2004-2009 Honda CRF250R Motocross Service & Repair Manual

This comprehensive repair manual covers all CRF250R motocross models. It details procedures for engine overhaul, suspension tuning, and electrical system diagnostics, including part numbers for essential components.

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Document Details

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Document Number / Seller:
26143 / Harold Gomez
File Size:
44.97 MB
File Type:
PDF
Language:
English
Pages:
406
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Dec 26, 2025

Models Covered & Key Technical Specifications

Honda CRF250R (2004-2009) - 2004-2009 Honda CRF250R Motocross Service & Repair Manual Honda CRF250R | Service Manual Collection Engine Specifications: 406 pages provide detailed technical resolution data that establishes the maximum print output Architecture. Torque Values: For accurate assembly, 12 N-m is specified as the tightening torque for the cam chain tensioner bolt Configuration. Coolant Capacity: The system requires 0.93 liters for initial filling Benchmarks. Valve Clearance: The engine requires 0.12 mm to 0.03 mm for intake valve clearance Range. Compression Ratio: 13.1:1 signifies the active compression ratio Threshold. Fuel Tank Capacity: The fuel system supports 7.3 liters for standard operation Baseline.

Professional Workshop Service Manual & Technical Specifications

Detailed Assembly Training Manual: Honda CRF250R Motocross Motorcycle (2004-2009) Overhaul-Reference

Component-Focus: CRF250R // Repair-Classification: Motorcycle / Motocross Logic // Diagnostic-Area: Engine & Chassis Specifications. Performance-Element Baseline Framework
Engine Specifications 406 pages Detailed technical resolution data
Torque Values 12 N-m Tightening torque configuration
Coolant Capacity 0.93 liters Initial filling benchmarks
Valve Clearance 0.12 mm - 0.03 mm Intake valve clearance range
Compression Ratio 13.1:1 Active compression ratio threshold
Fuel Tank Capacity 7.3 liters Standard operation baseline

Featuring a modular arrangement of sections covering:

Electrical System Documentation

Electrical system documentation covers wiring diagrams, ignition system specifications, and component testing procedures.

Suspension Service Documentation

Suspension service documentation covers front and rear suspension adjustments, fork service, and shock absorber inspection.

Disassembly Instructions

Disassembly instructions are documented for engine components, including the cylinder head, camshaft, and carburetor.

Wear Limits Specifications

Wear limits are specified for critical engine components such as piston rings, valve guides, and bearings.

System Operation Descriptions

System operation descriptions cover cooling system flow patterns, fuel system component locations, and lubrication system diagrams. This manual documents torque specifications for critical engine components to ensure proper seal compression uniformity.

FAQ

Confirm the **recommended** diagnostic procedures for starting issues? keyboard_arrow_down

1.8 N-m is the specified torque for the starter jet, and the pilot screw initial opening varies between 2-1/4 to 1-1/4 turns out depending on the model year.

What tools are needed for **calibrated** fluid capacity checks? keyboard_arrow_down

A carburetor float level gauge (part number 07401-0010000) is required for checking float levels, and a torque wrench is essential for all component installations.

Identify the **applicable** component identification for suspension adjustments. keyboard_arrow_down

Front suspension axle travel is 280 mm (11.0 in) for '04 models and 279 mm (11.0 in) for later models, with rear wheel travel at 312 mm (12.3 in).

What procedures are required for **exact** adjustment procedures for the throttle? keyboard_arrow_down

Throttle grip freeplay should be 3-5 mm (1/8 - 3/16 in) at the lever end, and adjustments are made using the upper adjuster or the carburetor end adjuster.

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Reviews (2)

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The manual is incredibly detailed and easy to follow. I had a smooth download process and received my link almost immediately. Highly recommend for anyone looking to maintain their bike!
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This service manual has everything you need for repairs. The diagrams are clear and the troubleshooting section is very helpful. Customer support was prompt and professional when I had questions. Worth every penny!