Honda CRF250L - running issues

g00ner

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My son has a 2013 CRF250L (20k miles) which has developed a fault, wonder if those with more knowledge than myself could give a few pointers?

Owned 6 months, was running fine and has completed several all day trail rides and numerous local trips until recently developed a low rpm stutter that feels very much like fuel starvation. It won’t cut out, but opening the throttle will result in ‘bogging’ and a reluctance to accelerate. Sometimes it will pull through and rev cleanly, sometimes a persistant hesitancy that makes riding impossible. It has got him home but with some difficulty.

Suspecting fuel, I’ve removed the fuel pump and given it a clean - there is no inline filter, rather a gauze at the fuel pick up inside the tank. It wasn’t spotless but then wasn’t caked in gunge either. I also replaced the air filter, spark plug and gave it an oil/filter change.

Initially this made no difference, but after adding some FedEx fuel system cleaner (at higher than normal dilution but safe according to the FedEx website) the issue cleared. Solved I thought! After a problem free 150 mile ride and leaving it overnight, the issue has returned. More fuel cleaner and another pump clean hasn’t cured it this time.

Googling suggests a plethora of possible issues from dirty throttle body, dodgy ht lead (though the first problem fix with cleaner seems to discount this), blocked cap vent (cleaned), fuel pump connections (all appear ok), knackered fuel pressure regulator, tps sensor, injector etc etc etc.

I’ve priced a new fuel pump via Honda and it isn’t cheap! Local bike shop will carry out a check (diagnostic £90) which seems the next logical step though there isn’t any fault code indicators showing on the dash.

The bike starts fine and ticks over evenly, I can hear the pump prime. Gently open the throttle a few hundred revs and you can feel a hesitation, open more, particularly if abruptly, it bogs down. Continue and get the revs much higher up and it revs cleanly but it can’t be ridden like that.

I’ve exhausted my mechanical nous, is there anything I should be checking before admitting defeat and ferrying it to a man who hopefully can
 
My first thought was that it needs a re-calibration of the TPS.

Maybe a marque forum search might deliver a DIY method, without paying dealer diag fees?
 
I saved this months and months ago in case I ever needed to do it on my bike.

Hopefully helpful…
 

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Sounds like a blocked fuel filter to me. Has the CRF just got one filter before the pump?

Dunno about Hondas, but KTMs have another filter inside the pump and one inline before the injector.
 
Sounds like a fuel filter, fuel pump.

Water in the tank ??

Does it consistently run clean at a higher throttle opening??
 
Sounds like a fuel filter, fuel pump.

Water in the tank ??

Does it consistently run clean at a higher throttle opening??
Yes it does, higher revs it’ll hold a steady throttle but it is much higher revs - more than you’d subject the bike to normally.

Tank has been removed and is very clean. Fresh fuel too but with redex added
 
Sounds like a blocked fuel filter to me. Has the CRF just got one filter before the pump?

Dunno about Hondas, but KTMs have another filter inside the pump and one inline before the injector.
Pump is in the tank, just a gauze over the fuel pick up. Post 2017 they changed the design to two filters I believe
 
I can buy a full assembly for £550

Individual electric pump £70
Pressure regulator £45
Gauze (copy) £25
Injector £150
Etc
 
If you're getting steady performance at open throttle (where fuel demand is much higher), then I wouldn't be thinking fuel supply is an issue. The pump is fuel flow are giving the engine all it needs.

However, that's not always the case. Just unlikely.

You could test the throttle position sensor. I don't know the values on this bike but it works in variable voltage.
 
You could also be mistaken diagnosing a throttle position fault for a engine speed fault.

Potentially a crank position sensor fault.

Although I would imagine some kind of engagement light would have been triggered by now.
 
Problem fixed. TPS / Air flow meter, sensor all housed in one unit. New one fitted, all is good. Worth the analysis from the local enduro/trials shop who plugged it in for my sanity at least.
 
Problem fixed. TPS / Air flow meter, sensor all housed in one unit. New one fitted, all is good. Worth the analysis from the local enduro/trials shop who plugged it in for my sanity at least.

Good news. A few of us suspected that was the issue.
 
Thanks for sharing. (I am planning a long trip on my 2017 CRF 250 Rally and such knowledge is helpful (although, hopefully, won't be needed!))
 


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