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CRF250X'04
User Manual
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HONDA CRF250X'04 User Manual

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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
• 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
STARTING MOTOR
4 =CRF250X’04 E-12
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 RECEIVER, CLUTCH CABLE .................... -------- -------- 1 22838-KSC-670 7657075
2 MOTOR ASSY., STARTER ........................ -------- -------- 1 31200-KSC-671 7657505
3 TERMINAL SET, BRUSH............................ -------- -------- 1 31201-MBE-008 6083083
4 SPRING, CARBON BRUSH........................ -------- -------- 2 31204-KS5-901 2541969
5 BOLT, SETTING.......................................... -------- -------- 2 31205-MBE-008 7318736
6 HOLDER SET, BRUSH .............................. -------- -------- 1 31206-MBE-008 6083109
7 RING............................................................ -------- -------- 2 31207-MBE-008 6083117
8 NUT-WASHER (6MM) ................................ -------- -------- 2 90071-MB0-000 1243534
9 O-RING (24.4X3.1) (ARAI) .......................... -------- -------- 1 91309-425-003 1113422
O-RING (24.4X3.1)...................................... -------- -------- 1 91312-MG7-003 2618221
10 O-RING........................................................ -------- -------- 2 91320-MBE-008 6092456
KSC4E1200
11 O-RING........................................................ -------- -------- 1 91320-MB0-000 1292184
12 BOLT, FLANGE (6X28) .............................. -------- -------- 2 96001-06028-00 2106003
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-21
STARTING CLUTCH
4 =CRF250X’04 E-13
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 GEAR, BALANCER DRIVE (32T)................ -------- -------- 1 13415-KRN-670 7605736
2 GEAR, PRIMARY DRIVE (18T) .................. -------- -------- 1 23121-KSC-670 7657109
3 GEAR, STARTING DRIVEN (38T) .............. -------- -------- 1 28110-KSC-670 7657372
4 CLUTCH OUTER, STARTING .................... -------- -------- 1 28115-KSC-670 7657380
5 HOLDER, STARTER GEAR........................ -------- -------- 1 28120-KSC-670 7657398
6 CLUTCH, ONE-WAY .................................. -------- -------- 1 28125-MT7-004 7657406
7 RING, FRICTION ........................................ -------- -------- 1 28127-MS2-612 7318520
8 GEAR, STARTING REDUCTION................ -------- -------- 1 28131-KSC-670 7657414
9 GEAR, STARTING IDLE ............................ -------- -------- 1 28141-KSC-670 7657422
10 BOLT, SPECIAL (12X28) ............................ -------- -------- 1 90013-MEB-670 6852339
11 WASHER, PLAIN (12MM) .......................... -------- -------- 1 90402-KW6-960 6852545
KSC4E1300
12 WASHER, THRUST (12MM) ...................... -------- -------- 2 90452-166-600 0914150
13 BEARING, NEEDLE (30X37X20)................ -------- -------- 1 91025-KT7-003 5820634
14 PIN C, DOWEL (8X14) ................................ -------- -------- 1 94303-08140 0256800
15 CIRCLIP (OUTER) (12MM) ........................ -------- -------- 2 94510-12000 0112847
16 BOLT, SOCKET (8X28) .............................. -------- -------- 3 96600-08028-00 2920577
1-22 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C11
CRANKCASE
4 =CRF250X’04 E-14
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CRANKCASE, R. ........................................ -------- -------- 1 11100-KSC-670 7656358
2 TUBE A, BREATHER .................................. -------- -------- 1 11105-KSC-670 7656366
3 TUBE B, BREATHER .................................. -------- -------- 1 11107-KSC-670 7656374
4 TUBE C, BREATHER.................................. -------- -------- 1 11108-KSC-670 7656382
5 GASKET, CRANKCASE.............................. -------- -------- 1 11191-KRN-670 7605439
6 CRANKCASE, L. ........................................ -------- -------- 1 11200-KSC-670 7656390
7 PLATE, CAM CHAIN GUIDE ...................... -------- -------- 1 11206-KRN-670 7605454
8 SCREEN, OIL FILTER ................................ -------- -------- 1 15421-KK0-000 1593714
9 JOINT (THREE-WAY) ................................ -------- -------- 1 16961-MCT-010 6958649
10 VALVE, REED ............................................ -------- -------- 1 18601-MBW-003 6082036
11 LEVER, CLUTCH LIFTER .......................... -------- -------- 1 22810-KSC-670 7657067
KSC4E1400
12 PLATE, CLUTCH LEVER............................ -------- -------- 1 22813-KRN-670 7606569
13 SCREW, SPECIAL FLAT (6X12) ................ -------- -------- 2 90003-KRN-670 7649148
14 BOLT, STUD (10X135)................................ -------- -------- 4 90031-KRN-670 7607351
15 PLATE, BEARING HOLDER ...................... -------- -------- 2 90441-KRN-670 7649130
16 WASHER (8MM).......................................... -------- -------- 2 90474-333-000 0290981
17 CIRCLIP, SPECIAL (33MM)........................ -------- -------- 1 90604-MEB-670 6914147
18 GUIDE, TUBE.............................................. -------- -------- 1 90610-MEB-670 6852610
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-23
CRANKCASE
4 =CRF250X’04 E-14
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 JET, OIL (#100) .......................................... -------- -------- 1 90901-KRN-670 7607492
20 BEARING, RADIAL BALL (30X72X16)........ -------- -------- 1 91001-KRN-671 7607500
21 BEARING, SPECIAL ROLLER.................... -------- -------- 1 91002-KRN-671 7607518
22 BEARING, SHELL (33X38X8) (TOYO) ...... -------- -------- 1 91022-KA4-740 1662444
23 OIL SEAL (35X52X7) (ARAI) ...................... -------- -------- 1 91201-MEB-671 6852735
24 OIL SEAL (39X56X7) (ARAI) ...................... -------- -------- 1 91202-MEB-671 6852743
25 OIL SEAL (14X22X5) (NOK) ...................... -------- -------- 1 91203-KA4-771 1917558
OIL SEAL (14X22X5) .................................. -------- -------- 1 91203-KK3-830 2735249
26 OIL SEAL (20X33X5) (ARAI) ...................... -------- -------- 1 91203-MEB-671 6852750
27 OIL SEAL (12X18X3) (ARAI) ...................... -------- -------- 1 91205-MEB-671 6852776
28 PIN A, DOWEL (14X20) .............................. -------- -------- 2 94301-14200 0295626
KSC4E1400
29 CLIP, TUBE (B10) ...................................... -------- -------- 4 95002-02100 0250985
30 BOLT, FLANGE (6X12) .............................. -------- -------- 1 96001-06012-00 2105930
31 BOLT, FLANGE (6X40) .............................. -------- -------- 1 96001-06040-00 2106037
32 BOLT, FLANGE (6X45) .............................. -------- -------- 5 96001-06045-00 2106045
33 BOLT, FLANGE (6X60) .............................. -------- -------- 1 96001-06060-00 2112225
34 BOLT, FLANGE (6X70) .............................. -------- -------- 5 96001-06070-00 2112233
35 BOLT, FLANGE (6X75) .............................. -------- -------- 2 96001-06075-00 2552685
1-24 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C12
CRANKCASE
4 =CRF250X’04 E-14
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
36 BOLT, FLANGE (8X25) .............................. -------- -------- 1 96300-08025-00 1829969
37 BOLT, FLANGE (8X70) .............................. -------- -------- 1 96300-08070-00 7607583
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-25
CRANKSHAFT • PISTON
4 =CRF250X’04 E-15
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CRANKSHAFT ............................................ -------- -------- 1 13000-KSC-670 7656440
2 RING SET, PISTON (STD).......................... -------- -------- 1 13011-KRN-670 7605660
3 PISTON ...................................................... -------- -------- 1 13101-KRN-670 7605678
4 PIN, PISTON .............................................. -------- -------- 1 13111-KRN-670 7605728
5 CLIP, PISTON PIN ...................................... -------- -------- 2 13115-KM7-700 4025748
6 KEY, WOODRUFF SPECIAL (25X1) .......... -------- -------- 1 13331-360-000 0359034
KRN4E1300
1-26 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C13
BALANCER
4 =CRF250X’04 E-16
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SHAFT, BALANCER.................................... -------- -------- 1 13420-KSC-670 7656457
2 GEAR, BALANCER DRIVEN (32T) ............ -------- -------- 1 13422-KRN-670 7605751
3 GEAR, WATER PUMP DRIVE (19T) .......... -------- -------- 1 19245-KRN-670 7606502
4 COLLAR, WATER PUMP GEAR ................ -------- -------- 1 19246-KSC-670 7657000
5 BOLT, HEX. (6X16) .................................... -------- -------- 2 90038-KY4-900 6852354
6 NUT, HEX. (14MM)...................................... -------- -------- 1 90204-MN5-000 2810935
7 WASHER (14MM)........................................ -------- -------- 1 90433-KE1-000 1806181
8 PLATE, BEARING HOLDER ...................... -------- -------- 2 90441-KA4-700 1187723
9 BEARING, SPECIAL ROLLAR (20X32X14) -------- -------- 1 91004-MEB-671 6852693
10 BEARING, RADIAL BALL TMB (6003)........ -------- -------- 1 91005-MEB-671 6852701
KSC4E1600
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-27
TRANSMISSION
4 =CRF250X’04 E-17
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SHAFT, MAIN.............................................. -------- -------- 1 23210-KSC-670 7657117
2 COUNTERSHAFT ...................................... -------- -------- 1 23221-KSC-670 7657125
3 COLLAR, COUNTERSHAFT ...................... -------- -------- 1 23225-KSC-670 7657133
4 GEAR, COUNTERSHAFT LOW (31T) ........ -------- -------- 1 23411-KSC-670 7657141
5 COLLAR (17MM) ........................................ -------- -------- 1 23413-KSC-670 7657158
6 GEAR, MAINSHAFT SECOND (16T).......... -------- -------- 1 23421-KSC-670 7657166
7 GEAR, COUNTERSHAFT SECOND (28T) -------- -------- 1 23431-KSC-670 7657174
8 COLLAR (24MM) ........................................ -------- -------- 1 23432-KSC-670 7657182
9 GEAR, MAINSHAFT THIRD (21T) .............. -------- -------- 1 23441-KSC-670 7657190
10 GEAR, COUNTERSHAFT THIRD (28T) .... -------- -------- 1 23451-KSC-670 7657208
11 COLLAR, COUNTERSHAFT THIRD GEAR -------- -------- 1 23452-KSC-670 7657216
KSC4E1700
12 GEAR, MAINSHAFT FOURTH (24T) .......... -------- -------- 1 23461-KSC-670 7657224
13 COLLAR, MAINSHAFT FOURTH GEAR .... -------- -------- 1 23462-KSC-670 7657232
14 GEAR, COUNTERSHAFT FOURTH (25T) -------- -------- 1 23471-KSC-670 7657240
15 COLLAR (20MM) ........................................ -------- -------- 1 23472-KZ4-000 3019106
16 GEAR, MAINSHAFT FIFTH (27T) .............. -------- -------- 1 23481-KSC-670 7657257
17 GEAR, COUNTERSHAFT FIFTH (22T) ...... -------- -------- 1 23491-KSC-670 7657265
18 SPROCKET, DRIVE (14T) .......................... -------- -------- 1 23801-KSC-670 7657273
1-28 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C14
TRANSMISSION
4 =CRF250X’04 E-17
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 COLLAR, DRIVE SPROCKET .................... -------- -------- 1 23802-KSC-670 7657281
20 BOLT, FLANGE SOCKET (6X14) .............. -------- -------- 2 90071-MF5-000 1438969
21 BOLT, UBS (8X33) ...................................... -------- -------- 1 90112-413-000 0631085
22 WASHER, THRUST INVOLUTE (22X21X1) -------- -------- 1 90404-KW3-000 3479854
23 PLATE, BEARING HOLDER ...................... -------- -------- 2 90441-KA4-700 1187723
24 WASHER, THRUST (17.2MM).................... -------- -------- 3 90446-357-000 0322180
25 WASHER (24X32X1) .................................. -------- -------- 1 90452-KSR-A00 7602592
26 WASHER, THRUST (22X30X1) .................. -------- -------- 1 90452-KZ4-000 3022480
