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2012 - Honda Motorcycles

1. Make several photocopies of this page for future use Technical Information 155 142 170 qxd 11 4 18 10 35 2 156 Optional Parts List These parts and tools may be ordered from your FRAME Remarks authorized dealer Shock spring 296 9 Ibf in 52 0 N mm FRAME Remarks Standard No mark Driven sprocket lt gt Drive chain links S factory products Standard 49 Teeth Aluminum lt 116 gt or SR Optional 48 Teeth Aluminum cz aftermarket parts 50 Teeth Aluminum Driven chain DID520DMA4 120RB Optional 285 5 Ibf in 50 0 N mm size link RK520TXZ 120RJ Softer eS White Handlebar Ge paint lower holder Standard 3 mm offset Stiffer 307 7 Ibf in 53 9 N mm Optional no offset ee Gen TOOLS Remarks Fork spring 25 12 Ibf in 4 4 N mm Pinspanner A To adjust spring preload Standard M two spanners required O No mark Workstand D For maintenance Ke Optional 23 98 Ibf in 4 2 N mm A Forcheeking tireai Softer ir gauge or checking tire air pressure Q Shae mark Stiffer 26 20 Ibf in 4 59 N mm OF 2 scribe marks 156 Technical Information 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
2. Torque Item Remarks Ibfeft Nem kgfem FRAME 23 Caliper mounting bolts 22 30 3 1 NOTE 4 24 Front brake disc nuts 12 16 1 6 NOTE 1 25 Rear brake disc nuts 12 16 1 6 NOTE 1 26 Brake pedal pivot bolt 27 36 3 7 NOTE 5 27 Spoke front 2 7 3 7 0 4 rear 2 7 3 7 0 4 28 Rim locks 9 12 1 2 29 Subframe bolts upper 24 33 3 4 Lower left 24 33 3 4 Lower right 36 49 5 0 30 Fork center bolt 51 69 7 0 31 Fork center lock nut 16 22 2 2 32 Disc cover bolts 10 13 1 3 33 Fork protector bolts 5 2 7 0 7 NOTE 4 34 Muffler clamp bolt 15 21 2 1 35 Muffler mounting Frontside 19 26 2 7 A B bolts Rear side 19 26 2 7 36 Driven sprocket nuts 24 32 3 3 NOTE 1 37 Seat mounting bolts 19 26 2 7 38 Front brake reservoir cap screws 0 7 1 0 0 1 39 Rear brake reservoir cap bolts 0 7 1 0 0 1 40 Fork air pressure release screw 1 0 1 3 0 1 41 Shroud B bolts 3 7 5 0 5 42 Drive chain roller upper 9 12 1 2 NOTE 6 lower 9 12 1 2 NOTE 1 43 Throttle cable lock nut 3 0 4 0 4 44 Steering damper mounting bolts 15 20 2 0 NOTE 4 45 Brake lever adjuster lock nut 4 4 5 9 0 6 46 Brake pedal adjuster lock nut 4 4 5 9 0 6 47 Mud guard screws 0 8 1 1 0 1 48 Side cover bolts 7 10 1 0 49 Fuel pump mounting bolts 8 11 1 1 NOTES 1 U nut 2 UBS nut 3 Apply molybdenum oil to the threads and flange surface 4 Alock bolt replace with a new one 5 Apply locking
3. IMPORTANT NOTICES FOR COMPETITION USE ONLY This Motorcycle is designed manufactured and sold for closed course competition use only It does not conform to Federal Motor Vehicle Safety Standards or U S EPA Noise and Emission Standards Operation on public streets roads highways or for off road recreation is illegal State and federal laws prohibit operation of this vehicle except in an organized racing or competitive event on a closed course or by permit issued by the local governmental jurisdiction This vehicle is sold as is with no warranties FOR EXPERIENCED RIDERS NO PASSENGERS This motorcycle is designed as an operator only vehicle and for use by experienced riders only The 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 in this owner s manual may not match your vehicle Honda Motor Co Ltd 2011 ontents qxd 11 4 18 10 13 Y1 5 2012 Honda CRF250R OWNER S MANUAL
4. Motorcycle Safety 3 D 001 027 qxd 11 4 18 10 13 Y4 j Safety Labels Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your dealer for replacement IMPORTANT INFORMATION Operator only No passengers This Honda Motorcycle is sold as is without warranty and the entire risk as to quality and performance is with the buyer Read owner s manual For Canada This vehicle is designed manufactured and sold for competition use only It does not conform THIS COMPETITION VEHICLE IS FOR USE to Federal Motor Vehicle Safety Standards or EXCLUSIVELY IN CLOSED COURSE COMPETITION U S EPA Noise and Emissions Standards AND IS NOT INTENDED FOR USE ON PUBLIC Operation on public streets roads highways or HIGHWAYS for off road recreation is illegal CE VEHICULE DE COMPETITION EST DESTINE A State and Federal laws prohibit operation of this ETRE UTILISE EXCLUSIVEMENT DANS LES COURSES vehicle except in an organized racing or EN CIRCUIT FERME ET N EST PAS DESTINE AUX competitive event on a closed course Or by VOIES PUBLIQUES permit issued by the local governmental agency having jurisdiction 4 Motorcycle Safety DANGER ZuM NEVER OPEN WHEN HOT Hot coolant will scald you D gt N OUVREZ PAS QUAND CHAUD gt NICHT BE HEISSEM MOTOR FFNEN P RURDITEUTESL Baht San D 001 027 qxd 11 4 18 10 13 75 Read this section carefully b
5. Clogged fuel pump filter P 44 INCORRECT rs Loose insulator e Damaged insulator WEAK OR INTERMITTENT SPARK t Faulty carbon or wet fouled spark plug P 67 e Faulty ECM e Faulty alternator e Faulty ignition coil e Broken or shorted spark plug wire e Faulty CKP sensor e Loose or disconnected ignition system wires e Faulty engine stop button e Faulty regulator rectifier e Faulty condenser oe POOR PERFORMANCE AT HIGH SPEED CHECK 1 Check the ignition timing CORRECT 2 Remove the air cleaner P 52 POSSIBLE CAUSES INCORRECT gt Faulty ECM e Faulty CKP sensor DIRTY t Not cleaned frequently AIR CLEANER NOT DIRTY l 3 Check the PGM F system P 7 CORRECT l 4 Check the fuel pump operation and inspect the fuel flow CORRECT l 5 Check the valve timing CORRECT y 6 Try spark test enough INCORRECT Faulty PGM FI system P 9 INCORRECT gt Faulty fuel pump unit Clogged fuel pump filter P 44 INCORRECT Camshaft not installed properly P 73 GOOD SPARK y 7 Check the valve springs GOOD l 8 Remove and inspect the cam obe height CORRECT WEAK OR INTERMITTENT SPARK
6. 1 oil code 2 oil classification Servicing Your Honda 49 048 067 qxd 11 4 18 10 21 N 750 Engine Oil Checking amp Adding Oil Run the engine at idle for 3 minutes then shut it off Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine Support the CRF in an upright position on a level surface Remove the engine oil fill cap dipstick 1 wipe it clean and insert the engine oil fill cap dipstick without screwing it in Remove the oil fill cap dipstick Check that the oil level is between the upper 2 and lower 3 level marks on the engine oil fill 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 add the recommended oil until it reaches the upper level mark Do not overfill Reinstall the engine oil fill cap dipstick Repeat steps 1 5 2 3 50 upper level mark lower level mark Servicing Your Honda S 6 Check that the O ring 4 is in good condition and replace it if necessary 7 Reinsert the engine oil fill cap dipstick 1 1 engine oil fill cap dipstick 4 O ring 8 Check for oil leaks Changing Engine Oil amp Filter 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil fill cap dipstick 1
7. cc0e00 159 Authorized Manual 160 Contacting Honda 161 Your Deale teilen 162 The Honda Rider s Club USA only 163 QUICK REFERENCE Contents Contents D 001 027 qxd 11 4 18 10 13 Y1 This section presents some of the most important information and recommendations to help you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF SS Important Safety Informatpon cece Important Safety Drecauttons cee Accessories amp Modifications cceeeeeereerees Safety Labels Motorcycle Safety Motorcycle Safety 1 D 001 027 qxd 11 4 18 10 13 H 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 As an experienced rider you know there is much you can do to protect yourself when you ride The following are a few precautions we consider to be most important Never Carry a Passenger Your CRF is designed for one operator only Carrying a passenger can cause a crash in which you and others can be hurt Wear Protective Gear Whether you re practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know Your
8. 028 043 qxd 11 4 18 10 15 3732 S Ke Maintenance Component Locations front brake fluid reservoir clutch lever front brake lever pi SSS ee ss fe oe Rez 3 TY Ge throttle grip fuel fill cap Ze radiator cap j rear brake fluid reservoir rear suspension high speed compression damping adjuster front suspension compression rear suspension low speed damping adjuster compression damping adjuster air cleaner crankcase breather tube i steering damper rear suspension opie _ Ste RS adjuster spring pre load adjuster s As spark plug oS S Se i N 6 ae D LS GRN INAS O St ji A transmission J oil check bolt rear brake pedal front suspension rebound damping adjuster rear brake caliper 1 1 engine oil drain bolt drive chain engine oil fill cap fast idle knob dipstick f engine oil filter rear suspension rebound damping adjuster pales transmission oil engine idle speed drain bolt 32 Servicing Your Honda a E 028 043 qxd 11 4 18 10 15 3733 oe Refer to Safety Precautions on page 23 Installation 1 Removal 1 Remove the seat mounting bolts 1 2 Remove the seat 2 by sliding it backward 2 1 seat mounting bolts 2 seat 1 2 3 4 Install the seat while aligning the seat front prong 1 with the seat bracket 2 and seat rear prong 3 with the ECM bracket 4 Install and tighten the seat mount
9. 001 027 qxd 11 4 18 10 14 720 20 Basic Operating Instructions D 001 027 qxd 11 4 18 10 14 Y21 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 An ECM 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 160 An optional tool kit may be available Check with your dealer s parts department S Before You Service Your Honda The Importance of Maintenance eee 22 Maintenance Safer 23 Important Safety Drecauttons eee 23 Maintenance Schedule 0 cece eeeereereeereees 24 General Competition Maintenance ssesseeeee 26 Before amp After Competition Maintenance 30 Between Motos amp Practice Maintenance 30 After Competition Maintenance 0 000 30 Service Preparations Maintenance Component Locapons 32 Seal Ie ee han Geek O a aie A AR 33 Fuel Tank o isc8 4 heads ss cbstrt hese Soke ike i aens 34 Subirame ses
10. Front Suspension Adjustments 19 Tighten the fork damper 17 to the specified torque using the lock nut wrench 18 Actual 25 lbf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 500 mm long deflecting beam type torque wrench e Lock nut wrench O7WMA KZ30100 When using the lock nut wrench use a 20 in 500 mm long deflecting beam 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 18 lock nut wrench 17 fork damper 20 For ease of releasing air pressure after the forks are installed loosen the fork bridge lower pinch bolts and position the outer tubes so that the fork air pressure release screws are in front of the compression damping adjusters Align the top of the outer tube 19 with the top surface of the top bridge 20 122 Adjustments for Competition 23 19 outer tube 20 top bridge 21 Tighten the fork bride lower pinch bolts 16 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 22 Tighten the fork bridge upper pinch bolts 21 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m NOTICE Over tightening the pinch bolts can deform the 24 outer tubes Deformed outer tubes must be f replaced 21 fork bridge upper pinch bolts 16 fork bridge lower pinch bolts ae 25 Cle
11. 142 170 qxd 11 4 18 10 35 L 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 air cleaner clean amp oiled sealed in a plastic bag chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs fuel feed hose and retainers fuel pump filter number plate amp side covers handlebar grips levers brake clutch clutch lever handlebar mount clutch cable throttle assembly throttle cable shift lever brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins Additional Spares fuel pump front brake master cylinder rear brake assembly wheels amp tires front amp rear mounted clutch discs and plates engine amp transmission oil S 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 adj
12. 5 Install the washer A 7 washer B 8 muffler mounting B bolt 9 and muffler mounting A bolt 10 7 washer A 8 washer B 9 muffler mounting B bolt 10 muffler mounting A bolt 6 Tighten the muffler clamp bolt 11 to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 11 muffler clamp bolt Exhaust Pipe Muffler Tighten the muffler mounting B bolt 9 and muffler mounting A bolt 10 to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 9 muffler mounting B bolt 10 muffler mounting A bolt cont d Servicing Your Honda 101 088 102 qxd 11 4 18 10 27 27102 D Exhaust Pipe Muffler 8 Install the right side cover 12 and bolt 13 9 Install the seat mounting bolt 14 and tighten it to the specified torque 19 Ibf ft 26 N m 2 7 kgf m Tighten the bolt 12 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 12 12 right side cover 13 bolt 14 seat mounting bolt 102 Servicing Your Honda S Exhaust Pipe Removal 1 Remove the muffler page 100 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket Exhaust Pipe Installation 1 Install a new exhaust pipe gasket 1 as shown 2 Install the exhaust pipe 2 and exhaust pipe joint nuts 3 jd a Been e 1 exhaust pipe gasket new 2 exhaust pipe 3 exhaust pipe joint nuts 3 Install t
13. 6 fork cap and fork damper threads 7 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper 1 Recommended Oil HP Fork Oil SS 19 Recommended Amount 8 3 US oz 245 cm 1 fork damper 8 Pump the fork damper piston rod 4 slowly several times to bleed the air from the fork damper 1 1 1 fork damper 4 fork damper piston rod 9 Apply fork oil to the fork cap bushings 7 new O rings 8 and piston ring 9 on the fork cap assembly 2 2 fork cap assembly 8 O rings 7 fork cap bushings 9 piston ring D 109 133 qxd 11 4 18 10 31 11 10 Extend the fork damper piston rod 4 to maximum length holding it install the fork cap assembly 2 to the fork damper 1 with vertical position Be careful not to damage the fork cap piston ring If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level 1 fork damper 2 fork cap assembly 4 fork damper piston rod S Front Suspension Adjustments 11 Place the fork damper 1 in a vise with a 13 Check the fork damper piston rod sliding piece of wood or soft jaws to avoid damage surface for damage Tighten the fork cap assembly 2 while 14 Cover the fork damper piston rod end with holding the cutout of the fork damper using shop towel 11 to prevent fork damage the lock nut wrench 3 to the specified Cover the
14. 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 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 10 minutes before taking a plug reading a brand new plug will not show 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 page 133 Check the PGM FI 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 twice to prevent loosening a First tighten the plug NGK 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 10 Connect the direct ignition coil Take care to avoid pinching any cables or wires 11 Install the fuel tank and seat pages 33 35 Servicing Your Honda 67 D 068 087 qxd 11 4 18 10 24 768
15. POSSIBLE CAUSES INCORRECT gt Brake dragging e Worn or damaged wheel bearings e Bent axle shaft e Drive chain too tight INCORRECT gt Faulty valve core e Punctured tire NO GOOD gt Clutch slipping e Improperly adjusted clutch lever freeplay p 58 e Worn clutch discs plates p 61 e Warped clutch discs plates p 61 e Weak clutch springs p 61 e Sticking clutch lifter e Additive in engine oil NO GOOD gt Dirty air cleaner element e Clogged muffler e Fast idle knob stuck open or damaged e Restricted fuel fill cap breather tube e Restricted fuel flow YES m Worn piston and cylinder e Use of poor quality fuel e Excessive carbon build up in combustion chamber e Ignition timing too advance Faulty ECM e Lean fuel mixture INCORRECT Faulty ECM e Faulty CKP sensor 7 10 11 12 Test cylinder compression CORRECT Check the PGM FI system p 7 CORRECT Check the fuel pump operation and inspect the fuel flow CORRECT Check the spark plug condition p 63 CORRECT Y Check the engine oil level and condition p 46 CORRECT y Remove the cylinder head cover and inspect lubrication LOW e Valve clearance too small e Valve stuck open e Wor
16. and remove the piston Under racing conditions the piston and rings should be replaced every 6 races or about every 15 0 hours of running Replace the piston pin every 6 races or about every 15 0 hours of running 3 piston 1 piston pin clip 2 piston pin Piston Piston Rings Piston Pin Piston Ring Removal Spread each piston ring 1 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 1 piston ring Servicing Your Honda 79 D 068 087 qxd 11 4 18 10 24 780 Piston Piston Rings Piston Pin Piston Piston Pin Piston Ring Piston Ring Installation Wii top ting Inspection Ve ae 1 Clean the piston ring thoroughly s A We recommend you consult the Service Manual 2 Apply engine oil to the piston rings and install paa SC npg or your dealer for correct Service Limit them AN measurements 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 mark 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 the top ring and the upper side rail Space the ring end gaps 90 degrees apart between the upper side r
17. necessary before increasing fuel pressure 1 Connect the fuel pump sub harness connector 1 1 fuel pump sub harness connector 2 Before connecting the battery harness cables to a 12V battery make sure that the battery harness selector switches are OFF 3 Connect the battery harness 2 and battery harness adapter 3 between the main and sub harness as shown Connect the battery harness positive cable first then connect the battery harness negative cable to a 12V battery terminals e Battery harness 070MZ MENO100 e Battery harness adapter O7OMZ KRNO100 48 Servicing Your Honda 2 battery harness 3 battery harness adapter 4 Position the fuel tank on the main frame 5 Turn the PUMP selector switch 4 ON The selector switches can be used to change power delivery as follows ECM selector switch ON Power to ECM only PUMP selector switch ON Power to fuel pump only Both selector switches ON Power to ECM and fuel pump 6 Run the fuel pump for about 3 5 seconds and fuel pressure will rise 7 Turn the PUMP selector switch OFF Check that there is no leakage in the fuel line 4 PUMP selector switch 8 Remove the battery harness 048 067 qxd 11 4 18 10 21 3749 Refer to Safety Precautions on page 23 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the e
18. 10W 30 10W 40 10 0 30 20 10 20 30 40 50 C 20 0 20 40 60 80 100 120F JASO T 903 standard The 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 1 oil code 2 oil classification 048 067 qxd 11 4 18 10 21 1 transmission oil fill cap EH Checking amp Adding Oil 3 sealing washer 2 oil check bolt 1 2 Run the engine at idle for 3 minutes then shut it off Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CRF in an upright position on a level surface Remove the transmission oil fill 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 transmission oil filler hole until oil starts to flow out of the oil check bolt hole Install the oil check bolt with a new sealing washer and transmission oil fill cap Repeat step 1 4 After inspecting the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 9 Ibf ft 12 Nam
19. Check that the steering moves smoothly from side to side 6 Install the number plate page 103 103 108 qxd 11 4 18 10 29 105 D Refer to Safety Precautions on page 23 Steering Head Bearings Inspection 1 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 2 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 adjustment procedures or see your dealer S Additional Maintenance Procedures 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 Make sure the end of the handlebar holders 2 is aligned with the paint mark 3 on right or left side 4 Check the torque of the handlebar upper holder bolts 4 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first handlebar handlebar holders 1 2 3 paint mark 4 handlebar upper holder bolts Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate
20. Cylinder Head Cover Installation 1 Check that the spark plug hole packing 1 is in good condition and replace it if necessary Apply engine oil to the spark plug hole packing and install it to the cylinder head cover 2 2 Check that the cylinder head cover packing 3 is in good condition and replace it if necessary Install the cylinder head cover packing into the cylinder head cover groove 1 spark plug hole packing 2 cylinder head cover 3 cylinder head cover packing S Check the rubber seals 4 are in good condition replace them if necessary Install the rubber seals onto the cylinder head cover with the UP marks 5 facing up 4 rubber seal 5 UP marks Valve Clearance 4 Install the cylinder head cover 2 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 2 cylinder head cover 6 cylinder head cover bolts 5 Connect the spark plug cap 7 and breather tube 8 7 spark plug cap 8 breather tube 6 Install the fuel tank and the seat pages 33 35 Servicing Your Honda 75 D 068 087 qxd 11 4 18 10 24 Piston Piston Rings Piston Pin N 776 Cylinder Head Removal CO N Dv A VM 76 Clean the area above the engine before disassembly to prevent dirt falling into the engine Drain the radiator coolant after cooling the motorcycle page 143 Remove the seat and hang
21. Inspection 1 Check the damper rod 1 operation The damper rod is fully extended and compressed by hand Release the damper rod then check that it extends to its maximum length If the damper rod does not extend its maximum length disassemble and inspect for steering damper Refer to the Honda Service Manual or see your dealer 1 damper rod 104 Servicing Your Honda S 2 Check the condition of the spherical bearings 2 Move the spherical bearing with your finger The spherical bearing should move smoothly and quietly Replace the spherical bearing if it does not move smoothly and quietly Refer to the Honda Service Manual or see your dealer 2 spherical bearings Installation 1 Clean and apply a locking agent to the steering damper mounting bolt threads 2 Install the steering damper 1 with its UP mark 2 facing up and forward Turn the damper rod and its stopper ring 3 facing toward the front side 3 Install the collar 4 and steering damper mounting bolts 5 Be sure to install the collar with its wide flange side facing toward the steering head pipe side 4 Tighten the steering damper mounting bolts to the specified torque 15 Ibf ft 20 N m 2 0 kgf m ae A NY 1 steering damper 2 UP mark 3 stopper ring 4 collar 5 steering damper mounting bolts 5 Place your CRF on the workstand or equivalent support with the front wheel off the ground
