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Front Suspension Adjustments
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1. STARTER SWITCH ENGINE STOP BUTTON dt FUSE 15A E Eg A CLUTCH SWITCH Se BATTERY gl IF Oo N 12V6AH lf e s ANN he Es st gt pse VETR gt Eg GEEGEE goact Zo s IE ad HE EL EN EN EN EE di Br 6P 6P STARTER MOTOR N TEER TT TT EET ae BE VET Ee BERS GEGEE Szro BI 4P ri pl co zo 2 0 an aoa B Bl seh Gr LKA Gr Eai zom g ns B ac A x Bu Bu Le Fa 3 w TAILLIGHT G G e Le BI KHB E y HEADLIGHT 12V35W LER are BI jee 2 SE 53 ae Bl Bl 4P ople Eas 3E Bo o ro 6 a L a Do A mn ALTERNATOR Oo Vv IGNITION COIL al THROTTLE POSITION SENSOR IGNITION PULSE GENERATOR SPARK PLUG TTTT Bl BLACK Br BROWN ENGINE STOP BUTTON STARTER SWITCH Y YELLOW O ORANGE Bars sr g Bu BLUE Lb LIGHT BLUE G GREEN Lg LIGHTGREEN re OTOI R RED P PINK W WHITE Gr GRAY Coron Y R JBuBr Technical Information 163 164 Technical Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized ManualS ees ss ee ee ee ee ee 166 Contacting Honda sesse esse see ese ee ee ee ee 167 Your Honda Dealer ees ss ss ee ee ee ee ee ee ee 168 The Honda Rider s Club USA only 169 Consumer Information Consumer Information 165 Authorized Manuals The Service Manual used by your authorized Honda dealer is avai
2. 5 1 main jet 5 baffle plate 2 jet needle 6 float 3 needle jet 7 float valve 4 air jet Adjustments for Competition 131 Carburetor Adjustments amp Tuning Tips Carburetor Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by loosening the carburetor drain screw 1 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 1 carburetor drain screw 3 Tighten the carburetor drain screw 4 Remove the fuel tank page 37 5 Lift the subframe to the upright position page 39 132 Adjustments for Competition 6 Raise the rear wheel off the ground by placing a optional workstand or equivalent under the engine 7 Remove the shock absorber upper mounting nut 2 and bolt 3 2 upper mounting nut 3 upper mounting bolt 8 Disconnect the throttle position sensor connector 4 lt 4 4 dj 4 throttle position sensor connector 9 Loosen the insulator band screw 5 and remove the carburetor 6 from the insulator 7 ETN D 5 insulator band screw 7 insulator 6 carburetor 10 Loosen the hot start cable nut 8 and remove the hot start valve 9 from the carburetor a 8 hot start cable nut 9 hot start v
3. FREQUENCY NOTE Sensi aie co ae oe a rs sce Pars Ref Page ITEMS THROTTLE OPERATION l 55 HOT STARTER I 60 AIR FILTER NOTE 1 C 51 CRANKCASE BREATHER I 53 SPARK PLUG I 61 RADIATOR COOLANT NOTE 2 I 48 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 66 ENGINE OIL NOTE 3 I R 44 ENGINE OIL FILTER NOTE 3 R 44 ENGINE IDLE SPEED l 136 PISTON AND PISTON RINGS R 77 PISTON PIN R TE TRANSMISSION OIL NOTE 5 I R 46 COOLING SYSTEM I 48 DRIVE CHAIN LL R 95 DRIVE CHAIN SLIDER l 97 DRIVE CHAIN ROLLER I 97 DRIVE SPROCKET l 96 DRIVEN SPROCKET I 96 BRAKE FLUID NOTE 2 I 88 BRAKE PADS WEAR I 90 BRAKE SYSTEM I 87 CLUTCH SYSTEM NOTE 5 l 56 CONTROL CABLES LL 98 EXHAUST PIPE MUFFLER I 62 SUSPENSION 83 84 SWINGARM SHOCK LINKAGE L 32 FORK OIL FORK TUBE SLIDER NOTE 3 R 86 DAMPER R 113 NUTS BOLTS FASTENERS 99 WHEELS TIRES I 91 92 STEERING HEAD BEARINGS I 98 We recommended these items be serviced by referring to the Honda shop manual This maintenance schedule is based upon average riding condition Machine subjected to severe use reduire more freguent servicing NOTE 1 Clean after every heat for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride 4 Inspect after the first break in ride 5 Replace the transmission oil if the clutch discs and plates are replaced 28 Servicing Your Honda General Competition Maintenance Perform maintena
4. 5 bolts 8 diaphragm 6 reservoir cap 7 set plate 9 upper level mark 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 9 Do not overfill 3 Reinstall the diaphragm and reservoir cap Check the diaphragm installation as shown 4 Install and tighten the bolts 5 to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m Other Inspection e Make sure there are no fluid leaks e Check for deterioration or cracks in the hoses Brakes Servicing Your Honda 89 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval pages 27 and 28 Front Brake Pads Inspect the brake pads 1 through the front wheel to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness indicator 0 04 in 1 mm 1 replace wear indicator grooves 0 04 in 1 mm gt 1 _ replace 1 brake pads 2 front brake caliper 3 brake disc 90 Servicing Your Honda Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must
5. Viscosity SAE 10W 40 weight JASO T 903 MA standard others without friction modifiers such as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdenum additives 4 stroke engine oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label e Your CRF does not need oil additives Use the recommended oil e Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance i cae EE ie NOT RECOMMENDED OK e Oil is a major factor affecting the performance and service life of the transmission and clutch Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10 20 30 40 50C 20 0 20 40 60 80 100 120 F Transmission Oil JASO T 903 standard 4 3 7 n 3 The JASO T 903 standard is an index for engine Checking amp Adding Oil Replacing Transmission Oil oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA cla
6. Check the radiator mount for looseness Make sure the siphon hose 2 is connected and not clogged Check the radiator fins for clogging Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the mechanical seal is damaged If oil leaks through the check hole the transmission oil seal is damaged See the Honda Service Manual or consult your Honda dealer for replacing the mechanical seal or the engine oil seal Both seals should be replaced at the same time Coolant Coolant Replacement j 25 A Refer to Safety Precautions on page 25 ma DN AL N Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically gualified Refer to the Honda Service Manual page 166 A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap To properly dispose of drained coolant refer to You amp the Environment page 145 NOTICE Improper disposal of drained fluids is harmful to the environment water hoses siphon hose water leakage check hole water pump cover 1 2 3 4 EE Servicing Your Honda 49 Coolant Cooling System Bleed Air 1 radiator cap 50 Remo
7. contd Servicing Your Honda 67 Valve Clearance Measure the decompressor arm clearance by inserting a feeler gauge 1 between the decompressor arm adjusting screw 6 and right side rocker arm 7 X 1 feeler gauge 6 decompressor arm adjusting screw 7 right side rocker arm DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor clearance is 0 011 in 0 28 mm 0 014 in 0 35 mm 0 025 in 0 63 mm If only decompressor arm clearance needs adjustment see Decompressor Arm clearance Adjustment page 73 68 Servicing Your Honda Use the tensioner stopper tool Camshaft Holder Assembly Removal Tensioner stopper 070MG 0010100 1 Record the intake valve clearance exhaust 3 Turn the tensioner shaft clockwise with the valve clearance and decompressor arm tensioner stopper 3 until it stops in order to clearance retract the tensioner fully 2 Remove the cam chain tensioner lifter cover Then insert the tensioner stopper fully to hold bolt 1 and sealing washer 2 the stopper in the fully retracted position jy ME 1 cam chain tensioner lifter cover bolt 3 tensioner stopper 2 sealing washer 4 Remove the cam sprocket bolt 4 Rotate the primary drive gear bolt crankshaft clockwise one turn and remove the other sprocket bolt 4 and cam sprocket 5 Then attach a piece
8. POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK 1 Check if air cleaner is over oiled P 51 CORRECT N Check if the connecting boot is leaking POSSIBLE CAUSES INCORRECT gt Over oiled air cleaner LEAKING NOT LEAKING 3 Check carbureator pilot screw adjustment CORRECT 4 Check carburetor jets and accelerator pump for clogs m Loose insulator clamp Damaged insulator INCORRECT gt e Improper pilot screw adjustment CLOGGED Contaminants in the NOT CLOGGED 5 Try spalk test GOOD SPARK T 6 Check the throttle position sensor CORRECT 7 Check for low compression CORRECT WAKE OR INTERMITTENT SPARK INCORRECT LOW fuel e Not cleaned frequently enough P 133 gt e Faulty carbon or wet fouled spark pulg P 61 e Faulty ignition control module e Faulty alternator e Faulty engine stop button e Faulty ignition coil e Broken or shorted spark plug wire e Faulty ignition pulse generator e Faulty throttle position sensor gt Ring worn e Cylinder worn or damaged e Piston worn or damaged e Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED POSSIBLE CAUSES CHECK 1 Disconnect fuel line at carburetor and check for clogg
9. CHECK 1 Check the fuel flow to carburetor NOT REACHING gt CARBURETOR REACHING CARBURETOR Y 2 Try spark test GOOD SPARK WEAK OR NO gt SPARK M 3 Test cylinder compression NORMAL 4 Start by following normal starting procedure LOW p gt ENGINE STARTS BUT SOON STOPS ENGINE DOES NOT FIRE 5 Remove and inspect spark plug DRY WET PLUG 6 START WITH CHOKE ON 146 Tips No fuel in fuel tank Clogged fuel tube or fuel strainer screen p 41 Sticking float valve Clogged fuel fill cap breather tube p 41 Faulty spark plug p 61 Fouled spark plug p 61 Faulty ignition control module Broken or shorted spark plug wire Faulty exciter coil Broken or shorted ignition coil Faulty engine stop button Loose or disconnected ignition system wires Faulty ignition pulse generator Valve stuck open Worn cylinder and piston ring Leaking damaged cylinder head gasket Improper valve timing Improper decompressor clearance p 73 Seized valve Improper choke operation Pilot screw incorrectly adjusted Insulator leaking Improper ignition timing Faulty ignition coil or ignition pulse generator Fuel contaminated Improper hot start operation p 60 Carburetor flooded Choke closed Throttle valve open Air cleaner dirty p 51
10. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine High Air Temperature 35 C 95 F or above Turn the fuel valve 1 ON Do not use the choke Keep the throttle fully closed Start the engine following step 4 under Normal Air Temperature AYN Low Air Temperature 10 C 50 F or below 1 If the temperature is below 0 C 32 F open the throttle two or three times The engine requires a richer mixture for starting in cold weather When the throttle is so opened the accelerator pump will feed extra fuel to the cylinder thereby facilitating starting in cold weather 2 Follow steps 1 4 under Normal Air Temperature 3 Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF NOTICE Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine Basic Operating Instructions 15 Starting amp Stopping the Engine Hot Engine Starting 5 A I Pull the hot start lever 3 all the way in and Flooded Engine How to Stop the Engine start the engine following step 4 under Normal Air Temperature Starting the engine after a stall during riding or 2 As soon as the engine starts release the hot start lever after a fall 1 Shift the transmission into neutral 2 Pull the hot start lever all the way in and star
11. Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a loss of traction and slower lap times 126 Adjustments for Competition Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF using the methods described on pages 108 123 Remember to make all adj
12. Take care to prevent catching your fingers between the chain and sprocket Servicing Your Honda 33 Before amp After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your CRF or use cleaners refer to Appearance Care page 104 34 Servicing Your Honda Maintenance Component Locations front brake fluid reservoir hot start lever front brake lever clutch lever throttle grip radiator cap fuel fill cap rear suspension high speed front suspension rear suspension spark plug air cleaner damping adjuster rebound damping rebound damping N engine idle j rear suspension low speed adjuster adjuster y speed battery i en el eed Spring damping adjuster a eae pre load adjuster front brake calipe
13. Test stiffer high and low speed compression adjustments simultaneously If it still feels soft replace the spring with a stiffer spring optional and begin with the standard settings to stiffer setting Rear end sways Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing after jumping Test stiffer high speed compression adjustment If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after landing Test stiffer low speed compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a harder spring optional if necessary Suspension bottoms after end of 1 Test softer rebound dumping adjustment continuous bumps 2 If it still bottoms test stiffer high and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a stiffer spring optional if necessary 129 Adjustments for Competition Carburetor Adjustments amp Tuning Tips The carburetor used on your CRF will seldom experience trouble with the standard settings under average load and average climatic and barometric conditions However to fine tune the engine s power output the carburetor
14. 1 opens the pump rod 2 depress the diaphragm 3 At this time the inlet check valve 4 is shut resulting in a sharp increase in pressure in the pump chamber 5 The outlet check valve 6 then opens supplying fuel to the main bore via the accelerator nozzle 7 1 throttle valve 5 pump chamber 2 pump rod 6 outlet check valve 3 diaphragm 7 accelerator nozzle 4 inlet check valve Carburetor Adjustments amp Tuning Tips Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the slow air jet 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 slow air jet 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters the venturi past the needle jet Baffle Plate The baffle plate 5 prevents foaming of fuel or abnormal fuel level around the main jet Float Bowl The float 6 and float valve 7 operate to maintain a constant level of fuel in the float bowl uf 2
15. 13 13 12 accelerator pump cover screws 13 accelerator pump cover 6 Remove the D ring 14 O ring 15 spring 16 and diaphragm 17 Clean the diaphragm When installing the D ring into the accelerator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 14 18 gt 14 13 accelerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 21 k 20 o sa 19 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube guides 8 Remove the pump rod 23 while pushing the link lever 25 Clean the pump rod and rod passage 24 Install the pump rod into the link lever 25 Push the rod forcibly into the link lever until it snaps into place 23 pump rod 24 rod passage 25 link lever 9 Measure the float level 26 with the float level gauge 27 during float tab just contacting the float valve and the carburetor intake 28 facing up The float level should be 0 31 in 8 0 mm If the float level is out of specification adjust it by bending the float tab carefully 28 ha 26 float level 27 float level gauge 28 carburetor intake 10
16. adjustment procedures or see your Honda dealer Servicing Your Honda Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that the handlebar has not moved from its proper position by inspecting the paint mark 4 Check the torque of the handlebar upper holder 2 bolts 16 Ibf ft 22 N m 2 2 kgf m Tighten the front bolts first 1 handlebar 2 handlebar upper holders Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant Be certain that the throttle cables have no kinks or other damage Additional Maintenance Procedures LEFT SIDE Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Torque Item Ibfeft Nem kgfem ENGINE 1 Cylinder head cover bolts 7 10 1 0 2 Exhaust pipe joint nuts 15 21 2 1 3 Water pump cover bolts 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 5 Transmission oil check bolt 7 10 1 0 6 Clutch cover bolts 7 10 1 0 7 Cylinder bolt 7 10 1 0 8 Oil filter cover bolts 9 12 1 2 9 Cylinder head bolts 7 10 1 0 7 cylinder bolt 10 Drive sprocket bolt 23 31 3 2 o A filter cover bolts 9 cylinder head bolts RIGHT SIDE 1 10 drive sprocket bolt oN Se o g e D
17. consistent damping 1 compression damping adjuster 2 rebound damping adjuster 108 Adjustments for Competition Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure is 0 psi 0 kPa 0 kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings Remove the pressure release screw 1 Check that the O ring 2 is in good condition Install the pressure release screw to the specified torque 0 9 Ibf ft 1 2 N m 0 1 kgf m WN 1 pressure release screw 2 O ring Front Suspension Damping Rebound Damping Adjustment The fork rebound damping adjuster 1 has 16 positions or more Turning the adjuster s
18. plates have been burnt heat discolored Clutch Disc Plate Installation 1 Coat the clutch disc A 1 B 2 and plates 3 with clean transmission oil 2 Starting and ending with the two clutch disc A 1 alternately install the six clutch disc B 2 and seven clutch plates 3 1 clutch disc A 2 clutch disc B 3 clutch plates 3 Apply grease to the clutch lifter rod 4 4 Insert the clutch lifter rod into the mainshaft 5 Apply transmission oil to the needle bearing 5 and washer 6 and install them to the clutch lifter 7 6 Install the clutch lifter onto the rod Se 6 washer 7 clutch lifter 4 clutch lifter rod 5 needle bearing Install the clutch pressure plate 8 Install the six clutch springs and bolts 9 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 9 Ibf ft 12 N m 1 2 kgf m oon 8 clutch pressure plate 9 clutch spring bolts springs 10 Install a new O ring 10 in the groove of the clutch cover 11 11 Install the clutch cover by tightening the six cover bolts to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 10 O ring 11 clutch cover Clutch System 12 Lubricate the dust seals 12 rear brake pedal 13 pivot and pivot bolt 14 with Honda Lithium Grease or equivalent 13 Install the dust seals 12 washer 16 and pivot bolt 14 and tighten the bolt to the specified torque 27 Ibf
19. standard position 3 0 in 0 mm Chassis Adjustments Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to recheck the race sag and adjust it if necessary In the past a general rule was lengthen the wheelbase to add straight line stability shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CRF unless you are racing on a track with more fast sections than normal As a general recommendation keep the wheelbase as short as possible This positions the wheels closer together improves turning response increases weighting traction on the rear wheel and lightens weighting on the front wheel With your CRF you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 137 Gearing You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized driven sp
20. 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 Ibf ft 15 N m 1 5 kgf m 1 O ring 2 crankshaft hole cap 74 Servicing Your Honda Cylinder Head Cover Installation 1 Check the spark plug hole packing 1 is in good condition replace it if necessary Apply engine oil to the spark plug hole packing and install it to the spark plug hole 2 1 spark plug hole packing 2 spark plug hole 2 Inspect the cylinder head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 3 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 5 4 Tighten the cylinder head cover A bolt 6 and cylinder head cover B bolts 7 to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover A bolt 7 cylinder head cover B bolts 5 Connect the spark plug cap 8 and breather tube 9 8 spark plug cap 9 breather tube 6 Install the fuel tank and the seat page 36 38 ns oo Oo Piston Piston Rings Piston Pin 9 Disconnect the air suction 1 and vacuum 13 Disconnet the primary wire connector 8 Cylinder Head Removal hoses 2 california only Remove the bolts cl
21. Aluminum lt 114 gt Optional 50 Teeth Aluminum lt 114 gt 52 Teeth Aluminum lt 116 gt Handlebar lower holder Standard 3 mm offset Optional no offset TOOLS Remarks FRAME Remarks Pin spanner A To adjust spring preload Shock spring 308 0 Ibf in 5 50 kgf mm two spanners required Standard No mark SS Workstand A For maintenance Z factory products or Red Air gauge For checking tire air pressure ES paint Es aftermarket parts Optional 296 8 Ibf in 5 30 kgf mm Softer eS Blue SY paint Stiffer 319 2 Ibf in 5 70 kgf mm ES Pink EE A paint 330 4 Ibf in 5 90 kgf mm ES Silver OF paint Fork spring 26 32 Ibf in 0 47 kgf mm Standard No mark OT factory products or _ 1 scribe mark aftermarket parts Optional 25 20 Ibf in 0 45 kgf mm Softer en 2 scribe marks Stiffer 27 44 Ibf in 0 49 kgf mm 3 scribe marks OT The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked Before replacing the springs be sure to mark them so they can be distinguished from other optional springs Technical Information 161 Spare Parts amp Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding In addition to the usual nuts and bolts consider the following Spare Parts spark plugs shims air cleaner clean amp oiled sealed in a plastic bag chain amp masterlink
22. If that doesn t solve the problem install the optional stiff spring Final travel too soft e Bottoms on landings Bottoms on large bumps especially downhill bumps If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments If initial and middle travel are stiff Install the optional stiff spring If initial travel is stiff after installing the optional stiff spring Test soft compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil capacity in increments of 0 2 oz 5 cc Entire travel too soft e Front end shakes e Fork bottoms over any type of terrain Install the optional stiff spring Test stiffer compression damping adjustments in one click increments Increase rebound damping in one click increments Adjustments for Competition 127 Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff e Stiff on small bumps while riding at full throttle in a straight line e Stiff on small cornering bumps e Front end wanders while riding at full throttle in a straight line Test softer compression damping adjustme
23. Inspection 20 Brake in Guidelines eee se se ee ee ee ee 21 170 Table of Contents Servicing Your Honda scssscssssscsssscssssees 23 Before You Service Your Honda The Importance of Maintenance eee 24 Maintenance Safety ie sesse se ee ee Ge 25 Important Safety Precautions esse esse esse 25 Maintenance Schedule iese se ee ee se 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal es EVER SE ES Ee EG Ee 36 Fuel Tank Removal sees sees sesse se ee ee Ge 37 Subframe Upright Position sesse ese se 39 Service Procedures Fluids amp Filters IS AS AR N IE AR HE 41 oitui de EE OR cei teste aei 43 Transmission Oil esse ees ee ee ee ee Re ee 46 BE EE ER te BL LE 48 Fidel AR EO EE N 51 Crankcase Breather cccccssssccceceesesseeeeeees 53 Engine Throttle ster sies na ses ige De gede bose sie 54 Elutch SY Stemties ses coh es ete Eeue Br Re ge ee 56 Hot Start Level aieeaii Re ee 60 Spark dl RO ata eid 61 Exhaust Pipe Muffler oaeee 62 Spark ATrester ti Ee EE EER SEE ep Ee ios 65 Valve Clearance sees sesse se ee ee ee Re Re ee 66 Piston Piston Rings Piston PIN esse sees sesse 75 Chassis eise ei OE EE 83 eed ARE EE RE eea EEEN 87 MAA IE OE Oe 91 Tires BE TUDES EE EO ER EO 92 Side Stand EE AE OE OE OE 94 Drive A
24. Instructions 13 Basic Operating Instructions Safe Riding Precautions Side Stand Tripmeter Before riding your CRF for the first time please The side stand 1 is used to support your CRF The tripmeter 1 is used to record the distance review the Important Safety Precautions while parked page 19 To operate use your foot traveled USA miles Canada kilometers per beginning on page 2 and the previous section to lower the side stand until it is fully extended trip or section of route titled Before Riding Before riding raise the side stand To operate pull the tripmeter reset knob 2 out OFF and turn it until the meter shows all zeros For your safety avoid starting or operating the 0 then push the knob in ON engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob 14 Basic Operating Instructions Always follow the proper starting procedure described below Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Fuel Valve ON OFF RES 1 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor O