27 WASHER (22X32X1.5)................................ -------- -------- 1 90453-KSR-A00 7602600
28 WASHER, SPLINE (20MM) ........................ -------- -------- 2 90455-HM8-A40 6769079
29 WASHER, SPRING (24MM)........................ -------- -------- 1 90501-KSC-670 7658255
30 SET-RING (20MM) ...................................... -------- -------- 2 90601-360-000 0341321
31 SET-RING, COUNTER SECOND .............. -------- -------- 1 90602-360-000 0341339
32 BEARING, RADIAL BALL (17X35X10)........ -------- -------- 2 91001-KZ4-J11 6013148
33 BEARING, RADIAL BALL (22X47X14)........ -------- -------- 1 91004-KSC-671 7658297
34 BEARING, RADIAL BALL (22X47X14)........ -------- -------- 1 91005-KSR-A01 7602667
35 PLATE, COUNTERSHAFT BEARING ........ -------- -------- 2 91012-KA3-710 1354620
36 OIL SEAL (28X37X7) .................................. -------- -------- 1 91201-KSR-A01 7602683
37 D-RING (22MM) .......................................... -------- -------- 1 91301-KSR-A01 7602691
38 SCREW, FLAT (6X10) ................................ -------- -------- 2 93600-06010-0H 0786715
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-29
GEARSHIFT DRUM
4 =CRF250X’04 E-18
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 FORK, R. GEARSHIFT................................ -------- -------- 1 24211-KSC-670 7657315
2 FORK, L. GEARSHIFT ................................ -------- -------- 1 24221-KSC-670 7657323
3 FORK C, GEARSHIFT ................................ -------- -------- 1 24231-KSC-670 7657331
4 SHAFT A, SHIFT FORK .............................. -------- -------- 1 24241-KSC-670 7657349
5 SHAFT B, SHIFT FORK .............................. -------- -------- 1 24242-KSC-670 7657356
6 DRUM, GEARSHIFT .................................. -------- -------- 1 24311-KSC-670 7657364
7 CENTER, SHIFT DRUM.............................. -------- -------- 1 24312-KA3-741 1557511
8 PIN, SHIFTER ............................................ -------- -------- 1 24315-HA0-000 1832062
9 SHIFTER, DRUM ........................................ -------- -------- 1 24321-KZ4-620 4573473
10 COLLAR, SHIFTER .................................... -------- -------- 1 24322-MM4-000 2541670
11 PAWL A, RATCHET .................................... -------- -------- 1 24324-KA3-711 1383603
KSC4E1800
12 PAWL B, RATCHET .................................... -------- -------- 1 24325-KA3-711 1383611
13 PLUNGER, PAWL ...................................... -------- -------- 2 24326-KBH-901 4170684
14 PLATE, GUIDE............................................ -------- -------- 1 24328-KRN-670 7606783
15 SPRING, PAWL PLUNGER ........................ -------- -------- 2 24329-KA3-740 1552546
16 STOPPER, DRUM ...................................... -------- -------- 1 24430-KA3-740 1552553
17 SPRING, DRUM STOPPER........................ -------- -------- 1 24435-KZ4-690 4301743
18 SPINDLE, GEARSHIFT .............................. -------- -------- 1 24610-KRN-670 7606791
1-30 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C15
GEARSHIFT DRUM
4 =CRF250X’04 E-18
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 SPRING, GEARSHIFT RETURN ................ -------- -------- 1 24651-MEB-670 6845366
20 PIN, GEARSHIFT RETURN SPRING ........ -------- -------- 1 24652-HA0-000 1821206
21 PIVOT, SHIFT DRUM STOPPER ARM ...... -------- -------- 1 90022-MG8-000 2045862
22 BOLT, FLANGE SOCKET (6X14) .............. -------- -------- 2 90071-MF5-000 1438969
23 WASHER (6.1MM) ...................................... -------- -------- 1 90435-HB3-000 2137719
24 PLATE, BEARING HOLDER ...................... -------- -------- 2 90441-KA4-700 1187723
25 WASHER (14MM)........................................ -------- -------- 1 90451-155-000 1032143
26 BEARING, RADIAL BALL (6905U).............. -------- -------- 1 91004-KY4-900 5340658
27 BOLT, HEX. (6X16) .................................... -------- -------- 2 93301-06016-0A 2449106
28 CIRCLIP (OUTER) (14MM) ........................ -------- -------- 1 94510-14000 0213389
29 ROLLER (4X8) ............................................ -------- -------- 1 96220-40080 1357383
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-31
KICK STARTER SPINDLE
4 =CRF250X’04 E-19
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 PLATE, OIL GUIDE .................................... -------- -------- 1 15201-KSC-670 7656481
2 PINION, KICK STARTER (32T) .................. -------- -------- 1 28210-KSC-670 7657430
3 GEAR, STARTER IDLE (30T) .................... -------- -------- 1 28230-KRN-670 7606825
4 RATCHET, STARTER ................................ -------- -------- 1 28241-KA3-710 1353648
5 SPRING, RATCHET.................................... -------- -------- 1 28242-KA3-710 1353655
6 SPINDLE, KICK STARTER ........................ -------- -------- 1 28251-KZ4-000 3019189
7 SPRING, STARTER RETURN .................... -------- -------- 1 28261-KA3-710 1353689
8 PLATE, RATCHET SLIDER ........................ -------- -------- 1 28262-KS6-701 2731453
9 COLLAR, KICK SPINDLE............................ -------- -------- 1 28282-KZ4-B00 5224225
10 WASHER, THRUST (17MM) ...................... -------- -------- 2 90452-178-000 1187749
11 WASHER (16.8X24) .................................... -------- -------- 3 90501-444-000 0763029
KSC4E1900
12 CIRCLIP (OUTER) (17MM) ........................ -------- -------- 1 90601-001-000 0003707
13 BOLT, HEX. (6X16) .................................... -------- -------- 2 93301-06016-0A 2449106
14 CIRCLIP (OUTER) (16MM) ........................ -------- -------- 1 94510-16000 0069344
1-32 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-C16
CARBURETOR
4 =CRF250X’04 E-20
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 GASKET SET .............................................. -------- -------- 1 16010-KRN-671 7605983
2 VALVE SET, FLOAT.................................... -------- -------- 1 16011-KZ3-J11 5993837
3 FLOAT SET ................................................ -------- -------- 1 16013-MEB-671 6911556
4 TOP SET .................................................... -------- -------- 1 16014-KRN-671 7605991
5 CHAMBER SET, FLOAT ............................ -------- -------- 1 16015-KSC-671 7656499
6 SCREW SET A............................................ -------- -------- 1 16016-KSC-671 7656507
7 ARM SET, LINK .......................................... -------- -------- 1 16018-MEB-671 6911598
8 START SET, HOT ...................................... -------- -------- 1 16019-MEB-671 6911606
9 DIAPHRAGM SET, PUMP .......................... -------- -------- 1 16021-KRN-671 7606015
10 SCREW SET B............................................ -------- -------- 1 16028-MEB-671 6911622
11 SCREW SET, JET NEEDLE........................ -------- -------- 1 16029-MEB-671 6911630
KSC4E2000
12 SHAFT SET, THROTTLE............................ -------- -------- 1 16032-MEB-671 6911648
13 LEVER SET, PUMP .................................... -------- -------- 1 16033-MEB-671 6911655
14 VALVE SET, FLOATING ............................ -------- -------- 1 16037-MEB-671 6911663
15 JOINT SET, FUEL ...................................... -------- -------- 1 16038-KRN-671 7606023
16 VALVE SET, STARTER .............................. -------- -------- 1 16046-MEB-671 6911689
17 SENSOR ASSY., THROTTLE .................... -------- -------- 1 16060-KSC-671 7659162
18 BOLT, COVER ............................................ -------- -------- 1 16080-MEB-671 6911705
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-33
CARBURETOR
4 =CRF250X’04 E-20
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 BOLT, STOPPER ........................................ -------- -------- 1 16081-KRN-671 7606049
20 SCREW, PAN.............................................. -------- -------- 1 16083-MEB-671 6911739
21 CARBURETOR ASSY. (FCR02A A) .......... -------- -------- A 1 16100-KSC-671 7656515
CARBURETOR ASSY. (FCR03A A) .......... -------- -------- AC 1 16100-KSC-771 7656523
22 VALVE, THROTTLE .................................... -------- -------- 1 16112-MEB-671 6911747
23 COVER, THROTTLE .................................. -------- -------- 1 16157-MEN-671 7531007
24 GASKET, FLOAT CHAMBER...................... -------- -------- 1 16163-MEB-671 6911762
25 HOLDER, NEEDLE JET.............................. -------- -------- 1 16165-MEB-671 6911770
26 ROLLER ...................................................... -------- -------- 1 16172-MEB-671 6911788
27 WASHER, PLAIN ........................................ -------- -------- 1 16177-MEB-671 6911796
28 WASHER, PLAIN ........................................ -------- -------- 1 16178-MEB-671 6911804
KSC4E2000
29 BINDER ...................................................... -------- -------- 1 16179-KZ4-690 4368296
30 BINDER
(NOT AVAILABLE) .................................. -------- -------- 1 16179-428-670 4241816
BINDER ...................................................... -------- -------- 1 16179-428-671 0684217
31 PLATE, BUFFER ........................................ -------- -------- 1 16185-MEN-671 7531023
32 TUBE, OVERFLOW .................................... -------- -------- 1 16196-MEB-671 6911820
33 TUBE, AIR VENT ........................................ -------- -------- 1 16197-MEB-671 6911838
1-34 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-D1
CARBURETOR
4 =CRF250X’04 E-20
Engine
Serial Number
Ref Description From To AREA QTY Part Number H/C
34 TUBE, AIR VENT ........................................ -------- -------- 1 16198-MEB-671 6911846
35 TUBE, AIR VENT ........................................ -------- -------- 1 16199-KSC-671 7656531
36 NEEDLE SET, JET (NCYU) ........................ -------- -------- AC 1 16203-KSC-771 7656549
NEEDLE SET, JET (NCVT) ........................ -------- -------- A 1 16234-MEN-671 7531122
37 SCREW-WASHER (4X8) ............................ -------- -------- 4 93892-04008-08 0634618
SCREW-WASHER (4X8) ............................ -------- -------- 4 93892-04008-18 0995902
38 SCREW-WASHER (4X14) .......................... -------- -------- 4 93892-04014-08 0624866
SCREW-WASHER (4X14) .......................... -------- -------- 4 93892-04014-18 1171842
39 CLIP, TUBE (B17) ...................................... -------- -------- 5 95002-02079 4171690
40 JET, MAIN (#128)........................................ -------- -------- AC (1) 99101-357-1280 0341719
JET, MAIN (#130)........................................ -------- -------- 1 99101-357-1300 0341727
41 JET, SLOW (#40) ........................................ -------- -------- 1 99103-KA3-0400 2094266
JET, SLOW (#40) ........................................ -------- -------- 1 99103-440-0400 1324722
42 JET, SLOW AIR (#100) .............................. -------- -------- 1 99104-MEB-1000 6911879
43 JET, LEAK (#65).......................................... -------- -------- AC 1 99108-KSC-0650 7660558
JET, LEAK (#55).......................................... -------- -------- A 1 99108-MEB-0550 6911887
44 JET, BY-STARTER (#68) ............................ -------- -------- 1 99112-KRN-0680 7607609
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 1-35
FRAME SECTION
Chapter Table of Contents
Page Title Grid Page
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
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F6 2-45
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F7 2-47
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F8 2-49
CAUTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F9 2-50
MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F9 2-51
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-F10 2-52
FEBRUARY, 2004 2-12004 American Honda Motor Co., Inc.
