseness (such as
cylinder head nuts, engine mounting
bolts/nuts, axle nuts, handlebar holder bolts,
fork bridge pinch bolts, drive chain adjuster,
drive chain guide, wire harness connectors,
kickstarter mounting bolt) ...................150-152
• Indicator..........................................................7
WARNING
Improperly maintaining this motorcycle or
failing to correct a problem before riding
can cause a crash in which you can be
seriously hurt or killed.
Always perform a pre-ride inspection
before every ride and correct any
problems.
14 Before Riding
This section gives basic information on how to
start and stop your engine as well as break-in
guidelines.
Safe Riding Precautions................................16
Starting & Stopping the Engine .........................17
Fast Idle Knob ..............................................17
Preparation....................................................17
Starting Procedure ........................................17
How to Stop the Engine................................18
Break-in Guidelines ...........................................19
Basic Operating Instructions 15Basic Operating Instructions 15
Basic Operating Instructions
16 Basic Operating Instructions16 Basic Operating Instructions
Basic Operating Instructions
Safe Riding Precautions
Before riding your CRF for the first time, please
review the
Important Safety Precaution
beginning on page 2 and the previous section,
titled
Before Riding.
For your safety, avoid starting or operating the
engine in an enclosed area such as a garage.
Your CRF’s exhaust contains poisonous carbon
monoxide gas which can collect rapidly in an
enclosed area and cause illness or death.
Basic Operating Instructions 17Basic Operating Instructions 17
Starting & Stopping the Engine
Always follow the proper starting procedure
described below.
Your CRF can be kickstarted with the
transmission in gear by pulling in the clutch lever
before operating the kickstarter.
Fast Idle Knob
The fast idle knob has two functions:
• When pulled out, the fast idle knob assists in
first-time start-up for cold weather starting.
• When pushed in, it acts as an idle adjustment
screw. Refer to
Idle Speed Adjustment on
page 61.
Preparation
Make sure that the transmission is in neutral.
Starting Procedure
Always follow the proper starting procedure
described as follows.
Check the engine oil, transmission oil and coolant
levels before starting the engine (pages 50, 53, 54).
Cold Engine Starting
1. Shift the transmission into neutral.
2. If the temperature is 95°F (35°C) or below,
pull the fast idle knob (1) fully out.
(1) fast idle knob
3. With the throttle closed, operate the
kickstarter starting from the top of the
kickstarter stroke, and kick through to the
bottom with a rapid, continuous motion.
4. About a minute after the engine starts, push
the fast idle knob back all the way to fully
OFF.
If idling is unstable, open the throttle slightly.
(1)
Warm Engine Starting
1. Shift the transmission into neutral.
2. Kick-start the engine (Do not open the
throttle).
If Dif
ficult to Start After Stalling
1. Shift the transmission into neutral.
2. With the throttle fully opened, repeat
kickstarter operation approximately 10 times
to discharge excessive fuel from the engine.
3. Kick-start the engine. (Do not open the
throttle.)
Snapping the throttle or fast idling for more than
5 minutes may cause exhaust pipe discoloration.
18 Basic Operating Instructions
Starting & Stopping the Engine
18 Basic Operating Instructions
How to Stop the Engine
(1)
(2)
(1) throttle (2) engine stop button
Normal Engine Stop
1. Shift the transmission into neutral.
2. Lightly open the throttle (1) two or three
times, and then close it.
3. Push and hold the engine stop button (2) until
the engine stops completely.
Emer
gency Engine Stop
To stop the engine in an emergency, push and
hold the engine stop button.
Basic Operating Instructions 19
Break-in Guidelines
Help assure your CRF’s future reliability and
performance by paying extra attention to how
you ride during the first operating day or 15
miles (25 km).
During this period, avoid full-throttle starts and
rapid acceleration.
