Home

Honda CRF250R 2007 Owner`s Manual

Contents

1. 36 Transmission Oil 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 54 Spark Plug 55 Valve Clearance 56 Piston Piston Rings Piston Pin 64 Chassis Suspension 72 Front Suspension Inspection 72 Rear Suspension Inspection 73 Fork Oil Change 74 Brakes 77 Wheels 81 Tires amp Tubes 82 Drive Chain 84 Exhaust Pipe Muffler 87 Additional Maintenance Procedures 91 Appea
2. 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 54 Spark Plug 55 Valve Clearance 56 Piston Piston Rings Piston Pin 64 Chassis Suspension 72 Front Suspension Inspection 72 Rear Suspension Inspection 73 Fork Oil Change 74 Brakes 77 Wheels 81 Tires amp Tubes 82 Drive Chain 84 Exhaust Pipe Muffler 87 Additional Maintenance Procedures 91 Appearance Care
3. 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 54 Spark Plug 55 Valve Clearance 56 Piston Piston Rings Piston Pin 64 Chassis Suspension 72 Brakes 77 Wheels 81 Tires amp Tubes 82 Drive Chain 84 Exhaust Pipe Muffler 87 Additional Maintenance Procedures 91 Appearance Care 93 ADJUSTMENTS FOR COMPETITION 95 Front Suspension Adjustments 96 Rear Suspension Adjustments 109 Suspension Adjustments for Track Conditions 113 Suspension Adjustment Guidelines 114 Carburetor Adjustments amp Tuning Tips 117 Chassis Adjustments 129 Gearing
4. 13 troubleshooting 137 steering stem inspection 91 stopping engine 14 storage 135 subframe 32 S R P O M L I H G 134 160 qxd 06 6 15 14 49 158 Index 159 Index suspension front 72 96 rear 73 109 suspension adjustment front 96 rear 109 for track conditions 113 guidelines 114 transmission oil 39 tuning tips 117 throttle freeplay 46 inspection 47 tires air pressure 82 flat 82 selection 83 tools
5. 145 Competition Logbook 146 Optional Parts List 148 Spare Parts amp Equipment 149 Wiring Diagram 150 134 160 qxd 06 6 15 14 49 139 Vehicle Identification 140 Technical Information Serial Numbers The VIN and engine serial numbers are required when you register your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head RIGHT SIDE 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 1 2 134 160 qxd 06 6 16 12 00 140 Specifications Technical Information 141 Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Item English 85 5 in 32 6 in 50 3 in 58 2 in 38 0 in 17 6 in 14 2 in Metric Type Dimension Frame F suspension R suspension Front tire Twin tube Telescopic fork travel 11 0 in 279 mm stroke 12 4 in 315 mm Pro link travel 12 3 in 313 mm 80 100 21 51M DUNLOP D742FA Rear tire 100 90 19 57M DUNLOP 15 psi 100 kPa 1 0 kgf cm2 T
6. 34 starting 13 stop button 14 stopping 14 won t start 137 environment protecting 136 filter air 43 oil 37 flooded engine starting 13 fork front suspension adjustment 96 front suspension inspection 72 oil recommendation 74 front brake lever adjustment 77 front suspension maintenance 97 fuel line 34 filter 35 recommendation 34 refueling 34 system 34 oxygenated 145 tank capacity 34 valve 13 F E D C B A Index 134 160 qxd 0
7. 149 torque specifications 142 144 transporting 134 troubleshooting 137 tubes replacing 82 valve fuel 13 vehicle identification no VIN 140 washing your motorcycle 93 wheels 81 wiring diagram 150 W V T 134 160 qxd 06 6 15 14 49 159 The maintenance schedule page 21 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 Maintenance Check the items listed on the Pre ride inspection checklist each time before you ride page 9 unleaded gasoline pump octane number of 91 or higher tank 1 9 US gal 7 3R Pro Honda GN4 4 stroke oil or an equivalent Pro Honda GN4 4 stroke oil or an equivalent Pre ride Inspection Fuel tank Capacity Engine oil Transmission oil Record important information here VIN Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr
8. 18 safety 19 schedule 20 manual service 152 modifications 3 oil engine 36 fork 74 transmission 39 operating controls 5 instructions 11 operation component locations 6 optional parts list 148 sprockets 130 oxygenated fuels 145 pads brake 80 parts optional 148 personal fit adjustments 132 pinging engine 34 plug spark 55 pre load rear suspension 109 pre ride inspection 9 protective apparel 2 rea
9. 153 Your Honda Dealer 154 The Honda Rider s Club 155 Consumer Information 151 Consumer Information 134 160 qxd 06 6 15 14 49 151 152 Consumer Information The Service Manual used by your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form Authorized Manuals S H I P T O NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation Customer
10. 9 Pre ride Inspection 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions 12 Starting amp Stopping the Engine 13 Preparation 13 Starting Procedure 13 Flooded Engine 13 How to Stop the Engine 14 Break in Guidelines 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat Removal 29 Fuel Tank Removal 30 Subframe Removal 32 Service Procedures Fluids amp Filters Fuel System 34 Engine Oil
11. 130 Tire Selection for Track Conditions 131 Personal Fit Adjustments 132 TIPS 133 Transporting Your Motorcycle 134 Storing Your Honda 135 You amp the Environment 136 Troubleshooting 137 TECHNICAL INFORMATION 139 Vehicle Identification 140 Specifications 141 Torque Specifications 142 Oxygenated Fuels 145 Competition Logbook 146 Optional Parts List 148 Spare Parts amp Equipment 149 Wiring Diagram 150 CONSUMER INFORMATION 151 Authorized Manuals 152 Contacting Honda 153 Your Honda Dealer 154 The Honda Rider s Club 155 TABLE OF CONTENTS 156 INDEX 157 QUICK REFERENCE Contents Content
12. 149 Wiring Diagram 150 CONSUMER INFORMATION 151 Authorized Manuals 152 Contacting Honda 153 Your Honda Dealer 154 The Honda Rider s Club 155 TABLE OF CONTENTS 156 INDEX 157 QUICK REFERENCE 134 160 qxd 06 6 15 14 49 156 Index 157 accessories 3 adjustments altitude and temperature 124 carburetor 117 chassis 129 control freeplay 46 49 54 77 engine idle speed 48 for competition 95 gearing 130 personal fit 132 suspension front 96 suspension rear 109 suspension track conditions 113 tire selection 131 after competition maintenance 26 air clea
13. 118 Adjustments for Competition 119 Carburetor Adjustments amp Tuning Tips Carburetor Circuit Functions The carburetor has several major circuits each providing the fuel air mixture over a given portion of throttle valve opening These major circuits overlap as shown below Leak Jet The smaller the number the smaller the jet bore diameter This controls the amount of fuel returned to the float chamber under pressure therefore the flow amount is increased or decreased With a small jet pressure is raised faster and the elapsed time before the fuel starts flowing is shorter Carburetor Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by loosening the drain screw 1 1 drain screw 3 Tighten the drain screw 2 1 1st 2nd 3rd 4th 5th LEANER RICHER 1 Jet Needle The jet needle controls fuel air mixture over fully closed to 3 4 throttle The straight section 1 affects throttle response at smaller throttle openings By changing the position of the clip 2 in its groove you can improve acceleration at medium low and medium speed Main jet The main jet affects fuel air ratio from half 1 2 to full throttle 4 4 The size should be reduced at higher altitudes Honda carburetor jet sizes are numbered in increments of 2 or 3 When changing the main jet size increase or decrease it gradually until the desired jetting is obtained Because Honda
14. Front 15 psi 100 kPa 1 0kgf cm2 Rear 15 psi 100 kPa 1 0kgf cm2 standard R0409B 8 NGK optional R0409B 9 NGK D I D 520DMA2 114 Tires Tire Pressure cold Spark ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or equivalent distilled water Coolant Plug Drive Chain link Front Type bias ply tube 80 100 21 51M DUNLOP D742FA Rear 100 90 19 57M DUNLOP D756 Quick Reference 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 component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are Transmission oil amp engine oil insufficient quantity improper oil Air cleaner dirty leaking because of improper installation poor seal 134 160 qxd 06 6 16 8 47 160
15. 118 133 qxd 06 6 15 14 47 132 Tips Tips 133 Here s helpful advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 134 Storing Your Honda 135 You amp the Environment 136 Troubleshooting 137 118 133 qxd 06 6 15 14 47 133 Transporting Your Motorcycle 134 Tips If you use a truck or motorcycle trailer to transport your Honda we recommend that you follow these guidelines Use a loading ramp Make sure the fuel valve is off 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 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 tha
16. 2 795 mm 60 80 Leak jet Standard 70 CARBURETOR Remarks Main jet Standard 175 Slow jet Standard 42 165 185 in increments of 2 or 3 38 48 in increments of 2 or 3 Jet Needle Standard needle NKBT Straight diameter 2 775 mm Jet needle number standard series FRAME Remarks Driven sprocket Standard Driven chain size link D I D 520DMA2 120RB lt gt Drive chain links 51 Teeth Aluminum lt 114 gt Optional Optional 50 Teeth Aluminum lt 114 gt 52 Teeth Aluminum lt 114 gt Handlebar lower holder Standard 3 mm offset no offset General flow characteristics Leaner Richer at 1 16 to 1 4 throttle 175 TOOLS Remarks Pin spanner A Air gauge For checking tire air pressure Workstand To adjust spring preload two spanners required For maintenance Blue White 308 0 lbf in 5 50 kgf mm 319 2 lbf in 5 70 kgf mm Red Pink These parts and tools may be ordered from your authorized Honda dealer 1 scribe mark aftermarket parts 3 scribe marks 1 scribe mark and 3 scribe marks 75 degrees apart Size Jet needle number Straight diameter 2 775 mm Optional Parts List 134 160 qxd 06 6 15 14 49 148 Technical Information 149 Spare Parts amp Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding In addition to the usual nuts and bol
17. 4 hot start cable holder 10 Disconnect the rear suspension 5 upper mounting nut and bolt 6 5 rear suspension 6 upper mounting nut bolt 11 Remove the throttle drum cover bolt 7 and throttle drum cover 8 7 throttle drum cover bolt 8 throttle drum cover 12 Loosen the lock nut 9 adjusters 10 and disconnect the throttle cables 11 from the throttle drum 12 9 lock nut 11 throttle cables 10 adjusters 12 throttle drum 2 3 4 6 5 7 8 10 11 9 12 118 133 qxd 06 6 15 14 46 120 Carburetor Adjustments amp Tuning Tips Adjustments for Competition 121 Carburetor Disassembly Assembly 1 Pull up the cable clamp 1 and remove the carburetor top bolts 2 Then remove the carburetor top 3 1 cable clamp 2 carburetor top bolts 3 carburetor top 2 Remove the jet needle holder assembly 4 from the throttle valve 5 4 jet needle holder assembly 5 throttle valve 3 Remove the link arm torx screw 6 When installing the link arm torx screw apply a locking agent to the link arm torx screw threads 4 Remove the throttle valve 7 throttle valve roller 8 and floating valve 9 6 link arm torx screw 8 throttle valve roller 7 throttle valve 9 floating valve When installing the floating valve 9 onto the throttle valve 7 make sure the floating valve s flat side faces out and the hole 10 faces
18. 6 8 12 13 6 carburetor top bolts 7 carburetor top 9 clip 10 jet needle holder 11 jet needle 18 Remove the clip 9 and jet needle 11 from the jet needle holder 10 Change the jet needle clip position or jet needle as required 9 11 10 118 133 qxd 06 6 15 14 47 127 Carburetor Adjustments amp Tuning Tips 128 Adjustments for Competition Spark Plug Reading Refer to Spark Plug on page 55 Check any jetting change by reading the spark plug 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 Using spark plugs with an improper heat range or incorrect reach can cause engine damage Before removing the spark plug clean the spark plug area thoroughly to prevent dirt from entering the cylinder Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately To obtain an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Push the engine stop button and pull the clutch lever in to release the clutch 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 ex
19. Use the recommended oil 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 Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range NOT RECOMMENDED OK 024 054 qxd 06 6 15 14 31 36 Servicing Your Honda 37 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 1 code number of the sales company of the oil 2 oil classification Checking amp Adding Oil 1 engine oil filler cap dipstick 2 upper level mark 3 lower level mark 1 Run the engine at idle for 3 minutes then shut it off 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine 3 Support the CRF in an upright position on a level surface 4 Remove the engine oil filler cap dipstick 1 wipe it clean and insert the engine oil filler cap dipstick without screwing it in Remove the engine oil filler cap dipstick 5 Check that the oil level is between the upper 2 and lower 3 level marks on the engine oil filler cap dipstick If the oil is at or near the upper level mark
20. 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hours of running Piston Ring Removal Spread each piston ring 1 and remove by lifting it up at a point just opposite the gap Do not damage the piston ring by spreading the ends too far NOTICE 2 1 4 3 3 2 1 1 piston pin clip 3 piston 2 piston pin 1 1 piston ring 055 073 qxd 06 6 15 14 35 66 Servicing Your Honda 67 Piston Piston Rings Piston Pin Piston Ring Installation 1 Clean the piston ring thoroughly 2 Apply engine oil to piston rings and install them Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation To install the oil ring install the spacer first then install the side rails Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring mark top ring oil ring side rail side rail spacer Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your Hond
21. 4 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 5 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover bolts 4 Connect the direct ignition coil 7 and breather tube 8 7 direct ignition coil 8 breather tube 5 Install the fuel tank and the seat pages 29 31 19 20 2 1 4 3 5 6 7 8 055 073 qxd 06 6 15 14 35 63 64 Servicing Your Honda 12 Remove the engine hanger nuts bolts 3 and engine hanger plates 4 3 engine hanger nuts bolts 4 engine hanger plates 4 3 Piston Piston Rings Piston Pin Cylinder Head Removal 1 Clean the area above the engine before disassembly to prevent dirt falling into the engine 2 Drain the engine oil page 37 3 Drain the radiator coolant after cooling the motorcycle page 42 4 Remove the seat and fuel tank pages 29 30 5 Remove the subframe page 32 6 Remove the carburetor page 119 7 Remove the exhaust pipe page 90 8 Disconnect the spark plug page 55 9 Remove the cylinder head cover page 56 10 Position the piston at top dead center on the compression stroke page 56 Remove the camshaft page 58 11 Loosen the water hose clamp 1 and disconnect the water hose 2 1 water hose clamp 2 water hose 2 1 055 073 qxd
22. 49 Clutch System Refer to Safety Precautions on page 19 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 lock nut 2 adjuster 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 3 cable end adjuster increase freeplay decrease freeplay 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 13 16 in 10 20 mm at the tip of lever Tighten the lock nut 1 2 3 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns 4 5 4 lock nut 5 integral cable adjuster increase freeplay decrease freeplay 6 Adjust the cable end adjuster for minor adjustement Clutch Lever Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear 1 024 054 qxd 06 6 15 14 31 49 Other Inspections amp Lubrication Check that the
23. Installation can be done in the reverse order of removal Exhaust Pipe Removal 1 Remove the muffler page 87 2 Remove the exhaust joint pipe page 89 3 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and old gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket old 2 1 3 1 2 3 074 094 qxd 06 6 15 14 38 90 Servicing Your Honda 91 Servicing Your Honda 91 Additional Maintenance Procedures Refer to Safety Precautions on page 19 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 Handlebar Inspection 1 Remove the handlebar pad 2 Check the handlebar 1 for bends or cracks 3 Check that the handlebar has not moved from its proper position by inspecting the paint mark 3 4 Check the torque of the upper holder 2 bolts 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first 1 handlebar 2 handlebar upper holders 3 paint mark Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable Be sure the throttle returns freely from fully open to fully closed automatica
24. 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 an index at the back of the book As you read this manual you will find information that is preceded by a sy
25. NOTE 1 1 U nut 2 UBS nut 3 Apply oil to the threads and flange surface 4 Alock bolt 5 Apply locking agent to the threads NOTES 37 38 Driven sprocket nuts Seat mounting bolts 24 19 32 26 3 3 2 7 Exhaust joint pipe mounting bolt 35 19 26 2 7 Exhaust joint pipe clamp bolt 36 15 21 2 1 Frame 27 26 26 30 28 37 34 38 31 23 44 39 41 32 25 21 40 26 27 24 21 38 34 33 22 28 35 36 42 43 134 160 qxd 06 6 15 15 16 144 Technical Information 145 Oxygenated Fuels 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 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 ma
26. cleaner retaining bolt 1 securely 024 054 qxd 06 6 15 14 31 44 Servicing Your Honda 45 Crankcase Breather Refer to Safety Precautions on page 19 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 tube 1 2 024 054 qxd 06 6 15 14 31 45 46 Servicing Your Honda Throttle Refer to Safety Precautions on page 19 Throttle Freeplay 1 freeplay Inspection Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range Upper Adjustment Minor adjustments are generally made with the upper adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you can not get the proper adjustment with the upper adjuster 1 2 4 3 5 lock nut increase 6 lower adjuster decrease 1 Remove the fuel tank page 30 2 Loosen the lock nut 5 3 Turn the lower adjuster 6 in direction to decrease freeplay and in direction to increase freeplay 4 Tighten the l
27. response increases weighting traction on the rear wheel and lightens weighting on the front wheel With your CRF you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits 1 2 3 1 standard position 0 in 0 mm 2 top of outer tube 3 upper fork clamp 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 3 118 133 qxd 06 6 15 14 47 129 Gearing 130 Adjustments for Competition 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 alum