HEADLIGHT
4 =CRF250X’04 F-1
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 RUBBER, PROTECTOR GASKET.............. -------- -------- 2 18293-GZ5-000 4220042
2 SCREW, PAN (4X55) .................................. -------- -------- 1 33103-KSC-670 7657596
3 SPRING, BEAM ADJUSTING .................... -------- -------- 1 33107-KAE-770 7657604
4 PIPE, CP .................................................... -------- -------- 2 33113-MBW-D21 6648687
5 NUT, BEAM ADJUSTING............................ -------- -------- 1 33117-KBR-730 7657612
6 SOCKET, HEADLIGHT .............................. -------- -------- 1 33130-KSC-672 7657638
7 HEADLIGHT UNIT ...................................... -------- -------- 1 33150-KSC-672 7657653
8 BULB, HEADLIGHT (12V35/36.5W)
(STANLEY).............................................. -------- -------- 1 34901-GJ1-003 2020311
9 VISOR SET, FR. *NH196* (WL) (ROSS
WHITE).................................................... -------- -------- 1 61300-KSC-000ZA 7658107
KSC4F0100
10 GROMMET, SIDE COVER.......................... -------- -------- 2 83501-MG7-000 2015360
11 BOLT, FLANGE (6X16) .............................. -------- -------- 2 90147-KPB-J10 7372956
12 WASHER, FR. COVER SETTING .............. -------- -------- 2 90501-124-000 0398420
13 SCREW, TAPPING (5X10) (PO) ................ -------- -------- 2 93911-25120 6675300
2-2 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E1
METER
4 =CRF250X’04 F-2
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 METER ASSY., TRIP (MPH) ...................... -------- -------- 1 37200-MN1-671 2696524
2 RUBBER, METER SETTING ...................... -------- -------- 2 37215-KSC-000 7657729
3 CABLE ASSY., SPEEDOMETER................ -------- -------- 1 44830-KSC-000 7657810
4 CABLE (INNER) .......................................... -------- -------- 1 44831-KSC-300 7657828
5 STAY, CONNECTOR .................................. -------- -------- 1 50130-KSC-000 7657919
6 NUT, CAP (5MM) ........................................ -------- -------- 2 94021-05000-0S 0843458
KSC4F0200
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-3
HANDLE LEVER • SWITCH • CABLE
4 =CRF250X’04 F-3
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CABLE A, THROTTLE ................................ -------- -------- 1 17910-KSC-000 7656747
2 COVER, THROTTLE CABLE ...................... -------- -------- 1 17913-KB7-000 1219583
3 CABLE B, THROTTLE ................................ -------- -------- 1 17920-KSC-000 7656754
4 CABLE, HOT STARTER.............................. -------- -------- 1 17950-KSC-000 7656762
5 CABLE, CLUTCH ........................................ -------- -------- A 1 22870-KSC-000 7657083
CABLE, CLUTCH ........................................ -------- -------- AC 1 22870-KSC-770 7657091
6 CLIP, PURSE LOCK.................................... -------- -------- 1 32171-GF9-621 5375456
7 SWITCH ASSY., ENGINE STOP ................ -------- -------- 1 35130-KSC-670 7657695
8 SWITCH ASSY., STARTER ........................ -------- -------- 1 35150-KSC-671 7657711
9 SWITCH ASSY., FR. STOP (TATEISHI) .... -------- -------- 1 35340-ML4-005 3468683
10 GRIP, THROTTLE ...................................... -------- -------- 1 53140-MEB-671 7577604
KSC4F0300
11 GRIP, R. HANDLE ...................................... -------- -------- 1 53165-GBF-J60 6497317
12 GRIP, L. HANDLE ...................................... -------- -------- 1 53166-GBF-J60 6497325
13 HOUSING, THROTTLE (UPPER) .............. -------- -------- 1 53167-MEB-671 6919427
14 HOUSING, THROTTLE (LOWER) .............. -------- -------- 1 53168-KSC-000 7658016
15 SLIDER, THROTTLE CABLE...................... -------- -------- 1 53169-MEB-670 6848832
16 BRACKET, L. HANDLE LEVER .................. -------- -------- 1 53172-KSC-000 7658024
17 PLATE, CLUTCH SWITCH.......................... -------- -------- 1 53173-KSC-000 7658032
2-4 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E2
HANDLE LEVER • SWITCH • CABLE
4 =CRF250X’04 F-3
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 HOLDER, L. LEVER BRACKET.................. -------- -------- 1 53174-KCE-670 4773164
19 COVER, L. HANDLE LEVER ...................... -------- -------- 1 53177-KSC-000 7658040
20 LEVER, L. HANDLEBAR ............................ -------- -------- 1 53178-KSC-000 7658057
21 DIAL, CLUTCH CABLE ADJUSTING.......... -------- -------- 1 53179-MEN-671 7541436
22 LEVER, HOT STARTER.............................. -------- -------- 1 53190-MEN-670 7532450
23 BOLT, WIRE ADJUSTING .......................... -------- -------- 1 53192-MEN-670 7532468
24 BOLT, HANDLE LEVER PIVOT .................. -------- -------- 1 90113-MEN-670 7533003
25 COLLAR, PIVOT.......................................... -------- -------- 1 90501-MEN-670 7533078
26 BAND, WIRE .............................................. -------- -------- 4 90650-KV6-003 2687788
27 SCREW, PAN (4X12) .................................. -------- -------- 1 93500-04012-0A 0169466
SCREW, PAN (4X12) .................................. -------- -------- 1 93500-04012-1A 0866384
28 SCREW, PAN (4X14) .................................. -------- -------- 2 93500-04014-0G 1171735
29 SCREW, PAN (5X10) .................................. -------- -------- 1 93500-05010-0A 0156976
30 NUT, HEX. (6MM)........................................ -------- -------- 1 94001-06000-0S 0156067
NUT, HEX. (6MM)........................................ -------- -------- 1 94001-06200-0S 2043255
31 WASHER, SPRING (4MM).......................... -------- -------- 1 94111-04000 0058958
32 BOLT, FLANGE (6X18) .............................. -------- -------- 2 96001-06018-07 2737757
33 BOLT, FLANGE (6X22) .............................. -------- -------- 2 96001-06022-00 2112191
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-5
FR. BRAKE MASTER CYLINDER
4 =CRF250X’04 F-4
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 HOSE, FR. BRAKE...................................... -------- -------- 1 45125-KSC-000 7657844
2 BOOT .......................................................... -------- -------- 1 45504-KN5-006 2004612
3 MASTER CYLINDER SUB-ASSY., FR.
BRAKE (NISSIN) .................................... -------- -------- 1 45510-KCE-671 4772570
4 CAP, MASTER CYLINDER ........................ -------- -------- 1 45513-KCE-671 4772588
5 HOLDER, MASTER CYLINDER.................. -------- -------- 1 45517-GW0-751 4772596
6 SEPARATOR .............................................. -------- -------- 1 45518-KA3-731 1552918
7 DIAPHRAGM .............................................. -------- -------- 1 45520-KA3-731 1656545
8 RING............................................................ -------- -------- 1 45523-KA3-731 1554740
9 RING............................................................ -------- -------- 1 45523-MEB-003 6847412
10 MASTER CYLINDER SET .......................... -------- -------- 1 45530-KCE-671 6150924
KSC4F0400
11 LEVER SET, R. HANDLE............................ -------- -------- 1 53170-MEB-003 6848840
12 SPRING, BRAKE LEVER............................ -------- -------- 1 53174-KN5-006 2014884
13 COVER, R. HANDLE LEVER...................... -------- -------- 1 53176-ML3-791 3832813
14 BOLT SET, ADJUSTING ............................ -------- -------- 1 90111-MEB-003 6852446
15 BOLT, HANDLEBAR PIVOT........................ -------- -------- 1 90114-166-006 1047349
16 BOLT, OIL (10X22)...................................... -------- -------- 2 90145-MS9-612 5369418
17 WASHER, OIL BOLT .................................. -------- -------- 4 90545-300-000 0189902
2-6 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E3
FR. BRAKE MASTER CYLINDER
4 =CRF250X’04 F-4
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 CIRCLIP ...................................................... -------- -------- 1 90651-MA5-671 1251404
19 SCREW, FLAT (4X12) ................................ -------- -------- 2 93600-04012-0G 1218601
SCREW, FLAT (4X12) ................................ -------- -------- 2 93600-04012-1G 1237346
20 NUT, FLANGE (6MM).................................. -------- -------- 1 94050-06000 0471623
21 BOLT, FLANGE (6X22) .............................. -------- -------- 2 96001-06022-00 2112191
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-7
HANDLE BAR • TOP BRIDGE
4 =CRF250X’04 F-5
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
3 GUIDE, FR. BRAKE HOSE ........................ -------- -------- 1 45468-KS7-830 2750511
4 HANDLEBAR .............................................. -------- -------- 1 53100-MEN-670 7532393
5 PROTECTOR, HANDLE.............................. -------- -------- 1 53121-MEN-670 7532401
6 HOLDER, HANDLE (LOWER) .................... -------- -------- (2) 53132-KA3-831 3326626
HOLDER, HANDLE (LOWER) .................... -------- -------- 2 53132-KZ4-J20 6267504
7 RUBBER, HANDLEBAR.............................. -------- -------- 4 53133-KA3-832 2504728
8 BRIDGE, FORK TOP .................................. -------- -------- 1 53300-KSC-000 7658081
9 EMBLEM, PRODUCT.................................. -------- -------- 1 86150-KPG-901 7580889
10 BOLT, FLANGE (6X16) .............................. -------- -------- 1 90106-MJ0-000 3010642
11 BOLT, FLANGE (8X45) .............................. -------- -------- 4 90107-KZ4-J40 6825277
12 BOLT, FLANGE (8X35) .............................. -------- -------- 4 90124-KZ4-J40 6825335
KSC4F0500
13 NUT, STEERING STEM.............................. -------- -------- 1 90304-KZ4-J30 6483465
14 NUT, U (10MM) .......................................... -------- -------- 2 90306-KZ4-711 4310660
15 WASHER, STEERING STEM...................... -------- -------- 1 90503-KZ4-J40 6825384
16 WASHER, PLAIN (10MM) .......................... -------- -------- 2 90507-KA3-830 1915057
18 HOLDER B1, HANDLEBAR (UPPER) ........ -------- -------- 2 95014-22100 0301713
2-8 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E4
STEERING STEM
4 =CRF250X’04 F-6
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 GUIDE, SPEEDOMETER CABLE .............. -------- -------- 1 44832-KSC-000 7657836
2 GUIDE, FR. BRAKE HOSE ........................ -------- -------- 1 45468-KS7-830 2750511
3 DUST SEAL, STEERING HEAD ................ -------- -------- 1 53214-KZ3-861 3837986
4 DUST SEAL, STEERING HEAD (ARAI)...... -------- -------- 1 53214-KZ4-701 3226065
5 STEM SUB-ASSY., STEERING .................. -------- -------- 1 53219-KSC-000 7658073
6 THREAD, STEERING HEAD TOP .............. -------- -------- 1 53229-KZ4-J30 6483184
7 BOLT, FLANGE (6X16) .............................. -------- -------- 1 90106-MJ0-000 3010642
8 BOLT, FLANGE (8X45) .............................. -------- -------- 4 90107-KZ4-J40 6825277
9 BEARING, HEAD PIPE (TOYO).................. -------- -------- 2 91015-KZ4-701 3226719
10 BOLT, FLANGE (6X10) .............................. -------- -------- 1 95701-06010-00 2410876
KSC4F0600
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-9
FRONT FENDER
4 =CRF250X’04 F-7
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 FENDER SUB-ASSY., FR........................... -------- -------- 1 61110-MEN-670 7532609
2 WASHER, FENDER SETTING.................... -------- -------- 4 90506-430-000 0681023
3 COLLAR, FR. FENDER .............................. -------- -------- 4 90512-KZ4-J20 6267819
4 BOLT, FLANGE (6X16) .............................. -------- -------- 4 96001-06016-00 2105955
KRN4F0500
2-10 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E5
FRONT SHOCK ABSORBER
4 =CRF250X’04 F-8
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CLAMP A, FR. BRAKE HOSE .................... -------- -------- 1 45461-GBF-J00 5601356
2 CLAMP B, FR. BRAKE HOSE .................... -------- -------- 1 45462-GBF-J00 5601364
3 WIRE, SPEEDOMETER CABLE GUIDE .... -------- -------- 1 45462-KAE-740 7657851
4 SPRING, FR. FORK (4.12N/MM,0.42KGF/
MM) (SHOWA) ........................................ -------- -------- 2 51401-KSC-003 7659436
5 TUBE (OUTER) .......................................... -------- -------- 2 51410-KSC-003 7659444
6 RING, BACK-UP.......................................... -------- -------- 2 51412-KZ3-B01 5245618
7 BUSH, GUIDE ............................................ -------- -------- 2 51414-KZ3-B01 5245626
8 BUSH, SLIDER............................................ -------- -------- 2 51415-KZ3-B01 5245634
9 PIPE, R. SLIDE............................................ -------- -------- 1 51420-KSC-003 7659451
10 DAMPER, FR............................................... -------- -------- 2 51430-KSC-003 7659469
KSC4F0800
