Contents
MOTORCYCLE SAFETY...............................1
Important Safety Information..............................2
Important Safety Precautions..........................2
Loading................................................................3
Accessories & Modifications ..............................4
Safety Labels.......................................................5
OPERATING CONTROLS .............................7
Operation Component Locations ........................8
BEFORE RIDING ............................................9
Are You Ready to Ride? ...................................10
Is Your Motorcycle Ready to Ride?..... .............11
Pre-ride Inspection ........................................11
BASIC OPERATING INSTRUCTIONS ......13
Safe Riding Precautions................................14
Starting & Stopping the Engine ........................15
Shifting Gears....................................................17
Braking ..............................................................18
Parking ..............................................................19
Post-ride Inspection...........................................20
Break-in Guidelines ..........................................21
SERVICING YOUR HONDA........................23
Before You Service Your Honda
The Importance of Maintenance .......................24
Maintenance Safety...........................................25
Important Safety Precautions........................25
Maintenance Schedule ......................................26
General Competition Maintenance ...................29
Before & After Competition Maintenance........33
Between Motos & Practice Maintenance .....33
After Competition Maintenance ...................33
Service Preparations
Maintenance Component Locations..................35
Seat Removal ....................................................36
Fuel Tank Removal ...........................................37
Subframe Upright Position................................39
Service Procedures
Fluids & Filters
Fuel System.......................................................41
Engine Oil .........................................................43
Transmission Oil ...............................................46
Coolant ..............................................................48
Air Cleaner ........................................................51
Crankcase Breather ...........................................53
Engine
Throttle ..............................................................54
Clutch System ...................................................56
Hot Start Lever..................................................60
Spark Plug .........................................................61
Exhaust Pipe/Muffler ........................................62
Spark Arrester....................................................65
Valve Clearance.................................................66
Piston/Piston Rings/Piston Pin..........................74
Chassis
Suspension.........................................................82
Brakes................................................................86
Wheels...............................................................90
Tires & Tubes ....................................................91
Side Stand..........................................................93
Drive Chain .......................................................94
Additional Maintenance Procedures .................97
Electrical
Battery ...............................................................99
Headlight & Taillight ......................................101
Appearance Care .............................................102
ADJUSTMENTS FOR COMPETITION ...105
Front Suspension Adjustments........................106
Rear Suspension Adjustments .........................120
Suspension Adjustments for Track
Conditions .......................................................124
Suspension Adjustment Guidelines.................125
Carburetor Adjustment & Turning Tips ..........128
Chassis Adjustments........................................135
Gearing ............................................................136
Tire Selection for Track Conditions................137
Personal Fit Adjustments ................................138
TIPS ................................................................139
Transporting Your Motorcycle ........................140
Storing Your Honda.........................................141
You & the Environment ..................................143
Troubleshooting...............................................144
TAKING CARE OF THE
UNEXPECTED .............................................145
If a Fuse Blows ...............................................146
If Your Battery Is Low (or Dead)....................147
If You Crash ....................................................148
TECHNICAL INFORMATION ..................149
Vehicle Identification ......................................150
Specifications ..................................................151
Torque Specifications......................................154
High Altitude Carburetor Adjustment .............157
Emission Control Systems ..............................158
Oxygenated Fuels............................................160
Competition Logbook .....................................161
Optional Parts List ..........................................163
Spare Parts & Equipment ................................164
Wiring Diagram...............................................165
CONSUMER INFORMATION ...................167
Authorized Manuals ........................................168
Warranty Coverage..........................................169
Warranty Service .............................................170
Contacting Honda............................................171
Your Honda Dealer..........................................172
The Honda Rider’s Club (USA only) .............173
INDEX ............................................................174
QUICK REFERENCE
Contents
2012
Honda CRF250X
OWNER’S MANUAL & COMPETITION HANDBOOK
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only.
USA only:
It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway
Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal. The vehicle is equipped with a USDA qualified spark
arrester. Obey local laws and regulations.
It conforms to US EPA, California, and Environment Canada emission regulations for off-road motorcycles.
Introduction
Congratulations on choosing your Honda CRF
off-road motorcycle.
When you own a Honda, you’re part of a
worldwide family of satisfied customers-people
who appreciate Honda’s reputation for building
quality into every product.
Your Honda was designed as a recreational
motorcycle for off-road use by one rider only.
Before riding, take time to get acquainted with
your CRF and how it works. To protect your
investment, we urge you to take
responsibility for keeping your CRF well
maintained. Scheduled service is a must, of
course. But it’s just as important to observe the
break-in guidelines, and perform all the pre-ride
and other periodic checks detailed in this manual.
You should also read the owner ’s manual before
you ride. It’s full of facts,
instructions, safety information, and helpful tips.
To make it easy to use, the manual
contains a table of contents, a detailed list of
topics at the beginning of each section, and an
index at the back of the book.
As you read this manual, you will find
information that is preceded by a
symbol. This information is intended to help you
avoid damage to your Honda, other property, or
the environment.
Unless you are mechanically qualified and have
the proper tools, you should see your dealer for
the service and adjustment procedures discussed
in this manual.
NOTICE
The official Honda Service Manual for your CRF
is available (page 168). 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.
Read the Warranties Booklet (page 169)
throughly so you understand the coverages that
protect your new Honda and are aware of your
rights and responsibilities.
This motorcycle has no cooling fan. For this
reason, engine overheating and coolant loss will
occur if the engine is kept idling too long when
hot. Additionally, when riding in mud or sand, or
any condition that causes high engine load at low
vehicle speed, the time it takes for the engine to
overheat will be shortened, especially when the
ambient temperature is high. Continuing to
operate the unit in these conditions will result in
engine damage.
Whenever you ride, tread lightly. By staying on
established trails and riding only in approved
areas, you help protect the environment and keep
off-road riding areas open for the future.
If you have any questions, or if you ever need a
special service or repairs, remember that your
dealer knows your CRF best and is dedicated to
your complete satisfaction.
Please report any change of address or ownership
to your dealer so we will be able to
contact you concerning important product
information.
You may also want to visit our website at
USA: www.powersports.honda.com.
Canada: www.honda.ca.
Happy riding!
California Proposition 65
Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
Introduction
A Few Words About Safety
Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.
To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
This information alerts you to potential hazards that could hurt you or others.
Of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good
judgment.
You will find important safety information in a variety of forms, including:
•
Safety Labels –– on the motorcycle.
•
Safety Messages –– 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.
• Safety Headings –– such as Important Safety Reminders or Important Safety Precautions.
•
Safety Section –– such as Motorcycle Safety.
•
Instructions –– how to use this motorcycle correctly and safety.
This entire book is filled with important safety information –– please read it carefully.
Safety Messages
DANGER
WARNING
CAUTION
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
Loading.................................................................3
Accessories & Modifications ...............................4
Safety Labels........................................................5
Motorcycle Safety 1
Important Safety Information
Important Safety Precautions
Your CRF can provide many years of pleasure, if
you take responsibility for your own safety and
understand the challenges you can meet in
competitive racing.
There is much that you can do to protect yourself
when you ride. You’ll find many helpful
recommendations throughout this manual. The
following are a few that we consider to be most
important.
Always Wear a Helmet. It’s a proven fact:
helmets significantly reduce the number and
severity of head injuries. So always wear an
approved motorcycle helmet. We also
recommended that you wear eye protection,
sturdy boots, gloves, and other protective gear.
Never Carry a Passenger. Your CRF is designed
for one person only. There are no handholds,
footrests, or seat for a second person –so never
carry a passenger. A passenger could interfere
with your ability to move around to maintain
your balance and control of the motorcycle.
Ride Off-road Only. Your CRF is designed and
manufactured for off-road use only. The tires are
not made for pavement, and the CRF does not
have turn signals and other features required for
use on public roads. If you need to cross a paved
or public road, get off and walk your CRF across.
Always Wear Protective Gear. We recommend
that you wear sturdy boots, gloves, and other
protective gear. The exhaust system becomes
very hot during operation, and it remains hot
after operation. Never touch any part of the hot
exhaust system. Wear clothing that fully covers
your legs.
can be difficult, especially if you are stranded
off-road far from your base. To help avoid
problems, inspect your CRF before every ride
and perform all recommended maintenance.
2 Motorcycle Safety
Do not wear loose clothing which could catch on
the control levers, kickstarter, footpegs, drive
chain, or wheels.
Take Time to Learn and Practice. Developing
off-road riding skills is a gradual, step-by-step
process. Start by practicing at low speed in a safe
area and slowly build your skills.
Personal instruction from an experienced rider
can also be valuable.
If you need assistance, ask your dealer about
riding groups in your area.
Also be sure to read the
Tips & Practice Guide
for the Off-Highway Motorcyclist
booklet that
came with your CRF (USA only).
Be Alert for Off-road Hazards. The terrain can
present a variety of challenges when you ride
off-road. Continually ‘‘read” the terrain for
unexpected turns, drop-offs, rocks, ruts, and other
hazards. Always keep your speed low enough to
allow time to see and react to hazards.
Ride within Your Limits. Pushing limits is
another major cause of motorcycle crashes.
Never ride beyond your personal abilities or
faster than conditions warrant. Remember that
alcohol, drugs, fatigue, and inattention can
significantly reduce your ability to make good
judgments and ride safety.
Don’t Drink and Ride. Alcohol and riding don’t
mix. Even one drink can reduce your ability to
respond to changing conditions, and your
reaction time gets worse with every additional
drink. So don’t drink and ride, and don’t let your
friends drink and ride either.
Keep Your Honda In Safe Condition. It’s
important to keep your CRF properly maintained
and in safe riding condition. Having a breakdown
Loading
Your CRF was designed as a rider-only
motorcycle. It was not designed to carry a
passenger or cargo. A passenger or cargo could
interfere with your ability to move around to
maintain your balance and control of the CRF.
In addition, exceeding the weight limits or
carrying an unbalanced load can seriously affect
your CRF’s handling, braking, and stability.
Adding accessories or making modifications that
change this CRF’s design and performance can
also make it unsafe. Also, the weight of any
accessories will reduce the maximum load the
motorcycle can carry.
More specific information on load limits,
accessories, and modifications follows.
Loading
How much weight you put on your CRF, and
how you load it, are important to your safety. If
you decide to carry cargo, you should be aware
of the following information.
Loading Guidelines
As discussed on page 2, we recommended that
you do not carry any cargo on this motorcycle.
However, if you decide to carry cargo, ride at
reduced speeds and follow these commonsense
guidelines:
• Keep cargo small and light. Make sure it
cannot easily be caught on brush or other
objects, and that it does not interfere with
your ability to shift position to maintain
balance and stability.
• Place weight as close to the center of the
motorcycle as possible.
• Do not attach large or heavy items (such as a
sleeping bag or tent) to the handlebar, fork, or
front fender.
• Check that both tires are inflated properly.
Motorcycle Safety 3
WARNING
Overloading or carrying a passenger can
cause a crash and you can be seriously
hurt or killed.
Follow all loading guidelines in this
manual.
Accessories & Modifications
Accessories
We strongly recommend that you use only Honda
Genuine accessories that have been specifically
designed and tested for your CRF. Because
Honda cannot test all other accessories, you must
be personally responsible for proper selection,
installation, and use of non-Honda accessories.
Check with your dealer for assistance and always
follow this guideline:
• Make sure the accessory does not reduce
ground clearance and lean angle, limit
suspension travel or steering travel, alter your
riding position, or interfere with operating any
controls.
Modifications
We strongly advise you not to remove any
original equipment or modify your CRF in any
way that would change its design or operation.
Such changes could seriously impair your CRF ’s
handling, stability, and braking, making it unsafe
to ride.
We also advice you not to make any
modifications or remove any equipment (such as
the USDA qualified spark arrester or emission
control system components) that would make the
motorcycle illegal in your area.
4 Motorcycle Safety
Accessories & Modifications
Modifying your CRF or using non-Honda
accessories can make your CRF unsafe.
Before you consider making any modifications or
adding an accessory, be sure to read the
following information.
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.
Motorcycle Safety 5
For Canada
Safety Labels
This page shows the locations of safety labels on your CRF . Some labels warn you of potential hazards that could cause serious injury. Others provide
important safety information. Read these labels carefully and don ’t remove them.
If the label comes off or becomes hard to read, contact your dealer for replacement.
6 Motorcycle Safety
Operating Controls 7
Operating Controls
Read this section carefully before you ride. It
presents the location of the basic controls on your
CRF.
Operation Component Locations .........................8
8 Operating Controls
Operation Component Locations
clutch lever
hot start lever
front brake lever
engine stop button
throttle grip
tripmeter
start button
choke knob
fuel valve shift lever
kickstarter
rear brake pedal
Before Riding 9
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 105.
Before Riding
Are You Ready to Ride?.....................................10
Is Your Motorcycle Ready to Ride? ...................11
Pre-ride Inspection ...........................................11
10 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 operate the controls.
Before each ride, it’s also important to make sure
you and your CRF are both ready to ride.
For information about suspension, carburetor,
and other adjustments, see page 105.
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.
Before Riding 11
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 .............................................44
• Transmission oil level...................................47
• Coolant for proper level................................48
• Cooling system and hoses for condition.......49
• Spark plug for proper heat range, carbon
fouling and direct ignition coil connector
for looseness .................................................61
• Air cleaner for condition and
contamination................................................51
• Clutch operation and freeplay.......................56
• Hot start lever freeplay .................................60
• Breather drain for cleaning ...........................53
• Steering head bearings and related parts
for condition..................................................97
• Carburetor throttle operation ........................55
• Engine idle speed for stable and proper
RPM ............................................................134
• Tires for damage or improper inflation
pressure ........................................................91
• Spokes for looseness.....................................90
• Rim locks for looseness ................................90
• Front and rear suspension for proper
operation ..................................................82,83
• Front and rear brakes, check operation ........87
• Drive chain for correct slack and
adequate lubrication......................................94
• Drive chain sliders and drive chain rollers
for damage or wear .......................................96
• Exhaust pipe/Muffler inspection...................62
• Every possible part for looseness (such as
cylinder head nuts, engine mounting
bolts/nuts, axle nuts, handlebar holder bolts,
fork bridge pinch bolts, drive chain adjuster,
drive chain guide, wire harness connectors,
kickstarter mounting bolt, etc.) ......98,154-156
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.
