Honda 1999

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Honda 1999 | Manualzz
 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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