HONDA CRF250X'04 User Manual

PARTS CATALOG

CRF250X’04

FEBRUARY, 2004

American Honda Motor Co., Inc. 14KSC401M (Fiche Version)

2004 American Honda Motor Co., Inc., 14KSC401P (Paper Version)

(Order through Helm)

TABLE OF CONTENTS

Introduction Grid / Page

• HOW TO USE THIS CATALOG .................................... A2 4

• LOCATION OF SERIAL NUMBER ................................ A2 5

• SERIAL NUMBERS ...................................................... A3 6

• CONSTRUCTION OF VEHICLE IDENTIFICATION

NUMBER ................................................................ A3 7

• BULK HOSE PART NUMBER PATTERN...................... A4 8

• MASTER INDEX ............................................................ A5 10

Part Groups

• ENGINE SECTION ........................................................ 1-C1 1-1

• FRAME SECTION.......................................................... 1-E1 2-1

Index

• PART NUMBER INDEX ................................................ B1 3-1

• DESCRIPTION INDEX .................................................. 1-G1 4-1

FEBRUARY, 2004 32004 American Honda Motor Co., Inc.

HOW TO USE THIS CATALOG

4 2004 American Honda Motor Co., Inc. FEBRUARY, 2004

LOCATION OF SERIAL NUMBER

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 5

SERIAL NUMBERS

Models and applicable serial numbers

Models and applicable serial numbers given in this parts catalog can be identified as follows.

Engine Frame Carburetor

Area Serial Serial Serial

Model Code No. No. No.

CRF250X’04 A ME11E-5000001~ JH2ME110*4K000001~ FCR02A A
CRF250X’04 AC ME11E-5000001~ JH2ME111*4K000001~ FCR03A A

6 2004 American Honda Motor Co., Inc. FEBRUARY, 2004

CONSTRUCTION OF VEHICLE IDENTIFICATION NUMBER

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 7

BULK HOSE PART NUMBER PATTERN

8 2004 American Honda Motor Co., Inc. FEBRUARY, 2004

MASTER INDEX

Title Grid Page Title Grid Page

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F6 2-45

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F7 2-47

ENGINE SECTION

CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-2

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-3

CAMSHAFT • VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C2 1-5

CAM CHAIN • TENSIONER . . . . . . . . . . . . . . . . . . . . . 1-C5 1-11

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-12

R. CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-13

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C7 1-14

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-16

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-17

L. CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-18

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-20

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-21

STARTING CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-22

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-23

CRANKSHAFT • PISTON . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-26

BALANCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-27

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C14 1-28

GEARSHIFT DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C15 1-30

KICK STARTER SPINDLE . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-32

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-33

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F8 2-49

CAUTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F9 2-50

MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F9 2-51

COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F10 2-52

FRAME SECTION

HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E1 2-2

METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E1 2-3

HANDLE LEVER • SWITCH • CABLE. . . . . . . . . . . . . . 1-E2 2-4

FR. BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . 1-E3 2-6

HANDLE BAR • TOP BRIDGE . . . . . . . . . . . . . . . . . . . 1-E4 2-8

STEERING STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E4 2-9

FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E5 2-10

FRONT SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . 1-E5 2-11

FRONT BRAKE CALIPER. . . . . . . . . . . . . . . . . . . . . . . 1-E7 2-14

FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E7 2-15

REAR BRAKE CALIPER. . . . . . . . . . . . . . . . . . . . . . . . 1-E8 2-17

RR. BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . 1-E9 2-19

REAR WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E10 2-20

FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E11 2-22

SEAT • SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E12 2-24

AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E12 2-25

AIR SUCTION VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 1-E14 2-28

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E15 2-30

PEDAL • KICK STARTER ARM . . . . . . . . . . . . . . . . . . 1-E16 2-32

STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-E16 2-33

STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F1 2-34

SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F1 2-35

RR CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F3 2-38

REAR FENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F4 2-41

TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F5 2-42

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F5 2-43

WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F6 2-44

FEBRUARY, 2004 102004 American Honda Motor Co., Inc.

ENGINE SECTION

Chapter Table of Contents

Page Title Grid Page

CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-2

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C1 1-3

CAMSHAFT • VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C2 1-5

CAM CHAIN • TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C5 1-11

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-12

R. CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C6 1-13

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C7 1-14

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-16

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C8 1-17

L. CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C9 1-18

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-20

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C10 1-21

STARTING CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-22

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C11 1-23

CRANKSHAFT • PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-26

BALANCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C13 1-27

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C14 1-28

GEARSHIFT DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C15 1-30

KICK STARTER SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-32

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-C16 1-33

FEBRUARY, 2004 1-12004 American Honda Motor Co., Inc.