25. Ltd 2005 2006 Honda CRF450X OWNER S MANUAL amp COMPETITION HANDBOOK Introduction Congratulations on choosing your Honda CRF off road motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your Honda was designed as a recreational motorcycle for off road use by one rider only Before riding take time to get acquainted with your CRF and how it works To protect your investment we urge you to take responsibility for keeping your CRF well maintained Scheduled service is a must of course But it s just as important to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual You should also read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a NOTICE symbol This information is intended to help you avoid damage to your Honda other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in
26. Old shim thickness Make sure of the correct shim thickness by measuring the shim with the micrometer e Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3 000 mm 1 valve lifter 2 shim 1 80 mm 1 825 mm 1 85 mm 1 875 mm 70 Servicing Your Honda Camshaft Holder Assembly Installation 1 Install the newly selected shims 1 on the valve retainers NOTICE Do not let the shims fall into the crankcase p a 1 shims 2 Apply molybdenum disulfide oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to outer surface of the each valve lifters 3 Install the valve lifters in their original locations in the camshaft holder assembly 4 3 valve lifters 4 camshaft holder assembly Valve Clearance 4 Install the camshaft holder assembly onto the cylinder head with the intake cam lobes 5 facing up as illustrated below Apply oil to the camshaft holder assembly bolt threads and seating surface Tighten the camshaft holder assembly bolts 6 to the specified torque 10 Ibf ft 14 N m 1 4 kgf m Tighten the camshaft holder assembly bolts in a crisscross pattern in 2 or 3 steps Exhaust side AF 6 4 camshaft holder assembly 5 intake c
27. Place weight as close to the center of the motorcycle as possible e Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front fender e Check that both tires are inflated properly Loading Motorcycle Safety 3 Accessories amp Modifications Accessories amp Modifications Modifying your CRF or using non Honda accessories can make your CRF unsafe Before you consider making any modifications or adding an accessory be sure to read the following information A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories 4 Motorcycle Safety Accessories We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your CRF Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your Honda dealer for assistance and always follow this guideline e Make sure the accessory does not reduce ground clearance and lean angle limit suspension travel or steering travel alter your riding position or interfere with operating any controls Modifications We strongly advise you not to remove any original equipment or modify your CRF in any way that would change its des
28. Remove the leak jet 29 from the float bowl 18 Clean the leak jet 29 18 S 29 leak jet 18 float bowl Carburetor Adjustments amp Tuning Tips To assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures Tighten the following parts to the specified torque float bowl screws 1 5 Ibf ft 2 1 N m 0 2 kgf m accelerator pump cover screws 1 5 Ibf ft 2 1 N m 0 2 kgf m top cover bolts 1 5 Ibf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 Ibf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 Ibf ft 2 1 N m 0 2 kgf m shock absorber upper mounting nut 32 Ibf ft 44 N m 4 5 kgf m e After installing the carburetor adjust the throttle cable 1 freeplay and hot start cable 2 freeplay e After installing the carburetor check the throttle position sensor connector 3 for correct routing as necessary e After installing the carburetor check the air vent hoses 4 and overflow hose 5 for kinking or pinching and correct routing as necessary 1 2 va i E G EN HO l A JA 1 throttle cables 2 hot start cable 3 throttle sensor connector contd Adjustments for Competition 135 Carburetor Adjustments amp Tuning Tips Idle Speed Adjustment 1 If the engine is cold start it and warm it up 3 minutes Then shut it off Connect a tachometer to the engine Shift into neutral Start the engine Keep
29. a replacement tube equivalent to the original Tire Replacement The tires that came on your CRF were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions A WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owners manual 80 100 21 51M Front DUNLOP D742F 110 100 18 64M Rear DUNLOP D756 Type bias ply tube type e Use a replacement tire equivalent to the original e Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Tires amp Tubes Servicing Your Honda 93 Side Stand Refer to Safety Precautions on page 25 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease 94 Servicing Your Honda Refer to Safety Precautions on page 25 An endless riveted master link chain connects the drive and driven sprockets The O ring chain uses rubber between the side plates of the pin and roller links to seal in the manufacturer installed lubricating grease and keep out mois
30. an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system 158 Technical Information If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containi
31. by pumping the damper rod several times TUTTLE 1 fork damper 5 Clean the fork cap and fork damper threads 1 fork damper 1 fork damper Front Suspension Adjustments 6 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 5 US oz 192 cm 6 8 Imp oz 4 fork oil 7 Pump the fork damper piston rod 5 slowly several times to bleed the air from the fork damper 1 ED 5 piston rod contd Adjustments for Competition 113 Front Suspension Adjustments 8 Extend the fork damper piston rod to maximum length Adjust the oil level of the fork damper as shown Oil Level 1 65 1 85 in 42 47 mm 1 65 1 85 in 42 47 mm 1 fork damper 4 fork oil 9 Apply fork oil to the bushing 6 and new O rings 7 on the fork cap assembly 2 Extend the fork damper piston rod to maximum length holding it install the fork cap assembly to the fork damper 1 Be careful not to damage the fork cap bushing If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 2 od Pe Sy u 7 1 fork damper 6 bushing 2 fork cap assembly 7 O rings 114 Adjustments for Competition 10 Tighten the fork cap assembly 2 whil
32. cd 91 Miress amp TUBES ss GE ER Re Skop LERE ee ve ogie ed 92 1de Stander EE ee cece Meet niece 94 Drive Chait N OR ER EE a 95 Additional Maintenance Procedures 98 Electrical Battery stat N EE AE ET EG 100 Headlight amp Taillight ees se see see se de 102 Appearance Cafe sees es EE ee Ee sed esi 104 Adjustments for Competition 006 107 Front Suspension Adjustments cee 108 Rear Suspension Adjustments eee 122 Suspension Adjustments for Track Conditions ei ciate cial eeu 126 Suspension Adjustment Guidelines 127 Carburetor Adjustments amp Turning Tips 130 Chassis AdjustmentS iese see se see ee Ge de 137 ETE RE EE RE N N hel 138 Tire Selection for Track Conditions 139 Personal Fit Adjustments cece see se see 140 dil RR EER NE 141 Transporting Your Motorcycle esse see 142 Storing Your Honda eee see see esse es se ee 143 You amp the Environment esse esse esse see see see 145 Troubleshooting sesse esse ee RA Ge dee 146 Taking Care of the Unexpected 0 147 Ifa F se lo AR RE EE N 148 If Your Battery is Low or Dead esse sesse 149 Technical InformatiOn e sesse sesse se esse se sees 151 Vehicle Identification cee sesse se ek ee dee 152 Specifications see steer atei es ee 153 Torque SpecificatONnS esse ese ek ek dee 154 Emission Control Systems n se 157 Oxygena
33. ft 36 N m 3 7 kgf m If the brake pedal return spring 15 was removed connect it 14 Insert the pin 17 12 dust seals 13 brake pedal 14 pivot bolt 15 return spring 16 washer 17 pin 15 Fill the crankcase with transmission oil page 47 Servicing YourHonda 59 Hot Start Lever Refer to Safety Precautions on page 25 Adjustment Adjustments can be made with the cable end adjuster Hot Start Lever Freeplay Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will increase freeplay and turning it counterclockwise will decrease freeplay After adjustment tighten the lock nut 1 hot start lever 2 freeplay Inspection Check freeplay 2 7 3 lock nut increase Freeplay 1 16 1 8 in 2 3 mm 4 cable adjuster decrease If necessary adjust to the specified range 60 Servicing Your Honda Refer to Safety Precautions on page 25 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions Standard IFR8H11 NGK or VK24PRZ11 DENSO Optional IFR9H11 NGK or VK27PRZ11 DENSO Use only the recommended type of spark plugs in the recommended heat range NOTICE Using a spark plug with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause ignition problems This motorcycle uses a spark plug th
34. headlight unit with its TOP mark 9 facing up 1 Remove the two front visor bolts 1 and pull out the front visor 2 6 headlight bulb socket 4 Install a new headlight bulb 7 into the headlight unit while aligning the tabs with the 1 front visor bolts groove of the headlight unit 2 front visor 5 dust cover 9 TOP mark 6 headlight bulb socket If you touch the bulb with your bare hands clean 7 Connect the headlight connector 4 and 2 Release the headlight connector 4 from the it with a cloth moistened with denatured alcohol install it to the clamp 3 clamp 3 and disconnect the headlight to prevent early bulb failure Install the front visor by aligning its grommets connector 10 with the tabs 11 on the steering stem Remove the dust cover 5 Install and tighten the front visor bolts E Ha 7 headlight bulb 8 align 3 clamp 5 dust cover 3 clamp 10 grommets 4 headlight connector 4 headlight connector 11 tabs 102 Servicing Your Honda Headlight amp Taillight This model is equipped with an electric starter Headlight Aim and battery for easy engine starting There is a possibility of damage to the lighting The headlight aim can be raised or lowered system if the battery is carelessly removed Turn the adjusting screw 1 clockwise to move Never kick start the engine without the battery the headlight up or turn the adjusting screw connected count
35. higher rating greatly increases the chance of damage to the electrical system If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace the spare fuse that was installed If the replacement fuse of the same rating burns out in a short time there is probably a serious electrical problem on your CRF Leave the blown fuse in that circuit and have your CRF checked by your Honda dealer Jump starting is not recommended especially if you use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your CRF s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge see your Honda dealer If Your Battery is Low or Dead Taking Care of the Unexpected 149 150 Taking Care of Unexpected This section contains dimensions capacities and other technical data Vehicle Identification eee ee ee ee 152 Specifications enes o NSS Vee ESE KG ELKE GESE es 153 Torque SpecificatiOnS esse se ee ee ee ee 154 Emission Control Systems ccc sesse esse ee 157 Oxygenated Fuels esse ese see se ke ee ee ee 158 Competition Logbook 0 0 0 ei ses see se se ee ee 159 Optional Parts List iese ese see se ee ee ee ee 161 Spare Parts amp Equipment sesse esse esse 162 Wiring Diagr
36. incurring obligation Mich Add 6 Calif Add 8 25 Orders are mailed within 10 days Please allow Handli adequate time for delivery Charge g 5 00 Grand Total 166 Consumer Information ok KA dd dzZMEKPY NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a guotation Customer Name Attention Street Address No P O Box Number City Apt State Zip Code Daytime Telephone Number send cash Master Account Number Card VISA Discover Check or money order enclosed payable to Helm Inc U S funds only Do not Check here if your billing address is different from the shipping address shown above Expiration Date Mo Yr Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order HELM PO BOX 07280 DETROIT MICHIGAN 48207 Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your H
37. injury when you ride 10 Before Riding A WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Be sure you always wear a helmet eye protection and other protective apparel when you ride Competitive riding can be tough on a motorcycle so it s important to inspect your CRF and correct any problems you find before each ride Check the following items page numbers are at the right A WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems Is Your Motorcycle Ready to Ride Pre ride Inspection Check the following before each ride Engine Ol level isi esels se NELSON gs ng dad 44 Transmission oil level ee eee eee se se ee 47 Coolant for proper level eee eee se 48 Cooling system and hoses for condition 49 Spark plug for proper heat range carbon fouling and high tension cord terminal for LOOSENESS EE ARE EER 61 Air cleaner for condition and CONtaminatON ees esse see se se ee ee Se Ge ee 51 Clutch operation and freeplaY iese esse see se 56 Steering head bearings and related parts eise oie SE EA AA 98 Carburetor throttle operation iese ses see se 55 Engine idle speed for stable and proper RPM ER EE ne De EE er De dee Ee ei 136 Tires for damage or improp
38. its 162 torque specifications sesse ese ee 154 156 trans MG AE N EE EE EE 142 troubleshooting eie ese ss ek ee ee ee ee 146 tubes replacing iese esse ee Ge ee ee Ge ee 92 V valve tuele ESE Ee GE tae lates 15 vehicle identification iese sesse se ee ee ee 152 W washing your motorcycle ees se esse esse ese 104 ed ve bi vat OR ED EE ER OE 3 WHEE RE RE HEEN 91 writing diagram sesse esse ese de sed ee ee ee ee ed 163 174 Index Memo 175 Ouick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important notes How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are e Transmission oil amp engine oil insufficient quantity improper oil e Air cleaner dirty leaking because of improper installation poor seal 176 Ouick Reference Record important information here Frame No Engine No Owners Name Address City State Phone Dealer s Name Address City State Phone Service Mgr Maintenance The maintenance schedule pages 27 28 lists service frequencies for about 2 5 hours about 7 5 hours about 15 0 hours about 22 5 ho
39. l l 103 T CLUTCH SYSTEM l l l l l 56 6 SIDE STAND l l 94 9 SUSPENSION l 83 84 i SPARK ARRESTER C every 1 000 mi 1 600 km or 65 5 every 100 operating hours NUTS BOLTS FASTENERS I 99 WHEELS TIRES I l l l 91 92 STEERING HEAD BEARINGS I 98 Should be serviced by your Honda dealer unless the owner has the proper tools and service data and are mechanically qualified Refer to the Official Honda Service Manual page 168 In the interest of safety we recommended these items be serviced only by your Honda dealer Maintenance Schedule Summary of Maintenance Schedule Notes and Procedures NOTES 1 Service more frequently when ridden in wet or dusty conditions 2 California only 3 Replace every 2 years Replacement requires mechanical skill Servicing Your Honda 27 Maintenance Schedule MAINTENANCE SCHEDULE COMPETITION USE All items should be checked before each competition event See your Honda dealer unless you are mechanically qualified and have the proper tools Damage from competition use is not covered by the Distributor s Limited Warranty on your Honda Perform the Pre ride Inspection page 11 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace
40. ni ieia 17 eel sl AE EE wn dae a 18 ei di DE OE N EDE N 19 Post ride Inspection 20 Break in Guidelines 0 0 ee see se ee ee ee ee 21 Servicing Your Honda ccsssscsssscssssscsscees 23 Before You Service Your Honda The Importance of Maintenance eee 24 Maintenance Safety ee see se ee ee ee ee 25 Important Safety PrecautionS iese sesse see 25 Maintenance Schedule iese se ese ee ee 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal Eie EE Ee KEES Ge Re cae 36 Fuel Tank Removal sees esse see se ee es ee ed 37 Subframe Upright Position see se esse ee 39 Contents Service Procedures Fluids amp Filters IS AE SA N ER kig 41 oil AS ER ORE EE 43 Transmission Oil occ see see ee ee Ge Ge 46 Coolant cas AE N EL 48 ide RE EE N 51 Crankcase Breather 0 0 0 ce sesse ee ee ee 53 Engine Throttle tse breek Ses liese ke ges oes bee Reg 54 Clutch Systeri peinp LE OE Ru Ee ee Eg 56 Hot Start Lever iese ee ate ese ene ee RE Ek 60 Spark dl NE OE 61 Exhaust Pipe Muffler iese sesse esse es se ese ee se 62 SParkATrester tie ie ve ee Sep ee RE bu ge ns 65 Valve Clearance esse sees sede see ee ee Ge Ge 66 Piston Piston Rings Piston PIN esse sees sesse 75 Chassis SUSPETiS1OT vise Ee Ee GE Ee ee Pe GEE ER Ee Es 83 El ARE EE N EL 87 AE RE EE EE
41. on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD 21 outer tube 22 guide bushing 15 Drain the fork oil from the outer tube 21 Drain the fork oil from the oil hole 25 of the fork damper SCUTTLE EEE EL TUTTLE SOUT 21 outer tube 25 oil hole Front Suspension Adjustments 16 Temporarily install the fork damper to the outer tube 17 Set the axle holder 26 of the slider in a vise with a piece of wood or soft jaws to avoid damage NOTICE Overtightening the vise can damage the axle holder 18 Loosen the fork center bolt 27 ON 26 axle holder 27 fork center bolt cont d Adjustments for Competition 111 Front Suspension Adjustments 19 Push out the fork center bolt 27 from the axle holder 26 of the slider by pushing the fork damper While the fork center bolt 27 is pushed out install the piston base 28 or a mechanic s stopper tool between the axle holder 26 and lock nut 29 20 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool 55 mm 25mm 30 mm D 21 Hold the lock nut 29 and remove the fork center bolt 27 from the fork damper NOTICE Do not remove the l
42. pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 30 0 hours of running 1 piston pin clip 2 piston pin 3 piston Piston Piston Rings Piston Pin 4 Spread each piston ring 4 and remove by lifting it up at a point just opposite the gap NOTICE Do not damage the piston ring by spreading the ends too far 4 piston ring Servicing Your Honda 77 Piston Piston Rings Piston Pin Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your authorized Honda dealer for correct Service Limit measurements 78 Servicing Your Honda Piston Ring Installation 1 Clean the piston ring groove throughly 2 Apply engine oil to the piston rings and install them NOTICE Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation e To install the oil ring install the spacer first then install the side rails e Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower
43. plate chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front visor amp side covers handlebar grips levers brake clutch amp hot start clutch lever handlebar mount clutch cable hot start cable throttle assembly throttle cable shift lever brake pedal spokes front amp rear each side sprockets smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins headlight bulbs battery fuses Additional Spares front brake assembly rear brake assembly wheels amp tires front amp rear mounted clutch disc and plates 162 Technical Information engine amp transmission oil seat ignition components radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CRF purchased from your Honda dealer e Clutch Center Holder 07724 0050001 or 07724 005000
44. products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department 168 Consumer Information Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the club There are handreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include e 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundat
45. reduce boot sole lifespan Sharpen only the points of the teeth Filing the grooves deeper will weaken the footpegs Be sure the footpegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition Water Leakage Check Hole After every race check the leakage check hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged mechanical seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced 32 Servicing Your Honda Steering Head Bearings i Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Fork Oil Performance Disassemble clean and inspect the fork and replace the oil regularly Contamination due to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performance of the suspension Refer to the Honda Service Manual page 168 Use only Pro Honda HP Fork Oil SW U S A only or equivalent which contains special additives to assure maximum performance of your CRF s front suspension Frame Because your CRF is a high performance machine the frame should not be overlooked as part of your overall competition maintenance prog
46. rollers loose fitting links damaged O rings or otherwise appears unserviceable Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced Replacement Chain DID520MXV 0 53 in 13 4 mm 1 drive chain plate inner 96 Servicing Your Honda 4 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly worn drive chain Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket ie Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD NOTICE Use of a new chain with worn sprockets will cause rapid chain wear 5 Lubricate the drive chain 6 Recheck chain slack and adjust if necessary Drive Chain Drive Chain Sliders Drive Chain Rollers Lubrication 1 Check the chain slider 1 for wear 1 Measure the diameter of the drive chain Lubricate the drive chain with 80 90 gear oil If the wear is 3 16 in 5 mm or more replace rollers 1 Replace them if below the service or drive chain lubricant designed specifically for it limit use with O ring chains Wipe off the exc
47. the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If you re using a new plug ride for at least ten minutes before taking a plug reading a brand new plug will not color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere Check the carburetor fuel system and ignition timing 8 With the sealing gasket attached thread the spark plug in by hand to prevent cross threading 9 Tighten the spark plug e If the old plug is good 1 8 turn after it seats e If installing a new plug tighten it twise to prevent loosening a First tighten the plug NGK 3 4 turn after it seats DENSO 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats 10 Connect the spark plug cap 11 Install the fuel tank and seat page 38 Servicing Your Honda 61 Exhaust Pipe Muffler Exhaust Pipe Muffler Inspection Check the mounting bolts and joint nuts for tightness Check the exhaust pipe and muffler for cracks or deformation A damaged exhaust pipe and muffler may reduce engine performance 62 Servicing Your Honda Muffler Removal 1 Remove the seat bolt 1 side cover bolt 2 and right side cover 3 1 seat bolt 2 side cover bolt 3 right side cover 2 Loosen the muffler c
48. the motorcycle in an upright position Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 rpm NAUN 1 throttle stop screw 4 air vent hoses 5 overflow hose 136 Adjustments for Competition The following suggestions may improve a specific concem Subtle changes in overall handling may also be noted Rear End If you have a problem with rear wheel traction raise the rear end of your CRF by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your CRF s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your CRF wants to turn too quickly lower the rear of the motorcycle by reducing the rear spring pre load This will increase fork rake and trail and should improve stability in a straight line The effective suspension travel will be transferred toward the firmer end of wheel travel Keep the race sag adjustment page 124 in the 90 110 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the fork tube 1 with the top of the upper fork clamp 2 STANDARD POSITON 1 top of outer tube 1 2 upper fork clamp 3
49. tires are cold If you check air pressure when your tires are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are Front 15 psi 100 kPa 1 0 kgf cm Rear 15 psi 100 kPa 1 0 kgf cm If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Inspection Take time to inspect your tires and wheels before you ride 1 Ne N 7YN 77 A my fp NR 1 tire tread depth e Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 mm or any time you notice a reduction in traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim Tube Replacement If a tube is punctured or damaged you should replace it as soon as possible A repaired tube may not have the same reliability as a new one and it may fail while you are riding Use