22. 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 With the engine stop button pushed repeat kickstarter operation approximately five times to drain the engine oil completely 6 After the oil has drained apply engine oil to the drain bolt threads and tighten it with a new sealing washer to the specified torque 12 lbf ft 16 N m 1 6 kgf m Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 NOTICE Improper disposal of drained fluids is harmful to the environment 1 engine oil fill cap dipstick 2 engine oil drain bolt 3 sealing washer new 048 067 qxd 11 4 18 10 21 2751 7 It is recommended to replace the oil and filter 8 every 6 races or about every 15 0 hours However if you replace only the oil before 9 the recommended interval see page 25 10 oe Remove the oil filter cover bolts 4 and oil filter cover 5 Remove the oil filter 6 from the oil filter cover Check that the oil filter cover O ring 7 is in good condition 1 oil filter cover bolts oil filter cover oil filter spring rubber seal OUT SIDE mark 4 5 6 7 oil filter cover O ring 8 9 0 NOTICE Using the wrong oil filter may result in leaks or engine damage 11 12 Apply grease to the
23. isi aie eee des eee Sees 18 SUSPENSION Ter 125 contacting Honda 161 KEE 145 suspension track conditions 00 0 eee 129 EU EE 5 environment protecting eeeeeeerereereeseeee 144 Hre sglechog nnne ENEE 138 COOLANE EE 54 after competition maintenance leer 30 CUSCOMET SELVICE eee eseeseceseceseceeeeseeeneeeneeees 162 F Alt Glen ee 56 Cylinder syste eee eeeeeseceseceeeeeeeeeeeeseeeeaees 79 air pressure filter front SUSPENSION ssessseeeeeeeesereresreresreees 110 D SIE Series 56 DES tee 95 fuel pump ee EES 44 apparel protettiv ersero eniin 2 damping adjustments TEE 50 appearance Cam 107 Dem Lg 110 fork authorized manuals 160 EE eeh 126 front suspension adustmenmt eee 110 Steering damper oo cece ceseeeeeeereeeeeeneees 134 front suspension pspecHon 85 B dealer E 162 oil recommendation 87 diagram Wiring 20 eee cee ceeeceneeeeeeneeeeeeees 158 front brake lever adjustment eee eee 90 basic OPCTAtiON 0 eee eeeeseceteceeeceteeeeeeeneeeaees 15 drive Chain E 97 front suspension maintenance ee eee 112 before riding ee eee ee idee 11 fuel between motos amp practice maintenance 30 Jee ue erat reen 40 brakes line replacement 0 eee eeceeeceeeeereeeeeeeees 41 fluid level 2 ati2ett euug techs tenn eneas 91 EK E 153 lever front adjustment ele eeeeeeeeeees 90 pump filters csc ttle ete 44 Pad Wear tis aoe ais 93 refueling EE 40 pedal height 2290 90 NEIE EE 40
24. s Club of America USA only We re sure you ll be as pleased with the service your dealer continues to provide after the sale as you are with the quality and dependability of your Honda 142 170 qxd 11 4 18 10 35 N 7163 The Honda Rider s Club of America HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country You can log on to the HRCA Clubhouse website for more information at www hrca honda com The Honda Rider s Club USA only Consumer Information 163 as 142 170 qxd 11 4 18 10 35 1164 Index A C E EERSTEN ees eee ite eel 3 capacity fyel gerett teri 40 engine adjustments CALC APPCATANCE oo eee ee e ra 107 Idle Deeg bereede Eed 61 G ss E ian 136 chain drive Acvisnnkiwanwa died aia 97 lacks Deet conni e NEEN 145 control freeplay seeen 59 62 chassis adjustments s s s 136 NUMBER eae e iaa 148 fOr COMPEtitION repornirea 109 Cleaner ait eege gege 56 Ol sic eee Sie etn eile ie 49 SCALING cera ee See aa 137 cleaning appearance care eee eee eeeeseeneeees 107 PINGING avis hen eee ie 40 personal fit EE 139 clutch system adjustment ee eeeeeeeee eres 62 Starting ice anana a a e a 17 steering damper asiiirshessei reesei 134 competition Jogbook 154 SLOP DUON ssenhor teas ia iai res 18 suspension Front 110 consumer information sseeeeeeeeeeerereeeeeee 159 SLOPPING
25. 1 Check the upper drive chain roller 1 and lower drive chain roller 2 for wear or damage 2 Measure the diameter of the drive chain rollers and replace them if below the service limit Service Limit Upper roller 1 5 in 89 mm Lower roller 1 2 in 31 mm Replace the roller if necessary as follows Install the upper drive chain roller Green with the gt mark 3 facing toward the frame and lower drive chain roller Black as shown Tighten the drive chain roller bolt and nut to the specified torque Upper roller bolt 9 lbf ft 12 N m 1 2 kgf m Lower roller nut 9 lbf ft 12 N m 1 2 kgf m 1 upper drive chain roller 3 gt mark 2 lower drive chain roller 98 Servicing Your Honda Adjustment 1 Loosen the rear axle nut 1 2 Loosen both lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm 4 index mark 1 2 lock nut 5 axle plate 3 adjusting bolt 6 reference mark 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 as necessary Loosen the adjusting bolt counterclockwise lightly until it touches the axle plate Then while holding the adjusting bolt with a wrench tighten the lock nut to the specified torque 20 Ibf ft 27 N m 2
26. 1 2 kgf m transmission oil fill cap 4 O ring S Check that the O ring 4 is in good condition and replace it if necessary Reinstall the transmission oil fill cap 1 Check for oil leaks Replacing Transmission Oil Run the engine at idle for 3 minutes then shut it off Support the CRF in an upright position on a level surface Remove the transmission oil fill cap 1 from the right crankcase cover Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 After the oil has drained apply fresh engine oil to the transmission oil drain bolt threads Install and tighten the transmission oil drain bolt with a new sealing washer to the specified torque 12 lbf ft 16 N m 1 6 kgf m Transmission Oil 1 transmission oil fill cap 2 transmission oil drain bolt 3 sealing washer 7 Fill the crankcase with recommended oil Capacity 0 72 US qt 0 68 after draining 8 Install the transmission oil fill cap 9 Check the transmission oil level by following the steps in Checking amp Adding Oil this page Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 NOTICE Improper disposal of drained fluids is harmful to the environment Servicing Your Honda 53 048 067 qxd 11 4 18 10 21 1754 Coolant Your CRF
27. 18 of the cylinder head Align 17 radiator hose 0 43 0 04 in 18 water hose joint 11 0 1 0 mm 9 Tighten the radiator hose clamp screw 19 as 11 throttle body illustrated below 12 insulator 13 insulator band screw 7 Set the rear shock absorber 14 and install the rear shock absorber upper bolt 15 and nut 16 Tighten the rear shock absorber upper nut to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 0 0 04 in 0 1 0 mm 19 radiator hose clamp screw 14 rear shock absorber 15 rear shock absorber upper bolt 16 nut 84 Servicing Your Honda 10 Connect the ECT sensor connector 20 20 ECT sensor connector 11 Install the shims valve lifters camshaft and camshaft holder page 73 Install the crankshaft hole cap page 74 Install the cylinder head cover page 75 Install the spark plug page 67 Install the exhaust pipe page 102 Install the subframe page 37 and muffler page 101 Install the fuel tank and seat pages 33 35 Fill and bleed the cooling system page 143 Check for the following compression leaks abnormal engine noise secondary air leaks coolant leaks oil leaks 068 087 qxd 11 4 18 10 24 785 Suspension Refer to Safety Precautions on page 23 e Refer to Suspension Adjustment Guidelines 4 page 130 Make all rebound and e DEE Loose wo
28. Faulty carbon or wet fouled spark plug P 67 e Faulty ECM e Faulty alternator e Faulty ignition coil e Broken or shorted spark plug wire Faulty CKP sensor Loose or disconnected ignition system wires e Faulty engine stop button Faulty regulator rectifier e Faulty condenser WEAR Faulty valve springs WORN ber e Faulty camshaft a POOR HANDLING Steering is heavy e Steering stem adjusting nut too tight e Damaged steering head bearings e Faulty HPSD Either wheel is wobbling e Excessive wheel bearing play e Bent rim e Improperly installed wheel hub e Excessively worn swingarm pivot bearings e Bent frame The motorcycle pulls to one side e Front and rear wheels not aligned e Bent fork e Bent swingarm e Bent axle shaft e Bent frame 142 170 qxd 11 4 18 10 35 La This section contains dimensions capacities and other technical data S Vehicle Identification ee eesceseceeeeereeeeee 148 Specifications sees eects 149 Torque Specifications ese eesceseeeeeeeneeeees 150 Oxygenated Fues 153 Competition Logbook AA 154 Optional Parts List eee eeeesseceseeeeeeeeeeees 156 Spare Parts amp Equipment eeeeeeeee 157 Wiring Diagram eee ceeceeeeeseeereeeeeeeceseeees 158 Technical Information Technical Information 147 142 170 qxd 11 4 18 10 35 N LA Vehicle Identification 7 The VIN vehi
29. Spring pre load length Standard spring Standard 10 27 in 260 8 mm Min 9 9 in 251 mm Spring pre load length Optional spring Min Softer 285 5 Ibf in 50 0 N mm 9 9 in 252 mm Min Stiffer 307 7 Ibf in 53 9 N mm 9 8 in 249 mm Adjustments for Competition 125 109 133 qxd 11 4 18 10 31 oU D Rear Suspension Adjustments Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters The high speed damping adjuster 1 is effective when damping adjustment is desired for high speed operation The low speed damping adjuster 2 should be used when damping adjustment is desired at relatively low speeds e Both the high and low speed damping can be increased by turning the appropriate adjuster clockwise e Adjust the high speed adjuster in 1 12 turn increments 1 high speed damping adjuster 2 low speed damping adjuster 126 Adjustments for Competition S High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed damping adjuster has 3 1 2 turn 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 1 3 4 turns and the punch marks are aligned Low Speed Damping The low speed damping can be adjuste
30. 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 127 in the 3 7 4 5 in 95 115 mm range 136 Adjustments for Competition a Fork Height Angle The position of the fork tubes in the clamps is not adjustable Align the groove in the outer tube with the top surface of the upper fork clamp Standard Position The standard position 1 align the top of the outer tube 2 not the top of the fork cap with the top surface of the upper fork clamp 3 1 standard position 2 1 0 in 0 mm 2 top of outer tube he 3 upper fork clamp 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 re check race sag and adjust 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 weighti
31. Wash the air cleaner 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 to dry thoroughly After drying apply 1 7 oz 50 cm of clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil from the inside of the element Place the element into a plastic bag 7 and spread the oil evenly by hand NN 7 plastic bag 7 Assemble the air cleaner element and holder Install the holder tab 5 in the hole 6 of the air cleaner element 8 Apply 0 1 0 2 oz 3 5 g of Pro Honda White Lithium Grease or equivalent to the air cleaner housing contact area of the air cleaner element 9 Install the air cleaner assembly 2 into the air cleaner housing by aligning its tabs 8 with the stay 9 of the air cleaner housing 10 Carefully position the sealing flange of the element to prevent dirt intrusion 2 air cleaner assembly 8 air cleaner assembly tabs 9 air cleaner housing stay ae Air Cleaner 11 Install and tighten the air cleaner retaining bolt 1 securely TRS SN 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 12 Install the seat page 33
32. 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 S Suspension Adjustments for Track Conditions Adjustments for Competition 129 D 109 133 qxd 11 4 18 10 31 7120 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF using the methods described on pages 110 129 Remember to make all adjustments in one click or 1 12 turn 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 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 stiffer position at this time Mud track Adjust to a stiffer position because mud build up increases your CRF
33. 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 water 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 recommended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection 54 Servicing Your Honda S 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 Addi
34. 0 US oz 296 cms MIN 400 0 30 60 90 120 150 180 210 240 270 300 Stroke mm Adjustments for Competition 111 ae B D 109 133 qxd 11 4 18 10 31 211 Front Suspension Adjustments Front Suspension Disassembly e If your CRF is brand new put enough part throttle break in time about hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first 3 hours of riding See an official Honda Service Manual or your dealer for this service When disassembling the fork turn the compression 1 and rebound 2 damping adjusters counterclockwise to the softest position to prevent damaging the adjustment needle be sure to record the number of turns from the starting position 1 compression damping 2 rebound damping adjuster adjuster 112 Adjustments for Competition S 1 Remove the number plate page 103 2 Place your CRF on an optional workstand or equivalent support with the front wheel off the ground 3 Remove the handlebar lower holder nuts washers mounting rubbers 3 and handlebar 4 NOTICE Keep the master cylinder upright to prevent air from entering system 3 handlebar lower holder nuts washers and mounting rubbers 4 handlebar 4 Loosen the fork bridge upper pinch bolts 5 5 Loosen the fork damper 6 using a lock nut wrench 7
35. 1 Relieve the fuel pressure this page 2 Hang the fuel tank to the left side of the frame page 34 3 Remove the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary Injector side 3 Fuel Pump side fo Ae ae ae eg 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connect fitting 5 Remove the bolt 4 clamp and setting rubber 65 4 bolt 5 clamp and setting rubber 6 Pull and release the joint rubber 6 of the Fuel System injector side from the retainer 7 6 joint rubber injector side only 7 retainer 7 Place a shop towel 8 over the fuel quick connect fitting Injector side 8 shop towel Fuel Pump side cont d Servicing Your Honda 41 028 043 qxd 11 4 18 10 15 3742 Fuel System 8 Hold the connector with one hand and squeeze the retainer tabs 9 with the other hand to remove them from the locking pawls 10 Pull the connector off then remove the retainer e Use a shop towel to absorb the remaining fuel in the fuel feed hose e Be careful not to damage the hose or other parts e Do not use tools e If the connector does not move keep the retainer tabs pressed down and alternately pull and push the connector until it comes off easily A WARNING Gasoline is highly flammable and explosive You can be burned or
36. 129 Do not attempt to disassemble service or dispose of the damper see your dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only e When your CRF is new break it in for 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 page 126 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 126 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound damping adjusters in one click or in 1 12 turn increments Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment If you have a problem finding an acceptable adjustment return to the standard position and begin again 86 Servicing Your Honda S 1 Bounce the rear of the motorcycle up and down and check for smooth suspension action Remove the subframe page 36 Check for a broken or collapsed spring 4 Check the rear shock absorber 1 for a bent shaft or oil leaks Ww N 1 rear shock absorber 5 Push the rear wheel sideways to check for worn or loose swingarm bearings There should be no movement If t
37. 8 kgf m ns Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda HP Chain Lube or an equivalent is recommended Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers 088 102 qxd 11 4 18 10 27 799 D Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing 1 Remove the master link retaining clip 1 with pliers Do not bend or twist the clip Remove the master link 2 Remove the drive chain 2 master link 1 retaining clip 2 Clean the drive chain in high flash point solvent and allow it to dry 3 Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain Size link DID520DMA4 116RB RK520TXZ 116RJ S 4 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed 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 a wor Sprocket
38. Brite Hand Pad 7447 maroon Teflon tape Technical Information 157 142 170 qxd 11 4 18 10 35 N 7158 Wiring Diagram ENGINE STOP SWITSH FUEL PUMP REGULATOR MIL RECTIFIER CONDENSER A A Kg wee sP BI CO WPC 5P BI ow 50 om gt ENG STOP WPC 33P BI ae E WPC 2P WPC 4P Zo az f Z 3o z 3 Bar xo WPC 4P D scs W Bo GES 330 S Za gaz S gt g o zs Sr as Hell ae Cl EH me ae one 3 gt x moe a E ov o 8 a aE 352758 a SS Zos Soy WPC 2P wec ap EH wea WPC ap BI Gr Bu BI WPC 6P BI IGNITION MAP SENSOR COIL IAT SENSOR WPC 2P Gr ECT SENSOR See GE E TP SENSOR ea Pe I PLUG INJECTOR FRAME GROUND NO 1 CKP SENSOR NO 2 CKP SENSOR ALTERNATOR O ORANGE Lb_ LIGHT BLUE Lg LIGHT GREEN 158 Technical Information 142 170 qxd 11 4 18 10 35 2159 Consumer Information This section contains information about Authorized Manuals cccccccececeseseeeeeeeees 160 contacting Honda and how to get an official Contacting Honda 161 Honda Service Manual Your Dealer EE 162 The Honda Rider s Club USA only 163 Consumer Information 159 142 170 qxd 11 4 18 10 35 7160 Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm Inc USA only Canada See your dealer to order authorized manuals Also available but not necessary
39. CKP sensor connector 7 ECM connector Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system 8 Instruments amp Controls D 001 027 qxd 11 4 18 10 14 8 Indicator DTC Index Refer to MIL Blink Pattern on page 7 MIL blinks Function Failure Symptom Fail safe Function 1 MAP sensor circuit malfunction Engine operates normally 2 MAP sensor performance problem Engine operates normally 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circuit malfunction Engine operates normally 12 Injector circuit malfunction he GE e Injector fuel pump and ignition shut down 19 No 1 CKP sensor circuit malfunction j SE ignition shut down 69 No 2 CKP sensor circuit malfunction f E Gul ap ond ignition shut down Should be serviced by your dealer unless the owner has proper tools and is technically qualified The series of 12 19 and 69 MIL blinks cannot be checked because the engine cannot be started If the engine does not start check all connector connections and or refer to an official Honda Service Manual page 160 for troubleshooting of the PGM FI symptom Instruments amp Controls 9 001 027 qxd 11 4 18 10 14 10 10 Instruments amp Controls D 001 027 qxd 11 4 18 10 14 Yil Before each ride you need to make sure y
40. 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 Uncover the end of the muffler and remove the rag from the muffler outlet Fill the fuel tank with the recommended fuel page 40 and increase the fuel pressure page 48 Pour a fresh recommended coolant mixture page 54 slowly into the radiator filler hole up to the filler neck Capacity 1 16 US qt 1 10 after disassembly 1 09 US qt 1 03 after draining Lean your CRF slightly right and left several times to bleed trapped air in the cooling system If the coolant level lowers add coolant and repeat the above procedure Install the radiator cap securely Perform all maintenance checks page 13 Tips 143 142 170 qxd 11 4 18 10 35 1 144 You amp the Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environmentally responsible motorcycle owner Choose Sensible Cleaners Use a biodegradable detergent when you wash your CRF Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disp
41. Teeth Teeth Ki W REPLACE REPLACE Normal Seef Teeth GOOD NOTICE Use of a new chain with worn sprockets will cause rapid chain wear 5 Measure a section of the drive chain to determine whether the chain is worn beyond its service limit Put the transmission in gear and then turn the rear wheel forward until the lower section of the chain is pulled taut With the chain held taut and any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service a Drive Chain Service limit 10 20 in 259 0 mm MEASURE A SPAN OF 17 PINS 16 PITCHES 6 Lubricate the drive chain 7 Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation 8 Recheck chain slack and adjust as necessary More About Drive Chain e The master link is the most critical element of drive chain security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining clip when the drive ch
42. Valve Clearance Refer to Safety Precautions on page 23 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 25 The checking or adjusting of the clearance should be performed while the engine is cold The valve clearance will change as engine temperature rises 68 Servicing Your Honda S Cylinder Head Cover Removal Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and hang the fuel tank to the left of the frame pages 33 34 2 Disconnect the breather tube 1 and spark plug cap 2 1 breather tube 2 spark plug cap 3 Remove the cylinder head cover bolts rubber seals 3 and cylinder head cover 4 4 cylinder head cover 4 Remove the spark plug hole packing ae Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 crankshaft hole cap 2 Remove the spark plug page 67 068 087 qxd 11 4 18 10 24 69 3 Rotate the crankshaft by turning the primary drive gear bolt 2 crankshaft clockwise until aligning the punch mark 3 on the primary drive gear with the A mark 4 on the right crankcase cover In this position the piston may either be
43. agent to the threads 6 SH bolt 142 170 qxd 11 4 18 10 35 27153 Some conventional gasolines are being blended with alcohol or 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 S If you notice any undesirable operating symptoms try another service station or switch to another
