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Important safety instructions included. Read through carefully before you ride. Owner's Manual Thank you for purchasing a Honda Motorcycle. For your safety and comfort, please familiarise yourself with this manual before riding. At time of purchase Motorcycle rider’s licence * Please obtain this owners manual. This motorcycle has a total displacement Ask your dealer about the following: of 249em3(cc). You must hold a * Tips on handling and riding. corresponding motorcycle rider's license in * Contents/period of the warranty. order to ride on public roads. * Service requirements a ° Filling out the purchase receipt and the The vehicle is designed to carry a warranty card. maximum of two people, including the » Signing the Warranty registration form "der. Note that you cannot carry a — to verify that all the features of the passenger for the first 12 months after machine have been explained to you. Obtaining your motorcycle license. ‘Safety Warnings About this manual * This manual contains the information for the correct handling, safe riding and basic maintenance. Please read through “Safety Warning”, “Safe riding” and “Maintenance safety tips” as they are particularly important. * Even if you are familiar with motorcycles already, please read this manual as this model has some special features. Please also read the maintenance note. * When re-selling the vehicle please hand the manual and the maintenance record to the next owner. * Honda Motor Co., reserves the right to alter specifications and make other changes at any time without notice or obligation. Safety warnings * Safety warnings The following safety warnings are used in this manual to alert you to the potential for danger to the rider, the passenger and the others. Always read the warnings thoroughly. Warning: High potential of causing death or severe injury. Caution: Potential of causing death or severe injury. Note: Potential of minor injury. * Other symbols: MS Advice: To keep your motorcycle in peak condition. = Tips: To ensure best performance and pleasant riding. Contents INSTRUMENTS AND INDICATORS........... INStruments.............eor cie Speedometer... He Odometer.….…........…...........rsrernannencace Trip meter..…...…...........……errerseseeer ae sun Indicators / Warning Lamps................ Speed warning....................... e... Oil pressure warning... Coolant temperature warning................ Turn signal indicator.............—..e——e——————.. High beam pilot lamp........................ Neutral indicator...............——— e... SWIICHES........2222 0200 a 00e ne ane a aan ane na em 000 Ignition SWitCh............—.— ==... Head lamp dimmer switch..................... Engine stop switch.............................. Horn Switckh................e......ceeeeeeneeen Turn signal switch... Features / Accessories....................... 21 Handilebar IOCK.,................--.m.eeeresexe... 21 ST 22 Helmet holder.................—...._.——._._meee.s 23 Document bag...................ee.e.reccevevees 24 Tool kit holder................————.—ee.—..—.e.... 24 Fuel Supply. .................—....._..e==recives 25 U eee 26 Basic Operation..................e.—.—.weeese.. 27 Starting the engine.................—————..... 27 Changing gear..........................eeevem... 30 Riding tips................ew==rw=ecreremevcererrers 31 Braking..............———...eresvesrorcirenncene 33 Suspension — Rear.................re=e.e.e— 35 Suspension — Front.................. == 36 Contents MAINTENANCE SAFETY TIPS................. 37 Maintenance....................—.......iie 40 Daily inspection................e.......r...... 40 Regular Service...............—.—....eevevcccoree 45 Maintenance Schedule........................... 46 Basic maintenance.....................—._—_._.... 49 Engine oil.........................eemireecene.. 50 Transmission oil... eee 51 Adding Oil............ee=erdsveruaszoneon. 51 Coolant... a, 54 Coolant level....................... een. 54 Adding coolant.................eeeeeee.. 55 Drive Chain.................. eine. 56 Chain tension... 56 Lubrication / Cleaning....................... 57 BrakesS..........eceerseoseorecrercaocooooaceo 58 Front brake... eee 58 Brake fluid level............................... 57 Brake pads Wear...................e.emmevee 60 Rear brake... in, 59 Brake fluid level............................... 60 Brake pads wear...............e...—.—....eme... 62 Clutch... ee, 61 Fuses and relays..................e..——..... 64 Inspection / replacement. .................... 64 TYP. eee an race nee nr are ne ee 66 Pressure......….….....….…rrrscca ner era 66 Tread.............. care een a encens 66 Replacement tyres..….…..…....…….……….…………….….…. 67 Air Filter... i, 68 Air filter element replacement............... 68 (EN 69 Damper Unteren 71 For our environment... 71 Colour labels... 72 Genuine Honda muffiers........................ 73 Vehicle Identification Number.................... 74 Overheat...................—.—.....ieemierrereorareeeo. 75 Engine does notstart.................. e... 76 Specifications... e 77 Service Data and Noise Warning............... 