50. to obtain the desired handling results Decreasing the race sag dimension example 3 5 in 90 mm improves turning ability for tight terrain at the cost of slightly reduced straight line stability Increasing the race sag dimension example 4 3 in 110 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the loaded without rider dimension Do this with your CRF set at the standard race sag BIKE LOADED without rider EXAMPLE 21 7 in 550 mm Example Unloaded 23 6 in 600 mm Loaded 21 7 in 650 mm Sag 2 0 in 50 mm Without Rider 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CRF sags more than 1 0 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will
51. will find important safety information in a variety of forms including e Safety Labels on the motorcycle e Safety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean y Teid d You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions NA ieg You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions y e7 Gua N You CAN be HURT if you don t follow instructions e Safety Headings such as Important Safety Reminders or Important Safety Precautions e Safety Section such as Motorcycle Safety e Instructions how to use this motorcycle correctly and safety This entire book is filled with important safety information please read it carefully Safety Messages Contents Motorcycle Safety scsssscssssccssscsssscssseccsssceees 1 Important Safety Information iese ee 2 SR TA ORE N AAK 3 Accessories amp Modifications ee see see se se 4 Satety Labels Ed RE EE de EE dace 5 Operating Controls scccsccsssscsssscsssccssscsees 7 Operation Component Locations iese esse 8 Before Riding esse esse esse esse ee RR RS GR GE ES 9 Are You Ready to Ride eener 10 Is Your Motorcycle Ready to Ride sesse 11 Basic Operating Instructions ssessee0 13 Safe Riding Precautions iese see se see 14 Starting amp Stopping the Engine ee 15 SHEN GEASS rece AE ersari
52. you are riding a track with sections where you choose to over rev the engine temporarily rather than shifting up higher gearing might help Sometimes you have to sacrifice performance on one section of the track to gain a better overall time Your goal is the fastest overall lap time even if the cost is some sections where the gearing feels wrong If you decide to try a gearing change have someone check your times with a stopwatch before and after the change to get an accurate appraisal of the change Seat of the pants feelings can t be trusted Eliminating wheelspin with a gearing change can make you feel like you re going slower when in reality you ve decreased your time by increasing your speed with better traction These gearing recommendations should be evaluated by considering your ability your riding style and the track Choosing the correct tire tread pattern and rubber compound can affect your placing in competition The tires on your CRF offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tire
53. 0 C 32 F 1 L 1 outer tube 3 lock nut wrench 10 C 50 F 2 fork damper 2 Sor i G y Z 20 F Sa 20 C 68 F 30 C 86 F 1 outer tube 8 oil hole 0 20 40 60 80 100 120 140 160 Inverted time minutes contd Servicing Your Honda 85 Suspension 5 Pour the recommended fork oil page 85 into the outer tube Fork Oil Capacity Standard 0 47 kgf mm Fork Spring Oe No mark factory products or 1 scribe mark aftermarket parts Optional Softer 0 45 kgf mm Fork Spring O 2 scribe marks Standard oil 11 4 US oz capacity 338 cm3 Maximum oil 13 8 US oz Slightly stiffer as capacity 407 cm3 it nears full compression Minimum oil 10 5 US oz Slightly softer as capacity 311 cm3 it nears full compression 3 scribe marks Optional Stiffer 0 49 kgf mm Fork Spring Standard oil 11 2 US oz Standard oil 11 3 US oz capacity 332 cm3 capacity 335 cm3 Maximum oil 13 6 US oz Slightly stiffer as Maximum oil 13 7 US oz Slightly stiffer as capacity 402 cm3 it nears full capacity 405 cms it nears full compression compression Minimum oil 10 3 US oz Slightly softer as Minimum oil 10 5 US oz Slightly softer as capacity 306 cm3 it nears full capacity 309 cm3 it nears full compression compression 86 Servicing Your Honda Be sure th
54. 16 ground wire 17 and clamp bolts 18 then tighten the bolts Connect the primary wire connector 19 17 IM 19 18 EE N EER 16 sege ED HON Vi EX 16 ignition coil 17 ground wire 18 clamp bolts 19 primary wire connector 82 Servicing Your Honda 10 Install and tighten the left radiator lower mounting bolt washer 20 Install the left radiator grill 21 Ae ym ee NN 20 left radiator lower mounting bolt washer 21 left radiator grill 11 Install the camshaft holder assembly page 71 12 Install the crankshaft hole cap page 74 13 Install the cylinder head cover page 74 14 Install the spark plug and plug cap page 74 15 Install the PAIR control valve 22 O ring 23 and tighten the bolts 24 california only 16 Connect the vacuum 25 and air suction 26 hoses california only 22 PAIR control valve 23 O ring 24 bolts 25 vacuum hose 26 air suction hose Install the exhaust pipe page 64 Install the carburetor page 135 Install the subframe and muffler page 40 63 Install the fuel tank and seat page 36 38 Pour the recommended coolant page 50 Refer to Safety Precautions on page 25 Loose worn or damaged suspension components may adversely affect the handling and stability of your CRF If any suspension components appear worn or damaged see your Honda dealer for furth
55. 16 1 6 NOTE 2 26 Brake pedal pivot bolt 27 36 3 7 27 Spokes front 2 7 3 68 0 4 rear 2 7 3 7 0 4 28 Rim locks 9 12 1 2 29 Subframe bolts upper 22 30 3 1 lower 36 49 5 0 30 Drive chain roller uppen 9 12 1 2 NOTE 3 lower 9 12 1 2 NOTE 2 31 Fork center bolt 51 69 7 0 32 Fork center lock nut 16 22 2 2 33 Disc cover bolts 10 13 1 3 34 Fork protector bolts 5 2 7 0 7 NOTE 4 35 Muffler mounting bolts front 19 26 2 7 rear 19 26 2 7 36 Muffler clamp bolt 15 21 2 1 37 Driven sprocket nuts 24 32 3 3 NOTE 2 38 Seat bolts 19 26 2 7 39 Front brake reservoir cap screws 0 7 1 0 0 1 40 Rear brake reservoir cap bolts 0 7 1 0 0 1 41 Fork air pressure release screw 0 9 1 2 0 1 42 Side stand mounting bolts upper 41 55 5 6 lower 22 30 3 1 NOTES 1 Apply oil to the threads and flange surfaces 2 U nut 3 SH bolt Exhaust Emission Requirements The California Air Resources Board CARB requires that your CRF comply with applicable exhaust emissions standards during its useful life when operated and maintained according to the instructions provided California only The Vehicle Emission Control Information Label 1 is attached on the rear fender fim 1 Vehicle Emission Control Information Label Noise Emission Requirements The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 1 865 mile
56. 2 O7WMA KZ30100 070MG 0010100 O7JMA MR60100 07958 2500001 e Lock Nut Wrench e Tensioner Stopper e Spoke Wrench e Piston Base Chemical Products Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke Oil Engine Oil Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives only 4 stroke Oil Transmission Oil Honda thread Lock Pro Honda HP Fork Oil 5W Honda DOT 4 Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Canada Pro Honda Foam Filter Oil Hondabrite Cleaner Honda Contact Cleaner Honda Dielectric Compound Honda Hand Grip Cement Honda Hondalock Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive White Lithium Grease Wheel Bearing Grease Silicone Sealer high temperature grease Pro Honda HP Coolant Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape Wir ing Diagram IGNITION CONTROL MODULE REGULATOR RECTIFIER STARTER MAGNETIC SWITCH Od
57. 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F NOTICE Recommended Fork Oil The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid viscosity weight 5 W suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when i 7 equivalent removing the fork damper 1 V 7 f NO GOOD Fork Oil Change 7 Refer to Suspension Removal on page 108 1 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it g LA stops NO GOOD sk 2 Hold the outer tube 1 then remove the fork MILE damper 2 from the outer tube using the lock 4 dust seal 6 slider nut wrench 3 5 guide bushing 7 outer tube 1 outer tube 3 Drain the fork oil from the outer tube 1 Amount of fork oil left in the fork Drain the fork oil from the oil hole 8 of the within damper and spring unit cc minute Tork damper 5 10 20 35 55 85 145 CF 30 86 27 15 3 10 6 94 83 7 9 7 9 20 68 29 4 16 5 11 8 10 6 94 82 82 8 K oe 10 50 28 2 21 2 16 5 15 3 12 9 11 8 11 8 k 0 32 30 6 22 4 18 8 16 5 16 5 15 3 14 1 35
58. Always use new gaskets when reassembling components Fuse Check the fuse before looking elsewhere for the cause of an electrical problem Battery Electrical accessories use current from the battery even when the engine is off Limited operation also allows the battery to discharge If you have electrical accessories on your CRF or do not ride frequently we recommend that you charge the battery frequently see Battery charging page 100 If you do not expect to ride your CRF for at least two weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Honda Dielectric Grease on all electrical connections Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Honda Thread Lock or an equivalent prior to torquing the nuts Servicing YourHonda 31 General Competition Maintenance Suspension Linkage Lubrication Disassemble clean inspect and lubricate all pivot bearings after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Use Honda Moly 60 paste
59. EE N EEN OE 95 Additional Maintenance Procedures 98 Electrical Battery RE AE EE 100 Headlight amp Taillight 0 0 0 eee se ek ee see 102 Appearance Care i essed se ie i 104 Adjustments for Competition 000 107 Front Suspension Adjustments cee 108 Rear Suspension Adjustments cece 122 Suspension Adjustments for Track rs ete ia lo EE EE ON 126 Suspension Adjustments Guidelines 127 Carburetor Adjustments amp Tuning Tips 130 Chassis Adjustment cc esse see se ek ek dee 137 GATING as RE EE ON 138 Tire Selection for Track Conditions 139 Personal Fit Adjustments o 140 dl ER ER N N EE 141 Transporting Your Motorcycle eee 142 Storing Your Honda eee see ee esse ee ee 143 You amp the Environment esse esse esse see see see 145 Troubleshooting ce see se ese ee ee RA Ge dee 146 Taking Care of the Unexpected 0006 147 Tf a Fuse BlOWS neniecon ionan 148 If Your Battery is Low or Dead esse sesse 149 Table of Contents Technical InformatiONn seesesse sesse see sesse se ese 151 Vehicle Identification ees esse ee ee ee ee 152 jle iste tse OE ER OE N 153 Torque Specifications 154 Emission Control Systems esse sees see se see 157 Oxygenated Fuels iese sesse ese ee ee ee ee 158 Competition Logbook sesers 159 Optional Parts LS sesse ee ek ee ee 161 Spare Parts amp Equipment esse e
60. IMPORTANT NOTICES FOR RECREATIONAL OFF ROAD OR COMPETITION USE ONLY This motorcycle is designed and manufactured for recreational off road use or competition only and is covered by noise control warranty It does not conform to federal motor vehicle safety standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester If you need to cross a paved or public road get off and walk your motorcycle across Do not modify any emission related items except for competition use Any emission related modifications should be restored to standard factory specifications before resuming recreational off road use NO PASSENGERS This motorcycle is designed and constructed as an operator only model The motorcycle load limit and seating configuration do not safety permit the carrying of a passenger This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured on the front cover may not match your vehicle Honda Motor Co
61. Manual or see your Honda dealer for brake bleeding 88 Servicing Your Honda Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 89 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake pedal freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding Adding Front Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an eguivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 1 2 1 screws 3 diaphragm 2 reservoir cap 4 upper level mark 1 Remove the screws 1 reservoir cap 2 and diaphragm 3 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 4 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 0 7 Ibf ft 1 N m 0 1 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out
62. N Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor OFF Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor RES Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor Starting Procedure Always follow the proper starting procedure described as follow Par ON WET or Ie 3 2 1 fuel valve 2 choke knob Check the engine oil transmission oil and coolant levels before starting the engine pages 44 47 48 To restart a warm engine follow the procedure for High Air Temperature Normal Air Temperature 10 C 35 C 50 F 95 F 1 Turn the fuel valve 1 ON 2 Pull the choke knob 2 fully ON if the engine is cold 3 Keep the throttle fully closed 4 Pull the clutch lever all the way in and depress the start button Or operate the kickstarter to start the engine Starting from the top of the stroke kick through to the bottom with a rapid continuous motion Do not operate the throttle NOTICE Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case Starting amp Stopping the Engine 5 Warm up the engine don t operate the throttle 6 About 15 seconds after the engine starts push the choke knob back all the way to fully OFF If idling is unstable open the throttle slightly NOTICE
63. OC PP SG 6 Cw ONES xe JQ PT 3 OL EP DEI 4 6 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts Servicing Your Honda 99 Battery Refer to Safety Precautions on page 25 Your CRF has a maintenance free type battery You do not have to check the battery electrolyte level or add distilled water as you would with a conventional type battery NOTICE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed Electrical accessories use current from the battery even when the engine is stopping Limited operation also allows the battery to discharge If you have electrical accessories on your CRF or do not ride frequently we recommended that you charge the battery frequently see Battery Charging on page 101 If you do not expect to ride your CRF for at least two weeks we recommended you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your CRF see Battery Storage this page If your battery seems weak and or is leaking electrolyte cause slow starting or other electrical problems see your Honda dealer WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Battery Storage If you plan
64. SE sg ee cits 162 logbook competition ees esse ee ee se 159 eie ders AE EE EE HEN 41 P Ete dd RE EE RE ii i 61 mantenan e EE EE EE ee N EE REE 61 er EE EE ME N Ed 90 Specification Sh iss ED erge k ae GE ee gee 153 154 Parts optional iss iessessvecebalesespacseerbesdeeees Needs 161 spring pre load rear suspension esse sesse 122 personal fit adjustment eee ee ee ee 140 starting PINGING ENGINE Een Ee ees N ee EE ie 41 EM SANG shi EE EER SOs ie ee EE ee oge ed 15 MURE SEER EE NE N 61 troubleshooting eee see see se ee ee Ge 16 pre load rear SUSPENSION sees se ee ee ee 122 steering head bearing inspection iese esse ee 98 pre ride inspection 00 ees ee ee ee ee 11 Stopping Engine es ee ee ee ee ee ee 16 protective apparel sis see ee Ee ee ateei 2 ER EE EI catered 143 Subframe enced EE N N OE Ge 39 cont d Index 173 Index suspension PONE sisise teins ea vera nee ae AG aed 83 RE AE EE RE EE 84 suspension adjustment MONT ds Aten AE OR EE 108 EE OR EE AN 122 for track conditions lees se se ee ee 139 guideline Sapian naraven GERS Ee be Dee ge 127 T transmission Oi eee ee se se ee ee Ge ee 46 TUMIN 8 CIPS Ese de ed Ee ve RE seth Ese eie 130 throttle PES PAY ciecsssciscchbccasebestesthsavtewsbes ssedissniacdtt stages 54 INSPECUION EE eie ieai 55 tires Alt PLESSUTEs aie EES ER eileen ease 92 ERA RE EN EEN 92 SClECHOMD seis RR OE EE NE 93 TOOLS De GED ee N ee tra
65. U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive SSH lt S oS Brake Fluid Replacement Refer to Brake Pad Wear in your Owner s Manual page 90 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper bracket pins Check pad thickness periodically and replace when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Replace the hydraulic fluid in the brake system every two years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid Swingarm Pivot Lubrication Clean inspect and lubricate when servicing suspension linkage pivots Be sure all of the suspension pivot seals are in good condition Use Honda Moly 60 paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Swingarm Do not attempt to weld or otherwise repair a damaged swingarm Welding will weaken the swingarm Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file Be aware that filing them too sharp will
66. air cleaner specified for your model Using the wrong Honda air cleaner or a non Honda air cleaner which is not of equivalent quality may cause premature engine wear or performance problems Air Cleaner Housing Sealing Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity Use Hondalock or an equivalent on the attaching studs Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration Handgrips Always use Honda Hand Grip Cement U S A only or equivalent when replacing handgrips Throttle grip Align the index mark on the throttle grip with the edge of the throttle cable guide Left handlebar grip Align the A mark on the left handlebar grip with the paint mark on the handlebar Refer to the Honda Service Manual page 166 for installation instructions For added security you may choose to safety wire the hand grips to the handlebar and throttle to prevent the possibility of them loosening Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the grip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the drum and the handlebar thoroughly and apply a light coating of commercially available cable lubricant Inspect the cable carefully for kinks or other d
67. alve 11 Remove the throttle drum cover bolt 10 and throttle drum cover 11 10 throttle drum cover bolt 11 throttle drum cover 12 Remove the throttle cables 12 by looseing the throttle cable lock nut 13 and adjusting nuts 14 12 throttle cables 13 throttle cable lock nut 14 adjusting nuts Carburetor Adjustments amp Tuning Tips 3 Remove the link arm set screw 7 Carburetor Disassembly Assembly When installing the link arm set screw apply a locking agent to the link arm set screw 1 Pull up the cable clamp 1 and remove the threads carburetor top bolts 2 4 Remove the throttle valve 8 throttle valve Then remove the carburetor top 3 roller 9 and floating valve 10 1 cable clamp 2 carburetor top bolts 3 carburetor top 2 Remove the jet needle holder 4 and jet needle 5 from the throttle valve 6 8 throttle valve 10 floating valve es 7 link arm set screw 9 throttle valve roller 6 4 jet needle holder 5 jet needle 6 throttle valve contd Adjustments for Competition 133 Carburetor Adjustments amp Tuning Tips When installing the floating valve 10 onto the throttle valve 8 make sure the floating valve s flat side faces out and the hole 11 faces down 8 8 throttle valve 10 floating valve 11 hole 134 Adjustments for Competition 5 Remove the accelerator pump cover screws 12 and accelerator pump cover
68. am sesse eiiiai 163 Technical Information Technical Information 151 Vehicle Identification 7 The frame number 2 is stamped on the right Serial Numbers side of the steering head The VIN frame and engine serial numbers are RIGHT SIDE required when you register your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of the manual The VIN vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number 152 Technical Information For USA amp CANADA Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85 8 in 2 180 mm Type Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 32 3 in 821 mm Cylinder arrangement Single 6 se from Transmission 5 speed constant mesh Overall height 50 1 in 1 273 mm vertica Primary reduction 2 739 Wheelbase 58 4in 1 483 mm Bore and stroke 3 78 x 2 44 in 96 0 x 62 1 Gear ratio 2 230 Seat height on 295 nm Di
69. am lobes 6 camshaft holder assembly bolts cont d Servicing Your Honda 71 Valve Clearance 5 Rotate the primary drive gear bolt 7 crankshaft clockwise and align the punch mark 8 with the index mark 9 Make sure the piston is at TDC Top Dead Center on the compression stroke 7 9 7 primary drive gear bolt 8 punch mark 9 index mark 72 Servicing Your Honda 6 Place the cam sprocket 10 and align the index line 11 on the cam sprocket with the A mark 12 on the camshaft holder assembly Install the cam chain 13 over the sprocket without rotating the sprocket 0 cam sprocket 1 index line 2 A mark 3 cam chain 7 Clean and apply a locking agent to the cam sprocket bolt threads coating width 0 26 0 04 in 6 5 1 mm from tip Temporarily install the cam sprocket bolt 14 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt 14 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Turn the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt to the specified torque see above NOTICE Do not let the bolts and sprocket fall into the crankcase 14 cam sprocket bolts 8 Remove the tensioner stopper 15 from the cam chain tensioner lifter Decompressor Arm Clearance Adju
70. amage that may restrict throttle control in any way Move the handlebar from lock to lock to be sure there is no cable interference Check to be sure the top of the carburetor is screwed on tight Make certain the throttle operation is perfect after servicing and inspecting General Competition Maintenance Fuel Contamination Refer to Fuel System in your Owner s Manual page 41 and in this supplement Fuel System page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel joint and fuel filter Replace the fuel joint O ring if there are any signs of damage or deterioration page 41 Loosen the carburetor drain screw and examine the fuel that flows out of the float bowl If you notice anything in the fuel such as water or dirt remove the float bowl and inspect Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel joint and filter Replace the fuel joint O ring if there are any signs of damage or deterioration page 42 Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 77 its contents page 132 For maximum efficiency drain and replace fuel that has remained in your fuel tank for more than a month Gaskets
71. ame lower mounting bolts Servicing Your Honda 39 Subframe Upright Position Installation 1 Loosen the subframe upper mounting bolts 1 2 Loosely attach the lower ends of the subframe 2 to the mainframe while connecting the air cleaner connecting boot to the carburetor Be careful not to bend the subframe Install the subframe lower mounting bolts 3 Tighten the subframe upper mounting bolts first then tighten the subframe lower mounting bolts to the specified torque upper bolts 22 Ibf ft 30 N m 3 1 kgf m lower bolts 36 Ibf ft 49 N m 5 0 kgf m 1 subframe upper mounting bolts 2 subframe 3 subframe lower mounting bolts 40 Servicing Your Honda 3 Tighten the screw 4 on the air cleaner connecting boot clamp 5 Install the muffler page 63 Install the left side cover 6 and left side cover bolt 7 Close the air cleaner box cover 8 and turn the quick fastener 9 clockwise ns screw air cleaner connecting boot clamp 2 4 5 6 left side cover 7 left side cover bolt 8 air cleaner box cover 9 quick fastener 6 Install the right side cover 10 and right side cover bolt 11 10 right side cover 11 right side cover bolt 7 Install the seat page 36 Refer to Safety Precautions on page 25 Fuel Recommendation Type Unleaded Pump Octane Number 91 or higher We recommend that you use unleaded fuel becaus