44. alternately 3 1 spring seat 2 judder spring 3 clutch discs 4 clutch plates 5 clutch disc A 66 Servicing Your Honda S Apply grease to the clutch lifter rod 6 ends Insert the clutch lifter rod into the mainshaft Apply engine oil to the needle bearing of the clutch lifter 7 Install the clutch lifter 7 onto the clutch lifter rod Ch LD E Ne 6 clutch lifter rod 7 clutch lifter 8 Install the clutch pressure plate 8 9 Install the five clutch springs and clutch spring bolts 9 10 Tighten the bolts in a crisscross pattern in two or three steps to the specified torque 9 Ibf ft 12 N m 1 2 kgf m SS a 8 clutch pressure plate 9 clutch spring bolts clutch springs ae 11 Apply oil to a new O ring 10 and install in the groove of the clutch cover 11 12 Install the cover by tightening the cover bolts A and B in a crisscross pattern in two or three steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 10 O ring new 11 clutch cover 048 067 qxd 11 4 18 10 21 67 Refer to Safety Precautions on page 23 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions Standard R0451B 8 NGK 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 rea
45. amp COMPETITION HANDBOOK AAS WNS du CB VIRIN e Contents qxd 11 4 18 10 13 ve Introduction Congratulations on choosing your Honda CRF motocross 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 CRF is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned closed course events by experienced riders only Be aware that motocross is a physically demanding sport that requires more than just a fine motorcycle To do well you must be in excellent physical condition and be a skillful rider For the best results work diligently on your physical conditioning and practice frequently 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 a
46. ao SE ar 12 6 USoz 372cm Technical Information 149 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Engine RIGHT SIDE LEFT SIDE 150 Technical Information 142 170 qxd 11 4 18 10 35 7150 2 Apply oil to the threads Torque Item Remarks 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 NOTE 1 5 Transmission oil check bolt 9 12 1 2 6 Clutch cover bolts 7 10 1 0 7 Coolant drain bolt 7 10 1 0 8 Engine oil drain bolt 12 16 1 6 NOTE 2 9 Cylinder bolt 7 10 1 0 10 Oil filter cover bolts 9 12 1 2 11 Cylinder head bolts 7 10 1 0 12 Drive sprocket bolt 23 31 3 2 13 Transmission oil drain bolt 12 16 1 6 NOTE 2 14 Cylinder head stud bolts 33 45 4 6 NOTE 2 NOTES 1 Apply grease to the threads _ 142 170 qxd 11 4 18 10 35 Frame N7151 Torque Specifications It Torque Remark ie Ibfeft Nem kgfem ons 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 bolts 16 22 2 2 5 Handlebar
47. 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 direction and back out one turn in direction and make the adjustment with the integral cable adjuster S 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 until it 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 Tighten the lock nut Check the adjustment Start the engine pull the clutch lever in and shift into gear Make sure the engine 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 ns 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 Inspect the clutch discs and plates page 6
48. break in guidelines 0 0 00 ee ceeeeceesteceneeeeeeeeeeees 19 tank capacity end dee ee et A0 164 Index as 142 170 qxd 11 4 18 10 35 7165 Index G M R gap spark Plug oo cee caninin atiet 67 maintenance rear suspension Maintenance 125 S sgbok deene Ee EE 153 after competition 0 eee eee eeeeereeereeeeeeeeeees 30 Rider s Club Honda USA only 163 GE 40 before amp after compenton eee 30 riding PCAN G EE EEEE esse 137 between motos amp practice 30 SEELEN heh Ate Aes ats 2 guidelines component locations ce eeeeeeeeeeeereeeneees 32 basic operation eee eecesecesecereeereeeneeeneees 15 Steering damper eee ceseceseeereeeeeeeees 135 general competition eee eeeeeeeereeeneees 26 IN 11 SUSPENSION adjustment Le eee eessen 130 Me e rte 22 important safety pformaton eee 2 SALTY EE 23 Safety Drecautionsg ee eee esecseceseceeeeeeeeeneee 2 H Sheet ee 24 Manual service 160 S handlebar inspection 105 modifications insane i a ai a ai 3 Honda safety COMLACTING aee ENNER 161 O a few words about Safety Messages Rid r S Cl brem nnn non 163 important information s es 2 service manual 160 oil Important precautions eee eeeeeeeeeeeeeeeee 2 HEIEREN 49 labels ieies en geet A 4 I FOK iaei eare E E el es 87 maintenance scesi aaia 23 ET EE 52 riding Drecautiong ee eee eeeeseeereeenee
49. 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 a Is Your Motorcycle Ready to Ride Pre ride Inspection Check the following before each ride Engine oil level nirai 50 e Transmission oil Ievel 53 e Fuel line for condition eeeeeeeeeeeeeeeee 40 e Coolant for proper Ievel 54 e Cooling system and hoses for condition 55 e Spark plug for proper heat range carbon fouling and spark plug wire terminal for IOOSCNESS jis seieeseseni ees 67 e Air cleaner for condition and Contam1 nation 56 e Clutch lever adjustment and freeplay 62 e Breather drain for cleamnng cece eee 58 e Steering head bearing and related parts for CONIION 0 eee ceeeeereeeeeeseceeeeeseeees 105 e Steering damper operatton eee 103 e Throttle operation ees eeeeseceteeeeeeees 59 e Tires for damage or improper inflation PLESSULE e eege Ee 95 e Spokes for looseness 94 e Rim locks for looseness 94 e Front and rear suspension for proper ODER ee 85 86 e Front and rear brakes check operation 90 e Drive chain for correct sl
50. 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 consistent damping 1 compression damping adjuster 2 rebound damping adjuster 110 Adjustments for Competition S 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 0O 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 rings 2 is in good condition Install and tighten the pressure release screw t
51. 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 owner s manual 80 100 21 51M Front DUNLOP MX51F 100 90 19 57M Rear DUNLOP MX51 Type bias ply tube When replacing use the original equipment tires or equivalent tires of the same size construction speed rating and load range as the originals 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 96 Servicing Your Honda 088 102 qxd 11 4 18 10 27 797 D Refer to Safety Precautions on page 23 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 When the motorcycle is ridden on unusually dusty or muddy tracks more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF and check that your transmission is in neutral Inspection 1 Turn the engine off raise the rear wheel off the ground by placing an optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check the drive chain slack 1 in the upper drive chain run m
52. filter side of the spring end then install the spring 8 into a new oil filter Position the spring against the engine crankcase and install a new oil filter with the rubber seal 9 facing out away from the engine You should see the OUT SIDE mark 10 on the filter body near the rubber seal Use a new Honda Genuine oil filter or a filter of equal quality specified for your model a Engine Oil NOTICE If the oil filter is not installed properly it will cause serious engine damage 13 14 15 16 17 Apply engine oil to a new O ring and install it to the oil filter cover 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 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69 after draining and oil filter change 0 70 US qt 0 67 after draining Install the engine oil fill cap dipstick Check the engine oil level by following the steps in Checking amp Adding Oil page 50 Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 NOTICE Improper disposal of drained fluids is harmful to the environment Servicing Your Honda 51 048 067 qxd 11 4 18 10 21 2752 Transmission Oil Refer to Safety Precautions on page 23 Using the proper oil and regularly checking adding and changin
53. lower holder nuts 32 44 4 5 6 Front axle nut 65 88 9 0 7 Front axle pinch bolts 15 20 2 0 8 Rear axle nut 94 128 13 1 NOTE 1 9 Chain adjuster lock nuts 20 27 2 8 NOTE 2 10 Front engine hanger nut 40 54 5 5 Front engine hanger plate nuts 19 26 2 7 11 Lower engine hanger nut 40 54 5 5 12 Cylinder head hanger bolts 40 54 5 5 13 Cylinder head hanger plate bolts 24 33 3 4 14 Shock absorber 32 44 4 5 NOTE 1 15 Swingarm pivot nut 65 88 9 0 NOTE 1 16 Fork fork damper 25 34 3 5 fork cap 22 30 3 1 17 Rear shock arm nuts swingarm side nut width 17 mm 39 53 5 4 NOTE 1 3 shock link side nut width 19 mm 39 53 5 4 NOTE1 3 18 Rear shock link nuts frame side 39 53 5 4 NOTE 1 3 19 Shock spring lock nut 32 44 4 5 20 Kickstarter arm bolt 28 38 3 9 NOTE 4 21 Front brake master cylinder holder bolts 7 3 9 9 1 0 22 Brake hose bolts 25 34 3 5 NOTES 1 U nut 2 UBS nut EH EEN SH bolt Apply molybdenum oil to the threads and flange surface Alock bolt replace with a new one Apply locking agent to the threads Technical Information 151 142 170 qxd 11 4 18 10 35 LS Torque Specifications Frame 40 _ Re ell e SN WF N a e 47 36 K hoe Sane O SECHS SE LUY 27 38 43 i 45 A EE 40 48 35 29 41 Dir E 48 35 29 LRN 152 Technical Information
54. maintenance stand 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 23 001 027 qxd 11 4 18 10 14 1724 Maintenance Schedule To maintain the safety and reliability of your CRF regular inspection and service is required as shown in the Maintenance Schedule that follows The Maintenance Schedule list items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in an official Honda Service Manual available for purchase from your dealer page 160 Service intervals in the maintenance schedule are expressed in terms of races and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remembe
55. nut and fork center bolt hole 30 fork center bolt lock nut 31 push rod 23 axle holder 29 piston base Do not attempt to separate the fork assembly and drop the axle holder out from the outer tube which can damage the guide bushings 38 To avoid damage hold both the outer tube and silder 32 fork damper assembly 33 fork assembly 34 fork spring Over tighten the vise can damage the fork damper 2 Loosen the fork cap assembly 2 while holding the fork damper 1 using the lock nut wrench 3 e Lock nut wrench O07WMA KZ30100 NO GOOD 1 fork damper 2 fork cap assembly 3 lock nut wrench 35 spring retainer 36 collar washer 37 O ring contd 115 Adjustments for Competition ae D 109 133 qxd 11 4 18 10 31 2116 Front Suspension Adjustments 3 Remove the fork cap assembly 2 from the fork damper threads and then pop it out by pumping the fork damper piston rod 4 slowly 4 Remove the fork cap assembly 2 Be careful not to damage the fork cap bushings Do not disassemble the fork cap assembly Replace the fork cap as an assembly if it is damaged 2 fork cap assembly 4 fork damper piston rod 5 Empty the fork oil from the fork damper oil spring chamber 5 by pumping the damper rod several times 5 fork damper oil spring chamber 116 Adjustments for Competition S 6 Clean the fork cap and fork damper threads 6
56. of fork oil left in the fork within damper and spring minute unit cm3 5 10 20 35 55 85 145 KSE 30 86 16 5 14 1 12 7 11 8 11 10 1 8 6 20 68 17 4 15 13 7 12 6 11 5 10 5 9 1 10 50 18 9 16 5 14 8 13 7 12 5 11 4 9 8 0 32 20 18 4 15 9 14 5 13 7 13 11 7 cm gr 10 C 50 F 0 C 32 F p 20 C 68 F a A 30 C 86 F wat Qe fn 1 1 1 1 1 1 1 0 20 40 60 80 100 120 140 160 minutes cont d Amount of fork oil Servicing Your Honda 87 088 102 qxd 11 4 18 10 27 7788 D Suspension 5 Pour the recommended fork oil into the outer tube 1 1 outer tube 88 Servicing Your Honda S Fork Oil Capacity Standard 25 12 tin 4 4 N mm Fork Spring Co No mark Optional Stiffer 26 20 tin 4 59 N mm Fork Spring OF 2 scribe marks Standard oil 12 6 US oz Standard oil 12 7 US oz capacity 372 cms capacity 375 cms Maximum oil 12 9 US oz Slightly stiffer as Maximum oil 12 9 US oz Slightly stiffer as capacity 380 cm3 it nears full capacity 382 cm3 it nears full compression compression Minimum oil 10 0 US oz Slightly softer as Minimum oil 10 1 US oz Slightly softer as capacity 296 cm3 it nears full capacity 299 cm3 it nears full compression compression Optional Softer 23 98 tin 4 2 N mm Fork Spring C gt 1 scribe ma
57. oil holes with shop towel 11 to torque prevent blow out of fork oil 22 Ibf ft 30 N m 3 1 kgf m Blow the extra oil off from the fork damper e Lock nut wrench O7WMA KZ30100 oil chamber 5 by pumping the fork damper piston rod to full stroke NOTICE NOTICE Over tightening the vise can damage the fork damper Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 1 fork damper 3 lock nut wrench 2 fork cap assembly 12 Completely screw in the fork center bolt lock nut 10 to the fork damper piston rod 4 5 fork damper oil chamber 11 shop towel 4 4 fork damper piston rod DO fork center bolt lock nut cont d Adjustments for Competition 117 BEEN D 109 133 qxd 11 4 18 10 31 N 7118 an Front Suspension Adjustments 15 Drain the extra oil from the oil holes 12 of the fork damper oil chamber 5 Fork Assembly ee Improper disposal of drained fluids is harmful to By doing this procedure about 0 2 US oz 5 cm 1 Drain the fork oil from the fork assembly 1 the environment of fork fluid will be drained from the damper by placing it upside down P Amount of fork oil left in the fork spring chamber through the oil hole and cause About 0 2 US oz 5 4 cm cc of fork oil will without damper and spring unit cm3 8 1 US oz 240 cm of fork fluid to be left in the be left in the outer tube slid
58. ratio 2 357 Gear ratio II 1 888 Gear ratio III 1 555 Gear ratio IV 1 333 Gear ratio V 1 136 Final reduction 3 769 R suspension Pro link travel 12 3 in 813 mm 80 100 21 51M Engine oil capacity After draining 0 70USqt 0 672 Gear shift pattern Left foot operated return system 1 N 2 3 4 5 After draining and oil filter change 0 73 US qt 0 69 After disassembly 0 90 US qt 0 85 2 Front tire DUNLOP MX51F i 100 90 19 57M Rear tire DUNLOP MX51 Tire type bias ply tube Transmission oil capacity After draining 0 72USqt 0 682 Electrical Ignition ECM Starting system Kickstarter ree PRT NGK R0451B 8 After disassembly 0 79USqt 0 752 Spark plug gap 0 024 0 028 in 0 6 0 7 mm Tire pressure front cold 15 psi 100 kPa 1 0 kgf cm Tire pressure rear cold 15 psi 100 kPa 1 0 kgf cm F brake swept area Single disc brake 51 8 in 334 5 cm Throttle body Identification number GQ26A Idle speed 2 000 100 rpm Cooling system R brake swept area Single disc brake 60 6 in 391 1 cm unleaded gasoline pump Cooling capacity after draining 1 09 US qt 1 03 2 after disassembly 1 16 US qt 1 102 Fuel octane number of 91 or higher Fuel capacity 1 5 US gal 5 7 2 Caster angle 27 23 Trail length 4 6 in 118 mm
59. ring 21 from the damage or discoloration the O ring 16 fuel pump unit holder 22 If the hooks and tabs are damaged or discolored replace the fuel pump unit as an Wipe the spilled out fuel immediately assembly 8 Release the hooks of the fuel pump unit holder from the grooves 14 on the fuel pump base tabs while pushing the holder against the base and slightly spreading the base tabs ZS Be careful not to damage the hooks and tabs 22 21 12 13 14 gy fuel pump assembly fuel pump filter O ring fuel pump unit holder 11 fuel pump base 15 fuel pump unit holder assembly 16 O ring 19 20 21 22 12 Check the fuel pump filter 20 for clog damage or deterioration and replace if necessary 13 Remove the fuel pump filter from the fuel pump assembly 20 10 Remove the fuel pump stopper 17 and damper rubber 18 12 hooks 14 grooves 1 3 tabs 1 7 20 19 fuel pump assembly 20 fuel pump filter 17 fuel pump stopper 18 damper rubber Servicing Your Honda 45 044 047 qxd 11 4 18 10 20 3746 Fuel System Installation 1 Install a new fuel pump filter 1 onto the fuel pump assembly 2 aligning its hook 3 with the joint boss 4 completely Be careful not to damage the hook 1 new fuel pump filter 3 hook 2 fuel pump assembly 4 joint boss 46 Servicing Your Honda S 2 Apply a small am
60. speed is over 5 500 rpm The MIL has two types of blinks a long blink and short blink The long blinking lasts for 1 2 seconds the short blinking lasts for 0 4 seconds One long blink is the equivalent of ten short blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number Indicator Current DTC Freeze DTC The DTC is indicated in two ways according to the failure status In the case that the ECM detects an active problem the MIL will come on and will start to blink the DTC when the engine is started In the case that the ECM does not detect an active problem but has recorded a previous problem in its memory the MIL will not come on If it is necessary to retrieve any past problems stored in the memory refer to an official Honda Service Manual Instruments amp Controls 7 D 001 027 qxd 11 4 18 10 14 8 Indicator Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them A faulty PGM FI system is often related to poorly connected or corroded connections Check the following connections 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 No 1 No 2
61. 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 Symptom Action Stiff suspension 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 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 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 1 Test stiffer high and low speed compression adjustments simultaneously 2 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 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing 1 Test stiffer high speed compression adjustment after jumping 2 If it still bottoms test stiffer high and low speed compression ad
62. the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable Be sure the throttle returns freely and automatically from fully open to fully closed in all steering positions ae Servicing YourHonda 105 D 103 108 qxd 11 4 18 10 29 7106 Additional Maintenance Procedures RIGHT SIDE 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 2 Exhaust pipe joint nuts 15 21 3 Water pump cover bolts 7 10 4 Crankshaft hole cap 11 15 5 Transmission oil check bolt 9 12 1 2 6 Clutch cover bolts 7 10 1 0 7 Coolant drain bolt T 10 1 0 8 Engine oil drain bolt 12 16 1 6 9 Cylinder bolt 7 10 1 0 1 cylinder head cover bolts 10 Oil filter cover bolts 9 12 1 2 2 exhaust pipe joint nuts 9 cylinder bolt 11 Cylinder head bolts 7 10 C10 3 water pump cover bolts 10 oil filter cover bolts 12 Drive sprocket bolt 233 31 32 9 crankstialt hole cap 11 cylinder head bolts p P 5 transmission oil check bolt 42 dri ket bolt 13 Transmission oil drain bolt 12 16 1 6 6 clutch cover bolts 12 drive sprocket bolt 14 Cylinder head stud bolts 33 45 4 6 7 coolant drain bolt 13 transmission oil
63. the cylinder bolt 14 15 and cylinder head 16 Loosen the nuts in a crisscross pattern in two or three steps NOTICE Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase a A ve EI Lee 13 cylinder head bolts 14 cylinder bolt 15 cylinder head stud bolts washers 16 cylinder head contd Servicing Your Honda 77 D 068 087 qxd 11 4 18 10 24 8 Piston Piston Rings Piston Pin 18 Remove the dowel pins 17 cylinder head gasket 18 and cam chain guide 19 NOTICE Do not let the dowel pins and cam chain fall into the crankcase 17 dowel pins 19 cam chain guide 18 cylinder head gasket 78 Servicing Your Honda 068 087 qxd 11 4 18 10 24 379 D Cylinder Removal 1 Remove the cylinder bolt 1 and cylinder 2 NOTICE Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder Oe ES 1 cylinder bolt 2 cylinder 2 Remove the dowel pins 3 and cylinder gasket 4 NOTICE Do not let the dowel pins fall into the crankcase 3 dowel pins l 4 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 pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3
64. the fuel tank pages 33 34 Remove the muffler page 100 and subframe page 36 Remove the exhaust pipe page 102 Remove the spark plug page 67 Remove the cylinder head cover page 68 Set the piston at TDC on the compression stroke page 68 Remove the camshaft holder camshaft valve lifters and shims page 70 Servicing Your Honda S 10 Disconnect the ECT sensor connector 1 1 ECT sensor connector 11 Loosen the radiator hose clamp screw 2 and disconnect the radiator hose 3 we en 2 radiator hose clamp screw 3 radiator hose 12 Remove the shock absorber upper nut 4 and bolt 5 4 shock absorber upper nut 5 bolt 13 Loosen the insulator band screw 6 and pull the throttle body 7 out from the insulator 8 Do not hang the throttle body and support it with a suitable strap 6 insulator band screw 7 throttle body 8 insulator 068 087 qxd 11 4 18 10 24 Y77 D 14 Remove the cylinder head hanger bolts 9 Remove the cylinder head hanger plate bolts 10 left cylinder head hanger plate 11 and right cylinder head hanger plate 12 9 cylinder head hanger bolts 10 cylinder head hanger plate bolts 11 left cylinder head hanger plate 12 right cylinder head hanger plate S Piston Piston Rings Piston Pin 15 Remove the cylinder head bolts 13 17 Remove the cylinder head stud bolts washers 16 Loosen
65. to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles scooters ATVs MUVs PWCs 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 61KRN52 2012 CRF250R Service Manual 61CMO002 Common Service Manual 31KRN680 2012 CRF250R Owner s Manual 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 160 Consumer Information 142 170 qxd 11 4 27 1426 161 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 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 Mo
66. 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 oe Lower Gearing more driven 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 This 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 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 g
67. 1 water hoses 2 overflow tube S 6 Check the bleed hole 3 below the water pump cover 4 for leakage Clean away any clogged dirt or sand if necessary Check for signs of seal leakage A small amount of coolant weeping from the bleed hole is normal If water leaks through the bleed hole the mechanical seal is damaged If oil leaks through the bleed hole the oil seal is damaged See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both seals should be replaced at the same time 3 bleed hole 4 water pump cover Coolant Coolant Replacement Refer to Safety Precautions on page 23 Coolant should be replaced by your dealer unless you have the proper tools and service data and are mechanically qualified Refer to the Honda Service Manual page 160 A WARNING Removing the radiator cap while the engine is hot can cause 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 144 NOTICE Improper disposal of drained fluids is harmful to the environment Servicing Your Honda 55 048 067 qxd 11 4 18 10 21 756 Air Cleaner Refer to Safety Precautions on page 23 The air cleaner uses polyurethane inner and outer pieces which can t be separated A
