it Importers eisure T rail eee) Trail Bikes a . Honda CRM Parts Specialists Oakleys Yard, Beech Ave, Long Eaton, Nottingham, NG10 2AX. Tel or Fax 0115 973 2466 HONDA CRM250 Mk1, 2&3 Service & Workshop Manualeisure Trail G Independant Importers of Japanese Trail Bikes and Honda CRM Parts Specialists Le Oakleys Yard, Beech Ave, Long Eaton, Nottingham, NG10 2AX. Tel or Fax 0115 973 2466 Honda CRM 250 Mk1,2 & 3 General Specification CRM250 Mk1 | CRM250 Mk2_| CRM250 Mk3 [66.00 x7: 66.00 x 72.00mm 66.00 x 72.00mm. 246ce 246ce 246cc 2 : 6.4 67 | ax F “[37PS/8,500rpm ‘40PS/8,000rpm ‘40PS/8,000rpm | Max torque | 3.4kg-m/6,500rpm | 3.7kg-m/6,500rpm ‘4.0kg-m/6,500rpm Gearbox OilGrade | SAE 10W-30 ‘SAE 10W-30 SAE 10W-30 Gearbox Oil Qty {600 - 650cc 600 — 650cc 600 ~ 650cc [Coolant aty 93 litres 4.25 litres 4.25 litres Thermostat Closes 65 degC 62 degC 62 degC. [Thermostat Opens 80 deg C 72deg C 72degC | ‘Spark Plug (Std) NGK BR8ES NGK BR8ES —_NGK BR8ES ‘Spark Plug (Racing) | _NGK B8EG or EGV__| _NGK B8EG or EGV__| NGK B8EG or EGV Spark Plug Gap ).7 = 0.8mm 0.8mm 0.7 = 0.8mm [Ignition Tis Ode BTDC/1,300rpm | 12deg BTDC/1,300rpm | 10deg BTDC/1,300rpm_ Bore Wear Limit 66.15mm 66.15mm_ 66.15mm_ Fuel System Fuel Tank Capacity 10 litres 10 litres 11 litres Fuel Tank Reserve 2.2 litres 2.2 litres 2.5 litres Carburettor PE31A 32mm PE31C_ 32mm PES1E 32mm Air Screw Setting 2-1/4 turns out _ 1-1/4 turns out 1-1/4 turns out Float Ht 16.00mm 16.00mm_ 46.00mm_ Tick-over Speed 4,300rpm 1,300rpm 4,300rpm- Needle Clip Position 3 (middle) 3 (middle) — 3 (middle) Main Jet Size _ 132 128 150 Pilot Jet Size 45 48 45 Chassis Spec Gross Wt 423Kg 127K 127Kg Wheelbase 2400mm 2300mm 2300mm Rake 26.6 deg 27.5 deg 27.6 deg Trail 104mm 113mm. 113mm Front Rim/Tyre Size | _1.60/3.00-21 (90/8021) | 1.60/3.00-21 (90/90-21) | 1.60/3.00-21 (90/90-21) Rear Rim/Tyre Size 2.15/4.60-18 (120/90-18) | 2.18/4.60-18 (120/90-18) | 2.16/4.60-18 (120/90-18) Tyre Pressure (road) 25-28 psi I 25-28 psi | Tyre Pressure (Offroad) 12-46 psi 12-16 psi Drive Chain RKIDID 108 links RKIDID 110 links ‘Std Sprockets 14/42 14142 Front Fork Oil 75 — 10wt 5—7.5wt Front Fork Oil (per leg) 535cc 653cc [Front Fork Oil Level 432mm 108mm. FiFork Comp Adjust 2.5 Turns Ckwise = Hd | 2.5 Turns Ckwise = Hd R’Shock Comp Adjust Clockwise = Hard Clockwise = Hard Ifyou are unclear about any of the information above please give us a call.Service Intervals/Tasks (Off-road use) 250 Kms 1,000 Kms. ‘Two-stroke oil top-up. Tyre pressures. Drive chain adjustmentilube. Brake pad condition. ‘Change gearbox oil. ‘Change spark plug. ‘Check coolant level. Clean air fitter. Check oil pump adjustment. Check wheel bearings/spokes. Check brake fluid levels. Inspect tyres for wear/damage. Gearbox Oil Change 1. Stand bike as vertical possible, Place suitable container under engine, remove drain plug and allow to drain for 10-15 minutes. Refit drain plug. Remove oil level plug and using a Quality Gearbox oll of SAE 10W-30 grade, fill gearbox until oil drips from level hole, usually between 600- 650cc, refit level plug. Note hold bike vertical whilst waiting for oll to emerge from level hole. Checking Coolant Level 3. Remove right radiator panel and visually check coolant level in ‘expansion/header tank if below lower level top up with coolant of minimum 30% anti-freeze strength. Normally it is not necessary to remove radiator cap unless system is or needs draining. Note Never remove radiator cap unless engine is cold. To release rad. cap first remove small securing screw. 19 Coolant System Although not a service requirement if the system needs draining first remove coolant drain plug on water pump then remove rad, cap and coolant will gush out ! To refill refit drain plug, fill radiator to bottom of filler neck, refit rad. cap and check header tank level, ride bike and recheck. \ it Drain Plug Coolant rain PlugAir Filter Maintenance 1. Remove left side panel to gain access to Air filter box, then pull out restrictor plate (Mk1/2 only) if fitted. 