12 Before Riding
Basic Operating Instructions 13Basic Operating Instructions 13
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................................14
Side Stand .....................................................14
Tripmeter.......................................................14
Starting & Stopping the Engine .........................15
Preparation ....................................................15
Fuel Valve .....................................................15
Starting Procedure ........................................15
Flooded Engine.............................................16
How to Stop the Engine................................16
Shifting Gears.....................................................17
Braking ...............................................................18
Parking ...............................................................19
Post-ride Inspection............................................20
Break-in Guidelines ...........................................21
Tripmeter
The tripmeter (1) is used to record the distance
traveled (USA: miles, Canada: kilometers) per
trip or section of route.
To operate, pull the tripmeter reset knob (2) out
(OFF) and turn it until the meter shows all zeros
(0), then push the knob in (ON).
14 Basic Operating Instructions14 Basic Operating Instructions
Basic Operating Instructions
Safe Riding Precautions
Before riding your CRF for the first time, please
review the
Important Safety Precautions
beginning on page 2 and the previous section,
titled
Before Riding.
For your safety, avoid starting or operating the
engine in an enclosed area such as a garage.
Your CRF’s exhaust contains poisonous carbon
monoxide gas which can collect rapidly in an
enclosed area and cause illness or death.
(1) side stand
(1) tripmeter
(2) tripmeter reset knob
(1)
(2)
(1)
OFF ON
Side Stand
The side stand (1) is used to support your C RF
while parked (page 19). To operate, use your foot
to lower the side stand until it is fully extended.
Before riding, raise the side stand.
Starting & Stopping the Engine
Always follow the proper starting procedure
described below.
Your CRF can be started with the transmission in
gear by pulling in the clutch lever before
operating the kickstarter or start button.
Preparation
Make sure that the transmission is in neutral.
Turn the fuel valve ON.
Fuel Valve
Starting Procedure
Always follow the proper starting procedure
described as follow.
To restart a warm engine, follow the procedure
for ‘‘High Air Temperature.”
Normal
Air Temperature 10°C-35°C (50°F-95°F)
1. Turn the fuel valve (1) ON.
2. Pull the choke knob (2) fully ON, if the
engine is cold.
3. Keep the throttle fully closed.
4. Pull the clutch lever all the way in, and depress
the start button. Or operate the kickstarter to
start the engine. Starting from the top of the
stroke, kick through to the bottom with a rapid,
continuous motion. Do not operate the throttle.
Allowing the kickstarter to snap back freely
against the pedal stop can damage the engine
case.
5. Warm up the engine; don’t operate the
throttle.
6. About 15 seconds after the engine starts, push
the choke knob all the way to fully OFF. If
idling is unstable, open the throttle slightly.
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
NOTICE
NOTICE
Basic Operating Instructions 15
(1) fuel valve
The three-way fuel valve is used to control the
flow of fuel from the fuel tank to the carburetor .
ON–Turning the fuel valve ON before attempting
to start the engine allows fuel to flow from the
fuel tank to the carburetor.
OFF–Turning the fuel valve OFF prevents the
flow of fuel from the fuel tank to the carburetor .
RES–Turning the fuel valve to RES allows fuel
to flow from the reserve fuel supply to the
carburetor.
(1) fuel valve (2) choke knob
Check the engine oil, transmission oil and
coolant levels before starting the engine
(pages 44,47,48).
Snapping the throttle or fast idling for more than
5 minutes may cause exhaust pipe discoloration.
ON OFF RES
(1)
(1)
(2)
Starting & Stopping the Engine
Flooded Engine
Starting the engine after a stall during riding or
after a fall:
1. Shift the transmission into neutral.
2. Pull the hot start lever all the way in and start
the engine.
(Do not open the throttle).
3. As soon as the engine starts, release the hot
start lever.
Starting a flooded engine:
(Using the start button)
1. Do not use the choke.
2. Shift the transmission into neutral with the
throttle fully opened.
3. Pull the hot start lever and clutch lever all the
way in and depress the start button for 5
seconds.
If the engine starts, quickly close the throttle,
then open it slightly if idling is unstable. If the
engine does not start, wait 10 seconds, and
then follow the regular starting procedure.
4. As soon as the engine starts, release the hot
start lever.
(Using the kickstarter)
1. Do not use the choke.
2. Shift the transmission into neutral with the
throttle fully opened, repeat kickstarter
operation approximately ten times very slowly
to discharge excessive fuel from the engine.
Close the throttle.
3. Pull the hot start lever all the way in and start
the engine (Do not open the throttle.)
4. As soon as the engine starts, release the hot
start lever.
16 Basic Operating Instructions
How to Stop the Engine
(1)
(2)
(1) throttle (2) engine stop button
Normal Engine Stop
1. Shift the transmission into neutral.
2. Turn the fuel valve OFF.
3. Lightly open the throttle (1) two or three
times, and then close it.
4. Push 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.
Emer
gency Engine Stop
To stop the engine in an emergency, push and
hold the engine stop button.
High
Air Temperature 35°C (95°F) or above
1. Do not use the choke.
2. Keep the throttle fully closed.
3. Start the engine following step 4 under
“Normal Air Temperature”.
Low
Air Temperature 10°C (50°F) or below
1. Follow steps 1-4 under “Normal Air
Temperature”.
2. Continue warming up the engine until it runs
smoothly and responds to the throttle when
the choke knob is pushed back all the way to
fully OFF.
Extended use of the choke may impair piston and
cylinder wall lubrication and damage the engine.
Hot Engine Starting
1. Pull the hot start lever (3) all the way in and
start the engine following step 4 under
“Normal Air Temperature”.
2. As soon as the engine starts, release the hot
start lever.
NOTICE
(3)
(3) hot start lever
Shifting Gears
Remember to close the throttle and pull the
clutch lever in completely before shifting.
Improper shifting may damage the engine,
transmission, and drive train.
Learning when to shift gears comes with
experience. Upshift to a higher gear or reduce
throttle before engine rpm (speed) gets too high.
Downshift to a lower gear before you feel the
engine laboring (lugging) at low rpm.
Downshifting can help slow your motorcycle,
especially on downhills. However, downshifting
when engine rpm is too high can cause engine
damage.
To prevent transmission damage, do not coast or
tow the motorcycle for long distances with the
engine off.
NOTICE
Basic Operating Instructions 17
Your CRF has five forward gears in a one-down,
four-up shift pattern.
To start riding, after the engine has been warmed
and the side stand raised.
1. Close the throttle and pull the front brake
lever in.
2. Pull the clutch lever all the way in.
3. Depress the shift lever from neutral down to
first gear.
4. Release the front brake lever. Gradually open
the throttle while you slowly release the
clutch lever. If the engine rpm (speed) is too
low when you release the clutch lever, the
engine will stall.
If the engine rpm (speed) is too high or you
release the clutch lever too quickly, your CRF
may lurch forward.
5. When you attain a moderate speed, close the
throttle, pull the clutch lever in, and raise the
shift lever. After shifting, release the clutch
lever and apply the throttle.
6. To continue shifting up to each higher gear,
repeat step 5.
7. To shift down to a lower gear, close the
throttle, pull the clutch lever in, and depress
the shift lever. After shifting, release the
clutch lever and apply the throttle.
NOTICE
NOTICE
Braking
To slow or stop, apply the front brake lever and
rear brake pedal smoothly, while downshifting to
match your speed. Gradually increase braking as
you feel the brakes slowing your speed. To
prevent stalling the engine, pull the clutch lever
in before coming to a complete stop. For support,
put your left foot down first, then your right foot
when you are through using the rear brake pedal.
For maximum braking, close the throttle and
firmly apply the front brake lever and rear brake
pedal controls.
Applying the brakes too hard may cause the
wheels to lock and slide, reducing control of your
CRF. If this happens, release the brake controls,
steer straight ahead until you regain control, then
reapply the brakes more gently.
Generally, reduce your speed or complete
braking before beginning a turn. Avoid braking or
closing the throttle quickly while turning. Either
action may cause one or both wheels to slip. Any
wheel slip will reduce your control of your CRF.
When riding in wet or raining conditions, or on
loose surfaces, the ability to maneuver and stop
will be reduced. All of your actions should be
smooth under these conditions. Rapid
acceleration, braking, or turning may cause loss
of control. For your safety, exercise extreme
caution when braking, accelerating, or turning.
When descending a long, steep grade, use engine
compression braking by downshifting, with
intermittent use of both brakes.
When you brake to a stop, pull the clutch lever in
before stopping completely to prevent stalling the
engine. For support, put your left foot on the
ground first, then your right foot when you have
finished braking.
18 Basic Operating Instructions
Parking
Lower the side stand to support your CRF.
If you’re through riding for the day, turn the fuel
valve OFF. Always choose a level surface to
park.
Basic Operating Instructions 19
Post-ride Inspection
When you return home after riding, thoroughly
clean your CRF and remove any dirt, mud, brush,
rocks or other objects you may have picked up
along the way.
After cleaning, carefully inspect your CRF for
leaks or damage.
Be sure to lubricate the drive chain (page 96) to
prevent rusting.
20 Basic Operating Instructions
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
Basic Operating Instructions 21
Break-in Guidelines
22 Basic Operating Instructions
Servicing Your Honda 23
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
required servicing and step-by-step instructions
for specific maintenance tasks. You’ll also find
important safety precautions, information on oils,
and tips for keeping your Honda looking good.
The ICM (Ignition Control Module) system is
used on this motorcycle; consequently, routine
ignition timing adjustment is unnecessary. If you
want to check the ignition timing, refer to the
Honda Service Manual (page 168).
For information about the exhaust emission and
noise emission requirements of the U.S.
Environmental Protection Agency (EPA), the
California Air Resouses Board (CARB), and
Environment Canada (EC), see page 158.
An optional tool kit may be available.
Check with your dealer’s parts department.
USA only
Maintenance, replacement or repair of the
emission control devices and systems may be
performed by any motorcycle repair
establishment or individual using parts that
are “certified” to EPA standards.
Before You Service Your Honda
The Importance of Maintenance ........................24
Maintenance Safety............................................25
Important Safety Precautions........................25
Maintenance Schedule .......................................26
General Competition Maintenance ....................29
Before & After Competition Maintenance.........33
Between Motos & Practice Maintenance .....33
After Competition Maintenance ...................33
Service Preparations
Maintenance Component Locations...................35
Seat Removal .....................................................36
Fuel Tank Removal ............................................37
Subframe Upright Position.................................39
Service Procedures
Fluids & Filters
Fuel System........................................................41
Engine Oil ..........................................................43
Transmission Oil ................................................46
Coolant ...............................................................48
Air Cleaner .........................................................51
Crankcase Breather ............................................53
Engine
Throttle ...............................................................54
Clutch System ....................................................56
Hot Start Lever...................................................60
Spark Plug ..........................................................61
Exhaust Pipe/Muffler .........................................62
Spark Arrester.....................................................65
Valve Clearance..................................................66
Piston/Piston Rings/Piston Pin...........................74
Chassis
Suspension..........................................................82
Front Suspension Inspection........................82
Rear Suspension Inspection.........................83
Recommended Fork Oil ..............................84
Fork Oil Change ..........................................84
Brakes.................................................................86
Wheels................................................................90
Tires & Tubes .....................................................91
Side Stand...........................................................93
Drive Chain ........................................................94
Additional Maintenance Procedures ..................97
Electrical
Battery ................................................................99
Headlight & Taillight .......................................101
Appearance Care ..............................................102
Remember, proper maintenance is your
responsibility. Be sure to inspect your CRF
before each ride and follow the Maintenance
Schedule in this section.
24 Servicing Your Honda
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
A well-maintained motorcycle is essential for
safe, economical, and trouble-free riding. It will
also help reduce air pollution. Careful pre-ride
inspections and good maintenance are especially
important because your CRF is designed to be
ridden over rough off-road terrain.
To help you properly care for your CRF, this
section of the manual provides a Maintenance
Schedule. The service intervals in this schedule
are based on average riding conditions.
More frequent service is needed if you subject
your CRF to severe use or ride in unusually wet
or dusty areas.
Frequent servicing of the air cleaner is especially
important to help you avoid a possible costly
engine repair.
If your CRF overturns or is involved in a crash,
be sure your dealer inspects all major parts, even
if you are able to make some repairs.
Servicing Your Honda 25
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 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 a
side stand or an optional workstand to provide
support.
• To reduce the possibility of a fire or
explosion, be careful when working around
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene — not
gasoline — to clean parts. Keep cigarettes,
sparks, and flames away from all fuel-related
parts.
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.
26 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 Schedules –
Regular OFF-ROAD Use (non-competition) and
Competition Use – that follow.
The Maintenance Schedule lists items that can be
performed with basic mechanical skills and hand
tools. Procedures for these items are provided in
this manual.
The Maintenance Schedule also includes items
that involve more extensive procedures and may
require special training, tools, and equipment.
Therefore, we recommend that you have your
dealer perform these tasks unless you have
advanced mechanical skills and the required
tools. Procedures for items in these schedules
are provided in a service manual available for
purchase from your dealer (page 168).
Because your CRF does not have an odometer,
service intervals in the maintenance schedules are
expressed in terms of riding days as well as
miles. To avoid overlooking required service, we
urge you to develop a convenient way to record
the number of days and/or distance traveled
(USA: miles, Canada: kilometers) you ride.
If you do not feel capable of performing a given
task or need assistance, remember that your
Honda dealer knows your CRF best and is fully
equipped to maintain and repair it. If you decide
to do your own maintenance, use only Honda
Genuine Parts or their equivalents for repair or
replacement to ensure the best quality and
reliability.
Perform the pre-ride inspection (page 11) at each
scheduled maintenance period.
Each item on the maintenance schedule requires
some mechanical knowledge. Certain items
(particularly those marked *and**) may require
more technical information and tools. Consult
your dealer.
* Should be serviced by your dealer, unless the
owner has proper tools and service data and is
mechanically qualified.
Refer to the official Honda Service Manual
(page 168).