68. 5 Clutch System Other Inspections amp Lubrication e Check that the clutch lever assembly is positioned properly the end of the holder 1 aligned with the paint mark 2 on the handlebar and the securing bolts are tight 2 1 _ ie beggen Ca aa on e N 1 holder 2 paint mark 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 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 Servicing Your Honda 63 048 067 qxd 11 4 18 10 21 64 Clutch System F 4 Remove the clutch pressure plate 5 7 Remove the eight clutch discs seven clutch Clutch Cover Disc Plate Removal f plates judder spring and spring seat 8 1 Drain the transmission oil page 53 2 Remove the clutch cover bolt A 1 clutch cover bolts B 2 and clutch cover 3 clutch discs clutch plates judder spring and spring seat 4 clutch spring bolts clutch springs e 5 clutch pressure plate 8 5 Remove the clutch lifter 6 and clutch lifter rod 7 6 Turn the lifter bearing plate of the clutch lifter 1 clutch cover bolt A 3 clutch cover E clutch cover bolts B 6 bearing with your finger T
69. Adjustment Guidelines 135 Chassis Adiustments ceeeeeeeeeseeeneeeeeeees 136 Rear End ess ees geet ee 136 Fork Height Angle eerren 136 Wheelbase s istcsettsstestile stetatbelicabatasistelite 136 GATING eich sedis Daisies ied Meteo abe 137 Tire Selection for Track Conditions 138 Personal Fit Adjustments 0 00 0 eeeeeeseeeseeees 139 Control Positioning eee eseceseeeeeeeeee 139 Handlebar Position Width amp Shape 139 E 141 Transporting Your Motorcycle eee 142 Storing Your Honda 143 Preparation for Storage cece eeeeeeeeee 143 Removal from Storage 143 You amp the Environment 144 Troubleshooting cesceeceseeeseeeseeeneeeeeees 145 TECHNICAL INFORMATION c000 147 Vehicle Identification eee eeeeseeseeeeeeees 148 Serial Numbers cee eseesesseceseceneeeeeeees 148 Specifications s hs ts26cccee cessed csuignes sbedestrtoeetestareeuned 149 Torque Specifications cee ceeeeseeseeneceneeees 150 Nuts Bolts Fasteners cccccccceeeseeeeeeee 150 Oxygenated Fues 153 Competition Logbook s es 154 Optional Parts List 0 ee inpats 156 Spare Parts amp Equipment eee 157 Spate Eatte chien harden 157 General Kee EE 157 Honda Special Tools 157 Chemical Products cee ceeeeseeseeseeeneeees 157 Other Products 00 0 0 eeeeeeeseeseceseceteeeeeeeeee 157 Wiring Diagram cece eeceeeeneeeneeeneeeeeeees 158 CONSUMER INFORMATION
70. B 8 NGK Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or equivalent distilled water Drive Chain link DID520DMA4 116RB RK520TXZ 116RJ a
71. CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilites or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safely 2 Motorcycle Safety oe 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 Maintaining your CRF properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured 001 027 qxd 11 4 18 10 13 23 Accessories amp Modifications Accessories amp Modifications Installing non Honda accessories removing original equipment or modifying your CRF in any way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride 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
72. F s are about right for riders weighing between 170 lb 77 kg and 200 Always start with full hard when adjusting lb 91 kg less riding gear So if you re a damping heavier rider you have to go up on the oil Do not turn the adjuster screw more than the capacity or get a stiffer spring Do not use less oil given positions or the adjuster may be damaged than the minimum specified for each spring or Be sure that the compression and rebound there will be a loss of rebound damping control adjusters are firmly located in a detent and not near full extension If the fork is too hard on big between positions bumps turn the damping adjuster counterclockwise 1 click and lower the oil capacity in increments of 0 2 US oz 5 cm in both fork legs until the desired performance is obtained Do not however lower the oil capacity below the minimum oil capacity Minimum oil capacity Standard spring 10 0 US oz 296 cm Softer spring 10 2 US oz 801 em Stiffer spring 10 1 US oz 299 em When adjusting oil capacity bear in mind that z the air in the fork will increase in pressure while 1 compression 2 rebound damping riding therefore the higher the oil capacity the damping adjuster screw higher the eventual pressure of any air in the adjuster screw fork 1600 r Oil capacity 12 9 US oz 380 cm3 1400 MAX 1200 Oil capacity 12 6 US oz 372 cm8 _ 1000 STANDARD ES 800 Z 600 b Oil capacity 10
73. Full term CKP sensor Crankshaft Position sensor DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor HPSD Honda Progressive Steering Damper IAT sensor Intake Air Temperature sensor MAP sensor Manifold Absolute Pressure sensor MIL Malfunction Indicator Lamp PGM FI Programmed Fuel Injection TDC Top Dead Center TP sensor Throttle Position sensor D Contents qxd 11 4 18 10 13 ve an 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 this manual contains a section devoted to Motorcycle Safety as well as a number of Safety Messages throughout the manual Safety Messages are preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WOH You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION You CAN be HURT if you don t follow instructions 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 judgement Safety Messages Contents qxd 11 4 18 10 13 D4 5 Contents MOTORCYCLE SAFETY ccs
74. RECT I Incorrect spark plug heat range e Incorrect spark plug gap Dirty air cleaner element WEAK OR NO gt Faulty spark plug P 67 SPARK e Fouled spark plug P 67 e Faulty ECM e Broken or shorted spark plug wire e Faulty alternator e Faulty ignition coil e Faulty engine stop button e Loose or disconnected ignition system wires e Faulty CKP sensor e Faulty regulator rectifier e Faulty condenser INCORRECT gt Faulty PGM FI system P9 INCORRECT TC Fe Faulty fuel pump Clogged fuel pump filter P 44 LOW Valve clearance too small e Valve stuck open e Worn cylinder and piston ring e Damaged cylinder head gasket e Improper valve timing Seized valve ENGINE STARTS BUT SOON STOPS gt Insulator leaking e Improper ignition timing Faulty ECM or CKP sensor Fast idle knob stuck open or damaged Fuel contaminated 1 Check the wheel spin smoothly CORRECT 2 Check the tire pressure p 91 CORRECT 3 Check the engine speed change accordingly when clutch is engaged GOOD Check the engine speed increase GOOD Check the engine knocking when accelerate or run the engine at high speed NO Check the ignition timing CORRECT ENGINE LACKS POWER CHECK
75. Servicing Your Honda 57 048 067 qxd 11 4 18 10 21 72758 Crankcase Breather Refer to Safety Precautions on page 23 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 Draining 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 crankcase breather tube 58 Servicing Your Honda as 048 067 qxd 11 4 18 10 21 759 Refer to Safety Precautions on page 23 Throttle Freeplay 1 freeplay Inspection Check freeplay 1 Freeplay 1 8 3 16 in 8 5 mm If necessary adjust to the specified range Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 4 3 2 dust cover 3 lock nut 4 upper adjuster increase decrease S Pull the dust cover 2 back Loosen the lock nut 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten the lock nut to the specified torque 3 0 Ibf ft 4 N m 0 4 kgf m Return the dust cover to its normal position 5 After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all stee
76. T 4 brake fluid or an equivalent 5 bolts 8 diaphragm 6 reservoir cap 9 upper level mark 7 set plate 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 Set the diaphragm as shown 4 Reinstall the set plate and reservoir cap 5 Tighten the bolts to the specified torque 0 7 Ibf ft 1 0 N m 0 1 kgf m ae 088 102 qxd 11 4 18 10 27 793 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 page 25 Front Brake Pads Inspect the brake pads 2 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 2 replace wear indicator grooves 0 04 in 1 mm replace 1 front brake caliper 3 brake disc 2 brake pads S Rear Brake Pads Inspect the brake pads 5 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 be replaced minimum thickness indicator 0 04 in 1 mm 5 replace 4 rear brake
77. able 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 Loosen the connecting tube clamp screw and remove the subframe s three mounting bolts then remove the subframe See page 36 oe 3 Check that the spring preload 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 the adjusting nut changes the spring length by 0 06 in 1 5 mm 4 After adjustment hold the adjusting nut and tighten the shock spring lock nut to the specified torque 32 Ibf ft 44 Nam 4 5 kgf m 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 spanners 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 9 in 251 mm To decrease spring pre load Loosen the lock nut with the optional pin spanners 3 and turn the adjusting nut to increase the spring length 4 Do not increase to more than 10 31 in 261 8 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 17 20 Ib 7 80 kg a Rear Suspension Adjustments Pin spanners should be used for turning the lock nut and adjusting nut See page 156 for optional pin spanners
78. ace periodically as specified in the Maintenance durability may be affected by an air cleaner that has Schedule page 25 N deteriorated and allows dirt to pass through it 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 Pro Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 56 Use a Honda Genuine air cleaner or an equivalent 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 Engine Oil and Filter Drain and replace the engine oil often to ensure the greatest service life of the piston cylinder and crankshaft Also replace the engine oil filte
79. ack and adequate lubrication i oerien oriai 97 98 e Drive chain sliders and drive chain rollers for damage or wear 97 98 e Exhaust pipe Muffler for looseness 100 Every possible part for looseness such as cylinder head nuts engine mounting bolts nuts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bor 150 1 bie ee Before Riding 13 001 027 qxd 11 4 18 10 14 14 14 Before Riding D 001 027 qxd 11 4 18 10 14 Y15 This section gives basic information on how to start and stop your engine as well as break in guidelines S Safe Riding Drecaunons eee eee ereees 16 Starting amp Stopping the Engine 17 Fast Idle Koob 17 Preparation guer Gossett dE 17 Starting Procedure oe eeeeeeeeseeereeeneees 17 How to Stop the Engine 18 Break in Guidelines 00 0 cece ceeeeeseeeneeeseeeneees 19 Basic Operating Instructions Basic Operating Instructions 15 D 001 027 qxd 11 4 18 10 14 716 Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collec
80. ail spacer and the lower side rail 80 Servicing Your Honda 068 087 qxd 11 4 18 10 24 781 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 a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the inner surface of the connecting rod small end 3 Install the piston 1 with the O mark 2 and or the large valve recess 3 facing the intake side of the engine 4 Apply engine oil to the piston pin 4 and inner surface of the piston pin hole 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 6 Piston Piston Rings Piston Pin 2 M a al Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entering the engine 2 Clean off any gasket material from the gasket surface of the crankcase 3 Remove the shop towel Do not let any gasket debris fall into the crankcase 4 Install the dowel pins 1 and a new cylinder gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 1 dowel pins 2 cylinder gasket 5 Cl
81. ain is reassembled You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets Servicing Your Honda 99 D 088 102 qxd 11 4 18 10 27 7100 an Exhaust Pipe Muffler 2 Loosen the muffler clamp bolt 4 Exhaust Pipe Muffler Inspection Muffler Removal Check the mounting bolts and exhaust pipe joint nuts for tightness Check the exhaust pipe and muffler for cracks or deformation A damaged exhaust pipe and muffler may reduce engine performance 1 Remove the seat mounting bolt 1 side cover bolt 2 and right side cover 3 4 muffler clamp bolt 3 Remove the muffler mounting A bolt 5 muffler mounting B bolt 6 washe A 7 washer B 8 and muffler 9 1 seat mounting bolt 3 right side cover 2 side cover bolt 5 muffler mounting A bolt 8 washer B 6 muffler mounting B bolt 9 muffler 7 washer A 100 Servicing Your Honda D 088 102 qxd 11 4 18 1027 101 Muffler Installation 1 Remove the old gasket from exhaust pipe 1 2 Install the muffler clamp 2 and a new gasket 3 to the exhaust pipe 1 exhaust pipe 3 gasket new 2 muffler clamp 3 Install the muffler 4 4 Install the muffler clamp 2 by aligning the tab 5 of the muffler clamp with the cutout 6 of the muffler 2 muffler clamp 5 tab 4 muffler 6 cutout S
82. als should be replaced at the same time a Handgrips Always use Pro Honda Handgrip Cement 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 Service Manual for installation instructions For added security you may choose to bind the hand grips to the handlebar and throttle pipe with safety wires 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 handgrip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the throttle pipe and the handlebar thoroughly Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way Move the handlebar from lock to lock to be sure there is no cable interference Make certain the throttle operation is perfect after servicing and inspecting Servicing Your Honda 29 028 043 qxd 11 4 18 10 15 7730 Before amp After Competition Maintenance 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
83. an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Depress and hold the engine stop button and pull the clutch lever in 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Light gray or white color streaks the porcelain insulator and center electrode indicate lean air fuel mixture Wet or black sooty streaks on the porcelain indicate rich air fuel mixture Tuning Tips NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged P D e f 3 side electrode 1 3 1 porcelain insulator 2 center electrode Spark Plug Coloring Guidelines Condition Spark Plug Appearance Mixture Normal Dark brown to light tan correct color with dry electrode Overheating Light gray or white color lean Lean Wet Wet or sooty rich Rich Remember that in addition to improper air fuel mixture e A lean condition can be caused by air leaks in the inlet tract or exhaust system the passage of too much air because of the use of the wrong air cleaner use of a less restrictive aftermarket exhaust system A rich cond
84. an the threads of the fork protector socket bolts 22 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protectors 23 fork protector bolts Tighten the fork protector socket bolts to the specified torque 5 2 Ibf ft 7 N m 0 7 kgf m 22 22 fork protector socket bolts 23 fork protectors Align the brake caliper 24 and hose 25 with the left 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 Assemble the stay B 26 brake hose 25 and stay A 27 Install and tighten them to the left fork protector using the brake hose clamp bolts 28 D 109 133 qxd 11 4 18 10 31 27123 an Front Suspension Adjustments 26 Clean the threads of the brake caliper mounting bolts 29 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper 24 on the slider and tighten the brake caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 30 Install the handlebar 34 mounting rubbers washers and handlebar lower holder nuts 35 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 30 disc cover collar 31 right side collar 28 Install the front wheel between the fork legs while inserting the disc between the pads being careful not to damage the pads 29 Insert the front ax
85. aran ie dhe ean ee ee 36 Service Procedures Fluids amp Filters Fuel Systems 0 anoite eais 40 Engine Menger serait cera 49 Transmission Ou 52 COOLANT eebe Ee ee seaes 54 Ee Gleaner EE 56 Crankcase Breather ccccccsssccceseserscseeeeees 58 Engine d Kale EE 59 Engine Idle Speed 61 Clutch System Gerd 62 Spark UE 67 Valve Clearance nnne eege E 68 Piston Piston Rings Piston Dm 76 Servicing Your Honda Chassis SUSPENSION n ala eeart ee 85 Front Suspension Inspection s es 85 Rear Suspension Inspection eee 86 Recommended Fork Ou 87 Fork Oil Change 87 Brakes gue dee ei we dae see 90 KEE 94 Tires amp Tubee eut aiaiai 95 Drive EE NIE 97 Exhaust Pipe Muffler AA 100 Steering Damper stees dekegde degen 103 Additional Maintenance Procedures 105 Appearance Care sonics nri 107 Servicing Your Honda 21 D 001 027 qxd 11 4 18 10 14 2 The Importance of Maintenance Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section A WARNING Improperly maintaining this motorcycle or failing to correct a p
86. bolt threads and seating surface Tighten the camshaft holder bolts A 17 and B 18 to the specified torque 12 lbf ft 16 N m 1 6 kgf m 16 Tighten the camshaft holder bolts in a criss cross pattern in two or three steps A 14 camshaft holders 17 camshaft holder bolts A 18 camshaft holder bolts B 74 Servicing Your Honda 8 Remove the tensioner stopper 19 from the 10 cam chain tensioner lifter 11 19 tensioner stopper 9 Install a new sealing washer 20 and tighten the cam chain tensioner lifter cover bolt 21 12 13 B 20 sealing washer 21 cam chain tensioner lifter cover bolt 23 Sringaew Rotate the camshaft by rotating the crankshaft clockwise several times Insert the feeler gauge 22 between the intake valve lifter and cam If the feeler gauge cannot be inserted the shim is caught between the valve lifter and the valve retainer Remove the camshaft holders place the shim correctly and reinstall the camshaft holders Valve Clearances IN 0 005 0 001 in 0 EX 0 011 0 001 in 0 22 feeler gauge Install the spark plug page 67 Coat a new O ring 23 with oil and install it onto the crankshaft hole cap 24 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 24 crankshaft hole cap 068 087 qxd 11 4 18 10 24 Y75 D
87. brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Oxygenated 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 Oxygenated Fuels Technical Information 153 142 170 qxd 11 4 18 10 35 1154 Competition Logbook 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 steering damper 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 sub
88. but do not remove them yet e Lock nut wrench 07WMA KZ30100 NOTICE Do not use an adjustable wrench to loosen the fork damper it may damage them 5 fork bride upper pinch bolts 6 fork damper 7 lock nut wrench 6 Remove the disc cover socket bolt 8 8 disc cover socket bolt D 109 133 qxd 11 4 18 10 31 27113 7 Remove the front axle nut 9 and loosen the axle pinch bolts 10 on both forks Pull the front axle shaft 11 out of the wheel hub and remove the front wheel with disc cover collar brake hose clamp bolts stay A brake caliper mounting bolts 12 13 14 stay B 15 16 brake caliper Ge 11 front we Shai 10 Remove the fork protector socket bolts 17 9 rontaxlenut and fork protectors 18 10 axle pinch bolts 8 Remove the brake hose clamp bolts 12 stay A 17 13 and stay B 14 9 Remove the brake caliper mounting bolts 15 and brake caliper 16 e Do not support the brake caliper by the brake hose e 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 17 17 fork protector socket bolts 18 fork protectors Front Suspension Adjustments 11 Loosen the fork bridge lower pinch bolts 19 then pull the fork legs down and out 19 fork bridge lower pinch bolts 12 Clean the fork assembly especially the sliding sur
89. caliper 6 brake disc 5 brake pads 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 Brakes Servicing Your Honda 93 D 088 102 qxd 11 4 18 10 27 794 Wheels Refer to Safety Precautions on page 23 Keeping the wheels true round and maintaining correct spoke tension 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 page 25 However information for wheel removal is provided for emergency situations Wheel Rims amp Spokes 1 wheel rim 2 spoke 1 Inspect the wheel rims 1 and spokes 2 for damage 94 Servicing Your Honda S 2 Tighten any loose spokes and rim locks 3 to the specified torque Front Spoke 2 7 Ibf ft 3 7 N m 0 4 kgf m Rear Spoke 2 7 Ibf ft 3 7 N m 0 4 kgf m Rim Lock 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Axles a
90. ce Camshaft Removal 1 Record the intake valve clearance and exhaust valve clearance page 69 70 Servicing Your Honda S 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool e Tensioner stopper 070MG 0010100 07AMG 001A100 3 Turn the tensioner shaft clockwise with the tensioner stopper 3 until it stops in order to retract the tensioner fully Then insert the tensioner stopper fully to hold the stopper in the fully retracted position 3 tensioner stopper D 068 087 qxd 11 4 18 10 24 Y71 4 Make sure the piston is at TDC on the compression stroke page 68 Remove the camshaft holder bolts A 4 B 5 and camshaft holders 6 Loosen the camshaft holder bolts in a crisscross pattern in two or three steps 4 camshaft holder bolts A 5 camshaft holder bolts B 6 camshaft holders NOTICE Do not let the set rings fall into the crankcase If the set rings are remained on the camshaft holder remove the set rings carefully S 5 Slide the left camshaft bearing 7 and remove the camshaft 8 and cam chain 9 then attach a piece of wire to the cam chain to 7 left camshaft bearing 8 camshaft 9 cam chain 6 Remove the valve lifters 10 Position the removed intake valve lifters and shims to indicate their location such as intak