28. track or on similar terrain Your logbook can also tell you when maintenance was performed and when it will be necessary again Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components If you choose to sell your CRF the accurate maintenance records in your logbook might be the deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black jetting changes in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include basic track conditions altitude and temperature carburetion changes suspension settings chassis adjustments tested and selected gearing tire selection air pressure Competition Records your placings thoughts to improve performance next time both yours and your CRF strategy notes Maintenance Records regular interval maintenance repairs running time on engine 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
29. you do not have to add oil Before a race or if the oil level is below or near the lower level mark add the recommended oil until the upper level mark is reached Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil amp Filter 1 Run the engine 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 filler cap dipstick 1 from the left crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the engine oil drain bolt 2 and sealing washer 3 5 With the engine stop button pushed repeat kickstarter operation approximately 5 times to drain the engine oil completely 6 After the oil has drained apply fresh engine oil to the engine oil drain bolt threads 7 Install and tighten the engine oil drain bolt with a new sealing washer to the specified torque 12 lbf ft 16 N m 1 6 kgf m 1 engine oil filler cap dipstick 2 engine oil drain bolt 3 sealing washer 8 It is recommended to replace the oil and filter every 6 races or about every 15 0 hours However if you replace only the oil before the recommended interval see page 21 cont d 2 1 2 1 2 1 3 1 3 2 024 054 qxd 06 6 16 9 03 37 38 Servicing Your Honda Engine Oil 1
30. 06 6 15 14 35 64 Servicing Your Honda 65 Piston Piston Rings Piston Pin 13 Remove the cylinder head bolts 5 14 Loosen the cylinder bolt 6 5 cylinder head bolts 6 cylinder bolt 7 cylinder head nuts washers 8 cylinder head 16 Remove the dowel pins 9 cylinder head gasket 10 and cam chain guide 11 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 9 dowel pins 11 cam chain guide 10 cylinder head gasket 5 6 8 7 9 10 11 15 Remove the cylinder head nuts washers 7 and cylinder head 8 Loosen the nuts in a crisscross pattern in two or three steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase NOTICE 055 073 qxd 06 6 15 14 35 65 66 Servicing Your Honda Piston Piston Rings Piston Pin Cylinder Removal 1 Remove the cylinder bolt 1 and cylinder 2 Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder NOTICE 1 cylinder bolt 2 cylinder 2 Remove the dowel pins 3 and cylinder gasket 4 Do not let the dowel pins fall into the crankcase NOTICE 3 dowel pins 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
31. 1 and clutch plates 2 with clean transmission oil 2 Install the eight clutch discs and seven clutch plates alternately starting with a clutch disc 1 clutch discs 2 clutch plates 3 Apply grease to the clutch lifter rod 3 ends 4 Insert the clutch lifter rod into the mainshaft 5 Apply engine oil to the needle bearing of the clutch lifter 6 Install the clutch lifter 4 onto the clutch lifter rod 3 clutch lifter rod 4 clutch lifter 7 Install the clutch pressure plate 5 8 Install the five clutch springs and clutch spring bolts 6 9 Tighten the bolts in a crisscross pattern in two or three steps to the specified torque 9 lbf ft 12 N m 1 2 kgf m 5 clutch pressure plate 6 clutch spring bolts clutch springs 7 O ring 8 clutch cover 1 1 2 4 3 5 6 8 7 10 Apply transmission oil to a new O ring 7 and install in the groove of the clutch cover 8 11 Install the cover by tightening the five cover bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m 024 054 qxd 06 6 15 14 31 52 Servicing Your Honda 53 Clutch System 9 dust seals 12 washer 10 rear brake pedal 13 brake pedal return spring 11 brake pedal pivot bolt 17 Fill the crankcase with transmission oil page 40 10 13 11 12 9 12 Apply grease to the brake pedal pivot bolt 11 sliding surface 13 Install the dust seals 9 in
32. Name Attention Street Address No P O Box Number Apt City State Zip Code Daytime Telephone Number P A Y M E N T Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Master Card Account Number VISA VISA Discover Check here if your billing address is different from the shipping address shown above Expiration Date Mo Yr Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order HELM P O BOX 07280 DETROIT MI CHIGAN 48207 Item Description Qty Publication Item No Price Each Total Price Sub Total Purchaser s Sales Tax Mich Add 6 Calif Add 8 25 Handling Charge 5 00 Grand Total Prices are subject to change without notice and without incurring obligation Orders are mailed within 10 days Please allow adequate time for delivery Publication Item No Description Price Each 61KRN03 2007 CRF250R Service Manual 48 00 61CM002 Common Service Manual 48 00 31KRN630 2007 CRF250R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation 134 160 qxd 06 6 15 14 49 152 Consumer Information 153 Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not a
33. Servicing Your Honda Subframe Removal Refer to Safety Precautions on page 19 Removal 1 Remove the muffler page 87 2 Remove the exhaust joint pipe page 89 3 Remove the seat page 29 4 Disconnect the crankcase breather tube 1 5 Unhook the fuel tank band 2 6 Unhook the air cleaner cover rubber 3 7 Loosen the screw 4 on the air cleaner connecting tube clamp 5 1 crankcase breather tube 2 fuel tank band 3 air cleaner cover rubber 4 screw 5 air cleaner connecting tube clamp 1 3 2 5 4 8 Remove the subframe lower mounting bolts 6 and subframe upper mounting bolt 7 Then remove the subframe 8 by pulling it straight backward 7 8 6 6 subframe lower mounting bolts 7 subframe upper mounting bolt 8 subframe 024 054 qxd 06 6 15 14 31 32 Servicing Your Honda 33 Subframe Removal 2 Tighten the screw 4 on the air cleaner connecting tube clamp 5 3 Hook the air cleaner cover rubber 6 4 Hook the fuel tank band 7 5 Connect the crankcase breather tube 8 4 screw 5 air cleaner connecting tube clamp 6 air cleaner cover rubber 7 fuel tank band 8 crankcase breather tube 8 6 7 5 4 Installation 1 Loosely attach the upper and lower ends of the subframe 1 to the mainframe while connecting the air cleaner connecting tube to the carburetor Be careful not to bend the subframe Install th
34. Spring Standard oil capacity 12 7 US oz 375 cm3 Maximum oil capacity 14 1 US oz 416 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 8 US oz 320 cm3 1 scribe mark and 3 scribe marks 75 degrees apart Be sure the oil capacity is the same in both fork legs cont d 13 Remove the fork damper from the fork 14 Pour the recommended fork oil 11 into the outer tube slider 1 Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent 095 117 qxd 06 6 15 14 41 105 Front Suspension Adjustments 106 Adjustments for Competition 15 Check that the O ring 12 on the fork damper assembly 4 is in good condition Apply the recommended fork oil to the O ring Pull up the outer tube 1 slowly and install the fork damper assembly 4 into the outer tube 1 outer tube 12 O ring 4 fork damper assembly 16 Insert both fork legs into the fork clamps Tighten the fork brige lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 17 Tighten the fork damper assembly 4 to the specified torque using the lock nut wrench 14 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 50 cm long torque wrench When using the lock nut wrench use a 20 inches long deflecting beam type torque wrench The lock nut wrench increase the torq
35. 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 Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 3 mm using optional handlebar lower holders or 6 mm by rotating the standard holders 180 degrees Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment 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 1 1 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
36. brake bleeding 1 2 074 094 qxd 06 6 15 14 38 78 Servicing Your Honda 79 Brakes Adding Front Brake Fluid 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 Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent NOTICE 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 lbf ft 1 0 N m 0 1 kgf m Adding Rear Brake Fluid 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 Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent NOTICE 5 bolts 8 diaphragm 6 reservoir cap 9 up
37. bumps While braking front end dives during initial travel then feels stiff Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large bumps especially downhill bumps Stiff on large bumps when cornering Entire travel too stiff Stiff suspension on any type of terrain Action 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 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 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 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
38. carefully and don t remove it If the label comes off or becomes hard to read contact your Honda dealer for replacement 001 023 qxd 06 6 15 14 28 4 Operating Controls 5 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 001 023 qxd 06 6 15 14 28 5 6 Operating Controls Operation Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip choke knob fuel valve shift lever kickstarter rear brake pedal 001 023 qxd 06 6 15 14 28 6 Before Riding 7 Before each ride you need to make sure you and your Honda are both ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustment for competition see page 95 Before Riding Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection 9 001 023 qxd 06 6 15 14 28 7 8 Before Riding 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 ope
39. 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 Clutch System 50 Servicing Your Honda 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 increase 4 integral cable adjuster 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 4 Tighten the lock nut Check the adjustment 5 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 If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the Honda Service Manual page 152 3 4 Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster 2 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in direction will increase freeplay and
40. conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth to keep the engine rpm high where the engine produces the most power This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep the front end light so it can float from the peak of one sand whoop to the next Generally with higher gearing it is easier to maintain that perfect attitude maximum rear wheel traction and a light front end because you remain in the powerband longer in each gear The higher gearing allows you to steer more efficiently with throttle control and body English If 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 o
41. crankcase NOTICE 1 dowel pins 2 cylinder gasket 5 Clean any gasket material off the cylinder 1 3 2 1 4 5 2 6 5 1 2 055 073 qxd 06 6 15 14 35 68 Servicing Your Honda 69 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 Do not damage the piston rings and cylinder walls NOTICE 3 cam chain 4 cylinder 5 piston rings 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 Do not let the dowel pins fall into the crankcase NOTICE 1 dowel pins 2 cylinder head gasket 5 4 3 7 6 8 1 2 cont d 055 073 qxd 06 6 15 14 35 69 70 Servicing Your Honda Piston Piston Rings Piston Pin 2 Route the cam chain through the cylinder head 3 Install the cylinder head Do not damage mating surfaces when installing the cylinder head 3 Apply engine oil to the cylinder head nut threads Install the washers and cy
42. drying soak the air cleaner element in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil Apply air cleaner oil to the entire surface inner and outer and rub it with both hands to saturate the air cleaner element with oil Squeeze out excess oil 9 Apply a thin coat of Pro Honda White Lithium Grease or equivalent to the sealing surface between the air cleaner element and air cleaner element holder cont d 4 1 3 2 8 7 5 9 6 10 Assemble the air cleaner element and holder Install the holder tab 7 of the holder in the hole 8 of the air cleaner tab 9 024 054 qxd 06 6 15 14 31 43 44 Servicing Your Honda Air Cleaner 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 14 Reinstall the seat page 29 making sure it is securely attached NOTICE 1 air cleaner retaining bolt 2 two access top tabs 3 air cleaner assembly 4 mark 10 groove 4 10 3 1 2 11 Install the air cleaner assembly 3 into the air cleaner housing keeping the two access top tabs 2 up 12 Carefully position the sealing flange of the element to prevent dirt intrusion 13 Align the groove 10 of the air cleaner assembly with the mark 4 of the air cleaner housing by rotating the air cleaner assembly clockwise Install and tighten the air
43. engine guard 5 6 oil filter cover bolts 7 oil filter cover 8 oil filter 9 oil filter cover O ring 10 spring 11 rubber seal 12 OUT SIDE mark 024 054 qxd 06 6 15 14 31 38 Refer to Safety Precautions on page 19 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the transmission and clutch Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission Oil Recommendation Your CRF does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation 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 Servicing Your Honda 39 Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Transmission Oil Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range NOT RECOMMENDED OK API classification 4 stroke engine oil only Viscosity weight JASO T903 standard
44. fork damper Install the center bolt to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 7 center bolt O ring 11 Measure the length between the axle holder and outer tube and record it Standard 12 5 0 1 in 317 2 mm 12 Compare the length 10 at assembly and at disassembly They should be the same length If the length at assembly is longer than at disassembly check the center bolt and lock nut installation 10 length 8 7 9 5 2 6 2 8 8 2 7 10 095 117 qxd 06 6 15 14 41 104 Front Suspension Adjustments Adjustments for Competition 105 1 outer tube slider 11 fork oil 1 11 Fork Oil Capacity Standard 0 45 kgf mm Fork Spring Standard oil capacity 12 6 US oz 372 cm3 Maximum oil capacity 14 0 US oz 413 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 7 US oz 317 cm3 Optional Softer 0 43 kgf mm Fork Spring Standard oil capacity 12 5 US oz 369 cm3 Maximum oil capacity 13 9 US oz 410 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 6 US oz 314 cm3 No mark factory products 3 scribe marks 1 scribe mark aftermarket parts or Optional Stiffer 0 47 kgf mm Fork
45. inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page 80 there is probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system 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 lbf ft 5 9 N m 0 6 kgf m 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm 6 Apply silicone grease to the contacting faces of the adjuster 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 pe
46. is handy for this because any dirt that penetrates this sealing area will show up clearly page 43 Use the 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 Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 40 Air cleaner Housing Sealing Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with Pro Honda Handgrip Cement or an equivalent if there is any doubt to its sealing integrity Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration General Competition Maintenance 001 023 qxd 06 6 15 14 28 23 24 Servicing Your Honda General Competition Maintenance 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 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
47. jets are available for your CRF See your Honda dealer Any engine or air cleaner housing modifications or the use of an aftermarket exhaust system may require jetting changes Carburetor Components Cold Start Circuit A very rich mixture must be delivered to the cylinder when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot start lever is pulled back the hot start valve 1 opens allowing air to be supplied to the main bore 2 through the hot start air passage 3 This extra air enters the air fuel mixture from the slow circuit resulting in a lean condition 1 hot start valve 2 main bore 3 hot start air passage 1 5 2 4 3 2 1 3 095 117 qxd 06 6 15 14 42 117 Carburetor Adjustments amp Tuning Tips 118 Adjustments for Competition Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened As the throttle valve 1 opens the pump rod 2 depress the diaphragm 3 At this time the inlet check
48. lifter rod 10 7 Remove the eight clutch discs and seven clutch plates 11 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 9 clutch lifter 11 clutch discs and plates 10 clutch lifter rod 1 2 3 4 5 6 7 8 9 11 10 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 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 004 in 0 10 mm Replace the clutch discs and plates as a set 2 2 clutch plate 024 054 qxd 06 6 15 14 31 51 52 Servicing Your Honda Clutch System Clutch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 1 46 in 37 2 mm If one or more springs are beyond the service limit replace the springs as a set Replace the clutch discs clutch plates and clutch springs as a set if the clutch plates have been burnt heat discolored Clutch Disc Plate Installation 1 Coat the clutch discs
49. 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 and apply a light coating of oil 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 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 quite tight so it s important to keep these dowels absolutely clean page 66 Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 Fuel Contamination Refer to Fuel System in your Owner s Manual page 34 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the fuel tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioratio
50. qxd 06 6 15 14 35 59 60 Servicing Your Honda Valve Clearance Shim Selection 1 Clean the valve shim contact area in the valve lifter 1 with compressed air 1 valve lifter 2 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 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with a micrometer 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 2 2 shim 055 073 qxd 06 6 15 14 35 60 Servicing Your Honda 61 Valve Clearance 5 Place the cam sprocket 7 and align the timing mark 8 on the cam sprocket with the surface of the cylinder head 9 Install the cam chain 10 over the sprocket without rotating the sprocket 4 primary drive gear bolt 5 punch mark 6 index mark 7 cam sprocket 8 timing mark 9 surface of the cylinder head 10 cam chain 4 6 5 7 10 9 8 Camshaft Installation 1 Install the newly select
51. several times 1 fork damper 5 Clean the fork cap and fork damper threads 1 fork damper 7 Pump the fork damper piston rod 5 slowly several times to bleed the air from the fork damper 1 1 fork damper 5 fork damper piston rod 1 fork damper 9 Apply fork oil to the fork cap bushing 4 and new O ring 6 on the fork cap assembly 2 Extend the fork damper piston rod to maximum length holding it install the fork cap assembly to the fork damper 1 Be careful not to damage the fork cap bushings If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again 1 fork damper 4 fork cap bushing 2 fork cap assembly 6 O ring 2 1 4 1 1 1 5 1 65 1 85 in 42 47 mm 1 1 2 4 6 8 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper 1 as shown Oil Level 1 65 1 85 in 42 47 mm 6 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper 1 Recommended Oil Pro Honda HP Fork Oil 5W or equivalent Recommended Amount 6 5 US oz 192 cm3 3 Remove the fork cap assembly 2 from the fork damper 1 Be careful not to damage the fork cap bushing 4 Do not disassemble the fork cap assembly Replace the fork cap as an assembly if it is damaged c
52. the Engine 1 2 1 throttle grip 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle grip 1 two or three times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow result in hard starting Emergency Engine Stop To stop the engine in an emergency depress the engine stop button 001 023 qxd 06 6 15 14 28 14 Basic Operating Instructions 15 Break in Guidelines Help assure your CRF s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced 001 023 qxd 06 6 15 14 28 15 16 Basic Operating Instructions 001 023 qxd 06 6 15 14 28 16 Servicing Your Honda 17 Servicing Your Honda 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
53. the list on page 148 for the optional carburetor parts To prevent engine damage always adjust the main jet before adjusting the jet needle If there is any doubt always choose the next richer jet so there is a margin for safety 118 133 qxd 06 6 15 14 47 125 Carburetor Adjustments amp Tuning Tips 126 Adjustments for Competition Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions sea level altitude and 20 C 68 F air temperature If your conditions are different you may need to adjust the carburetor settings using the tuning information on page 124 and 125 Confirm your settings are correct before proceeding Minor Adjustments 1 Adjust the carburetor setting using the tuning information on page 124 and 125 2 When the engine is warm enough to run without the choke push the choke knob down to its off position 3 Adjust the pilot screw 1 to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the pilot screw clockwise to lean the mixture If the engine surges lean exiting a corner turn the pilot screw counter clockwise to richen the mixture The minimum to maximum range of pilot screw adjustments is 1 3 4 to 2 1 2 turns out from the lightly seated position If you exceed 2 1 2 turns out the next larger slow jet is needed If you are under 1 3 4 turn out the next smaller slow jet is needed 1
54. 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 Racing Records Information worth recording for this section of your logbook may include Your placing in each moto and overall finishing position Thoughts on what you could do to improve your performance next time 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 Any places on the course where you chose the wrong line and were passed too easily 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 Dates and results of cylinder piston and ring examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance Engine transmission and suspension oil changes chain sprocket chain guide and slider replacements coolant changes an
55. 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 level by 0 2 oz 5 cc Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil level by 0 2 oz 5 cc 095 117 qxd 06 6 15 14 42 115 Suspension Adjustment Guidelines 116 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track Symptoms and Adjustment Always begin with the standard settings Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 6 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 If after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustments until the correct settings are obtained as described Hard surfaced track Sand track Mud track Begin with the standard setting
56. valve 4 is shut resulting in a sharp increase in pressure in the pump chamber 5 The outlet check valve 6 then opens supplying fuel to the main bore via the accelerator nozzle 7 Leak jet 8 operation is related to both the length of time before the fuel starts flowing after the opening of the throttle time lag and the flow amount 1 throttle valve 5 pump chamber 2 pump rod 6 outlet check valve 3 diaphragm 7 accelerator nozzle 4 inlet check valve 8 leak jet Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 air passage 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters the venturi past the needle jet Baffle Plates The baffle plates 5 prevents foaming of fuel or abnormal fuel level around the mainjet Float Bowl The float 6 and float valve 7 operate to maintain a constant level of fuel in the float bowl 1 main jet 5 baffle plates 2 jet needle 6 float 3 needle jet 7 float valve 4 air jet 1 8 7 6 2 5 4 3 3 2 1 5 4 6 4 2 7 5 1 3 118 133 qxd 06 6 15 14 46
57. 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 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 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 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 001 023 qxd 06 6 15 14 28 19 20 Servicing Your Honda 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 lists 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 equipm
58. your CRF were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions Use a replacement tire equivalent to the original 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 Front Rear Type 80 100 21 51M DUNLOP 100 90 19 57M DUNLOP D742FA D756 bias ply tube 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 074 094 qxd 06 6 15 14 38 83 84 Servicing Your Honda Drive Chain Refer to Safety Precautions on page 19 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 raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Drive Chain Inspection 1
59. 0 2 1 1 0 1 5 1 2 1 0 1 0 1 2 1 0 3 2 1 6 NOTE 1 NOTE 2 Transmission oil check bolt 5 1 Apply grease to the threads 2 Apply oil to the threads NOTES 8 9 7 11 10 1 2 5 4 6 3 RIGHT SIDE LEFT SIDE 134 160 qxd 06 6 15 14 49 142 Torque Specifications Technical Information 143 Frame Item Torque Remarks lbf ft N m kgf m 12 Upper engine hanger plate nuts engine side frame side 40 25 54 34 5 5 3 5 11 Lower engine hanger bracket nut 47 64 6 5 10 Front engine hanger bracket nut 47 64 6 5 8 Rear axle nut 94 128 13 1 7 Front axle pinch bolts 15 20 2 0 6 Front axle nut 65 88 9 0 14 Swingarm pivot nut 65 88 9 0 NOTE 1 18 19 Shock spring lock nut Kickstarter arm bolt 32 28 44 38 4 5 3 9 17 Rear shock link nuts frame side 39 53 5 4 16 Rear shock arm nuts swingarm side shock link side 39 39 53 53 5 4 5 4 15 Fork fork damper fork cap 25 22 34 30 3 5 3 1 NOTE 1 3 NOTE 1 3 NOTE 1 3 13 Shock absorber 32 44 4 5 NOTE 1 9 Chain adjuster lock nuts 20 27 2 8 NOTE 2 NOTE 1 5 Handlebar lower holder nuts 32 44 4 5 4 Handlebar upper holder bolts 16 22 2 2 3 Fork bridge lower pinch bolts 15 20 2 0 2 Fork bridge upper pinch bolts 16 22 2 2 1 Steering stem nut 80 108 11 0 FRAME 1 U
60. 0 mm Engine Carburetor Cooling capacity at draining at disassembly Cooling system 12 9 1 Clutch type Transmission Primary reduction Gear ratio I Gear ratio II Gear ratio III Gear ratio IV Gear ratio V Final reduction Item English Metric Drive train Electrical Wet multi plate type 5 speed constant mesh 3 166 2 142 1 750 1 450 1 227 1 041 3 923 Gear shift pattern Ignition Starting system Spark plug Standard For extended high speed riding ICM Kickstarter Left foot operated return system 1 N 2 3 4 5 NGK R0409B 8 NGK R0409B 9 Spark plug gap 0 024 0 028 in 0 6 0 7 mm 2 172 mm 827 mm 1 277 mm 1 479 mm 965 mm 446 mm 361 mm 15 22 cu in 249 4 cm3 134 160 qxd 06 6 15 14 49 141 Torque Specifications 142 Technical Information Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Engine Item 1 2 3 4 6 7 8 9 10 11 ENGINE Cylinder head cover bolts Exhaust pipe joint nuts Water pump cover bolts Crankshaft hole cap Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Transmission oil drain bolt Torque Remarks lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 10 21 10 15 12 10 10 12 10 31 16 1
61. 06 6 15 14 31 28 Servicing Your Honda 29 Seat Removal Refer to Safety Precautions on page 19 Removal 1 Remove the seat mounting bolts 1 2 Remove the seat 2 by sliding it backward 1 seat mounting bolts 2 seat Installation 1 Install the seat while aligning the front prong 3 with the seat bracket 4 and rear prong 5 with the tab 6 of the subframe 2 Install and tighten the seat mounting bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 3 front prong 4 seat bracket 5 rear prong 6 tab 2 1 3 5 4 6 024 054 qxd 06 6 15 14 31 29 30 Servicing Your Honda Fuel Tank Removal Refer to Safety Precautions on page 19 Removal 1 Turn the fuel valve 1 OFF 5 Pull the breather tube 5 out of steering stem nut 6 Unhook the fuel tank band 6 and air cleaner cover rubber 7 7 Remove the fuel tank bolt 8 5 breather tube 6 fuel tank band 7 air cleaner cover rubber 8 fuel tank bolt 8 Disconnect the fuel line 9 from the fuel valve The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 9 Remove the fuel valve bolt 10 and fuel valve 9 fuel line 10 fuel valve bolt WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel onl
62. 1 Safe Riding Precautions 12 Starting amp Stopping the Engine 13 Break in Guidelines 15 SERVICING YOUR HONDA 17 Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat Removal 29 Fuel Tank Removal 30 Subframe Removal 32 Service Procedures Fluids amp Filters Fuel System 34 Engine Oil 36 Transmission Oil 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle
63. 1 outer tube 6 guide bushing 5 fork dust seal 7 slider 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 9 of the fork damper 1 outer tube 9 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Amount of fork oil left in the fork within damper and spring unit cc minute C F 30 86 20 68 10 50 0 32 5 27 29 4 28 2 30 6 10 15 3 16 5 21 2 22 4 20 10 6 11 8 16 5 18 8 35 9 4 10 6 15 3 16 5 55 8 3 9 4 12 9 16 5 85 7 9 8 2 11 8 15 3 145 7 9 8 2 11 8 14 1 3 2 1 1 4 5 6 7 1 1 9 1 074 094 qxd 06 6 15 14 38 74 Servicing Your Honda 75 Suspension 5 Pour the recommended fork oil into the outer tube 1 Fork Oil Capacity Standard 0 45 kgf mm Fork Spring or Standard oil capacity 12 6 US oz 372 cm3 Maximum oil capacity 14 0 US oz 413 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 7 US oz 317 cm3 Optional Softer 0 43 kgf mm Fork Spring Standard oil capacity 12 5 US oz 369 cm3 Maximum oil capacity 13 9 US oz 410 cm3 Slightly st
64. 15 15 tensioner stopper 9 Install a new sealing washer 16 and tighten the cam chain tensioner lifter cover bolt 17 16 sealing washer 17 cam chain tensioner lifter cover bolt 16 17 11 set ring 12 camshaft holder 7 Install the camshaft holders 12 onto the cylinder head with the intake cam lobes 13 facing up as illustrated below Apply oil to the camshaft holder bolt threads and seating surface Tighten the camshaft holder bolts 14 to the specified torque 12 lbf ft 16 N m 1 6 kgf m Tighten the camshaft holder bolts in a criss cross pattern in two or three steps 12 11 055 073 qxd 06 6 15 14 35 62 Servicing Your Honda 63 Valve Clearance 12 Install the spark plug page 55 13 Coat a new O ring 19 with oil and install it onto the crankshaft hole cap 20 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 19 O ring 20 crankshaft hole cap Cylinder Head Cover Installation 1 Check the spark plug hole packing 1 is in good condition replace it if necessary Install the spark plug hole packing to the spark plug hole 2 1 spark plug hole packing 2 spark plug hole 2 Inspect the cylinder head cover packing 3 for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover
65. 17 positions or more Turning the adjuster one full turn advances the adjuster 4 positions Rebound damping can be increased by turning the adjuster clockwise 2 1 1 3 095 117 qxd 06 6 15 14 42 110 Rear Suspension Adjustments Adjustments for Competition 111 4 Calculate the race sag dimension To do this subtract the loaded with rider dimension step 3 from the unloaded dimension step 2 Standard Race Sag 3 9 in 100 mm Adjust spring pre load as necessary to obtain the desired handling results Decreasing the race sag dimension example 3 5 in 90 mm improves turning ability for tight terrain at the cost of slightly reduced straight line stability Increasing the race sag dimension example 4 3 in 110 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the loaded without rider dimension Do this with your CRF set at the standard race sag 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 abo
66. 27 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 25 handlebar 26 mounting rubbers 27 washers handlebar holder nuts 26 Install the number plate 28 by aligning its hole 29 with the tab 30 on the steering stem 28 number plate 30 tab 29 hole 27 Install and tighten the number plate bolt 31 31 number plate bolt 28 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 29 While keeping the forks parallel alternately tighten the right axle pinch bolts 32 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 32 right axle pinch bolts To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 30 Install the disc cover 33 and tighten the disc cover bolts 34 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m NOTICE 33 disc cover 34 disc cover bolts 31 Turn the rebound damping and compression damping adjuster screws back to their original settings 25 26 27 29 28 30 31 32 33 34 095 117 qxd 06 6 15 14 42 108 Rear Suspension Adjustments Adjustments for Competition 109 Pin spanners should be used for turning the lock nut and adjusting nut See page 148 for optional pin spanners Spring pre load length Standard spring Standa
67. 3 Apply grease to the filter side of the spring end then install the spring 10 into a new oil filter 14 Position the spring against the engine crankcase and install a new oil filter with the rubber seal 11 facing out away from the engine You should see the OUT SIDE mark 12 on the filter body near the rubber seal Use a new genuine Honda oil filter or a filter of equal quality specified for your model If the oil filter is not installed properly it will cause serious engine damage 15 Apply engine oil to a new O ring and install it to the oil filter cover 16 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 lbf ft 12 N m 1 2 kgf m 17 Install the left engine guard and bolt then tighten it 18 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69R at oil and filter change 0 70 US qt 0 66R at oil change 19 Install the engine oil filler cap dipstick 20 Check the engine oil level by following the steps in Checking amp Adding Oil page 37 NOTICE 4 left engine guard bolt 5 left engine guard 5 4 10 12 9 8 11 7 6 10 Remove the oil filter cover bolts 6 and oil filter cover 7 11 Remove the oil filter 8 from the oil filter cover 12 Check that the oil filter cover O ring 9 is in good condition 9 Remove the left engine guard bolt 4 and left
68. 6 6 15 14 49 157 158 Index Index gap spark plug 55 gasohol 145 gasoline 34 gearing 130 guidelines suspension adjustment 114 handlebar inspection 91 Honda contacting 153 Rider s Club 155 service manual 152 your dealer 154 identification vehicle 140 idle speed engine 48 inspection pre ride 9 labels safety 4 logbook competition 146 maintenance additional procedures 91 after competition 26 before amp after competition 26 between motos amp practice 26 component locations 28 general competition 22 importance
69. 93 001 023 qxd 06 6 15 14 28 17 18 Servicing Your Honda WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual 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 001 023 qxd 06 6 15 14 28 18 Servicing Your Honda 19 Maintenance Safety 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 Important Safety Precautions 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
70. 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 118 133 qxd 06 6 15 14 47 131 Personal Fit Adjustments 132 Adjustments for Competition The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning 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 Position the shift lever
71. Suspension Adjustment Adjustments for Type of Track Adjustments for Too Soft Stiff Damping Hard surfaced track Sand track Mud track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below 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 Adjust to a stiffer position because mud build up increases your CRF s weight Example Turn the compression damping adjuster to a stiffer setting Install the optional stiff spring Soft suspension Symptom Initial travel too soft Steering is too quick Front end darts while cornering or riding in a straight line Middle travel too soft Front end dives when cornering Final travel too soft Bottoms on landings Bottoms on large bumps especially downhill bumps Entire travel too soft Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping i
72. Suspension Adjustments 109 Suspension Adjustments for Track Conditions 113 Suspension Adjustment Guidelines 114 Carburetor Adjustments amp Tuning Tips 117 Chassis Adjustments 129 Gearing 130 Tire Selection for Track Conditions 131 Personal Fit Adjustments 132 Adjustments for Competition 95 Adjustments for Competition 095 117 qxd 06 6 15 14 41 95 1 2 96 Adjustments for Competition 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 Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel Compression damping Turning the compression damping screw adjusts how quickly the fork compresses Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends Fork springs Optional springs are available in softer and stiffer types than the standard rate page 148 The inverted fork on your CRF features sealed damper cartridges with dual separate air and oil chambers to prevent aeration The design also isolates the oil in each fork tube slider whi