11 BUSH B, SLIDER ........................................ -------- -------- 2 51431-KZ3-B01 5245667
12 COLLAR, REBOUND NEEDLE .................. -------- -------- 2 51437-KZ3-J41 6830269
13 BOLT, CENTER .......................................... -------- -------- 2 51440-KSC-003 7659477
14 RING, OIL SEAL STOPPER........................ -------- -------- 2 51447-KZ3-003 3009743
15 BOLT ASSY., FR. FORK ............................ -------- -------- 2 51450-KSC-003 7659485
16 NUT, LOCK ................................................ -------- -------- 2 51451-KZ3-B01 5245709
17 BUSH C, SLIDER ........................................ -------- -------- 4 51453-KZ3-B01 5245725
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-11
FRONT SHOCK ABSORBER
4 =CRF250X’04 F-8
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 BOLT, PLUG .............................................. -------- -------- 2 51456-KZ3-J41 6830293
19 RING, STOPPER ........................................ -------- -------- 2 51476-KZ3-711 4371662
20 FORK SUB-ASSY., R. FR. .......................... -------- -------- 1 51480-KSC-003 7659493
21 SEAL SET, FR. FORK ................................ -------- -------- 2 51490-KSC-003 7659501
22 PIPE, L. SLIDE ............................................ -------- -------- 1 51520-KSC-003 7659519
23 FORK SUB-ASSY., L. FR. .......................... -------- -------- 1 51580-KSC-003 7659527
24 PROTECTOR, L. FR. FORK *TNATURAL*
(NATURAL) ............................................ -------- -------- 1 51610-MEB-750ZA 7187347
25 PROTECTOR, R. FR. FORK *TNATURAL*
(NATURAL) ............................................ -------- -------- 1 51620-KCZ-J70ZA 7657992
26 BOLT, FLANGE (8X40) .............................. -------- -------- 4 90108-KZ4-J40 6825285
KSC4F0800
27 BOLT, FLANGE (6MM)................................ -------- -------- 2 90113-KZ3-000 3010659
28 BOLT, PROTECTOR .................................. -------- -------- 6 90113-MAC-780 5195003
29 DUST SEAL ................................................ -------- -------- 2 91254-KSC-003 7660525
30 O-RING (26.7X3.5)...................................... -------- -------- 2 91256-KZ3-A71 5642491
31 O-RING (27.7X1.9)...................................... -------- -------- 2 91257-MEB-751 7187784
32 O-RING (18.8X1.9)...................................... -------- -------- 2 91258-KZ3-B01 5246327
33 O-RING (3.5X1.5)........................................ -------- -------- 2 91301-KZ3-711 4337317
2-12 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E6
FRONT SHOCK ABSORBER
4 =CRF250X’04 F-8
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
34 O-RING (44.7X2.4)...................................... -------- -------- 2 91356-KZ3-003 3010865
35 O-RING (37.2X2.4) (SHOWA) .................... -------- -------- 2 91356-MW0-003 4046785
36 BOLT, FLANGE (6X12) .............................. -------- -------- 1 96001-06012-00 2105930
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-13
FRONT BRAKE CALIPER
4 =CRF250X’04 F-9
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SEAL SET, PISTON .................................... -------- -------- 2 06431-MA3-405 4124277
2 SCREW, BLEEDER .................................... -------- -------- 1 43352-568-003 0505735
3 CAP, BLEEDER .......................................... -------- -------- 1 43353-461-771 0954230
4 PAD SET, FR............................................... -------- -------- 1 45105-MY6-405 4079059
5 PISTON ...................................................... -------- -------- 2 45107-KZ4-J31 6482558
6 SPRING, PAD.............................................. -------- -------- 1 45108-MY1-006 4302873
7 RETAINER .................................................. -------- -------- 1 45112-KS6-701 2465409
8 BOLT A, BOLT ............................................ -------- -------- 1 45131-HA5-672 3254380
9 BUSH, PIN .................................................. -------- -------- 1 45132-166-016 1046275
10 BOOT B ...................................................... -------- -------- 1 45133-MA3-006 1012012
11 CALIPER SUB-ASSY., L. FR. (NISSIN)...... -------- -------- 1 45150-MEN-006 7531940
KSC4F0900
12 BRACKET SUB-ASSY., L. FR. CALIPER .. -------- -------- 1 45190-MEN-006 7531957
13 PLUG, PIN .................................................. -------- -------- 1 45203-MG3-016 3189743
14 PIN, HANGER ............................................ -------- -------- 1 45215-HA5-672 3214038
15 BOLT, FLANGE (8X40) .............................. -------- -------- 2 90110-KZ4-J40 6825293
2-14 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E7
FRONT WHEEL
4 =CRF250X’04 F-10
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SPOKE SET, FR. (240MM) ........................ -------- -------- 36 06440-KZ4-J40 6828636
2 CAP, VALVE................................................ -------- -------- 1 42714-KA3-710 1321322
3 AXLE, FR. WHEEL...................................... -------- -------- 1 44301-KSC-000 7657778
4 COLLAR, L. FR. WHEEL ............................ -------- -------- 1 44311-KZ4-J40 6824684
5 COLLAR, FR. DISTANCE .......................... -------- -------- 1 44620-MAC-680 4570933
6 HUB SUB-ASSY., FR. ................................ -------- -------- 1 44635-KSC-000 7657786
7 WHEEL SUB-ASSY., FR............................. -------- -------- 1 44650-KSC-000 7657794
8 RIM, FR. WHEEL (21X1.60)........................ -------- -------- 1 44701-MEN-003 7531882
9 TIRE, FR. (80/100-21 D742) (DUNLOP) .... -------- -------- 1 44711-MEN-004 7531908
10 TUBE, TIRE (2.75/3.50-21) ........................ -------- -------- 1 0Y400-33100 2579605
TUBE (275/325-21) .................................... -------- -------- 1 08400-33100 1204833
KSC4F1000
TUBE (275/300X21) .................................... -------- -------- 1 08400-34010 0646893
TUBE, TIRE (275/300-2) ............................ -------- -------- 1 44712-MC4-005 1275502
TUBE, TIRE (2.75/3.00-21) (BS) ................ -------- -------- 1 44712-340-003 0265405
TUBE, TIRE (2.75/3.00-21) (DUNLOP)
(NOT AVAILABLE) .................................. -------- -------- 1 44712-400-004 0439364
TUBE, TIRE (2.75/3.00-21) ........................ -------- -------- 1 44712-437-971 2060689
TUBE, TIRE (2.75/3.00-21) (BS) ................ -------- -------- 1 44712-446-003 0766964
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-15
FRONT WHEEL
4 =CRF250X’04 F-10
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
10 TUBE, TIRE (2.75/3.00-21) (INOUE) .......... -------- -------- 1 44712-446-631 1006485
11 FLAP, TIRE (DUNLOP) .............................. -------- -------- 1 44713-KS6-641 2520070
12 STOPPER, BEAD (1.60) ............................ -------- -------- 1 44715-MA0-770 1076975
13 BOX ASSY., SPEEDOMETER GEAR ........ -------- -------- 1 44800-KSC-003 7657802
14 DISK, FR. BRAKE ...................................... -------- -------- 1 45351-KZ4-J30 6482574
15 COVER, FR. DISK *TNATURAL*
(NATURAL) ............................................ -------- -------- 1 51614-KZ4-J40ZA 6824973
16 BOLT, DISK (6X19) .................................... -------- -------- 6 90105-MAC-680 4571774
17 BOLT, FR. DISK COVER ............................ -------- -------- 2 90114-MAC-780 5195011
18 NUT, FR. AXLE .......................................... -------- -------- 1 90301-KZ4-J40 6826580
19 NUT, U (6MM) ............................................ -------- -------- 6 90301-473-003 1187707
KSC4F1000
20 BEARING, RADIAL BALL (6904) ................ -------- -------- 2 91062-MAC-681 4571840
21 OIL SEAL (26X37X7) (ARAI) ...................... -------- -------- 1 91201-KS6-004 2159663
22 DUST SEAL (46X58X7) .............................. -------- -------- 1 91251-KSC-003 7658321
23 O-RING (5.5X1.4)........................................ -------- -------- 1 91319-ME5-003 1377399
24 NUT, HEX. (8MM)........................................ -------- -------- 1 94001-08000-0S 0167338
25 WASHER, SPRING (8MM).......................... -------- -------- 1 94111-08000 0058982
2-16 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E8
REAR BRAKE CALIPER
4 =CRF250X’04 F-11
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 PAD SET, RR. ............................................ -------- -------- 1 06435-KZ4-J41 6825830
2 SEAL SET, PISTON .................................... -------- -------- 1 06451-MZ2-405 4179362
3 SPRING, PAD.............................................. -------- -------- 1 43108-KZ4-J41 6824528
4 RETAINER, BRACKET................................ -------- -------- 1 43112-KZ4-J41 6824536
5 BOLT, PIN .................................................. -------- -------- 1 43131-KW3-006 3335676
6 CALIPER SUB-ASSY., RR. BRAKE
(NISSIN) .................................................. -------- -------- 1 43150-KZ4-J41 6824544
7 BRACKET SUB-ASSY., RR. ...................... -------- -------- 1 43190-KZ4-J41 6824551
8 PIN, HANGER ............................................ -------- -------- 1 43215-KZ4-J41 6824569
9 COVER, RR. DISK *TNATURAL*
(NATURAL) ............................................ -------- -------- 1 43330-KZ4-J40ZA 6824585
KSC4F1100
10 GUARD, RR. CALIPER *TNATURAL*
(NATURAL) ............................................ -------- -------- 1 43340-KZ4-J40ZA 6824593
11 SCREW, BLEEDER .................................... -------- -------- 1 43352-568-003 0505735
12 CAP, BLEEDER .......................................... -------- -------- 1 43353-461-771 0954230
13 PISTON (22 A) ............................................ -------- -------- 1 45107-MCT-006 6826333
14 O-RING (2.5X1.5)........................................ -------- -------- 1 45111-MAJ-G41 4979928
15 BUSH, PIN .................................................. -------- -------- 1 45132-166-016 1046275
16 BOOT B ...................................................... -------- -------- 1 45133-MA3-006 1012012
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-17
REAR BRAKE CALIPER
4 =CRF250X’04 F-11
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
17 BOLT, FLANGE (6X10) (NSHF).................. -------- -------- 4 90004-GHB-600 4938304
KSC4F1100
2-18 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E9
RR. BRAKE MASTER CYLINDER
4 =CRF250X’04 F-12
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 HOSE, RR. BRAKE .................................... -------- -------- 1 43310-KZ4-J41 6824577
2 MASTER CYLINDER ASSY., RR. BRAKE
(NISSIN) .................................................. -------- -------- 1 43500-KZ4-J42 7161409
3 BOOT .......................................................... -------- -------- 1 43504-MB2-006 1429455
4 CAP, MASTER CYLINDER ........................ -------- -------- 1 43513-KZ4-J41 6824627
5 PISTON SET, MASTER CYLINDER .......... -------- -------- 1 43520-KZ4-J42 7182744
6 PLATE, DIAPHRAGM.................................. -------- -------- 1 43521-KZ4-J41 6824643
7 DIAPHRAGM .............................................. -------- -------- 1 43522-KZ4-J41 6824650
8 ROD, PUSH ................................................ -------- -------- 1 43530-KZ4-J41 6824668
9 CIRCLIP, MASTER CYLINDER .................. -------- -------- 1 46182-500-013 0506139
10 JOINT, BRAKE ROD .................................. -------- -------- 1 46504-KZ4-J41 6824742
KSC4F1200
11 BOLT, FR. DISK COVER ............................ -------- -------- 2 90114-MAC-780 5195011
12 BOLT, OIL (10X22)...................................... -------- -------- 2 90145-MS9-612 5369418
13 WASHER, OIL BOLT .................................. -------- -------- 4 90545-300-000 0189902
14 BOLT-WASHER (4X16) .............................. -------- -------- 2 93401-04016-00 5384581
15 NUT, HEX. (6MM)........................................ -------- -------- 1 94002-06000-0S 0181032
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-19
REAR WHEEL
4 =CRF250X’04 F-13
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SPOKE SET, RR. INSIDE .......................... -------- -------- 16 06420-KSC-000 7656325
2 SPOKE SET, RR. (OUTER) ........................ -------- -------- 16 06421-KSC-000 7656333
3 SPROCKET, FINAL DRIVEN (54T) ............ -------- -------- (1) 41201-KSR-J00 7598014
SPROCKET, FINAL DRIVEN (52T) ............ -------- -------- (1) 41203-KZ4-J30 6482467
SPROCKET, FINAL DRIVEN (53T) ............ -------- -------- 1 41204-KZ4-J30 6482475
4 RETAINER, RR. WHEEL BEARING .......... -------- -------- 1 41231-KZ4-J20 6266852
5 AXLE, RR. WHEEL...................................... -------- -------- 1 42301-KZ4-J40 6826291
6 COLLAR, L. RR. AXLE................................ -------- -------- 1 42305-KZ4-J40 6824478