CYLINDER HEAD COVER

4 =CRF250X’04 E-1

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 SEAL, RING ................................................ -------- -------- 1 12226-MEB-670 6842496

2 COVER, CYLINDER HEAD ........................ -------- -------- 1 12310-KRN-670 7605629

3 PLATE, BREATHER.................................... -------- -------- 1 12316-KRN-670 7605637

4 GASKET, HEAD COVER ............................ -------- -------- 1 12391-KRN-670 7605645

5 BOLT, HEAD COVER.................................. -------- -------- 2 90017-MY9-790 5427810

6 RUBBER, SETTING .................................... -------- -------- 2 90543-MV9-670 3699139

7 BOLT, FLANGE (6X12) .............................. -------- -------- 2 96300-06012-00 1829878

KSC4E0100

1-2 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C1

CYLINDER HEAD

4 =CRF250X’04 E-2

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 CYLINDER HEAD ASSY............................. -------- -------- A 1 12010-KRN-671 7656424

CYLINDER HEAD ASSY............................. -------- -------- AC 1 12010-KSC-770 7659147

2 GUIDE, VALVE (OS) .................................. -------- -------- 2 12204-KRN-P00 7605595

3 GUIDE, EX. VALVE (OS) ............................ -------- -------- 2 12205-KRN-P00 7605603

4 GASKET, CYLINDER HEAD ...................... -------- -------- 1 12251-KRN-671 7605611

5 INSULATOR, CARBURETOR .................... -------- -------- 1 16211-KRN-670 7606072

6 BAND, INSULATOR .................................... -------- -------- 1 16218-KSC-670 7659170

7 BAND B, INSULATOR ................................ -------- -------- 1 16218-MCJ-000 6393698

8 NUT, SQUARE (5MM) ................................ -------- -------- 2 16222-MV4-300 3694882

9 JOINT, BOOST............................................ -------- -------- AC 1 17113-KSC-670 7656572

10 PIPE, WATER.............................................. -------- -------- 1 19523-MEB-670 6844963

KSC4E0200

11 SPARK PLUG (IMR8C-9H) (NGK) .............. -------- -------- 1 31911-MBW-E11 7050990

SPARK PLUG (IMR9C-9H) ........................ -------- -------- (1) 31912-MBW-E11 6846034

SPARK PLUG (VUH24D) (DENSO)............ -------- -------- 1 31921-MBW-E12 7051006

SPARK PLUG (VUH27D) (DENSO)............ -------- -------- (1) 31922-MBW-E12 7051014

12 BOLT, FLANGE (7X60) .............................. -------- -------- 2 90001-KRN-670 7607336

13 BOLT, FLANGE (7X50) .............................. -------- -------- 2 90002-KRN-670 7607344

14 BOLT, RECESSED (5X28).......................... -------- -------- 2 90005-MCJ-000 6852297

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-3

CYLINDER HEAD

4 =CRF250X’04 E-2

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

15 CAP (14MM)................................................ -------- -------- 1 90084-MEN-670 7532948

16 NUT, CAP (9MM) ........................................ -------- -------- 4 90232-MB6-680 2072841

17 WASHER, PLAIN (9MM) ............................ -------- -------- 4 90401-KRN-670 7607435

18 WASHER, CAMSHAFT THRUST................ -------- -------- 2 90446-KRN-670 7607443

19 WASHER, SEALING (5MM)........................ -------- -------- AC 1 90452-323-000 0255224

20 STRAP, CABLE (118MM) *NH1L* (BLACK) -------- -------- 1 90672-SA0-003 1170653

21 PIN, DOWEL (9X14).................................... -------- -------- 4 90701-MR7-000 3453677

22 O-RING (13.8X2.5)...................................... -------- -------- 1 91303-377-000 0499525

23 O-RING (19X3) (NOK) ................................ -------- -------- 1 91312-KE7-003 1768720

24 BOLT, STUD (8X22).................................... -------- -------- 2 92900-08022-0B 1411610

25 PIN A, DOWEL (12X20) .............................. -------- -------- 2 94301-12200 0165324

KSC4E0200

26 BOLT, FLANGE (6X14) .............................. -------- -------- 1 96001-06014-00 2154672

27 BOLT, FLANGE (6X28) .............................. -------- -------- 2 96001-06028-00 2106003

1-4 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C2

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 SEAL, VALVE STEM (NOK)........................ -------- -------- 4 12209-GB4-681 1905173