73. Turn the engine off raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 0 1 4 in 25 35 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 Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or binding links excessive wear Replace the drive chain page 86 if it has damaged rollers loose pins or kinks that cannot be free Lubricate the drive chain page 85 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed NOTICE 1 chain slider 2 Check the chain guide slider 2 for wear Replace the chain guide slider if it is worn to the bottom of the wear limit 3 2 chain guide slider 3 wear limit 2 1 3 1 2 3 Drive Chain Sliders 1 Check the chain slider 1 for wear If the wear is 0 2 in 5 mm or m
74. 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 001 023 qxd 06 6 15 14 28 9 10 Before Riding 001 023 qxd 06 6 15 14 28 10 Basic Operating Instructions 11 Basic Operating Instructions 11 Basic Operating Instructions This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 12 Starting amp Stopping the Engine 13 Preparation 13 Starting Procedure 13 Flooded Engine 13 How to Stop the Engine 14 Break in Guidelines 15 001 023 qxd 06 6 15 14 28 11 12 Basic Operating Instructions 12 Basic Operating Instructions 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 w
75. a 21 Maintenance Schedule ITEMS THROTTLE OPERATION HOT START SYSTEM AIR FILTER CRANKCASE BREATHER SPARK PLUG RADIATOR COOLANT VALVE CLEARANCE DECOMPRESSOR SYSTEM ENGINE OIL ENGINE OIL FILTER ENGINE IDLE SPEED PISTON AND PISTON RINGS PISTON PIN TRANSMISSION OIL COOLING SYSTEM DRIVE CHAIN DRIVE CHAIN SLIDER DRIVE CHAIN ROLLER DRIVE SPROCKET DRIVEN SPROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 I I C I I I I I I I I L I I I I I I I I I L I I I I R L R I R R R R R 46 54 43 45 55 41 57 36 37 48 66 66 39 41 84 84 85 86 86 78 80 77 49 91 87 72 25 73 74 100 92 142 144 81 82 91 R I FORK TUBE SLIDER DAMPER FREQUENCY NOTE Ref Page 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 Every 12 races or about 30 0 hours This maintenance schedule is based upon average riding condition Machines subjected to severe use require more frequent servicing NOTE 1 Clean after every moto for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after
76. a dealer for correct Service Limit measurements 055 073 qxd 06 6 15 14 35 67 68 Servicing Your Honda Piston Piston Rings Piston Pin 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 IN mark 2 and or the large valve recesses 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 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 NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 piston cut out 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 Do not let the dowel pins fall into the
77. age 81 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 Servicing Your Honda 25 General Competition Maintenance 024 054 qxd 06 6 15 14 31 25 26 Servicing Your Honda 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 Clean accumulated dirt from under the fenders and off the wheels suspension components handgrips controls and footpegs A stiff nylon parts cleaning brush works well Check tire air pressure Check spoke tension and rim lock nut security Check sprocket bolt and nut security Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result 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 Suspend the front wheel above the ground and use the pressu
78. aged See the Honda Service Manual or consult your Honda dealer for replacing the water seal or the oil seal Both seals should be replaced at the same time Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the Honda Service Manual page 152 To properly dispose of drained coolant refer to You amp the Environment page 136 Improper disposal of drained fluids is harmful to the environment NOTICE Coolant WARNING 2 1 4 3 1 water hoses 2 overflow tube 3 water leakage check hole 4 water pump cover 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 024 054 qxd 06 6 15 14 31 42 Servicing Your Honda 43 Air Cleaner Refer to Safety Precautions on page 19 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer c
79. an help you determine the correct service interval for your riding conditions Your CRF s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear NOTICE Cleaning 1 Remove the seat page 29 2 Remove the air cleaner retaining bolt 1 3 Align the two access top tabs 2 of the air cleaner assembly 3 and mark 4 of the air cleaner housing by rotating the air cleaner assembly counterclockwise 5 Remove the air cleaner element 5 from the air cleaner holder 6 1 air cleaner retaining bolt 2 two access top tabs 3 air cleaner assembly 4 mark 4 Remove the air cleaner keeping the two access top tabs up 5 air cleaner element 8 hole 6 air cleaner holder 9 air cleaner tab 7 holder tab 6 Wash the air cleaner element in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner element is made in two pieces inner and outer which cannot be separated 7 Clean the inside of the air cleaner housing 8 Allow the air cleaner element to dry thoroughly After
80. ate 134 160 qxd 06 6 15 14 49 135 You amp the Environment 136 Tips 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 disposal 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 Improper disposal of drained fluids is harmful to the environment NOTICE 134 160 qxd 06 6 15 14 49 136 Troubleshooting Tips 137 The it
81. ates 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 Dont 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 2 Motorcycle Safety 001 023 qxd 06 6 15 14 28 2 Accessories amp Modifications Motorcycle Safety 3 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 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 001 023 qxd 06 6 15 14 28 3 4 Motorcycle Safety Safety Labels Read this label
82. aust joint pipe 5 Install each muffler mounting bolt 7 and washer 8 6 Tighten each muffler clamp bolt 9 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 7 Tighten each muffler mounting bolt 7 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 7 muffler mounting bolt 8 washer 9 muffler clamp bolt 10 side cover 12 seat mounting bolt 11 side cover bolt 3 4 1 2 5 6 7 8 9 12 10 11 8 Install and tighten the side covers 10 and side cover bolts 11 9 Install the seat mounting bolts 12 and tighten them to the specified torque 19 lbf ft 26 N m 2 7 kgf m 074 094 qxd 06 6 15 14 38 88 Exhaust Pipe Muffler Servicing Your Honda 89 Exhaust Joint Pipe Removal 1 Remove the muffler page 87 2 Remove the mud guard 1 by removing the screws 2 1 mud guard 2 screws 3 Loosen the joint pipe clamp bolt 3 4 Remove the exhaust joint pipe mounting bolt 4 and exhaust joint pipe 5 1 2 5 4 3 3 joint pipe clamp bolt 4 exhaust joint pipe mounting bolt 5 exhaust joint pipe Exhaust Joint Pipe Installation 1 Remove the old gasket 2 Install the joint pipe clamp 1 by aligning the tab 2 of the joint clamp with the cut out 3 of the exhaust joint pipe 4 1 joint pipe clamp 3 cut out 2 tab 4 exhaust joint pipe 3 Install a new gasket 5 to the exh
83. aust pipe 6 4 Install the exhaust joint pipe 4 to the exhaust pipe and temporarily install the joint pipe clamp bolt and exhaust joint pipe mounting bolt 4 3 1 2 4 5 6 4 exhaust joint pipe 5 gasket 6 exhaust pipe 5 Install the exhaust joint pipe mounting bolt 6 Install the muffler page 88 but do not tighten the bolt yet 7 Tighten the joint pipe clamp bolt to the specified torque 15 lbf ft 21 N m 2 1 kgf m 8 Tighten the exhaust joint pipe mounting bolt to the specified torque 19 lbf ft 26 N m 2 7 kgf m 9 Tighten the muffler clamp bolts and muffler mounting bolts page 88 10 Installation can be done in the reverse order of removal 074 094 qxd 06 6 15 14 38 89 90 Servicing Your Honda 90 Servicing Your Honda Exhaust Pipe Muffler 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 1 exhaust pipe gasket new 2 exhaust pipe 3 exhaust pipe joint nuts 3 Install the exhaust joint pipe page 89 but do not tighten the bolt yet 4 Install the muffler page 88 but do not tighten the bolt yet 5 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 6 Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt page 89 7 Tighten the muffler clamp bolts and muffler mounting bolts page 88 8
84. ch 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 1 2 Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure is 0 psi 0 kPa 0 kgf cm2 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 2 Remove the pressure release screw 1 3 Check that the O ring 2 is in good condition 4 Install and tighten the pressure release screw to the specified torque 0 9 lbf ft 1 2 N m 0 1 kgf m 1 pressure release screw 2 O ring Front Suspension Damping Rebound Damping Adjustment The fork rebo
85. compression CORRECT LOW 1 Check the fuel flow to carburetor REACHING CARBURETOR No fuel in fuel tank Clogged fuel tube or fuel filter P 34 Sticking float valve Clogged fuel fill cap breather tube Faulty spark plug P 55 Faulty ignition control module Faulty exciter coil Faulty ignition coil Faulty engine stop button Loose or disconnected ignition system wires Faulty ignition pulse generator Valve stuck open Worn cylinder and piston ring Leaking damaged cylinder head gasket Improper valve timing Seized valve Improper choke operation Pilot screw incorrectly adjusted Insulator leaking Improper ignition timing Faulty ignition coil or ignition pulse generator Fuel contaminated Improper hot start operation Carburetor flooded Choke closed Throttle valve open Air cleaner dirty 5 Removed and inspect spark plug 6 START WITH CHOKE ON DRY WET PLUG 134 160 qxd 06 6 15 14 49 137 138 Tips 134 160 qxd 06 6 15 14 49 138 Technical Information Technical Information 139 This section contains dimensions capacities and other technical data Vehicle Identification 140 Specifications 141 Torque Specifications 142 Oxygenated Fuels
86. d damping adjusters in one click or in 1 12 turn increments If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Bounce the rear of the motorcycle up and down and check for smooth suspension action 2 Remove the subframe page 32 3 Check for a broken or collapsed spring 4 Check the rear shock absorber 1 for a bent shaft or oil leaks 1 rear shock absorber 5 Push the rear wheel sideways to check for worn or loose swingarm bearings There should be no movement If there is have the bearings replaced by your Honda dealer 1 055 073 qxd 06 6 15 14 35 73 Suspension 74 Servicing Your Honda Recommended Fork Oil Fork Oil Change Refer to Front Suspension Disassembly on page 97 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 lower end of the slider 4 viscosity weight 5 W suggested oil Pro Honda HP Fork Oil or equivalent 1 outer tube 3 lock nut wrench 2 fork damper 4 slider lower end The outer tube 1 can drop on the slider and damage the fork dust seal 5 and guide bushing 6 when the fork damper is removed To avoid damage hold both the outer tube and slider 7 when removing the fork damper NOTICE
87. d 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 2 1 074 094 qxd 06 6 15 14 38 93 94 Servicing Your Honda 94 Servicing Your Honda 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 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 using a wet sponge and a mild detergent then rin
88. d related component replacements 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 134 160 qxd 06 6 15 14 49 146 Date Running Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Technical Information 147 Competition Logbook 134 160 qxd 06 6 15 14 49 147 148 Technical Information FRAME Remarks Shock spring Standard Stiffer Optional Softer Stiffer Fork spring Standard Optional Softer 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 296 8 lbf in 5 30 kgf mm No mark factory products Red paint aftermarket parts or 285 6 lbf in 5 10 kgf mm 25 2 lbf in 0 45 kgf mm 24 1 lbf in 0 43 kgf mm 26 3 lbf in 0 47 kgf mm Jet needle number 1 2 clip position leaner than standard series leaner only at 1 8 to 3 4 throttle NKUR 2 755 mm NKUS 2 765 mm NKUT 2 775 mm NKUU 2 785 mm NKBR 2 755 mm NKBS 2 765 mm standard needle NKBT 2 775 mm NKBU 2 785 mm NKBV 2 795 mm NKUV
89. d the spark plug will be fouled if the throttle is opened and closed repeatedly Excessive fuel in the engine makes kickstarting difficult 6 About a minute after the engine starts push the choke knob all the way to fully OFF If idling is unstable open the throttle slightly Warm Engine Starting 1 Turn the fuel valve ON 2 Shift the transmission into neutral 3 Pull the hot start lever 3 and kick start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 1 fuel valve 2 choke knob 3 3 hot start lever Starting the engine after a stall during riding or after a fall 1 Shift the transmission into neutral 2 Pull the hot start lever and kick start the engine Do not open the throttle 3 As soon as the engine starts release the hot start lever Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine 1 Shift the transmission into neutral 2 With the throttle fully opened repeat kickstarter operation approximately ten times very slowly to discharge excessive fuel from the engine 3 Pull the hot start lever and kick start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 001 023 qxd 06 6 15 14 28 13 14 Basic Operating Instructions Starting amp Stopping the Engine 14 Basic Operating Instructions How to Stop
90. d transmission oil filler cap Repeat step 1 4 5 After inspecting the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 9 lbf ft 12 N m 1 2 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 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 transmission oil filler cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil has drained apply fresh engine oil to the transmission oil drain bolt threads 6 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 7 Fill the crankcase with recommended oil Capacity 0 63 US qt 0 60R at oil change 8 Check the transmission oil level by following the steps in Checking amp Adding Oil this page Transmission Oil 2 1 2 1 2 3 1 3 2 1 transmission oil filler cap 2 transmission oil drain bolt 3 sealing washer 024 054 qxd 06 6 16 9 06 40 Servicing Your Honda 41 Your CRF s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling syste
91. dal 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 1 2 3 8 13 16 in 10 20 mm 3 1 2 Front Brake Lever Adjustment 074 094 qxd 06 6 15 14 38 77 78 Servicing Your Honda Brakes Fluid Level Inspection Front Brake Fluid Level Check 1 LWR mark With 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 80 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake lever freeplay exceeds 13 16 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for brake bleeding 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 80 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake pedal freeplay exceeds 13 16 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda dealer for
92. down 7 throttle valve 9 floating valve 10 hole 3 1 2 5 4 6 7 8 9 7 10 7 9 cont d 118 133 qxd 06 6 15 14 47 121 Carburetor Adjustments amp Tuning Tips 122 Adjustments for Competition 5 Remove the accelerator pump cover screws 11 and accelerator pump cover 12 11 accelerator pump cover screws 12 accelerator pump cover 6 Remove the U ring 13 O ring 14 spring 15 and diaphragm 16 Clean the diaphragm When installing the U ring into the accelerator pump cover 12 make sure the U rings flatside faces down away from the float bowl 17 12 accelerator pump cover 15 spring 13 U ring 16 diaphragm 14 O ring 17 float bowl 7 Remove the holder screw 18 throttle stop screw holder 19 float bowl screws 20 tube guides 21 and float bowl 17 17 float bowl 18 holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 8 Remove the pump rod 22 Clean the pump rod and rod passage 23 Install the pump rod into the link lever 24 Push the rod forcibly into the link lever until it snaps into place 22 pump rod 24 link lever 23 rod passage 25 float level 26 float level gauge 27 carburetor intake 10 Remove the leak jet 28 from the float bowl 17 Clean the leak jet 9 Measure the float level 25 with the float level gauge 26 while the floa
93. e warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are 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 Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 mm or any time you notice a reduction in traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim Tube Replacement If a tube is punctured or damaged you should replace it as soon as possible A repaired tube may not have the same reliability as a new one and it may fail while you are riding Use a replacement tube equivalent to the original 1 1 tire tread depth 074 094 qxd 06 6 15 14 38 82 Servicing Your Honda 83 Tires amp Tubes Tire Replacement The tires that came on
94. e holder 28 in a vise with a piece of wood or soft jaws to avoid damage Overtightening the vise can damage the axle holder 19 Loosen the center bolt 29 NOTICE 28 axle holder 29 center bolt 20 Push out the center bolt from the axle holder of the slider by pushing the fork damper 21 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool 19 slider 21 length 20 dust seal 15 Hold the outer tube 22 then remove the fork damper 23 from the outer tube using a lock nut wrench 24 Gently slide the outer tube down onto the lower end of the slider 25 26 20 21 20 19 24 25 22 23 27 29 28 33 mm cont d The outer tube can drop on the slider and damage the fork dust seal 20 and guide bushing 26 when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork cap NOTICE 20 fork dust seal 26 guide bushing 16 Drain the fork oil from the outer tube Drain the fork oil from the oil hole 27 of the fork damper 22 outer tube 24 lock nut wrench 23 fork damper 25 slider lower end 095 117 qxd 06 6 15 14 41 99 Front Suspension Adjustments 100 Adjustments for Competition 22 Apply pressure to the fork damper and insert a special tool or mechanic s stopper tool 30 see below between the axle holder 28 a