72. amp 9 and ignition coil 10 Remove the bolts 3 O ring 4 and PAIR 10 Clean the area above the engine before control valve 5 california only disassembly to prevent dirt falling into the engine Drain the engine oil page 44 Drain the radiator coolant after cooling the motorcycle page 143 Remove the seat and fuel tank page 36 37 Lift the subframe to the upright position page 39 Remove the carburetor page 132 Remove the exhaust pipe page 64 Remove the spark plug page 61 8 primary wire connector 9 bolts clamp 1 air suction hose 4 O ring 10 ignition coil 2 vacuum hose 5 PAIR control valve 10 ig 3 bolts 14 Loosen the radiator hose clamp 11 and 11 Remove the camshaft holder assembly lifters disconnect the radiator hose 12 and shims page 68 12 Remove the left radiator grill 6 and left radiator lower mounting bolt washer 7 Wj es 11 radiator hose clamp 12 radiator hose 6 left radiator grill 7 left radiator lower mounting bolt washer cont d Servicing Your Honda 75 Piston Piston Rings Piston Pin 15 Remove the engine hanger nut 13 engine 16 Remove the cylinder head bolts 20 19 Remove the dowel pins 24 cylinder head hanger bolt 14 and fuel hose guide 15 17 Loosen the cylinder bolt 21 gasket 25 and cam chain guide 26 Remove the engine hanger plate bolts 16 clutch cable stay 17 left engine hange
73. amper assembly 4 to the outer tube slider 1 1 outer tube slider 3 spring 4 fork damper assembly 4 Set the axle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage NOTICE Overtightening the vise can damage the axle holder 5 Temporarily install the fork damper to the fork Push out the fork damper piston rod from the axle holder of the slider by pushing the fork damper Apply pressure to the fork damper and insert the piston base 5 or mechanic s stopper tool between the axle holder and lock nut Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the piston rod until it stops Check the push rod installation by turning the push rod right and left 7 Install a new O ring 7 to the fork center bolt 8 Install the fork center bolt to the fork damper piston rod aligning the center bolt adjusting rod 9 with the push rod Tighten the fork center bolt fully by hand 2 lock nut 5 piston base 6 push rod 7 O ring 8 fork center bolt 9 adjusting rod 8 Measure the length of the lock nut 2 and fork center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 0 06 0 08 in 1 5 2 0 mm a Ja 2 lock nut 8 fork center bolt 9 Tighten the lock nut 2 to the for
74. at has an iridium tip in the center electrode and a platinum tip in the side electrode Be sure to observe the following when servicing the spark plug e Do not clean the spark plug If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one e Use only a wire type feeler gauge to check the spark plug if necessary To prevent damaging the iridium tip of the center electrode and platinum tip of the side electrode never use a leaf type feeler gauge e Do not adjust the spark plug gap If the gap is out of specification replace the spark plug with a new one Spark Plug Replacement amp Inspection 1 Remove the seat and fuel tank page 37 2 Disconnect the spark plug cap 1 3 Clean any dirt from around the spark plug base 4 Remove the spark plug 2 5 Check the electrode for wear or deposits the sealing gasket 3 for damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 039 0 043 in 1 0 1 1 mm 3 sealing gasket 4 spark plug gap Spark Plug 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch by pulling the lever in Coast to a stop then remove and inspect
75. be replaced minimum thickness indicator 0 04 in 1 mm 4 replace 4 brake pads 5 rear brake caliper 6 brake disc Other Inspections Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Refer to Safety Precautions on page 25 Maintenance of spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first few rides spokes will loosen more rapidly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims amp Spokes 1 rim lock nut 3 spokes 2 wheel rim 4 spoke nut 1 Inspect the wheel rims 2 and spokes 3 for damage 2 Tighten any loose spoke nut 4 and rim lock nut 1 to the specified torque Front Spoke Nut 2 7 Ibf ft 3 68 N m 0 4 kgf m Rear Spoke Nut 2 7 Ibf ft 3 7 N m 0 4 kgf m Rim Lock Nut 9 Ibf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noti
76. ble clamp screws to the specified torque 0 7 Ibf ft 1 0 N m 0 1 kgf m 22 Align the brake caliper 23 and hose with the let fork leg making sure that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency 23 Clean the threads of the caliper mounting bolts 22 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper 23 on the slider and tighten the caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 18 fork protector bolts 19 tripmeter cable clamp bolts 20 brake hose clamp bolts 22 caliper mounting bolts 21 fork protectors 23 brake caliper 120 Adjustments for Competition 24 Check the left side collar 24 and tripmeter gear box 25 for wear or damage Install the left side collar 24 to the left wheel hub Install the trip meter gear box 25 while aligning its tabs 26 of the tripmeter gear box with the grooves 27 on the right wheel hub 24 left side collar 25 tripmeter gear box 26 tabs 27 grooves 25 Clean the clamping surface of the axle and axle holders Install the front wheel 28 between the fork legs while inserting the disc between the pads and align 29 the tab of the tripmeter gear box as shown Check that the tripmeter gear box O ring 30 is in good condition replace it if necessary Apply a thin layer of grease to the axle 31 and insert
77. bolts 16 22 2 2 5 Handlebar lower holder nuts 32 44 4 5 6 Front axle nut 65 88 9 0 7 Front axle holder pinch bolts 15 20 2 0 8 Rear axle nut 94 128 13 1 NOTE 2 9 Chain adjuster lock nuts 20 27 2 8 NOTE 3 10 Lower engine mounting nut 40 54 5 5 11 Upper engine hanger plate bolts 19 26 2 7 12 Upper engine hanger nut 40 54 5 5 13 Front engine mounting nut 40 54 5 5 14 Shock absorber upper 32 44 4 5 NOTE 2 lower 32 44 4 5 NOTE 2 15 Swingarm pivot nut 65 88 9 0 NOTE 2 16 Fork fork damper 25 34 3 5 fork cap 22 30 3 1 17 Rear shock link nuts swingarm side 39 53 5 4 NOTE 1 2 shock arm side 39 53 5 4 NOTE 1 2 18 Rear shock arm nuts 39 53 5 4 NOTE 1 2 19 Shock spring lock nut 32 44 4 5 20 Kickstarter arm bolt 28 38 3 9 NOTES 1 Apply oil to the threads and flange surface 2 U nut 3 UBS nut 4 SH bolt 5 Apply locking agent to the threads Technical Information 155 Torque Specifications Frame od 22 38 35 Ere A 31 32 156 Technical Information 4 Apply locking agent to the threads Torque Item Remarks Ibfeft Nem kgfem FRAME 21 Front brake master cylinder holder bolts 7 3 9 9 1 0 22 Brake hose bolts 25 34 3 5 23 Caliper mounting bolts 22 30 3 1 NOTE 4 24 Front brake disc nuts 12 16 1 6 NOTE 2 25 Rear brake disc nuts 12
78. ceable see the Honda Service Manual for inspection instructions Axles amp Wheel Bearings See the Honda Service Manual for inspection information 1 Check the axle shaft for runout 2 Check the condition of the wheel bearings Wheels Servicing YourHonda 91 Tires amp Tubes Refer to Safety Precautions on page 25 To safely operate your CRF the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire replacement Air Pressure Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damage on hard terrain Overinflated tires make your CRF ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap 92 Servicing Your Honda Always check air pressure when your
79. crew one full turn clockwise advances the adjuster four positions To adjust the rebound damping to the standard setting proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 7 clicks Make sure that both fork legs are adjusted to the same position Compression Damping Adjustment This adjustment affects how quickly the fork compresses The fork compression damping adjuster 2 screw has 16 positions or more Turning the adjuster screw one full turn changes the adjuster four positions To adjust the adjuster to the standard position proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 14 clicks Make sure that both fork legs are adjusted to the same position Both compression and rebound damping can be increased by turning the adjuster clockwise NOTICE Always start with full hard when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the rebound and compression adjusters are firmly located in a detent and not between positions 1 rebound damping adjuster screw 2 compression damping adjuster screw Fo
80. cylinder gasket 4 Clean the any gasket material off the cylinder contd Servicing Your Honda 79 Piston Piston Rings Piston Pin 5 Apply clean engine oil to the cylinder wall piston outer surface and piston rings Route the cam chain 3 through the cylinder 4 Install the cylinder over the piston rings by hand while compressing the piston rings 5 NOTICE Do not damage the piston rings and cylinder walls 3 cam chain 5 piston rings 4 cylinder 80 Servicing Your Honda 6 Temporarily install the cylinder bolt 6 and connect the breather tube 7 to the cylinder 4 z xX 6 cylinder bolt 7 breather tube 7 Install the cam chain guide 8 and fit the cam chain guide tabs 9 in the cylinder cut outs 10 Push the cam chain guide until it bottoms in the crankcase guide hole 8 cam chain guide 9 cam chain guide tabs 10 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 1 dowel pins 2 cylinder head gasket Piston Piston Rings Piston Pin 2 Route the cam chain through the cylinder 4 Install and tighten the cylinder bolt 5 and head 3 cylinder head bolts 6 to the specified torque Install the cylinder head 7 Ibf ft 10 N m 1 0 kgf m mm NOTICE Do not damage mating surfaces when ins
81. d perform all recommended maintenance Your CRF was designed as a rider only motorcycle It was not designed to carry a passenger or cargo A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the CRF In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your CRF s handling braking and stability Adding accessories or making modifications that change this CRF s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the motorcycle can carry More specific information on load limits accessories and modifications follows Loading How much weight you put on your CRF and how you load it are important to your safety If you decide to carry cargo you should be aware of the following information A WARNING Overloading or carrying a passenger can cause a crash and you can be seriously hurt or killed Follow all loading guidelines in this manual Loading Guidelines As discussed on this page we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines e Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability e
82. djusters to stiffer settings Install the optional stiff spring Reduce standard Race Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment e Always begin with the standard settings e Turn the low speed compression and rebound damping adjusters in one click increments and the high speed compression damping adjuster in 1 12 turn increments at a time Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment e If after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustments until the correct settings are obtained as described Stiff suspension Symptom Action Suspension feels stiff on small 1 Test softer low speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large 1 Test softer high speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff N Test softer high and low speed compression adjustments and rebound adjustment simultaneously If it still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings Soft suspension Entire travel too soft
83. dling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Fuel System Fuel Line 1 fuel valve 3 fuel line 2 fuel filter 1 Check the fuel valve 1 and fuel filter 2 for contamination 2 Check for leaks 3 Check the fuel line 3 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Check for interference between the frame and tank and adjust if necessary Servicing YourHonda 41 Fuel ystem Fuel Filter The fuel filter is mounted on the bottom left side of the fuel tank Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor To service the fuel filter 1 2 3 Drain the fuel from the fuel tank into an approved gasoline container Remove the fuel tank page 37 Remove the fuel joint 1 from fuel tank by removing the bolts 2 Wash the fuel filter 3 in high flash point cleaning solvent Reassemble the fuel joint in the reverse order of removal Check that the O ring 4 is in good condition and install it onto the fuel joint Install the fuel joint in the fuel tank Install the fuel tank page 38 and refill the fuel Turn the fuel valve to ON or RES check for leaks 1 fuel joint 3 fuel filter 2 bolts 4 O ring 42 Servicing Your Honda Refer to Safety Precautions on page 25 Using the
84. e holding the cut out of the fork damper 1 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 3 lock nut wrench 1 fork damper 2 fork cap assembly 11 Hold the fork damper 1 in an upright position and pump the fork piston rod 5 to 3 9 in 100 mm slowly several times OEN 4 3 9 in 100 mm is 1 fork damper 5 piston rod 12 Screw in the lock nut 8 to the fork damper piston rod 5 fully 5 piston rod 8 lock nut Turn the rebound adjuster and compression adjuster counterclockwise to the softest position Check the fork damper piston rod sliding surface for damage Apply fork oil to the fork damper piston rod sliding surface Cover the fork piston rod end with soft jaws to prevent fork damage NOTICE Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked Front Suspension Adjustments 15 Blow out the oil from the fork damper spring 13 Blow the extra oil off to the fork damper 1 14 Drain the extra oil from the fork damper 1 spring chamber 9 by pumping the fork chamber using compressed air to the oil hole damper piston rod to full stroke By doing this procedure about 0 6 US oz 17 Wipe the oil completely off the fork damper cm of fork fluid will be drained from the 16 If you can not use compressed air remove the damper spring chamber through the oil hole and pressure release screw 10 o
85. e Maintenance Schedule also includes items that involve more extensive procedures and may reguire special training tools and eguipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the reguired tools Procedures for items in these schedules are provided in a service manual available for purchase from your Honda dealer page 168 Because your CRF does not have an odometer service intervals in the maintenance schedules are expressed in terms of riding days as well as miles To avoid overlooking reguired service we urge you to develop a convenient way to record the number of days and or distance traveled USA miles Canada kilometers you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability 26 Servicing Your Honda Perform the pre ride inspection page 11 at each scheduled maintenance period Each item on the maintenance schedule requires some mechanical knowledge Certain items particularly those marked and may require more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has the proper tool
86. e Re Maser eed 36 Fuel Tank Removal iese sesse se se see ee se de 37 Subframe Upright Position esse ese se ee ee 39 Service Procedures Fluids amp Filters Fuel System eisiinccd hvsedeute sities GEE na ie ee 41 Engine Oil VEER DE ee EE eed ise 2d 43 Transmission Oil see ee ee Re 46 BT EE EA AR EE N 48 Alt Gleaner EE HR EE 51 Crankcase Breather ees ees ee RA issa 53 Engine dB ele al a tiie biedaiin 54 Cl teh System Ese DE De ER ed ee 56 Hot Start Lever ss sees se ee se ee ee ee 60 Ni du EE BEE HE 61 Exhaust Pipe Muffler o ae 62 SDark Afrester i s se EP ie Re GEE RR eg Deels cele 65 Valve ClearafiCe ses iese onan DEE Nege 66 Piston Piston Rings Piston Pin esse esse see se 75 Servicing Your Honda Chassis SUSPENSIONS aiai i p e ia a eia 83 EE GAAN EK EK AT aUe 87 AL RE OR N ees 91 Tires Ai TUDES isa GE EE GR Ee GE Ge a 92 1de Stand GE GE GE GE 94 Drive GER AE N aaaen 95 Additional Maintenance Procedures 98 Electrical Battery EE N RE 100 Headlight amp Taillight 0 00 se se ee se 102 Appearance Care see ee ee ee ee Ge 104 Servicing Your Honda 23 The Importance of Maintenance A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre ride inspections and good maintenance are especially important because your CRF is designed to be ridden over rough off road terrain To help you
87. e crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 6 If it is free it is an indication that the valves are closed and that the piston is on the compression stroke If it is tight and the valves are open rotate the primary drive gear bolt 360 and realign the punch mark to the index mark DE Ke OLE N 3 primary drive gear bolt 5 index mark 4 punch mark 6 exhaust rocker arm Valve Clearance And Decompressor Arm Clearance Inspection 1 Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cam lobes 3 N N 1 feeler gauge 2 valve lifters 3 intake cam lobes Valve Clearance IN 0 006 0 001 in 0 16 0 03 mm Valve Clearance 2 Measure the exhaust valve clearance by inserting a feeler gauge 1 between the exhaust rocker arm 4 and shims 5 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shims Valve Clearances EX 0 011 0 001 in 0 28 0 03 mm If intake valve clearance and exhaust valve clearance need adjustment see Camshaft Holder Assembly Removal page 68 and select the correct shim for each valve
88. e it produces fewer engine deposits and extends the life of exhaust system components Your engine is designed to use any gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 158 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank Refueling Procedure Fuel Tank Capacity 2 27 US gal 8 62 1 fuel fill cap 2 breather tube 3 steering stem nut 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube in the steering stem nut A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when han
89. e oil capacity is the same in both fork legs 6 Check that the O ring 9 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring Temporarily install the fork damper 2 to the outer tube After installing the fork leg page 119 tighten the fork damper to the specified torque 25 Ibf ft 34 N m 3 5 kgf m 9 _ gt Sa aa fii 2 fork damper 9 O ring Refer to Safety Precautions on page 25 Both the front and rear brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page 90 there is probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system Front Brake Lever Adjustment LESS Z cr an St Ce THAN d AE 3 8 13 16 in r i 10 20 mm ee Se 3 1 lock nut 3 piston 2 adjuster 1 Loosen the lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip tur
90. end that you do not transport your CRF on its side This can damage the motorcycle and leaking gasoline could be a hazard If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry Change the engine oil and filter page 44 Change the transmission oil page 47 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and loosening the carburetor drain screw Drain gasoline into an approved container Retighten the carburetor drain screw A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel WN e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 5 Remove the bolt 1 and right engine guard 2 Remove the center engine guard mounting bolts collars 3 and center engine guard 4 1 bolt 2 right engine guard 3 center engine guard mounting bolts collars 4 center engine
91. er inflation ES RE N EE REESS 92 Spokes for loosenesS ee ee ee ee se 91 Rim locks for looseness 91 Front and rear suspension for proper Operationen Ge Nege es VEE SEL Kees Sek eel ee 83 84 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication cece see see ee se 96 Drive chain guide sliders and rollers for damage OF WEL se se see ee ee Ge ee 97 Exhaust pipe Muffler inspection removal and installation 0 0 0 0 62 64 Every possible part for looseness such as cylinder head nuts engine mounting bolts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt etc esse se ee ee 154 156 Before Riding 11 12 Before Riding This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions cee see se ee 14 Side Stand ER EE E 14 Mb al sai oi RA N EN 14 Starting amp Stopping the Engine 15 Preparations iese er ees svete EE ede lets 15 Fuel Val ciinei nnomina 15 Starting Procedure s 15 Flooded Engine cece ese ese ese ee irssi 16 How to Stop the Engine iese esse esse ees ee 16 Shifting Gears issie NG EE ase 17 le elle ER EA EE beds 18 ie di RE EE EE EN 19 Post ride Inspection 20 Break in Guidelines sesse se se see ee se se 21 Basic Operating Instructions Basic Operating
92. er inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection When your CRF is new break it in for approximately one hour to ensure that the suspension has worked in page 21 After break in test run your CRF with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CRF for 3 0 hours See page 109 for fork disassembly Replace the fork oil every 7 5 hours of running See page 86 for oil level adjustment after changing the fork oil Replace the damper oil every 22 5 hours of running See page 113 for oil level adjustment after changing the damper oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination 1 fork protector Refer to Suspension adjustment information page 108 for make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and
93. erclockwise to move the headlight down to If it becomes necessary to kick start the engine proper adjustment with the battery removed remove the relays to the battery to prevent damage to the lighting 1 adjusting screw Taillight The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service Servicing Your Honda 103 Appearance Care Refer to Safety Precautions on page 25 Frequent cleaning and polishing will keep your Honda looking newer longer Frequent cleaning also identifies you as an owner who values his motorcycle A clean CRF is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations e To clean your CRF you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CRF or discolor the seat and decals If your CRF is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CRF High pressure washers like those at coin operated car washes can damage certain parts of your CRF The force of water under extreme pressure can penetrate the dust seals of the s
94. ess oil or SERVICE LIMIT chain lubricant UPPER ROLLER 1 5 in 39 mm LOWER ROLLER 1 4 in 35 mm 2 Replace the roller if necessary as follows Install the upper drive chain roller Green 1 with the mark 2 facing toward the frame and lower drive chain roller Black 3 with the mark 2 side facing out Tighten the drive chain roller bolt and nut to the specified torque Upper roller bolt 9 Ibf ft 12 N m 1 2 Ad kgf m Genel olier DiE nut 9 Ibf ft 12 N m 1 2 2 Check the chain guide slider 2 for wear kgf m Replace the chian guide slider if it is worn to the bottom of the wear limit groove 3 1 upper drive chain roller 3 lower drive chain roller 2 gt mark 2 chain guide slider 3 wear limit groove Servicing Your Honda 97 Additional Maintenance Procedures Refer to Safety Precautions on page 25 Steering Head Bearing Inspection 98 With your CRF on a box or workstand front wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings Stand in front of your CRF grab the fork at the axle look at the steering head and push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or play is felt but you do not see any movement in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or
95. fer to Safety Precautions on page 25 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule page 27 The checking or adjusting of the valve clearance should be performed while the engine is cold The valve clearance will change as engine temperature rises 66 Servicing Your Honda Cylinder Head Cover Removal Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat page 36 2 Remove the fuel tank page 37 3 Disconnect the breather tube 1 and spark 1 breather tube 2 spark plug cap 4 Remove the cylinder head cover A bolt 3 cylinder head cover B bolts 4 and cylinder head cover 5 3 cylinder head cover A bolt 4 cylinder head cover B bolts 5 cylinder head cover 5 Remove the plug hole packing and cylinder head cover packing Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 crankshaft hole cap 2 Rotate the crankshaft by turning the primary drive gear bolt 3 clockwise until the punch mark 4 on the primary drive gear aligns with the index mark 5 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If th