This same procedure should be followed each
time when:
• piston is replaced
• piston rings are replaced
• cylinder is replaced
• crankshaft or crank bearings are replaced
20 Basic Operating Instructions
Servicing Your Honda 21
Servicing Your Honda
Keeping your CRF well maintained is absolutely
essential to your safety. It’s also a good way to
protect your investment, get maximum
performance, avoid breakdowns, and have more
fun.
To help keep your CRF in good shape, this
section includes a Maintenance Schedule for
required servicing and step-by-step instructions
for specific maintenance tasks. You’ll also find
important safety precautions, information on oils,
and tips for keeping your Honda looking good.
An ECM system is used on this motorcycle;
consequently, routine ignition timing adjustment
is unnecessary. If you want to check the ignition
timing, refer to the Honda Service Manual (page
160).
An optional tool kit may be available. Check
with your dealer’s parts department.
Before You Service Your Honda
The Importance of Maintenance ........................22
Maintenance Safety............................................23
Important Safety Precautions........................23
Maintenance Schedule .......................................24
General Competition Maintenance ....................26
Before & After Competition Maintenance.........30
Between Motos & Practice Maintenance .....30
After Competition Maintenance ...................30
Service Preparations
Maintenance Component Locations...................32
Seat ....................................................................33
Fuel Tank ...........................................................34
Subframe ...........................................................36
Service Procedures
Fluids & Filters
Fuel System........................................................40
Engine Oil ..........................................................49
Transmission Oil ................................................52
Coolant ...............................................................54
Air Cleaner.........................................................56
Crankcase Breather ............................................58
Engine
Throttle...............................................................59
Engine Idle Speed ..............................................61
Clutch System ....................................................62
Spark Plug ..........................................................67
Valve Clearance..................................................68
Piston/Piston Rings/Piston Pin...........................76
Chassis
Suspension..........................................................85
Front Suspension Inspection ...........................85
Rear Suspension Inspection ............................86
Recommended Fork Oil..................................87
Fork Oil Change..............................................87
Brakes.................................................................90
Wheels................................................................94
Tires & Tubes.....................................................95
Drive Chain ........................................................97
Exhaust Pipe/Muffler .......................................100
Steering Damper...............................................103
Additional Maintenance Procedures ................105
Appearance Care ..............................................107
22 Servicing Your Honda
The Importance of Maintenance
Keeping your CRF well-maintained is absolutely
essential to your safety. It’s also a good way to
get maximum performance during each moto.
Careful pre-ride inspections and good
maintenance are especially important because
your CRF is designed to be ridden in off-road
competition.
Remember, proper maintenance is your
responsibility. Be sure to inspect your CRF
before each ride and follow the Maintenance
Schedule in this section.
WARNING
Improperly maintaining this motorcycle 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.
Servicing Your Honda 23
Maintenance Safety
This section includes instructions on how to
perform some important maintenance tasks.
Some of the most important safety precautions
follow. However, we cannot warn you of every
conceivable hazard that can arise in performing
maintenance. Only you can decide whether or
not you should perform a given task.
Important Safety Precautions
• Make sure the engine is off before you begin
any maintenance or repairs.
This will help eliminate several potential
hazards:
Carbon monoxide poisoning from engine
exhaust.
Be sure there is adequate ventilation
whenever you operate the engine.
Burns from hot motorcycle parts. Let the
engine and exhaust system cool before
touching.
Injury from moving parts. Do not run the
engine unless instructed to do so.
• Read the instructions before you begin, and
make sure you have the tools and skills
required.
• To help prevent the motorcycle from falling
over, park it on a firm, level surface, using an
optional workstand or a maintenance stand to
provide support.
• To reduce the possibility of a fire or
explosion, be careful when working around
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene — not
gasoline — to clean parts. Keep cigarettes,
sparks, and flames away from all fuel-related
parts.
WARNING
Failure to properly follow maintenance
instructions and precautions can cause
you to be seriously hurt or killed.
Always follow the procedures and
precautions in this owner’s manual.
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