2 CAMSHAFT ................................................ -------- -------- A 1 14100-KSC-670 7656465

CAMSHAFT ................................................ -------- -------- AC 1 14100-KSC-770 7656473

3 WEIGHT, DECOMPRESSION .................... -------- -------- 1 14102-KRN-670 7605785

4 PLATE, WEIGHT SETTING ........................ -------- -------- 1 14105-KRN-670 7605793

5 SPRING, DECOMPRESSION .................... -------- -------- 1 14106-KRN-670 7605801

6 ARM, EX. ROCKER .................................... -------- -------- 1 14440-KRN-670 7605827

7 SHAFT, EX. ROCKER ARM........................ -------- -------- 1 14451-KRN-670 7605835

8 VALVE, IN. .................................................. -------- -------- 2 14711-KRN-670 7605876

9 VALVE, EX. ................................................ -------- -------- 2 14721-KRN-670 7605884

10 LIFTER, VALVE .......................................... -------- -------- 2 14731-KRN-670 7605892

KRN4E0300

11 SPRING, IN. VALVE.................................... -------- -------- 2 14751-KRN-670 7605900

12 SPRING, EX. VALVE .................................. -------- -------- 2 14761-KRN-670 7605918

13 RETAINER, VALVE SPRING ...................... -------- -------- 4 14771-KRN-670 7605926

14 SEAT, VALVE SPRING .............................. -------- -------- 4 14775-KRN-670 7605934

15 COTTER, VALVE ........................................ -------- -------- 8 14781-MAT-000 5212840

16 SHIM, TAPPET (1.200) .............................. -------- -------- 2 14901-KT7-013 4064283

SHIM, TAPPET (1.225) .............................. -------- -------- 2 14902-KT7-013 4105565

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-5

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

16 SHIM, TAPPET (1.250) .............................. -------- -------- 2 14903-KT7-013 4105573

SHIM, TAPPET (1.275) .............................. -------- -------- 2 14904-KT7-013 4105581

SHIM, TAPPET (1.300) .............................. -------- -------- 2 14905-KT7-013 4105599

SHIM, TAPPET (1.325) .............................. -------- -------- 2 14906-KT7-013 4105607

SHIM, TAPPET (1.350) .............................. -------- -------- 2 14907-KT7-013 4105615

SHIM, TAPPET (1.375) .............................. -------- -------- 2 14908-KT7-013 4105623

SHIM, TAPPET (1.400) .............................. -------- -------- 2 14909-KT7-013 4105631

SHIM, TAPPET (1.425) .............................. -------- -------- 2 14910-KT7-013 4105649

SHIM, TAPPET (1.450) .............................. -------- -------- 2 14911-KT7-013 4105656

SHIM, TAPPET (1.475) .............................. -------- -------- 2 14912-KT7-013 4105664

SHIM, TAPPET (1.500) .............................. -------- -------- 2 14913-KT7-013 4105672

KRN4E0300

SHIM, TAPPET (1.525) .............................. -------- -------- 2 14914-KT7-013 4105680

SHIM, TAPPET (1.550) .............................. -------- -------- 2 14915-KT7-013 4105698

SHIM, TAPPET (1.575) .............................. -------- -------- 2 14916-KT7-013 4105706

SHIM, TAPPET (1.600) .............................. -------- -------- 2 14917-KT7-013 4105714

SHIM, TAPPET (1.625) .............................. -------- -------- 2 14918-KT7-013 4105722

SHIM, TAPPET (1.650) .............................. -------- -------- 2 14919-KT7-013 4105730

SHIM, TAPPET (1.675) .............................. -------- -------- 2 14920-KT7-013 4105748

1-6 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C3

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

16 SHIM, TAPPET (1.700) .............................. -------- -------- 2 14921-KT7-013 4105755

SHIM, TAPPET (1.725) .............................. -------- -------- 2 14922-KT7-013 4105763

SHIM, TAPPET (1.750) .............................. -------- -------- 2 14923-KT7-013 4105771

SHIM, TAPPET (1.775) .............................. -------- -------- 2 14924-KT7-013 4105789