** In the interest of safety, we recommend these
items be serviced only by your dealer.
Maintenance Procedures:
I: inspect and clean, adjust, lubricate, or replace
if necessary
C: clean
A: adjust
L: lubricate
R: replace
Maintenance Schedule
Servicing Your Honda 27
Summary of Maintenance Schedule Notes and
Procedures;
NOTES:
1. Service more frequently when ridden in wet
or dusty conditions.
2. USA and Canada type only.
3. Replace every 2 years. Replacement requires
mechanical skill.
(NOTE 1)
(NOTE 3)
(NOTE 2)
(NOTE 1)
(NOTE 3)
I
R
R
I
I
I
R
I, L
I
I
I
I
I
C
I
I
I
R
R
I
I
I
R
I
I
I
I
I
I
I
C
I
C
I
I
I
R
R
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
C
I
I
I
R
R
I
I
I
R
I
I
I
I
I
I
I
C
I
C
I
I
I
R
R
I
I
R
I
I
R
I
I
I
I
I
I
I
I
I
I
I
41
42
55
51
53
61
66
44
44
–
134
48,50
49
–
47
94,96
96
87
89
87
101
56
93
82,83
65
98,154-156
90,91
97
FUEL LINE
FUEL STRAINER SCREEN
THROTTLE OPERATION
AIR CLEANER
CRANKCASE BREATHER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
DECOMPRESSOR SYSTEM
ENGINE IDLE SPEED
RADIATOR COOLANT
COOLING SYSTEM
SECONDARY AIR SUPPLY SYSTEM
TRANSMISSION OIL
DRIVE CHAIN
DRIVE CHAIN SLIDER
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
HEADLIGHT AIM
CLUTCH SYSTEM
SIDE STAND
SUSPENSION
SPARK ARRESTER
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARINGS
FREQUENCY
ITEMS
NOTE
mi
km
Month
100
150
1
600
1,000
6
1,200
2,000
12
I, L: every 300 mi (500 km) or 3 months
C: every 1,000 mi (1,600 km) or
every 100 operating hours
1,800
3,000
18
2,400
4,000
24
Refer
to
Page:
Whichever
Comes First
Initial
Maintenance
Regular Maintenance Interval
Should be serviced by your dealer, unless the o wner has proper tools and ser vice data and is mechanically qualified. Refer to the official Honda
Service Manual (page 168).
In the interest of safety, we recommended these items be serviced only by your dealer.
*
**
MAINTENANCE SCHEDULE – REGULAR OFF-ROAD USE (NON-COMPETITION)
28 Servicing Your Honda
Maintenance Schedule
MAINTENANCE SCHEDULE – COMPETITION USE
All items should be checked before each competition event. See your dealer unless you are mechanically qualified and have the p roper tools.
Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda.
Perform the Pre-ride Inspection (page 11) at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.
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)
55
60
51
53
61
48
66
44
44
134
76
76
47
49
94-96
96
96
95
95
87
89
86
56
97
62
82,83
32
84
111
98,154-156
90,91
97
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
R
I
FORK TUBE/SLIDER
DAMPER
FREQUENCY
NOTE Ref. Page
About
2.5 hours
About
7.5 hours
About
15.0 hours
About
22.5 hours
About
30.0 hours
This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing.
NOTE: 1. Clean after every heat for dusty riding conditions.
2. Replace every 2 years. Replacement requires mechanical skill.
3. Replace after the first break-in ride.
4. Inspect after the first break-in ride.
5. Replace the transmission oil, if the clutch discs and plates are replaced.
Servicing Your Honda 29
General Competition Maintenance
Perform maintenance on firm, level ground using
the side stand, a workstand, or equivalent
support.
When tightening bolts, nuts or screws, start with
the larger diameter or inner fasteners, and tighten
them to the specified torque using a crisscross
pattern.
Use Honda Genuine Parts or their equivalent
when servicing your CRF.
Clean parts in non-flammable (high flash point)
cleaning solvent (such as kerosene) when
disassembling. Lubricate any sliding surface,
O-rings, and seals before reassembling. Grease
parts by coating or filling where specified.
After any engine disassembly, always install new
gaskets, O-rings, cotter pins, piston pin clips,
snap rings, etc. when reassembling. After
reassembly, check all parts for proper installation
and operation.
All Pre-ride Inspection Items
Refer to Pre-ride Inspection page 11.
30 Servicing Your Honda
Spark Plug
Some non-resistor plugs may cause ignition problems. Refer
to the recommendations elsewhere in this manual for specific
types so you will be sure to use the proper reach and heat
range. Replace periodically as specified in the Maintenance
Schedule (pages 27, 28).
Engine oil and Filter
Drain and replace the engine oil often to ensure the greatest
service life of the piston, cylinder and crankshaft.
Also replace the engine oil filter often to ensure the greatest
service life. Frequent oil changes will also assure consistent
engine power and response. (page 44).
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 through it. Inspect the air
cleaner closely each time it’s serviced for evidence of small
tears or seam separation. Keep a spare air cleaner oiled and
ready to install, sealed in a plastic bag. Riding in dusty
conditions may require servicing the air cleaner or replacing
it with a pre-serviced air cleaner between motos. Be careful
not to over oil the air cleaner. While it is important to oil the
air cleaner thoroughly, over oiling will cause an overall rich
running condition, probably more noticeable off idle and in
low-rpm performance. Follow the servicing instructions in
the Maintenance section. Use Pro Honda Foam Filter Oil or
an equivalent. Be sure to grease the air cleaner flange where
it contacts the air cleaner housing. Pro Honda White
Lithium Grease, or an equivalent, is handy for this because
any dirt that penetrates this sealing area will show up clearly
(page 51).
Use a Honda Genuine air cleaner or an equivalent air cleaner
specified for your model.
Using the wrong Honda air cleaner or a non-Honda air
cleaner which is not of equivalent quality may cause
premature engine wear or performance problems.
Transmission Oil
Drain and replace the transmission oil often to ensure the
greatest service life of the transmission and clutch. Frequent
changes will also assure consistent shifting and clutch
performance (page 47).
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 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
General Competition Maintenance
Handgrips
Always use Pro Honda Handgrip Cement or equivalent when
replacing handgrips.
Throttle grip
Align the index mark on the throttle grip with the edge of the
throttle cable guide. Left handlebar grip: Align the “∆” mark
on the left handlebar grip with the paint mark on the
handlebar.
Refer to the Honda Service Manual (page 168) for installation
instructions.
For added security, you may choose to bind the handgrips to
the handlebar and throttle pipe with safety wires to prevent
the possibility of them loosening. Position the twisted wire
ends away from your palms and be sure to bend the wire
ends well into the handgrip rubber so they will not snag your
glove.
Throttle Control
Remove the throttle control every few rides, clean the inside
of the throttle pipe and handlebar thoroughly. Inspect the
cable carefully for kinks or other damage that may restrict
throttle control in any way. Move the handlebar from lock to
lock to be sure there is no cable interference. Make certain
the throttle operation is perfect after servicing and
inspecting.
Fuel Filter
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 deterioration (page 42).
Cylinder
Put a little grease on the cylinder mounting dowels to
prevent corrosion from dissimilar metals. The tolerances are
extremely tight, so it’s important to keep these dowels
absolutely clean (page 76).
Fuel Contamination
Refer to Fuel System, in your Owner’s Manual (page 41).
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 deterioration (page
42).
Loosen the carburetor drain screw and examine the fuel that
flows out of the float bowl. If you notice anything in the
fuel, such as water or dirt, remove the float bowl and inspect
its contents (page 131).
For maximum efficiency, drain and replace fuel that has
been in the fuel tank for more than a month.
Gaskets
Always use new gaskets when reassembling components.
Engine Mounting Bolts and Nuts
Make sure the engine mounting bolts and nuts are tightened
to the proper torque specification (page 155). For added
peace of mind, remove the nuts, clean the threads, and apply
Pro Honda Hondalock or an equivalent before 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. For additional corrosion
protection, apply Pro Honda Dielectric Grease to all
electrical connections.
Battery
Electrical accessories use current from the battery – even
when the engine is off.
Limited operation also allows the battery to discharge. If you
have electrical accessories on your CRF – or do not ride
frequently, we recommend that you charge the battery
frequently (see Battery Charging, page 100).
If you do not expect to ride your CRF for at least two weeks,
we recommend you remove the battery – or at least
disconnect the battery cables (negative cable first).
Servicing Your Honda 31
Swingarm Pivot Lubrication
Clean, inspect and lubricate the swingarm and suspension
linkage pivots with grease. Be sure all of the dust seals are
in good condition.
Swingarm
Do not attempt to weld or otherwise repair a damaged
swingarm. Welding will weaken the swingarm.
Footpegs
Worn footpeg teeth can be repaired by filing the grooves
between the teeth with a triangular-shaped file.
Be aware that filing them too sharp will reduce boot sole
lifespan. Sharpen only the points of the teeth. Filing the
grooves deeper will weaken the footpegs. Be sure the pegs
are free to pivot freely and that the pivot pin retaining cotter
pins are in good condition.
Fuse
Check the fuse before looking elsewhere for the cause of an
electrical problem.
Brake Fluid Replacement
Refer to Brake Pad Wear in your Owner’s Manual, page 89.
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).
Bleed Hole
After every race, check the bleed hole, located just below the
water pump cover on the right crankcase cover. Clean away
any clogged dirt or sand, if necessary. Check for signs of
seal leakage. A small amount of “weeping” from the bleed
hole is normal.
Fork Oil/Performance
Disassemble, clean and inspect the fork and replace the oil
regularly. Contamination due to the tiny metal particles
produced from the normal action of the fork, as well as
normal oil breakdown, will deteriorate the performance of
the suspension. Refer to the Honda Service Manual (page
168). Use only Pro Honda HP Fork Oil 5W (U.S.A. only) or
equivalent which contains special additives to assure
maximum performance of your CRF’s front suspension.
Frame
Because your CRF is a high-performance machine, the frame
should not be overlooked as part of your overall competition
maintenance program. Periodically inspect the frame
closely for possible cracking or other damage. It makes
good racing sense.
Spokes
Check spoke tension frequently between the first few rides.
As the spokes, spoke nuts and rim contact points seat-in, the
spokes may need to be retightened. Once past this initial
seating-in period, the spokes should hold their tension. Still,
be sure your race maintenance program includes checking
spoke tension and overall wheel condition on a regular basis
(page 90).
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.
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.
GREASE
General Competition Maintenance
32 Servicing Your Honda
Before & After Competition Maintenance
Between Motos & 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 security.
• Check sprocket bolt and nut security.
• Clean the sides of the drive chain with a stif f,
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.
(1) chain adjuster index marks
• Suspend the front wheel above the ground and
use the pressure release screws (2) to release
the built-up pressure (in excess of normal
atmospheric pressure: 0 psi (0 kPa, 0 kgf/cm
2
))
in the fork tubes. This pressure is caused by
normal fork action while riding. (If you are
riding at altitude, remember that fork pressure
of 0 at sea level will increase as elevation
increases.)
(2) pressure release screw
(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
the brake discs.
Clean and lubricate the drive chain (page 96).
Be sure the chain is wiped clean and is dry
before lubricating the chain.
Take care to prevent catching your fingers
between the chain and sprocket.
Servicing Your Honda 33
Before & 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 stif f bristled
nylon brush and some clean rags.
Take care to prevent catching your fingers
between the chain and sprocket.
A variety of reasonably priced cleaning brushes
are available from variety, drug, food, and
hardware stores. Some of these brushes are
extremely useful in removing dirt from the many
tight contours of the metal pieces of your CRF.
Avoid using stiff, abrasive brushes on the plastic
or rubber parts.
If your CRF was exposed to sea air or salt water ,
rinse it as soon as possible after the event, dry it,
and apply a spray lubricant to all metal parts.
If you decide to wash your CRF or use cleaners,
refer to
Appearance Care (page 102).
34 Servicing Your Honda
Maintenance Component Locations
front brake caliper
spark plug
throttle stop screw
(engine idle speed)
choke knob
coolant reserve tank
crankcase breather
tube
spark arrester
rear suspension
spring pre-load
adjuster
drive chain
transmission
oil drain bolt
engine oil
drain bolt
engine oil fill
cap/dipstick
engine oil filter
air cleaner
battery
rear suspension high speed
damping adjuster
rear suspension low speed
damping adjuster
rear brake
caliper
main
fuse
rear brake
fluid reservoir
rear brake
pedal
transmission
oil check bolt
transmission oil
fill cap
front suspension rebound
damping adjuster
rear suspension
rebound damping
adjuster
front suspension
compression damping
adjuster
clutch lever
hot start lever
front brake lever
fuel fill cap
throttle grip
radiator cap
front brake fluid reservoir
Servicing Your Honda 35
Seat Removal
Refer to Safety Precautions on page 25.
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 seat front
prong (3) with the seat bracket (4) and seat
rear prong (5) with the tab (6) of the frame.
2. Install and tighten the seat mounting bolts to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(2)
(1)
(3)
(5)
(6)
(4)
36 Servicing Your Honda
(3) seat front prong
(4) seat bracket
(5) seat rear prong
(6) tab
Fuel Tank Removal
Refer to Safety Precautions on page 25.
Removal
1. Turn the fuel valve OFF.
2. Remove the seat (page 36).
3. Remove the shroud A bolts/collars (1).
4. Remove the shroud B bolts (2) and shrouds
(3).
(1) shroud A bolts/collars
(2) shroud B bolts
(3) shroud
5. Pull the breather tube (4) out of steering stem
nut.
6. Unhook and remove the fuel tank band (5).
7. Unhook the air cleaner cover rubber (6).
8. Remove the fuel tank bolt (7).
(4) breather tube
(5) fuel tank band
(6) air cleaner cover rubber
(7) fuel tank bolt
9. Disconnect the fuel line (8) from the fuel
valve (9). The fuel line leading to the
carburetor must be disconnected, not the fuel
line leading to the fuel tank.
(8) fuel line (10) fuel valve bolt
(9) fuel valve
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.
(3)
(2)
(1)
(4)
(7)
(5)
(6)
(9)
(8)
(10)
Servicing Your Honda 37
10. Remove the fuel valve bolt (10) and fuel
valve.