91. ch can cause engine damage Using a non resistor spark plug may cause ignition problems This motorcycle uses a spark plug that has an iridium tip in the center electrode and a platinum tip in the side the 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 To check the spark plug gap use only a wire type feeler gauge 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 S Spark Plug Inspection amp Replacement 1 Remove the seat and hang the fuel tank to the left of the frame pages 33 34 2 Disconnect the spark plug cap 1 3 Clean any dirt from around the spark plug base 4 Remove the spark plug 2 y K SE ug EN eg A 2 spark plug 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 0 024 0 028 in 0 6 0 7 mm 3 3 sealing gasket 4 spark plug gap Spark Plug
92. ch the upper and lower end of the subframe to the main frame while connecting the air cleaner connecting tube 6 to the throttle body 7 5 Loosely install all subframe bolts 2 ECM 3 bracket 4 shroud tabs 5 air cleaner housing cover tabs 6 air cleaner connecting tube 7 throttle body ae 6 Align the subframe with the rear wheel and tighten the subframe upper bolts 8 left subframe lower bolt 9 and right subframe lower bolt 10 to the specified torque subframe upper bolts 24 Ibf ft 33 N m 3 4 kgf m left subframe lower bolt 24 Ibf ft 33 N m 3 4 kgf m right subframe lower bolt 36 Ibf ft 49 N m 5 0 kgf m Left side jes Right side 8 subframe upper bolts 9 left subframe lower bolt 10 right subframe lower bolt cont d Servicing Your Honda 37 028 043 qxd 11 4 18 10 15 7738 Subframe 7 Make sure the air cleaner connecting tube tab 11 aligns with the air cleaner connecting tube clamp hole 12 11 air cleaner connecting tube tab 12 air cleaner connecting tube clamp hole 8 Tighten the screw 13 on the air cleaner connecting tube clamp to the specified torque 0 5 Ibf ft 0 7 N m 0 1 kgf m Check the distance between the band ends is 0 18 0 06 in 4 5 1 5 mm E 0 18 0 06 in 4 5 1 5 mm 13 screw 38 Servicing Your Honda S 9 Hook the fuel tank band 14 Install the ECM mounting rubber 15 t
93. cle identification number 1 is Serial Numbers stamped on the right side of the steering head The VIN and engine serial number are required RIGHT SIDE 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 this manual gt 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 148 Technical Information as 142 170 qxd 11 4 18 10 35 1149 S Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85 9 in 2 181 mm Type Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 32 6 in 827 mm Overall height 50 0 in 1 271 mm Cylinder arrangement Single 5 inclined from Transmission 5 speed constant mesh vertical Bore and stroke 3 02 x 2 12 in 76 8 x 53 8 mm Displacement 15 22 cu in 249 4 cm Compression ratio 13 2 1 Wheelbase 58 6 in 1 489 mm Seat height 37 4 in 951 mm Footpeg height 16 5 in 418 mm Ground clearance 12 7 in 322 mm Frame Type Twin tube F suspension Telescopic fork travel 10 8 in 275 mm stroke 12 2 in 810 mm Valve clearance cold Intake 0 005 0 001 in 0 12 0 03 mm Exhaust 0 011 0 001 in 0 28 0 03 mm Primary reduction 3 166 Gear
94. 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 Pro Honda Hondalock 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 torque Upon impact the fully tightened assemblies should rotate on the teflon tape oe 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 0 12 in 3 mm using optional handlebar lower holders or 0 24 in 6 mm by rotating the standard h
95. csssssessssseeeee 1 SERVICING YOUR HONDA csscsesseee 21 Chassis Important Safety Informatpon eee 2 Before You Service Your Honda SUSPENSION AECH estate ie 85 Important Safety Drecautons cee 2 The Importance of Maintenance eeeeseeeeeeee 22 e 90 Accessories amp Modifications ce eseeeeeeseees 3 Maintenance Safer 23 Wee 94 Safety Labels gd Eege ee iene 4 Important Safety Drecauttons cee 23 Wires 86 TUDES steet ges deg ee 95 Maintenance Schedule s s s 24 Drive Chain BEE 97 INSTRUMENTS amp CONTROLG s000 5 General Competition Maintenance sesseee 26 Exhaust Pipe Muffler A 100 Operation Component Locations eee 6 Before amp After Competition Maintenance 30 Steering Damper ai 103 Indicator deed 7 Between Motos amp Practice Maintenance 30 Additional Maintenance Procedures 105 MIL Blink Pattern 7 After Competition Maintenance 30 Current DTC Freeze DTC eee eeeeeeeeeeees 7 Appearance Caress eessen Nee eege 107 Circuit Inspection 8 Service Preparations DITC need eeneg AE 9 Maintenance Component Locations 32 e 33 BEFORE RIDING ssssseseseessssccesorsesesoesecossosseee 11 Puel Tank nianie e se 34 Are You Ready to Ride eneee 12 el uge ue 36 Is Your Motorcycle Ready to Rude 13 Pre ride Inspecton 13 Service Procedures Fluids amp Filters BASIC OPERATING INSTRUCTIONS 15 Fuel System gege 40 Safe R
96. d by turning the center screw of the compression adjuster The low speed 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 8 clicks and make sure that 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 the adjuster 6 positions e Rebound damping can be increased by turning the adjuster clockwise a 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 10 clicks and make sure that the punch marks on the adjuster and the shock absorber are aligned D 109 133 qxd 11 4 18 10 31 oU 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 susp
97. d fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate oe Front Suspension Adjustments eee 110 Rear Suspension Adjustments cece 125 Suspension Adjustments for Track Conditions Seeerei 129 Suspension Adjustment CGoudelnes 130 Tuning KEE 133 Steering Damper Adjustment eee 134 Steering Damper Adjustment Guidelines 135 Chassis Adiustments ceeceseceseeereeeeeeeees 136 Gearing aleet dE 137 Tire Selection for Track Condrtons 138 Personal Fit Adjustments s es 139 Adjustments for Competition Adjustments for Competition 109 D 109 133 qxd 11 4 18 10 31 7110 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 capacity are only felt during the final 3 9 in 100 mm of fork travel e Compression damping Turning the compression damping adjuster 1 adjusts how quickly the fork compresses e Rebound damping Turning the rebound damping adjuster 2 adjusts how quickly the fork extends e Fork springs Optional springs are available in softer and stiffer types than the standard rate page 156 The inverted fork on your CRF features sealed damper
98. dations should be evaluated by considering your ability your riding style and the track Adjustments for Competition 137 134 141 qxd 11 4 18 10 34 N 7138 S Tire Selection for Track Conditions 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 tires 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
99. ddle 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 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 US oz 5 cm Entire travel too stiff e Stiff suspension on any t
100. der fuel tank drive chain throttle body 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 Pro Honda Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge a Appearance Care 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 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 4 After washing rinse your CRF thoroughly with plenty of clean water to remove any residue Dry your CRF with a chamois or a soft towel Lubricate the drive chain to preve
101. dex 165 142 170 qxd 11 4 18 10 35 1166 Index Stopping engin scsieniin senei 18 RIETSER Ed 143 subira MEss eea ee iea EE E 36 suspension frontni air a 85 neat RAES AEE TETEE EE 86 suspension adjustment PONG eA ol WR E EEEE EEE 110 EE 125 for track conditions 00 eee eeeeeceeteeeeeeeeees 129 guidelines ni ne aa aed 130 T transmission ol 52 DOUD tIP Sissi a e e Ahan 133 throttle freeplay His Hiatal tds ee e 59 INSPECUON ee avs eit eee 60 tires AIT PLESSULE Eege 95 E EE 95 Selecto a eege ENNEN 138 tOOIS Arie ee eee ee eee ite 157 torque specifications CN SING sj eel Hi ANE 150 UE UE 151 152 transportin EE 142 troubleshooting eee esseceeceseceeeeeeeeeeeesaeens 145 tubes replacing ssiri iin 95 N Vale Te 68 vehicle identification no ONIN 148 W washing your motorcycle sessesseseseeseese 107 Wheels eon ea E eech 94 wiring diagram eeeseseeeeereeeersreeresresresresres 158 166 Index _ 142 170 qxd 11 4 18 10 35 NY 167 MEMO _ 142 170 qxd 11 4 18 10 35 MEMO 168 _ 142 170 qxd 11 4 18 10 35 169 MEMO 142 170 qxd 11 4 18 10 35 7170 Quick 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 compone
102. 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 or dusty areas Your 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 Honda Genuine air cleaner specified for your model or an air cleaner of equal quality NOTICE Using the wrong air cleaner may result in premature engine wear 56 Servicing Your Honda S 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 Remove the seat page 33 2 Remove the air cleaner retaining bolt 1 and air cleaner assembly 2 1 air cleaner retaining bolt 2 air cleaner assembly 048 067 qxd 11 4 18 10 21 757 3 Remove the air cleaner element 3 from the air cleaner holder 4 by releasing the holder tab 5 from the hole 6 of the air cleaner element 3 air cleaner element 4 air cleaner holder 5 holder tab 6 hole 4
103. drain bolt 7 14 cylinder head stud bolts 8 engine oil drainbolt 106 Servicing Your Honda 103 108 qxd 11 4 18 10 29 107 D S Refer to Safety Precautions on page 23 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 e 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 suspension pivot points and steering head bearings driving dirt inside and needed lubrication out If you use a high pressure washer avoid spraying the following areas wheel hubs muffler outlet under seat engine stop button brake master cylinders un
104. e a special tool 2 2 in 55 mm 19 Push the fork center bolt 28 out from the axle holder 23 of the slider by pushing the fork damper While the fork center bolt is pushed out install the piston base 29 or a mechanic s stopper tool between the axle holder and fork center bolt lock nut 30 e Piston base 07958 2500001 20 Hold the fork center bolt lock nut and remove the fork center bolt from the fork damper NOTICE Do not remove the lock nut from the fork damper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you may not reassemble the fork damper 109 133 qxd 11 4 18 10 31 Y115 D 23 S Front Suspension Adjustments Remove the fork damper assembly 32 from the fork assembly 33 Remove the fork from the vise Remove the fork spring 34 spring retainer 35 and collar washer 36 from the fork assembly Remove the O ring 37 Damper Oil Change 1 Place the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage NOTICE NOTICE 23 axle holder 28 fork center bolt 29 piston base 30 fork center bolt lock nut 21 22 Remove the push rod 31 from the fork damper Remove the piston base 29 or mechanic s stopper tool between the axle holder 23 and fork center bolt lock nut 30 while pushing the fork damper NOTICE Be careful not to damage the lock
105. e brake fluid level and the brake pads for wear If the braking response of the front brake lever or rear pedal feels unusual check the brake pads if the brake pads are not worn beyond the recommended limit page 93 there is probably air in the brake system Refer to an official Honda Service Manual or see your dealer to have the air bled from the system 90 Servicing Your Honda S Front Brake Lever Adjustment 1 lock nut 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 turn the adjuster counterclockwise 3 While holding the adjuster tighten the lock nut to the specified torque 4 4 Ibf ft 5 9 N m 0 6 kgf m 4 Apply silicone grease to the contacting faces of the adjuster 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 rear brake pedal 3 or in direction to lower it 2 Tighten the lock nut to the specified torque at the desired pedal height 4 4 lbf ft 5 9 N m 0 6 kgf m 1 lock nut raise the pedal height 2 adjusting bolt lower the pedal height 3 rear brake pedal D 088 102 qxd 11 4 18 10 27 Y9l Fluid Level Inspection Front Brake Fluid Level Check 1 LWR mark Wit
106. e or exhaust right or left NOTICE Do not let the valve lifters or shims fall into the crankcase 10 valve lifters Valve Clearance 7 Remove the shims 11 Servicing Your Honda 71 D 068 087 qxd 11 4 18 10 24 3772 Valve Clearance Shim Selection 1 Clean the valve shim contact area in the valve lifter 1 with compressed air 1 2 72 valve lifter Measure the shim thickness with a micrometer and record it Sixty nine different thickness shims 2 are available from the thinnest 1 200 mm thickness shim to the thickest 2 900 mm thickness in intervals of 0 025 mm Servicing Your Honda S 3 Calculate the new shim thickness using the equation below B C D A A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness e Make sure of the correct shim thickness by measuring the shim with a 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 2 900 mm 1 80 mm 1 825 mm 1 85 mm 1 875 mm 068 087 qxd 11 4 18 10 24 N 3773 p Valve Clearance 7 3 Rotate the primary drive gear bolt 4 Camshaft Installation crankshaft clockwise and align the punch mark 5 with the A mark 6 1 Install the newly selected shims 1 on t
107. e specification For added peace of mind remove the nuts clean the threads and apply Pro Honda Hondalock or an equivalent before torquing the nuts a Fuel Line Refer to Fuel System on page 40 Check the fuel line for deterioration damage or leakage Replace the fuel line every year Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion For additional corrosion protection apply Pro Honda Dielectric Grease to all the electrical connections 028 043 qxd 11 4 18 10 15 1729 Suspension Linkage Lubrication Disassemble clean inspect and lubricate all suspension linkage pivot bearings with grease after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear B ss Swingarm Pivot Lubrication Clean inspect and lubricate swingarm and suspension linkage pivots with grease Be sure all of the dust seals are in good condition 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 reduce boot sole lifespan Sharpen only the points of the teeth Filing the grooves deeper will weaken the footpegs Be sure the pegs are free to pivot fr
108. ealer 3 throttle 60 Servicing Your Honda S Inspect the condition of the throttle cables from the throttle grip down to the throttle body 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 048 067 qxd 11 4 18 10 21 Y6l Refer to Safety Precautions on page 23 Remember idle speed adjustment is not a cure all for other problems in your engine s PGM FI system Adjusting the idle will not compensate for a fault elsewhere The engine must be at normal operating temperature for accurate idle speed adjustment When pushed in the fast idle knob acts as the idle adjust screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed Idle Speed Adjustment 1 If the engine is cold start it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral Start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the fast idle knob 1 Idle speed 2 000 100 rom 1 fast idle knob increase decrease Engine Idle Speed Servicing Your Honda 61 048 067 qxd 11 4 18 10 21 762 Clutch System Refer to Safet
109. ean any gasket material off the cylinder 1 piston 4 piston pin 2 O mark 5 piston pin clip 3 large valve recess 6 piston cut out cont d Servicing Your Honda 81 D 068 087 qxd 11 4 18 10 24 782 Piston Piston Rings Piston Pin 6 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 82 Servicing Your Honda S 7 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankcase guide hole 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and a new cylinder head gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 1 dowel pins 2 cylinder head gasket 068 087 qxd D 11 4 18 10 24 on 83 2 Route the cam chain through the cylinder head 3 Install the cylinder head NOTICE Do not damage mating surfaces when installing the cylinder head 3 Apply engine oil to the cylinder head stud bolt threads Install the washers and cylinder head stud bolts 4 Tighte
110. earing 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 Average conditions use the standard sprocket Gearing 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 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 trade off is gearing that feels wrong in some sections 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 gearing 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 recommen
111. eat a couple of times to help the suspension overcome any situation and settle to a good reference point Rear Suspension Adjustments Ask the other helper to measure the loaded with rider dimension REAR FENDER MOUNTING BOLT LOADED MEASUREMENT with rider EXAMPLE 19 5 in 495 mm CHAIN ADJUSTER LOCK NUT Example Unloaded 23 6 in 600 mm Loaded 19 5 in 495 mm Race Sag 4 1 in 105 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 4 1 in 105 mm Adjust spring pre load as necessary to obtain the desired handling results Decreasing the race sag dimension example 3 7 in 95 mm improves turning ability for tight terrain at the cost of slightly reduced straight line stability Increasing the race sag dimension example 4 5 in 115 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 contd Adjustments for Competition 127 D 109 133 qxd 11 4 18 10 31 27128 Rear Suspension Adjustments 5 Measure the loaded without rider dimension Do this with your CRF set at the standard
112. ed on this page Symptoms and Adjustment e Always begin with the standard settings Steering Damper Adjustment Guidelines e Turn the steering damper adjuster in one click increments at a time Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment Symptom Action Steering is wobbling on large bumps Adjust the steering damper adjuster to stiffer setting Steering is wobbling at sand track Adjust the steering damper adjuster to stiffer setting Steering is heavy when cornering Adjust the steering damper adjuster to softer setting Adjustments for Competition 135 134 141 qxd 11 4 18 10 34 7136 Chassis Adjustments The following suggestions may improve a specific concern 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 suspension spring pre load Instead of running 4 1 in 105 mm of sag you can run 3 7 in 95 mm so the rear of the motorcycle will sit a little higher This should produce more traction because of the change to the swingarm and 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 suspension spring pre load
113. eely and that the pivot pin retaining cotter pins are in good condition S General Competition Maintenance Brake Fluid Replacement Refer to Brake Pad Wear in your Owner s Manual page 93 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 the pads 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 Refer to the Honda Service Manual page 160 for brake fluid replacement instructions Replace the hydraulic fluid in the brake system every 2 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 Bleed Hole After every race check the bleed hole below the water pump cover for leakage Clean away any clogged dirt or sand if necessary Check for signs of seal leakage A small amount of coolant weeping from the bleed hole is normal If water leaks through the bleed hole the mechanical seal is damaged If oil leaks through the bleed hole the oil seal is damaged See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil seal Both se
114. efore you ride It presents the location of the basic controls on your CRF Operation Component Locations eee Indicator MIL Blink Patten Current DTC Freeze DC Circuit Inspection DTC Index Instruments amp Controls Instruments amp Controls 5 D 001 027 qxd 11 4 18 10 13 Y6 j Operation Component Locations clutch lever front brake lever throttle grip engine stop button fast idle knob engine idle speed kickstarter ss d OLN P S SE E o O KE ZS O OX RO E zb Bei shift lever rear brake pedal 6 Instruments amp Controls D 001 027 qxd 11 4 18 10 13 Y7 The MIL on your CRF keeps you informed alerts you to possible problems and makes your riding safer and more enjoyable Refer to the MIL frequently 1 MIL The MIL flashes when there is any abnormality in the PGM FI system It should also light for a few seconds and then go off when the engine is started If the MIL comes on at any other time reduce speed and refer to an official Honda Service Manual available for purchase from your dealer page 160 If the MIL does not come on when it should have your dealer check it for problems a MIL Blink Pattern The MIL will blink the appropriate DTC number if the ECM detects an active problem while the engine is running at less than 5 500 rpm The MIL will stay ON when the engine
115. enance Perform maintenance on firm level ground using the optional workstand or equivalent support When tightening bolts nuts or screws start with the larger diameter or inner fasteners and tighten them to the specified torque using a crisscross pattern Use Honda Genuine Parts or their equivalent 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 13 26 Servicing Your Honda D 001 027 qxd 11 4 18 10 14 H General Competition Maintenance Spark Plug Spark Plug Cap Air Cleaner Some non resistor plugs may cause ignition problems Refer Install a small plastic tie wrap around the spark plug cap to Clean and oil your air cleaner regularly because the volume to the recommendations elsewhere in this manual for specific reduce any possibility of it loosening or of water of air able to pass through it has a great effect on types so you will be sure to use the proper reach and heat penetration performance Both engine performance and long term range Repl
116. eneees 16 identification vehicle eee eeeeeseereeeneeees 148 Operating instructions eee eeeeeeeeeeeree tees 15 schedule maintenance eseese 24 idle speed engine eeeeseeeeeeeereerererrersrssee 61 operation component locations eee 6 BEA erer 33 indicator optional Serial numberg aono a 148 MUS nk geedeg cee ahaa AEN 7 E EE 156 service circuit INSPECTION 0 ee eee eeeeseeeneceteeeteeeteeeeee 8 BECKER eegene See EE 137 CUSTOM ET ms 2 0 i ne i iE Nant 162 ENK Set arre en ea et ia oa Eai 9 oxygenated fuels sirni 153 er 160 inspection PLE T1de eee eee ceteceeeeeeeeeeeeeees 13 Spare Parts Sco deed is e eA EAEN E ESN LETEA 157 Ela EE 5 P Spark KOCK anaiona n 40 spark plug L pads Draken she in enna Ak 93 MAINLEN ANCE sss ienei eaa 67 Parts optional 156 ET OT 133 labels satety cnni nran ee es 4 personal fit adjustments 0 eee eeeeeeeeeee 139 SPECiliCallONS nnne a Ta 149 logbook compenton 154 pinging engine issnisinoniineenn i ii 40 spring pre load rear suspension eee 125 plugs Le TT 67 starting pre load rear guspensgion eee eee eeeeeeeeees 125 ENGINE EE 17 pre ride iINSPECtION 0 Lecce estecsteceteeeeeeeeee 13 Droublesbhootng ces eeseesecsseceeeeeeeeeeeeeees 145 protective apparel 0 eee esceeeeeeeeeeeeereeeeees 2 steering damper le UE 134 SuIdeliMes eseu nei SE es 135 Operation INSPECTION eee eeeeseceteeeteeees 104 Steering stem inspection eee eeeeeeeeeeeee 105 contd In