80 For Your Own Safety The topics described here are the basic instructions for handling the vehicle. Please follow the instructions from your owners manual. Before Riding Please conduct the daily inspection. Keep the vehicle clean at all times and inspect the specified items. Please conduct the regular service. For Your Own Safety * Stop the engine before refueling and * Exhaust gas is toxic. Operate the keep well clear of naked flames. engine in a well-ventilated place. For Your Own Safety Protective apparel Riding apparel should be bright or reflective. Both rider and passenger are required by law to wear a helmet. Secure the chin- strap properly. Helmets approved to AS1698 are the only legal helmets in Australia. Wear protective clothing and gear such as: * Face shield or goggles. * Motorcycle boots or any footwear that covers the ankles. * Leather gloves. * Long pants and a long sleeved jacket. Allow freedom of movement. Avoid flared pants and loose sleeved jackets, which could get caught with the brake and gear shift pedals. À caution Wearing the helmet incorrectly increases the risk of serious injury or death in an accident. Both rider and passenger must wear helmets, protective gear and protective clothing. For Your Own Safety Riding Tips * Keep both hands on the handlebars and * Do not jerk the handlebars or attempt to both feet on the footpegs at all times ride with only one hand. This safety rule whilst in motion. applies to any two-wheeled vehicle. * The pillion passenger should place both feet on the rear footpegs and use both hands to stay in position. It is the rider's responsibility to check that the passenger is positioned correctly. For Your Own Safety Luggage Modification < Controllability and stability of the vehicle Any modification which affects the function changes by loading luggage. Be careful and the structure of the vehicle may affect in terms of loading and securing the the controllability and exhaust noise, which luggage. may affect the durability of the motorcycle. * Do not place any items around the steering handle. It may obstruct the Any illegal modification may cause steering. inconvenience to the surroundings. Any e Do not place any items in front of the damage caused by these modifications is headlamp. It may melt the lens or totally out of our warranty. damage the item itself. | For Your Own Safety Parking Park on stable and flat ground. Do not obstruct the traffic flow when parking your vehicle. Park the vehicle so as to keep the hot muffler away from other people. While running the engine or immediately after shutdown, do not touch the engine or muffler. Do not touch the muffler or the engine while the engine is running or immediately after shutdown. Park the motorcycle so that the engine and the muffler can be kept away from other people. 9 Parking with the sidestand * Park on flat and stable ground with the handlebars turned fully to the left. The vehicle may have difficulty staying upright in the following circumstances: * The handlebars turned to the right. * Parked on sloped, soft, sandy or bumpy ground. If there is no other choice, take maximum precautions to keep the vehicle stable. Parts Engine oil reservoir Front brake lever Kick start lever A ) . € gh) Turn signal positio! > R Y relay fuse Transmission oil filler cap Pillion footpeg Rear brake pedal 10 Parts Fuel cock Tool box Clutch level Helmet holder Pillion footpeg Gear shift pedal Radiator reservoir Side Stand 11 Document holder Instruments and Indicators Instruments and Indicators Speed range a Instruments | \ — Speedometer Indicates the travelling speed. Ride safely and observe the legal speed limit. Odometer Shows accumulated distance traveled in kilometres. The black number on white background shows 100m increments. Tripmeter Shows distance traveled per trip. Reset to zero by rotating the reset knob in the direction of the arrow as shown. 12 Indicators / Warning Lamps Indicators / Warning lamps Speed warning lam tional | lluminates when the speedometer indicates |-* IID approx 85km/h. In normal operation, the oil pressure arning lamp turns on when the main switch Oil pressure warning lamp s turned ON, and it turns OFF when the Lights when the oil pressure drops while the [correct oil pressure is reached. engine is running. Should the warning lamp light while the engine is running, stop immediately and check the oil level Low oil warning If there is sufficient oil or if the lamp stays on after refilling the oil, contact an authorized Honda dealer as soon as possible. SE, advice Riding with the oil pressure warning lamp “ON” could result in damaging the engine. O~—_overspeed warning Such damage will not be covered by Warranty. 13 Indicators / Warning Lamps Coolant temperature warning lamp Lights when the coolant temperature rises beyond a certain limit while the engine stop = Tip switch is in the (run) position and the Prolonged idling during hot weather can ignition switch is “ON”. ВО cause the warning lamp to light. In this If the lamp lights when the engine is case, you have to cool the engine either running, stop the engine immediately and by taking a gentle ride or by turning the check the coolant level (p.54). engine off. | SG Advice LL Continuing riding with the lamp “ON” : Water temp. warning (overheating) may result in damaging the engine. Such damage will not be covered by Warranty. Normally the lamp lights when the engine top switch is in the (run) position and the ignition switch is turned ON and it turns OFF after a few seconds. lt lights for a ew seconds when the engine is stalled, hich is not a fault. 