11. Remove the fuel tank.
Fuel Tank Removal
(1)
(3)
(2)
(8)
(9)
(10)
Installation
1. Install the fuel tank on the frame.
2. Install the fuel valve (1) and tighten fuel valve
bolt (2).
3. Connect the fuel line (3) to the fuel valve.
(1) fuel valve (3) fuel line
(2) fuel valve bolt
4. Install and tighten the fuel tank bolt (4).
5. Hook the air cleaner cover rubber (5).
6. Install the fuel tank band (6).
7. Put the breather tube (7) in the steering stem
nut.
8. Install the shrouds (8) and shroud B bolts (9).
Tighten the shroud B bolts to the specified
torque:
3.7 lbf·ft (5 N·m, 0.5 kgf·m)
9. Install the shroud A bolts/collars (10).
(8) shroud
(9) shroud B bolts
(10) shroud A bolts/collars
(4) fuel tank bolt (6) fuel tank band
(5) air cleaner cover rubber (7) breather tube
38 Servicing Your Honda
(7)
(4)
(6)
(5)
10. Install the seat (page 36).
Subframe Upright Position
Refer to Safety Precautions on page 25.
The subframe may be adjusted to an upright
position to permit servicing of the rear
suspension.
Upright Position
1. Remove the right side cover bolt (1), collar
(2), seat mounting bolt (3) and right side
cover (4).
4. Remove the muffler (page 62).
5. Remove the wire band (12).
(12) wire band
6. Loosen the screw (13) on the air cleaner
connecting tube clamp (14).
(13) screw
(14) air cleaner connecting tube clamp
Servicing Your Honda 39
7. Loosen the subframe mounting upper bolt
(15) and remove the subframe mounting lower
bolts (16).
(15) subframe mounting upper bolt
(16) subframe mounting lower bolts
8. Lift the subframe (17) as shown.
Tighten the subframe mounting upper bolt to
the specified torque:
22 lbf·ft (30 N·m, 3.1 kgf·m)
(1) right side cover bolt (3) seat mounting bolt
(2) collar (4) right side cover
2. Open the air cleaner housing cover (5) by
turning the quick fastener (6)
counterclockwise and remove the left side
cover bolt (7), collar (8), seat mounting bolt
(9) and left side cover (10).
3. Remove the seat (11) (page 36).
(12)
(14)
(13)
(16)
(15)
90°
(17)
(17) subframe
(5) air cleaner housing cover (9) seat mounting bolt
(6) quick fastener (10) left side cover
(7) left side cover bolt (11) seat
(8) collar
(3)
(1)
(2)
(4)
(5)
(6)
(7)
(10)
(11)
(9)
(8)
Subframe Upright Position
4. Tighten the screw (5) on the air cleaner
connecting tube clamp (6).
7. Install the seat (8) (page 36).
8. Install the left side cover (9), seat mounting
bolt (10), collar (11) and left side cover bolt
(12). Close the air cleaner housing cover (13)
and turn the quick fastener (14) clockwise.
(8) seat (12) left side cover bolt
(9) left side cover (13) air cleaner housing cover
(10) seat mounting bolt (14) quick fastener
(11) collar
9. Install the right side cover (15), seat mounting
bolt (16), collar (17) and right side cover bolt
(18).
(7) wire band
6. Install the muffler (page 63).
(1) subframe mounting upper bolt
(2) subframe
(3) subframe mounting lower bolts
(4) hoses
Installation
1. Loosen the subframe mounting upper bolt (1).
2. Loosely attach the lower ends of the subframe
(2) to the mainframe while connecting the air
cleaner connecting tube to the carburetor.
Install the subframe mounting lower bolts (3).
Tighten the subframe mounting lower bolts
and subframe mounting upper bolt to the
specified torque:
upper bolt:
22 lbf·ft (30 N·m, 3.1 kgf·m)
lower bolts: 36 lbf·ft (49 N·m, 5.0 kgf·m)
3. Check the hoses (4) for slack.
40 Servicing Your Honda
(3)
(1)
(2)
(4)
(6)
(5)
(5) screw
(6) air cleaner connecting tube clamp
5. Install the wire band (7).
(7)
(8)
(13)
(14)
(12)
(11)
(10)
(9)
(16)
(18)
(17)
(15)
(15) right side cover
(16) seat mounting bolt
(17) collar
(18) right side cover bolt
10. Tighten the seat mounting bolts to the
specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
Fuel System
Refer to Safety Precautions on page 25.
Fuel Recommendation
Use only unleaded fuel in your Honda. If you
ride your Honda in a country where leaded fuel
might be available, take precautions to use only
unleaded fuel.
Your engine is designed to use any unleaded
gasoline that has a pump octane number of 91 or
higher. Gasoline pumps at service stations
normally display the pump octane number. For
information on the use of oxygenated fuels, see
page 160.
Use of lower octane gasoline can cause persistent
“pinging” or “spark knock” (a louder rapping
noise) which, if severe, can lead to engine
damage. (Light pinging experienced while
operating under a heavy load, such as climbing a
hill, is no cause for concern.)
If pinging or spark knock occurs at a steady
engine speed under normal load, change brands
of gasoline. If pinging or spark knock persists,
consult your dealer.
Never use stale or contaminated gasoline. Avoid
getting dirt, dust or water in the fuel tank.
Type Unleaded
Pump Octane Number 91 (or higher)
Refueling Procedure
Fuel Tank Capacity: 1.93 US gal (7.3R)
Reserve Capacity: 0.42 US gal (1.6R)
(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 by turning the cap
clockwise 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.
(2)
(1)
(3)
Servicing Your Honda 41
Fuel Line
(1)
Fuel System
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 .
Therefore, the fuel filter should be serviced
frequently.
To service the fuel filter:
1. Remove the fuel tank (page 37).
2. Drain the fuel from the fuel tank into an
approved gasoline container. Disconnect the
fuel valve (1) and fuel lines (2).
3. Remove the fuel joint (3) from fuel tank by
removing the bolts (4).
(5) fuel filter (6) O-ring
(6)
(5)
(1) fuel lines
1. Check for leaks.
2. Check the fuel lines (1) for cracks,
deterioration, damage or leakage. Replace the
fuel line, if necessary.
3. Check for interference between the frame and
tank and adjust if necessary.
(1)
42 Servicing Your Honda
(1) fuel valve (3) fuel joint
(2) fuel lines (4) bolts
(4)
(1)
(3)
(2)
4. Wash the fuel filter (5) in high flash-point
cleaning solvent.
5. Check that the O-ring (6) is in good condition
and install it onto the fuel joint. Install the
fuel filter in the fuel tank by tightening the
bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
Attach the fuel valve and fuel lines.
6. Install the fuel tank (page 38) and refill the
fuel.
Turn the fuel valve to ON or RES; check for
fuel leaks.
JASO T 903 standard
The JASO T 903 standard is an index for engine
oils for 4-stroke motorcycle engines.
There are two classes: MA and MB.
Oil conforming to the standard is labeled on the
oil container.
For example, the following label shows the MA
classification.
(1) oil code
(2) oil classification
(2)
(1)
(2)
* 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 25.
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
(USA & Canada), or Honda
4-stroke oil, or an equivalent
motorcycle oil*
viscosity
(weight)
SAE 10W-30
JASO T 903 standard
MA
• Your CRF does not need oil additives.
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.
• Oil is a major factor affecting the peformance
and service life of the engine.
Other viscosities shown in the following chart
may be used when the average temperature in
your riding area is within the indicated range.
NOT RECOMMENDED OK
Servicing Your Honda 43
Engine Oil
Checking & Adding Oil
(1) engine oil fill cap/dipstick
(2) upper level mark
(3) lower level mark
(4) O-ring
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 fill cap/dipstick (1),
wipe it clean, and insert the engine oil fill
cap/dipstick without screwing it in. Remove
the engine oil fill cap/dipstick.
5. Check that the oil level is between the upper
(2) and lower (3) level marks on the engine
oil fill cap/dipstick.
• If the oil is at or near the upper level mark,
you do not have to add oil.
• If the oil is below or near the lower level
mark and add the recommended oil until
the upper level mark. (Do not overfill)
Reinstall the engine oil fill cap/dipstick.
Repeat steps 1–5.
(1) engine oil fill cap/dipstick
(2) engine oil drain bolt
(3) sealing washer
7. It is recommended to replace the oil and filter
about every 15.0 hours. However, if you
replace only the oil before the recommended
interval, see page 28.
(1)
(4)
(2)
(3)
(1)
44 Servicing Your Honda
(1)
(3)
(2)
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinsert the engine oil fill cap/dipstick.
8. Check for oil leaks.
Changing Engine Oil & Filter
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Support the CRF in an upright position on a
level surface.
3. Remove the engine oil fill cap/dipstick (1)
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 engine oil to
the engine oil drain bolt threads and tighten it
with a new sealing washer to the specified
torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 143).
Improperly disposal of drained fluids is harmful
to the environment.
NOTICE
Engine Oil
8. Remove the left engine guard bolt/washer (4)
and left engine guard (5).
Using the wrong oil filter may result in leaks or
engine damage.
11.Apply grease to the filter side of the spring
end, then install the spring (10) into the new
oil filter.
12.Position the spring against the engine
crankcase and install a new oil filter with the
rubber seal (11) facing out, away from the
engine. You should see the “OUT-SIDE” mark
(12) on the filter body, near the rubber seal.
Use a new Honda Genuine 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.
13.Apply engine oil to a new O-ring and install it
to the oil filter cover.
14.Install the oil filter cover being careful not to
damage the O-ring, then tighten the oil filter
cover bolts to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
15.Install the left engine guard and bolt/washer,
then tighten them.
16.Fill the crankcase with the recommended oil.
Capacity:
0.73 US qt (0.69R)
after draining and filter change
0.70 US qt (0.66R)
after draining
NOTICE
NOTICE
17.Install the engine oil fill cap/dipstick.
18.Check the engine oil level by following the
steps in
Checking & Adding Oil (page 44).
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 143).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
(4) left engine guard bolt/washer
(5) left engine guard
9. Remove the oil filter cover bolts (6) and oil
filter cover (7).
(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
(5)
(4)
(10)
(12)
(9)
(8)
(11)
(7)
(6)
Servicing Your Honda 45
10. Remove the oil filter (8) and O-ring (9) from
the oil filter cover.
* 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
• Oil is a major factor affecting the performance
and service life of the transmission and clutch.
Other viscosities shown in the following chart
may be used when the average temperature in
your riding area is within the indicated range.
NOT RECOMMENDED OK
46 Servicing Your Honda
• 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.
Refer to
Safety Precautions on page 25.
Using the proper oil, and regularly checking,
adding, and changing oil will help extend the
service life of the transmission and clutch. Even
the best oil wears out. Changing oil helps get rid
of dirt and deposits. Operating the engine with
old or dirty oil can damage your engine.
Running the engine with insufficient oil can
cause serious damage to the engine and
transmission.
Oil Recommendation
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)
(2)
(1) oil code
(2) oil classification
API classification
(4-stroke engine oil
only)
Viscosity
(weight)
JASO T903
standard
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
such as molybdenum
additives
Pro Honda GN4 4-stroke oil
(USA & Canada), or Honda
4-stroke oil, or an equivalent
motorcycle oil*
Transmission Oil
(1)
(2)
(3)
(1)
(3)
(2)
(1) transmission oil fill cap
(2) transmission oil drain bolt
(3) sealing washer
Servicing Your Honda 47
Checking & Adding Oil
(1) transmission oil fill 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 fill cap (1), oil
check bolt (2) and sealing washer (3) from the
right crankcase cover. A small amount of oil
should flow out of the oil check bolt hole.
Allow any excess oil to flow out of the oil
check bolt hole.
If no oil flows out of the oil check bolt hole,
add oil slowly through the transmission oil fill
hole until oil start to flow out of the oil check
bolt hole.
Tighten the oil check bolt with a new sealing
washer and transmission oil fill cap. Repeat
step 1– 4.
5. After inspection 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. Check that the O-ring on the transmission oil
fill cap is in the good condition and replace it
if necessary.
7. Install the transmission oil fill 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 fill 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 engine oil to
the transmission oil drain bolt threads and
tighten it with a new sealing washer to the
specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
6. Fill the crankcase with recommended oil.
Capacity:
0.71 US qt (0.67R) draining
7. Check the transmission oil level by following
the steps in
Checking & Adding Oil (this
page).
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 143).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
Coolant
48 Servicing Your Honda
Your CRF’s liquid cooling system
dissipates engine heat through the coolant jacket
that surrounds the cylinder and cylinder head.
Maintaining the coolant will allow the cooling
system to work properly and prevent freezing,
overheating, and corrosion.
Coolant Recommendation
Use Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
corrosion protection inhibitors specifically
recommended for use in aluminum engines.
Check the antifreeze container label.
Use only distilled water as a part of the coolant
solution. Water that is high in mineral content or
salt may be harmful to the aluminum engine.
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.
NOTICE
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 & Adding Coolant
Refer to Safety Precautions on page 25.
1. With the engine at normal operating
temperature, check the coolant level in the
reserve tank. It should be between the UPPER
(1) and LOWER (2) level marks.
If the reserve tank (3) is empty, or if coolant
loss is excessive, check for leaks and see your
dealer for repair.
(1) UPPER level mark (3) reserve tank
(2) LOWER level mark
2. Open the air cleaner housing cover (4) by
turning the quick fastener (5)
counterclockwise and remove the left side
cover bolt (6), collar (7), seat mounting bolt
(8) and left side cover (9).
(4) air cleaner housing cover (7) collar
(5) quick fastener (8) seat mounting bolt
(6) left side cover bolt (9) left side cover
3. Remove the reserve tank cap (10).
Always add coolant to the reserve tank.
Do not attempt to add coolant by removing
the radiator cap.
(10) reserve tank cap
(3)
(1)
(2)
(5)
(6)
(7)
(8)
(9)
(4)
(10)
Coolant
(4) air cleaner housing cover
(5) quick fastener
(6) left side cover bolt
(7) collar
(8) seat mounting bolt
(9) left side cover
(10) reserve tank cap
Servicing Your Honda 49
4. Add coolant to the reserve tank as require to
bring the coolant level to the UPPER level
mark.
