1997–1999 Honda CRF250R Service Manual (P/N 61KZ352)

• Honda OEM shop manual for the 1997-1999 CR250R two-stroke competition motorcycle, cataloged as Honda item/part number 61KZ352; supplied here as a 316-page PDF organized into 18 sections.
• Covers engine removal and installation, cylinder-head and cylinder inspection, piston service, and Composite Racing Valve (CRV) operating checks, disassembly, decarbonizing, linkage adjustment, and governor/cam work.
• Fuel and cooling repair coverage spans carburetor adjustment and overhaul, temperature/altitude tuning charts, reed-valve inspection, 1997-1998 power-jet solenoid testing, cooling-system pressure tests, coolant replacement and air bleeding, and water-pump service.
• Detailed bottom-end and drivetrain procedures address clutch, kickstarter, and gearshift linkage service; crankcase separation and assembly; crankshaft removal and installation; transmission teardown, inspection, and reassembly; plus bearing and oil-seal replacement.
• Suspension and chassis chapters cover wheel and steering-stem service, year-specific fork disassembly, fork-damper refill and air bleeding, rear-shock bladder replacement, damper overhaul and nitrogen charging, shock linkage, swingarm, and bearing repair.
• Front and rear hydraulic brake sections provide fluid replacement and bleeding, pad and disc inspection, master-cylinder rebuilding, caliper overhaul, and brake-pedal service.
• Electrical diagnosis includes ICM, ignition-coil, exciter-coil, and pulse-generator tests, ignition-timing inspection, model-specific wiring diagrams, cable and harness routing, and symptom-based engine and handling troubleshooting.

Honda's safety notice states that detailed explanations of standard workshop procedures and safety principles are not repeated. This manual is suited to experienced mechanics and owners already comfortable with precision measurement, specialty tools, and pressurized suspension work; it is not written as a beginner's repair course.

Model-Year Coverage That Matters

Honda does not treat all three model years as mechanically identical. The manual marks 1997-only, After 1997, 1997-1998 only, and After 1998 procedures throughout, so the correct parts, test connections, and specifications can be selected before repair work begins.

For 1999, the PWK00A carburetor replaces the PJ28L used in 1997-1998, with its own jetting data, tuning chart, and disassembly/assembly details. The 1997-1998 power-jet solenoid circuit is not used on the post-1998 configuration. The later model also has a separate ICM/alternator connector test path and wiring schematic, a different CRV flap-valve removal and installation path, model-specific handlebar lower-holder bushings, a different lower-engine-mount torque specification, and distinct fork and shock setup data.

Factory Procedures, Specifications, and Tools

This goes well beyond routine maintenance. The engine chapters support top-end repair and complete bottom-end work, while the suspension material reaches into twin-chamber fork and gas-reservoir shock service. A competition-use maintenance schedule and frequent-replacement guidance sit alongside the repair chapters. Specification tables provide component-specific torque values, inspection and wear limits, clearances, approved fluids and capacities, carburetor setup data, cooling-system test pressures, suspension baselines, and ignition resistance and peak-voltage values.

Honda identifies required service tools by number. Examples include crankcase pullers 07937-4300000 / 07937-4300001, fork-seal driver 07VMD-KZ30100 / 07VMD-KZ3010A, lock-nut wrench 07WMA-KZ30100, and peak-voltage adapter 07HGJ-0020100.

Exploded assembly drawings and procedural illustrations show component orientation, measurement points, and tool placement. Particularly useful references include separate 1997-1998 and post-1998 wiring diagrams, year-specific cable and harness routing views, CRV valve-position diagrams, carburetor temperature/altitude tuning charts, the twin-chamber fork oil-flow section view, and troubleshooting flowcharts for starting, power loss, high-speed performance, and handling.

Manual-Specific Service Cautions

The CRV procedure warns that the sub-exhaust valve shaft can bend during removal and prevent the exhaust valve from operating correctly. During cylinder installation, rotating the cylinder can catch a piston ring on a port and break it; the fork section also notes that overtightened bridge pinch bolts can deform the outer tubes and require replacement.

Rear-shock work involves high-pressure nitrogen, while fuel and brake repair introduce flammable gasoline and brake fluid that can damage painted, plastic, and rubber parts. Follow Honda's safety instructions and use the specified equipment. Pre-ride checks and some suspension setup guidance for rider weight and riding conditions remain in the separate Owner's Manual.