14 Indicators / Warning Lamps Turn Signal Indicator High beam pilot lamp Side stand indicator Flashes when the turn signal is ON. High Beam Pilot Lamp Lights if the high beam is selected. Turn signal indicator Neutral Indicator Neutral indicator Lights if the engine is in neutral gear and the main switch key is at ON position. 15 Switches Ignition Switch The ignition switch operates the electrical circuits. Do not touch the switch whilst riding. Turning the ignition switch to “OFF” or “LOCK” will prevent the engine from starting. * The headlamp turns “ON” when the engine is started. * Lock the handlebars and pull the key out whenever you leave the vehicle. 16 Key Remove position Function Key ON Start, day/night ops Unable (With » Headlamp “ON” Engine * Able to use turn Running) signals, horns, and stops lamps. OFF Stop Yes * All electrical systems disabled LOCK Handlebar lock engaged YES * All electrical systems disabled Switches Headlamp Dimmer Switch Push the corresponding side of the switch. (Hi) High beam (Lo) Low beam Select LO (low beam) during the day. 17 Head lamp Hi/Lo selector Switches Engine Stop Switch The engine stop switch allows you to stop the engine immediately in an emergency situation. The engine stop switch should be left in RUN position during normal riding and used only in case of emergency. Switching between RUN and OFF whilst riding leads to unstable engine running and riding instability. It may also damage the engine. NG: Advice If using this switch in an emergency topped engine, turn the ignition switch OFF to avoid battery becoming flat. 18 Engine stop switch Switches Horn Switch The horn sounds by pushing the horn switch when the ignition switch is ON. 19 Switches Turn_Signal Switch The turn signal switch is used to operate the turn signal lamps when turning left or right or changing lanes. The engine must be running. Push the switch to the turning direction. Push in to cancel. * The turn signal does not cancel automatically. Always cancel the switch after turning to avoid confusing other drivers. * Use correct wattage bulbs. Incorrect wattage bulbs may affect the rate at which the Indicators flash. 20 Turn signal switch Switches Handlebar Lock To prevent theft, always apply the handlebar lock when parking. Use of a chain lock or similar device is also recommended. To engage the lock 1. Turn fully to the left or right. 2. Insert the key to the ignition switch. 3. Push the key in and turn it to “Lock” position, 4. Remove the key. To disengage the lock Follow the above procedure in reverse order. in, Park in a safe place away from traffic. Jiggle the handlebar to check the lock is engaged. Ignition switch key 21 Switches 1. 2. installation 1. Set the projection of the seat to the tank guide to attach the seat. Push the rear end of the seat down to locate the mounting holes on either side. insert and tighten the 2 x 12mm bolts. Pull up on front of seat to ensure it is secure. Refit side covers — insert front locating lug into frame bracket and lock rear mounting screw. Removal Remove both side covers Remove 2 x 12mm screws from seat mountings. иное но ОВ = 22 Helmet Holder Helmet Holder Helmet holder pin Helmet holder The helmet holder may only be used when the motorcycle is parked. Using the holder will interfere with the operation and may damage the motorcycle. Also it will damage the helmet, reducing its protection. To use the helmet holder 1. Remove the seat 2. Pass the helmet holder wire through the ring on the helmet strap and hook to the helmet holder. Keep the helmet holder wire in storage when the holder is not in use. 23 Document Holder Document Holder The document holder is located under the left hand side cover. Keep the owners manual and the service manual in a plastic bag and store in the holder. * Refer to pg22 to remove the left hand side cover. When washing the motorcycle, do not apply water from underneath to prevent water going inside the seat. Tool Kit Holder The tool kit holder is located under the rear fender. Use the ignition key open/close the tool kit holder. 24 _ Leftsidecover Fuel Supply The CRM250AR uses only unleaded petrol. Always stop the engine before refueling and keep well clear of naked flames, sparks or 1 heat sources. Refueling . Lift up the key cover. Insert the ignition key and turn to the right to open the fuel fill cap. À caution Petrol is highiy flammable. Improper handling will result in severe injury. When handling the petrol: * Always stop the engine and keep away from flames, sparks or heat sources. e Refuel outside. * Wipe off spilled petrol straight away. Ignition key Level plate Fuel tank cap Key cover 25 Fuel Supply 2. Do not fill higher than the bottom of the filler neck (see diagram) or petrol may seep out through the breather hole on the fuel tank cap. . Close the cap firmly and remove the key. The key cannot be removed unless the cap is properly locked. жен bil Ab ——]o—]o]]Ú——e—;—] — Hd A A E — E же — — — тнт mme 00e ню Що Fuel Cock The fuel cock lever has three positions: “ON” fuel supplied to carburettor when the engine starts. “OFF” select when the motorcycle is not in use for a long period or being serviced. - “RES” reserve fuel tank (holds approx 2 26 litres of fuel) is selected. Turn to RES when you run out of fuel in ON position whilst riding. Refuel as soon as possible and turn back to ON to ~ prevent complete fuel starvation. ON OFF RES Basic Operation Starting the Engine Engine exhaust fumes contain carbon monoxide and other harmful substances. Always start the engine in well ventilated area. MS Advice * Do not rev the engine unless required to do so. Abrupt throttle movement wastes fuel and may damage the engine. 