5. Install the reserve tank cap (10).
6. Install the left side cover (9), seat mounting
bolt (8), collar (7) and left side cover bolt (6).
Close the air cleaner housing cover (4) and
turn the quick fastener (5) clockwise.
Tighten the seat mounting bolt to the specified
torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
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 radiator hose clamp for
looseness.
3. Check the radiator mount for looseness.
4. Make sure the siphon hose (2) is connected
and not clogged.
5. Check the radiator fins for clogging.
6. Check the bleed hole (3) below the water
pump cover (4) for leakage. Check for signs
of seal leakage. A small amount of “weeping”
from the bleed hole is normal. See the Honda
Shop Manual or consult your dealer for
replacing the mechanical seal or oil seal. Both
seals should be replaced at the same time.
(1) water hoses
(2) siphon hose
(3) bleed hole
(4) water pump cover
(4)
(5)
(6)
(10)
(9)
(8)
(7)
(2)
(1)
(3)(4)
Coolant Replacement
Refer to Safety Precautions on page 25.
Coolant should be replaced by your dealer, unless
you have the proper tools and service data and
are mechanically qualified. Refer to the Honda
Service Manual (page 164).
Coolant
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.
50 Servicing Your Honda
To properly dispose of drained coolant, refer to
You & the Environment, page 143.
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
Coolant System Bleed Air
1. Remove the radiator cap (1).
(1) radiator cap
2. Fill the system with the recommended coolant
through the filler opening up to filler neck.
Use a fresh recommended coolant mixture
(page 48).
Capacity:
1.27 US qt (1.20R) after disassembly
1.19 US qt (1.13R) after draining
3. Turn the quick fastener (2) counterclockwise
and open the air cleaner housing cover (3).
4. Remove the left side cover bolt (4), collar (5),
seat mounting bolt (6) and left side cover (7).
5. Remove the reserve tank cap (8) and fill the
reserve tank to the UPPER level line (9).
(2) quick fastener (6) seat mounting bolt
(3) air cleaner housing cover (7) left side cover
(4) left side cover bolt (8) reserve tank cap
(5) collar (9) UPPER level line
6. Bleed air front the system as follows:
• Shift the transmission into neutral. Start the
engine and let it idle 2-3 minutes.
• Snap the throttle three-four times to bleed air
from the system.
• Stop the engine and, if necessary, add
coolant up to the proper level. Reinstall the
radiator cap.
• Check the level of coolant in the reserve
tank and fill to the UPPER level if it is low .
If the radiator cap is not installed properly, it
will cause excessive coolant loss and may result
in overheating and engine damage.
7. Install the radiator reserve tank cap and left
side cover, and close the air cleaner housing
cover.
8. Install the seat mounting bolt and tighten it to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
NOTICE
(1)
(9)
(3)
(8)
(6)
(7)
(4)
(5)
(2)
Air Cleaner
Refer to Safety Precautions on page 25.
The air cleaner uses polyurethane inner and outer
pieces which can’t be separated.
A dirty air cleaner will reduce engine power.
Proper air cleaner maintenance is very important
for off-road vehicles. A dirty, water-soaked,
worn-out, or defective air cleaner will allow dirt,
dust, mud, and other impurities to pass into the
engine.
Service the air cleaner more frequently if you
ride in unusually wet or dusty areas. Your dealer
can help you determine the correct service
interval for your riding conditions.
Your CRF’s air cleaner has very specific
performance requirements. Use a new Honda
Genuine air cleaner specified for your model or
an air cleaner of equal quality.
Using the wrong air cleaner may result in
premature engine wear.
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
NOTICE
Cleaning
1. To open the air cleaner housing cover (1), turn
the quick fastener (2) counterclockwise.
3. Pull the air cleaner element (5) out from the
air cleaner holder (6).
(1) air cleaner housing cover
(2) quick fastener
2. Remove the air cleaner element retaining bolt
(3) and air cleaner element assembly (4) while
turning it as shown.
(5) air cleaner element (8) hole
(6) air cleaner holder (9) air cleaner tab
(7) tab
4. Wash the air cleaner in clean non-flammable
cleaning solvent. Then wash in hot, soapy
water, rinse well, and allow to dry thoroughly.
The air cleaner element is made in two pieces:
inner and outer, which cannot be separated.
5. Clean the inside of the air cleaner housing.
6. Allow the air cleaner to dry thoroughly. After
drying, apply 1.7 US oz (50 cm
3
) of clean Pro
Honda Foam Filter Oil or an equivalent air
cleaner oil from the inside of the element.
Place the element into a plastic bag and
spread the oil evenly by hand.
(cont’d)
(3) air cleaner element retaining bolt
(4) air cleaner element assembly
Servicing Your Honda 51
(1)
(2)
(4)
(3)
(9)
(7)
(5)
(6)
(8)
Air Cleaner
Improper installation of the air cleaner element
assembly may allow dirt and dust to enter the
engine and cause rapid wear of the piston rings
and cylinder.
11.Close the air cleaner housing cover (1) and
turn the quick fastener (2) clockwise.
NOTICE
(3) air cleaner element retaining bolt
(10) access tab
(11) “
∆” mark
52 Servicing Your Honda
(10)
(11)
(3)
10. Carefully position the sealing flange of the
element to prevent dirt intrusion.
Align the access tab (10) of the air cleaner
element with the “
∆” mark (11) of the air
cleaner housing by rotating the air cleaner
element assembly counterclockwise. Install
and tighten the air cleaner element retaining
bolt (3) securely.
(1)
(2)
(1) air cleaner housing cover
(2) quick fastener
7. Assemble the air cleaner element and holder.
Install the tab (7) of the holder in the hole (8)
of the air cleaner tab (9).
8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro
Honda White Lithium Grease or equivalent to
the air cleaner housing contact area of the air
cleaner element.
9. Install the air cleaner element assembly into
the air cleaner housing.
Crankcase Breather
Servicing Your Honda 53
Refer to Safety Precautions on page 25.
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 crankcase breather tube (2) and drain
the deposits into a suitable container.
2. Reinstall the crankcase breather tube plug.
(1) crankcase breather tube plug
(2) crankcase breather tube
(2)
(1)
Throttle
Refer to Safety Precautions on page 25.
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)
(3)
(4)
(+)
(–)
(5) lower lock nut (+) increase
(6) lower adjuster (–) decrease
1. Remove the fuel tank (page 37).
2. Loosen the lower lock nut (5).
3. Turn the lower adjuster (6) in direction ( –) to
decrease freeplay, and in direction (+) to
increase freeplay.
4. Tighten the lock 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 38)
If you can’t get the freeplay within the specified
range, contact your dealer.
(5)
(6)
(+)
(–)
1. Pull the dust cover (2) back.
2. Loosen the upper 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 to the specified torque:
3.0 lbf·ft (4 N·m, 0.4 kgf·m)
Install the dust cover and make the
adjustment with the lower adjuster.
(2) dust cover (+) increase
(3) upper lock nut (–) decrease
(4) upper adjuster
54 Servicing Your Honda
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
dealer.
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)
Servicing Your Honda 55
Clutch System
Refer to Safety Precautions on page 25.
Clutch Freeplay
Cable End Adjustment
Minor adjustments are generally made with the
clutch cable end adjuster.
(2) cable end adjuster
(+) increase freeplay
(–) decrease freeplay
Turning the cable end adjuster (2) in direction (+)
will increase freeplay and turning it in direction
(–) will decrease freeplay.
If the adjuster is threaded out near its limit or the
correct freeplay cannot be reached, turn the
adjuster all the way in and back out one turn and
make the adjustment with the integral cable
adjuster.
Integral Cable
Adjustment
The integral cable adjuster is used if the cable
end adjuster is threaded out near its limit, or if
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 freeplay.
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.
Inspect the clutch discs and plates (page 58).
(1) clutch lever
Inspection
Check freeplay.
Freeplay:
3/8 – 13/16 in (10 – 20 mm)
If necessary, adjust to the specified range.
Improper freeplay adjustment can cause
premature clutch wear.
Make sure to adjust the clutch lever (1) freeplay
after the clutch cable is disconnected.
56 Servicing Your Honda
(1)
(–)
(+)
(2)
(–)
(+)
(3)
(4)
Clutch System
Other Inspections & Lubrication
• Check that the clutch lever assembly is
positioned properly (the end of the holder (1)
aligned with the paint mark (2) on the
handlebar) and the securing bolts are tight.
Clutch Cover/Disc/Plate Removal
1. Drain the transmission oil (page 47).
2. Remove the rear brake pedal (1) by removing
the pin (2) and pivot bolt (3), washer (4) and
dust seals (5).
Servicing Your Honda 57
(1) rear brake pedal (4) washer
(2) pin (5) dust seals
(3) pivot bolt
3. Remove the five clutch cover bolts (6) and
clutch cover (7).
(6) clutch cover bolts (7) clutch cover
4. Remove the five clutch spring bolts and clutch
springs (8).
Loosen the bolts in a crisscross pattern in two or
three progressive steps
.
5. Remove the clutch pressure plate (9).
(8) clutch spring bolts/clutch springs
(9) clutch pressure plate
6. Remove the clutch lifter assembly (10) and
clutch lifter rod (11).
7. Remove the eight clutch discs, seven clutch
plates, judder spring and spring seat (12).
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.
(10) clutch lifter assembly
(11) clutch lifter rod
(12) clutch discs, clutch plates, judder spring and
spring seat
(2)
(1)
(6)
(7)
(9)
(8)
(10)
(11)
(12)
(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)
(4) (5)
(1)
(3)
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 a set.
(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.
Clutch Disc/Plate Installation
1. Install the spring seat (1) and judder spring (2)
onto the clutch center as shown.
Coat the clutch discs (3) and plates (4) with
engine oil.
2. Install the clutch disc A (larger I.D. disc) (5)
onto the clutch outer.
Stack the seven clutch plates and seven clutch
discs alternately.
(1) spring seat (4) clutch plates
(2) judder spring (5) clutch disc A
(3) clutch discs
3. Apply engine oil to the clutch lifter assembly
(6) and clutch lifter rod (7) contact surface.
Insert the clutch lifter rod into the mainshaft.
4. Install the clutch lifter assembly onto the rod.
(6) clutch lifter assembly (7) clutch lifter rod
(1)
58 Servicing Your Honda
(3)
(5)
(2)
(4)
(1)
(6)
(7)
Clutch System
Clutch Spring Inspection
(1) clutch spring
Measure the free length of each spring.
Service Limit:
1.50 in (38.0 mm)
Replace the clutch springs as a set if any one of
them is beyond the service limit or if the clutch
plates have been burn/heat discolored.
(1)
(2) clutch plate
(2)
Clutch System
10.Apply grease to the rear brake pedal pivot bolt
sliding surface.
11. Install the rear brake pedal (12), dust seals
(13), washer (14) and pivot bolt (15) and
tighten the pivot bolt to the specified torque:
27 lbf·ft (36 N·m, 3.7 kgf·m)
Connect the brake pedal return spring (16) if
it was removed.
12. Insert the pin (17).
(12) rear brake pedal (15) pivot bolt
(13) dust seals (16) return spring
(14) washer (17) pin
13. Fill the crankcase with transmission oil
(page 47).
Servicing Your Honda 59
(17)
(12)
(15)
(16)
(14)
(13)
5. Install the clutch pressure plate (8).
6. Install the five clutch springs and clutch
spring bolts (9).
7. 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)
(8) clutch pressure plate
(9) clutch spring bolts/clutch springs
8. Apply engine oil to a new O-ring (10) and
install it in the groove of the clutch cover
(11).
9. Install the clutch cover by tightening the
clutch cover bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(10) O-ring (11) clutch cover
(8)
(9)
(11)
(10)
Hot Start Lever
Refer to Safety Precautions on page 25.
Hot Start Lever Freeplay
(1) hot start lever
(2) 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 end
adjuster.
Loosen the lock nut (3) and turn the adjuster (4).
Turning the adjuster in direction (+) will increase
freeplay and turning it in direction ( –) will
decrease freeplay. After adjustment, tighten the
lock nut.
(3) lock nut (+) increase
(4) adjuster (–) decrease
60 Servicing Your Honda
(1)
(2)
(4)
(3)
Refer to Safety Precautions on page 25.
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 problems.
This motorcycle uses spark plug that have an
iridium tip in center electrode and a platinum tip
in side 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 Inspection & Replacement
1. Remove the seat and fuel tank (pages 36,37).
2. Disconnect the direct ignition coil (1).
3. Clean any dirt from around the spark plug base.
4. Remove the spark plug (2).
(1) direct ignition coil
(2) spark plug
5. Check the electrodes 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:
0.031 – 0.035 in (0.8 – 0.9 mm)
(3) sealing gasket
(4) spark plug gap
(3)
(4)
Servicing Your Honda 61
Standard IMR8C-9H (NGK) or
VUH24D (DENSO)
Optional IMR9C-9H (NGK) or
VUH27D (DENSO)
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 color initially.
If the electrodes appear burnt, or the insulator is
white or light gray (lean) or the electrodes and
insulator are black or fouled (rich), there is a
problem elsewhere.
Check the carburetor, fuel system and ignition
timing.
8. With the plug washer 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 twise to
prevent loosening:
a) First, tighten the plug:
NGK: 1/2 turn after it seats.
DENSO: 1 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 light, the thr eads
may be damaged.
NOTICE
(2)
(1)
10. Connect the direct ignition coil. Take care to
avoid pinching any cables or wires.
11. Install the fuel tank and seat (pages 36,38).
Exhaust Pipe/Muffler
Exhaust Pipe/Muffler Inspection
Check the flange bolts for tightness.
Check the exhaust pipe and muffler for cracks or
deformation.
A damaged exhaust pipe and muffler may reduce
engine performance.
(1) seat mounting bolt (3) collar
(2) side cover bolt (4) right side cover
2. Loosen the muffler clamp bolt (5).
3. Remove the muffler A bolt/washer (6),
muffler B bolt (7) and muffler (8).
