2000–2001 Honda CR250R Factory Service Manual (P/N 61KZ361)

The Honda CR250R factory service manual (P/N 61KZ361) covers the 2000–2001 models, from scheduled maintenance through internal engine, transmission, and chassis repair.

Search, Bookmarks, and Wiring Detail

Finding procedures and reading diagrams: Most pages have searchable OCR text, but recognition errors can affect searches, and one CRV service page has no searchable text. Embedded bookmarks link to the contents and all 18 sections. Small wiring labels are readable when enlarged.

One printable, English-language PDF contains 286 pages, including one cover page and two introductory pages.

Two-Stroke Engine, CRV, and Chassis Service

These selected topics show part of the coverage; the manual also includes silencer packing replacement and control-cable servicing.

• Engine repair: Step-by-step procedures for engine removal, top-end inspection, crankcase separation, crankshaft service, transmission disassembly, and reassembly.

• Clutch and shift mechanism: Clutch inspection and replacement, kickstarter teardown, gearshift linkage service, and related wear limits.

• Composite Racing Valve: Exhaust-valve decarbonizing, operating checks, linkage adjustment, and governor/cam inspection.

• Fuel system: Separate carburetor overhaul procedures and tuning charts for the two production versions, plus reed-valve inspection and replacement.

• Cooling system: Radiator-cap and system pressure testing, coolant replacement and air bleeding, radiator removal, and water-pump seal and bearing service.

• Wheels, suspension, and brakes: Wheel-bearing replacement, steering-stem service, fork and shock work, Pro-Link linkage inspection, and hydraulic brake repair.

• Ignition diagnosis: No-spark troubleshooting, coil and pulse-generator testing, alternator service, ignition-timing checks, and a wiring diagram.

This manual suits mechanics and experienced owners familiar with engine rebuilding and equipped for bearing work, suspension service, and electrical testing.

Engine Inspection and CRV Assembly

The engine sections pair exploded views with inspection limits and component-specific torque values, giving mechanics a reference for assessing wear and planning reassembly. Cylinder/piston selection distinguishes matching A or B size codes.

Crankshaft and transmission service require engine removal; the top-end and clutch procedures can be performed with the engine in the frame. The Crankcase Bearing/Oil Seal Location views support bearing replacement, while the transmission section details gear, bushing, shift-fork, and shift-drum inspection.

Cylinder-installation cautions explain how rotating the cylinder can catch and break piston rings. The CRV instructions address linkage misalignment that prevents exhaust-valve operation; the governor is removed and inspected as an assembly, with dismantling of that assembly specifically excluded.

Carburetor Tuning and Cooling Tests

The PWK00B and TMX11A carburetor sections have separate disassembly and assembly instructions. Their Tuning Information Charts relate jetting choices to temperature and altitude, with optional jet-needle information for further tuning.

The Coolant Gravity Chart supports hydrometer testing. Water-pump coverage extends to shaft inspection and oil-seal, water-seal, and bearing replacement.

Twin-Chamber Fork and Pro-Link Rear Suspension

Front Suspension section views and Oil Flow drawings explain the twin-chamber fork. Service coverage includes damper bleeding, seal and bushing replacement, and post-assembly operation checks. The fork cautions identify outer-tube deformation from overtightened pinch bolts.

Rear-suspension procedures cover shock bladder replacement, damper-rod assembly, spherical bearings, and swingarm/linkage bearings. Shock service involves pressurized nitrogen and requires the manual's pressure-release and charging precautions.

The hydraulic brake section covers front and rear master-cylinder and caliper rebuilding, brake-disc inspection, and fluid replacement and air bleeding. Frame/body-panel and exhaust-system removal procedures provide access for the covered service work.

Ignition Fault Tracing and Routing Views

The no-spark troubleshooting chart connects ignition-coil, exciter-coil, pulse-generator, engine-stop-switch, and ICM checks with possible faults. Test instructions identify the peak-voltage adapter 07HGJ-0020100 and the required meter characteristics.

Cable & Harness Routing views complement the Wiring Diagram. Separate troubleshooting flowcharts cover starting problems, loss of power, poor running at different engine speeds, and handling faults.

A Preview of Carburetor, Engine, and Cooling Specifications

Carburetor settings: The fuel-system tables specify a float level of 16.0 mm for PWK00B and 15.0 mm for TMX11A, alongside the corresponding carburetor service procedures.

Engine reference data: The standard piston-ring end gap is 0.40–0.55 mm; the maintenance section gives a spark-plug tightening torque of 18 N·m.

Cooling specifications: Coolant capacity at a coolant change is 1.22 liters. Radiator-cap testing uses a cap relief-pressure specification of 108–137 kPa.