95. e pinch bolts 11 on both forks 8 Pull the front axle shaft 12 out of the wheel hub and remove the front wheel 10 front axle nut 12 front axle shaft 11 front axle pinch bolts 9 Remove the fork protector bolts 13 brake hose clamp bolts 14 and fork protectors 15 Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads 13 fork protector bolts 14 brake hose clamp bolts 15 fork protectors 16 brake caliper mounting bolts 17 brake caliper 11 Loosen the fork leg lower pinch bolts 18 then pull the fork legs down and out 18 lower pinch bolts 7 6 8 9 12 11 11 10 17 15 14 16 13 13 18 10 Remove the brake caliper mounting bolts 16 and brake caliper 17 095 117 qxd 06 6 15 14 41 98 Front Suspension Adjustments Adjustments for Competition 99 12 Clean the fork assembly especially the sliding surface of the slider 19 and dust seal 20 13 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 14 Measure the length 21 between the axle holder and outer tube and record it before disassembling the fork Standard 12 5 0 1 in 317 2 mm 27 oil hole 17 Temporarily install the fork damper to the outer tube 18 Set the axl
96. e subframe upper mounting bolt 2 and subframe lower mounting bolts 3 Tighten the upper mounting bolt and lower mounting bolts to each specified torque upper bolt 22 lbf ft 30 N m 3 1 kgf m lower bolt 36 lbf ft 49 N m 5 0 kgf m 1 subframe 2 subframe upper mounting bolt 3 subframe lower mounting bolts 2 1 3 6 Install the seat page 29 7 Install and tighten the exhaust joint pipe and muffler pages 88 89 024 054 qxd 06 6 15 14 31 33 34 Servicing Your Honda Fuel System Refer to Safety Precautions on page 19 Fuel Recommendation We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Your engine is designed to use any gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 145 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid gett
97. ealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 024 054 qxd 06 6 15 14 31 47 48 Servicing Your Honda Engine Idle Speed Refer to Safety Precautions on page 19 The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled servicing including carburetor adjustment Remember idle speed adjustment is not a cure all for other problems in your engine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere The engine must be at normal operating temperature for accurate idle speed adjustment Idle Speed Adjustment 1 Turn the pilot screw 1 in until it is lightly seated and record the number of turns Turn the pilot screw out the same number of turns 2 If the engine is cold start it and warm it up 3 minutes and then shut it off 3 Connect a tachometer to the engine 4 Shift into neutral and start the engine 5 Keep the motorcycle in an upright position 6 Adjust idle speed with the throttle stop screw 2 Idle speed 1 700 100 rpm 2 1 1 pilot screw 2 throttle stop screw 024 054 qxd 06 6 15 14 31 48 Servicing Your Honda
98. ed shims 1 on the valve retainers 2 Do not let the shims fall into the crankcase NOTICE 1 shims 2 valve retainers 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 surface of the cam and outer surface of the each the valve lifters 3 3 Install the valve lifters and camshaft into the cylinder head 3 valve lifters 4 Rotate the primary drive gear bolt 4 crankshaft clockwise and align the punch mark 5 with the index mark 6 2 1 2 3 cont d 055 073 qxd 06 6 15 14 35 61 62 Servicing Your Honda Valve Clearance 6 Apply grease to the set rings 11 and install it onto the camshaft holders 12 12 camshaft holders 13 intake cam lobes 14 camshaft holder bolts 10 Rotate the camshaft by rotating the crankshaft clockwise several times 11 Insert the feeler gauge 18 between the intake valve lifter and cam lobe 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 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 18 feeler gauge 14 14 12 13 18 18 8 Remove the tensioner stopper 15 from the cam chain tensioner lifter
99. emoval Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and fuel tank pages 29 30 2 Disconnect the breather tube 1 and direct ignition coil 2 Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 breather tube 2 direct ignition coil 3 Remove the cylinder head cover bolts 3 and cylinder head cover 4 3 cylinder head cover bolts 4 cylinder head cover 4 Remove the spark plug hole packing 1 crankshaft hole cap 2 Remove the spark plug page 55 2 1 4 3 1 Refer to Safety Precautions on page 19 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 The checking or adjusting of the clearance should be performed while the engine is cold The valve clearance will change as engine temperature rises 055 073 qxd 06 6 16 7 21 56 Servicing Your Honda 57 Valve Clearance Valve Clearance Inspection 1 Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cam lobes 3 2 Measure the exhaust valve clearance by inserting a feeler gauge 1 between the exhaust rocker arm 4 and exhaust val
100. ems that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of the Honda Service Manual are followed by an asterisk POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK POSSIBLE CAUSES 1 Check if air cleaner is over oiled P 43 CORRECT INCORRECT INCORRECT LEAKING CLOGGED INCORRECT WAKE OR INTERMITTENT SPARK CORRECT CORRECT NOT LEAKING NOT CLOGGED GOOD SPARK 2 Check if the insulator is leaking 3 Check carbureator pilot screw adjustment P 126 4 Check carburetor jets and accelerator pump for clogs 5 Try spark test 6 Check the throttle position sensor LOW CORRECT 7 Test cylinder compression Over oiled air cleaner Loose insulator clamp Damaged insulator Fuel air mixture too lean Turn the pilot screw out P 126 Fuel air mixture too rich Turn the pilot screw in P 126 Contaminants in the fuel Not cleaned frequently enough P 119 Faulty carbon or wet fouled spark pulg P 55 Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Faulty throttle position sensor Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 D
101. eness 55 Air cleaner for condition and contamination 43 Clutch lever adjustment and freeplay 49 Hot start lever freeplay 54 Breather drain for cleaning 45 Steering head bearing and related parts for condition 91 Carburetor throttle operation 47 Tires for damage or improper inflation pressure 82 Spokes for looseness 81 Rim locks for looseness 81 Front and rear suspension for proper operation 72 73 Front and rear brakes check operation 77 Drive chain for correct slack and adequate lubrication 84 Drive chain guide sliders and drive chain rollers for damage or wear 84 85 Exhaust pipe Muffler inspection 87 Every possible part for looseness such as cylinder head nuts engine mounting bolts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt 92 142 144
102. ent Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purchase from your Honda dealer page 152 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 remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability Perform the pre ride inspection page 9 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 1 Clean after every moto for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride 4 Inspect after the first break in ride 5 Replace the transmission oil if the clutch discs and plates are replaced Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean L lubricate R replace 001 023 qxd 06 6 15 14 28 20 Servicing Your Hond
103. f wood or soft jaws to avoid to damage Overtightening the vise can damage the axle holder 5 Temporarily install the fork damper to the fork Push out the fork damper piston rod from the axle holder of the slider by pushing the fork damper Apply pressure to the fork damper and insert the special tool or mechanic s stopper tool 5 between the axle holder and lock nut 2 Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the piston rod until it stops Check the push rod installation by turning the push rod right and left 7 Install a new O ring 7 to the center bolt 8 Install the center bolt to the fork damper piston rod aligning the center bolt adjusting rod 9 with the push rod Tighten the center bolt fully by hand NOTICE 2 lock nut 7 O ring 5 stopper tool 8 center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten the lock nut to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 2 lock nut 8 center bolt 10 Apply fork oil to the center bolt O ring 7 Remove the piston base or mechanic s stopper tool while applying pressure to the
104. ge 123 13 Install the subframe page 33 14 Install the fuel tank page 31 and the seat page 29 15 Pour a fresh recommended coolant mixture page 41 Check for the following compression leaks abnormal engine noise secondary air leaks coolant leaks 055 073 qxd 06 6 15 14 35 71 72 Servicing Your Honda Suspension Refer to Safety Precautions on page 19 Loose worn or damaged suspension components may adversely affect the handling and stability of your CRF If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection When your CRF is new break it in for approximately one hour to ensure that the suspension has worked in page 15 After break in test run your CRF with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CRF for 3 hours See page 97 for fork disassembly Replace the fork oil every 3 races or 7 5 hours of running See page 74 for oil level adjustment after changing the fork oil Replace the damper fork oil every 9 races or 22 5 hours of running See page 100 for damper fork oil level adjustment after changing the fork oil Use Pro Honda HP Fork Oil 5W or an equ
105. he 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 23 Clean the threads of the caliper mounting bolts 22 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slider and tighten the caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 18 fork protector bolts 19 fork protectors 20 brake hose clamp bolts 21 brake caliper 22 caliper mounting bolts 24 Clean the surfaces where the axle and axle clamps contact each other Install the left and right side collars into the wheel hub Insert the front axle shaft through the wheel hub from the right side Make sure the front axle shaft is seated firmly onto the left fork leg clamp inner surface Tighten the front axle nut 23 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the left axle pinch bolts 24 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 23 front axle nut 24 left axle pinch bolts Fit the brake caliper 21 over the disc taking care not to damage the brake pads 21 brake caliper 19 18 18 22 21 20 23 24 21 cont d 095 117 qxd 06 6 15 14 42 107 Front Suspension Adjustments 108 Adjustments for Competition 25 Install the handlebar 25 mounting rubbers 26 washers and handlebar holder nuts
106. he remaining fuel in the float bowl by loosening the drain screw 2 Then tighten the drain screw after draining the fuel 118 133 qxd 06 6 15 14 47 126 Carburetor Adjustments amp Tuning Tips Adjustments for Competition 127 12 Change the main jet 4 and slow jet 5 as required 4 main jet 5 slow jet 13 Reinstall the float bowl plug 14 If you ve determined that the jet needle or clip position of jet needle must be changed you must remove the carburetor top 15 Remove the fuel tank page 30 16 Rotate the carburetor to the left and remove the carburetor top bolts 6 and carburetor top 7 17 Remove the jet needle holder assembly 8 8 jet needle holder assembly 19 Reinstall the jet needle holder assembly carburetor top and carburetor top bolts 20 Rotate the carburetor and align the lug 12 on the carburetor with the slot 13 on the insulator 12 lug 13 slot 21 Tighten the connecting and insulator band screws 22 Install the fuel tank page 31 23 Start the engine If the engine idle speed is too high or too low or engine is not idling adjust the engine idle speed page 48 24 Repeat steps 4 23 until the engine gives maximum power with the correct spark plug reading It is always better to jet a little rich than a little lean It is advisable to record the settings course conditions lap times and climatic and barometric conditions for future reference 4 5 7
107. hich can collect rapidly in an enclosed area and cause illness or death 001 023 qxd 06 6 15 14 28 12 1 2 Basic Operating Instructions 13 Basic Operating Instructions 13 Starting amp Stopping the Engine 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 Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Starting Procedure Always follow the proper starting procedure described as follow Check the engine oil transmission oil and coolant levels before starting the engine pages 37 40 41 Cold Engine Starting 1 Turn the fuel valve 1 ON 2 Shift the transmission into neutral 3 If the temperature is 95 F 35 C or below pull the choke knob 2 fully out 4 If the temperature is below 32 F 0 C open the throttle two or three times The engine requires a richer mixture for starting in cold weather When the throttle is so opened the accelerator pump will feed extra fuel to the cylinder thereby facilitating starting in cold weather 5 With the throttle closed operate the kickstarter starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion Do not open the throttle As the carburetor is equipped with an accelerator pump excessive fuel will be charged into the engine an
108. iffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 6 US oz 314 cm3 1 scribe mark aftermarket parts No mark factory products 3 scribe marks Optional Stiffer 0 47 kgf mm Fork Spring Standard oil capacity 12 7 US oz 375 cm3 Maximum oil capacity 14 1 US oz 416 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 8 US oz 320 cm3 1 scribe mark and 3 scribe marks 75 degrees apart 1 Be sure the oil capacity is the same in both fork legs 1 outer tube cont d 074 094 qxd 06 6 15 14 38 75 Suspension 76 Servicing Your Honda 6 Check that the O ring 10 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 2 fork damper 10 O ring 7 Temporarily install the fork damper to the outer tube After installing the fork leg page 106 tighten the fork damper to the specified torque Actual 25 lbf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 lbf ft 31 N m 3 2 kgf m 10 2 074 094 qxd 06 6 15 14 38 76 Servicing Your Honda 77 Brakes Refer to Safety Precautions on page 19 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
109. ing dirt dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 1 9 US gal 7 3R 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube in the steering stem nut WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Fuel Line 1 fuel line 1 Check for leaks 2 Check the fuel line 1 for cracks deterioration damage or leakage Replace the fuel line if necessary 3 Check for interference between the frame and fuel tank and adjust if necessary 3 2 1 1 024 054 qxd 06 6 15 14 31 34 Servicing Your Honda 35 Fuel System 3 fuel filter 4 O ring 4 3 1 2 Fuel Filter The fuel filter is mounted on the bottom left side of the fuel tank Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor To service the fuel filter 1 Drain the fuel fro
110. ingers between the chain and sprocket A variety of reasonably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your CRF or use cleaners refer to Appearance Care page 93 024 054 qxd 06 6 15 14 31 27 28 Servicing Your Honda Maintenance Component Locations front brake caliper choke knob crankcase breather tube drive chain transmission oil drain bolt engine oil drain bolt engine idle speed engine oil filter engine oil filler cap dipstick air cleaner rear brake caliper rear suspension rebound damping adjuster transmission oil filler cap transmission oil check bolt rear brake pedal front suspension rebound damping adjuster rear suspension high speed damping adjuster rear suspension low speed damping adjuster front suspension compression damping adjuster spark plug rear suspension spring pre load adjuster rear brake fluid reservoir clutch lever hot start lever front brake fluid reservoir front brake lever fuel fill cap radiator cap throttle grip 024 054 qxd
111. insulator are black or fouled rich there is a problem elsewhere page 128 Check the carburetor fuel system and ignition timing 8 With the sealing gasket attached Thread the spark plug in by hand to prevent cross threading 9 Tighten the spark plug If the old plug is good 1 8 turn after it seats 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 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 NOTICE 1 direct ignition coil 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 sealing gasket 4 spark plug gap 1 2 3 4 Standard Optional R0409B 8 NGK R0409B 9 NGK 10 Connect the direct ignition coil Take care to avoid pinching any cables or wires 11 Install the fuel tank and seat pages 29 31 055 073 qxd 06 6 15 14 35 55 56 Servicing Your Honda Valve Clearance Cylinder Head Cover R
112. inum driven sprockets Like the optional springs these sprockets are listed in the Optional Parts List section of this manual page 148 Unless you have the required mechanical knowhow tools and Honda Service Manual sprocket changing should be done by your Honda dealer Higher Gearing less driven sprocket teeth increases top speed in each gear provided the engine will pull the higher gearing reduces frequency of shifting wider gear ratios reduces engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain However the engine may not pull the higher gearing the spacing between gears may be too wide engine rpm may be too low Lower Gearing more driven sprocket teeth decrease top speed in each gear increases frequency of shifting narrower gear ratios increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However spacing between gears may be too narrow 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
113. ire pressure front cold bias ply tube Tire type 15 psi 100 kPa 1 0 kgf cm2 Tire pressure rear cold D756 Fork oil capacity except fork damper per leg F brake swept area R brake swept area Fuel recommendation unleaded gasoline pump octane number of 91 or higher Fuel capacity Caster angle Trail length Single disc brake 51 8 in2 334 5 cm2 Single disc brake 60 6 in2 391 1 cm2 27 50 1 93 US gal 4 8 in 12 6 US oz 372 cm3 123 mm 7 3R Item English 3 07 x 2 06 in 0 24 in 0 98 US qt 1 06 US qt 0 93R 1 00R Cylinder arrangement Bore and stroke Displacement Compression ratio Valve clearance cold Intake Exhaust 0 005 0 001 in 0 12 0 03 mm 0 011 0 001 in 0 28 0 03 mm Engine oil capacity After draining After draining and oil filter change After disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR01D 175 NKBT Needle clip position standard Slow jet standard Pilot screw opening Float level Idle speed Liquid cooled 4 stroke Single 10 inclined from vertical 0 70 US qt 0 73 US qt 0 90 US qt 0 63 US qt 0 74 US qt 3rd groove 42 2 1 4 turns out 1 700 100 rpm Type Metric 0 66R 0 69R 0 85R 0 60R 0 70R 78 0 x 52 2 mm 6