SHIM, TAPPET (1.800) .............................. -------- -------- 2 14925-KT7-013 4105797

SHIM, TAPPET (1.825) .............................. -------- -------- 2 14926-KT7-013 4105805

SHIM, TAPPET (1.850) .............................. -------- -------- 2 14927-KT7-013 4105813

SHIM, TAPPET (1.875) .............................. -------- -------- 2 14928-KT7-013 4105821

SHIM, TAPPET (1.900) .............................. -------- -------- 2 14929-KT7-013 4105839

SHIM, TAPPET (1.925) .............................. -------- -------- 2 14930-KT7-013 4105847

SHIM, TAPPET (1.950) .............................. -------- -------- 2 14931-KT7-013 4105854

SHIM, TAPPET (1.975) .............................. -------- -------- 2 14932-KT7-013 4105862

SHIM, TAPPET (2.000) .............................. -------- -------- 2 14933-KT7-013 4105870

SHIM, TAPPET (2.025) .............................. -------- -------- 2 14934-KT7-013 4105888

SHIM, TAPPET (2.050) .............................. -------- -------- 2 14935-KT7-013 4105896

SHIM, TAPPET (2.075) .............................. -------- -------- 2 14936-KT7-013 4105904

SHIM, TAPPET (2.100) .............................. -------- -------- 2 14937-KT7-013 4105912

SHIM, TAPPET (2.125) .............................. -------- -------- 2 14938-KT7-013 4105920

SHIM, TAPPET (2.150) .............................. -------- -------- 2 14939-KT7-013 4105938

SHIM, TAPPET (2.175) .............................. -------- -------- 2 14940-KT7-013 4105946

SHIM, TAPPET (2.200) .............................. -------- -------- 2 14941-KT7-013 4105953

SHIM, TAPPET (2.225) .............................. -------- -------- 2 14942-KT7-013 4105961

SHIM, TAPPET (2.250) .............................. -------- -------- 2 14943-KT7-013 4105979

SHIM, TAPPET (2.275) .............................. -------- -------- 2 14944-KT7-013 4105987

SHIM, TAPPET (2.300) .............................. -------- -------- 2 14945-KT7-013 4105995

SHIM, TAPPET (2.325) .............................. -------- -------- 2 14946-KT7-013 4106001

SHIM, TAPPET (2.350) .............................. -------- -------- 2 14947-KT7-013 4106019

SHIM, TAPPET (2.375) .............................. -------- -------- 2 14948-KT7-013 4106027

SHIM, TAPPET (2.400) .............................. -------- -------- 2 14949-KT7-013 4106035

SHIM, TAPPET (2.425) .............................. -------- -------- 2 14950-KT7-013 4106043

SHIM, TAPPET (2.450) .............................. -------- -------- 2 14951-KT7-013 4106050

17 SHIM, TAPPET (1.200) .............................. -------- -------- 2 14901-KT7-013 4064283

SHIM, TAPPET (1.225) .............................. -------- -------- 2 14902-KT7-013 4105565

SHIM, TAPPET (1.250) .............................. -------- -------- 2 14903-KT7-013 4105573

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-7

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

17 SHIM, TAPPET (1.275) .............................. -------- -------- 2 14904-KT7-013 4105581

SHIM, TAPPET (1.300) .............................. -------- -------- 2 14905-KT7-013 4105599

SHIM, TAPPET (1.325) .............................. -------- -------- 2 14906-KT7-013 4105607

SHIM, TAPPET (1.350) .............................. -------- -------- 2 14907-KT7-013 4105615

SHIM, TAPPET (1.375) .............................. -------- -------- 2 14908-KT7-013 4105623

SHIM, TAPPET (1.400) .............................. -------- -------- 2 14909-KT7-013 4105631

SHIM, TAPPET (1.425) .............................. -------- -------- 2 14910-KT7-013 4105649

SHIM, TAPPET (1.450) .............................. -------- -------- 2 14911-KT7-013 4105656

SHIM, TAPPET (1.475) .............................. -------- -------- 2 14912-KT7-013 4105664

SHIM, TAPPET (1.500) .............................. -------- -------- 2 14913-KT7-013 4105672

SHIM, TAPPET (1.525) .............................. -------- -------- 2 14914-KT7-013 4105680