7 COLLAR, R. RR. AXLE .............................. -------- -------- 1 42306-KZ4-J20 6266886
8 COLLAR, RR. WHEEL SIDE ...................... -------- -------- 2 42311-KZ4-J40 6824486
9 COLLAR, RR. WHEEL DISTANCE ............ -------- -------- 1 42620-KZ4-J20 6266902
KSC4F1300
10 HUB SUB-ASSY., RR. WHEEL .................. -------- -------- 1 42635-MEN-000 7531791
11 WHEEL SUB-ASSY., RR............................. -------- -------- 1 42650-KSC-000 7657752
12 RIM, RR. WHEEL (18X2.15) ...................... -------- -------- 1 42701-KSC-003 7657760
13 TIRE, RR. (100/100-18 59M D756)
(DUNLOP) .............................................. -------- -------- 1 42711-KSC-004 7659352
14 CAP, VALVE................................................ -------- -------- 1 42714-KA3-710 1321322
15 STOPPER, BEAD (2.15) ............................ -------- -------- 1 42715-MA0-770 1093558
2-20 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E10
REAR WHEEL
4 =CRF250X’04 F-13
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
16 CAP, RIM HOLE.......................................... -------- -------- 1 42717-329-000 0293308
17 DISK, RR. BRAKE ...................................... -------- -------- 1 43351-KZ4-J40 6824601
18 TUBE, TIRE (3.25/3.50-19) (DUNLOP)
(NOT AVAILABLE) .................................. -------- -------- 1 44712-300-004 1006477
19 FLAP, TIRE (1.85-19) (DUNLOP)................ -------- -------- 1 44713-300-004 1006493
20 BOLT, DISK (6X19) .................................... -------- -------- 4 90105-MAC-680 4571774
21 SCREW, FLAT (8X31) ................................ -------- -------- 6 90125-KA4-000 1028208
22 NUT, U (6MM) ............................................ -------- -------- 4 90301-473-003 1187707
23 NUT, U (22MM) .......................................... -------- -------- 1 90305-KZ4-J20 6267751
24 NUT, U (8MM) ............................................ -------- -------- 6 90309-ML3-791 4059903
25 WASHER (22X35X2) .................................. -------- -------- 1 90401-KZ4-J20 6267777
26 WASHER (8MM).......................................... -------- -------- 6 90465-MC4-000 1223734
27 BEARING, RADIAL BALL (69052RS) ........ -------- -------- 1 91051-KZ4-J21 6267843
28 BEARING, RADIAL BALL (6905RS) .......... -------- -------- 2 91052-KZ4-J21 6267850
29 DUST SEAL (32X43X7) .............................. -------- -------- 2 91251-KZ4-J21 6267876
30 NUT, HEX. (8MM)........................................ -------- -------- 1 94001-08000-0S 0167338
31 WASHER, SPRING (8MM).......................... -------- -------- 1 94111-08000 0058982
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-21
FUEL TANK
4 =CRF250X’04 F-14
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 PETCOCK ASSY......................................... -------- -------- 1 16950-KSC-003 7656556
2 SCREEN SET, FUEL STRAINER .............. -------- -------- 1 16952-KCY-671 4888244
3 JOINT ASSY., FUEL.................................... -------- -------- 1 16955-KSC-003 7656564
4 O-RING (11.8X3.55).................................... -------- -------- 1 16997-467-000 0825158
5 COLLAR, TANK SET (6.3X10.5X17.5)........ -------- -------- 1 17509-KZ3-B00 5244942
6 TANK, FUEL................................................ -------- -------- 1 17510-KSC-000 7656697
7 RUBBER, FUEL TANK MOUNTING .......... -------- -------- 1 17512-KRN-000 7606189
8 STAY, FR. TANK ........................................ -------- -------- 1 17515-KSC-000 7656705
9 BAND, RR. TANK........................................ -------- -------- 1 17516-KZ3-B00 5244991
10 COLLAR, FR. SEAT .................................... -------- -------- 1 17518-KZ4-710 4301511
11 TUBE, FUEL CAP BREATHER .................. -------- -------- 1 17521-KZ4-J20 6266332
KSC4F1400
12 CAP ASSY., FUEL TANK............................ -------- -------- 1 17620-MEB-670 6844310
13 GASKET, FUEL CAP .................................. -------- -------- 1 17624-KT1-780 2664282
14 TUBE B, FUEL ............................................ -------- -------- 1 17681-KSC-000 7656713
15 TUBE A, FUEL MAIN .................................. -------- -------- 1 17684-KSC-000 7656721
16 TUBE A, FUEL RESERVE .......................... -------- -------- 1 17685-KSC-000 7656739
17 RUBBER, MUFFLER .................................. -------- -------- 1 18334-ML3-680 3008828
2-22 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E11
FUEL TANK
4 =CRF250X’04 F-14
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 SHROUD SET, R. RADIATOR (TYPE1)
(WL) ........................................................ -------- -------- 1 19071-KSC-000ZB 7656937
19 SHROUD SET, L. RADIATOR (TYPE1)
(WL) ........................................................ -------- -------- 1 19072-KSC-000ZB 7656952
20 COLLAR ...................................................... -------- -------- 2 84706-415-000 0843615
21 BOLT, FLANGE (5X12) .............................. -------- -------- 4 90106-KRN-000 7607385
22 SCREW, PAN (5X13) .................................. -------- -------- 1 90108-MN0-000 2528560
23 COLLAR A .................................................. -------- -------- 4 90501-KZ4-J20 6267785
24 COLLAR, SHROUD (UPPER) .................... -------- -------- 4 90502-KRN-000 7607468
25 SCREW, SPECIAL (5MM) .......................... -------- -------- 1 91422-MT8-770 3362118
26 TY-RAP, CABLE.......................................... -------- -------- 1 91560-MS8-600 5246343
27 CLIP, TUBE (B12) ...................................... -------- -------- 6 95002-02120 0335034
28 BOLT, FLANGE (6X16) .............................. -------- -------- 3 96001-06016-00 2105955
29 BOLT, FLANGE (6X18) .............................. -------- -------- 6 96001-06018-00 2105963
30 BOLT, FLANGE (6X30) .............................. -------- -------- 1 96001-06030-00 2537041
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-23
SEAT • SIDE COVER
4 =CRF250X’04 F-15
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SEAT .......................................................... -------- -------- 1 77100-KSC-010 7658123
2 LEATHER, SEAT (NO LETTERS
PRINTED)................................................ -------- -------- 1 77101-KSC-000 7658131
3 COLLAR, TOOL BOX SETTING ................ -------- -------- 2 83505-KM4-000 2067593
4 COVER, R. SIDE *R292R* (EXTREME
RED)........................................................ -------- -------- 1 83510-KSC-000ZA 7658172
5 PLATE *NH1* (BLACK) .............................. -------- -------- 1 83513-KSC-000ZA 7658198
6 HEAT GUARD ............................................ -------- -------- 1 83514-KSC-000 7659881
7 RUBBER, SIDE COVER STOPPER .......... -------- -------- 1 83515-KS7-830 2773919
8 COVER, L. SIDE *R292R* (EXTREME
RED)........................................................ -------- -------- 1 83610-KSC-000ZA 7658206
9 BOLT, DR (8X16) (SH)................................ -------- -------- 2 90123-MEN-670 7533045
KSC4F1500
10 NUT, SPEED (3MM).................................... -------- -------- 2 90313-GAH-780 4568598
11 COLLAR A .................................................. -------- -------- 2 90501-KZ4-J20 6267785
12 BOLT, FLANGE (6X14) .............................. -------- -------- 2 96001-06014-00 2154672
2-24 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E12
AIR CLEANER
4 =CRF250X’04 F-16
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CLIP, OIL DRAIN ........................................ -------- -------- A 1 15707-634-000 0366120
CLIP, BREATHER TUBE ............................ -------- -------- AC 1 17316-611-000 0340984
2 CLIP, OIL DRAIN TUBE .............................. -------- -------- 1 15771-551-000 0574863
3 CLIP, BREATHER TUBE ............................ -------- -------- AC 1 15772-551-000 0501353
CLIP, TUBE (B12) ...................................... -------- -------- A 1 95002-02120 0335034
4 JOINT, FUEL TUBE .................................... -------- -------- A 1 16959-MY1-000 4524104
T-JOINT ...................................................... -------- -------- AC 1 17193-MN5-000 2803435
5 CLAMP, HOSE ............................................ -------- -------- 1 16965-VM0-771 1995588
6 COVER ASSY., AIR CLEANER .................. -------- -------- 1 17211-KSC-000 7656580
7 STAY, AIR CLEANER ELEMENT .............. -------- -------- 1 17212-MEN-670 7531155
8 ELEMENT, AIR CLEANER.......................... -------- -------- 1 17213-KSC-000 7656598
KSC4F1600
9 BASE ASSY., ELEMENT ............................ -------- -------- 1 17214-MEN-670 7531163
10 PLATE, FR. AIR CLEANER HOUSING ...... -------- -------- 1 17217-MEB-770 7186554
11 MUDGUARD, AIR CLEANER HOUSING.... -------- -------- 1 17218-KRN-000 7606106
12 SEAL, AIR CLEANER HOUSING................ -------- -------- 1 17218-KSC-000 7656606
13 SEAL, AIR CLEANER COVER (A).............. -------- -------- 1 17219-KSC-000 7656614
14 COVER, R. SIDE ........................................ -------- -------- 1 17221-KSC-000 7656622
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-25
AIR CLEANER
4 =CRF250X’04 F-16
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
15 WASHER, AIR CLEANER COVER
SETTING ................................................ -------- -------- 1 17224-KN5-670 2003168
16 STUD (6X21) .............................................. -------- -------- 1 17225-KN5-670 2003176
17 HOUSING, AIR CLEANER.......................... -------- -------- 1 17250-KSC-000 7656630
18 TUBE, AIR CLEANER CONNECTING........ -------- -------- A 1 17253-KSC-000 7656648
TUBE, AIR CLEANER CONNECTING........ -------- -------- AC 1 17253-KSC-770 7656655
19 BOLT, ELEMENT SETTING........................ -------- -------- 1 17291-KSC-000 7659196
20 CLIP A, BREATHER TUBE ........................ -------- -------- 1 17316-MN1-670 2691012
21 CLIP, BREATHER TUBE ............................ -------- -------- A 1 17316-611-000 0340984
-------- -------- AC 2 17316-611-000 0340984
22 TUBE, DRAIN.............................................. -------- -------- 1 17358-HA0-680 2077550
KSC4F1600
TUBE, DRAIN.............................................. -------- -------- 1 17358-HM8-000 5308127
23 JOINT, BREATHER TUBE .......................... -------- -------- A 1 17359-MAG-L00 5585328
JOINT, TWO-WAY ...................................... -------- -------- AC 1 18631-MAH-710 5421276
24 PLUG, BREATHER TUBE .......................... -------- -------- 1 17370-419-700 0669002
25 TUBE A, BREATHER .................................. -------- -------- 1 17372-KRN-000 7606148
26 TUBE B, BREATHER .................................. -------- -------- A 1 17374-KRN-000 7606155
TUBE B, BREATHER .................................. -------- -------- AC 1 17374-KSC-770 7656663
2-26 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E13
AIR CLEANER
4 =CRF250X’04 F-16
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
27 TUBE C, BREATHER.................................. -------- -------- 1 17375-KSC-000 7656671
28 PIPE, BREATHER ...................................... -------- -------- AC 1 17376-KSC-770 7656689
29 CLAMP, MASTER CYLINDER OIL HOSE .. -------- -------- 1 43514-KS6-701 2465318
30 PIN, BRAKE LOCK LEVER PIVOT ............ -------- -------- 1 53189-GCS-000 7658065
31 PIN, VISOR HINGE .................................... -------- -------- 1 64308-GG2-000 4773339
32 PLATE, SPRING.......................................... -------- -------- 1 64508-KV3-000 4045282
33 NUT, CLIP (6MM)........................................ -------- -------- 1 90305-GK8-000 1899202
34 COLLAR, AIR CLEANER ............................ -------- -------- 1 90501-KRN-000 7607450
35 CLIP (2X70) ................................................ -------- -------- 1 91413-679-000 0995712
36 SCREW, TAPPING (4X12).......................... -------- -------- 2 93903-24380 0562090
37 SCREW, TAPPING (5X16).......................... -------- -------- 7 93903-25380 1172139
38 SCREW, TAPPING (5X16).......................... -------- -------- 2 93913-25410 4485785
39 NUT, HEX. (5MM)........................................ -------- -------- 6 94002-05070-0S 2563013
40 E-RING (3MM) ............................................ -------- -------- 2 94540-03010 2395390
41 CLIP, TUBE (B12) ...................................... -------- -------- 2 95002-02120 0335034
42 BAND, AIR CLEANER CONNECTING
TUBE (60)................................................ -------- -------- 1 95018-60321 7533136
43 BOLT, FLANGE (6X16) .............................. -------- -------- 1 96001-06016-00 2105955
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-27
AIR SUCTION VALVE
4 =CRF250X’04 F-16-1