117. ension 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 suspension spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel oil and coolant 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 chain adjuster lock nut as illustrated here for three different situations oe unloaded motorcycle on an optional 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 an optional workstand with the rear wheel off the ground 2 Measure the unloaded dimension REAR FENDER MOUNTING BOLT gf 47 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 s
118. er when it is left inverted for about 20 minutes at 20 C 68 F 5 10 20 35 55 85 145 fork damper spring chamber 65 5 7 52 4 5 4 1 3 7 3 3 6 7 62 54 4 7 4 4 38 3 5 7 3 64 5 6 5 46 42 3 8 86 82 7 9 76 7 3 68 6 cm 0 C 32 F r 10 C 50 F lt E 20 C 68 F 30 C 86 F LEE ET ee 4 PATA Mellin TN 5 fork damper oil chamber 12 oil holes 1 fork assembly Amount of fork oil Di To properly dispose of drained fluids refer to a a E E Pour the drained oil into a suitable container and You amp the Environment page 144 minutes dispose of it in an approved manner page 144 2 Tighten the fork center bolt lock nut 2 fully and measure the thread length A as shown NOTICE Standard 0 43 0 51 in 11 13 mm e S DEN Wipe the oil completely off the fork damper Improper disposal of drained fluids is harmful to the environment 2 fork center bolt lock nut A thread length 118 Adjustments for Competition D 109 133 qxd 11 4 18 10 31 1 3 Install the collar 3 to the C ring 4 of the fork damper assembly 5 as shown Install the washer 6 and spring retainer 7 to the fork damper assembly Make sure the black side of the washer is seated on the collar side 3 S Blow out the oil completely off the fork spring 8 using compressed air Install the fork spri
119. face 20 of the slider and fork dust seal 21 13 Measure the length 22 between the axle holder and outer tube and record it before disassembling the fork 20 sliding surface 21 fork dust seal 22 length cont d Adjustments for Competition 113 109 133 qxd 11 4 18 10 31 114 D S Front Suspension Adjustments 14 Hold the outer tube then remove the fork damper 6 from the outer tube using a lock nut wrench 7 Gently slide the outer tube down onto the lower end axle holder 23 qmm 23 26 outer tube slider 27 oil holes 6 fork damper 7 lock nut wrench 23 axle holder slider in a vise with a piece of wood or soft jaws to avoid to damage NOTICE The outer tube 24 can drop on the slider 25 and damage the fork dust seal 21 To avoid damage hold both the outer tube and Over tightening the vise can damage the axle slider when removing the fork damper holder NOTICE NO GOOD 17 Remove the fork center bolt 28 x 21 21 fork dust seal 24 outer tube 25 slider 28 fork center bolt 23 axle holder 114 Adjustments for Competition ae 15 Drain the fork oil from the outer tube slider 26 and oil holes 27 of the fork damper 16 Place the lower end axle holder 23 of the 18 Make the mechanic s stopper tool out of a thin piece of steel 0 08 in 2 0 mm thick as shown if you do not hav
120. g 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 52 Servicing Your Honda S Oil Recommendation API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label Viscosity SAE 10W 30 weight JASO T903 MA standard others without friction modifiers as molybdenum additives Pro Honda GN4 4 stroke oil USA amp Canada or Honda 4 stroke oil Canada only or suggested oil an equivalent motorcycle 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 NOT RECOMMENDED OK a Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range
121. grips controls and footpegs A stiff nylon parts cleaning brush works well e Check tire air pressure e Check spoke tension and make sure the rim locks are secure e Check to make sure the sprocket bolts and nuts are secure 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 the engine is running Injury to your fingers or hands may result After adjustment check that the chain adjuster 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 30 Servicing Your Honda 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 0 kPa 0 kgf cm 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 2 pressure release screw 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 Lubrica
122. h the motorcycle in an upright position check the fluid level It should be above the LWR mark 1 If the level is at or below the LWR mark check the brake pads for wear page 93 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the pulling distance for the front brake lever feels excessive there is probably air in the brake system and it must be bled Refer to an official Honda Service Manual or see your dealer for brake bleeding Honda recommends using Honda DOT 4 brake fluid from a scaled container or an equivalent Other Checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings S 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 93 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the travel for the rear brake pedal feels excessive there is probably air in the brake system and it must be bled Refer to an official Honda Service Manual or see your dealer for brake bleeding Honda recommends using Honda DOT 4 brake fluid from a scaled container or an equivalent Other Checks Make sure there are no fluid leaks Check for deterio
123. he valve retainers 2 NOTICE Do not let the shims fall into the crankcase 9 timing marks 10 cam sprocket 11 surface of the cylinder head 4 primary drive gear bolt 6 A mark 5 punch mark 5 Apply grease to the set rings 13 and install it 4 Apply molybdenum oil solution to the Onto the camshatt bearing grooves 13 camshaft journals and cam lobes Place the camshaft 7 with the intake cam lobes 8 facing up and align the timing marks 1 shims 2 valve retainers 9 on the cam sprocket 10 with the surface of the cylinder head 11 Install the cam chain 12 over the sprocket without rotating the camshaft 2 Apply molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the outer surface of the each the valve lifters 3 Install the valve lifters to the proper position 13 set rings 15 camshaft bearing grooves 7 cam shaft 12 cam chain 8 intake cam lobes cont d 3 valve lifters Servicing Your Honda 73 068 087 qxd 11 4 18 10 24 174 D S Valve Clearance Each camshaft holder has an identification mark 16 lOB a0 Si No 8 E CO 16 identification marks 6 Install the camshaft holders 14 in their proper position by aligning the camshaft bearing grooves 15 with the set rings 13 7 Apply oil to the camshaft holder
124. he bearing plate should turn smoothly and quietly Discard the 3 Remove the five clutch spring bolts and clutch clutch lifter if the bearing plate does not turn springs 4 smoothly Loosen the bolts in a crisscross pattern in two or three progressive steps 6 clutch lifter 7 clutch lifter rod 64 Servicing Your Honda 048 067 qxd 11 4 18 10 21 65 Clutch Disc Plate Inspection Replace the clutch discs 1 if they show 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 an assembly 1 clutch disc S 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 0 004 in 0 10 mm Replace the clutch discs and plates as a set 2 clutch plate If you feel the clutch slippage when replacing the clutch discs and plates replace the clutch springs Clutch System Servicing Your Honda 65 048 067 qxd 11 4 18 10 49 66 Clutch System Clutch Disc Plate Installation 1 Install the spring seat 1 and judder spring 2 onto the clutch center as shown 2 Coat the clutch discs 3 and plates 4 with engine oil 3 Install the clutch disc A larger I D disc 5 onto the clutch outer Stack the seven clutch plates and seven clutch discs
125. he engine Do not open the throttle If Difficult to Start After Stalling Shift the transmission into neutral 1 2 With the throttle fully opened repeat kickstarter operation approximately 10 times to discharge excessive fuel from the engine 3 Kick start the engine Do not open the throttle Snapping the throttle or fast idling for more than 5 minutes may cause exhaust pipe discoloration Basic Operating Instructions 17 001 027 qxd 11 4 18 10 14 718 D Starting amp Stopping the Engine How to Stop the Engine 1 throttle 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Lightly open the throttle 1 two or three times and then close it 3 Push and hold the engine stop button 2 until the engine stops completely Emergency Engine Stop To stop the engine in an emergency push and hold the engine stop button 18 Basic Operating Instructions D 001 027 qxd 11 4 18 10 14 19 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 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 Break in Guidelines Basic Operating Instructions 19
126. he muffler page 101 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 5 Tighten the muffler clamp bolt muffler mounting A bolt and B bolt page 101 6 Installation can be done in the reverse order of removal D 103 108 qxd 11 4 18 10 29 27103 Refer to Safety Precaution on page 23 Loose worn or damaged steering damper components may adversely affect the handling and stability of your CRE If any steering damper components appear worn or damaged see your dealer for further inspection Your dealer is qualified to determine whether or not replacement parts are needed Do not attempt to disassemble the steering damper see your dealer The instructions found in this owner s manual are limited to adjustment and service of the steering damper assembly only Steering Damper Operation Inspection e When your CRF is new break it in for approximately 1 hour to ensure that the steering damper is broken page 19 e After break in test run your CRF with the steering damper at the standard setting before making any adjustments e Check the spherical bearings and dust seal for dust dirt and foreign materials e Make all 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 e If you have a problem finding an acceptable adju
127. here is have the bearings replaced by your dealer 068 087 qxd 11 4 18 10 24 2787 Recommended Fork Oil suggested oil HP Fork Oil SS 19 Fork Oil Change Refer to Front Suspension Disassembly on page 112 1 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 2 Hold the outer tube 1 then remove the fork damper 2 from the outer tube using a lock nut wrench 3 Gently slide the outer tube down onto the axle holder 4 e Lock nut wrench O7WMA KZ30100 S 4 1 outer tube 2 fork damper 3 lock nut wrench 4 axle holder NOTICE The outer tube 1 can drop on the slider 5 and damage the fork dust seal 6 To avoid damage hold both the outer tube and slider when removing the fork damper 1 outer tube 5 slider 6 dust seal 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 7 of the fork damper Ce ze ee 1 outer tube 7 oil hole BEEN Suspension 4 Drain the fork oil by turning the outer tube 1 upside down About 0 4 US oz 12 cm of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 NOTICE Improper disposal of drained oil is harmful to the environment Amount
128. ide covers seat mounting bolts 6 7 9 0 1 2 bolts 2 2 2 3 3 3 Subframe Servicing Your Honda 39 028 043 qxd 11 4 18 10 15 2740 Fuel System Refer to Safety Precautions on page 23 Fuel Type Unleaded Pump Octane Number 91 or higher Use only unleaded fuel in your Honda If you ride your Honda in a country where leaded fuel might be available take precautions to use only unleaded fuel Your engine is designed to use any unleaded 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 153 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 dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank Dirty fuel will clog the fuel pump filter and can damage the fuel pump Commercially available fuel straining devices may reduce the occurrence of dirty fuel 40 Servicing Your Honda S Refueling Procedure 1 To
129. iding Precautions 16 Engine Oil sh cnhiwanwtan tek daa 49 Starting amp Stopping the Engine ee 17 Transmission Ou 52 Fast Idle Knabe 17 Coolant sisi sok ciliata Se EE 54 Btepgtpatgtt nenne a R 17 Air Cleanet 133 8 ei heehee ee eee 56 Starting Procedure 0 0 ee ceecceeeeeseeeneeeneeees 17 Crankcase Breather 0 0 0 ceeesceeceeeeeereeneeeeees 58 How to Stop the Engine 18 Break in Guidelines 00 0 eee ceeeeseeeeeeeeeeeeees 19 Engine Throttle niron ae Gi eee 59 Engine Idle Speed A 61 Clutch System os ennonn eiea 62 Spark Plug scsi inen enea a a ice 67 KI 68 Piston Piston Rings Piston Dm 76 Contents Contents qxd 11 4 18 10 13 Y5 ADJUSTMENTS FOR COMPETITION 109 Front Suspension Adjustments eee 110 Front Suspension Air Dreseure 110 Front Suspension Dampng 110 Bork Sprin 98 ee eege EEN EE 111 Front Suspension Disassembly 112 Damper Oil Change 115 Fork ASsembly ccscisecsecsssiesescesstesstecsestoseees 118 Rear Suspension Adrustmentz cc eeeeeee 125 Rear Suspension Spring Pre Load 125 Rear Suspension Damping eeeeeereceeee 126 Rear Suspension Race Sag oseere 127 Suspension Adjustments for Track Conditions i eeri en seein e EEs 129 Suspension Adjustment Guidelines 130 TUNING KEE 133 Spark Plug Reading eee eeeeeeeereeeeees 133 Steering Damper Adjustment eee 134 Steering Damper Damping eee 134 Steering Damper
130. idway between the drive 2 and driven sprockets 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm Drive Chain Drive Chain Sliders 1 Check the chain slider 1 for wear Replace it if below the service limit SERVICE LIMIT upper side 0 2 in 5 mm lower side 0 10 in 2 5 mm 1 drive chain slack 3 driven sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking 0 10 in N NOTICE 2 5 mm Excessive chain slack may allow the drive chain to damage the engine cases 1 chain slider 2 Check the chain guide slider 2 for wear Replace the guide slider if it is worn to the bottom of the wear limit 3 4 Inspect the drive chain for e damaged rollers e loose pins e dry or rusted links e kinked or binding links e excessive wear Replace the drive chain page 99 if it has damaged rollers loose pins or kinks that cannot be free Lubricate the drive chain page 98 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed page 98 2 chain guide slider 3 wear limit Servicing Your Honda 97 ae 088 102 qxd 11 4 18 10 27 7798 D Drive Chain Drive Chain Rollers
131. ing bolts to the specified torque 19 Ibf ft 26 N m 2 7 kgf m seat front prong seat bracket seat rear prong ECM bracket Seat Servicing Your Honda 33 028 043 qxd 11 4 18 10 15 3734 Fuel Tank Refer to Safety Precautions on page 23 Removal 1 Remove the seat page 33 2 Remove the shroud A bolts and collars 1 3 Remove the shroud B bolts 2 and shrouds 3 1 shroud A bolts and collars 2 shroud B bolts 3 shrouds 4 Install a hose clamp 4 to the breather tube 5 and shut the hose clamp securely 4 hose clamp 5 breather tube 5 Pull the breather tube 5 out of steering stem nut 6 Unhook the fuel tank band 6 34 Servicing Your Honda S 7 Remove the fuel tank bolt and collar 7 5 breather tube 6 fuel tank band 7 fuel tank bolt and collar 8 Unhook the fuel feed hose 8 from the clamp 9 8 fuel feed hose 9 Pull the fuel tank 10 out of the frame and hang it to the left of the frame Check the fuel tank stopper cable 11 for deterioration kinks or other damage Do not support the fuel tank by the fuel feed hose 8 ae 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 KE A 8 fuel feed hose 11 fuel tank sto
132. ition can be caused by a plugged or dirty air cleaner use of a more restrictive aftermarket exhaust system or excessive oil on the air cleaner Excessive smoking will occur Adjustments for Competition 133 134 141 qxd 11 4 18 10 34 1134 an Steering Damper Adjustment The steering damper can be adjusted for riding conditions by using following method Steering Damper Adjustment e Damping Turning the steering damper adjuster adjusts how quickly the steering The steering damper adjuster 1 has 13 positions damper extends and retracts or more Turning the adjuster one full turn clockwise advances the adjuster six positions To adjust the adjuster 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 9 12 clicks Damping can be increased by turning the adjuster clockwise NOTICE Always start with full hard when adjusting damping Do not turn the adjuster more than the given positions or the adjuster may be damaged Be sure that the damping adjuster is firmly located in a detent and not between positions 1 steering damper adjuster 134 Adjustments for Competition 134 141 qxd 11 4 18 10 34 N 7135 Follow the procedures described below to accurately adjust your CRF using the methods decrib
133. jects For example record results in black steering damper setting 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 154 Technical Information oe Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include e basic track conditions altitude and temperature e suspension settings e steering damper 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 guesstimate 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 a Racing Records Information worth recording for
134. justments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after landing 1 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 stiffer 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 132 Adjustments for Competition a D 109 133 qxd 11 4 18 10 31 133 An optional PGM FI setting tool can change the ignition timing and amount of the fuel injection page 157 Be sure to observe the PGM FI setting by checking the spark plug Spark Plug Reading Refer to Spark Plug on page 67 The following procedure is recommended You may not get an accurate reading if you simply turn off the engine and pull the plug for inspection Use a new spark plug Inspect the plug before installing it S NOTICE Using spark plugs with an improper heat range or incorrect reach can cause engine damage Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately Before removing the spark plug clean the spark plug area thoroughly to prevent dirt from entering the cylinder To obtain
135. le shaft through the forks and wheel hub from the right side Make sure 34 handlebar that the front axle shaft is seated firmly onto 35 mounting rubbers washers and handlebar lower A A holder nuts l the left fork leg clamp inner surface Tighten 5 SE rapar the front axle nut 32 to the specified torque 31 Install the number plate page 103 26 stay B 65 Ibf ft 88 N m 9 0 kgf m 27 stay A Tighten the left axle pinch bolts 33 to the 28 brake hose clamp bolts specified torque 29 brake caliper mounting bolts 15 Ibf ft 20 N m 2 0 kgf m 27 Clean the surfaces where the axle and axle clamps contact each other Apply grease to each dust seal lips of the front wheel Install the disc cover collar 30 and right side collar 31 into the wheel hub 32 front axle nut 33 left axle pinch bolts cont d Adjustments for Competition 123 ae B D 109 133 qxd 11 4 18 10 31 27124 Front Suspension Adjustments 32 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 33 While keeping the forks parallel alternately tighten the right axle pinch bolts 36 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m e an7 2 A i q VK ei V a b 36 right axle pinch bolts NOTICE To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp i
136. mp 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 D 088 102 qxd 11 4 18 10 27 3795 Refer to Safety Precautions on page 23 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 repair and 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 new caps S Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if
137. muffler 10 Unhook the fuel tank band 14 1 Remove the side covers 1 by removing the seat mounting bolts 2 and bolts 3 2 Remove the seat 4 6 muffler mounting A bolt 9 washer B 12 ECM mounting rubber 7 muffler mounting B bolt 10 muffler 13 ECM bracket 8 washer A 14 fuel tank band 1 side covers 3 bolts i 2 seat mounting bolts 4 seat 5 Disconnect the IAT sensor connector 11 7 Loosen the screw 15 on the air cleaner connecting tube clamp 16 3 Loosen the muffler clamp bolt 5 11 IAT sensor connector 15 screw 16 air cleaner connecting tube clamp 5 muffler clamp bolt 36 Servicing Your Honda 028 043 qxd 11 4 18 10 15 2737 S Subframe 8 Remove the right subframe lower bolt 17 and left subframe lower bolt 18 Remove the subframe upper bolts 19 Left side Ku Right side Gan 17 right subframe lower bolt 18 left subframe lower bolt 19 subframe upper bolts 9 Slightly pull the subframe 20 backward and disconnect the crankcase breather tube 21 from the air cleaner connecting tube Remove the subframe Be careful not to damage the ECM and wires 20 subframe 21 crankcase breather tube Installation 1 Connect the crankcase breather tube 1 1 crankcase breather tube 2 Position the ECM 2 in the bracket 3 3 Align the shroud tabs 4 with the air cleaner housing cover tabs 5 4 Loosely atta
138. n cylinder and piston ring e Damaged cylinder head gasket e Improper valve timing e Faulty decompressor system INCORRECT Faulty PGM FI system p 9 INCORRECT gt Faulty fuel pump unit Clogged fuel pump filter P 44 INCORRECT Incorrect spark plug Incorrect spark plug gap Dirty air cleaner element INCORRECT gt Engine oil level too high e Engine oil level too low Contaminated engine oil INCORRECT Faulty oil pump e Faulty pressure relief valve Clogged oil passage Clogged oil strainer screen Tips 145 142 170 qxd 11 4 18 10 35 1146 Troubleshooting POOR PERFORMANCE AT LOW AND IDLE SPEED CHECK 1 Check the spark plug condition P 63 CORRECT 2 Check the ignition timing CORRECT 3 Check the PGM FI system P 7 CORRECT 4 Check the fuel pump operation and inspect the fuel flow CORRECT 5 Check the insulator for leaks CORRECT 6 Try spark test 146 Tips POSSIBLE CAUSES INCORRECT Incorrect spark plug heat range e Incorrect spark plug gap e Plug not serviced frequently enough INCORRECT m gt Faulty ECM e Faulty CKP sensor INCORRECT gt Faulty PGM FI system P9 INCORRECT gt Faulty fuel pump unit