KRN4E0300

SHIM, TAPPET (1.550) .............................. -------- -------- 2 14915-KT7-013 4105698

SHIM, TAPPET (1.575) .............................. -------- -------- 2 14916-KT7-013 4105706

SHIM, TAPPET (1.600) .............................. -------- -------- 2 14917-KT7-013 4105714

SHIM, TAPPET (1.625) .............................. -------- -------- 2 14918-KT7-013 4105722

SHIM, TAPPET (1.650) .............................. -------- -------- 2 14919-KT7-013 4105730

SHIM, TAPPET (1.675) .............................. -------- -------- 2 14920-KT7-013 4105748

SHIM, TAPPET (1.700) .............................. -------- -------- 2 14921-KT7-013 4105755

1-8 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C4

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

17 SHIM, TAPPET (1.725) .............................. -------- -------- 2 14922-KT7-013 4105763

SHIM, TAPPET (1.750) .............................. -------- -------- 2 14923-KT7-013 4105771

SHIM, TAPPET (1.775) .............................. -------- -------- 2 14924-KT7-013 4105789

SHIM, TAPPET (1.800) .............................. -------- -------- 2 14925-KT7-013 4105797

SHIM, TAPPET (1.825) .............................. -------- -------- 2 14926-KT7-013 4105805

SHIM, TAPPET (1.850) .............................. -------- -------- 2 14927-KT7-013 4105813

SHIM, TAPPET (1.875) .............................. -------- -------- 2 14928-KT7-013 4105821

SHIM, TAPPET (1.900) .............................. -------- -------- 2 14929-KT7-013 4105839

SHIM, TAPPET (1.925) .............................. -------- -------- 2 14930-KT7-013 4105847

SHIM, TAPPET (1.950) .............................. -------- -------- 2 14931-KT7-013 4105854

SHIM, TAPPET (1.975) .............................. -------- -------- 2 14932-KT7-013 4105862

SHIM, TAPPET (2.000) .............................. -------- -------- 2 14933-KT7-013 4105870

SHIM, TAPPET (2.025) .............................. -------- -------- 2 14934-KT7-013 4105888

SHIM, TAPPET (2.050) .............................. -------- -------- 2 14935-KT7-013 4105896

SHIM, TAPPET (2.075) .............................. -------- -------- 2 14936-KT7-013 4105904

SHIM, TAPPET (2.100) .............................. -------- -------- 2 14937-KT7-013 4105912

SHIM, TAPPET (2.125) .............................. -------- -------- 2 14938-KT7-013 4105920

SHIM, TAPPET (2.150) .............................. -------- -------- 2 14939-KT7-013 4105938

SHIM, TAPPET (2.175) .............................. -------- -------- 2 14940-KT7-013 4105946

SHIM, TAPPET (2.200) .............................. -------- -------- 2 14941-KT7-013 4105953

SHIM, TAPPET (2.225) .............................. -------- -------- 2 14942-KT7-013 4105961

SHIM, TAPPET (2.250) .............................. -------- -------- 2 14943-KT7-013 4105979

SHIM, TAPPET (2.275) .............................. -------- -------- 2 14944-KT7-013 4105987

SHIM, TAPPET (2.300) .............................. -------- -------- 2 14945-KT7-013 4105995

SHIM, TAPPET (2.325) .............................. -------- -------- 2 14946-KT7-013 4106001

SHIM, TAPPET (2.350) .............................. -------- -------- 2 14947-KT7-013 4106019

SHIM, TAPPET (2.375) .............................. -------- -------- 2 14948-KT7-013 4106027

SHIM, TAPPET (2.400) .............................. -------- -------- 2 14949-KT7-013 4106035

SHIM, TAPPET (2.425) .............................. -------- -------- 2 14950-KT7-013 4106043

SHIM, TAPPET (2.450) .............................. -------- -------- 2 14951-KT7-013 4106050

SHIM, TAPPET (2.475) .............................. -------- -------- 2 14952-KT7-013 4106068

SHIM, TAPPET (2.500) .............................. -------- -------- 2 14953-KT7-013 4106076

SHIM, TAPPET (2.525) .............................. -------- -------- 2 14954-KT7-013 4106084