96. ffect holding a straight line These tires tend to wear more quickly than standard tires because of the combination of soft rubber and hard terrain Muddy Soil Use a more open tread pattern to avoid clogging For these conditions the relatively long knobs will probably be made from a harder rubber compound to reduce any tendency to bend back under acceleration or wear quickly Loose Sandy Soil Use a tire that is similar in construction to those needed for tacky soil and mud but with a few more knobs Adjustments for Competition 139 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning e Position the control levers so that you can use them comfortably when seated and standing Adjust the mounting bolt torque of the clutch and brake lever assemblies so that they can rotate on the handlebar in a fall If an assembly does not rotate it may bend or break a control lever Make sure that the bolts are torqued securely enough to prevent slippage during normal operation Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first 1 control lever mounting bolts As an alternative consider wrapping the handlebar area under the control assemblies with teflon tape Then tighten the assemblies to their normal tor
97. from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel becomes stiff Install the optional soft spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer compression damping adjustments in one click increments until the desired initial travel compression damping is obtained Lower the oil capacity by 0 2 oz 5 cc Entire travel too stiff e Stiff suspension on any type of terrain Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil capacity by 0 2 oz 5 cc 128 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track Suspension Adjustment Guidelines Hard surfaced track Begin with the standard settings If the suspension is too stiff soft adjust according to the chart below Sand track Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring preload Example Turn the compression damping adjuster and especially rebound damping adjuster to a stiffer setting Increase standard Race Sag 0 2 to 0 4 in 5 to 10 mm Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Adjust the compression and rebound damping a
98. gteradaces 13 damping adjustments fuel before riding te seke LE PES e ae Ee 9 TONG 26s OE EE Ao ER tezs 108 lennin OE RE OE OE 41 between motos amp practice maintenance 33 OAR OR ER AR OR des 123 Tibet sis cere EE AD RE Ee EE soe 42 brakes dealer your Honda sesse ese sees se ee ese ee ee ee ee 168 recommendation eise esse esse ee ees ee ee ee 41 di did EER RE N EE ani 88 diagram WINE esse ese see se ede ee ee Ge 163 did ki EE 41 lever front adjustment eee see se ee 87 diye CHAI si ES GEREED EE poke vest tees 95 SEA AE OR EE aS 41 pad Wear SA a N AE 90 oxygenated m eri e eee a ei 158 pedal height siasii iini niista 87 Pil dele BE ME N oren 41 break in guidelines se se ee ee ek ee 21 EIE N ORE ER AE 15 172 Index G M R gap Spark plugs ket see RES Gade Gee ER Ge GEE toasty 61 maintenance rear suspension maintenance ses sees see 84 PASOHOM EE ME AA AE N NNS 41 after competition esseeeeseeeseeessreresrreserreees 33 Rider s Club Honda esse sesse ee see se ee ee 169 PasOlME EE ER DR N a re 41 before amp after competition esse esse esse ee 34 riding ai AR NE N RE 138 between motos amp practice esse se esse 33 apparel EE EE EE EE edna De DEEG 2 guidelines suspension adjustment 0 127 component locations s es 35 basic OperatHHON iese see see see se ee ee Ge 13 general compe
99. guard 6 Remove the radiator cap and coolant drain bolt sealing washer 5 at the water pump 6 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washer is in good condition and reinstall the drain bolt and radiator cap 5 coolant drain bolt sealing washer 6 water pump Storing Your Honda 7 Remove the reserve tank cap 7 Disconnect the siphone tube 8 from the reserve tank 9 Pull out the reserve tank from the frame and drain the reserve tank coolant Empty the reserve tank coolant and rinse the inside of the reserve tank with water 7 reserve tank cap 8 siphone tube 9 reserve tank 8 Reinstall the reserve tank and reserve tank cap and connect the siphone tube cont d Tips 143 Storing Your Honda 9 Install the center engine guard 4 while aligning its tabs 10 with the grooves 11 of the radiator reserve tank Install the center engine guard mounting bolts and collars 3 then tighten them Install the right engine guard 2 and tighten the bolt 1 1 bolt 2 3 right engine guard center engine guard mounting bolts collars 4 center engine guard 10 tabs 11 grooves 10 Lubricate the drive chain 144 Tips 11 12 13 14 15 16 Remove the battery and charge it fully Store in an area protected from freezing temperatures and direct sunlight Slow charge the batter
100. he JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification 44 Servicing Your Honda Checking amp Adding Oil 1 engine oil filler cap dipstick 2 upper level mark 3 lower level mark 1 Run the engine for 3 minutes then shut it off 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine 3 Support the CRF in an upright position on a level surface 4 Remove the engine oil filler cap dipstick 1 wipe it clean and insert the engine oil filler cap dipstick without screwing it in Remove the engine oil filler cap dipstick 5 Check that the oil level is between the upper 2 and lower 3 level marks on the engine oil filler cap dipstick e If the oil is at or near the upper level mark you do not have to add oil e If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil amp Filter 1 Run the engine for 3
101. he adjuster 4 positions e Rebound damping can be increased by turning the adjuster clockwise Rear Suspension Adjustments 3 rebound damping adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seat This is the full hard position 2 Turn the adjuster counterclockwise 11 14 clicks with the punch marks on the adjuster and the shock absorber aligned Adjustments for Competition 123 Rear Suspension Adjustments Rear Suspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel travel used by your CRF at rest ready to ride with you on the seat As a general rule of thumb the race sag dimension should be about one third of the maximum travel On your CRF ride height is changed by adjusting the rear suspension spring pre load Spring Pre load amp Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of the chai
102. he surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only Exhaust Pipe Maintenance The exhaust pipe is stainless steel but may became stained by oil or mud Remove heat stains with a liquid kitchen abrasive Servicing Your Honda 105 106 Servicing Your Honda This section tells you how to fine tune your CRF for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both stiffer and softer than standard rates in order to tailor your CRF specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be ba
103. ign or operation Such changes could seriously impair your CRF s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your area Safety Labels This page shows the locations of safety labels on your CRF Some labels warn you of potential hazards that could cause serious injury Others provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement IMPORTANT INFORMATION This vehicle is designed and manufactured for off road use only It does not conform to Federal motor vehicle safety standards and operation on public streets roads or highways is illegal For your protection always wear your helmet while riding ADANGER Operator only No passengers Read the owner s manual carefully NEVER OPEN WHEN HOT This Honda motorcycle is sold as is without warranty Hot coolant will burn you and the entire risk as to quality and performance is with the buyer Motorcycle Safety 5 6 Motorcycle Safety Operating Controls Read this section carefully before you ride It Operation Component Locations iese see see 8 presents the location of the basic controls on your CRF Operating Controls 7 Operation Com
104. index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining proper wheel alignment will also extend brake pad wear Before amp After Competition Maintenance 1 chain adjuster index marks e Suspend the front wheel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases f 2 pressure release screws After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust inhibiting oil more heavily if the event was particularly wet or muddy Take care to avoid spraying any oil near the brake pads or the brake disc Remove the drive chain clean it and lubricate the chain and sprockets Be sure the chain is wiped clean and is dry before applying the chain lube
105. ing P 41 FUEL FLOW RESTRICTED FUEL FLOW UNRESTRICTED 2 Remove air cleaner P 51 AIR FILTER NOT DIRTY 3 Check carbureator jets for clogging DIRTY CLOGGED ___ gt NOT CLOGGED 4 Check valve timing CORRECT 5 Try spark test INCORRECT GOOD SPARK y 6 Check for low compression CORRECT WEAK OR INTERMITTENT SPARK LOW ge Lack of fuel in tank P 41 Clogged fuel line P 41 Clogged fuel fill cap breather tube P 41 Clogged fuel valve P 41 Clogged fuel filter P 41 Not cleaned frequently enough P 51 Contaminants in the fuel Cam sprocket not installed properly Faulty carbon or wet fouled spark pulg P 61 Faulty ignition control module Faulty alternator Faulty engine stop button Faulty ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing Taking Care of the Unexpected This section gives practical advice to help you Tf a Fuse BIOWS i ser RES EG GE EE ESE De Gee gee 148 solve problems If Your Battery is Low or Dead esse sees 149 Taking Care of the Unexpected 147 If a Fuse Blows All of the electrical circuits on your CRF have a fuse to protect them from damage ca
106. ion training Separate free training from the Specialty Vehicle Institute of America for ATV owners One full year of the Honda Red Rider magazine or Honda Red Rider ATV for ATV purchasers Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner Racing contingency programs and assistance at selected dual sport off road and motocross events Contact your Honda dealer for more information or call 1 800 847 HRCA or log on to www hrca honda com The Honda Riders Club USA only Consumer Information 169 Table of Contents The following presents the contents of each section of your owner s manual Motorcycle Safety scsssscssssccssscsssssssseccsssceees 1 Important Safety Precautions esse ese esse see 2 ET iii RS N EE ais 3 Accessories amp Modifications ees ee ee 4 Safety Labels neneton EE OE N EE 5 Operating Controls sesse sesse esse see SE Ge ES Se 7 Operation Component Locations cee 8 Before Riding esse sesse osse bes se eN GER Gee dee sk Ee 9 Are You Ready to Ride occ esse ese ee 10 Is Your Motorcycle Ready to Ride sesse 11 Basic Operating Instructions ssescse0 13 Safe Riding Precautions cceeeeeeeeees 14 Starting amp Stopping the Engine ee 15 Shifting Gears osinn E e O s 17 Braking vr DE EE E ALEE 18 Parking ih iii EL roa Ee GE ee Ee ig 19 Post ride
107. iring during acceleration After burning backfiring Poor performance driveability and poor fuel economy N PULP Emission Control Systems Source of Emission The combustion process produces carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd Utilizes lean carburetor settings and other systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons Exhaust Emission Control System California only The exhaust emission control system consists of a secondary air injection system No adjustments to this system should be made although periodic inspection of the components is recommended Secondary Air Injection System The secondary air injection system introduces filtered air into the exhaust gases in the exhaust port The secondary air injection system helps improve emission performance Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion muffler through the air cleaner and the carburetor Technical Information 157 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or
108. is results in a track surface that is slippery during the first few races then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions e Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth to keep the engine rpm high where the engine produces the most power This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep the front end light so it can float from the peak of one sand whoop to the next Generally with higher gearing it is easier to maintain that perfect attitude maximum rear wheel traction and a light front end because you remain in the powerband longer in each gear The higher gearing allows you to steer more efficiently with throttle control and body English If
109. k center bolt 8 closely by hand Tighten the lock nut to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 2 lock nut 8 fork center bolt Front Suspension Adjustments 10 Apply fork oil to the fork center bolt O ring 9 Remove the piston base or mechanic s stopper tool while applying pressure to the fork damper Install the fork center bolt to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 9 fork center bolt O ring 11 Measure the length 10 between the axle holder and outer tube 12 Compare the length 10 at assembly and at disassembly They should be the same length If the length at assembly is longer than at disassembly check the fork center bolt and lock nut installation i 10 length cont d Adjustments for Competition 117 Front Suspension Adjustments 13 Pour the recommended fork oil 11 into the outer tube slider 1 Fork Oil Capacity Optional Stiffer 0 49 kgf mm Fork Spring Standard 0 47 kgf mm Fork Spring No mark factory products or 1 scribe mark OT aftermarket parts Recommended Oil Pro Honda HP Fork Oil 5 W or eguivalent S scribe marks Optional Softer 0 45 kgf mm Fork Spring Standard oil 11 2 US oz Standard oil 11 3 US oz capacity 332 cm8 capacity 335 cm3 Maximum oil 13 6 US oz Slightly stiffer as Maximu
110. kcase Breather Refer to Safety Precautions on page 25 Crankcase Breather Service more frequently if your CRF is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 tube Servicing Your Honda 53 Throttle Refer to Safety Precautions on page 25 Throttle Freeplay 1 R GSF Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range 1 freeplay Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 3 2 dust cover 3 upper lock nut 4 upper adjuster increase decrease 54 Servicing Your Honda PD Pull the dust cover 2 back Loosen the upper lock nut 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay Tighten the lock nut Return the dust cover to its normal position After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn Tighten the lock nut install the dust cover and ma
111. ke the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you can not get the proper adjustment with the upper adjuster 5 lock nut 6 adjuster increase decrease 1 Remove the fuel tank page 37 2 Loosen the lock nut 5 3 Turn the adjuster 6 in direction to decrease freeplay and in direction to increase freeplay 4 Tighten the lock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 38 If you can t get the freeplay within the specified range see your Honda dealer Throttle Inspection 1 2 1 throttle Check that the throttle assembly is positioned properly and the securing bolts are tight Check for smooth rotation of the throttle 1 from fully open to fully closed in all steering positions If there is a problem see your Honda dealer Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced Check the cables for tension or stress in all steering positions Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion Throttle Servicing Your Honda 55 Clutch System Refer to Safe
112. l be shortened especially when the ambient temperature is high Continuing to operate the unit in these conditions will result in engine damage Whenever you ride tread lightly By staying on established trails and riding only in approved areas you help protect the environment and keep off road riding areas open for the future If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You
113. l settings 37 axle pinch bolts 38 tripmeter cable Adjustments for Competition 121 Rear Suspension Adjustments The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the rear shock absorber assembly only Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the Honda Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Optional pin spanners are available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Lift the subframe to the uplight position page 39 122 Adjustments for Competition 3 Check that the spring pre load is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of
114. lable from Helm Inc USA only Canada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Publication Item No Description Price Each G1MEYO1 2006 CRF450X Service Manual 48 00 61CMOO02 Common service Manual 48 00 31MEY610 2006 CRF450X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form USA only Canada See your Honda dealer to order authorized manuals Publication D seid Price Total Item No tem Description Qty Each Price Sub Total Prices are subject to change without notice and 3 es Purchaser s Sales Tax without
115. lamp bolt 4 3 Remove the rear muffler mounting bolt washer 5 front muffler mounting bolt 6 and muffler 7 Nana 4 muffler clamp bolt 5 rear muffler mounting bolt washer 6 front muffler mounting bolt 7 muffler 4 Remove the muffler gasket Muffler Installation 1 Install a new gasket 1 on the exhaust pipe 2 Install the muffler clamp 2 by aligning the tab 4 of the muffler clamp with the cut out 5 of the muffler 3 3 Install the muffler 3 1 gasket 4 tab 2 muffler clamp 5 cut out 3 muffler Exhaust Pipe Muffler 4 Install the front muffler mounting bolt 6 6 Install the right side cover 9 and side cover rear muffler mounting bolt washer 7 and bolt 10 loosely tighten them 7 Install the seat bolt 11 and tighten it to the Tighten the front muffler mounting bolt and specified torque rear muffler mounting bolt to the specified 19 Ibf ft 26 N m 2 7 kgf m torque 19 Ibf ft 26 N m 2 7 kgf m 5 Tighten the muffler clamp bolt 8 to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 9 right side cover 11 seat bolt 10 side cover bolt 4 antie LANN 6 front muffler mounting bolt 7 rear muffler mounting bolt washer 8 muffler clamp bolt Servicing Your Honda 63 Exhaust Pipe Muffler Exhaust Pipe Removal Exhaust Pipe Installation 1 Remove the muffler page 62 1 Install a new exhaust pipe gasket 1 exhaust 2 Rem
116. lanced by installing the optional fork springs of a similar rate Front Suspension AdjustmentS sesse eee 108 Rear Suspension Adjustments cece 122 Suspension Adjustments for Track Conditions EE EE EE MOE IE OT 126 Suspension Adjustments Guidelines 127 Carburetor Adjustments amp Tuning Tips 130 Chassis Adjustment ces se se se ee ee ee 137 BE EE EEN 138 Tire Selection for Track Conditions 139 Personal Fit Adjustments s es 140 Adjustments for Competition Adjustments for Competition 107 Front Suspension Adjustments The front suspension can be adjusted for the rider s weight and riding conditions by using one or more of the following methods e Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel e Compression damping Turning the compression damping screw adjusts how quickly the fork compresses e Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends e Fork springs Optional springs are available in softer and stiffer types than the standard rate page 161 The inverted fork on your CRF features sealed damper cartridges with dual separate air and oil chambers to prevent aeration The design also isolates the oil in each fork tube slider which may contain air bubbles and or metal particles from the sealed cartridge to provide more
117. lecting been type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 14 lock nut wrench 4 fork damper 18 For ease of releasing air pressure after the forks are installed Loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters Align 15 the top surface of the upper fork clamp 16 with the outer tube 1 upper surface as shown Front Suspension Adjustments 1 outer tube 16 upper fork clamp 15 align 19 Tighten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 20 Tighten the fork upper pinch bolts 17 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m NOTICE Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced 13 lower pinch bolts 17 upper pinch bolts cont d Adjustments for Competition 119 Front Suspension Adjustments 21 Clean the threads of the fork protector bolts 18 and axle holder thoroughly Apply locking agent to the fork protector bolt threads Install the fork protectors 21 fork protector bolts brake hose clamp bolts 20 and tripmeter cable clamp screws 19 Tighten the fork protector bolts to the specified torque 5 2 IDf f 7 N m 0 7 kgf m Tighten tripmeter ca
118. lement in clean Pro Honda Foam Filter Oil or an equivalent Canada Honda Foam Filter Oil or an equivalent air cleaner oil Apply air cleaner oil to the entire surface of the air cleaner element and rub it with both hands to saturate the air cleaner with oil Squeeze out excess oil NN cont d Servicing Your Honda 51 Air Cleaner 7 10 Apply a thin coat of Honda White Lithium Grease or equivalent to the air cleaner element of the air cleaner element holder contacting surface Assemble the air cleaner element and holder Install the tab 7 of the holder in the hole 8 of the air cleaner element tab 9 Install the air cleaner assembly into the air cleaner housing Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner element holder with the A mark 11 of the air cleaner housing by rotating the air cleaner assembly counterclockwise Install and tighten the air cleaner retaining bolt 3 securely 3 air cleaner retaining bolt 10 access tab 11 A mark 52 Servicing Your Honda NOTICE Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 11 Close the air cleaner housing cover 1 and turn the quick fastener 2 clockwise amp 1 air cleaner housing cover 2 quick fastener Cran
119. low speed in a safe area and slowly build your skills Personal instruction from an experienced rider can also be valuable If you need assistance ask your dealer about riding groups in your area Also be sure to read the Tips amp Practice Guide for the Off Highway Motorcyclist booklet that came with your CRF USA only Be Alert for Off Road Hazards The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Ride within Your Limits Pushing limits is another major cause of motorcycle accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safety Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition It s important to keep your CRF properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your CRF before every ride an
120. m frame only 4 After washing rinse your CRF thoroughly with plenty of clean water to remove any residue 5 Dry your CRF with a chamois or a soft towel 6 Lubricate the drive chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance Condensation Control Some condensation can form within the transmission cavity as well This is natural and just one more reason you should change the engine and transmission oil often After Cleaning Lubrication There are some things you should do just after washing your CRF to help prevent rust and corrosion Once your CRF is clean and dry you should protect any bare steel from rusting by applying a light coating of a rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean and is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Appearance Care Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish t
121. m oil 13 7 US oz Slightly stiffer as capacity 402 cm8 it nears full capacity 405 cms it nears full compression compression Minimum oil 10 3 US oz Slightly softer as Minimum oil 10 5 us 06 Slightly softer as capacity 306 cm8 it nears full capacity 309 cms it nears full compression compression Be sure the oil capacity is the same in both fork legs 1 outer tube 11 fork oil C 2 scribe marks Standard oil 11 4 US oz capacity 338 cm3 Maximum oil 13 8 US oz Slightly stiffer as capacity 407 cm3 it nears full compression Minimum oil 10 5 US oz Slightly softer as capacity 311 cm3 it nears full 118 Adjustments for Competition compression 14 Check that the O ring 12 on the fork damper assembly 4 is in good condition Apply the recommended fork oil to the O ring 15 Pull up the outer tube 1 slowly and install the fork damper assembly 4 into the outer tube 12 4 12 1 1 outer tube 12 O ring 4 fork damper assembly 16 Insert both fork legs into the fork clamps Tighten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 13 fork lower pinch bolts 17 Tighten the fork damper 4 to the specified torque using the lock nut wrench 14 Actual 25 Ibf ft 84 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 50 cm long torque wrench When using the lock nut wrench use a 20 inch long def