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CLIP, BREATHER TUBE ............................ -------- -------- AC 2 17316-611-000 0340984
2 CLIP, THROTTLE WIRE ............................ -------- -------- AC 1 17926-SK7-A00 3580594
3 VALVE ASSY., AIR SUCTION .................... -------- -------- AC 1 18600-KSC-771 7656812
4 STAY, AIR SUCTION VALVE...................... -------- -------- AC 1 18601-KSC-770 7656820
5 TUBE A, AIR SUCTION VALVE.................. -------- -------- AC 1 18602-KSC-770 7656838
6 TUBE B, AIR SUCTION VALVE.................. -------- -------- AC 1 18603-KSC-770 7656846
7 PIPE ASSY., AIR ........................................ -------- -------- AC 1 18640-KSC-770 7656853
8 TUBE, AIR PIPE.......................................... -------- -------- AC 1 18645-KSC-770 7659204
9 COLLAR, ELECTRIC PLATE ...................... -------- -------- AC 2 50302-KG1-000 1510833
10 RUBBER, RR. FENDER CUSHION ............ -------- -------- AC 2 80101-165-000 0715490
11 CLIP, FUEL HOSE ...................................... -------- -------- AC 1 90678-MN5-000 3056892
KSC4F1601
12 CLIP, HOSE ................................................ -------- -------- AC 1 90678-MR1-690 5714654
13 O-RING (9.8X1.9)........................................ -------- -------- AC 1 91301-PM5-A01 2710820
O-RING (9.8X1.9)........................................ -------- -------- AC 1 91305-PE2-003 1869478
14 BOLT-WASHER (6X28) .............................. -------- -------- AC 2 93404-06028-00 3028214
15 NUT, FLANGE (6MM).................................. -------- -------- AC 2 94050-06000 0471623
16 CLIP, TUBE (B17) ...................................... -------- -------- AC 2 95002-02079 4171690
2-28 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E14
AIR SUCTION VALVE
4 =CRF250X’04 F-16-1
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
17 BULK HOSE, VACUUM (3.5X1000)
(3.5X270) ................................................ -------- -------- AC 1 95005-35001-20M 5137153
18 BOLT, FLANGE (6X16) .............................. -------- -------- AC 2 96001-06016-00 2105955
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-29
MUFFLER
4 =CRF250X’04 F-17
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 GASKET, EX. MUFFLER ............................ -------- -------- 1 18291-KPS-900 7093362
2 GASKET, EX. PIPE .................................... -------- -------- 1 18291-MM5-860 2958239
3 MUFFLER.................................................... -------- -------- 1 18310-KSC-000 7656788
4 PIPE, EX. .................................................... -------- -------- 1 18320-KSC-000 7656796
5 PROTECTOR, EX. PIPE ............................ -------- -------- 1 18323-KRN-000 7606270
6 PROTECTOR, MUFFLER .......................... -------- -------- 1 18324-KRN-000 7606288
7 ARRESTER ASSY....................................... -------- -------- 1 18355-KSC-000 7656804
8 BAND, L. MUFFLER.................................... -------- -------- 1 18374-KE8-000 2957520
BAND, L. MUFFLER.................................... -------- -------- 1 18374-MG7-701 2917052
9 GASKET, MUFFLER .................................. -------- -------- 1 18392-MK4-000 2575074
10 NUT, SPRING (6MM) .................................. -------- -------- 4 19508-KA3-710 1331180
KSC4F1700
11 RUBBER, SIDE COVER (PD) .................... -------- -------- 2 83512-KA4-700 1187277
12 BOLT, FLANGE (6X10) .............................. -------- -------- 4 90101-KCE-000 4774303
13 BOLT, FLANGE (8X24) (SH) ...................... -------- -------- 1 90101-KZ3-J50 7187719
14 BOLT, FLANGE (8X18) .............................. -------- -------- 1 90123-KZ4-J40 6825327
15 BOLT, FLANGE (8X35) .............................. -------- -------- 1 90124-KZ4-J40 6825335
16 BOLT, SPECIAL (6MM) .............................. -------- -------- 4 90170-MEB-670 6852495
17 WASHER (6MM).......................................... -------- -------- 2 90406-KV3-780 4236956
2-30 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E15
MUFFLER
4 =CRF250X’04 F-17
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 NUT, FLANGE (8MM).................................. -------- -------- 2 94050-08000 0481143
19 WASHER, PLAIN (8MM) ............................ -------- -------- 1 94101-08000 0059097
20 WASHER, PLAIN (8MM) ............................ -------- -------- 1 94102-08800 0562215
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-31
PEDAL • KICK STARTER ARM
4 =CRF250X’04 F-18
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 PEDAL, CHANGE........................................ -------- -------- 1 24700-KRN-000 7606809
2 ARM ASSY., KICK STARTER .................... -------- -------- 1 28300-KRN-000 7606833
3 JOINT, KICK ARM ...................................... -------- -------- 1 28302-KRN-000 7606841
4 BOLT, KICK JOINT...................................... -------- -------- 1 28306-MEN-670 7531502
5 SPRING, KICK STARTER .......................... -------- -------- 1 28333-KK0-000 1595735
6 PEDAL, RR. BRAKE.................................... -------- -------- 1 46510-KSC-000 7657869
7 SPRING ASSY., RR. BRAKE RETURN...... -------- -------- 1 46511-KZ4-J00 5658190
8 SHAFT, BRAKE PIVOT .............................. -------- -------- 1 46513-KSC-000 7657877
9 DUST SEAL (17X20X2.5)............................ -------- -------- 1 46525-KK0-003 1645076
10 BOLT, KICK ARM........................................ -------- -------- 1 90103-KRN-000 7607369
11 WASHER (26X9) ........................................ -------- -------- 1 90404-MEN-670 7533060
KSC4F1800
12 PIN, SNAP (8MM)........................................ -------- -------- 1 90705-PFF-300 7660517
13 DUST SEAL (15X20X2.5)............................ -------- -------- 2 91251-444-000 0764092
14 PIN, COTTER (2.0X12) .............................. -------- -------- 1 94201-20120 0109579
15 PIN D, JOINT .............................................. -------- -------- 1 95015-54000 4459467
16 BOLT, FLANGE (6X22) .............................. -------- -------- 1 96001-06022-00 2112191
17 BALL, STEEL (#8) (1/4) .............................. -------- -------- 1 96211-08000 0079905
2-32 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-E16
STEP
4 =CRF250X’04 F-19
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 PIN, STEP JOINT........................................ -------- -------- 2 50603-KZ4-J40 6824809
2 BRACKET, R. STEP.................................... -------- -------- 1 50610-MEN-670 7532112
3 BRACKET, L. STEP .................................... -------- -------- 1 50611-MEN-670 7532120
4 ARM, R. STEP ............................................ -------- -------- 1 50616-MEN-670 7532138
5 SPRING, R. STEP RETURN ...................... -------- -------- 1 50617-KZ4-J40 6824841
6 SPRING, L. STEP RETURN........................ -------- -------- 1 50618-KZ4-J40 6824858
7 ARM, L. STEP ............................................ -------- -------- 1 50642-MEN-670 7532146
8 BOLT, FLANGE (8X24) (SH) ...................... -------- -------- 2 90101-KZ3-J50 7187719
9 BOLT, STEP (12MM) .................................. -------- -------- 2 90101-KZ4-J40 6825269
10 WASHER, PLAIN (8MM) ............................ -------- -------- 2 94102-08800 0562215
11 PIN, COTTER (2.5MM)................................ -------- -------- 2 94201-25150 0058396
KSC4F1900
PIN, COTTER (2.5MM)................................ -------- -------- 2 94201-25200 0058404
PIN, COTTER (2.5MM)................................ -------- -------- 2 94201-25250 0145581
PIN, COTTER (2.5MM)................................ -------- -------- 2 94201-25300 0156091
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-33
STAND
4 =CRF250X’04 F-20
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 BRACKET, SIDE STAND ............................ -------- -------- 1 50125-KSC-000 7657893
2 WORKSTAND (17") .................................... -------- -------- (1) 50500-KA3-820 1553007
3 BAR, SIDE STAND...................................... -------- -------- 1 50530-KSC-000 7657976
4 SPRING ASSY., SIDE STAND.................... -------- -------- 1 50540-KSC-000 7657984
5 BOLT, SIDE STAND PIVOT........................ -------- -------- 1 90108-MJ0-000 1975481
6 BOLT (10X24) (SH) .................................... -------- -------- 1 90122-MEN-670 7533037
7 BOLT, FLANGE (8X25) .............................. -------- -------- 1 90123-KSC-000 7660509
8 NUT, U (10MM) .......................................... -------- -------- 1 90304-GE8-003 1439249
KSC4F2000
2-34 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F1
SWINGARM
4 =CRF250X’04 F-21
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CHAIN, DRIVE (DID520MXV-120ZB)
(DAIDO) .................................................. -------- -------- 1 40540-KSC-003 7657745
2 MASTER LINK ............................................ -------- -------- 1 40545-KSC-003 7659329
3 GUIDE, RR. BRAKE HOSE ........................ -------- -------- 1 43468-KZ3-B00 5245428
4 SHAFT, SWINGARM PIVOT ...................... -------- -------- 1 52101-KZ4-J40 6824981
5 COLLAR, SWINGARM (49MM) .................. -------- -------- 1 52141-KZ3-J40 6830327
6 COLLAR, SWINGARM PIVOT (59MM) ...... -------- -------- 1 52141-KZ4-J40 6824999
7 WASHER, SWINGARM SIDE .................... -------- -------- 4 52143-KZ3-860 3837820
8 COLLAR, SWINGARM PIVOT SIDE .......... -------- -------- 2 52143-KZ4-J40 6825012
9 GUIDE, CHAIN ............................................ -------- -------- 1 52146-MEN-000 7532278
10 COLLAR, CHAIN GUIDE ............................ -------- -------- 2 52148-MEN-000 7532286
KSC4F2100
11 PLATE, CHAIN GUIDE................................ -------- -------- 1 52156-ML3-910 3225976
12 COLLAR, CHAIN TENSIONER ROLLER.... -------- -------- 1 52160-MEN-000 7532294
13 SLIDER, CHAIN .......................................... -------- -------- 1 52170-MEB-750 7187354
14 WASHER, CHAIN SLIDER.......................... -------- -------- 2 52171-KR6-000 2142156
15 ROLLER, CHAIN (32).................................. -------- -------- 1 52175-KSK-000 7570526
16 ROLLER, CHAIN (LOWER) ........................ -------- -------- 1 52176-KZ3-J40 6830335
17 SWINGARM SUB-ASSY., RR. .................... -------- -------- 1 52200-KSR-J00 7598808
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-35
SWINGARM
4 =CRF250X’04 F-21
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
18 BOLT, HEX. (8X47.5) .................................. -------- -------- 2 90105-MEN-000 7532997
19 SCREW, PAN (5X8) .................................... -------- -------- 2 90115-KV3-700 4074571
20 BOLT, FLANGE (8X32) .............................. -------- -------- 1 90124-MEB-770 7187743
21 NUT, U (6MM) ............................................ -------- -------- 2 90301-473-003 1187707
22 NUT, HEX. U (14MM).................................. -------- -------- 1 90305-KZ3-B01 5246202
23 NUT, U (8MM) ............................................ -------- -------- 1 90309-ML3-791 4059903
24 NUT, HEX. (8MM)........................................ -------- -------- 2 90309-357-000 0322164
25 WASHER (26X14X2.8)................................ -------- -------- 1 90501-GAH-000 4220927
WASHER (14MM)........................................ -------- -------- 1 90501-GBL-730 5246236
26 BEARING, RADIAL BALL (608UU) ............ -------- -------- 3 91011-GCT-003 6825400
27 BEARING, NEEDLE (TOYO) ...................... -------- -------- 2 91071-MJ0-003 2332153
KSC4F2100
BEARING, NEEDLE .................................... -------- -------- 2 91071-MJ0-004 2332161
28 BEARING, NEEDLE THRUST .................... -------- -------- 2 91072-KZ3-861 3838315
29 DUST SEAL (30X37X4) .............................. -------- -------- 2 91253-KZ3-861 3838331
30 DUST SEAL (22X29X4) .............................. -------- -------- 2 91283-ML7-003 2332179
31 SCREW, PAN (5X8) .................................... -------- -------- 2 93500-05008-0A 0145540
32 SCREW, PAN (5X8) .................................... -------- -------- 1 93500-05008-0G 0331363
33 WASHER, PLAIN (5MM) ............................ -------- -------- 1 94103-05700 0692491
2-36 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F2
SWINGARM
4 =CRF250X’04 F-21
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
34 BOLT, FLANGE (6X12) .............................. -------- -------- 1 96001-06012-00 2105930
35 BOLT, FLANGE (6X50) .............................. -------- -------- 2 96001-06050-00 2106052
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-37
RR CUSHION
4 =CRF250X’04 F-22