114. isconnect fuel line at carburetor and check for clogging P 34 UNRESTRICTED FUEL FLOW FUEL FLOW RESTRICTED CLOGGED DIRTY INCORRECT LOW WEAK OR INTERMITTENT SPARK NOT CLOGGED CORRECT CORRECT GOOD SPARK 2 Remove air cleaner P 43 4 Check carbureator jets for clogging 5 Check valve timing 6 Try spark test 7 Test cylinder compression AIR CLEANER NOT DIRTY 3 Install a larger carburetor main jet P 126 CORRECT CONDITION WORSE Lack of fuel in tank P 34 Clogged fuel line P 34 Clogged fuel fill cap breather tube P 34 Clogged fuel valve P 34 Clogged fuel filter P 35 Not cleaned frequently enough P 43 Jet size wrong rejet in the opposite direction P 126 Contaminants in the fuel Cam sprocket not installed properly Faulty carbon or wet fouled spark pulg P 55 Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing ENGINE DOES NOT START OR IS HARD TO START CHECK POSSIBLE CAUSES 4 Start by following normal starting procedure ENGINE DOES NOT FIRE ENGINE STARTS BUT SOON STOPS 2 Try spark test GOOD SPARK WEAK OR NO SPARK NOT REACHING CARBURETOR 3 Test cylinder
115. ise or lower the rear of your CRF have a more significant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the change in tire size Another way to check is to measure the rolling circumference of the old and new tires A higher profile tire will have a larger rolling circumference If you do switch to tires designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface 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
116. it replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service NOTICE 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 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 chain 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 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 1 retaining clip 2 master link 2 Clean the drive chain in high flash point solvent and allow it to dry 3 Inspect the dri
117. its the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indicate rich jetting NOTICE Condition Normal Overheating Lean Wet Rich Spark Plug Appearance Dark brown to light tan color with dry electrode Light gray or white color Wet or sooty Mixture correct lean rich 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 NOTICE 1 insulator 3 side electrode 2 center electrode Spark Plug Coloring Guidelines Remember that in addition to improper jetting 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 or a hole or holes deliberate or unintentional in the air cleaner housing A rich condition can be caused by a plugged or dirty air cleaner use of a more restrictive aftermarket exhaust system a clogged spark arrester or excessive oil on the air cleaner Excessive smoking will occur 2 3 1 118 133 qxd 06 6 16 8 21 128 Chassis Adjustments Adjustments for Competition 129 The following suggestions may improve a specific concern Subtle changes in overall handling may also be noted Rear End If you have a prob
118. ivalent which contains special additives to assure maximum performance of your CRF s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension Adjustment Guidelines page 114 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems 1 Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt 2 Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CRF is ridden 1 fork protector 2 dust seal 3 Inspect the wear rings 3 for wear or damage Replace the wear ring if it is 0 06 in 1 5 mm or flat with the outer tube 4 When replacing the wear ring remove the fork leg page 97 Install the wear ring with its end gap facing rearward 3 wear ring 4 outer tube 3 wear rings 4 Make a quick check of fork operation by
119. jet size numbers do not correspond with other carburetor manufacturer s jet size numbers use only Honda jets cont d WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 straight section 2 clip Slow Jet and Pilot Screw The slow jet and pilot screw affects fuel air ratio over fully closed to 1 4 throttle Adjust the pilot screw to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the pilot screw clockwise to lean the mixture If the engine surges lean exiting a corner turn the pilot screw counterclockwise to richen the mixture The minimum to maximum range of pilot screw adjustment is 1 3 4 to 2 1 2 turns out from the lightly seated position If you exceed 2 1 2 turns out the next larger slow jet is needed If you are under 1 3 4 turns out the next smaller slow jet is needed 118 133 qxd 06 6 15 14 46 119 Carburetor Adjustments amp Tuning Tips 120 Adjustments for Competition 4 Remove the fuel tank page 30 5 Remove the subframe page 32 6 Loosen the insulator band screw 2 2 insulator band screw 7 Disconnect the throttle sensor connector 3 8 Remove the carburetor 3 throttle sensor connector 9 Remove the hot start cable holder 4
120. k the other helper to measure the loaded with rider dimension Example Unloaded 23 6 in 600 mm Loaded 19 7 in 500 mm Race Sag 3 9 in 100 mm UNLOADED MEASUREMENT without rider EXAMPLE 23 6 in 600 mm REAR FENDER MOUNTING BOLT CHAIN ADJUSTER LOCK NUT LOADED MEASUREMENT on ground with rider EXAMPLE 19 7 in 500 mm REAR FENDER MOUNTING BOLT CHAIN ADJUSTER LOCK NUT LOADED MEASUREMENT on ground without rider EXAMPLE 21 6 in 550 mm Example Unloaded 23 6 in 600 mm Loaded 21 6 in 550 mm Sag 2 0 in 50 mm Without Rider cont d 095 117 qxd 06 6 16 8 10 111 Rear Suspension Adjustments 112 Adjustments for Competition Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too stiff for your weight will not allow the rear tire to hook up under acceleration and will pass more b
121. le shaft for runout 2 Check the condition of the wheel bearings 1 3 2 074 094 qxd 06 6 15 14 38 81 82 Servicing Your Honda Tires amp Tubes 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 Front 15 psi 100 kPa 1 0 kgf cm2 Rear 15 psi 100 kPa 1 0 kgf cm2 Refer to Safety Precautions on page 19 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 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 a new cap Always check air pressure when your tires are cold If you check air pressure when your tires ar
122. lem with rear wheel traction raise the rear end of your CRF by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your motorcycle s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your CRF wants to turn too quickly lower the rear of the motorcycle by reducing the rear spring pre load This will increase fork rake and trail and should improve stability in a straight line The effective suspension travel will be transferred toward the firmer end of wheel travel Keep the race sag adjustment page 111 in the 3 5 4 3 in 90 110 mm range 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
123. lems 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 Do not clean the spark plug If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one 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 Do not adjust the spark plug gap If the gap is out of specification replace the spark plug with a new one NOTICE Spark Plug Spark Plug Replacement amp Inspection 1 Remove the seat and fuel tank pages 29 30 2 Disconnect the direct ignition coil 1 3 Clean any dirt from around the spark plug bases 4 Remove the spark plug 2 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 appers color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and
124. level Minimum oil capacity Standard spring 10 7 US oz 317 cm3 Softer spring 10 6 US oz 314 cm3 Stiffer spring 10 8 US oz 320 cm3 When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork 1 rebound damping 2 compression adjuster screw damping adjuster screw 1 2 Force N Stroke mm Oil capacity 14 0 US oz 413 cm3 MAX Oil capacity 12 6 US oz 372 cm3 STANDARD Oil capacity 10 7 US oz 317 cm3 MIN 1 2 1 number plate bolt 2 number plate cont d 095 117 qxd 06 6 15 14 41 97 Front Suspension Adjustments 98 Adjustments for Competition 3 Remove the washers handlebar holder nuts 3 mounting rubbers 4 and handlebar 5 Keep the master cylinder upright to prevent air from entering system NOTICE 5 4 3 3 washers handlebar holder nuts 4 mounting rubbers 5 handlebar 4 Loosen the upper pinch bolts 6 5 Loosen the fork damper 7 using the lock nut wrench but do not remove them yet Do not use an adjustable wrench to loosen the fork damper it may damage them NOTICE 6 upper pinch bolts 7 fork damper 6 Remove the disc cover 8 by removing the disc cover bolts 9 8 disc cover 9 disc cover bolts 7 Remove the front axle nut 10 and loosen the front axl
125. linder head nuts 4 Tighten the cylinder head nuts in a crisscross pattern in two or three steps to the specified torque 29 lbf ft 39 N m 4 0 kgf m Do not let the washers and nuts fall into the crankcase NOTICE NOTICE 4 Install the cylinder bolt 5 and cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Install the engine hanger plates 7 engine hanger nuts bolts 8 of the frame side and engine hanger nut bolt 9 of the engine side Tighten the engine hanger nut to the specified torque frame side 25 lbf ft 34 N m 3 5 kgf m engine side 40 lbf ft 54 N m 5 5 kgf m 3 cylinder head 4 cylinder head nuts washers 5 cylinder bolt 6 cylinder head bolts 7 engine hanger plates 8 engine hanger nuts bolts of the frame side 9 engine hanger nut bolt of the engine side 4 3 6 5 8 9 7 055 073 qxd 06 6 15 14 35 70 Servicing Your Honda 71 Piston Piston Rings Piston Pin 6 Connect the radiator hose 10 to the cylinder head and tighten the radiator hose clamp 11 securely 10 radiator hose 11 radiator hose clamp 7 Install the shims valve lifters and camshaft page 61 8 Install the spark plug page 55 9 Install the crankshaft hole cap page 63 10 11 10 Install the cylinder head cover page 63 11 Install the exhaust pipe page 90 12 Install the carburetor pa
126. lly in all steering positions 1 3 2 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 Honda dealer 074 094 qxd 06 6 15 14 38 91 92 Servicing Your Honda 92 Servicing Your Honda Additional Maintenance Procedures Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Item 1 2 3 4 5 6 7 8 9 10 11 ENGINE Cylinder head cover bolts Exhaust pipe joint nuts Water pump cover bolts Crankshaft hole cap Transmission oil check bolt Clutch cover bolts Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Transmission oil drain bolt Torque lbf ft N m kgf m 7 15 7 11 9 7 7 9 7 23 12 10 21 10 15 12 10 10 12 10 31 16 1 0 2 1 1 0 1 5 1 2 1 0 1 0 1 2 1 0 3 2 1 6 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 7 cylinder bolt 8 oil filter cover bolts 9 cylinder head bolts 10 drive sprocket bolt 11 transmission oil drain b
127. locking the front brake and pushing down on the handlebar several times 2 1 3 4 3 3 055 073 qxd 06 6 15 14 35 72 Servicing Your Honda 73 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 113 Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only 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 110 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 110 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and reboun
128. m the fuel tank into an approved gasoline container 2 Remove the fuel tank page 30 3 Remove the fuel joint 1 from the fuel tank by removing the bolts 2 4 Wash the fuel filter 3 in high flash point cleaning solvent 5 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 4 is in good condition and install it onto the fuel joint 6 Install the fuel joint in the fuel tank 7 Install the fuel tank page 31 and refill the fuel Turn the fuel valve to ON check for fuel leaks 1 fuel joint 2 bolts 024 054 qxd 06 6 15 14 31 35 36 Servicing Your Honda Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Engine Oil Refer to Safety Precautions on page 19 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the engine Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 4 stroke oil or an equivalent viscosity weight SAE 10W 30 JASO T 903 MA Your CRF does not need oil additives
129. m 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 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 Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 19 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 1 radiato
130. mbol This information is intended to help you avoid damage to your Honda other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual The official Honda Service Manual for your CRF is available page 152 It is the same manual your dealer uses If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding NOTICE 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 Introduction Contents qxd 06 6 15 14 27 2 2007 Honda CRF250R OWNER S MANUAL amp COMPETITION HANDBOOK Contents qxd 06 6 15 14 27 1 A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility T
131. n page 35 Loosen the drain screw and examine the fuel that flows out of the float bowl If you notice anything in the fuel such as water or dirt remove the float bowl and inspect its contents page 121 For maximum efficiency drain and replace fuel that has remained in your fuel tank for more than a month Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Pro Honda Dielectric Grease on all electrical connections 024 054 qxd 06 6 15 14 31 24 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 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 fili
132. n one click increments Test softer compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments If initial and middle travel are stiff Install the optional stiff spring If initial travel is stiff after installing the optional stiff spring Test softer compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil level in increments of 0 2 oz 5 cc Install the optional stiff spring Test stiffer compression damping adjustments in one click increments Increase rebound damping in one click increments 095 117 qxd 06 6 15 14 42 114 Suspension Adjustment Guidelines Adjustments for Competition 115 Stiff suspension Symptom Initial travel too stiff Stiff on small bumps while riding at full throttle in a straight line Stiff on small cornering bumps Front end wanders while riding at full throttle in a straight line Middle travel too stiff Stiff on bumps when cornering Front end wanders when cornering Stiff suspension on bumps especially downhill
133. ncreasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a loss of traction and slower lap times 095 117 qxd 06 6 15 14 42 113 Suspension Adjustment Guidelines 114 Adjustments for Competition Follow the procedures described below to accurately adjust your CRF using the methods described on pages 96 113 Remember to make all adjustments in one click increments Test ride after each adjustment Front
134. nd lock nut 31 23 Hold the lock nut and remove the center bolt 29 from the fork damper 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 can not reassemble the fork damper NOTICE 28 axle holder 30 stopper tool 29 center bolt 31 lock nut 24 Remove the push rod 32 from the fork damper 25 Remove the special tool or mechanic s stopper tool between the axle holder and lock nut 31 while applying pressure to the fork damper Be careful not to damage the lock nut and fork center bolt hole NOTICE 31 lock nut 32 push rod 26 Remove the fork damper assembly 33 from the fork assembly 34 Remove the fork from the vise Remove the fork spring 35 from the fork 33 fork damper assembly 35 fork spring 34 fork assembly 1 fork damper 3 lock nut wrench 2 fork cap assembly 28 30 31 29 32 31 33 35 34 1 2 3 Damper Oil Change 1 Set the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage 2 Loosen the fork cap assembly 2 while holding the fork damper using the lock nut wrench 3 095 117 qxd 06 6 15 14 41 100 Front Suspension Adjustments Adjustments for Competition 101 1 fork damper 2 fork cap assembly 4 fork cap bushing 4 Empty the fork oil from the fork damper 1 by pumping the damper rod
135. ndicator wear indicator grooves replace replace 0 04 in 1 mm 0 04 in 1 mm 1 3 2 2 replace 0 04 in 1 mm minimum thickness indicator 5 6 4 5 074 094 qxd 06 6 15 14 38 80 Servicing Your Honda 81 Wheels Refer to Safety Precautions on page 19 Maintenance of spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first few rides spokes will loosen more rapidly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule page 21 However information for wheel removal is provided for emergency situations Wheel Rims amp Spokes 1 wheel rim 3 rim lock 2 spoke 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Front Spoke 2 7 lbf ft 3 68 N m 0 4 kgf m Rear Spoke 2 7 lbf 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 amp Wheel Bearings See the Honda Service Manual for inspection information 1 Check the ax
136. ner 43 air pressure front suspension 96 tires 82 appearance care 93 authorized manuals 152 basic operation 11 before riding 7 between motos amp practice maintenance 26 brakes fluid level 78 lever front adjustment 77 pad wear 80 pedal height 77 break in guidelines 15 capacity fuel 34 carburetor adjustment 117 circuit functions 119 components 117 disassembly assembly 121 idle speed 48 minor adjustments 126 care appearance 93 chain drive 84 cha
137. ng recommendations to be accurate you must use the standard settings as a baseline Also don t change any of the settings until you ve determined what changes are necessary Adjustment Pilot screw opening Slow jet Jet needle Needle clip position Main jet Float level Identification number Standard settings 2 1 4 turns out 42 NKBT 3rd groove 175 0 24 in 6 0 mm FCR01D Adjustments for Altitude amp Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture 118 133 qxd 06 6 15 14 47 124 Carburetor Adjustments amp Tuning Tips Adjustments for Competition 125 Special Tuning Conditions There are some unique atmospheric conditions or situations that may require additional adjustments It should not be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting changes are necessary check for air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Condition long straights uphill sections sand mud high humidity raining hotter than 113 F 45 C Main Jet Adjustment next larger next smaller Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race conditions change drastically However there are some unique atmospheric condition
138. ng 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 freely and that the pivot pin retaining cotter pins are in good condition Brake Fluid Replacement Refer to Brake Pad Wear in your Owner s Manual page 80 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 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 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 Wa