122. may require specific adjustments for competition use However in order to comply with emission regulations we recommend that you make no carburetor changes unless you use your CRF for competition only 130 Adjustments for Competition Carburetor Components Cold Start Circuit A very rich mixture must be delivered to the cylinder when a cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 2 starter jet 3 air passage 4 throttle valve 5 orifice Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot start lever is pulled back the hot start valve 1 opens allowing air to be supplied to the main bore 2 through the hot start air passage 3 This extra air enters the air fuel mixture from the slow circuit resulting in a lean condition 1 hot start valve 2 main bore 3 hot start air passage Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened As the throttle valve
123. minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil filler cap dipstick 1 from the left crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the engine oil drain bolt 2 and sealing washer 3 5 After the oil has drained tighten the engine oil drain bolt with a new sealing washer to the specified torque 1 engine oil filler cap dipstick 2 engine oil drain bolt 3 sealing washer 6 It is recommended to replace the oil and filter about every 15 0 hours However if you replace only the oil before the recommended interval see page 27 28 7 Remove the bolt 4 and left engine guard 5 A La Y j E Eae E w jood r g 4 bolt 5 left engine guard 8 Remove the oil filter cover bolts 6 and oil filter cover 7 9 Remove the oil filter 8 from the filter cover 10 Check that the oil filter cover O ring 9 is in good condition 6 oil filter cover bolts 7 oil filter cover 8 oil filter 9 oil filter cover O ring 10 spring 11 rubber seal 12 OUT SIDE mark 11 Apply grease to the filter side of the spring end then install the spring 10 into a new oil filter 8 12 Position the spring against the engine crankcase and install a new oil filter with the rubber seal 11 facing out away from the engine You should see the OUT SIDE mark 12 on the filter body near the
124. mmended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection 48 Servicing Your Honda Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 25 1 With the engine at normal operating temperature check the coolant level in the reserve tank It should be between the UPPER 1 and LOWER 2 level marks If the reserve tank 3 is empty or if coolant loss is excessive check for leaks and see your Honda dealer for repair 1 UPPER level mark 2 LOWER level mark 3 reserve tank 2 Remove the reserve tank cap 4 Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap 4 reserve tank cap 3 Add coolant to the reserve tank as require to bring the coolant level to the UPPER level mark 4 Install the reserve tank cap 4 NWN Cooling System Inspection Check the cooling system for leaks see the Honda Service Manual for troubleshooting of leaks Check water hoses 1 for cracks deterioration and clamp bands for looseness
125. n adjuster lock nut as illustrated here for three different situations unloaded motorcycle on workstand with rear suspension fully extended no rider loaded with rider motorcycle on ground with rider loaded without rider motorcycle on ground without rider 1 Support your CRF on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 124 Adjustments for Competition REAR FENDER MOUNTING BOLT UNLOADED MEASUREMENT without rider EXAMPLE 23 6 in 600 mm CHAIN ADJUSTER LOCK NUT 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the loaded with rider dimension REAR FENDER MOUNTING BOLT LOADED with rider EXAMPLE 19 7 in 500 mm CHAIN ADJUSTER LOCK NUT Example Unloaded 23 6 in 600 mm Loaded 19 7 in 500 mm Race Sag 3 9 in 100 mm 4 Calculate the race sag dimension To do this subtract the loaded with rider dimension step 3 from the unloaded dimension step 2 Standard Race Sag 3 9 in 100 mm Adjust spring pre load as necessary
126. n the adjuster counterclockwise 3 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm 6 Apply silicone grease to the contacting faces of the adjuster and piston 3 Brakes Rear Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in direction to raise the pedal 3 or in direction to lower it 2 Tighten the lock nut to the specified torque at the desired pedal height 4 4 Ibf ft 5 9 N m 0 6 kgf m 1 lock nut 2 adjusting bolt 3 brake pedal raise the pedal height lower the pedal height Servicing Your Honda 87 Brakes Fluid Level Inspection Front Brake Fluid Level Check 1 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 1 If the level is at or below the LOWER level mark check the brake pads for wear page 89 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake lever freeplay exceeds 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service
127. n the fork cap cause 5 9 US oz 175 cm of fork fluid to be left Hold the fork damper up side down for 10 in the chamber minutes and drain the oil from the fork damper spring chamber 1 1 fork damper 9 spring chamber Hei oe 1 fork damper 10 pressure release screw Adjustments for Competition 115 Front Suspension Adjustments Fork Assembly 1 Drain the fork oil from the outer tube slider by placing it upside down About 7 cc of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 20 C 1 outer tube slider 116 Adjustments for Competition Amount of fork oil left in the fork without damper and spring unit cc 5 10 20 35 55 85 145 30 86 7 1 59 4 7 42 35 35 35 20 68 10 6 8 2 7 1 5 9 5 6 4 7 4 7 10 50 11 8 8 3 7 2 6 2 5 8 4 9 4 8 12 9 10 6 9 4 8 2 7 9 7 1 5 9 ce 16 0 C 32 F z ME 10 C 50 F x er 20 C 68 F B Ory ea 30 C 86 F od 5 E mj E lt 20 40 60 80 100 120 140 160 Inverted time minutes 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper ra ye 2 lock nut A thread length 3 Using compressed air blow all oil off the fork spring 3 Install the fork spring Install the fork d
128. nce on firm level ground using the side stand a workstand or eguivalent Support Use genuine Honda parts or their eguivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride Inspection Items Refer to Pre ride Inspection page 11 Servicing Your Honda 29 General Competition Maintenance Spark Plug Some non resistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule pages 27 28 Spark Plug Cap Install a small plastic tie wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration Engine Oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston cylinder and crankshaft Also replace engine oil filter often to ensure the greatest service life Frequent changes will also assure consistent performance of power and response page 44 30 Se
129. ng more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated the fuels can damage paint and plastic Be careful not to spill fuel when filling the fuel tank Wipe up any spills immediately NOTICE Oxygenated fuels can damage paint and plastic Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments gearing and tire selection This detailed information along with your comments can prove valuable when you compete at the same track or on similar terrain Your logbook can also tell you when maintenance was performed and when it will be necessary again Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components If you choose to sell your CRF the accurate maintenance records in your logbook might be the deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adju
130. ngine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CRF should move smoothly and accelerate gradually If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual page 166 Other Inspections amp Lubrication Clutch Cover Disc Plate Removal e Check that the clutch lever assembly is 1 Drain the transmission oil page 47 positioned properly and the securing bolts are 2 Remove the brake pedal 1 by removing the tight pin 2 pivot bolt 3 washer 4 and dust e Check the clutch cable for kinks or signs of wear If necessary have it replaced e Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion seals 5 Clutch Operation 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage 1 brake pedal 4 washer 5 pin bi 5 dust seals pivot bo Clutch System 3 Remove the six clutch cover bolts 6 and clutch cover 7 6 clutch cover bolts 7 clutch cover 4 Remove the six clutch spring bolts and clutch springs 8 Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 5 Remove the clutch p
131. not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top out when you dismount your CRF Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too stiff for your weight will not allow the rear tire to hook up under acceleration and will pass more bumps on to you Rear Suspension Adjustments Adjustments for Competition 125
132. nts in one click increments Reduce the rebound damping adjustments in one click increments Check for dirt in the dust seals Check the fork oil for any contamination If the front end dives while cornering reduce the rebound damping in one click increments If that doesn t solve the problem install the optional stiff spring If the stiff spring makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained Middle travel too stiff e Stiff on bumps when cornering e Front end wanders when cornering e Stiff suspension on bumps especially downhill bumps e While braking front end dives during initial travel then feels stiff If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff e Doesn t bottom on landings but feels stiff e Stiff on large bumps especially downhill bumps e Stiff on large bumps when cornering If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action
133. ock nut from the fork damper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you cannot reassemble the fork damper 112 Adjustments for Competition 26 axle holder 27 fork center bolt 28 piston base 29 lock nut 22 Remove the push rod 30 from the fork damper 23 Remove the piston base or mechanic s stopper tool between the axle holder 26 and lock nut 29 while applying pressure to the fork damper NOTICE Be careful not to damage the lock nut and fork center bolt hole a 30 push rod 26 axle holder 29 lock nut 24 Remove the fork damper assembly 31 from the fork assembly 32 Remove the fork from the vise Remove the fork spring 33 from the fork 31 32 31 fork damper assembly 33 fork spring 32 fork assembly 1 2 1 fork damper Damper Oil Change Set the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage Loosen the fork cap assembly 2 while holding the fork damper 1 using the lock nut wrench 3 ws 1 2 3 lock nut wrench 2 fork cap assembly 3 Remove the fork cap assembly 2 from the fork damper 1 Be careful not to damage the fork cap bushing Do not disassemble the fork cap assembly Replace the fork cap as an assembly if it is damaged 1 es 1 fork damper 2 fork cap assembly 4 Empty the fork oil from the fork damper 1
134. of wire to the cam chain 6 to prevent it from falling into the crankcase NOTICE Do not let the bolts sprocket and cam chain fall into the crankcase 4 cam sprocket bolts 5 cam sprocket 6 cam chain Valve Clearance 5 Make sure the piston is at TDC Top Dead 7 Remove the intake valve lifters 9 and shims Center on the compression storoke Loosen 10 the camshaft holder bolts 7 in a crisscross pattern in 2 or 3 steps NOTICE 6 Remove the camshaft holder bolts and camshaft holder assembly 8 Do not let the valve lifters and shims fall into the crankcase The intake valve lifter and intake valve shim may be sticking in the camshaft holder assembly Keep the intake valve lifters and shims so as to allow identification of the originally installed location such as intake or exhaust right or left 7 bolts 8 camshaft holder assembly 9 intake valve lifters 10 shims Servicing Your Honda 69 Valve Clearance 1 F 2 Measure the shim thickness and record it 3 Calculate the new shim thickness using the Shim Selection Seventy three different thickness shims 2 are equation below available from the thinnest 1 200 mm 1 Clean the shim contact area in the valve lifter thickness shim to the thickest 3 000 mm A B C D 1 with compressed air thickness in intervals of 0 025 mm A New shim thickness 2 B Recorded valve clearance C Specified valve clearance ve D
135. olts collars 2 shroud B bolts 3 shroud Fuel Tank Removal 5 Pull the breather tube 4 out of steering stem 9 Disconnect the fuel line 8 from the fuel nut valve 9 The fuel line leading to the 6 Unhook and remove the fuel tank band 5 carburetor must be disconnected not the fuel 7 Unhook the air cleaner cover rubber 6 line leading to the fuel tank 8 Remove the fuel tank bolt collar 7 10 Remove the bolt 10 and fuel valve 11 Remove the fuel tank A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 4 breather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt collar EER EER 8 fuel line 10 bolt 9 fuel valve Servicing Your Honda 37 Fuel Tank Removal Installation 1 Install the fuel tank on the frame 2 Install the fuel valve 1 and tighten the bolt 2 3 Connect the fuel line 3 to the fuel valve io R 1 fuel valve 3 fuel line 2 bolt 4 Install the collar and fuel tank bolt 4 and tighten it 5 Hook the air cleaner cover rubber 5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 4 fuel tank bolt collar 6 fuel tank band 5 air cleaner cover rubber 7 breather tube 38 Servicing Your H
136. onda 8 Install the shroud 8 by aligning its tab 11 with subframe 12 8 shroud 12 subframe 11 tab 9 Install the shroud B bolts 9 and shroud A bolts collars 10 10 Tighten the shroud B bolts to the specified torque 3 7 IDf ft 5 N m 0 5 kgf m 9 shroud B bolts 10 shroud A bolts collars 11 Install the seat page 36 Refer to Safety Precautions on page 25 The subframe may be adjusted to an upright position to permit servicing of the rear suspension and carburetor Upright Position 1 Remove the seat page 36 2 Remove the right side cover bolt 1 and right side cover 2 1 right side cover bolt 2 right side cover 3 Open the air cleaner box cover 3 by turning the quick fastener 4 counterclockwise and remove the left side cover bolt 5 and left side cover 6 3 4 3 air cleaner box cover 4 quick fastener 5 left side cover bolt 6 left side cover Subframe Upright Position 4 Remove the muffler page 62 5 Loosen the screw 7 on the air cleaner connecting boot clamp 8 7 Lift the subframe 11 as shown Tighten the subframe upper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m ON screw air cleaner connecting boot clamp 11 subframe 6 Loosen the subframe upper mounting bolts 9 and remove the subframe lower mounting bolts 10 9 subframe upper mounting bolts 10 subfr
137. onda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4C 7B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following information in your letter e name address and telephone number e product model year and frame VIN serial number e date of purchase e dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 167 Your Honda Dealer Once you purchase your new Honda get familiar with the organization of your Honda dealer so you can utilize the full range of services available The service department is there to perform regular maintenance and unexpected repairs It has the latest available service information from Honda The parts department offers Genuine Honda parts Pro Honda products Hondaline accessories USA only and Honda accessories and
138. onomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle esse see 142 Storing Your Honda esse esse esse see ee ee ee ee 143 You amp the Environment esse esse sesse esse ese ese ee 145 Troubleshooting iese sees ee ek ek ee ee 146 Tips Tips 141 Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda we recommend that you follow these guidelines e Use a loading ramp e Make sure the fuel valve is off e Secure the motorcycle in an upright position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall over 142 Tips To secure your CRF brace the front wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on your CRF Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recomm
139. or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your CRF s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear Cleaning 1 To open the air cleaner housing cover 1 turn the quick fastener 2 counterclockwise 1 air cleaner housing cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 3 Remove the air cleaner assembly 4 while turning it as shown 3 air cleaner retaining bolt 4 air cleaner assembly Air Cleaner 3 Remove the air cleaner element 5 out from the air cleaner holder 6 5 air cleaner element 8 hole 6 air cleaner holder 9 air cleaner tab 7 tab 4 Wash the air cleaner element in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner element is made in two pieces inner and outer which cannot be separated Clean the inside of the air cleaner housing Allow the air cleaner element to dry thoroughly After drying soak the air cleaner e
140. ove the exhaust pipe joint nuts 1 pipe 2 and exhaust pipe joint nuts 3 and exhaust pipe 2 and exhaust pipe gasket 3 tighten the nuts to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 1 exhaust pipe joint nuts 2 exhaust pipe 1 exhaust pipe gasket 3 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 63 64 Servicing Your Honda Spark Arrester 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark The spark arrester must be serviced every 1 000 arrester must be free of breaks and holes mi 1 600 km of running or 100 operating hours Replace if necessary to maintain its efficiency Spark Arrester Inspection Regular servicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment 1 Allow the engine and muffler to cool 2 Remove the four bolts 1 spark arrester 2 and gasket 3 from the muffler 4 Install the spark arrester and a new gasket in the muffler and tighten the four bolts 1 to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 1 bolts 1 bolts 3 gasket 2 spark arrester Servicing Your Honda 65 Valve Clearance Re
141. p bolts 13 and fork protectors 14 Remove the caliper mounting bolts 15 and brake caliper 16 The fork protector bolts and caliper mounting bolts have a locking agent applied Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads 11 fork protector bolts 12 tripmeter cable clamp bolts 13 brake hose clamp bolts 14 fork protectors 15 caliper mounting bolts 16 brake caliper 10 Loosen the fork leg lower pinch bolts 17 then pull the fork legs down and out 17 lower pinch bolts 11 Clean the fork assembly especially the sliding surface of the slider 18 and dust seal 19 12 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 13 Measure the length 20 between the axle holder and outer tube and record it before disassembling the fork Standard 12 4 0 09 in 315 2 mm 19 18 N 4 20 18 slider 19 dust seal 20 length 14 Hold the outer tube 21 then remove the fork damper 22 from the outer tube using the lock nut wrench 23 Gently slide the outer tube down onto the lower end of the slider 24 21 23 21 outer tube 22 fork damper 23 lock nut wrench 24 slider lower end NOTICE The outer tube can drop
142. page 126 Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only 2 Lift the subframe to the upright position page 39 3 Check for a broken or collapsed spring 4 Check the shock absorber 1 for a bent shaft e When your CRF is new break it in for or oil leaks approximately one hour with the standard suspension settings before attempting to adjust the rear suspension Make all compression and rebound damping adjustments in the specified increment or turns described in pages 122 and 123 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 123 After adjusting the adjusters simultaneously suspension may be 1 shock absorber fine tuned by turning one of the compression and rebound damping adjusters in one click or 5 Push the rear wheel sideways to check for in 1 2 turn increments worn or loose swingarm bearings There e If you have a problem finding an acceptable should be no movement If there is have the adjustment return to the standard position and bearings replaced by your Honda dealer begin again 84 Servicing Your Honda Suspension
143. ponent Locations hot start lever tripmeter clutch lever front brake lever engine stop button throttle grip choke knob kickstarter fuel valve shift lever rear brake pedal 8 Operating Controls Before each ride you need to make sure you and your Honda are both ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustments see page 107 Are You Ready to Ride ow sesse sees see see ee 10 Is Your Motorcycle Ready to Ride i sesse 11 Pre ride Inspection esse esse see se ee ee 11 Before Riding Before Riding 9 Are You Ready to Ride Before riding your CRF for the first time we recommend that you read this owner s manual make sure you understand the safety messages and know how to operate the controls Before each ride it s also important to make sure you and your CRF are both ready to ride For information about suspension carburetor and other adjustments see page 107 Whether you re preparing for competition or for practice always make sure you are e In good physical and mental condition e Free of alcohol and drugs e Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of
144. proper oil and regularly checking adding and changing oil will help extend the service life of the engine Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine Oil Recommendation API SG or higher except oils classification labeled as energy conserving on the circular API service label viscosity SAE 10W 40 weight JASO T 903 standard MA or MB Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Engine Oil e Your CRF does not need oil additives Use the recommended oil e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication GEEN cee ee NOT RECOMMENDED OK e Oil is a major factor affecting the peformance and service life of the engine Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10 20 30 40 50 C 20 0 20 40 60 80 100 120 F Servicing YourHonda 43 Engine Oil JASO T 903 standard T
145. properly care for your CRF this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair If your CRF overturns or is involved in a crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section 24 Servicing Your Honda A WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedure
146. que Upon impact the fully tightened assemblies should rotate on the Teflon tape 140 Adjustments for Competition e Position the shift lever and brake pedal so they are close to your boot for rapid access but not so close that either is depressed when sitting or standing comfortably on your CRF Handlebar Position Width amp Shape e Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 3 mm using optional handlebar lower holders or 6 mm by rotating the standard holders 180 degrees Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment e Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cutoff just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your particular body size or riding style Each of the erg
147. r plate 18 and right engine hanger plate 19 g p NOTICE Do not let the dowel pins and cam chain fall into the crankcase 20 cylinder head bolts 21 cylinder bolt 18 Loosen the cylinder head nuts 22 in a crisscross pattern in 2 or 3 steps Remove the cylinder head nuts washers and 24 dowel pins 26 cam chain guide cylinder head 23 25 cylinder head gasket NOTICE Do not let the cylinder head nuts and washers fall into the crankcase 13 engine hanger nut 14 engine hanger bolt 15 fuel hose guide 16 engine hanger plate bolts 17 clutch cable stay 18 left engine hanger plate 19 right engine hanger plate 22 cylinder head nuts washers 23 cylinder head 76 Servicing Your Honda Cylinder Removal 1 Disconnect the breather hose 1 from the cylinder 2 Remove the cylinder bolt 2 and cylinder 3 NOTICE Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder 3 re q tT A 2 eee Sess 1 breather hose 3 cylinder 2 cylinder bolt 2 Remove the dowel pins 4 and cylinder gasket 5 NOTICE Do not let the dowel pins fall into the crankcase 4 dowel pins 5 cylinder gasket Piston Removal 1 Place clean shop towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a