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CUSHION ASSY., RR. ................................ -------- -------- 1 52400-KSC-003 7659535
2 SPRING, RR. SHOCK ABSORBER (47.1N/
MM,4.8KGF/MM) (SHOWA) .................... -------- -------- 1 52401-KSC-003 7659543
SPRING, RR. SHOCK ABSORBER (48N/
MM,4.9KGF/MM) (SHOWA) .................... -------- -------- (1) 52401-KZ3-J41 6830350
SPRING, RR. SHOCK ABSORBER (4.55).. -------- -------- (1) 52402-KZ3-J21 6271712
SPRING, RR. SHOCK ABSORBER (50N/
MM,5.1KGF/MM) (SHOWA) .................... -------- -------- (1) 52403-KZ3-J41 6830376
3 DAMPER, RR. ............................................ -------- -------- 1 52410-KSC-003 7659550
4 STOPPER, SPRING SEAT ........................ -------- -------- 1 52419-KZ3-J21 7590409
5 ROD, PISTON ............................................ -------- -------- 1 52421-KSC-003 7659568
6 ADJUSTER, SPRING.................................. -------- -------- 1 52422-KZ3-J31 6483036
KSC4F2200
7 NUT, ADJUSTER ........................................ -------- -------- 1 52423-KZ3-J21 6271779
8 CASE, DAMPER.......................................... -------- -------- 1 52425-KRN-671 7607187
9 CAP, AIR VALVE ........................................ -------- -------- 1 52425-381-771 0427237
10 ROD ............................................................ -------- -------- 1 52426-KSC-003 7659576
11 RUBBER, STOPPER .................................. -------- -------- 1 52427-KZ3-891 4127155
12 PLATE, END................................................ -------- -------- 1 52428-KZ3-J31 6483093
13 CASE, ROD GUIDE .................................... -------- -------- 1 52429-KSC-003 7659584
2-38 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F3
RR CUSHION
4 =CRF250X’04 F-22
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
14 RING, PISTON ............................................ -------- -------- 1 52431-KZ3-J31 6483101
15 O-RING (3.5X43.7)...................................... -------- -------- 1 52434-KZ3-J21 6271837
16 O-RING (42.5X2.0)...................................... -------- -------- 2 52434-KZ3-J31 6483119
17 RING, STOPPER ........................................ -------- -------- 1 52435-KZ3-J21 6271845
18 OIL SEAL SET ............................................ -------- -------- 1 52436-KSC-003 7659592
19 NUT, HEX. (12MM)...................................... -------- -------- 1 52438-KA4-741 1917301
20 ADJUSTER, COMPRESSION DAMPING
FORCE .................................................... -------- -------- 1 52440-MEN-671 7532385
21 BLADDER.................................................... -------- -------- 1 52451-KZ3-891 4127205
22 RING, STOPPER (SHOWA)........................ -------- -------- 1 52452-KS7-831 2755536
23 CAP, CHAMBER (SHOWA) ........................ -------- -------- 1 52453-KS7-831 2755544
24 RING, STOPPER ........................................ -------- -------- 1 52455-KZ3-J21 6271860
25 COLLAR D, SHOCK ABSORBER .............. -------- -------- 1 52463-KZ4-B00 5225198
26 COLLAR C, CUSHION ARM ...................... -------- -------- 1 52463-KZ4-J40 6825111
27 COLLAR D, SHOCK SIDE .......................... -------- -------- 2 52464-KZ4-B00 5225206
28 COLLAR B, CUSHION ................................ -------- -------- 1 52464-KZ4-J20 6267421
29 ARM SUB-ASSY., CUSHION...................... -------- -------- 1 52465-KSC-000 7658008
30 COLLAR A, CONNECTING ROD................ -------- -------- 1 52473-KZ4-J20 6267447
31 COLLAR, LINK SIDE .................................. -------- -------- 6 52475-KZ4-J20 6267454
32 WASHER, THRUST .................................... -------- -------- 2 52476-KZ4-J20 6267462
33 ROD SUB-ASSY., SHOCK CONNECTING -------- -------- 1 52479-KZ4-J40 6825137
34 SEAT, SPRING............................................ -------- -------- 1 52486-KZ3-J21 6271878
35 RING, STOPPER (SHOWA)........................ -------- -------- 1 52487-KA4-831 1917350
36 LABEL, RR. DAMPER WARNING .............. -------- -------- 1 87516-KZ1-600 4111100
38 BOLT, LINK (12X96).................................... -------- -------- 1 90130-KZ4-J20 6267736
39 BOLT, LINK (12X81.5) ................................ -------- -------- 1 90130-KZ4-J40 6825350
40 BOLT, LINK (12X120).................................. -------- -------- 1 90131-KZ4-J40 6825368
41 BOLT, CUSHION (UPPER) (10X53) .......... -------- -------- 1 90152-MEB-750 7187750
42 BOLT, RUBBER (LOWER) (10X43.5) ........ -------- -------- 1 90153-KZ4-710 4310645
43 NUT, HEX. U (12MM).................................. -------- -------- 3 90306-KBP-901 5246210
44 NUT, U (10MM) .......................................... -------- -------- 2 90306-KZ4-711 4310660
45 WASHER, PLAIN (12MM) .......................... -------- -------- 3 90501-KZ4-J40 6825376
46 BEARING, NEEDLE (20X26X15)................ -------- -------- 4 91051-KSC-003 7658313
47 BEARING, NEEDLE (20X26X14)................ -------- -------- 2 91053-KZ4-J21 6267868
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-39
RR CUSHION
4 =CRF250X’04 F-22
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
48 BEARING, NEEDLE (19X26X15)................ -------- -------- 1 91074-KZ4-B01 5226584
49 BEARING, SPHERICAL (10) ...................... -------- -------- 1 91074-MAC-741 4822235
50 O-RING (21.5X1.5)...................................... -------- -------- 1 91256-KZ3-731 3833134
51 O-RING (26.2X1.9)...................................... -------- -------- 1 91257-KZ3-891 4127270
52 DUST SEAL (25X32X4) .............................. -------- -------- 6 91262-KZ3-731 3530649
53 DUST SEAL, SHOCK.................................. -------- -------- 1 91351-KZ3-731 3537834
54 DUST SEAL (17X26X3) .............................. -------- -------- 2 91351-KZ4-B01 5226600
55 DUST SEAL, SHOCK (16X26X3)................ -------- -------- 1 91351-MAC-671 4310702
KSC4F2200
2-40 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F4
REAR FENDER
4 =CRF250X’04 F-23
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
4 CUSHION, OIL TANK.................................. -------- -------- 1 55101-KBA-900 7658099
5 NUT, SPECIAL (6X7) .................................. -------- -------- 2 61304-958-003 0955575
6 WASHER, SEAT SETTING ........................ -------- -------- 1 77302-124-000 0398362
7 FENDER SET, RR. *R292R* (WL)
(EXTREME RED) .................................... -------- -------- 1 80101-KSC-000ZA 7658149
8 COLLAR, RR. FENDER .............................. -------- -------- 2 90503-KRN-000 7607476
12 WASHER, PLAIN (6MM) ............................ -------- -------- 1 94101-06800 0345900
14 BOLT, FLANGE (6X16) .............................. -------- -------- 4 96001-06016-00 2105955
KSC4F2300
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-41
TAILLIGHT
4 =CRF250X’04 F-24
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 TAILLIGHT UNIT ........................................ -------- -------- 1 33701-KSC-671 7657687
2 CLAMP ........................................................ -------- -------- 2 37215-KAF-008 3116092
3 STAY, TAILLIGHT ...................................... -------- -------- 1 80130-KSC-000 7658156
4 GROMMET, SIDE COVER.......................... -------- -------- 1 83501-MG7-000 2015360
5 SCREW, TAPPING (4X8) (PO) .................. -------- -------- 2 90102-SP1-003 3674413
6 SCREW, SPECIAL (5MM) .......................... -------- -------- 2 90104-KZ3-B00 5246137
KSC4F2400
2-42 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F5
BATTERY
4 =CRF250X’04 F-25
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 BATTERY (YTH5L-BS) (YUASA)................ -------- -------- 1 31500-KY4-905 6403281
2 COVER, BATTERY TERMINAL .................. -------- -------- 1 31505-KSC-000 7657513
3 CABLE, STARTER MAGNETIC BATTERY -------- -------- 1 32401-KSC-670 7657562
4 CABLE, STARTER MOTOR........................ -------- -------- 1 32410-KSC-670 7657570
5 COVER, STARTER MOTOR TERMINAL.... -------- -------- 1 32411-230-000 0208652
COVER, STARTER MOTOR TERMINAL.... -------- -------- 1 32411-253-000 0177360
6 COVER, BATTERY TERMINAL .................. -------- -------- 1 32414-MCF-000 6429088
7 CABLE, BATTERY GROUND .................... -------- -------- 1 32601-KSC-670 7657588
8 SWITCH ASSY., STARTER MAGNETIC .... -------- -------- 1 35850-KK6-740 6178479
9 BOLT, SOCKET (5X9) ................................ -------- -------- 2 90111-MR5-000 3141603
10 BAND, WIRE .............................................. -------- -------- 1 90652-KT1-771 2710416
KSC4F2500
11 BAND B2, BATTERY .................................. -------- -------- 1 95012-13001 1373356
12 FUSE, BLADE (15A).................................... -------- -------- 1 98200-31500 1644244
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-43
WIRE HARNESS
4 =CRF250X’04 F-26
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 CUSHION, IGNITION CONTROL MODULE
(CDI) ........................................................ -------- -------- 1 30401-KSC-000 7657455
2 MODULE, IGNITION CONTROL (CDI) ...... -------- -------- 1 30410-KSC-670 7657463
3 CAP ASSY., NOISE SUPPRESSOR .......... -------- -------- 1 30700-KRN-670 7606890
4 RECTIFIER, REGULATOR ........................ -------- -------- 1 31600-KSC-671 7657539
5 WIRE HARNESS ........................................ -------- -------- 1 32100-KSC-671 7657554
6 RELAY, STARTER ...................................... -------- -------- 1 38501-GAM-007 4180857
7 SUSPENSION, STARTER RELAY.............. -------- -------- 1 38506-MY2-691 4180873
8 BOLT, FLANGE (6X16) .............................. -------- -------- 1 96001-06016-00 2105955
9 FUSE, BLADE (15A).................................... -------- -------- 1 98200-31500 1644244
KSC4F2600
2-44 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F6
RADIATOR
4 =CRF250X’04 F-27
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 BOLT, SEALING (16MM) ............................ -------- -------- 1 12206-881-310 7656432
2 RADIATOR, R. ............................................ -------- -------- 1 19010-KSC-003 7656887
3 RADIATOR, L. ............................................ -------- -------- 1 19015-KRN-003 7606353
4 GRILLE, RADIATOR .................................. -------- -------- 2 19033-KRN-000 7606361
5 CAP, RADIATOR ........................................ -------- -------- 1 19037-KRN-003 7606379
6 RUBBER, RADIATOR MOUNTING ............ -------- -------- 4 19051-KRN-000 7606387
7 COLLAR, RADIATOR MOUNTING ............ -------- -------- 3 19052-MAC-680 4570628
8 SEAL, RADIATOR CAP .............................. -------- -------- 1 19055-KRN-003 7606395
9 HOSE A, WATER ........................................ -------- -------- 1 19061-KRN-000 7606411
10 HOSE B, WATER ........................................ -------- -------- 1 19062-KRN-000 7606429
11 HOSE D, WATER........................................ -------- -------- 2 19064-KRN-000 7606437
KSC4F2700
12 TUBE, RADIATOR BREATHER.................. -------- -------- 1 19104-KSC-000 7656960
13 CAP, RESERVE TANK................................ -------- -------- 1 19104-ME9-000 1368109
14 TUBE, RADIATOR DRAIN .......................... -------- -------- 1 19105-KSC-000 7656978
15 CAP ASSY., RESERVE TANK.................... -------- -------- 1 19105-MG8-000 2106995
16 GASKET, RESERVE TANK ........................ -------- -------- 1 19107-MG8-000 2045565
17 TANK, RADIATOR RESERVE .................... -------- -------- 1 19110-KSC-000 7656986
18 CLAMP B, WATER HOSE .......................... -------- -------- 8 19506-KS6-700 2464709
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-45
RADIATOR
4 =CRF250X’04 F-27
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 GUIDE, MAIN HARNESS............................ -------- -------- 1 50129-KSC-000 7657901
20 BOLT, FLANGE (6X23.5) ............................ -------- -------- 4 90001-GB4-000 6267702
21 NUT, CLIP (6MM)........................................ -------- -------- 2 90303-KRN-000 7607427
22 WASHER, RADIATOR MOUNTING............ -------- -------- 4 90403-KA3-830 1915008
23 COLLAR, GEARSHIFT LEVER SETTING .. -------- -------- 2 90522-170-700 0941138
24 CLIP, GRILLE.............................................. -------- -------- 2 90601-KSC-003 7658271
25 O-RING (13.5X1.4)...................................... -------- -------- 1 91307-PH7-660 2514651
O-RING (12.5X1.4)...................................... -------- -------- 1 91307-611-000 0347906
26 CLIP (2X70) ................................................ -------- -------- 1 91413-679-000 0995712
27 NUT, FLANGE (6MM).................................. -------- -------- 2 94050-06000 0471623