139. nswered in the owner s manual can be answered by your Honda 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 Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4C 7B telephone 866 784 1870 Please include the following information in your letter name address and telephone number product model year and VIN date of purchase dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda 134 160 qxd 06 6 15 14 49 153 154 Consumer Information Once you purchase your new Honda get familiar with the organization of your Honda dealer so you can utilize the full range of services available The service department is there to perform regular maintenance and unexpected repairs It has the latest available service information from Honda The parts department offers Genuine Honda parts Pro Honda products and Hondaline accessories The same quality that went into your Honda can be found in Gen
140. nting bolts then remove the subframe See page 32 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 1 lock nut 3 pin spanners 2 adjusting nut 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 2 in 260 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 53 lbs 7 95 kg 1 4 2 3 095 117 qxd 06 6 15 14 42 109 Rear Suspension Adjustments 110 Adjustments for Competition 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 7 10 clicks with the punch marks on the adjuster and the shock absorber aligned Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjuste
141. nut 2 UBS nut 3 Apply oil to the threads and flange surface 4 Alock bolt 5 Apply locking agent to the threads NOTES 21 Brake hose bolts 25 34 3 5 Front brake master cylinder holder bolts 20 7 3 9 9 1 0 3 9 6 14 15 21 20 18 5 7 11 10 12 12 13 17 16 16 13 8 4 1 2 134 160 qxd 06 6 15 14 49 143 Torque Specifications 144 Technical Information 22 23 24 25 26 27 28 29 30 31 32 33 34 Caliper mounting bolts Front brake disc nuts Rear brake disc nuts Brake pedal pivot bolt Spoke front rear Rim locks Subframe upper mounting bolts Iower Fork center bolt Fork center lock nut Disc cover bolts Fork protector bolts Muffler mounting bolts right left Muffler clamp bolt right left 22 12 12 27 2 7 2 7 9 22 36 51 16 10 5 2 19 15 30 16 16 36 3 68 3 7 12 30 49 69 22 13 7 26 21 3 1 1 6 1 6 3 7 0 4 0 4 1 2 3 1 5 0 7 0 2 2 1 3 0 7 2 7 2 1 NOTE 4 NOTE 1 NOTE 1 NOTE 5 NOTE 4 Item Torque Remarks lbf ft N m kgf m 39 40 41 Fork air pressure release screw Rear brake reservoir cap bolts Front brake reservoir cap screws FRAME 0 7 1 0 0 1 0 7 1 0 0 1 0 9 1 2 0 1 42 Shroud B bolts 3 7 5 0 5 43 Drive chain roller bolt nut 9 12 1 2 44 Throttle cable lock nut 3 0 4 0 4
142. o 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 and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions 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 DANGER WARNING CAUTION Contents qxd 06 6 15 14 27 3 Contents MOTORCYCLE SAFETY 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications 3 Safety Labels 4 OPERATING CONTROLS 5 Operation Component Locations 6 BEFORE RIDING 7 Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection 9 BASIC OPERATING INSTRUCTIONS 1
143. ock nut to the specified torque 3 0 lbf ft 4 N m 0 4 kgf m 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 31 If you can t get the freeplay within the specified range contact your Honda dealer 5 6 1 Pull the dust cover 2 back 2 Loosen the lock nut 3 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 lbf 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 steering positions If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn Tighten the lock nut install the dust cover and make the adjustment with the lower adjuster 2 dust cover increase 3 lock nut decrease 4 upper adjuster 024 054 qxd 06 6 15 14 31 46 Servicing Your Honda 47 Throttle Throttle Inspection 1 throttle 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle 1 from fully open to fully closed in all steering positions If there is a problem see your Honda d
144. od condition and reinstall the drain bolt sealing washer and radiator cap 1 drain bolt sealing washer 2 water pump 6 Lubricate the drive chain 7 Inflate the tires to their recommended pressures 8 Place your CRF on the workstand or equivalent to raise both tires off the ground 9 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 34 4 Pour a fresh recommended coolant mixture page 41 slowly into the radiator filler hole up to the filler neck Capacity 1 06 US qt 1 00R at disassembly 0 98 US qt 0 93R at 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 5 Perform all maintenance checks page 21 2 1 10 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 11 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 accumul
145. olt 1 4 5 6 3 2 7 8 10 11 9 RIGHT SIDE LEFT SIDE 074 094 qxd 06 6 15 14 38 92 Servicing Your Honda 93 Servicing Your Honda 93 Appearance Care Refer to Safety Precautions on page 19 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 To clean your CRF you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CRF or discolor the seat and decals If your CRF is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CRF High pressure washers like those at coin operated car washes can damage certain parts of your CRF The force of water under extreme pressure can penetrate the dust seals of the 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 muffle
146. ompression adjusters are firmly located in a detent and not between positions NOTICE Front Suspension Disassembly If your CRF is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for this service When disassembling the fork turn the rebound and compression 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 Place your CRF on the workstand or equivalent support with the front wheel off the ground 2 Remove the number plate bolt 1 and number plate 2 Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn and lower the oil level in increments of 0 2 oz 5 cc in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil
147. ont d 095 117 qxd 06 6 15 14 41 101 Front Suspension Adjustments 102 Adjustments for Competition 1 fork damper 5 fork damper piston rod 1 fork damper 8 spring chamber 10 pressure release screw 1 5 5 fork damper piston rod 7 lock nut Turn the rebound adjuster and compression adjuster counterclockwise to the softest position Check the fork damper piston rod sliding surface for damage Apply fork oil to the fork damper piston rod sliding surface Cover the fork piston rod end with soft jaws to prevent fork damage Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 13 Blow the extra oil off to the fork damper 1 spring chamber 8 by pumping the fork damper piston rod to full stroke NOTICE 9 oil hole 15 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure release screw 10 on the fork cap Hold the fork damper up side down for 10 minutes and drain the oil from the fork damper spring chamber 5 7 8 1 9 10 14 Drain the extra oil from the oil hole 9 By doing this procedure about 0 6 US oz 17 cm3 of fork fluid will be drained from the damper spring chamber through the oil hole and cause 5 9 US oz 175 cm3 of fork fluid to be left in the fork damper spring chambe
148. optional and begin with the standard settings to softer settings 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 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously 1 Test stiffer high 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 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 1 Test softer rebound dumping adjustment 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 095 117 qxd 06 6 15 14 42 116 Carburetor Adjustments amp Tuning Tips Adjustments for Competition 117 The carburetor used on your CRF should perform suitably with the standard recommended settings under average load climatic and barometric conditions However to fine tune the engine s power output the carburetor may require adjustments for specific competition needs Optional main jets and slow
149. orcycle purchased from your Honda dealer Lock Nut Wrench 07WMA KZ30100 Spoke Wrench 07JMA MR60100 Spoke Wrench 070MA KZ30100 Tensioner Stopper 070MG 0010100 Piston base 07958 2500001 Chemical Products Pro Honda GN4 4 stroke Oil Engine and Transmission Oil SAE80 or 90 gear oil Pro Honda HP Fork Oil 5W Pro Honda DOT4 Brake Fluid Pro Honda HP Chain Lube Pro Honda Foam Filter Oil Pro Honda Hondabrite Cleaner Pro Honda Dielectric Compound Pro Honda Handgrip Cement Pro Honda Hondalock Molybdenum Disulfide grease containing more than 40 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 Brite Hand Pad 7447 maroon 134 160 qxd 06 6 15 14 49 149 150 Technical Information Wiring Diagram THROTTLE POSITION SENSOR SPARK PLUG 134 160 qxd 06 6 15 14 49 150 This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 152 Contacting Honda
150. ore replace it 074 094 qxd 06 6 15 14 38 84 Servicing Your Honda 85 Drive Chain 1 upper drive chain roller 3 mark 2 lower drive chain roller 1 rear axle nut 4 index mark 2 lock nut 5 axle plate 3 adjusting bolt 6 reference mark 3 Tighten the rear axle nut to the specified torque 94 lbf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 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 lbf ft 27 N m 2 8 kgf m 3 2 1 6 5 2 3 1 4 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 or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers 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 Drive Chain Rollers 1 Check the upper drive chain roller 1 and lower drive chain roller 2 for wea
151. others suggested oil SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 MA without friction modifiers as molybdenum additives Pro Honda GN4 4 stroke oil or an equivalent 024 054 qxd 06 6 15 14 31 39 40 Servicing Your Honda 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 code number of the sales company of the oil 2 oil classification Checking amp Adding Oil 1 transmission oil filler cap 3 sealing washer 2 oil check bolt 1 Run the engine at idle for 3 minutes then shut it off 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission 3 Support the CRF in an upright position on a level surface 4 Remove the transmission oil filler cap 1 oil check bolt 2 and sealing washer 3 from the right crankcase cover A small amount of oil should flow out of the oil check bolt hole Allow any excess oil to flow out of the oil check bolt hole If no oil flows out of the oil check bolt hole add oil slowly through the 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 an
152. per 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 lbf ft 1 0 N m 0 1 kgf m 3 2 4 1 5 6 8 7 9 074 094 qxd 06 6 15 14 38 79 80 Servicing Your Honda Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval page 21 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 1 front brake caliper 3 brake disc 2 brake pads 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 4 rear brake 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 minimum thickness i
153. pilot screw Adjustment Procedure 1 Turn the pilot screw in until it is lightly seated and record the number of turns Turn the pilot screw out the same number of turns 2 Warm up the engine 3 Adjust the engine idle speed page 48 4 Make two or three laps of a course with the standard setting or corrected jetting page 124 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and reading its firing end page 128 It may take more than two or three laps to get a good spark plug reading with a new spark plug 5 Change carburetor settings or select suitable carburetor jets taking into consideration the engine conditions and factors for temperature and altitude page 124 2 drain screw 3 float bowl plug 1 3 2 6 Adjust the pilot screw as required 10 Loosen the connecting and insulator band screws Rotate the carburetor 11 Remove the float bowl plug 3 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 7 If you ve determined that the main and slow jets must be changed you must rotate the carburetor and remove the float bowl plug 8 Turn the fuel valve OFF and disconnect the fuel line from the fuel valve 9 Drain t
154. r 12 Screw in the lock nut 7 to the fork damper piston rod 5 fully 1 fork damper 3 lock nut wrench 2 fork cap assembly 11 Hold the fork damper 1 in an upright position and pump the fork damper piston rod 5 to 3 9 in 100 mm slowly several times 1 2 3 10 Tighten the fork cap assembly 2 while holding the fork damper 1 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 095 117 qxd 06 6 15 14 41 102 Front Suspension Adjustments Adjustments for Competition 103 Fork Assembly 1 Drain the fork oil from the outer tube slider 1 by placing it upside down About 7 cc of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube slider 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Blow out the oil completely off the fork spring 3 using the compressed air Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 fork spring 1 A 2 4 3 1 cont d 095 117 qxd 06 6 15 14 41 103 Front Suspension Adjustments 104 Adjustments for Competition 4 Set the axle holder in a vise with a piece o
155. r 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 cm3 through the overflow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 06 US qt 1 00R at disassembly 0 98 US qt 0 93R at coolant change 3 Install the radiator cap securely If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage NOTICE NOTICE Coolant 1 2 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 024 054 qxd 06 6 15 14 31 41 42 Servicing Your Honda 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 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water seal is damaged If oil leaks through the check hole the oil seal is dam
156. r 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 39 mm Lower roller 1 2 in 31 mm Replace the roller if necessary as follows Install the upper drive chain roller Green with the mark 3 facing toward the frame and lower drive chain rollar 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 074 094 qxd 06 6 15 14 38 85 86 Servicing Your Honda Drive Chain 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 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 lim
157. r outlet under seat engine stop button brake master cylinders under fuel tank drive chain carburetor steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points 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 NOTICE Washing Your Motorcycle with a Mild Detergent 1 Rinse your CRF thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover is for removing stains on the non coated aluminum frame only 4 After washing rinse your CRF thoroughly with plenty of clean water to remove any residue 5 Dry your CRF with a chamois or a soft towel 6 Lubricate the drive chain to prevent rusting 7 Start the engine an
158. r suspension maintenance 73 Rider s Club Honda 155 riding basic operation 11 before 7 important safety information 2 safety precautions 2 safety a few words about Safety Messages important information 2 important precautions 2 labels 4 maintenance 19 riding precautions 2 schedule maintenance 20 serial numbers 140 service customer 153 manuals 152 spare parts 149 spark knock 34 spark plug maintenance 55 reading 128 specifications 141 spring pre load rear suspension 109 starting engine
159. rance Care 93 ADJUSTMENTS FOR COMPETITION 95 Front Suspension Adjustments 96 Rear Suspension Adjustments 109 Suspension Adjustments for Track Conditions 113 Suspension Adjustment Guidelines 114 Carburetor Adjustments amp Tuning Tips 117 Chassis Adjustments 129 Gearing 130 Tire Selection for Track Conditions 131 Personal Fit Adjustments 132 TIPS 133 Transporting Your Motorcycle 134 Storing Your Honda 135 You amp the Environment 136 Troubleshooting 137 TECHNICAL INFORMATION 139 Vehicle Identification 140 Specifications 141 Torque Specifications 142 Oxygenated Fuels 145 Competition Logbook 146 Optional Parts List 148 Spare Parts amp Equipment
160. rate the controls Before each ride it s also important to make sure you and your CRF are both ready to ride For information about suspension carburetor and other adjustments see page 95 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs 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 WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Be sure you always wear a helmet eye protection and other protective apparel when you ride 001 023 qxd 06 6 15 14 28 8 Before Riding 9 Is Your Motorcycle Ready to Ride Competitive riding can be tough on a motorcycle so it s important to inspect your CRF and correct any problems you find before each ride Check the following items page numbers are at the right Pre ride Inspection Check the following before each ride Engine oil level 37 Transmission oil level 40 Coolant for proper level 41 Cooling system and hoses for condition 42 Spark plug for proper heat range carbon fouling and high tension cord terminal for loos
161. rd 10 2 in 259 mm Min 9 9 in 251 mm Spring pre load length Optional spring Min Softer 5 1 kgf mm 9 9 in 252 mm Min Stiffer 5 5 kgf mm 9 8 in 249 mm Min Stiffer 5 7 kgf mm 9 9 in 251 mm The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the 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 Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the Honda Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 87 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and remove the subframe s three mou
162. re release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 1 chain adjuster index marks 2 pressure release screw 1 2 After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust inhibiting oil more heavily if the event was particularly wet or muddy Take care to avoid spraying any oil near the brake pads or 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 the chain 024 054 qxd 06 6 15 14 31 26 Servicing Your Honda 27 Before amp After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your f
163. 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 ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 152 An optional tool kit may be available Check with your Honda dealer s parts department Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat Removal 29 Fuel Tank Removal 30 Subframe Removal 32 Service Procedures Fluids amp Filters Fuel System 34 Engine Oil 36 Transmission Oil
164. rs 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 Both the high and low speed damping can be increased by turning the appropriate adjuster clockwise Adjust the high speed adjuster in 1 12 turn increments 1 high speed damping adjuster 2 low speed damping adjuster 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 2 1 4 turns and the punch marks are aligned Low Speed Damping The low speed damping can be adjusted 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 9 clicks and the punch marks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has