148. r ERK choke knob i main fuse f M Q So i ees TRE S rd H gt ee ie die i Spark arrester rs VS RE SN g S D A ahs crankcase breather tube ST pe 7 SAW ZF EES ES P Je A oa RS Sy S sl i i KS A so wen Jah EV bh L Ky Fr IE AT Z Ss transmission K dj rear brake oil chack bolt pedal transmission oil drain bolt si hon transmission oil oil filter filer cap rear brake f F rear brake fluid front suspension compression engine oil drain bolt drive chain liper R calpe reservoir damping adjuster coolant reserve tank coolant reserve tank cap engine oil filler cap dipstick Servicing Your Honda 35 Seat Removal Refer to Safety Precautions on page 25 Installation 1 Install the seat 2 while aligning the seat Removal front prong 3 with the seat bracket 4 and 1 Remove the seat bolts 1 seat rear prongs 5 with the tabs 6 of the 2 Remove the seat 2 by sliding it backward frame 2 Install and tighten the seat bolts to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 1 seat bolts 2 seat 1 seat bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prongs 6 tabs 36 Servicing Your Honda Refer to Safety Precautions on page 25 Removal 1 Turn the fuel valve OFF 2 Remove the seat page 36 3 Remove the shroud A bolts collars 1 4 Remove the shroud B bolts 2 and shroud 3 1 shroud A b
149. ram Periodically inspect the frame closely for possible cracking or other damage It makes good racing sense Spokes Check spoke tension frequently between the first few rides As the spokes spoke nuts and rim contact points seat in the spokes may need to be retightened Once past this initial seating in period the spokes should hold their tension Still be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis page 91 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Honda Thread Lock or an equivalent and tighten to the specified torque Between Motos amp Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments e Clean accumulated dirt from under the fenders and off the wheels suspension components hand grips controls and footpegs A stiff nylon parts cleaning brush works well e Check tire air pressure e Check spoke tension and rim lock security e Check sprocket bolts and nuts security e Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result e After adjustment check that the chain adjuster
150. ransmission oil filler hole until oil start to flow out of the oil check bolt hole j 1 transmission oil filler cap Install the oil check bolt with a new sealing 2 transmission oil drain bolt washer and transmission oil filler cap Repeat 3 sealing washer step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 Ibf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Servicing YourHonda 47 Coolant Your CRF s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicate inhibitors may cause premature wear of radiator pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and water in this motorcycle This coolant solution is reco
151. ressure plate 9 l S 8 clutch spring bolts clutch springs 9 clutch pressure plate cont d Servicing Your Honda 57 Clutch System 6 Remove the washer 10 needle bearing 11 clutch lifter 12 and clutch lifter rod 13 7 Remove the eight clutch discs and seven clutch plates 14 Assemble the clutch lifter needle bearing and washer Turn the needle bearing with your finger The needle bearing should turn smoothly and quietly Replace the needle bearing and washer if the needle bearing does not turn smoothly 13 clutch lifter rod 14 clutch discs clutch plates 10 washer 11 needle bearing 12 clutch lifter 58 Servicing Your Honda Clutch Disc Plate Inspection Replace the clutch discs 1 for signs of scoring or discoloration Measure the thickness of each clutch disc Service Limit 0 112 in 2 85 mm Replace the clutch discs and clutch plates as a set 1 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 006 in 0 15 mm Replace the clutch discs and plates as a set 2 clutch plate Clutch Spring Inspection 1 1 clutch spring Measure the free length of each spring Service Limit 1 72 in 43 7 mm Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch
152. rk Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 Ibs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn and lower the oil level in increments of 0 2 oz 5 cm in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil level Standard spring 10 3 US oz 306 cm Softer spring 10 5 US oz 311 cm Stiffer spring 10 5 US oz 309 cm When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork 1800 r 1600 Oil level 13 6 US oz 402 cm8 gt 1400 MAX l pad E n 1200F Oil level 11 2 US oz 332 cm3 es 000 STANDARD Oo LL 800 600 F 400 F 200 F EE 0 0 30 60 90 120 150 180 210 240 270 300 Stroke mm Front Suspension Adjustments Front Suspension Disassembly e If your CRF is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life
153. rockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the driven sprocket will be sufficient There are two gearing choices with two optional driven sprockets Like the optional springs these sprockets are listed in the Optional Parts List section page 161 of this manual Unless you have the required mechanical knowhow tools and a Honda Service Manual sprocket changing should be done by your Honda dealer Higher Gearing less rear sprocket teeth e increases top speed in each gear provided the engine will pull the higher gearing e reduces frequency of shifting wider gear ratios e reduces engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain However e the engine may not pull the higher gearing e the spacing between gears may be too wide e engine rpm may be too low 138 Adjustments for Competition Lower Gearing more rear sprocket teeth e decrease top speed in each gear e increases frequency of shifting narrower gear ratios e increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However e spacing between gears may be too narrow e engine rpm may be too high Some tracks may be watered heavily prior to the first race then lightly or not at all during the day Th
154. roughout this manual The following are a few that we consider most important Always Wear a Helmet It s a proven fact helmets significantly reduce the number and severity of head injuries So always wear an approved motorcycle helmet We also recommended that you wear eye protection sturdy boots gloves and other protective gear Never Carry a Passenger Your CRF is designed for one person only There are no handholds footrests or seat for a second person so never carry a passenger A passenger could interfere with your ability to move around to maintain your balance and control of the motorcycle Ride Off Road Only Your CRF is designed and manufactured for off road use only The tires are not made for pavement and the CRF does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your CRF across Always Wear Protective Gear We recommend that you wear sturdy boots gloves and other protective gear The exhaust system becomes very hot during operation and it remains hot after operation Never touch any part of the hot exhaust system Wear clothing that fully covers your legs 2 Motorcycle Safety Do not wear loose clothing which could catch on the control levers kickstarter footpegs drive chain or wheels Take Time to Learn and Practice Developing off road riding skills is a gradual step by step process Start by practicing at
155. rvicing Your Honda Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 47 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 51 Use the Honda genuine air cleaner or an equivalent
156. s 3 000 km after the time of sale to the ultimate purchaser the time operated and maintained according to the instructions provided USA only Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED U S federal law prohibits or Canadian provincial laws may prohibit the following acts or the causing thereof 1 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 vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by your Honda dealer Hard starting or stalling after starting Rough idle Misfiring or backf
157. s especially the sidewall profile can change the attitude of your CRF and its handling Tire variations that raise or lower the rear of your CRF have a more significant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the change in tire size Another way to check is to measure the rolling circumference of the old and new tires A higher profile tire will have a larger rolling circumference If you do switch to tires designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface Tire Selection for Track Conditions If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on the transmission Complete consumer information can be obtained from the various tire manufacturer representatives and dealers Some general recommendations for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and a
158. s adjustment procedure is as follows Drive Chain Adjustment 1 Loosen the rear axle nut 1 2 Loosen the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decreace slack or clockwise to increase slack Align the index mark 4 on both sides of the swingarm with same reference marks 5 of the plates 1 rear axle nut 2 lock nut 3 adjusting bolt 4 index mark 5 reference marks 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 128 N m 13 1 kgf m Recheck chain slack and adjust if necessary Turn the adjusting bolts counterclockwise lightly until it touches the axle plate Then tighten the lock nuts to the specified torque by holding the adjusting bolts with a wrench 20 Ibf ft 27 N m 2 8 kgf m es Servicing Your Honda 95 Drive Chain Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing Your CRF has an endless riveted master link type chain It should only be removed or replaced by your Honda dealer The O rings can be damaged by steam cleaning high pressure washers and certain solvents 1 Clean the side surfaces of the chain with a dry cloth Use a high flash point solvent such as kerosene not gasoline Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings Replace the drive chain if it has damaged
159. s and precautions in this owners manual Important Safety Precautions e Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adeguate ventilation whenever you operate the engine Burns from hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or a workstand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Maintenance Safety Servicing Your Honda 25 Maintenance Schedule To maintain the safety and reliability of your CRF regular inspection and service is reguired as shown in the Maintenance Schedules Regular OFF ROAD Use non competition and Competition Use that follow The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual Th
160. s and service data and are mechanically qualified Refer to the official Honda Service Manual page 166 In the interest of safety we recommend these items be serviced only by your Honda dealer Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean L lubricate R replace MAINTENANCE SCHEDULE REGULAR OFF ROAD USE NON COMPETITION FREQUENCY Whichever Initial Comes First Maint Regular Maintenance Interval S Refer mi 100 600 1 200 1 800 2 400 to km 150 1 000 2 000 3 000 4 000 Page ITEMS NOTE Month 1 6 12 18 24 FUEL LINE I I 41 FUEL STRAINER SCREEN c Cc 42 THROTTLE OPERATION l 55 9 AIR CLEANER NOTE 1 C C c C 51 i CRANKCASE BREATHER NOTE 2 l l l l 53 A SPARK PLUG l l l l 61 E VALVE CLEARANCE l I l l I 66 z ENGINE OIL R R R R R 44 ENGINE OIL FILTER R R R R R 44 o DECOMPRESSOR SYSTEM l l l I I x ENGINE IDLE SPEED I l I l l 136 2 RADIATOR COOLANT NOTE 3 l R 49 50 COOLING SYSTEM l l l l l 49 SECONDARY AIR SUPPLY SYSTEM NOTE 2 l l 5 TRANSMISSION OIL R R R R R 47 DRIVE CHAIN NOTE 1 LL 1 L every 300 mi 500 km or 3 months 95 96 97 3 DRIVE CHAIN SLIDER NOTE 1 1 L every 300 mi 500 km or 3 months 97 fi BRAKE FLUID NOTE 3 l I l R 88 m BRAKE PAD WEAR l I I 90 E BRAKE SYSTEM l l l I 87 a HEADLIGHT AIM
161. seal Use a new genuine Honda oil filter or a filter of equal quality specified for your model NOTICE If the oil filter is not installed properly it will cause serious engine damage 13 Apply engine oil to a new O ring and install it to the oil filter cover 14 Install the oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 15 Install the left engine guard and bolt then tighten it Engine Oil 16 Fill the crankcase with the recommended oil Capacity 0 74 US dt 0 702 at oil and filter change 0 71 US qt 0 672 at oil change 17 Install the engine oil filler cap dipstick 18 Check the engine oil level by following the steps in Checking amp Adding Oil page 44 Servicing YourHonda 45 Transmission Oil Refer to Safety Precautions on page 25 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the transmission and clutch Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission 46 Servicing Your Honda Oil Recommendation API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label
162. see se ee ee Se Ge ee 122 chassis adjustment for track conditions 137 environment protecting ee esse see se se 145 suspension track conditions esse 139 Choke knob ae EE se Ee EE tte feeds 15 tire SELECTION ESE GER T 92 cleaner AI esha eke EE ee Sak edocs 51 F after competition maintenance cece 33 cleaning appearance Care see ese see se 104 ind SA EE NE HA 51 clutch system adjustment esse ese ee se se 56 filter air pressure consumer information ees sesse se ee ee ee 165 UORD 51 front suspension esse see se ee se ee ee 108 competition logbook ees sesse se ee ee se 159 IERE EE EE ee 44 lS RE N N RE 92 contacting Honda esse esse ese se es see ee ee ge 167 flooded engine starting 0 0 0 cee ss se se ee ee 16 apparel protectiVe ees sesse se ee ee Ge Ge ke de 2 controls operating 0 eee sesse se se ee Ge Ge 8 fork COOLANL AE ER AE EE ER Re tae 48 COOLANG A EE EE ROES DR RA te ser oltre tikes 48 front suspension adjustment eee 108 appearance Cafe si cas vedas RE De Se se ee gees ge 104 CUSLOMET SELVICE nieeenke ee Ge 168 front suspension inspection ees see 83 authorized manual ee cee se ee se Ge Ge de 168 cylinder SYSter ss side RD ens be sees ERGE ge gek bed See 77 oil recommendation iese esse se ee se 85 frame Number i s ges EE EERS DEE g 152 B D front brake lever adjustment cee see 87 front suspension maintenance eee 108 basic Opera eciericedeerercacthes socdedttavtebecta
163. should be followed each time when e piston is replaced e piston rings are replaced e cylinder is replaced crankshaft or crank bearings are replaced Basic Operating Instructions 21 22 Basic Operating Instructions Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CRF in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good The ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 166 Before You Service Your Honda The Importance of Maintenance sesse sesse 24 Maintenance Safety esse se se see ee se Ge ee 25 Important Safety PrecautionS iese ses see se 25 Maintenance Schedule iese see ee se se ee 26 General Competition Maintenance sesse 29 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Remov dls see EE i
164. side rail Pa ad i i GAAR top ring CSSSS CLL ii oil ring Svs Xa top ring oil ring Piston Installation 1 Place clean shop towels over the crankcase opening to keep the piston pin clips from falling into the crankcase 2 Apply molybdenum disulfide oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the connecting rod small end 3 Apply clean engine oil to the piston pin outer surface and piston pin hole inner surface 4 Install the piston 1 with the IN mark 2 and or the large valve recesses 3 facing the intake side of the engine Install the piston pin and new piston pin clips 5 NOTICE Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 2 IN mark 3 large valve recesses 4 piston pin 5 piston pin clip 6 cut out Piston Piston Rings Piston Pin Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entire the engine 2 Clean off any gasket material from the gasket surface of the crankcase 3 Install the dowel pins 1 and new cylinder gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 5 EN mm 1 dowel pins 2
165. splacement 27 41 cu in 449 4 cm EA ll 1 625 Footpeg height 17 0 in 431 mm Compression ratio 120 1 Gear ratio III 1 235 Ground clearance 13 6 in 345 mm Intake 0 006 0 001 in Gear ratio IV 1 000 Frame Valve cl 0 16 0 03 mm Gear ratio V 0 826 Ave clearance Cold spas Old 40 001 iin Type Twin tube 0 28 0 03 mm Final reduction 3 923 Telescopic fork F Left foot operated return F suspension travel 11 0 in 279 mm ae oil capacity r Gear spit pale in system 1 N 2 3 4 5 stroke 12 4 in 315 mm ter draining 0 71 US qt 0 67R Electrical Pro link After draining and R suspension travel 12 3 in 313 mm oil filter change 0 74 US at 0 70R Zaney EE EER 80 100 21 51M After disassembly 0 92USqt _0 87R dimen ae e size tro DUNLOP D742F Transmission oil Starting system Electric Kickstarter ey 110 100 18 64M capacity Spark plug Standard NGK Tire Size rear DUNLOP D756 After draining 0 69 US qt 0 65R ASS IFR8H11 Tire pressure front cold 15psi 100kPa 1 0 kgf cm After disassembly 0 79 US qt 0 75R aa n Tire pressure rear cold 15psi 100kPa 1 0 kgf cm Cooling system NGK EE katate Single disc brake capacity Optional IFR9H11 brake swept area 51 8 in 334 5 cm After draining 1 28 US qt 1 21R DENSO Single disc brake After disassembly 1 53 US qt 1 45R VK27PRZ11 R brake swept area 60 6 in 391 1 cm Carburetor Spark plug gap 0 039 0 043 in Fuel capacity 2 27 US gal 8 6R Type Piston valve 1 0 1 1 mm F
166. sse ese see 162 Wiring Diagram esse sesse esse ee ee Ge GR Ge de 163 Consumer Information ese esse sesse se esse sesse sesse 165 Authorized Manuals iese ses es se ee ee ee 166 Contacting Honda sesse cee ese ese see se Ge de 167 Your Honda Dealer 168 The Honda Rider s Club USA only 169 Table of Comtemtsc cisscscsscsesssssstscssestecsudeonscbente 170 VINER EE OR EE EE EE 172 Ouick Reference Table of Contents 171 Index A C E ACCESSOLIES RA OD OR AE 4 capacity TUL ssc es ee Rede RE ES Ee boe gee Ee gee 41 engine adjustments carburetor flooded ies Ee es SEE Ee ah Ee ED 43 CArDUTCLOR Ace EE ee ee oe ages 136 adjustment ses e ei ke be 136 idle speed i e ee EE ee eg es 136 CHASSIS sis EE N e ai les 137 circuit FUNCTIONS sees esse ese se se ee se 130 NUMDER was LO S 152 control freeplay 54 56 60 87 COMPONENUS iss slee gese epiese be ese DE geeis 130 PUN Ui AE EE EE 41 for competition eee eee se ee ee ee ee ee 107 disassembly assembly sesse see ee ee 133 Ed ER OE N 15 an N AE ET BL EA 138 idle speed ER GEES Gos aches deaths cede 136 SLOP DUTLOM AE OE N 16 personal fit is GES N SE Mer Dee Re aud 140 Care AppeatanCe cass csi VEE EE VEE ESE gee ear eg 104 Sr TEE N EE OE 16 SUSPENSION FONE sesse se se ee Ge Ge ee 108 Chat drive 3 5 Eed gidse base Pase EER De gee see Eeue 95 WOOD EA AR AE RE AE 16 SUSPENSION TAL ese see
167. ssification 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil has drained install the transmission oil drain bolt with a new sealing washer to the specified torque 16 Ibf ft 22 N m 2 2 kgf m PRODUCT MEETING JASO T 903 1 transmission oil filler cap 3 sealing washer 6 Fill the crankcase with recommended oil COMPANY GUARANTEEING THIS MA PERFORMANCE teel eek elt Capacity 0 69 US qt 0 652 at oil change 7 Check the transmission oil level by following the steps in Checking amp Adding Oil this page 1 code number of the sales company of the oil 1 Run the engine for 3 minutes then shut it off 2 oil classification 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission 3 Support the CRF in an upright position on a level surface 4 Remove the transmission oil filler cap 1 oil check bolt 2 and sealing washer 3 from the right crankcase cover A small amount of oil should flow out of the oil check bolt hole Allow any excess oil to flow out of the oil check bolt hole If no oil flows out of the oil check bolt hole add oil slowly through the t
168. start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt Check for signs of oil leakage Damaged or 3 leaking fork seals should be replaced before your CRF is ridden 2 dust seal Inspect the wear rings 3 for wear or damage Replace the wear ring if it is 0 08 in 2 0 mm or flat with the outer tube 4 When replacing the wear ring remove the fork leg page 109 Install the wear ring with its end gap facing rearward 3 wear ring Suspension 4 0 08 in 2 0 mm 3 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times Servicing Your Honda 83 Suspension 5 F 1 Bounce the rear of the motorcycle up and down Rear Suspension Inspection and check for smooth suspension action The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure The gas pressure in the reservoir is contained within a rubber bladder The shock absorber s spring preload and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions
169. stment 1 Make sure that the piston is at top dead center on the compression stroke page 55 Measure the right exhaust valve clearance by inserting a feeler gauge 1 between the right side rocker arm 2 and shim 3 Right Exhaust Valve Clearance 0 011 0 001 in 0 28 0 03 mm 15 tensioner stopper 9 Install a new sealing washer 16 and cam chain tensioner lifter cover bolt 17 1 feeler gauge 3 shim 2 right side rocker arm 2 Pull out the feeler gauge 16 sealing wahser 17 cam chain tensioner lifter cover bolt 10 After installing the cam shaft assembly perform the valve clearance and decompressor arm clearance inspection Valve Clearance 3 Loosen the lock nut 4 and adjusting screw 5 Insert the feeler gauge 1 between the adjusting screw and right side rocker arm 7 DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor clearance is 0 011 in 0 28 mm 0 014 in 0 35 mm 0 025 in 0 63 mm Turn the adjusting screw until there is a slight drag on the feeler gauge Hold the adjusting screw and tighten the lock nut to the specified torque 1 feeler gauge 5 adjusting screw 4 lock nut 6 right side rocker arm Recheck the decompressor arm clearance Servicing Your Honda 73 Valve Clearance Crankshaft Hole Cap Installation Coat a new O ring
170. stments that worked best at a particular location These items include e basic track conditions altitude and temperature e suspension settings e chassis adjustments tested and selected e gearing e tire selection e air pressure Competition Records e your placings e thoughts to improve performance next time both yours and your CRF s e strategy notes Maintenance Records e regular interval maintenance e repairs e running time on engine e running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft operators do but without the benefit of an electrical hourmeter All running time is broken down into hours and tenths of an hour each six minutes represents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include e Your placing in each moto and overall finishing position e Thoughts on what you could do to improve your performance next time e Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future e
171. t 7 Clean the battery box after removing the battery for storage Dry the battery box 8 Slow charge the battery see page 101 once every 30 days Installation 1 Reinstall the battery in the reverse order of removal Be sure to connect the positive terminal 4 first then the negative terminal 3 2 Check all bolts and other fasteners are secure 3 Install the battery band 1 as shown 1 battery band Battery Charging Be sure to read the information that came with your battery charger and follow the instructions on the battery Improper charging may damage the battery We recommended using a trickle charger 1 for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage P 1 trickle charger Battery Servicing Your Honda 101 Headlight amp Taillight Refer to Safety Precaution on page 25 3 To pull the headlight bulb out push and turn 5 While pushing the headlight bulb socket 6 the headlight bulb socket 6 counterclockwise turn it clockwise and install the headlight bulb 7 socket Headlight Bulb 6 Install the dust cover 5 tightly against the