(5) muffler clamp bolt (7) muffler B bolt
(6) muffler A bolt/washer (8) muffler
(1)
(4)
(2)
(3)
(6)
(8)
(7)
(5)
Muffler Removal
1. Remove the seat mounting bolt (1), side cover
bolt (2), collar (3) and right side cover (4).
62 Servicing Your Honda
Exhaust Pipe/Muffler
Muffler Installation
1. Remove the gasket.
2. Install a new gasket (1) on to the exhaust
pipe.
3. Install the muffler clamp (2) by aligning the
tab (4) of the muffler clamp with the cut-out
(5) of the muffler (3).
4. Install the muffler.
(1) gasket (4) tab
(2) muffler clamp (5) cut-out
(3) muffler
5. Install the muffler B bolt (6), muffler A
bolt/washer (7), muffler clamp bolt (8) and
loosely tighten them.
6. Tighten the muffler B bolt and muffler A
bolt/washer to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
7. Tighten the muffler clamp bolt to the specified
torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
(6) muffler B bolt (8) muffler clamp bolt
(7) muffler A bolt/washer
(9) right side cover (11) side cover bolt
(10) collar (12) seat mounting bolt
8. Install the right side cover (9), collar (10) and
side cover bolt (11).
9. Install the seat mounting bolt (12) and tighten
it to the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
Servicing Your Honda 63
(2)
(3)
(5)
(4)
(1)
(7)
(6)
(8)
(12)
(11)
(10)
(9)
Exhaust Pipe/Muffler
64 Servicing Your Honda
Exhaust Pipe Installation
1. Install a new exhaust pipe gasket (1), exhaust
pipe (2) and exhaust pipe joint nuts (3).
(1) exhaust pipe gasket
(2) exhaust pipe
(3) exhaust pipe joint nuts
2. Install the muffler (page 63) but do not tighten
the bolts yet.
3. Tighten the exhaust pipe joint nuts to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
4. Tighten the muffler clamp bolt, muffler
mounting A bolt/washer and muffler B bolt
(page 63).
5. Installation can be done in the reverse order of
removal.
Exhaust Pipe Removal
1. Remove the muffler (page 62).
2. Remove the exhaust pipe joint nuts (1),
exhaust pipe (2) and exhaust pipe gasket (3).
(1) exhaust pipe joint nuts
(2) exhaust pipe
(3) exhaust pipe gasket
(1)
(2)
(3)
(3)
(2)
(1)
Spark Arrester
Servicing Your Honda 65
Spark Arrester Inspection
The spark arrester must be serviced every 1,000
mi (1,600 km) of running or 100 operating hours
to maintain its efficiency.
Regular servicing prevents carbon buildup
(which can diminish engine performance) and
also complies with USDA regulations for regular
maintenance to assure proper function.
The spark arrester prevents random sparks from
the combustion process in your engine from
reaching the environment.
1. Allow the engine and muffler (1) to cool.
2. Remove the bolts (2), spark arrester (3), and
gasket (4) from the muffler.
(1) muffler (3) spark arrester
(2) bolts (4) gasket
3. Use a brush to remove carbon deposits from
the spark arrester screen. Be careful to avoid
damaging the spark arrester screen. The spark
arrester must be free of brakes and holes.
Replace, if necessary.
Check the gasket. Replace, if necessary.
4. Apply a seizure inhibitor (Three Bond 1901 or
equivalent) to the bolts threads. Install a new
gasket and the spark arrester in the muf fler (1)
and tighten the bolts (2) to the specified
torque:
4.4 lbf·ft (6 N·m, 0.6 kgf·m)
(1) muffler (2) bolts
(1)
(2)
(4) (3)
(1)
(2)
Valve Clearance
Cylinder Head Cover Removal
Before inspection, clean the engine thoroughly to
keep dirt from entering the engine.
1. Remove the seat (page 36).
2. Remove the fuel tank (page 37).
3. Disconnect the breather tube (1) and 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
4. Remove the cylinder head cover bolts/rubber
seals (3), and cylinder head cover (4).
(3) cylinder head cover bolts/rubber seals
(4) cylinder head cover
(1) crankshaft hole cap
2. Remove the spark plug (page 61).
3. Remove the cylinder head cover (this page).
(1)
(2)
(4)
(3)
(1)
Refer to Safety Precautions on page 25.
Excessive valve clearance will cause noise and
eventual engine damage. Little or no clearance
will prevent the valve from closing and cause
valve damage and power loss. Check the valve
clearance when the engine is cold at the intervals
specified in the Maintenance Schedule (pages 27,
28).
The checking or adjusting of the valve clearance
should be performed while the engine is cold.
The valve clearance will change as engine
temperature rises.
66 Servicing Your Honda
Valve Clearance
Valve Clearance Inspection
1. Set the piston at TDC on the compression
stroke (page 66).
2. Measure the intake valve clearance by
inserting a feeler gauge (1) between the valve
lifters (2) and intake cam lobe (3).
3. Measure the exhaust valve clearance by
inserting a feeler gauge (1) between the
exhaust rocker arm (4) and shims (5).
(1) feeler gauge
(4) exhaust rocker arm
(5) exhaust valve shims
Valve Clearances:
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 68) and select the correct shim for
each valve.
(5)
(1)
(3)
(2)
(5)
(1)
(4)
(1) feeler gauge
(2) valve lifters
(3) intake cam lobe
4. Rotate the crankshaft by turning the primary
drive gear bolt (2) clockwise until aligning the
punch mark (3) on the primary drive gear with
the “∆” 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 “∆”
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 “∆” mark.
(2)
(3)
(4)
(2) primary drive gear bolt (4) “∆” mark
(3) punch mark
(5) exhaust rocker arm
Servicing Your Honda 67
Valve Clearance
Camshaft Removal
1. Record the intake valve clearance and exhaust
valve clearance (page 67).
Make sure the piston is at TDC on the
compression stroke (page 66).
(1) cam chain tensioner lifter cover bolt
(2) sealing washer
Use the tensioner stopper tool.
• Tensioner stopper
070MG-0010100
07AMG-001A100 (USA only)
3. Turn the tensioner shaft clockwise with the
stopper tool (3) until it stops, in order to
retract the tensioner fully.
Then insert the stopper tool fully to hold the
stopper in the fully retracted position.
(3) stopper tool
(1)
(2)
(3)
(3)
68 Servicing Your Honda
2. Remove the cam chain tensioner lifter cover
bolt (1) and sealing washer (2).
Valve Clearance
(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 and shims fall into the
crankcase.
NOTICE
(7) valve lifters
7. Remove the shims (8).
(6)
(4)
(4)
(5)
(7)
(8)
(8)
Servicing Your Honda 69
(8) shims
4. Remove the camshaft holder bolts (4) and
camshaft holders (5).
Loosen the camshaft holder bolts in a criss-cross
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 not let the set rings of the camshaft
holders fall into the crankcase.
Valve Clearance
Shim Selection
1. Clean the valve shim contact area in the valve
lifter (1) with compressed air.
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
70 Servicing Your Honda
(1) valve lifter
5. Apply grease to the set rings and install it
onto the camshaft holders (13).
Apply engine oil to the camshaft holder bolt
threads and seating surface.
Install the camshaft holder bolts (14) and
tighten it to the specified to 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.
Valve Clearance
Camshaft Installation
1. Install the newly selected shims (1) on the
valve retainers (2).
Do not let the shims fall into the crankcase.
NOTICE
(1) shims (2) v alve retainers
2. Apply molybdenum disulfide oil solution (a
mixture of 1/2 engine oil and 1/2
molybdenum disulfide grease containing more
than 3% molybdenum disulfide additive) to
outer surface of the each valve lifters.
Install the valve lifters (3).
3. Rotate the primary drive gear bolt (4)
(crankshaft) clockwise and align the punch
mark (5) with the “∆” mark (6).
(7) camshaft (10) cam sprocket
(8) intake cam lobes (11) cylinder head
(9) timing marks (12) cam chain
(13) camshaft holders (14) camshaft holder bolts
(1)
(2)
(2)
(4)
(5)
(6)
(14)
(14)
(13)
Servicing Your Honda 71
(3) valve lifters
(4) primary drive gear bolt
(5) punch mark
(6) “
∆” mark
4. Apply molybdenum oil solution to the
camshaft journals and cam lobes.
Place the camshaft (7) with the intake cam
lobes (8) facing up and align the timing marks
(9) on the cam sprocket (10) with the top
surface of the cylinder head (11).
Install the cam chain (12) over the sprocket
without rotating the camshaft.
(cont’d)
(3)
(11)
(10)
(9)
(12)
(7)
(8)
(9)
Valve Clearance
72 Servicing Your Honda
(15) stopper tool
7. Insert the feeler gauge between the intake
valve lifter and cam lobe.
If the feeler gauge (16) cannot be inserted, the
shim is caught between the valve lifter and the
valve retainer. Remove the camshaft holders
to place the shim correctly, and reinstall the
camshaft holders.
Valve Clearance:
IN:
0.005 ± 0.001 in (0.12 ± 0.03 mm)
EX:0.011 ± 0.001 in (0.28 ± 0.03 mm)
(16) feeler gauge
6. Remove the stopper tool (15) from the cam
chain tensioner lifter.
8. Install a new sealing washer (17) and tighten
the cam chain tensioner lifter cover bolt (18).
(17) sealing washer
(18) cam chain tensioner lifter cover bolt
(16)
(16)
(15)
(17)
(18)
Crankshaft Hole Cap Installation
Coat a new O-ring (1) with engine oil and install
it onto the crankshaft hole cap (2).
Apply grease to the crankshaft hole cap threads.
Install and tighten the crankshaft hole cap to the
specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)
(1) O-ring
(2) crankshaft hole cap
(1)
(2)
(5) rubber seal
(6) “UP” marks
4. Install the cylinder head cover (4) and tighten
the cylinder head cover bolts (7) to the
specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
Valve Clearance
Cylinder Head Cover Installation
1. Check the spark plug hole packing (1) is in
good condition, replace it if necessary.
Apply engine oil to the spark plug hole packing
and install it to the spark plug hole (2).
(1) spark plug hole packing
(2) spark plug hole
2. Inspect the cylinder head cover packing (3)
for damage or deterioration, replace it if
necessary.
Install the cylinder head cover packing into
the groove of the cylinder head cover (4).
(3) cylinder head cover packing
(4) cylinder head cover
(4) cylinder head cover
(7) cylinder head cover bolts
(8) direct ignition coil
(9) breather tube
7. Install the fuel tank and seat (pages 36, 38).
(2)
(1)
(3)
(4)
Servicing Your Honda 73
(7)
(4)
(8)
(9)
3. Check the rubber seals (5) are in good
condition, replace them if necessary.
Install the rubber seals onto the cylinder head
cover with the “UP” marks (6) facing up.
(5)
(6)
(6)
5. Install the spark plug (page 61).
6. Connect the direct ignition coil (8) and
breather tube (9).
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 radiator coolant after cooling the
motorcycle (page 141).
3. Remove the seat and fuel tank (pages 36,37).
4. Lift the subframe to the upright position
(page 39).
5. Remove the carburetor (page 130).
6. Remove the exhaust pipe (page 64).
7. Disconnect the air suction (1) and vacuum
hoses (2).
8. Remove the air supply pipe bolt (3), PAIR
control valve bolts/nuts (4) and PAIR control
valve (5).
(1) air suction hose (4) PAIR control valve bolts/nuts
(2) vacuum hose (5) PAIR control valve
(3) air supply pipe bolt
9. Disconnect the direct ignition coil (5).
(5) direct ignition coil
11. Remove the cylinder head cover (page 66).
12. Remove the spark plug (6).
(6) spark plug
13. Position the piston to top dead center on the
compression stroke (page 66).
Remove the camshaft (page 68).
14. Loosen the radiator hose clamp (7) and
disconnect the radiator hose (8).
(7) radiator hose clamp
(8) radiator hose
(1)
(5) (3)
(2)
(4)
(5)
(6)
(8)
(7)
74 Servicing Your Honda
10. Remove any dirt around the spark plug base.
Piston/Piston Rings/Piston Pin
15.Remove the engine hanger nuts/bolts (9),
engine hanger plates (10), and clutch cable
guide (11).
(9) engine hanger nuts/bolts
(10) engine hanger plates
(11) clutch cable guide
16.Remove the cylinder head bolts (12).
17.Loosen the cylinder bolt (13).
(12) cylinder head bolts
(13) cylinder bolt
18.Remove the cylinder head nuts/washers (14)
and cylinder head (15).
Loosen the nuts in a criss-cross pattern in two or
three steps.
Do not let the nuts, washers and cam chain fall
into the crankcase.
NOTICE
(14) cylinder head nuts/washers
(15) cylinder head
19.Remove the dowel pins (16), cylinder head
gasket (17) and cam chain guide (18).
Do not let the dowel pins and cam chain fall into
the crankcase.
NOTICE
(16) dowel pins (18) cam chain guide
(17) cylinder head gasket
(11)
(10)
(9)
(13)
(12)
(18)
(17)
(16)
Servicing Your Honda 75
(15)
(14)
76 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 (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
(3)
(2)
(1)
(1) piston pin clip (3) piston
(2) piston pin
(1)
(1) piston ring
(3)
(4)
(1)
(2)
Piston/Piston Rings/Piston Pin
Piston Ring Installation
1. Remove the carbon deposits from the piston
crown and piston ring grooves with the
removed ring.
2. Apply engine oil to the 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 the top ring and the upper side rail.
Space the ring end gaps 90 degrees apart
between the upper side rail, spacer, and the
lower side rail.
NOTICE
top ring
oil ring
top ring
mark
side
rail
oil
ring
side
rail
spacer
Servicing Your Honda 77
Piston/Piston Pin/Piston Ring Inspection
We recommend you consult the Service Manual
or your dealer for correct Service Limit
measurements.
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 solution (a
mixture of 1/2 engine oil and 1/2
molybdenum disulfide grease containing more
than 3% molybdenum disulfide additive) to
the connecting rod small end.
3. 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) outer
surface.
Apply engine oil to the piston outer surface
and piston pin hole inner surface.
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 entire 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 new cylinder
gasket (2).