SHIM, TAPPET (2.550) .............................. -------- -------- 2 14955-KT7-013 4106092

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-9

CAMSHAFT • VALVE

4 =CRF250X’04 E-3

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

17 SHIM, TAPPET (2.575) .............................. -------- -------- 2 14956-KT7-013 4106100

SHIM, TAPPET (2.600) .............................. -------- -------- 2 14957-KT7-013 4106118

SHIM, TAPPET (2.625) .............................. -------- -------- 2 14958-KT7-013 4106126

SHIM, TAPPET (2.650) .............................. -------- -------- 2 14959-KT7-013 4106134

SHIM, TAPPET (2.675) .............................. -------- -------- 2 14960-KT7-013 4106142

SHIM, TAPPET (2.700) .............................. -------- -------- 2 14961-KT7-013 4106159

SHIM, TAPPET (2.725) .............................. -------- -------- 2 14962-KT7-013 4106167

SHIM, TAPPET (2.750) .............................. -------- -------- 2 14963-KT7-013 4106175

SHIM, TAPPET (2.775) .............................. -------- -------- 2 14964-KT7-013 4106183

SHIM, TAPPET (2.800) .............................. -------- -------- 2 14965-KT7-013 4106191

SHIM, TAPPET (2.825) .............................. -------- -------- 2 14966-KT7-013 3916574

KRN4E0300

SHIM, TAPPET (2.850) .............................. -------- -------- 2 14967-KT7-013 3916590

SHIM, TAPPET (2.875) .............................. -------- -------- 2 14968-KT7-013 3916608

SHIM, TAPPET (2.900) .............................. -------- -------- 2 14969-KT7-013 4106209

18 BEARING, RADIAL BALL (6905) ................ -------- -------- 1 91007-KRN-671 7607534

19 BOLT, FLANGE (6X12) .............................. -------- -------- 1 96001-06012-00 2105930

1-10 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C5

CAM CHAIN • TENSIONER

4 =CRF250X’04 E-4

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 CHAIN, CAM .............................................. -------- -------- 1 14401-KRN-671 7605819

2 TENSIONER, CAM CHAIN.......................... -------- -------- 1 14510-KRN-670 7605843

3 COLLAR, TENSIONER (6X9)...................... -------- -------- 1 14515-KF0-000 1417070

4 LIFTER ASSY., TENSIONER...................... -------- -------- 1 14520-KRN-670 7605850

5 GASKET, TENSIONER LIFTER.................. -------- -------- 1 14560-MEN-671 7649171

6 GUIDE, CAM CHAIN .................................. -------- -------- 1 14620-KRN-670 7605868

7 BOLT, FLANGE (6X10) (NSHF).................. -------- -------- 1 90004-GHB-600 4938304

8 BOLT, FLANGE (6X16) (NSHF).................. -------- -------- 2 90004-GHB-630 4774154

9 BOLT, FLANGE (6X25) .............................. -------- -------- 1 90088-MEB-670 6914105

10 WASHER, SEALING (6MM)........................ -------- -------- 1 90442-397-000 0687616

11 WASHER, SPECIAL (6MM) ........................ -------- -------- 1 90482-567-000 0546895

KRN4E0400

WASHER (18MM)........................................ -------- -------- 1 90581-701-000 0173823

WASHER (18MM)........................................ -------- -------- 1 90581-831-650 0166454

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-11

CYLINDER

4 =CRF250X’04 E-5

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 COLLAR, WATER PASS (16MM) .............. -------- -------- 1 11102-KRN-670 7605413

2 CYLINDER .................................................. -------- -------- 1 12100-KRN-670 7605553

3 GASKET, CYLINDER.................................. -------- -------- 1 12191-KRN-671 7605579

4 PIN A, DOWEL (12X20) .............................. -------- -------- 2 94301-12200 0165324

5 BOLT, FLANGE (6X28) .............................. -------- -------- 1 96001-06028-00 2106003

KRN4E0500

1-12 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C6

R. CRANKCASE COVER

4 =CRF250X’04 E-6

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 COLLAR, WATER PASS (16MM) .............. -------- -------- 1 11102-KRN-670 7605413