28 CLIP, TUBE (B8) ........................................ -------- -------- 1 95002-02080 0250647
KSC4F2700
29 CLIP, TUBE (B10) ...................................... -------- -------- 2 95002-02100 0250985
30 BOLT, FLANGE (6X16) .............................. -------- -------- 2 96001-06016-00 2105955
2-46 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F7
FRAME
4 =CRF250X’04 F-28
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 FRAME SET ................................................ -------- -------- 1 50010-KSC-000 7657885
2 STAY, CONNECTOR .................................. -------- -------- A 1 50126-KRN-000 7607039
3 CLIP, FUEL TUBE ...................................... -------- -------- 1 50197-KRN-000 7607054
4 FRAME, RR................................................. -------- -------- 1 50200-KSC-000 7657927
5 RUBBER, BATTERY .................................. -------- -------- 4 50283-KSC-300 7659402
6 RUBBER, SEAT RAIL ................................ -------- -------- 2 50283-MR7-300 3449915
7 GUARD, L. ENGINE.................................... -------- -------- 1 50360-KRN-000 7607070
8 GUARD, R. ENGINE .................................. -------- -------- 1 50370-KSC-000 7657935
9 CUSHION C, BATTERY.............................. -------- -------- 2 50386-130-690 7657943
10 BRACKET, R. HEAD HANGER .................. -------- -------- 1 50407-KSC-000 7657950
11 BRACKET, L. HEAD HANGER .................. -------- -------- 1 50408-KSC-000 7657968
KSC4F2800
12 COLLAR (6X4) ............................................ -------- -------- 2 52156-353-300 0447920
13 BOLT, FLANGE (10X117) .......................... -------- -------- 1 90101-KSC-000 7658222
14 BOLT, FLANGE (8X125) ............................ -------- -------- 1 90105-KRN-000 7607377
15 BOLT, FLANGE (5X12) .............................. -------- -------- 1 90106-KRN-000 7607385
16 BOLT, FLANGE (8X55) .............................. -------- -------- 2 90107-KRN-000 7607393
17 BOLT, FLANGE (10X58) ............................ -------- -------- 1 90109-KSC-000 7658230
18 BOLT, FLANGE (10X138) .......................... -------- -------- 1 90116-KW3-000 2909182
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-47
FRAME
4 =CRF250X’04 F-28
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
19 BOLT, FLANGE (10X26) ............................ -------- -------- 2 90122-KRN-000 7607419
20 NUT, U FLANGE (10MM)............................ -------- -------- 3 90302-KZ3-J40 6912612
21 WASHER (10MM)........................................ -------- -------- 2 90410-HC4-000 2728707
22 WASHER, HEAD HANGER PLATE ............ -------- -------- 1 90511-KRN-000 7607484
23 BAND, WIRE .............................................. -------- -------- 1 90651-KV6-003 2576296
24 BAND, WIRE .............................................. -------- -------- 4 90652-KT1-771 2710416
25 BOLT-WASHER (6X14) .............................. -------- -------- 2 93404-06014-00 6369680
26 NUT, FLANGE (8MM).................................. -------- -------- 2 94050-08000 0481143
27 BOLT, FLANGE (6X16) .............................. -------- -------- A 1 96001-06016-00 2105955
KSC4F2800
2-48 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F8
TOOLS
4 =CRF250X’04 F-29
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 SPANNER, PIN (A)...................................... -------- -------- (2) 89201-KS6-810 2159424
2 WRENCH, NIPPLE...................................... -------- -------- 1 89212-KZ4-J40 6826572
3 WRENCH, PLUG (16MM) .......................... -------- -------- 1 89216-MEB-670 6852222
4 TOOL, CARBURETOR MAINTENANCE .... -------- -------- 1 89217-KRN-000 7607328
5 GAUGE, AIR PRESSURE .......................... -------- -------- (1) 89301-KA4-811 1040914
KRN4F2400
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-49
CAUTION LABEL
4 =CRF250X’04 F-30
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
2 DIAGRAM, VACUUM HOSE ROUTING...... -------- -------- AC 1 87135-KSC-770 7660236
3 LABEL, DRIVE CHAIN ................................ -------- -------- 1 87507-KZ3-B10 5246087
4 MARK, CAUTION ........................................ -------- -------- 1 87560-KSC-000 7658214
5 LABEL, TRANSMISSION DRAIN................ -------- -------- 1 87564-KRN-000 7607310
KSC4F3000
2-50 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F9
MARKS
4 =CRF250X’04 F-31
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 MARK, R. RADIATOR SHROUD (TYPE1).. -------- -------- 1 87126-KSC-000ZA 7660145
2 MARK, L. RADIATOR SHROUD (TYPE1) .. -------- -------- 1 87127-KSC-000ZA 7660152
3 MARK (TYPE1) (HONDA) .......................... -------- -------- 2 87130-GEL-A00ZA 7566433
KSC4F3100
FEBRUARY, 2004 2004 American Honda Motor Co., Inc. 2-51
COOLING FAN
4 =CRF250X’04 FOP-1
Frame
Serial Number
Ref Description From To AREA QTY Part Number H/C
1 FAN SET, COOLING .................................. -------- -------- 1 19000-KSC-000 7656861
2 FAN, COOLING .......................................... -------- -------- 1 19009-KSC-000 7656879
3 NUT, SET .................................................... -------- -------- 3 19014-KEA-003 5213525
4 SHROUD, FAN............................................ -------- -------- 1 19020-KSC-300 7656903
5 MOTOR, COOLING FAN ............................ -------- -------- 1 19030-KSC-670 7656911
6 SWITCH ASSY., THERMOSTAT ................ -------- -------- 1 37760-MT2-003 3042678
7 NUT, TOOTHED (3MM) .............................. -------- -------- 1 90308-KM3-003 2455426
8 O-RING (13.5X1.4)...................................... -------- -------- 1 91307-PH7-660 2514651
O-RING (12.5X1.4)...................................... -------- -------- 1 91307-611-000 0347906
9 BOLT-WASHER (6X12) .............................. -------- -------- 3 93401-06012-08 2646610
10 SCREW-WASHER (4X8) ............................ -------- -------- 3 93891-04008-07 0747964
KSC4Y0100
11 CLIP (2X40) ................................................ -------- -------- 1 94591-24000 0450106
2-52 2004 American Honda Motor Co., Inc. FEBRUARY, 2004 1-F10
Part Number
Index
FEBRUARY, 2004 3-12004 American Honda Motor Co., Inc.
PART NUMBER INDEX
Part Number Grid Page Part Number Grid Page Part Number Grid Page
(0)
06420-KSC-000 2-20. . . . . . . . . . . . . 1-E10
06421-KSC-000 2-20. . . . . . . . . . . . . 1-E10
06431-MA3-405 2-14. . . . . . . . . . . . . 1-E7
06435-KZ4-J41 2-17. . . . . . . . . . . . . . 1-E8
06440-KZ4-J40 2-15. . . . . . . . . . . . . . 1-E7
06451-MZ2-405 2-17. . . . . . . . . . . . . 1-E8
08400-33100 2-15. . . . . . . . . . . . . . . 1-E7
08400-34010 2-15. . . . . . . . . . . . . . . 1-E7
0Y400-33100 2-15. . . . . . . . . . . . . . . 1-E7
(1)
11100-KSC-670 1-23. . . . . . . . . . . . . 1-C11
11102-KRN-670 1-12. . . . . . . . . . . . . 1-C6
11105-KSC-670 1-23. . . . . . . . . . . . . 1-C11
11107-KSC-670 1-23. . . . . . . . . . . . . 1-C11
11108-KSC-670 1-23. . . . . . . . . . . . . 1-C11
11191-KRN-670 1-23. . . . . . . . . . . . . 1-C11
11200-KSC-670 1-23. . . . . . . . . . . . . 1-C11
11206-KRN-670 1-23. . . . . . . . . . . . . 1-C11
11331-KSC-670 1-13. . . . . . . . . . . . . 1-C6
11333-KRN-670 1-18. . . . . . . . . . . . . 1-C9
11340-KRN-670 1-18. . . . . . . . . . . . . 1-C9
11351-KSC-670 1-13. . . . . . . . . . . . . 1-C6
11352-KRN-671 1-13. . . . . . . . . . . . . 1-C6
11394-KRN-670 1-13. . . . . . . . . . . . . 1-C6
11395-KRN-670 1-18. . . . . . . . . . . . . 1-C9
12010-KRN-671 1-3. . . . . . . . . . . . . 1-C1
12010-KSC-770 1-3. . . . . . . . . . . . . 1-C1
12100-KRN-670 1-12. . . . . . . . . . . . . 1-C6
12191-KRN-671 1-12. . . . . . . . . . . . . 1-C6
12204-KRN-P00 1-3. . . . . . . . . . . . . 1-C1
12205-KRN-P00 1-3. . . . . . . . . . . . . 1-C1
12206-881-310 2-45. . . . . . . . . . . . . . 1-F6
12209-GB4-681 1-5. . . . . . . . . . . . . 1-C2
12226-MEB-670 1-2. . . . . . . . . . . . . 1-C1
12251-KRN-671 1-3. . . . . . . . . . . . . 1-C1
12310-KRN-670 1-2. . . . . . . . . . . . . 1-C1
12316-KRN-670 1-2. . . . . . . . . . . . . 1-C1
12391-KRN-670 1-2. . . . . . . . . . . . . 1-C1
13000-KSC-670 1-26. . . . . . . . . . . . . 1-C13
13011-KRN-670 1-26. . . . . . . . . . . . . 1-C13
13101-KRN-670 1-26. . . . . . . . . . . . . 1-C13
13111-KRN-670 1-26. . . . . . . . . . . . . 1-C13
13115-147-000 1-14. . . . . . . . . . . . . . 1-C7
13115-KM7-700 1-26. . . . . . . . . . . . . 1-C13
13331-360-000 1-26. . . . . . . . . . . . . . 1-C13
13415-KRN-670 1-22. . . . . . . . . . . . . 1-C11
13420-KSC-670 1-27. . . . . . . . . . . . . 1-C13
13422-KRN-670 1-27. . . . . . . . . . . . . 1-C13
14100-KSC-670 1-5. . . . . . . . . . . . . 1-C2
14100-KSC-770 1-5. . . . . . . . . . . . . 1-C2
14102-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14105-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14106-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14401-KRN-671 1-11. . . . . . . . . . . . . 1-C5
14440-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14451-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14510-KRN-670 1-11. . . . . . . . . . . . . 1-C5
14515-KF0-000 1-11. . . . . . . . . . . . . . 1-C5
14520-KRN-670 1-11. . . . . . . . . . . . . 1-C5
14560-MEN-671 1-11. . . . . . . . . . . . . 1-C5
14620-KRN-670 1-11. . . . . . . . . . . . . 1-C5
14711-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14721-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14731-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14751-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14761-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14771-KRN-670 1-5. . . . . . . . . . . . . 1-C2
1-131-C6
14775-KRN-670 1-5. . . . . . . . . . . . . 1-C2
14781-MAT-000 1-5. . . . . . . . . . . . . 1-C2
14901-KT7-013 1-5. . . . . . . . . . . . . . 1-C2
1-71-C3
14902-KT7-013 1-5. . . . . . . . . . . . . . 1-C2
1-71-C3
14903-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-71-C3
14904-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14905-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14906-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14907-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14908-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14909-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14910-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14911-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14912-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14913-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14914-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14915-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14916-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14917-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14918-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
1-81-C4
14919-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
14920-KT7-013 1-6. . . . . . . . . . . . . . 1-C3
14921-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14922-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14923-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14924-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14925-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14926-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14927-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14928-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14929-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14930-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14931-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14932-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14933-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14934-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14935-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14936-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14937-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14938-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14939-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14940-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14941-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14942-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14943-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14944-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14945-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14946-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
14947-KT7-013 1-7. . . . . . . . . . . . . . 1-C3
1-81-C414919-KT7-013 . . . . . . . . . . . . . .
1-81-C4
1-81-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
1-91-C4
FEBRUARY, 20043-2 2004 American Honda Motor Co., Inc.
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