Do not let the dowel pins fall into the crankcase.
NOTICE
(1) dowel pins
(2) cylinder gasket
5. Clean any gasket material off the cylinder.
(1)
(3)
(2)
(1)
(2)
(4)
(5)
(6)
(5)
(1)
(2)
78 Servicing Your Honda
Piston/Piston Rings/Piston Pin
6. Apply 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
wall.
NOTICE
(3) cam chain (5) piston rings
(4) cylinder
7. Temporarily install the cylinder bolt (6).
8. Install the cam chain guide (7) and fit the cam
chain guide tabs (8) in the cylinder cut-outs
(9).
Push the guide until it bottoms in the
crankcase guide hole.
(6) cylinder bolt (8) cam chain guide tabs
(7) cam chain guide (9) cylinder cut-outs
Cylinder Head Installation
1. Install the dowel pins (1) and new cylinder
head gasket (2).
Do not let the dowel pins fall into the crankcase.
NOTICE
(1) dowel pins
(2) cylinder head gasket
(3)
(4)
(5)
(7)
(6)
(9)
(8)
(1)
(2)
Servicing Your Honda 79
(cont’d)
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 all cylinder head nut
threads and seating surface.
Install the washers and cylinder head nuts (4).
Tighten the cylinder head nuts 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.
Tighten the cylinder head nuts in a criss-cross
pattern in two or three steps.
NOTICE
NOTICE
4. Install the cylinder head bolts (5).
Tighten the cylinder bolt (6) and cylinder
head bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(3) cylinder head
(4) cylinder head nuts/washers
(5) cylinder head bolts
(6) cylinder bolt
(7) engine hanger plate
(8) clutch cable guide
(9) engine hanger nuts/bolts of the frame side
(10) engine hanger nut/bolt of the engine side
(3)
(4)
(6)
(5)
(10)
(8)
(9)
(7)
80 Servicing Your Honda
5. Install the engine hanger plates (7), clutch
cable guide (8), engine hanger nuts/bolts (9)
of the frame side and engine hanger nut/bolt
(10) 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)
Piston/Piston Rings/Piston Pin
6. Connect the radiator hose (11) to the cylinder
head and tighten the radiator hose clamp (12)
securely.
(11) radiator hose
(12) radiator hose clamp
7. Install the shims and camshaft (page 71).
8. Install the spark plug (page 61).
9. Install the cylinder head cover (page 73).
Connect the direct ignition coil (13).
(13) direct ignition coil
10.Install the PAIR control valve (14), PAIR
control valve bolts/nuts (15) and air supply
pipe bolt (16).
11.Tighten the PAIR control valve nuts and air
supply pipe bolt to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
12.Connect the vacuum (17) and air suction (18)
hoses.
13.Install the exhaust pipe (page 64).
14.Install the carburetor (page 133).
15.Install the subframe and muffler (pages 40, 63).
16.Install the fuel tank and the seat (pages 36, 38).
17.Fill and bleed the cooling system (page 48)
Check for the following:
- compression leaks
- abnormal engine noise
- secondary air leaks
- coolant leaks
- oil leaks
(11)
(12)
Servicing Your Honda 81
(13)
(14) PAIR control valve
(15) PAIR control valve bolts/nuts
(16) air supply pipe bolt
(17) vacuum hose
(18) air suction hose
(18)
(15)
(17)
(14) (16)
Suspension
Refer to Safety Precautions on page 25.
Loose, worn, or damaged suspension components
may adversely affect the handling and stability of
your motorcycle. If any suspension components
appear worn or damaged, see your 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 1 hour to ensure that the
suspension has worked in (page 21).
• After break-in, test run your CRF with the
front suspension at the standard setting before
attempting any adjustments.
• For optimum fork performance, we
recommend that you disassemble and clean
the fork after riding your CRF for 3 hours.
See page 107 for fork disassembly.
• Replace the fork oil every 7.5 hours of
running. See page 84 for oil level adjustment
after changing the fork oil.
• Replace the damper oil every 22.5 hours of
running. See page 111 for oil level adjustment
after changing the damper oil.
• Use Pro Honda HP Fork Oil 5W or an
equivalent which contains special additives to
assure maximum performance of your CRF's
front suspension.
• Periodically check and clean all front
suspension parts to assure top performance.
Check the dust seals for dust, dirt, and foreign
materials. Check the oil for any
contamination.
• Refer to
Suspension Adjustment Guidelines
(page 125). 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 stif f/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 107).
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
locking the front brake and pushing down on
the handlebar several times.
(2)
(1)
(3)
(4)
(3)
(3)
82 Servicing Your Honda
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 124).
Do not attempt to disassemble, service, or
dis
pose of the damper; see your 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.
• Refer to Suspension Adjustment Guidelines
(page 127) for making all rebound and
compression damping adjustments in one
click or 1/12 turn increments (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 the rear suspension is too stiff/soft, adjust it
by turning all the compression and rebound
adjusters according to the procedures
described in page 121. After adjusting the
adjusters simultaneously, suspension may be
fine-tuned by turning one of the compression
and rebound damping adjusters in one click or
in 1/12 turn increments.
• 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. Lift the subframe to the upright position
(page 39).
3. Check for a broken or collapsed spring.
4. Check the rear shock absorber (1) for a bent
rod 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 dealer.
(1)
Servicing Your Honda 83
Suspension
84 Servicing Your Honda
Recommended Fork Oil
Fork Oil Change
Refer to Front Suspension Disassembly on page
107.
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 the lock
nut wrench (3). Gently slide the outer tube
down onto the lower end of the slider (4).
• Lock nut wrench 07WMA-KZ30100
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 (5) and
damage the fork dust seal (6) and guide bushing
(7) when the fork damper is removed. To avoid
damage hold both the outer tube and slider when
removing the fork damper.
NOTICE
(1) outer tube (6) dust seal
(5) slider (7) guide bushing
3. Drain the fork oil from the outer tube (1).
Drain the fork oil from the oil hole (8) of the
fork damper.
(1) outer tube (8) 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
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 143).
Improper disposal of drained oil is harmful to the
environment.
NOTICE
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)
(6)
(7)
(5) (1)
(1)
(8)
(1)
Servicing Your Honda 85
Suspension
5. Pour the recommended fork oil (page 84) into
the outer tube.
Optional Softer 22.38 lbf/in (3.92 N/mm) Fork Spring
Standard oil
capacity
11.8 US oz
(350 cm
3
)
Maximum oil
capacity
13.7 US oz
(404 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.4 US oz
(308 cm
3
)
Optional Stiffer 24.61 lbf/in (4.31 N/mm) Fork Spring
Standard oil
capacity
11.8 US oz
(348 cm
3
)
Maximum oil
capacity
13.6 US oz
(402 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.3 US oz
(306 cm
3
)
1 scribe mark
3 scribe marks
6. Check taht the O-ring (9) on the fork damper
(2) is in good condition. Apply the
recommended fork oil to the O-ring.
(1) outer tube (9) O-ring
(2) fork damper
7. Temporarily install the fork damper (2) to the
outer tube (1).
After installing the fork leg (page 117) 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), using a 20 in
(50 cm) long deflecting beam type torque
wrench.
When using the lock nut wrench, use a 20 in
(50 cm) long deflecting beam type torque
wrench. The lock nut wrench increases the
torque wrench’s leverage, so the torque
wrench reading will be less than the torque
actually applied to the fork damper.
(9)
(2)
(1)
Fork Oil Capacity:
Standard 23.53 lbf/in (4.12 N/mm) Fork Spring
or
Standard oil
capacity
11.7 US oz
(345 cm
3
)
Maximum oil
capacity
13.5 US oz
(399 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.2 US oz
(303 cm
3
)
2 scribe marks
(aftermarket parts)
No mark
(factory products)
Be sure the oil capacity is the same in both fork legs.
86 Servicing Your Honda
Brakes
Refer to Safety Precautions on page 25.
Both the front and rear brakes are the hydraulic
disc type. As the brake pads wear, the brake
fluid level will drop. A leak in the system will
also cause the level to drop.
Frequently inspect the system to ensure there are
no fluid leaks. Periodically inspect the brake
fluid level and the brake pads for wear.
If the front brake lever or rear brake pedal
freeplay does not feel within the normal range
while riding, check the brake pads. If they are
not worn beyond the recommended limit (page
89), there is probably air in the brake system.
Refer to the Honda Service Manual or see your
dealer to have the air bled from the system.
(1) lock nut (3) piston
(2) adjuster
1. Loosen the lock nut (1).
2. To position the front brake lever farther away
from the handgrip, turn the adjuster (2)
clockwise.
To position the front 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
: LESS THAN 13/16 in (20 mm)
6. Apply grease to the contacting faces of the
adjuster and piston (3).
Rear Brake Pedal Height
The rear brake pedal height should be
approximately level with the right footpeg.
1. Loosen the lock nut (1) and turn the adjusting
bolt (2) in direction (+) to raise the rear brake
pedal (3) or in direction (–) to lower it.
2. Tighten the lock nut to the specified torque at
the desired pedal height:
4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
(1) lock nut (+) raise the pedal height
(2) adjusting bolt (–) lower the pedal height
(3) rear brake pedal
LESS
THAN
(1)
(2)
(3)
13/16 in (20 mm)
(2)
(1)
(3)
(+)
(–)
Front Brake Lever Adjustment
Servicing Your Honda 87
Brakes
Fluid Level Inspection
Front Brake Fluid Level Check
(1) LWR (LOWER) level mark
With the motorcycle in an upright position, check
the fluid level.
It should be above the LWR (LOWER) level
mark (1). If the level is at or below the L WR
(LOWER) level mark, check the brake pads for
wear (page 89).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the front 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 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 89).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the rear 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 dealer for brake
bleeding.
(1)
(2)
(5) (9)
(6) (8)
(7)
88 Servicing Your Honda
Brakes
Adding Front Brake Fluid
Spilled brake fluid will severely damage
instrument lenses and 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 as they
may not be compatible.
• The recommended brake fluid is Pro Honda
DOT 4 brake fluid or an equivalent.
NOTICE
(1) screws (4) upper level mark
(2) reservoir cap
(3) diaphragm
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
instrument lenses and 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 as 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) upper level mark
(7) set plate
1. Remove the bolts (5) reservoir cap (6), set
plate (7) and diaphragm (8).
Check the diaphragm installation as shown.
2. Fill the reservoir with DOT 4 brake fluid to
the upper level mark (9). Do not overfill.
3. Reinstall the diaphragm, set plate and
reservoir cap.
4. Tighten the bolts to the specified torque:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
Other Inspection
• Make sure there are not fluid leaks.
• Check for deterioration or cracks in the hoses
and fittings.
(4)
(2)
(3)
(1)
Servicing Your Honda 89
Brakes
Brake Pad Wear
Brake pad wear depends on the severity of usage
and track conditions. (Generally, the pads will
wear faster on wet and dirty tracks) Inspect the
pads at each regular maintenance interval
(pages 27 and 28).
Front Brake Pads
Inspect the brake pads (1) through the front
wheel to determine the pad wear. If either pad is
worn anywhere to a thickness of 0.04 in (1 mm),
both pads must be replaced.
(1) brake pads (3) brake disc
(2) front brake caliper
Rear Brake Pads
Inspect the brake pads (4) from the rear side of
the caliper to determine the pad wear. If either
pad is worn anywhere to a thickness of 0.04 in
(1 mm), both pads must be replaced.
(4) brake pads (6) brake disc
(5) rear brake caliper
minimum thickness
indicator
wear indicator
grooves
replace
replace
0.04 in
(1 mm)
0.04 in
(1 mm)
(1)
(1)
(2)
(3)
replace
0.04 in
(1 mm)
minimum thickness
indicator
(4)
(5)
(4)
(6)
Other Inspections
Check that the front brake lever and rear brake
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.
90 Servicing Your Honda
Wheels
Refer to Safety Precautions on page 25.
Keeping the wheels true (round) and maintaining
correct spoke tension is critical to safe
motorcycle operation. During the first few rides,
spokes will loosen more rapidly due to the initial
seating of the parts. Excessively loose spokes
may result in instability at high speeds and the
possible loss of control. It’s also important that
the rim locks are secure to prevent tire slippage.
It is not necessary to remove the wheels to
perform the recommended service in the
Maintenance Schedule (pages 27 and 28).
However, information for wheel removal is
provided for emergency situations.
Wheel Rims & Spokes
(1) wheel rims
(2) spokes
(3) rim lock
1. Inspect the wheel rims (1) and spokes (2) for
damage.
2. Tighten, any loose spokes and rim locks (3) to
the specified torque:
Spoke
: 2.7 lbf·ft (3.68 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 & Wheel Bearings
See the Honda Service Manual for inspection
information:
1. Check the axle shaft for runout.
2. Check the condition of the wheel bearings.
(1)
(2)
(3)
Servicing Your Honda 91
Tires & 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/cm
2
)
Rear 15 psi (100 kPa, 1.0 kgf/cm
2
)
Refer to Safety Precautions on page 25.
To safely operate your CRF, the tires must be the
proper type (off-road) and size, in good condition
with adequate tread, and correctly inflated.
The following pages give detailed information on
how and when to check your air pressure, how to
inspect your tires for wear and damage, and our
recommendations on tire replacement.
Air Pressure
Properly inflated tires provide the best
combination of handling, tread life, and riding
comfort. Generally, underinflated tires wear
unevenly, adversely affect handling, and are more
likely to fail from being overheated.
Underinflated tires can also cause wheel damage
on hard terrain. Overinflated tires make your
CRF ride harshly, are more prone to damage
from surface hazards, and wear unevenly.
Make sure the valve stem caps are secure. If
necessary, install new caps.
Always check air pressure when your tires are
“cold.” If you check air pressure when your tires
are “warm” — even if your CRF has only been
ridden for a few miles — the readings will be
higher. If you let air out of warm tires to match
the recommended cold pressures, the tires will be
underinflated.
The correct “cold” tire pressures are:
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.
• 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.
92 Servicing Your Honda
Tires & Tubes
Tire Replacement
The tires that came on your CRF were designed
to provide a good combination of
handling, braking, durability, and comfort across
a broad range of riding conditions.