2 COVER, R. CRANKCASE .......................... -------- -------- 1 11331-KSC-670 7656408

3 COVER, CLUTCH ...................................... -------- -------- 1 11351-KSC-670 7656416

4 GASKET, CLUTCH COVER........................ -------- -------- 1 11352-KRN-671 7605512

5 GASKET, R. COVER .................................. -------- -------- 1 11394-KRN-670 7605520

6 CAP, OIL FILLER ........................................ -------- -------- 1 15611-KA3-710 1352871

7 CAP (30MM)................................................ -------- -------- 1 90087-KW3-000 2909075

8 WASHER, SEALING (6.5MM) .................... -------- -------- 1 90463-ML7-000 2408680

9 GUIDE, CLUTCH CABLE............................ -------- -------- 1 90510-KSC-670 7658263

10 OIL SEAL (16.5X25X5) (NOK) .................... -------- -------- 1 91205-KA3-712 1354687

11 O-RING (15.8X2.4) (SHOWA) .................... -------- -------- 1 91304-MJ0-003 1762210

KSC4E0600

12 O-RING (27X2.0) ........................................ -------- -------- 1 91305-KF0-003 1761741

13 O-RING (11.9X2.2)...................................... -------- -------- 1 91370-461-000 0911586

14 BOLT, SLOT (6X10) .................................... -------- -------- 1 92301-06010-0A 2866853

15 PIN A, DOWEL (8X14) ................................ -------- -------- 2 94301-08140 0069310

16 BOLT, FLANGE (6X20) .............................. -------- -------- 5 96001-06020-00 2529154

17 BOLT, FLANGE (6X28) .............................. -------- -------- 9 96001-06028-00 2106003

18 BOLT, FLANGE (6X35) .............................. -------- -------- 2 96001-06035-00 2112209

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-13

CLUTCH

4 =CRF250X’04 E-7

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 CLIP, PISTON PIN (10MM) ........................ -------- -------- 1 13115-147-000 0463380

2 CLUTCH OUTER ........................................ -------- -------- 1 22100-KSC-670 7657018

3 CENTER, CLUTCH .................................... -------- -------- 1 22120-KSC-670 7657026

4 SEAT, JUDDER SPRING............................ -------- -------- 1 22125-435-000 0788802

5 DISK A, CLUTCH FRICTION ...................... -------- -------- 7 22201-KSC-670 7657034

6 DISK B, CLUTCH FRICTION ...................... -------- -------- 1 22202-KSC-670 7657042

7 PLATE, CLUTCH ........................................ -------- -------- 7 22321-KF0-770 2448538

8 PLATE, CLUTCH PRESSURE.................... -------- -------- 1 22351-KZ4-A90 6266597

9 PLATE, CLUTCH LIFTER .......................... -------- -------- 1 22352-KZ4-A90 6266605

10 SPRING, CLUTCH ...................................... -------- -------- 5 22401-KSC-670 7657059

11 SPRING, JUDDER ...................................... -------- -------- 1 22402-435-000 0788810

KSC4E0700

12 ROD, CLUTCH LIFTER .............................. -------- -------- 1 22851-KZ3-J20 6271142

13 COLLAR, CLUTCH (OUTER)...................... -------- -------- 1 28237-KSC-670 7657448

14 NUT (18MM)................................................ -------- -------- 1 90235-KA4-000 1028299

15 WASHER, LOCK (18MM)............................ -------- -------- 1 90441-KSC-670 7658248

16 WASHER, THRUST (20MM) ...................... -------- -------- 1 90456-KS6-000 2159564

17 WASHER (18X32X2) .................................. -------- -------- 1 90501-ML3-910 3226693

18 WASHER (12MM)........................................ -------- -------- 1 90608-072-000 0229765

1-14 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C7

CLUTCH

4 =CRF250X’04 E-7

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

19 BEARING, NEEDLE (12MM) ...................... -------- -------- 1 91001-147-003 1089549

BEARING, NEEDLE (12MM) (TOMUSON) -------- -------- 1 91001-147-006 0465625

20 BEARING, NEEDLE (27X31X16.8) ............ -------- -------- 2 91012-P68-003 7658305

21 BOLT-WASHER (6X20) .............................. -------- -------- 5 93404-06020-08 2410694

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-15

OIL PUMP

4 =CRF250X’04 E-8

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 SHAFT, OIL PUMP...................................... -------- -------- 1 15111-KRN-670 7605942

2 GEAR, OIL PUMP DRIVEN (18T) .............. -------- -------- 1 15133-KRN-670 7605959

3 ROTOR, OIL PUMP (INNER)...................... -------- -------- 1 15331-324-000 0246652

4 ROTOR, OIL PUMP (OUTER) .................... -------- -------- 1 15332-324-000 0246660

5 ROLLER (3X17.8) ...................................... -------- -------- 1 96220-30178 1644160

KRN4E0800

1-16 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C8

WATER PUMP

4 =CRF250X’04 E-9

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 IMPELLER, WATER PUMP ........................ -------- -------- 1 19215-KRN-670 7606460