27 Mr, This model is equipped with an automatic ignition cut off circuit that stops the engine automatically if the gearshift is set while the side stand is still down. Always retract the side stand before selecting a gear. Basic Operation Starting Procedure * When the engine is cold: 1. Check the engine stop switch is in RUN position. 2. Check the fuel cock lever is in ON position. 3. Turn the ignition ON. 4. Shift the gear change pedal to neutral position and check that the neutral indicator is ON. 5. Pull the choke lever all the way back. 6. Close the throttle and operate the kick start lever rapidly. 7. When the engine starts, gradually push the choke lever forward and warm up the engine until the rpm stabilizes, then push the choke lever all the way forward. 8. Check the side stand is retracted before riding. » Refer to p75 if the engine fails to start. 28 Basic Operation Starting Procedure 1. When the engine is hot: Check the engine stop switch is in the “RUN” position. . Check the fuel cock lever is in the “ON” position. . Turn the ignition switch “ON”, . Shift the gear change pedal into neutral position and check the neutral indicator is “ON”. . Close the throttle and operate the kick start lever rapidly. If the engine fails to start after one or two trials, follow procedure 6. . If the engine does not start with the throttle closed, open the throttle to 7 ~ 3 as shown in the diagram operate the kick start lever rapidly. . Check the side stand is retracted before selecting a gear. Refer to p 75 if the engine fails to start Changing Gears Changing Gear The CRM250AR has a six speed return gear change: * Release the throttle and fully squeeze the clutch lever before selecting / changing gear. * Operate the gear shift pedal gently but firmly using your toe (excessive force may damage the gear change system). You should be able to feel the gear changer click solidly into place. 30 Riding Tips Riding Tips * Check the side stand is retracted before riding — selecting a gear. * Use the gears within the speed ranges given in the table. * To save fuel and prolong the life of the motorcycle, avoid rapid acceleration or deceleration. AG Advice If you notice any unusual sound or other roblems, contact an authorized HONDA ealer as soon as possible. fin * Accelerate as gently as possible. * Always observe the speed limit. Running in Keep the engine in relatively lower rpm and avoid rapid acceleration and deceleration for the first 500km. This will prolong the life 31 of the engine. Riding Tips Changing down the gears Changing down gears provides greater acceleration in situation such as overtaking. Avoid changing down at high speed, which can damage both the engine and the transmission by running the engine at excessively high rpm. The table shows the maximum speed for each shift down. A Notes. Damage caused by incorrect Gear changing will not be covered by warranty. Maximum Speed 6" - 5" 140 km/h & below 5" 4" 120 km/h & below 4" _ 3° 80 km/h& below 3 _ pon 60 km/h& below ons _ 45 40 km/h& below 32 Braking Braking For optimum braking performance, apply front and rear brakes simultaneously. Brake as gently as possible to avoid locking the tyres which makes the motorcycle unstable / uncontrollable. In wet weather and surface, the tyres become more likely to lock and slide, therefore the stopping distance increases. Reduce the riding speed and allow longer braking distance under such circumstances. Avoid continuous braking to prevent overheating the brake system which causes brake fade and reduces the braking performance. 33 Braking performance may be affected by ~ puddles and wet weather. Always test the brakes gently after riding through such a condition (keep clear of the other traffic and slow down first). If necessary, apply the brakes periodically whilst riding at reduced speed until they dry out. Braking Engine braking Engine braking can be used to reduce speed instead of or in combination with, the brakes by simply retarding the throttle. Shift down gears if necessary. Avoid abrupt shift down or the motorcycle may fishtail. Use a combination of the engine braking and the intermittent braking on long or steep downhill slopes. Rear Suspension Rear Suspension 1. Suspension feel can be altered between Hard and Soft by adjustment of the screw on remote reservoir. 2. By turning the screw clockwise, you will increase compression damping of the rear suspension unit. A Notes. Adjustment of this screw will affect handling characteristics of your motorcycle. Do not adjust if you do not understand the operation of the rear suspension. Punched mark Hard CSS Soft < A Alignment mark Adjuster Front Suspension Front Suspension 1. Compression damping adjustment. 