165. s If the suspension is too stiff soft adjust according to the chart below 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 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 Stiff suspension Soft suspension Suspension bottoms Symptom Suspension feels stiff on small bumps Suspension feels stiff on large bumps Entire travel too stiff Entire travel too soft Rear end sways Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 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
166. s or race day situations that may require additional adjustments They are as follows To prevent engine damage always adjust the main jet before adjusting the jet needle Always choose the next richer jet if there is any doubt so there is a margin for safety Main Jet Go richer on the main jet by one size when the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy Go leaner on the main jet by one size when it is very humid or raining or it is hotter than 113 F 45 C After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner air leaks float level clogged carburetor jets spark plug fouling improper heat range or other cause freshness of fuel owner modifications such as exhaust system holes in the air cleaner housing etc ignition timing compression If the above check out then adjust the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition Refer to
167. s qxd 06 6 15 14 27 4 Motorcycle Safety 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 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications 3 Safety Labels 4 Motorcycle Safety 1 001 023 qxd 06 6 15 14 28 1 Important Safety Information Important Safety Precautions Your CRF can provide many years of pleasure if you take responsibility for your own safety and understand the challenges you can meet in competitive racing 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 most important Never Carry a Passenger Your CRF is designed for one operator only Carring a passenger can cause an accident 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 CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one oper
168. se well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame 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 NOTICE Exhaust Pipe Maintenance The exhaust pipe and exhaust joint pipe are stainless steel but may became stained by oil or mud Remove heat stains with a liquid kitchen abrasive 074 094 qxd 06 6 15 14 38 94 This section tells you how to fine tune your CRF for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both stiffer and softer than standard rates in order to tailor your CRF specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 96 Rear
169. ssis adjustments 129 choke knob 13 cleaner air 43 cleaning appearance care 93 clutch system adjustment 49 competition logbook 146 consumer information 151 contacting Honda 153 controls operating 5 coolant 41 customer service 153 cylinder system 64 damping adjustments front 96 rear 110 dealer your Honda 154 diagram wiring 150 drive chain 84 engine flooded 13 idle speed 48 number 140 oil 36 pinging
170. t tab is just contacting the float valve and the carburetor intake 27 is facing up The float level should be 0 24 in 6 0 mm If the float level is out of specification adjust it by bending the float tab carefully 17 float bowl 28 leak jet 12 11 12 13 17 12 13 15 14 16 20 18 19 17 21 24 22 24 22 23 25 26 27 28 17 118 133 qxd 06 6 15 14 47 122 Carburetor Adjustments amp Tuning Tips Adjustments for Competition 123 To assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures Route the throttle cables 1 hot start cable 2 and throttle sensor wire correctly After installing the carburetor adjust the throttle grip free play and hot start lever free play After installing the carburetor check the throttle sensor connector 3 for correct routing as necessary After installing the carburetor check the air vent hoses 4 and overflow hose 5 for kinking or pinching and correct routing as necessary 1 throttle cables 2 hot start cable 3 throttle sensor connector 4 air vent hoses 5 overflow hose 2 3 1 5 4 4 5 4 4 118 133 qxd 06 6 15 14 47 123 Carburetor Adjustments amp Tuning Tips 124 Adjustments for Competition Standard Tuning Recommendations For the followi
171. t you do not transport your CRF on its side This can damage the motorcycle and leaking gasoline could be a hazard 134 160 qxd 06 6 15 14 49 134 Storing Your Honda Tips 135 If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter page 37 3 Replace the transmission oil page 40 4 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and loosen the carburetor drain screw Drain gasoline into an approved container Tighten the drain screw WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 5 Remove the radiator cap and coolant drain bolt sealing washer 1 at the water pump 2 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washer is in go
172. tary training from the Specialty Vehicle Institute of America for purchasers of new ATVs One full year of Honda Red Rider magazine six issues Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner Racing contingency programs and assistance at selected dual sport off road and motocross events for off road motorcycles and selected ATVs If you purchased an off road motorcycle ATV or PWC your benefits do not include roadside assistance or trip interruption protection Contact your Honda dealer for more information or call 1 800 847 4722 or log on to www hrca honda com Consumer Information 155 The Honda Rider s Club 134 160 qxd 06 6 15 14 49 155 156 Table of contents Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETY 1 Important Safety Information 2 Important Safety Precautions 2 Accessories amp Modifications 3 Safety Labels 4 OPERATING CONTROLS 5 Operation Component Locations 6 BEFORE RIDING 7 Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride
173. ter Leakage Check Hole After every race check the leakage check hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced 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 Pro Honda HP Fork Oil 5W 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 p
174. 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 Perform the Pre ride Inspection at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace 001 023 qxd 06 6 15 14 28 21 22 Servicing Your Honda General Competition Maintenance 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 genuine Honda 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 9 001 023 qxd 06 6 15 14 28 22 Servicing Your Honda 23 Spark Plug Some non resistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you
175. to the rear brake pedal 10 14 Apply locking agent to the brake pedal pivot bolt threads 15 Install the washer 12 rear brake pedal and brake pedal pivot bolt 11 16 Tighten the brake pedal pivot bolt to the specified torque 27 lbf ft 36 N m 3 7 kgf m Connect the brake pedal return spring 13 if it was removed 024 054 qxd 06 6 15 14 31 53 54 Servicing Your Honda Hot Start Lever Refer to Safety Precautions on page 19 Hot Start Lever Freeplay 1 hot start lever 2 hot start lever freeplay Inspection Check freeplay 1 16 1 8 in 2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will increase freeplay and turning it counterclockwise will decrease freeplay After adjustment tighten the lock nut 3 lock nut increase 4 adjuster decrease 1 2 4 3 024 054 qxd 06 6 15 14 31 54 Servicing Your Honda 55 Refer to Safety Precautions on page 19 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions Use only the recommended type of spark plugs in the recommended heat range Using a spark plug with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause ignition prob
176. ts consider the following Spare Parts spark plugs air cleaner clean amp oiled sealed in a plastic bag optional carburetor jets needles chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front amp side number plates handlebar grips levers brake clutch amp hot start clutch lever handlebar mount clutch cable hot start cable throttle assembly throttle cable shift lever brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins Additional Spares front brake assembly rear brake assembly wheels amp tires front amp rear mounted clutch disc and plates engine amp transmission oil seat ignition components top end complete radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment Honda Special Tools Any special tools for your mot
177. 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 1 holder 2 paint mark Check the clutch cable for kinks or signs of wear If necessary have it replaced 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 2 1 024 054 qxd 06 6 15 14 31 50 Servicing Your Honda 51 Clutch System Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 40 2 Remove the rear brake pedal 1 by removing its pivot bolt 2 washer 3 and dust seals 4 1 rear brake pedal 3 washer 2 pivot bolt 4 dust seals 3 Remove the five clutch cover bolts 5 and clutch cover 6 5 clutch cover bolts 6 clutch cover 4 Remove the five clutch spring bolts and clutch springs 7 Loosen the bolts in a crisscross pattern in two or three progressive steps 5 Remove the clutch pressure plate 8 7 clutch spring bolts clutch springs 8 clutch pressure plate 6 Remove the clutch lifter 9 and clutch
178. ue wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 15 align 16 upper fork clamp 19 Tighten the fork bridge lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 20 Tighten the fork bridge upper pinch bolts 17 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced NOTICE 13 lower pinch bolts 17 upper pinch bolts 4 12 1 13 17 13 13 lower pinch bolts 14 4 4 fork damper assembly 14 lock nut wrench 18 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 pressure release screws are in front of the rebound damping adjusters Align 15 the top surface of the upper fork clamp 16 with the outer tube upper surface as shown 15 16 095 117 qxd 06 6 15 14 41 106 Front Suspension Adjustments Adjustments for Competition 107 21 Clean the threads of the fork protector bolts 18 and axle holder thoroughly Apply locking agent to the bolt threads Install the fork protectors 19 fork protector bolts and brake hose clamp bolts 20 Tighten the fork protector bolts to the specified torque 5 2 Ibf ft 7 N m 0 7 kgf m 22 Align the brake caliper 21 and hose with t
179. uine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda Your Honda Dealer 134 160 qxd 06 6 15 14 49 154 One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the Club There are hundreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow For street legal motorcycles and scooters only An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for successful completion of a Motorcycle Safety Foundation training course Separate complimen
180. umps on to you 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 39 to 0 98 in 10 to 25 mm If the rear of your CRF sags less than 0 39 in 10 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top out when you dismount your CRF 095 117 qxd 06 6 15 14 42 112 Suspension Adjustments for Track Conditions Adjustments for Competition 113 Soft Surface On soft ground sand and especially mud consider i
181. und damping adjuster has 16 positions or more Turning the rebound damping adjuster screw 1 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 9 clicks Make sure that both fork legs are adjusted to the same position Compression Damping Adjustment This adjustment affects how quickly the fork compresses The fork compression damping adjuster has 16 positions or more Turning the compression damping adjuster screw 2 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 8 clicks Make sure that both fork legs are adjusted to the same position 095 117 qxd 06 6 15 14 41 96 Adjustments for Competition 97 Front Suspension Adjustments Both compression and rebound damping can be increased by turning the adjuster clockwise Always start with full hard when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the rebound and c
182. ut one third of the maximum travel On your CRF ride height is changed by adjusting the rear suspension spring pre load Spring Pre load amp Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of the chain adjuster lock nut as illustrated here for three different situations unloaded motorcycle on 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 a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point As
183. ve shims 5 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shims Valve Clearances IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm If intake valve clearance and exhaust valve clearance need adjustment see Camshaft Removal page 58 and select the correct shim for each valve 5 1 3 2 1 5 4 1 feeler gauge 2 valve lifters 3 intake cam lobes 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 index mark 4 on the right crankcase cover In this position the piston may either be 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 index mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 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 index mark 2 3 4 2 primary drive gear bolt 4 index mark 3 punch mark 5 exhaust rocker arm 055 073 qxd 06 6 15 14 35 57 58 Ser
184. ve 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 D I D 520DMA2 114 1 2 Service limit 10 20 in 259 0 mm 074 094 qxd 06 6 15 14 38 86 Servicing Your Honda 87 Exhaust Pipe Muffler Exhaust Pipe Muffler Inspection Check the mounting bolts and joint nuts for tightness Check the exhaust pipe exhaust joint pipe and mufflers for cracks or deformation A damaged exhaust pipe exhaust joint pipe and mufflers may reduce engine performance Muffler Removal 1 Remove the seat mounting bolts 1 side cover bolts 2 and side covers 3 1 seat mounting bolt 3 side cover 2 side cover bolt 2 Loosen the muffler clamp bolts 4 3 Remove the mufflers 5 by removing the muffler mounting bolts 6 and washers 7 4 muffler clamp bolt 5 muffler 6 muffler mounting bolt 7 washer 1 3 2 5 6 7 4 074 094 qxd 06 6 15 14 38 87 88 Servicing Your Honda Exhaust Pipe Muffler Muffler Installation 1 Remove the old gasket 2 Install the muffler clamp 1 by aligning the tab 2 of the muffler clamp with the cut out 3 of each muffler 4 1 muffler clamp 3 cut out 2 tab 4 muffler 3 Install a new gaskets 5 to the exhaust joint pipe 6 4 Install each muffler to the exhaust joint pipe 5 gasket 6 exh
185. verall time Your goal is the fastest overall lap time even if the cost is some sections where the gearing feels wrong If you decide to try a gearing change have someone check your times with a stopwatch before and after the change to get an accurate appraisal of the 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 recommendations should be evaluated by considering your ability your riding style and the track 118 133 qxd 06 6 15 14 47 130 Tire Selection for Track Conditions Adjustments for Competition 131 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 ra
186. vicing Your Honda Valve Clearance Camshaft Removal 1 Record the intake valve clearance and exhaust valve clearance 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool Tensioner stopper 070MG 0010100 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 2 1 3 3 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 055 073 qxd 06 6 15 14 35 58 Servicing Your Honda 59 Valve Clearance 7 Remove the shims 8 8 shims 8 4 Remove the camshaft holder bolts 4 and camshaft holders 5 Loosen the camshaft holder bolts in a crisscross pattern in two or three steps 5 Remove the camshaft 6 and then attach a piece of wire to the cam chain to prevent it from falling into the crankcase Be careful to not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6 Remove the valve lifters 7 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left Do not let the valve lifters or shims fall into the crankcase NOTICE 7 valve lifters 6 4 5 4 7 055 073
187. will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule page 20 Engine Oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston cylinder and crankshaft Also replace engine oil filter often to ensure the greatest service life Frequent changes will also assure consistent performance of power and response page 37 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda White Lithium Grease or an equivalent
188. y outdoors Wipe up spills immediately 4 2 3 5 8 6 7 10 9 2 shroud A bolts collars 3 shroud B bolts 4 shroud 1 1 fuel valve 2 Remove the seat page 29 3 Remove the shroud A bolts collars 2 4 Remove the shroud B bolts 3 and shrouds 4 10 Remove the fuel tank 024 054 qxd 06 6 15 14 31 30 Servicing Your Honda 31 Fuel Tank Removal 2 1 3 4 7 5 6 8 9 12 11 10 Installation 1 Install the fuel tank on the frame 2 Install the fuel valve 1 and tighten the fuel valve bolt 2 3 Connect the fuel line 3 to the fuel valve 1 fuel valve 2 fuel valve bolt 3 fuel line 4 Install the collar and fuel tank bolt 4 then tighten it 5 Hook the air cleaner cover rubber 5 6 Hook the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 8 Install the shroud tab 8 onto the subframe 9 8 shroud tab 9 subframe 9 Install the shrouds 10 and shroud B bolts 11 10 shroud 11 shroud B bolts 12 shrouds A bolts collars 4 fuel tank bolt collar 5 air cleaner cover rubber 6 fuel tank band 7 breather tube 12 Install the seat page 29 10 Install and tighten the shroud A bolts collars 12 11 Tighten the shroud B bolts to the specified torque 3 7 lbf ft 5 N m 0 5 kgf m 024 054 qxd 06 6 15 14 31 31 32
189. y 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 If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel 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 Oxygenated fuels can damage paint and plastic NOTICE 134 160 qxd 06 6 15 14 49 145 146 Technical Information 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 carburetor adjustments gearing and tire selection This detailed information along with your comments can prove valuable when you compete at the same

Download Pdf Manuals

Related Search

Related Contents

manual KSK-3023BT_web  HTLV BLOT 2.4 - MP Biomedicals    My Book User Manual  Allied Telesis AT-G8LX10  NEC NP-UM330X User's Manual  - Bambozzi  Quickstart Guide Guide de démarrage  

Copyright © All rights reserved. Failed to retrieve file