139. n index at the back of the book Introduction S 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 CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment procedures discussed in this manual An official Honda Service Manual for your CRF is available page 160 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 an official Honda Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information You may also want to visit our website at USA www powersports honda com Canada www honda ca 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 ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or system Abbrev term
140. n the cylinder head stud bolts in a crisscross pattern in two or three steps to the specified torque 33 Ibf ft 45 N m 4 6 kgf m NOTICE Do not let the washers and nuts fall into the crankcase 3 cylinder head 4 cylinder head stud bolts washers Install the cylinder bolt 5 and cylinder head bolts 6 and tighten them to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 1 Piston Piston Rings Piston Pin 5 Install the left cylinder head hanger plate 7 and right cylinder head hanger plate 8 then loosely install the cylinder head hanger plate bolts 9 and cylinder head hanger bolts 10 Tighten the cylinder head hanger bolts and cylinder head hanger plate bolts to the specified torque cylinder head hanger bolts 40 Ibf ft 54 N m 5 5 kgf m cylinder head hanger plate bolts 24 Ibf ft 33 N m 3 4 kgf m 7 left cylinder head hanger plate 8 right cylinder head hanger plate 9 cylinder head hanger plate bolts 0 cylinder head hanger bolts contd Servicing Your Honda 83 068 087 qxd 11 4 18 10 24 784 D S Piston Piston Rings Piston Pin 6 Install the throttle body 11 to the insulator 12 by aligning the tab of the throttle body with the groove of the insulator and tighten the insulator band screw 13 so the distance between the band ends is 0 43 0 04 in 11 0 1 0 mm 8 Connect the radiator hose 17 to the water hose joint
141. ng Coolant Refer to Safety Precautions on page 23 1 With the engine cold remove the radiator cap 1 and check coolant level The coolant level is correct when it is at the bottom of the radiator filler neck 2 A WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 1 radiator cap 2 radiator filler neck 2 Add coolant up to the filler neck if the level is low Inspect the coolant level before each outing A coolant loss of 0 7 2 0 US oz 20 60 cm through the overflow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 16 US qt 1 10 after disassembly 1 09 US qt 1 03 after draining 3 Install the radiator cap securely NOTICE If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage 048 067 qxd 11 4 18 10 21 3755 Cooling System Inspection 1 Check the cooling system for leaks see the Honda Service Manual for troubleshooting of leaks 2 Check the water hoses 1 for cracks deterioration and hose clamp for looseness 3 Check the radiator mount for looseness 4 Make sure the overflow tube 2 is connected and not clogged 5 Check the radiator fins for clogging te SA
142. ng on the front wheel With your CRF you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits 134 141 qxd 11 4 18 10 34 N 7137 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 rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional aluminum driven sprockets Like the optional springs these sprockets are listed in the Optional Parts List section of this manual page 156 Unless you have the required mechanical knowhow tools and Honda Service Manual sprocket changing should be done by your dealer Higher Gearing less driven 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
143. ng storage also follow the following procedures 1 WN Preparation for Storage 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 50 Change the transmission oil page 53 Remove the radiator cap and coolant drain bolt and sealing washer 1 at the water pump cover 2 to drain coolant After the coolant has been completely drained reinstall the drain bolt with a new sealing washer and radiator cap Tighten the drain bolt to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 1 coolant drain bolt and washer 2 water pump cover 10 11 5 Lubricate the drive chain 6 Relieve the fuel pressure page 41 and drain the fuel from the fuel tank into an approved gasoline container Inflate the tires to their recommended pressures Place your CRF on an optional 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 non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Storing Your Honda Removal from
144. ng to the fork damper assembly 5 Install the fork damper assembly to the fork assembly 1 3 collar 4 C ring 5 fork damper assembly 6 washer 7 spring retainer 1 fork assembly 5 fork damper assembly 8 fork spring Front Suspension Adjustments 5 Place the lower end axle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage NOTICE Over tightening the vise can damage the axle holder 6 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 9 or mechanic s stopper tool between the axle holder and fork center bolt lock nut 2 Measure the thread length again Standard 0 43 0 51 in 11 13 mm Install the push rod 10 into the fork damper piston rod until it stops Apply fork oil to new O ring 11 and install it to the fork center bolt 12 Install the fork center bolt to the fork damper piston rod Tighten the fork center bolt fully 9 piston base 2 fork center bolt lock nut 11 O ring new 12 fork center bolt 10 push rod contd Adjustments for Competition 119 D 109 133 qxd 11 4 18 10 31 1120 an Front Suspension Adjustments 9 Measure the length of the fork center bolt lock 11 Remove the piston base or mechanic s stopper 14 Remove the fork damper from the fork nut 2 and f
145. ngine 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 30 weight JASO T 903 standard MA Pro Honda GN4 4 stroke oil USA amp Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil 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 S 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 NOT RECOMMENDED OK 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 O 20 40 60 80 100 120 F Engine Oil JASO T 903 standard The 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
146. nner surface 124 Adjustments for Competition S 34 Install and tighten the disc cover socket bolt 37 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m ES ae E r H d d K SE y 37 disc cover socket bolt 35 Turn the rebound damping 38 and compression damping 39 adjuster screws back to their original settings 38 rebound damping adjuster 39 compression damping adjuster D 109 133 qxd 11 4 18 10 31 27125 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 dealer The instructions found in this owner s manual are limited to adjustments of the shock 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 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 Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 100 An optional pin spanner is avail
147. nt rusting 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 zl CP Lin Servicing Your Honda 107 103 108 qxd 11 4 18 10 29 7108 D S Appearance Care 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 108 Servicing Your Honda 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 the surface using strokes parallel to the length of the frame Clean the frame u
148. nt 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 Quick Reference SS Record important information here VIN Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr Maintenance The maintenance schedule page 25 lists service frequencies for each race or about 2 5 hours every 3 races or about 7 5 hours every 6 races or about 15 0 hours every 9 races or about 22 5 hours and every 12 races or about 30 0 hours Pre ride Inspection Check the items listed on the Pre ride inspection checklist each time before you ride page 13 Fuel tank Capacity unleaded gasoline pump octane number of 91 or higher tank 1 5 US gal 5 7 Engine oil Pro Honda GN4 4 stroke oil or an equivalent Transmission oil Pro Honda GN4 4 stroke oil or an equivalent Tires ee 80 100 21 51M Pr gt 100 90 19 57M DUNLOP Mar S DUNLOP MX51 Type bias ply tube Tire Pressure cold Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm Spark Plug standard R0451
149. o the ECM bracket 16 11 Remove the old gasket from exhaust pipe 12 Install the muffler clamp 18 and a new gasket 19 to the exhaust pipe 20 14 fuel tank band 18 muffler clamp 20 exhaust pipe 15 ECM mounting rubber 19 gasket new 16 ECM bracket 13 Install the muffler 21 14 Install the muffler clamp 18 by aligning the tab 22 of the muffler clamp with the cutout 23 of the muffler 10 Connect the IAT sensor connector 17 i 17 IAT sensor connector 18 muffler clamp 21 muffler 22 tab 23 cutout 028 043 qxd 11 4 18 10 15 739 15 Install the washer A 24 washer B 25 muffler mounting B bolt 26 and muffler mounting A bolt 27 28 27 24 washer A 25 washer B 26 muffler mounting B bolt 27 muffler mounting A bolt 16 Tighten the muffler clamp bolt 28 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 28 muffler clamp bolt S 17 Tighten the muffler mounting B bolt 26 and muffler mounting A bolt 27 to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 18 Install the seat 29 19 Install the side covers 30 seat mounting bolts 31 and bolts 32 Then tighten the seat mounting bolts and side cover bolts to the specified torque seat mounting bolts 19 Ibf ft 26 N m 2 7 kgf m side cover bolts 7 Ibf ft 10 N m 1 0 kgf m muffler mounting B bolt muffler mounting A bolt seat s
150. o the specified torque 1 0 Ibf ft 1 3 N m 0 1 kgf m WN ae Front Suspension Damping Compression Damping Adjustment This adjustment affects how quickly the fork compresses The fork compression damping adjuster has 16 positions or more Turning the compression damping adjuster screw 1 one full turn changes the adjuster 4 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 7 clicks Make sure that both fork legs are adjusted to the same position Rebound Damping Adjustment The fork rebound damping adjuster has 16 positions or more Turning the rebound damping adjuster screw 2 one full turn clockwise advances the adjuster 4 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 11 clicks Make sure that both fork legs are adjusted to the same position D 109 133 qxd 11 4 18 10 31 S7111 an Front Suspension Adjustments Both compression and rebound damping can be increased by turning the adjuster clockwise Fork Springs NOTICE The fork springs in CR
151. olders 180 degrees Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment Personal Fit Adjustments e Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off 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 ergonomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Adjustments for Competition 139 _ 134 141 qxd 11 4 18 10 34 1140 140 Adjustments for Competition 134 141 qxd 11 4 18 10 34 Y141 Tips Here s helpful advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle ceeseeeeeee 142 Storing Your Honda 143 You amp the Environment s s s 144 Troubleshooting cee ceeeeseeseeseceteceneeeeeeeeee 145 Tips 141 142 170 qxd 11 4 18 10 35 Transporting Your M
152. on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the A 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 5 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 A mark 2 primary drive gear bolt 3 punch mark gt 5 exhaust rocker arm S Valve Clearance Inspection Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cams 3 1 feeler gauge 2 valve lifters 3 intake cams Valve Clearance 2 Measure the exhaust valve clearance by inserting a feeler gauge 1 between the exhaust rocker arm 4 and exhaust valve shims 5 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shims Valve Clearances IN 0 005 0 001 in 0 12 EX 0 011 0 001 in 0 28 If intake valve clearance and exhaust valve clearance need adjustment see Camshaft Removal page 70 and select the correct shim for each valve Servicing Your Honda 69 D 068 087 qxd 11 4 18 10 24 70 Valve Clearan
153. 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 1 fuel fill cap 2 breather tube 3 steering stem nut 2 Add fuel until the level reaches the bottom of the filler neck Fuel Tank Capacity 1 5 US gal 5 7 2 Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 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 3 Close the fuel fill cap and insert the breather tube in the steering stem nut Fuel Line 1 Hang the fuel tank to the left side of the frame page 34 2 Remove the fuel quick connect fitting cover 1 3 Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary Install the fuel quick connect fitting cover Install the fuel tank page 35 ns 1 fuel quick connect fitting cover 2 fuel line 028 043 qxd 11 4 18 10 15 41 Fuel Pressure Relieving 1 Disconnect the fuel pump sub harness connector 1 1 fuel pump sub harness connector 2 Start the engine and let it idle until the engine stalls S Fuel Line Replacement Disconnection
154. ork center bolt 12 clearance tool while pushing the fork damper 15 Pour the recommended fork oil 14 into the Standard 0 06 0 08 in 1 5 2 0 mm ET locking agent to the fork center bolt fork assembly 1 threads If the clearance is out of specification check the Install the fork center bolt 12 to the axle Recommended Oil HP Fork Oil SS 19 fork center bolt lock nut and fork center bolt holder and tighten it to the specified torque 0 06 0 08 in 1 5 2 0 mm a 12 1 fork assembly 14 fork oil p 2 fork center bolt lock nut 12 fork center bolt 12 fork Sne mmm 10 Tighten the fork center bolt lock nut 2 to the 12 Measure the length between the axle holder fork center bolt 12 closely by hand Tighten and outer tube the fork center bolt lock nut to the specified Standard 12 5 0 1 in 316 5 2 mm torque 13 Compare the length 13 at assembly and at 16 Ibf ft 22 N m 2 2 kgf m disassembly They should be the same length If the length at assembly is longer than at disassembly check the fork center bolt and fork center bolt lock nut installation 2 fork center bolt lock nut 12 fork center bolt 13 length 120 Adjustments for Competition 109 133 qxd 11 4 18 10 31 1121 S Front Suspension Adjustments 16 Install a new O ring 15 on the fork damper assembly 4 Apply the recommended fork oil to the O ring Fork Oil Capacit
155. osal 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 nonrecyclable wastes 144 Tips S NOTICE Improper disposal of drained fluids is harmful to the environment 142 170 qxd 11 4 18 10 35 1145 S Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of an official Honda Service Manual are followed by an asterisk ENGINE DOES NOT START OR IS HARD TO START CHECK 1 Check the spark plug condition P 63 CORRECT Y 2 Try spark test GOOD SPARK Y 3 Check the PGM FI system P 7 CORRECT 4 Check the fuel pump operation and inspect the fuel flow CORRECT 5 Test cylinder compression CORRECT 6 Start by following normal starting procedure POSSIBLE CAUSES INCOR
156. otorcycle 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 N5142 S 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 recommend that you do not transport your CRF on its side This can damage the motorcycle and leaking gasoline could be a hazard 142 170 qxd 11 4 18 10 335 37143 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 duri
157. ou 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 steering damper and other adjustments see page 109 S Is Your Motorcycle Ready to Ride Pre ride Inspection Before Riding Before Riding 11 D 001 027 qxd 11 4 18 10 14 1 Are You Ready to Ride Before riding your CRF for the first time we strongly 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 steering damper and other adjustments see page 109 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 injury when you ride 12 Before Riding oe A WARNING Not wearing a helmet increases the chance of serious injury or death ina crash Be sure you always wear a helmet eye protection and other protective apparel when you ride D 001 027 qxd 11 4 18 10 14 IM Competitive riding
158. ount of silicone grease to a new O ring 5 Install a new O ring to the fuel pump assembly 2 3 Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder 6 while routing the fuel pump red 7 and black 8 wires through the holder grooves 9 as shown 2 fuel pump assembly 7 red wire 5 O ring new 8 black wire 6 fuel pump unit holder 9 grooves 4 Install a new damper rubber 10 to the fuel pump filter as shown Install the fuel pump stopper 11 10 new damper rubber 11 fuel pump stopper ae 5 Apply a small amount of silicone grease to a new O ring 12 Install a new O ring to the fuel pump base 13 6 Install the fuel pump unit holder assembly 14 into the fuel pump base while aligning its hooks 15 with the grooves 16 in the fuel pump base tabs 17 If the gap between the hooks and tabs is more than 0 04 in 1 0 mm replace the fuel pump unit Be sure that the hooks are completely seated 15 E 14 O ring new fuel pump base fuel pump unit holder assembly hooks grooves 1 1 1 1 1 17 tabs _ 044 047 qgxd 11 4 18 10 20 3747 an Fuel System 7 Connect the fuel pump red 18 and black 19 9 Install a new O ring 23 into the fuel tank 12 Install the conical spring washers 28 collars wire terminals to the fuel pump base terminals groove 29 washers 30 stopper cable 31 s
159. ours 30 0 hours ITEMS FUEL LINE NOTE 6 R 40 FUEL PUMP FILTER NOTE 6 R 44 THROTTLE OPERATION 60 AIR FILTER NOTE 1 Cc 56 CRANKCASE BREATHER 58 SPARK PLUG 67 VALVE CLEARANCE NOTE 4 I 68 75 ENGINE OIL NOTE 3 R 49 ENGINE OIL FILTER NOTE 3 R 50 ENGINE IDLE SPEED 61 PISTON AND PISTON RINGS R 79 PISTON PIN R 80 TRANSMISSION OIL NOTE 5 R 52 RADIATOR COOLANT NOTE 2 54 COOLING SYSTEM 54 DRIVE CHAIN LL H 97 99 DRIVE CHAIN SLIDER 97 DRIVE CHAIN ROLLER 98 DRIVE SPROCKET 99 DRIVEN SPROCKET 99 BRAKE FLUID NOTE 2 EN BRAKE PADS WEAR 93 BRAKE SYSTEM 90 CLUTCH SYSTEM NOTE 5 62 CONTROL CABLES LL 105 EXHAUST PIPE MUFFLER 100 SUSPENSION 85 86 SWINGARM SHOCK LINKAGE L 86 FORK OIL EXCEPT DAMPER NOTE 3 R 87 FORK OIL DAMPER R 115 NUTS BOLTS FASTENERS l 106 150 152 WHEELS TIRES l 94 96 STEERING HEAD BEARINGS 105 WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL This maintenance schedule is based upon average riding condition Machine subjected to severe use require more frequent servicing NOTE 1 Clean after every moto for dusty riding condition 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 6 Replace every year Servicing Your Honda 25 D 001 027 qxd 11 4 18 10 14 726 General Competition Maint
160. pper cable 10 fuel tank 10 Check for interference between the frame and tank and adjust the cushion rubbers 12 if necessary 2 4 in 60 mm 12 cushion rubbers 028 043 qxd 11 4 18 10 15 3735 Installation 1 Install the fuel feed hose 1 to the clamp 2 if it is removed 1 fuel feed hose 2 clamp 2 Install the fuel tank 3 on the frame 3 Install the collar and fuel tank bolt 4 4 Hook the fuel tank band 5 3 fuel tank 4 collar and fuel tank bolt 5 fuel tank band S 5 Put the breather tube 6 in the steering stem nut 7 6 Remove the hose clamp 8 from the breather tube 6 breather tube 8 hose clamp 7 steering stem nut 7 Install the shrouds 9 by aligning shroud tabs Gr with the air cleaner housing cover tabs 9 shrouds 10 shroud tabs 11 air cleaner housing cover tabs 12 shroud B bolts 13 collars and shroud A bolts ae 8 Fuel Tank Install the shroud B bolts 12 collars and shroud A bolts 13 Tighten the shroud B bolts to the specified torque 3 7 lbf ft 5 N m 0 5 kgf m Install the seat page 33 Servicing Your Honda 35 028 043 qxd 11 4 18 10 15 736 an Subframe Refer to Safety Precautions on page 23 4 Remove the muffler mounting A bolt 6 6 Remove the ECM mounting rubber 12 from muffler mounting B bolt 7 washer A 8 the ECM bracket 13 Removal washer B 9 and
161. r often to ensure the greatest service life Frequent oil changes will also assure consistent engine power and response page 50 Transmission Oil Air cleaner Housing Sealing Drain and replace the transmission oil often to ensure the Remove and reseal the air cleaner housing boot where it greatest service life of the transmission and clutch Frequent connects to the air cleaner housing with Pro Honda Handgrip changes will also assure consistent shifting and clutch Cement or an equivalent if there is any doubt to its sealing performance page 53 integrity Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration Servicing Your Honda 27 028 043 qxd 11 4 18 10 15 7728 S General Competition Maintenance Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Use urea based multi purpose grease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent Fork Oil Performance Disassemble clean and inspect the front fork and replace 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 Use only HP Fo
162. r 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 Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability 24 Servicing Your Honda oe Perform the pre ride inspection page 13 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 1 Clean after every moto for dusty riding condition 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 6 Replace every year Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary clean adjust lubricate replace JTP D 001 027 qxd 11 4 18 10 14 N25 S Perform the Pre ride Inspection page 13 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean A Adjust L Lubricate R Replace Maintenance Schedule FREQUENCY Each race Every 3 races Every 6 races Every 9 races Every 12 races NOTE or about or about or about or about or about Ref Page 2 5 hours 7 5 hours 15 0 hours 22 5 h
163. race sag V LOADED MEASUREMENT 8 without rider EXAMPLE 21 6 in 550 mm Example Unloaded 23 6 in 600 mm Loaded 21 7 in 550 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 less than 0 4 in 10 mm from its own weight the spring is too stiff for your weight It is not compressed enough reduce the spring pre load or replace the shock spring with a softer spring 128 Adjustments for Competition S 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 rear shock 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