2. Un-hook securing clip and pull out filter and remove foam filter from cage. Wash filter in water-soluble de-greaser i.e. Jizer and allow to dry. Soak filter in Air filter oil and squeeze out excess. Fit filter on to cage and refit in air box ensuring filter is correctly located, secure holding clip and replace plate and sidepanel, il Pump Adjustment 3. Toensure correct setting of Oil pump, remove cover to expose Oil pump, hold throttle fully open, check mark on pulley aligns with pointer on pump, also inspect cable for fraying etc. 4, If mark does not line up, loosen locknut and turn cable adjuster until pulley mark lines up with pointer, Tighten locknut, operate throttle couple of times and re-check if ok refit cover. Bleeding Oi! Pump 5. Ifthe feed pipe from oil tank has been disconnected or oil tank drained, the oll Pump needs to be bled to remove any air in the system, after filling oil tank remove bleed screw shown and allow oll to drip out until bubbles stop and oil flows constantly, replace bleed screw. Fitter & Support diferent shape on MK3/AR nw on Pay ‘Aged wt PolePower valve Adjustment 2 Operating Cable \ cai te Power Valve Adjustment xaust Power Vatve 1. This illustration is a general view of Servo Motor, Operating Cables and Exhaust Valve layout. To check correct setting of exhaust Power valve, first remove small cover on left side of barrel secured by two 8mm headed bolts. ‘The Power Vaive operating rocker arm is now exposed, to check setting start engine and allow to warm ap until it will tick-over at normal speed (1300 rpm). Now inspect the Alignment marks and they should line up as shown above. Hf marks don't align slacken off locknut and turn cable adjuster in or out until correct adjustment is achived. Tighten locknut and rev engine then allow to idle and re-check. If ok replace cover and secure (no gasket is fitted). Chassis General Service Tasks Drive Chain Adjustment ‘To check correct tension it is best to sit astride bike and then fee! amount of play in chain (check mid-way between sprockets), in this position up/down play should be about 15 ~ 20mm. This converts to about 50mm if bike is mounted on stand with rear wheel of the ground, it should go without saying the chain should be regularly sprayed with chain lube, Brake Pad Wear & Fluid Level Inspect front and rear brake pad after every off-road jaunt as they can wear extremely fast in muddy abrasive conditions. If friction material is worn to below 2mm it's best to replace the pads as they may wear down to metal backing plate during next ride which will badly damage disc. Check fluid level regularly as it get low as pads wear. Normal compound brake pads are generally best as they don't wear brake disc’s, but if you are suffering excessive pad wear sintered (copper coloured ) pads will last longer, at expense of brake feel and long term disc wear. ‘Wheel bearings CRW'’s are quiet hard on wheel bearings so check play in both wheels regularly, always use quality sealed bearings and replacing the outer seals will increase bearing life.CRM250 Workshop Manual SA General Engine Details D We SOY 25) Mk2,3 & AR 05CRM250 Workshop ManualCRM250 Workshop Manual 1.8kg-m @)CRM250 Workshop Manual Clutch Actuator Detail (2?) Punch Gluch Centre Nut '25 shown to lock (MKSIAR) (25) 8.0kg-m MGIAR Extra Chitch Plates (31) 5.5kg-mCRM250 Workshop Manual Kickstart Mech. DetailsCRM250 Workshop ManualCRM250 Workshop Manual (il all Gearbox Component prior fo ascombiy w Gearbox Output Shaft Assembh ‘prior o assemblyCRM250 Workshop Manual Rotor Holding Too! | Timing Maris | | Ignition Timing Use a strobe to check that ‘F’ mark on Generator Rotor aligns with pointer on gasket face at 1200 rpm. If it is out of line you're in trouble as there is no means of For information the ‘T’ mark, when aligned, sets piston at TDC.CRM250 Workshop Manual Carburettor Assembly Mk1/2/3 Throttle ‘Spring Vent Pipe o—n @.. Emulsion Tube tale Adjstor |< ood Float 7 one e— ASOLO. Float Assembly Float Bow \ CRM Carb is prone to blocking especially the Pilot Jet, if you have trouble with erratic running give carb good clean and blow out with air line, often a new Pilot Jet is the only cure.1 Front Fork AssembI Fork Top & mo EN oe oe ot a\ sone Fork Tate Chepe Tao BP Poco wr see Daing Adtr & ate Scan Bot Rey Setting Oil ‘See Spee shoot forollteve SetingSuspension Rocker ‘Arm Exploded View Below rea Details Mk 2,3 & AR Suspension Arma 340 Fork Clamp Bot Torques @ Ter vonetote 24m © diton etenate 279CRM250, Workshop Manual Front Brake Caliper Assembly Note If your bikes brakes clean up caliper pistons and replace seals, ensuring there grooves are clean. Rear Brake Caliper Assembh: alia‘sieeq e6ueyo Buin CX ors eae eUeH HN WesbeId BULIM } TRON OSZNED i [==c—— HSERemember Leisure Trail UK Offer full spares back-up for all CRM250 Models Call Pete, Nick or Kev on 0115 973 2466