2. This adjustment affects how quickly the fork compresses. 3. Turning the screw clockwise will increase compression damping of the front fork leg unit. - Notes. Adjustment of this screw will affect handling characteristics of your motorcycle. Do not adjust if you do not understand the operation of the front suspension. RA < $ МА Xx Hard Soft< Damping adjust screw Maintenance Safety Tips Maintenance Safety Tips * Stop the engine and remove the key * Park on a flat and stable surface using when servicing. the side stand. Maintenance Safety Tips Wait for the engine, the muffler and the exhaust pipe to cool before starting work. . Engine exhaust fumes contain carbon monoxide and other harmful substances. Do not run the engine in poorly ventilated area such as a closed workshop. Maintenance Safety Tips о If the motorcycle requires test riding, * Always use proper tools. conduct in a safe place, away from other + Any servicing, repair or adjustment traffic. should be carried out by an authorized Honda dealer. 39 To ensure the safety and comfort of riding your motorcycle, it is required to Maintenance inspect some items daily and service the machine regularly. Always comply with the correct servicing procedure. Failure to do so could result in fatal or severe injury. Caution Follow the procedures and guidelines given in this owner's manual and the service manual. Observe all service and maintenance schedules. Fix all problems before you ride. * Inspection and maintenance procedures and requirements are described on the following pages. After the first MOND. 41 Replacement parts. ..............cc..e.—.. 41 Daily (pre-ride) inspection............... 42 Maintenance parts layout................ 43 Regular Service...............—.—._.——.e.... 45 Maintenance Schedule.................... 46 Basic maintenance......................... 49 Engine Oil..............rsssessra ane r a nee 50 Coolant.…..…..…....……..…sceasescanensanu une 54 Drive Chair 56 SC CE 58 Clutch... e 62 FUSES........ee.rrecarronacenvoorenreomecerztA. 04 TYPOS. ieee rare 66 Air filter... e. 68 Maintenance After the first month The first service after one month (or 1000km) is crucial to the life of the engine. Contact an authorized Honda dealer for all service requirements. Your Honda dealer has all the expertise and technical information necessary to correctly service or repair your machine. 41 Replacement parts Use only genuine Honda parts when servicing the motorcycle. Honda parts are designed specifically for Honda vehicles and are subject to rigorous examination procedures. Honda parts are available from authorized Honda dealers and are identified by the Honda logo. Only Honda genuine parts are covered by a manufacturers warranty. (12mths / unlimited kms). Some conditions apply. Maintenance Dail re-ride) Inspection All motorcycle riders are advised to carry out a daily pre-ride inspection to ensure safe and comfortable riding. Details of the daily inspection are given below. Underlined items are described in “Basic Maintenance” (p. 49-). The diagrams on the following pages show the inspection parts. 42 Dail re-ride) Inspection Checklist * Brakes - Lever free play (hydraulic) - Pedal free play (hydraulic) - Braking performance - Brake fluid level - Air pressure - Cracks / damage - Abnormal wear - Tread (x) - Coolant level (x) - Engine oil level (4-stroke only) (x) - Starting noise (x) - Low speed / acceleration (x) * Lamps and turn signals * Any problems detected on the previous day. (x) = Check as appropriate in line with usage time and distance traveled. Tyres * Engine Maintenance Maintenance Parts Layout Maintenance procedures and guidelines are given in “Basic Maintenance” pages of this manual. Front brake reservoir () Front brake lever Rear brake reservoir 2-stroke oil reservoir 43 Rear brake pedal Maintenance Head lamp Hi/Lo selector Turn signal switch 4 Stop tail lamp Front turn i signal lamp Head lamp Rear turn | signal lamp Radiator reservoir Tyres | Maintenance Regular Service The CRM250AR requires the first one month (or 1000km) service and every 6000km thereafter. For optimum safety and comfort, conduct these regular services. It is your responsibility to have your motorcycle serviced by an authorized Honda dealer. ° Contact your Honda dealer to arrange servicing. * If you are checking the motorcycle by yourself, do not carry out work beyond your knowledge and skill, for your own safety. All repair work should be referred to an Authorized Honda Dealer. « These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions will require more frequent service than specified in the MAINTENANCE SCHEDULE. « Consult your authorised Honda dealer for recommendations applicable to your Specifications are given on pages 77, 78 &79. Record the results of every service in the service manual maintenance log and store in a safe place. Maintenance Schedule Maintenance Schedule The following Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating condition. Maintenance work should be performed in accordance with standards and specifications of Honda by properly trained and equipped technicians. Your authorised Honda dealer meets all of these requirements. Perform the Pre-ride Inspection (page 42) at each scheduled maintenance period. 1; INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE FREQUENCY ODOMETER READING [NOTE (1)] x 1,000km | 1 | 6 [12] 18 | 24 | 30 | 36 | *Refer X1,000m | 0.6 | 4 { 8 | 12|16|20j24|"° Service ITEM NOTE MONTH 6 | 12 | 18 | 24 | 30 | 36 | Manual * | FUEL LINE | | | - * | THROTTLE OPERATION | | * * | CARBURETTOR CHOKE i i { * * | AIR CLEANER (NOTE 2) llr [RIT ]1]R - CRANKCASE BREATHER | (NOTE 3) сс | с | с | с | с - SPARK PLUG вв | ув |1 | в - * | VALVE CLEARANCE NA | - | - | - | - 1 - | - МА ENGINE OIL В | 8 | 8 | В | В | Я | Я - ENGINE OIL FILTER R R R R - » | CARBURETTOR NA |. I.]|.I. ff... . SYNCHRONISATION * | ENGINE IDLE SPEED | Nara * RADIATOR COOLANT (NOTE 4) | | R - * | COOLING SYSTEM | | - Maintenance Schedule FREQUENCY ODOMETER READING [NOTE (1)] X 1,000km 1 6 | 12 | 18 | 24 | 30 | 36 | *Refer X1,000mi | 06 | 4 | 8 | 12 | 16 | 20 | 24 | ©. Service ITEM NOTE | MONTH 6 | 12 | 18 | 24 | 30 | 36 | Manual DRIVE CHAIN EVERY 1,000km (600mi) I, L * DRIVE CHAIN SLIDER i i | - BRAKE FLUID (NOTE 4) var R]- BRAKE SHOE / PAD WEAR cla for BRAKE SYSTEM | | | - * | ВВАКЕ LIGHT SWITCH * | HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND * | SUSPENSION * | NUTS, BOLTS, FASTENERS + | WHEELS / TYRES — | STEERING HEAD BEARINGS 47 Maintenance Schedule EE — SHOULD BE SERVICED BY YOUR AUTHORISED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, REFER TO THE OFFICIAL HONDA SHOP MANUAL. <— < INTHE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORISED HONDA DEALER. Honda recommends that your authorised Honda dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1. At higher odometer readings, repeat at the frequency interval established here. 2 Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle. 4 Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. Basic Mantenance Basic Maintenance This section describes basic maintenance procedures that should be performed on a regular basis. Do not carry out any work beyond your knowledge and skill, and always use proper tools. Contact an Authorized Honda Dealer if you do not have proper tools or skills required for a particular job. 49 Engine Oil Reservoir Engine Oil Reservoir Oil tank cap 1. The engine on the CRM250 operates on a two(2) stroke mix. Oil input is controlled by an oil injection pump. 2. Two stroke oil is held in a reservoir located behind right hand radiator shroud. 3. To remove oil filler cap, you must first remove the radiator shroud by taking out the two (2) screws and one (1) bolt. 4. By releasing the steel clip, you can remove the oil filler cap. 5. Use only a high quality two (2) stroke oil. 6. Fill reservoir to oil level gauge indicated on upper part of reservoir. (Refer diagram). Right radiator shroud Transmission Oil Transmission Qil A Notes. The engine, the muffler and the exhaust pipes are extremely hot after stopping the engine. Oil filier Transmission oil should be checked as part of your pre-ride inspection. 1. To check transmission oil, hold bike in an upright position. Ensure bike is on level ground. 2. Remove check bolt. 3. The oil level should be up to the lower | Check bolt threads of the check bolt hole. 4. To add oil, remove filler cap and pour in the recommended transmission oil until it is at the correct level. 51 Transmission Oil Recommended Oil a Genuine Honda oil for 4-stroke motorcycle. MO advice | * The engine oil also lubricates the clutch. If you are using the products other than use of engine aig сло гесисе е Нопаа, select from the following ranges. the clutch to slip, affect engine start up, * APltype: SE or SF grade degrade engine performance and even » SAE rating: Select from the shorten the engine life. diagram on page 53 Do not use oil additives designed to reduce engine wear and tear. * Do not use oils containing Friction Modifiers. API Type SAE rating Ultra U SE grade 10W — 30 Ultra GP SF grade 10W — 40 or 20W - 50 52 Transmission Qil Temperature and Viscosity Oil change intervals. Choose the Transmission oil corresponding Initial: 1,000km to the atmospheric temperature in your After the first change: riding area. Every 6000km Contact an Authorized Honda Dealer for the oil change. (S A E Rating) -10 0 10 20 30 40°C Outside Temperature 53 Coolant 1. The Honda CRM250 has a liquid cooled engine, Coolant level should be checked as part of your basic maintenance. 2. You can do this by visually inspecting the coolant level, behind the left hand side cover. 3. Make sure bike is on level ground and ensure that coolant level falls within the upper and lower graduations. MN caution Do not remove the radiator cap while the engine is hot. Coolant can spurt out, causing severe scalding. Allow the engine and radiator to cool before attempting to remove the radiator cap. Reservoir L — ASE REX N Upper Limit Lower Limit 1. To top-up the reservoir, you must first remove the seat and left hand side cover. (refer page 22) 2. Remove filler cap and fil! reservoir with Honda Ultra coolant to leve! indicated on reservoir. 