172. t the engine Do not open the throttle 3 As soon as the engine starts release the hot start lever Starting a flooded engine 3 hot start lever 3 Using the start button 1 Do not use the choke 2 Shift the transmission into neutral with the 1 throttle 2 engine stop button throttle fully opened 3 Pull the clutch and hot start levers all the way Normal Engine Stop in and depress the start button for 5 seconds Shift the transmission into neutral 3 If the engine starts quickly close the throttle Turn the fuel valve OFF then open it slightly if idling is unstable If the Lightly open the throttle 1 2 3 times and engine does not start wait 10 seconds and then close it then follow the regular starting procedure Depress the engine stop button 2 until the 4 As soon as the engine starts release the hot engine stops completely start lever P Failure to close the fuel valve may cause the ns the kickstarter carburetor to overflow result in hard starting Do not use the choke 5 Shift the transmission into neutral with the Emergency Engine Stop throttle fully opened repeat kickstarter To stop the engine in an emergency depress the operation approximately 10 times very slowly engine stop button to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as
173. talling the cylinder head 3 Apply engine oil to all cylinder head nut threads 4 Install the washers and cylinder head nuts and tighten them in a crisscross pattern in 2 or 3 steps to the specified torque 49 Ibf ft 66 N m 6 7 kgf m 5 cylinder bolt NOTICE 6 cylinder head bolts Do not let the washers and nuts fall into the 5 Install the left engine hanger plate 7 right crankcase engine hanger plate 8 clutch cable stay 9 and engine hanger plate bolts 10 and tighten the engine hanger plate bolts until the engine hanger plates lightly contact the frame 6 Install the engine hanger bolt 11 fuel hose 7 left engine hanger plate guide 12 and engine hanger nut 13 and 8 right engine hanger plate tighten the engine hanger nut until it lightly 9 clutch cable stay contacts the engine hanger plates 10 engine hanger plate bolts 11 engine hanger bolt 12 fuel hose guide 7 Tighten the engine hanger plate bolts to the 13 engine hanger nut specified torque 19 Ibf ft 26 N m 2 7 kgf m Tighten the engine hanger nut to the specified torque 40 Ibf ft 54 N m 5 5 kgf m 3 cylinder head 4 cylinder head nuts washers contd Servicing Your Honda 81 Piston Piston Rings Piston Pin 8 Connect the radiator hose 14 to the cylinder head and tighten the radiator hose clamp 15 w 14 radiator hose 15 radiator hose clamp 9 Install the ignition coil
174. ted Fuels sees see ss ee ee ee ee 158 Competition Logbook s es 159 Optional Parts List ese see se ee ee ee 161 Spare Parts amp Equipment sesse esse esse 162 Wiring Diagram iese sesse ese es see se ee Sk Ge dee 163 Consumer Information e sesse sesse sesse ese se see see 165 Authorized Manuals i esse esse ese es ek ee dee 166 Contacting Honda esse esse esse esse ese ek ee dee 167 Your Honda Dealer iese se sees se ses se ee ee ee ee 168 The Honda Rider s Club USA only 169 Table of Contents scscssssssssssssssssssssesseees 170 WING MA T HE 172 Ouick Reference Motorcycle Safety This section presents some of the most important Important Safety Information eee eee 2 information and recommendations to help you Important Safety Precaution 0 0 0 eee 2 ride your CRF safely Please take a few ER TE ER EE RR 3 moments to read these pages This section also Accessories amp ModificatHOnS esse esse esse se 4 includes information about the location of the Safety Labels EE EE ee De Ge eee herbed ce 5 safety labels on your CRF Motorcycle Safety 1 Important Safety Information Important Safety Precautions Your CRF can provide many years of pleasure if you take responsibility for your own safety and understand the challenges you can meet in competitive racing There is much that you can do to protect yourself when you ride You ll find many helpful recommendations th
175. the adjuster nut changes the spring length by 1 16 in 1 5 mm 1 lock nut 2 adjusting nut 3 pin spanners 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 8 in 249 mm To decrease spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to increase the spring length 4 Do not increase to more than 10 22 in 259 5 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load 0 06 in 1 5 mm 18 1 Ibs 8 2 kg Pin spanners should be used for turning the lock nut and adjusting nut See page 161 for optional pin spanners Spring pre load length Standard spring Standard 10 18 in 258 5 mm Min 9 8 in 249 mm Spring pre load length Optional spring Min Softer 5 30 kgf mm 9 9 in 251 mm Min Stiffer 5 70 kgf mm 9 9 in 251 mm Min Stiffer 5 90 kgf mm 9 8 in 250 mm Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters The high speed compression damping adjuster 1 is effective when compression damping adjustment is desired for high speed operation The low speed compression damping adjuster 2 should be used when compression damping adjustment is desired at relativel
176. the axle from the right side 28 front wheel 29 align 26 Install and tighten the axle nut 32 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the left axle pinch bolts 33 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 30 O ring 31 axle 32 axle nut 33 left axle pinch bolts 27 Install the handlebar 34 mounting rubbers 35 washers and handlebar lower holder nuts 36 and tighten the handlebar lower holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 34 handlebar 35 mounting rubbers 36 washers handlebar lower holder nuts 28 Install the front visor page 102 29 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation Front Suspension Adjustments 30 While keeping the forks parallel alternately 32 Clean the threads of the disk cover bolts and tighten the right axle pinch bolts 37 to the axle holder thoroughly specified torque Install the disc cover 39 and tighten the bolts 15 Ibf ft 20 N m 2 0 kgf m 40 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m NOTICE To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the right fork leg clamp inner surface 31 Connect the tripmeter cable 38 and tighten the lock nut securely 39 disc cover 40 bolts 33 Turn the rebound damping adjusters back to their origina
177. the engine starts release the hot start lever 16 Basic Operating Instructions Ee 1 Your CRF has five forward gears in a one down four up shift pattern To start riding after the engine has been warmed and the side stand raised 1 Close the throttle and pull the brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the brake lever Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will stall If the engine rpm speed is too high or you release the clutch lever too quickly your CRF may lurch forward 5 When you attain a moderate speed close the throttle pull the clutch lever in and raise the shift lever After shifting release the clutch lever and apply the throttle 6 To continue shifting up to each higher gear repeat step 5 7 To shift down to a lower gear close the throttle pull the clutch lever in and depress the shift lever After shifting release the clutch lever and apply the throttle Remember to close the throttle and pull the clutch lever in completely before shifting NOTICE Improper shifting may damage the engine transmission and drive train Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Downshift to a lo
178. the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for this service 1 Place your CRF on the optional workstand or equivalent support with the front wheel off the ground 2 Remove the front visor page 102 3 Remove the handlebar pad Remove the handlebar lower holder nuts washers mounting rubbers 1 and handlebar 2 NOTICE Keep the master cylinder upright to prevent air from entering system 1 handlebar lower holder nuts washers mounting rubbers 2 handlebar cont d Adjustments for Competition 109 Front Suspension Adjustments 4 Loosen the upper pinch bolts 3 5 Loosen the fork damper 4 using the lock nut wrench but do not remove it yet NOTICE Do not use an adjustable wrench to loosen the fork damper it may damage them 3 upper pinch bolts 4 fork damper 6 Remove the disc cover 5 by removing the two bolts 6 5 disc cover 6 bolts 110 Adjustments for Competition 7 Remove the tripmeter cable 7 and front axle nut 8 and loosen the axle pinch bolts 9 on both fork legs 8 Pull the front axle shaft 10 out of the wheel hub and remove the front wheel 1 oos 7 trip meter cable 8 front axle nut 9 axle pinch bolts 10 front axle shaft 9 Remove the fork protector bolts 11 tripmeter cable clamp bolts 12 and brake hose clam
179. this manual Introduction The official Honda Service Manual for your CRF is available page 166 It is the same manual your dealer uses If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference Your new Honda is covered by Noise Control Warranty USA only There are responsibilities restrictions and exclusions which apply to this warranty Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the line of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the proper tools and service information and be mechanically qualified Failures that occur due directly to improper maintenance or lack of maintenance are not covered This motorcycle has no cooling fan For this reason engine overheating and coolant loss will occur if the engine is kept idling too long when hot Additionally when riding in mud or sand or any condition that causes high engine load at low vehicle speed the time it takes for the engine to overheat wil
180. tition 0 0 eee see ee ee 29 before te ses EE Ee eg eg sl thetic rand 9 H 1MPOTLANCE GES EE Ge ee ee ee ee ee 24 important safety information eee 2 UNA EE N EE N 25 safety precautions esse esse esse se ee ee ee ee 2 handlebar inspection esse se ee ee ge ee 98 este OR EE 27 28 Honda manual SELVICE siei ee ee ee ee Re ee ee ee ee 166 S Contac UNS vs EE Ee EE EE ye ee 167 MOC er ele te ER 4 Rider s Club RE ES Ee ED Se EE ske ees ie 169 safety Service Manual iese sesse ese see sed ee ee 166 O a few words about Safety Messages vourdealers EE EL EED ee Ee GE gee eg Rek 168 important information sesse ese ee ee ee 2 oil important precautions esse sesse ese ee ee de 2 I lS EE N ease 85 ElAEN EE EE EE EE NT 5 ELE ES GE AO AR EE 46 MAINTENANCE ees Eseg ee sade be bad ee Ee 25 identification Vehicle esse sesse es ee ee ee 152 operating riding precautions esse sesse se ee ee ee 14 idle speed engine oe ee ee ee ee ee Ge 136 CONTOS ie othe N EE ee EN Ge Ee ee tr EE 7 schedule maintenance esse se se se ee 27 28 inspection pre ride ee see se ee ee se Ge 11 operation component locations 8 serial numbers ii see rinn eg eg Fed gee 152 optional service L Parts TS sess sists eta n eai 161 CUSTOMER is EES eane ee e ees Ea 168 SPROCK EIS 012 AE HO 161 manuals ius Eie Ee ED ER sheets AE eg ee 166 labels safety ate Rd Ee EE gai aed ated 5 oxygenated fllels 0 eee ee se iiion 158 Spare paitsio ri esere VEE
181. to store your CRF we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the battery we recommend disconnecting the battery cables negative cable first 100 Servicing Your Honda You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging on page 101 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WAR The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery maintenance The battery is located under the seat Removal 1 Remove the seat page 36 2 Remove the battery band 1 3 Remove the positive terminal cover 2 4 Disconnect the negative terminal 3 first then the positive terminal 4 and remove the battery 5 1 battery band gt 4 positive terminal 2 positive terminal cover 5 battery 3 negative terminal 5 Unless you have been riding regulary charge the battery see page 101 6 Store your battery in an easy to reach location off the floor in an area protected from freezing temperatures and direct sunligh
182. ture and dirt The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when the motorcycle is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Inspection 1 Stop the engine and raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 3 driven sprocket 1 drive chain slack 2 drive sprocket If the chain is found to be slack in one segment of its length and taut in another this indicates that some of the links are either worn kinked or binding Kinking and binding can frequently be eliminated by thorough cleaning and lubrication If the drive chain require
183. ty Precautions on page 25 Clutch Lever Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected 56 Servicing Your Honda Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in direction will increase freeplay and turning it in direction will decrease freeplay If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn and make the adjustment with the integral cable adjuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained 3 lock nut 4 integral cable adjuster increase decrease 1 Turn the cable end adjuster in direction seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the e
184. uel reserve capacity 0 37 US gal 1 4R Identification number FCRO4A Light Caster angie Ef 10 Main jet 142 Head light 12V 35 W Trail length 4 32 in 109 7 mm Jet needle NCVU Fuse Fork oil capacity Needle clip position 2 f t i except fork damper 11 2 US oz 332 cm PP Nd groove om top Main iuse 15A per leg Slow jet 45 Pilot screw opening 1 1 4 turns out Float level 0 31 in 8 0 mm Idole speed 1 700 100 rpm Technical Information 153 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Engine 154 Technical Information Torque Item Remarks Nem ENGINE 1 Cylinder head cover bolts 7 10 2 Clutch cover bolts 10 3 Water pump cover bolts 10 4 Transmission oil check bolt 7 10 5 Crankshaft hole cap 11 15 6 Oil filter cover bolts 9 12 7 Cylinder bolt 7 10 8 Cylinder head bolts 7 10 9 Exhaust pipe joint nut 15 21 10 Drive Sprocket bolt 23 31 NOTE 1 1 UBS bolt Frame p PSEA X TS Q SO Df x NO Peele Oo x TOLJ Torque Specifications Torque Item Remarks Ibfeft Nem kgfem FRAME 1 Steering stem nut 80 108 11 0 2 Fork bridge upper pinch bolts 16 22 2 2 3 Fork bridge lower pinch bolts 15 20 2 0 4 Handlebar upper holder
185. urfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking accelerating or turning When descending a long steep grade use engine compression braking by downshifting with intermittent use of both brakes When you brake to a stop pull the clutch lever in before stopping completely to prevent stalling the engine For support put your left foot on the ground first then your right foot when you re through braking 18 Basic Operating Instructions Parking Lower the side stand to support your CRF If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park Basic Operating Instructions 19 Post ride Inspection When you return home after riding thoroughly clean your CRF and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your CRF for leaks or damage Be sure to lubricate the drive chain page 97 to prevent rusting 20 Basic Operating Instructions Break in Guidelines Help assure your CRF s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure
186. urs and about every 30 0 hours Pre ride Inspection Check the items listed on the Pre Ride inspection checklist each time before you ride page 11 Fuel Capacity unleaded gasoline pump octane number of 91 or higher tank 2 27 US gal 8 62 reserve 0 37 US gal 1 42 Engine oil Pro Honda GN4 or HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent Transmission oil Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdem additives 4 stroke oil or an equivalent Tires 80 100 21 51M 110 100 18 64M Front Rear DUNLOP D742F DUNLOP D756 Type bias ply tube type Tire Pressure Front 15 psi 100 kPa 1 0kgf cm cold Rear 15 psi 100 kPa 1 0kgf cm Spark Plug standard IFR8H11 NGK or VK24PRZ11 DENSO optional IFR9H11 NGK or VK27PRZ11 DENSO Drive Chain D 1 D 520MXV
187. used by excess current flow short circuit or overload If something electrical on your CRF stops working the first thing you should check for is a blown fuse Check the fuse before looking elsewhere for another possible cause of the problem Replace a blown fuse and check component operation e The main fuse and spare are located on the starter motor magnetic switch behind the right side cover Recommended Main Fuse 15A 1 2 To prevent an accidental short circuit stop the engine Open the air cleaner housing cover by turning the quick fastener 1 counterclockwise and remove the left side cover bolt 2 seat bolt 3 and left side cover 4 1 quick fastener 2 left side cover bolt 3 seat bolt 4 left side cover 148 Taking Care of the Unexpected 3 Remove the starter magnetic switch 5 with the rubber case 4 Disconnect the wire connector 6 of the starter magnetic switch 5 Pull out the main fuse 7 If it is blown 8 install the spare main fuse 9 g 7 ad Oo 5 starter magnetic switch 6 starter magnetic switch connector 7 main fuse 8 blown fuse 9 spare main fuse 6 Reconnect the wire connector and install the starter magnetic switch If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a
188. uspension pivot points and steering head bearings driving dirt inside and needed lubrication out 104 Servicing Your Honda If you use a high pressure washer avoid spraying the following areas wheel hubs muffler outlet area under seat engine stop button brake master cylinders under fuel tank drive chain carburetor steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points NOTICE High pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Washing Your Motorcycle with a Mild Detergent 1 Rinse your CRF thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover is for removing stains on the non coated aluminu
189. ustments in one click increments Test ride after each adjustment Front Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below Install the optional stiff spring Sand track Adjust to a stiffer position Example Turn the compression damping adjuster to a stiffer position Install the optional stiff spring Adjust compression damping to a softer position and rebound damping to a harder position at this time Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Turn the compression damping adjuster to a stiffer setting Adjustments for Too Soft Stiff Damping Symptom Action Soft suspension Initial travel too soft e Steering is too quick e Front end darts while cornering or riding in a straight line Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments Middle travel too soft e Front end dives when cornering If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments
190. ve the radiator cap 1 Fill the system with the recommended coolant through the filler opening up to filler neck 2 Use a fresh recommended coolant mixture page 48 Capacity 1 28 US qt 1 212 2 filler neck Servicing Your Honda 3 Remove the radiator reserve tank cap 3 and fill the reserve tank to the UPPER level line 4 3 radiator reserve tank cap 4 UPPER level line 4 Bleed air from the system as follows e Shift the transmission into neutral Start the engine and let it idle 2 3 minutes e Snap the throttle 3 4 times to bleed air from the system e Stop the engine and if necessary add coolant up to the proper level Reinstall the radiator cap e Check the level of coolant in the reserve tank and fill to the UPPER level if it is low NOTICE If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage 5 Install the radiator reserve tank cap Refer to Safety Precautions on page 25 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet
191. vents e Any places on the course where you chose the wrong line and were passed too easily e Notes on strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular maintenance items you ll want to record in your logbook should include e Dates and results of cylinder piston and ring examinations e Patterns for frequency of need for decarbonization with a particular oil e When you last performed shock linkage and swingarm pivot bearing maintenance e Engine transmission and suspension oil changes e chain sprocket chain guide and slider replacements e coolant changes and related component replacements e Spark plug brake pad and control cable replacements In addition you should record any irregularities noted in component wear so you ll remember to keep a close eye on these areas in the future Technical Information 159 Competition Logbook Date Running Time Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use 160 Technical Information These parts and tools may be ordered from your Honda dealer Optional Parts List FRAME Remarks Driven sprocket lt gt Drive chain links Standard 51 Teeth
192. wer gear before you feel the engine laboring lugging at low rpm NOTICE Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage NOTICE To prevent transmission damage do not coast or tow the motorcycle for long distances with the engine off Shifting Gears Basic Operating Instructions 17 Braking To slow or stop apply the front brake lever and rear brake pedal smoothly while downshifting to match your speed Gradually increase braking as you feel the brakes slowing your speed To prevent stalling the engine pull the clutch lever in before coming to a complete stop For support put your left foot down first then your right foot when you are through using the rear brake pedal For maximum braking close the throttle and firmly apply the front brake lever and rear brake pedal controls Applying the brakes too hard may cause the wheels to lock and slide reducing control of your CRF If this happens release the brake controls steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your speed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your CRF When riding in wet or raining conditions or on loose s
193. y page 101 once a month Inflate the tires to their recommended pressures Place your CRF on the optional Honda workstand or equivalent to raise both tires off the ground Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation Cover your CRF with a porous material Avoid using plastic or similar nonbreathing coated materials that restrict air flow and allow heat and moisture to accumulate Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the battery page 101 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 53 US qt 1 452 at disassembly 1 28 US qt 1 212 at draining Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from the system 6 Perform all maintenance checks page 11 You amp the Environment Owning and riding a motorcycle can be NOTICE enjoyable but you must do your part to protect nature When
194. y low speeds e Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise e Adjust the high speed compression damping adjuster in 1 12 turn increments 2 e 5 1 high speed compression damping adjuster 2 low speed compression damping adjuster High Speed Compression Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed compression damping adjuster has 2 turns or more To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 3 4 1 1 4 turns and the punch marks are aligned Low Speed Compression Damping The low speed compression damping can be adjusted by turning the center screw of the compression adjuster The low speed compression damping adjuster has 13 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seat This is the full hard setting 2 Turn the adjuster counterclockwise 10 clicks and the punch marks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 17 positions or more Turning the adjuster one full turn advances t
195. you show respect for the land Improper disposal of drained fluids is harmful to wildlife and other people you also help preserve the environment the sport of off road riding Following are tips on how you can be an environmentally responsible motorcycle owner e Choose Sensible Cleaners Use a biodegradable detergent when you wash your CRF Avoid aerosol spray cleaners that contain chloroflur carbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal e Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of non recyclable wastes Tips 145 Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of the Honda Service Manual are followed by an asterisk ENGINE DOES NOT START OR IS HARD TO START POSSIBLE CAUSES
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