2 COVER, WATER PUMP.............................. -------- -------- 1 19221-KRN-670 7606478

3 GASKET, WATER PUMP............................ -------- -------- 1 19226-KRN-670 7606486

4 GEAR, WATER PUMP (22T) ...................... -------- -------- 1 19240-KSC-670 7656994

5 WASHER, SEALING (7MM)........................ -------- -------- 2 90447-KE1-000 1662956

6 WASHER, SEALING (6.5MM) .................... -------- -------- 1 90463-ML7-000 2408680

7 BEARING, RADIAL BALL (12X28X7)

(TOYO) .................................................... -------- -------- 1 91001-KA4-003 1043371

8 OIL SEAL (12X22X5) .................................. -------- -------- 1 91201-148-003 0665653

OIL SEAL (12X22X5) .................................. -------- -------- 1 91201-965-000 1404771

9 SEAL, WATER PUMP ................................ -------- -------- 1 91211-KRN-671 7607559

KSC4E0900

10 PIN, DOWEL .............................................. -------- -------- 1 91320-KE1-000 1806413

11 BOLT, FLANGE (6X28) .............................. -------- -------- 3 96001-06028-00 2106003

12 BOLT, FLANGE (6X85) .............................. -------- -------- 1 96001-06085-00 2552693

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-17

L. CRANKCASE COVER

4 =CRF250X’04 E-10

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 COVER, OIL FILTER .................................. -------- -------- 1 11333-KRN-670 7605488

2 COVER, L. CRANKCASE............................ -------- -------- 1 11340-KRN-670 7605496

3 GASKET, L. COVER .................................. -------- -------- 1 11395-KRN-670 7605538

4 VALVE ASSY., RELIEF .............................. -------- -------- 1 15220-MEB-770 7186406

5 FILTER, ENGINE OIL.................................. -------- -------- 1 15412-MEN-671 7530892

6 SPRING, OIL FILTER.................................. -------- -------- 1 15414-MEB-670 6843221

7 DIPSTICK, OIL ............................................ -------- -------- 1 15650-KRN-670 7605975

8 COVER, DRIVE SPROCKET ...................... -------- -------- 1 23810-KSC-670 7657299

9 GUIDE, DRIVE CHAIN ................................ -------- -------- 1 23812-KSC-670 7657307

10 BOLT, FLANGE (6X16) (NSHF).................. -------- -------- 1 90004-GHB-630 4774154

11 BOLT, FLANGE (6X32) (NSHF).................. -------- -------- 5 90004-GHB-690 4774196

KSC4E1000

12 BOLT, FLANGE (6X40) (NSHF).................. -------- -------- 2 90004-GHB-710 4774212

13 BOLT, FLANGE (6X75) (NSHF).................. -------- -------- 1 90004-GHB-780 4822151

14 CAP (14MM)................................................ -------- -------- 1 90084-MEN-670 7532948

15 WASHER, THRUST (13MM) ...................... -------- -------- 1 90451-459-770 1075894

16 CIRCLIP, SPECIAL (INNER) (24MM) ........ -------- -------- 1 90602-MEB-670 6852594

17 O-RING (8.5X1.7)........................................ -------- -------- 1 90751-GK1-003 1915149

18 OIL SEAL (10X21X5) .................................. -------- -------- 1 91204-KRN-671 7607542

1-18 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C9

L. CRANKCASE COVER

4 =CRF250X’04 E-10

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

19 O-RING (39.8X2.2) (ARAI) .......................... -------- -------- 1 91302-PA9-003 0896985

20 O-RING (13.8X2.5)...................................... -------- -------- 1 91303-377-000 0499525

21 O-RING (18X3)............................................ -------- -------- 1 91307-035-000 0174961

22 CLIP (6X20) ................................................ -------- -------- 1 91410-679-000 0840215

23 PIN A, DOWEL (8X14) ................................ -------- -------- 1 94301-08140 0069310

24 PIN A, DOWEL (10X16) .............................. -------- -------- 1 94301-10160 0058206

25 CIRCLIP (INNER) (14MM) .......................... -------- -------- 1 94520-14000 0251835

26 BOLT, FLANGE (6X30) .............................. -------- -------- 2 96001-06030-07 4009569

FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-19

GENERATOR

4 =CRF250X’04 E-11

Engine

Serial Number

Ref Description From To AREA QTY Part Number H/C

1 ALTERNATOR ASSY., FLYWHEEL TYPE -------- -------- 1 31100-KSC-671 7657489

2 CLAMP, WIRE ............................................ -------- -------- 1 32112-KRN-670 7606932

3 CLIP, PURSE LOCK.................................... -------- -------- 1 32171-GF9-621 5375456

4 BOLT, FLANGE (5X16) .............................. -------- -------- 2 90005-896-000 1420611

5 SCREW-WASHER (4X24) .......................... -------- -------- 3 90010-MEB-670 6852313

6 WASHER, PLAIN (12MM) .......................... -------- -------- 1 90437-611-000 0394403

7 NUT, FLANGE (12MM)................................ -------- -------- 1 94050-12000 0671123

KSC4E1100

1-20 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C10