3. If level drops significantly, it may mean there is a leak in the cooling system. Contact an authorised dealer for technical support. ES Advice Use of poor quality water or radiator fluid other than the recommended type will cause corrosion / electrolysis. Drive Chain Drive Chain < Chain Slack Check > Place the motorcycle on the side stand and pull the chain up and down at the mid-point between the front and the rear sprockets. Measure the slack using a ruler. Drive chain slack: 30 ~ 40mm Adjust the slack if out of the range. Never ride the motorcycle if the slack is 60mm or more. Roll the motorcycle back and forward to observe the chain. If the chain is jerky or noisy , have it serviced / replaced. Contact an Authorized Honda Dealer for the adjustment or the replacement. Drive Chain Slack (Distance between the arrows) Drive Chain < Lubrication and Cleaning > Chain Oil: “Genuine Honda Chain Oil” Place the motorcycle on the side stand and Or gear oil (480 ~ #90). clean mud or dirt from the chain and sprocket. Move the motorcycle back and forward to clean entire chain. Avoid steam cleaning as the chain has rubber seals. Apply lubrication oil to both sides of the chain roller so as to have the oil reach entire part of the chain. Excessive lubrication may result in spattering oil on the body or on your clothing. Do not use chain spray and other ubrication oil containing solvents. hey may shorten the life of the chain. 57 Brakes Brakes Front Brake < Brake fluid level check > Place the motorcycle on flat surface and set the side stand. Move the handlebar to make sure the reservoir cap surface is level Check the fluid level is above the lower limit line (minimum line). If the fluid level is below the minimum, brake pads may be worn. Check the pads Ce Si) If the brake pads are fine, there may be a leak in the brake system. Contact an Authorized Honda Dealer. FRONT Lower limit Brakes < Brake pads inspection > o FRONT Honda recommends that the front brake pads be inspected regularly, between services. Brake caliper Pad wear limit Inspect the front brake pads from underneath the calipers. If the wear limit line is worn through to the side of the brake disc, replace the pads on both sides. Contact an Authorized Honda Dealer for brake pad replacement. Always replace brake pads as a set — failure to do so may cause uneven braking or instability. 59 Brakes Rear Brake < Brake fluid level check > Hold the motorcycle upright on a flat surface so that the brake fluid reservoir is level. Check the fluid level is between minimum and maximum lines. If the fluid level is below the minimum, brake pads may be worn. Check the pads (p. 60). If the brake pads are fine, there may be a leak in the brake system. Contact an Authorized Honda Dealer. Inspection window Brakes < Brake pads inspection > | REAR Honda recommends that the rear brake Pad wear limit pads be inspected regularly between services. Brake caliper | Inspect the rear brake pads from behind the brake calipers. If the wear limit line is worn through to the side of the brake disc, replace the pads on both sides. Contact an Authorized Honda Dealer for brake pad replacement. 61 Clutch Clutch < Free play in the clutch lever > Squeeze the clutch lever until resistance is felt. Measure the distance traveled at the tip of the clutch lever with a ruler. Free play: 10 ~ 20mm Adjust the free play if necessary (p.62). 62 Clutch < Free play adjustment > Adjust the free play with the adjusters on either the clutch lever and/or the clutch end of the clutch cable. - Loosen the lock nut fo use the adjuster. - After adjusting, tighten the lock nut. - Check the free play again. Start the engine and try changing gears. № the changes are jerky or the engine stalls or starts to move, re-adjust the free play. COARSE ADJUSTMENT Lock nut Adjuster FINE ADJUSTMENT Lock nut Fuses Fuses < Fuse inspection / replacement > Stop the engine before checking the fuses. Replace blown fuses with the fuses of same rating. Never use higher-rating fuses. They may cause overheating and electrical system damage. If a new fuse blows soon after replacement, there may be a fault in the relevant electrical system. Locate and repair the fault before installing a new fuse. NG Advice Replace the electrical parts only with genuine Honda accessories. Other parts can cause fuses to blow. Blown Fuses and Relays Fuses and Relays Remove the headlight and shroud Open the fuse holder. Locate the blown fuse. Replace with another of equivalent amperage. Close the fuse holder and install the headlight. SON о Relays Follow procedure above and identify relays from the wiring diagram in Service Manual. 65 Fuse Fuse holder Fuse holder Tyres Tyres Tyres should be kept in good condition and maintained at the rated pressure at all times. Worn tyres should be replaced immediately. A Caution Use of worn tyres or failure to maintain tyres at the correct pressure can cause an accident resulting in serious injury or death. Always maintain tyres at the correct pressure given in this owner's manual, and replace worn tyres immediately. < Air pressure > Check the air pressure while the tyres are cold. < Tread > Tyres should be replaced as soon as wear indicators start to appear on the tyre wall, or when the tread on the centre of the tyre reaches the level shown below. Front 3.0mm Rear 3.0mm Wear Indicator Г. Without pillion Front 1.50kgf/cm? passenger Rear 1.50kgf/em? With pillion Front 1.50kgf/cm? passenger Rear 1.50kgf/cm? Tyres < Replacement Tyres > Replace with only the approved tyres shown below. Use of other tyres can affect handling and stability. Contact an Authorized Honda Dealer when replacing a tyre. Front Size 3.00 —21 — 51P Type IRC GP-21F Rear Size 4.60 — 18 63P Type IRC GP-22R 67 MN Warning Use of tyres other than the designated tyres in the table can affect handling and stability and could cause serious injury or death. Replace tyres only with the approved types given in this owner's manual. Air Filter Air Filter < Replacing the air filter > The oil-soaked viscous air filter element does not require inspection under normal operating conditions but should be replaced every 20,000km. Under severe conditions the filter should be inspected and replaced more regularly. Replacements are available at your Authorized Honda Dealer. Air filter cover Element set holder Air filter set spring A set spring Air filter element Cleaning ° To prevent internal rust and potential starting problems, keep water out of the * Polish painted surfaces and plastic parts muffler. gently. » Keep brake parts dry. Water in the Strong rubbing with wax or polishing brake mechanism affects braking compounds can wear down the paint performance. coating and cause discoloration. After cleaning the motorcycle, start the engine and test the brakes (keep clear of other traffic and keep a low speed). If necessary, apply the brakes periodically while riding at reduced speed until they dry out. LE ZZ $ y * Dry and lubricate any moving parts that may be affected by water. 69 Cleaning Aluminum Parts (Aluminum wheel) Parts made out of Aluminum Alloy should be handled carefully. * Aluminum parts corrode if exposed to salt or mud. Sponge off salt water, road salt and other dirt immediately using mild detergent. Rinse with plenty of water and dry with soft cloth. * To prevent scratching, avoid abrasive cleaners and steel wool and do not use excessive force when cleaning or rubbing aluminum parts. 70 Evvironmental Consideration Damper Units Environmental Consideration The damper units contain compressed For environmental consideration, please Nitrogen Gas. Contact an Authorized handle used batteries, tyres, engine ail Honda Dealer when the damper units properly in terms of environmental require replacement. manners. warning Do not throw the damper unit into fire or disassemble the unit. It may explode which could cause serious injury or death. Please do not: * Throw into fire e Drill a hole in it, or * Disassemblie 71 Colour Label Colour Label Colour label When ordering coloured parts, quote the model name, colour and code on the colour A label. E The colour label is located on the frame under the seat. 72 Genuine Honda Mufflers Genuine Honda Mufflers В HONDA LOGO Use only genuine Honda mufflers with engraved Honda logo on the rear. TETONA 73 Vehicle identification Number Vehicle Identification Number (VIN) The VIN is required when ordering parts and registering your motorcycle, and can also be helpful if the motorcycle is stolen. Write down the VIN number together with the vehicle registration number and store in a safe place. Vehicle Identification Number(VIN) Engine Number If engine overheats If engine overheats < Procedure > Switch the engine OFF and wait for it to 3. Even if you do not encounter further cool down. overheating problems, have the engine checked by an Authorized Honda 1. Once the engine has cooled, check the Dealer as soon as possible. coolant level (p.54) and refill if necessary 2. Check for leaks from the radiator hoses and elsewhere in the cooling system. * |f a leak exists: Do not start the engine. Contact an Authorized Honda Dealer for assistance. * If no leak exists: The motorcycle may be able to be ridden. Contact an Authorized Honda Dealer if the engine overheats again. 75 If engine fails to start If engine fails to start Should the engine fail to start or inadvertently come to a stop, check: * The starting procedure (it should be as described in this owner's manual). * The petrol level in the fuel tank. 76 Repairs Contact an Authorized Honda Dealer for repairs. To prolong the life of your motorcycle, do not attempt to repair it by yourself. Have it serviced properly by an Authorized Honda Dealer. Specifications T MD32 2195mm Overall width 825mm Overall 1215mm Wheelbase 1460mm volume 0.249| 1 Positions 2 Front 3.00-21 51P Tyre size Rear 4.60 — 18 63Р Minimum clearance 320mm Fuel Minimum 2.3m ratio 6.7 1 - Maximum 40 PS 4 11 77 Spark plugs mechanism 78 Specifications CDI BTDC 15°/ 1 1 BR7ES BR8ES W22ESR-U W24ESR-U W27ESR-U 2.600 coil foot 2.538 1. 1.400 1.090 0 Specifications Drive chain slack 30-40mm pressure o Front 1.50 kgf/cm? Rear 1.50 kgf/cm? PResengor Front 1.50 kgf/cm? Rear 1.50 kgf/cm? Transmission oil Total capacity 1.21 Oil filter change 0.65 1 Oil change 0.541 Clutch lever free play 10 — 20mm Spark plug gap 0.8 — 0.9mm Air filter element | Type Viscous filter type Bulbs Headlamp 12V — 60/55W Stop lamp (rear) 12V — 18/5W Front turn signals 12V — 15W Rear turn signals 12V — 15W 79 Noise Warning Noise Control System (Australia Only) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: and (b) The use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person. Notes 81 Notes 82 Notes 83
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