164. ration or cracks in the hoses and fittings Brakes Servicing Your Honda 91 D 088 102 qxd 11 4 18 10 27 0 Brakes Adding Front Brake Fluid NOTICE Spilled brake fluid will severely damage the painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first e Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid as they may not be compatible e The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent 1 screws 2 reservoir cap 3 diaphragm 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 0 N m 0 1 kgf m 92 Servicing Your Honda S Adding Rear Brake Fluid NOTICE Spilled brake fluid will severely damage the painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first e Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid as they may not be compatible e The recommended brake fluid is Pro Honda DO
165. ring 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 make the adjustment with the lower adjuster W Ne Throttle Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the throttle body Itis also used if you cannot get the proper adjustment with the upper adjuster increase decrease 5 lock nut 6 lower adjuster 1 Loosen the lock nut 5 2 Turn the lower adjuster 6 in direction to decrease freeplay and in direction to increase freeplay 3 Tighten the lock nut to the specified torque 3 0 Ibf ft 4 N m 0 4 kgf m 4 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your dealer Servicing Your Honda 59 048 067 qxd 11 4 18 10 21 60 Throttle Throttle Inspection 1 Check that the throttle assembly is positioned properly the end of the throttle housing 1 is aligned with the paint mark 2 on the handlebar and the securing bolts are tight 1 1 throttle housing 2 paint mark 2 Check for smooth rotation of the throttle 3 from fully open to fully closed in all steering positions If there is a problem see your d
166. rk Be sure the oil capacity is the same in both fork legs Standard oil 12 8 US oz capacity 377 cms Maximum oil 13 0 US oz Slightly stiffer as capacity 385 cm3 it nears full compression Minimum oil 10 2 US oz Slightly softer as capacity 301 cms it nears full compression D 088 102 qxd 11 4 18 10 27 e 89 a Suspension 6 Check that the O ring 8 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 1 outer tube 2 fork damper 7 Temporarily install the fork damper to the outer tube 1 After installing the fork leg page 112 tighten the fork damper to the specified torque Actual 25 Ibf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 500 mm long torque wrench When using the lock nut wrench use a 20 in 500 mm long deflecting beam 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 Servicing Your Honda 89 D 088 102 qxd 11 4 18 10 27 790 Brakes Refer to Safety Precautions on page 23 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 th
167. rk Oil SS 19 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 program 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 94 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 Pro Honda Hondalock or an equivalent and tighten to the specified torque 28 Servicing Your Honda pE EA N Gaskets Always use new gaskets when reassembling components Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are extremely tight so it s important to keep these dowels absolutely clean pages 76 79 Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torqu
168. rn or damaged suspension components compression damping adjustments in one click f f may adversely affect the handling and stability of increments Adjusting two or more clicks at your CRF If any suspension components appear a time may cause you to pass over the best worn or damaged see your dealer for further adjustment Test ride after each adjustment inspection Your dealer is qualified to determine e If you become confused about adjustment whether or not replacement parts or repairs are settings return to the standard position and needed start over e If the fork is still too stiff soft after adjusting 3 compression damping determine which Front Suspension Inspection portion of the travel is still too stiff soft This ay wearin is an important step that will help you solve g e When your CRF is new break it in for suspension problems approximately 1 hour to ensure that the suspension has worked in page 19 1 Make sure that the fork protectors 1 and dust e After break in test run your CRF with the E are clean and not packed with mud and dirt 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 hours See page 112 for fork disassembly Replace the fork oil every 3 races or 7 5 hours of running See page 87 for oil capacity adjustment after changing the fork oil Replace the damper fork oil ever
169. roblem 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 22 Servicing Your Honda D 001 027 qxd 11 4 18 10 14 723 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 procedures and precautions in this owner s 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 adequate 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 S 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 an optional workstand or a
170. s weight Example Turn the compression damping adjuster to a stiffer setting Install the optional stiff spring Adjustments for Too Soft Stiff Damping Symptom Action Soft Initial travel too soft Test stiffer compression damping adjustments in one click increments suspension e Steering is too quick Test stiffer rebound damping in one click increments e Front end darts while cornering or riding in a straight line Middle travel too soft If suspension isn t stiff in initial travel e Front end dives when cornering 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 If that doesn t solve the problem install the optional stiff spring Final travel too soft If initial and middle travel aren t stiff Bottoms on landings Test stiffer compression damping adjustments in one click increments e Bottoms on large bumps especially downhill bumps If initial and middle travel are stiff Install the optional stiff spring If initial travel is stiff after installing the optional stiff spring Test softer compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adj
171. 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 Injector side Fuel Pump side 9 retainer tabs 10 locking pawls 42 Servicing Your Honda oe 9 To prevent damage and keep foreign matter out cover the disconnected connectors 11 and fuel joints 12 with plastic bags 13 11 e 13 GC AS 11 disconnected connector 12 fuel joint 13 plastic bags Connection 1 1 retainer new 2 connector Insert a new retainer 1 into the connector 2 by aligning its locking pawls 3 with the connector grooves 4 e Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected e If the joint rubber is damaged or cut replace it with a new one e Do not bend or twist the fuel feed hose e If any retainer needs replacing use the same manufacture s retainer as the ones being removed The various manufacture s feature different retainer specification Align 3 locking pawls 4 connector grooves 028 043 qxd 11 4 18 10 15 3743 S 2 Install the joint rubber 5 and seat it onto the 3 Make sure the connection is secure and that fuel joint as shown Align the fuel quick the pawls are firmly locked into place check connect fitting with the fuel joint Then press visually and by pulling the connector the quick fi
172. sing 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 To remove mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well with clean water Dry with a chamois or a soft towel If necessary remove heat stains by using a commercially available fine texture compound Then rinse by the same manner as removing mud or dust D 109 133 qxd 11 4 18 10 31 108 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 an
173. stment return to the standard position and begin again S 1 Unlock the number plate tab 1 from the handlebar pad Remove the bolts 2 and number plate 3 1 number plate tab 2 bolts 3 number plate 2 Check the steering damper 4 for deformation or oil leaks Check the damper rod 5 for bending or damage Replace the damper case or damper rod if there is any abnormarity Refer to the Honda Service Manual or see your Honda dealer for steering damper disassembly Check the torque of the steering damper mounting bolts 6 15 Ibf ft 20 N m 2 0 kgf m 4 steering damper 5 damper rod 6 steering damper mounting bolts BEEN Steering Damper 3 With your CRF on a box or an optional workstand front wheel elevated check that the steering moves smoothly from side to side 4 Install the number plate 3 by aligning its holes 7 with the tabs 8 on the steering stem Install and tighten the bolts 2 securely Route the number plate tab 1 around the handlebar pad 9 as shown 1 number plate tab 7 holes 2 bolts 8 tabs 3 number plate 9 handlebar pad Servicing Your Honda 103 103 108 qxd 11 4 18 10 29 104 Steering Damper Removal 1 Remove the number plate page 103 2 Remove the steering damper mounting bolts 1 collar 2 and steering damper 3 d i E 1 steering damper mounting bolts 2 collar 3 steering damper
174. t rapidly in an enclosed area and cause illness or death 16 Basic Operating Instructions D 001 027 qxd 11 4 18 10 14 Y17 Always follow the proper starting procedure described below Your CRF can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Fast Idle Knob The fast idle knob has two functions e When pulled out the fast idle knob assists in first time start up for cold weather starting e When pushed in it acts as an idle adjustment screw Refer to Idle Speed Adjustment on page 61 Preparation Make sure that the transmission is in neutral S Starting Procedure Always follow the proper starting procedure described as follows Check the engine oil transmission oil and coolant levels before starting the engine pages 50 53 54 Cold Engine Starting 1 Shift the transmission into neutral 2 If the temperature is 95 F 35 C or below pull the fast idle knob 1 fully out 1 fast idle knob 3 With the throttle closed operate the kickstarter starting from the top of the kickstarter stroke and kick through to the bottom with a rapid continuous motion 4 About a minute after the engine starts push the fast idle knob back all the way to fully OFF If idling is unstable open the throttle slightly Starting amp Stopping the Engine Warm Engine Starting 1 Shift the transmission into neutral 2 Kick start t
175. 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 D 109 133 qxd 11 4 18 10 31 1129 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
176. 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 events 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 ad 142 170 qxd 11 4 18 10 35 WY 155 E Competition Logbook Date Running Location Event Comments Suspension Settings Steering Damper Settings Gearing Chassis Adjustments Time Maintenance Performed etc
177. tion 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 brake disc Take care to prevent catching your fingers between the chain and sprocket Remove the drive chain clean and lubricate it Be sure the chain is wiped clean and is dry before lubricating it 028 043 qxd 11 4 18 10 15 Y31 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 off 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 107 S Before amp After Competition Maintenance Servicing Your Honda 31
178. topper 20 10 Install the fuel pump unit 24 into the fuel cable guide 32 and fuel pump mounting Push the wire terminals until they stops as tank 25 bolts 33 shown 13 Install the fuel tank Be careful not to damage the wires Be careful not to damage the wires Make sure that the convex surface of the conical 25 23 24 spring washers are upside 8 Apply 0 5 g maximum of engine oil to a new O ring 21 Install a new O ring onto the fuel pump unit 22 18 Bes AN 23 O ring new 25 fuel tank 28 conical spring washers At 24 fuel pump unit 29 collars 21 __ lt 30 washers 11 Install the fuel pump plate 26 with its 31 stopper cable See 32 stopper cable guide identification mark 27 facing toward the 33 fuel pump mounting bolts front side and facing up 14 Tighten the fuel pump mounting bolts to the specified torque in the specified sequence as shown 8 Ibf ft 11 N m 1 1 kgf m red wire terminal black wire terminal 18 26 19 20 fuel pump base terminals 21 22 O ring new 26 fuel pump plate 27 identification mark fuel pump unit 15 Connect the fuel line page 42 16 Increase the fuel pressure page 48 Servicing Your Honda 47 BEEN 048 067 qxd 11 4 18 10 21 748 Fuel System Fuel Pressure Increasing Make sure the fuel remains enough 0 3 US gal 1 0 minimum in the fuel tank and add fuel if
179. tor Co Inc P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 939 0909 Please include the following information in your letter e name address and telephone number e product model year and VIN e date of purchase e dealer name and address We will likely ask your dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 161 142 170 qxd 11 4 18 10 35 N 7162 Your Dealer Once you purchase your new Honda get familiar with the organization of your 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 Honda Genuine Parts Pro Honda products and Honda Genuine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department 162 Consumer Information S Your dealer can inform you about competition events in your area as well as provide you with information about the Honda Rider
180. tting onto the pipe of the fuel joint 4 Make sure the joint rubber 5 is in place between the flange 6 and retainer tab 7 until both retainer pawls lock with a click If it is hard to connect put a small amount of engine oil on the pipe end 5 joint rubber injector side only 6 flange 7 retainer tab 5 joint rubber injector side only 5 Install the rubber 8 clamp 9 and bolt 10 by aligning the clamp tab 11 with the groove 12 of the stay 8 rubber 11 clamp tab ao ES 12 groove o BEEN Fuel System 6 Install the fuel quick connect fitting cover 13 and set the rubber cover tab 14 to the hole 15 of the fuel quick connect fitting cover Be sure the rubber cover 16 is properly installed between the fuel quick connect fitting cover and fuel pump 13 fuel quick connect fitting cover 14 rubber cover tab 15 fuel quick connect fitting cover hole 16 rubber cover 7 Install the fuel tank page 35 8 Increase the fuel pressure page 48 Servicing Your Honda 43 044 047 qxd 11 4 18 10 20 3744 Fuel System Fuel Pump Filter Replacement Empty the fuel tank into an approved gasoline container using a commercially available hand siphon or an equivalent method Be careful not to damage the fuel pump while draining the fuel in the fuel tank A WARNING Gasoline is highly flammable and explosive Yo
181. u 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 44 Servicing Your Honda S Removal 1 Relieve the fuel pressure page 41 2 Disconnect the fuel line page 41 3 Remove the fuel pump mounting bolts 1 stopper cable guide 2 stopper cable 3 washers 4 collars 5 conical spring washers 6 and fuel pump plate 7 while holding the fuel tank 4 Remove the fuel tank Be careful not to drop the fuel tank when removing the stopper cable 1 fuel pump mounting bolts 2 stopper cable guide 3 stopper cable 4 washers 5 collars 6 conical spring washers 7 fuel pump plate ae 5 Remove the fuel pump unit 8 and O rings 9 Be careful not to damage the fuel pump unit 8 fuel pump unit 9 O rings 6 Disconnect the fuel pump wire terminals 10 from the fuel pump base 11 Be careful not to damage the wires when disconnecting the fuel pump wire terminals lt 10 11 10 fuel pump wire terminals 11 fuel pump base 044 047 qxd 11 4 18 10 20 3745 an Fuel System 7 Check the hooks 12 of the fuel pump unit 9 Remove the fuel pump unit holder assembly 11 Remove the fuel pump assembly 19 with holder and tabs 13 on the fuel pump base for 15 from the fuel pump base 11 and remove fuel pump filter 20 O
182. ustable 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 motorcycle purchased from your dealer e Lock Nut Wrench e Spoke Wrench O07WMA KZ30100 O7JMA MR60100 070MA KZ30100 070MG 0010100 07AMG 001A100 USA only 07958 2500001 07AMB KZ3A100 USA only You can purchase a PGM FI Setting Tool for your CRF from your dealer e Tensioner Stopper e Piston Base e Fork Rod Holder a Spare Parts amp Equipment e PGM FI Setting Tool 06380 N1D 670 Chemical Products Pro Honda GN4 4 stroke Oil Engine and Transmission Oil SAE80 or 90 gear oil HP Fork Oil SS 19 Pro Honda DOT4 Brake Fluid Pro Honda HP Chain Lube Pro Honda Foam Filter Oil Pro Honda Hondabrite Pro Honda Dielectric Grease Pro Honda Handgrip Cement Pro Honda Hondalock Molybdenum Disulfide grease containing more than 3 molybdenum disulfide additive Pro Honda White Lithium Grease Multi purpose Grease Rust inhibiting Oil Cable lubricant Pro Honda HP Coolant Urea based multi purpose grease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape Scotch
183. ustments 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 US oz 5 cm Entire travel too soft Install the optional stiff spring e Front end shakes Test stiffer compression damping adjustments in one click increments e Fork bottoms over any type of terrain Increase rebound damping in one click increments 130 Adjustments for Competition D 109 133 qxd 11 4 18 10 31 AV 131 SS Suspension Adjustment Guidelin es 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 adjustments 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 after the above adjustment 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 Mi
184. wet loamy terrain but less impressive grip on a hard surface 138 Adjustments for Competition 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 affect 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 134 141 qxd 11 4 18 10 34 L The following suggestions may make your ride both more comfortable and more responsive to your
185. y Optional Stiffer 26 20 Ibf in 4 59 N mm Fork Spring Standard 25 12 Ibf in 4 4 N mm Fork Spring Oe 2 scribe marks 17 Pull up the fork assembly 1 slowly and Ch No mark install the fork damper assembly 5 into the outer tube Standard oil 12 6 US oz Standard oil 12 7 US oz capacity 372 cm3 capacity 375 cms Maximum oil 128 US os Slightly stiffer as Maximum oil 12 9US oz Slightly stiffer as capacity 380 cm3 it nears full capacity 382 cm3 it nears full compression compression Minimum oil 10 0 US oz Slightly softer as Minimum oil 10 1 US oz Slightly softer as capacity 296 cm8 it nears full capacity 299 cm3 it nears full compression compression Be sure the oil capacity is the same in both fork Optional Softer 23 98 Ibf in 4 2 N mm Fork Spring legs 1 scribe mark 15 O ring new 1 fork assembly 5 fork damper assembly 18 Insert both fork legs into the fork clamps Standard oil 12 8 US oz Tighten the fork bridge lower pinch bolts 16 capacity 377 cm to the specified torque Maximum oil 13 0 US oz Slightly stiffer as 15 Ibf ft 20 N m 2 0 kgf m capacity 385 cm3 it nears full compression Minimum oil 10 2 US oz Slightly softer as capacity 301 cm3 it nears full compression 16 fork bridge lower pinch bolts contd Adjustments for Competition 121 109 133 qxd 11 4 18 10 31 17122 D
186. y 9 races or 22 5 hours of running See page 115 for damper fork oil level adjustment after changing the fork oil Use HP Fork Oil SS 19 or an equivalent which contains special additives to assure maximum performance of your CRF s front 2 Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CRF is ridden 3 wear rings 5 end gaps 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times suspension 1 fork protector 2 dust seal e Periodically check and clean all front suspension parts to assure top performance 3 Inspect the wear rings 3 for wear or damage Check the dust seals for dust dirt and foreign Replace the wear ring if it is 0 06 in 1 5 mm materials Check the oil for any or flat with the outer tube 4 contamination When replacing the wear ring remove the fork leg page 112 Install the wear ring with its end gap 5 facing rearward Servicing Your Honda 85 ae D 068 087 qxd 11 4 18 10 24 86 Suspension Rear Suspension Inspection 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 pre load and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page
187. y Precautions on page 23 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 Clutch Lever Freeplay turns Clutch Lever Adjustment The distance between the tip of the clutch lever and grip may be adjusted Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected 1 freeplay 3 cable end adjuster increase freeplay Inspection decrease freeplay Check freeplay 1 Freeplay 3 8 13 16 in 10 20 mm 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever If necessary adjust to the specified range 1 lock nut 2 adjuster freeplay 3 8 3 13 16 in 10 20 mm at the Improper freeplay adjustment can cause tip of lever Tighten the lock nut premature clutch wear 1 Loosen the lock nut 1 2 To position the clutch lever farther away from the handgrip turn the adjuster 2 counterclockwise To position the brake lever closer to the handgrip turn the adjuster clockwise 3 Tighten the lock nut Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected lock nut integral cable adjuster increase freeplay decrease freeplay 6 Adjust the cable end adjuster for minor adjustement 62 Servicing Your Honda a 048 067 qxd 11 4 18 10 21 1763 Cable End Adjustment Minor adjustments
188. 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 Tires amp Tubes 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 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 a replacement tube equivalent to the original Servicing Your Honda 95 088 102 qxd 11 4 18 10 27 796 D Tires amp Tubes Tire Replacement The tires that came on your CRF were designed to provide a good combination of handling braking durability and
189. ype 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 US oz 5 cm Adjustments for Competition 131 D 109 133 qxd 11 4 18 10 31 Suspension Adjustment Guidelines EE Rear Suspension Adjustment Adjustments for Type of Track 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 pre load 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 adjusters 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 adjusters in one click increments and the high speed compression 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

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