• When replacing, use the original equipment
tires or equivalent tires of the same size,
construction, speed rating, and load range as
the originals.
• Replace the tube any time you replace a tire.
The old tube will probably be stretched and, if
installed in a new tire, could fail.
Front
Rear
Type
80/100 – 21 51M
DUNLOP
100/100 – 18 59M
DUNLOP
bias-ply, tube
D742FA
D756
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.
Side Stand
Servicing Your Honda 93
Refer to Safety Precautions on page 25.
1. Check the side stand spring (1) for damage
and loss of tension.
2. Check the side stand assembly for freedom of
movement.
(1) side stand spring
If the side stand is stiff or squeaky, clean the
pivot area and lubricate the pivot bolt with
grease.
(1)
94 Servicing Your Honda
Drive Chain
Refer to Safety Precautions on page 25.
An endless (riveted master link) chain connects
the drive and driven sprockets. The O-ring chain
uses rubber between the side plates of the pin and
roller links to seal in the manufacturer-installed
lubricating grease and keep out moisture and dirt.
The service life of the chain depends on proper
lubrication and adjustment. Poor maintenance
can cause premature wear or damage to the drive
chain or sprockets.
Under severe usage, or when the motorcycle is
ridden in unusually dusty or muddy areas, more
frequent maintenance will be necessary.
Before servicing your drive chain, turn the
engine OFF, raise the rear wheel off the ground
by placing an 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
Regular off-road Use Maintenance Schedule
(page 27).
Drive Chain Inspection
1. Stop the engine and raise the rear wheel of f
the ground by placing the optional workstand
or equivalent support under the engine and
shift the transmission into neutral.
2. Check the drive chain slack (1) in the upper
drive chain run midway between the drive (2)
and driven sprockets (3). Drive chain slack
should allow the following vertical movement
by hand:
1 – 1 3/8 in (25 – 35 mm)
Excessive chain slack may allow the drive chain
to damage the engine cases.
NOTICE
Adjustment
1. Loosen the rear axle nut (1).
2. Loosen the lock nuts (2) and turn the
adjusting bolts (3) counterclockwise to
decreace slack or clockwise to increase slack.
Align the index mark (4) of the axle plates (5)
with same reference marks (6) on both sides
of the swingarm.
(1) rear axle nut (4) index mark
(2) lock nut (5) axle plate
(3) adjusting bolt (6) reference marks
3. Tighten the rear axle nut to the specified
torque:
94 lbf·ft (127 N·m, 13.0 kgf·m)
4. Recheck chain slack and adjust if necessary.
5. Turn the adjusting bolt counterclockwise
lightly until it touches the axle plate. Then,
tighten the lock nut to the specified torque by
holding the adjusting bolt with a wrench.
20 lbf·ft (27 N·m, 2.8 kgf·m)
(4)
(6)
(6)
(3)
(2)
(5)
(1)
(1) drive chain slack (3) driven sprocket
(2) drive sprocket
If the chain is found to be slack in one segment
of its length and taut in another, this indicates
that some of the links are either worn, kinked or
binding. Kinking and binding can frequently be
eliminated by thorough cleaning and lubrication.
If the drive chain requires adjustment, procedure
is as follows:
(2)
(1)
(3)
Servicing Your Honda 95
Drive Chain
Removal, Cleaning & Replacement
For maximum service life, the drive chain should
be cleaned, lubricated, and adjusted before each
outing. Your CRF has an endless (riveted master
link) type chain. It should only be removed or
replaced by your dealer.
The O-rings can be damaged by steam cleaning,
high pressure washers, and certain solvents.
1. Clean the side surfaces of the chain with a dry
cloth. Use a high flash point solvent such as
kerosene – not gasoline.
Do not brush the rubber O-rings. Brushing
will damage them. Use of a solvent may also
damage the O-rings.
2. Replace the drive chain if it has damaged
rollers, loose fitting links, damaged O-rings,
or other wise appears unserviceable.
3. Measure the drive chain plate (1). If the drive
chain plate is worn anywhere to a thickness of
0.53 in (13.4 mm), the drive chain must be
replaced.
Replacement Chain:
Size/link:
DID520MXV – 116LE
4. Inspect the sprocket teeth for possible wear or
damage. Replace them if necessary.
Never install a new drive chain on badly worn
sprockets, or use new sprockets with a badly
worn drive chain. Both chain and sprockets
must be in good condition, or the new
replacement chain or sprocket(s) will wear
rapidly.
Excessively worn sprocket teeth have a
hooked, worn appearance. Replace any
sprocket, which is damaged or excessively
worn.
5. Lubricate the drive chain.
6. Recheck chain slack and adjust if necessary.
Use of a new chain with worn sprockets will
cause rapid chain wear.
NOTICE
0.53 in
(13.4 mm)
(1)
(1) drive chain plate (inner)
(1) upper drive chain roller (2) lower drive chain roller
96 Servicing Your Honda
Drive Chain
Drive Chain Sliders
1. Check the chain slider (1) for wear.
If the wear is 3/16 in (5 mm) or more, replace
it.
(1) chain slider
2. Check the chain guide slider (2) for wear.
Replace the chian guide slider if it is worn to
the bottom of the wear limit groove (3).
(2) chain guide slider
(3) wear limit groove
Drive Chain Rollers
1. Measure the diameter of the drive chain
rollers. Replace them if below the service
limit.
Service Limit:
UPPER ROLLER: 1.1 in (29 mm)
LOWER ROLLER: 1.2 in (31 mm)
2. Replace the roller if necessary as follows.
Install the upper drive chain roller (Green) (1)
and lower drive chain roller (Black) (2) as
shown.
Tighten the drive chain roller bolt and nut to
the specified torque.
Upper roller bolt:
9 lbf·ft (12 N·m, 1.2 kgf·m)
Lower roller nut: 9 lbf·ft (12 N·m, 1.2 kgf·m)
(1)
(2)
(3)
(1)
(2)
Lubrication
Lubricate the drive chain with Pro Honda HP
Chain Lube or an equivalent chain lubricant or
drive chain lubricant designed specifically for use
with O-ring chains. Wipe off the excess oil or
chain lubricant.
Commercial chain lubricants not designed for
motorcycle drive chains may contain solvents
which could damage the O-rings.
Servicing Your Honda 97
Additional Maintenance Procedures
Refer to Safety Precautions on page 25.
Steering Head Bearing Inspection
1. With your CRF on a box or optional
workstand (front wheel elevated), turn the
handlebar to the right and left to check for
roughness in the steering head bearings.
Handlebar Inspection
1. Check the handlebar (1) for bends or cracks.
2. Check that the handlebar has not moved from
its proper position by inspecting the paint
mark (2).
3. Check the torque of the handlbar upper holder
bolts (3):
16 lbf·ft (22 N·m, 2.2 kgf·m)
Tighten the front bolts first.
(1) handlebar (3) handlebar upper holder bolts
(2) paint mark
(1)
(2)
(3)
2. Stand in front of your CRF, grab the fork (at
the axle), look at the steering head, and push
the fork in and out (toward the engine) to
check for play in the steering head bearings.
If any roughness or play is felt, but you do
not see any movement in the steering head,
the fork bushings may be worn. Refer to the
Honda Service Manual for replacement or
adjustment procedures, or see your dealer.
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 do not
operate smoothly, replace the cables.
Be sure the throttle returns freely and
automatically from fully open to fully closed, in
all steering positions.
98 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
12
13
Cylinder head cover bolts
Exhaust pipe joint nuts
Coolant drain bolt
Crankshaft hole cap
Transmission oil check bolt
Clutch cover bolts
Cylinder bolt
Oil filter cover bolts
Cylinder head bolts
Drive sprocket bolt
Engine oil drain bolt
Transmission oil drain bolt
Air supply pipe bolt
ENGINE
Torque
lbf
•
ft N
•
m kgf
•
m
7
15
7
11
9
7
7
9
7
23
12
12
7
10
21
10
15
12
10
10
12
10
31
16
16
10
1.0
2.1
1.0
1.5
1.2
1.0
1.0
1.2
1.0
3.2
1.6
1.6
1.0
(2) exhaust pipe joint nuts
(3) coolant drain bolt
(4) crankshaft hole cap
(5) transmission oil check bolt
(6) clutch cover bolts
(13) air supply pipe bolt
(13)
(5)
(4)
(6)
(2)
(3)
(9)
(8)
(1)
(7)
(10)
(11)
(12)
RIGHT SIDE
LEFT SIDE
(1) cylinder head cover bolts
(7) cylinder bolt
(8) oil filter cover bolts
(9) cylinder head bolts
(10) drive sprocket bolt
(11) engine oil drain bolt
(12) transmission oil drain bolt
Battery
Servicing Your Honda 99
Refer to Safety Precautions on page 25.
Your CRF has a maintenance-free type battery.
You do not have to check the battery electrolyte
level or add distilled water as you would with a
conventional-type battery.
Your battery is a maintenance-free type and can
be permanently damaged if the cap strip is
removed.
Electrical accessories use current from the
battery, even when the engine is stopping.
Limited operation also allows the battery to
discharge. If you have electrical accessories on
your motorcycle or do not ride frequently, we
recommended that you charge the battery
frequently (see
Battery Charging on page 100).
If you do not expect to ride your CRF for at least
two weeks, we recommended you remove the
battery, or at least disconnect the battery cables
(negative cable first).
If you plan to store your CRF, see
Battery
Storage
(this page).
If your battery seems weak and/or is leaking
electrolyte (cause slow starting or other electrical
problems), see your dealer.
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds.
Wash hands after handling.
Battery Storage
If you plan to store your CRF, we recommend
you remove the battery and store it where it can
be charged at least every 30 days to maintain its
service life.
If you do not remove the battery, we recommend
disconnecting the battery cables (negative cable
first).
NOTICE
You will get the best storage results from
removing the battery and slow charging it every
30 days (see
Battery Charging on page 100).
Before you remove the battery, be sure to read all
the information that follows, as well as the
information on the battery label.
WARNING
The battery gives off explosive hydrogen
gas during normal operation.
A spark or flame can cause the batter y to
explode with enough force to kill or
seriously hurt you.
Wear protective clothing and a face
shield, or have a skilled mechanic do the
battery maintenance.
The battery is located under the seat.
Removal
1. Remove the seat (page 36).
2. Remove the battery band (1).
3. Remove the positive terminal cover (2).
(1) battery band (4) positive (+) terminal
(2) positive terminal cover (5) battery
(3) negative (–) terminal
5. Unless you have been riding regulary, charge
the battery (see page 100).
6. Store your battery in an easy-to-reach location
off the floor, in an area protected from
freezing temperatures and direct sunlight.
7. Clean the battery box after removing the
battery for storage. Dry the battery box.
8. Slow charge the battery (see page 100) once
every 30 days.
Installation
1. Reinstall in the reverse order of removal. Be
sure to connect the positive (+) terminal first,
then the negative (–) terminal.
2. Check all bolts and other fasteners are secure.
(3)
(4)
(5)
(2)
(1)
4. Disconnect the negative (–) terminal (3) first,
then the positive (+) terminal (4) and remove
the battery (5).
100 Servicing Your Honda
Battery
Battery Charging
Be sure to read the information that came with
your battery charger and follow the instructions
on the battery. Improper charging may damage
the battery.
We recommended using a charger (1) designed
specifically for your Honda, which can be
purchased from your dealer. These units can be
left connected for long periods without risking
damage to the battery. However, do not
intentionally leave the charge connected longer
than the time period recommended in the
charger’s instructions.
Avoid using an automotive-type battery charger.
An automotive charger can overheat a
motorcycle battery and cause permanent damage.
(1) charger
(1)
(4) dust cover (6) “TOP” mark
6. To install the headlight, reverse the removal
procedure.
Servicing Your Honda 101
Headlight & Taillight
Refer to Safety Precaution on page 25.
Headlight Bulb
1. Remove the front visor bolts (1) and pull out
the front visor (2).
(1) front visor bolts
(2) front visor
2. Disconnect the headlight connector (3).
Remove the dust cover (4).
(5) headlight bulb socket
4. To install a new headlight bulb, push and turn
the headlight bulb socket clockwise.
If you touch the bulb with your bare hands, clean
it with a cloth moistened with denatured alcohol
to prevent early bulb failure.
5. Install the dust cover (4) tightly against the
headlight unit with its “TOP” mark (6) facing
up.
(2)
(1)
(3)
(4)
(5)
(1)
(1) adjusting screw
Taillight
The taillight uses LED illumination.
If the taillight does not function properly, see
your dealer for service.
This model is equipped with an electric starter
and battery for easy engine starting.
There is a possibility of damage to the lighting
system if the battery is carelessly removed.
Never kick-start the engine without the battery
connected.
If it becomes necessary to kick-start the engine
with the battery removed, remove the relays to
the battery to prevent damage to the lighting.
Headlight Aim
The headlight aim can be raised or lowered.
Turn the adjusting screw (1) clockwise to move
the headlight up or turn the adjusting screw
counterclockwise to move the headlight down to
proper adjustment.
(4)
(6)
(3) headlight connector
(4) dust cover
3. To pull the headlight bulb out, push and turn
the headlight bulb socket (5) counterclockwise.
102 Servicing Your Honda
Appearance Care
Refer to Safety Precautions on page 25.
Frequent cleaning and polishing will keep your
Honda looking newer longer. Frequent cleaning
also identifies you as an owner who values his
motorcycle. A clean CRF is also easier to inspect
and service.
While you’re cleaning, be sure to look for
damage, wear, and gasoline or oil leaks.
General Recommendations
• 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
muffler 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 (Scotch-Brite Hand Pad
#7447-maroon) is for removing stains on the
non-coated aluminum frame only.
4. After washing, rinse your CRF thoroughly
with plenty of clean water to remove any
residue.
5. Dry your CRF with a chamois or a
soft towel.
6. Lubricate the drive chain to prevent rusting.
7. Start the engine and let it idle for several
minutes. The engine heat will help dry moist
areas.
8. As a precaution, ride at a slow speed and
apply the brakes several times. This will help
dry the brakes and restore normal braking
performance.
If the inside of the headlight lens appears clouded
immediately after washing, it should cleaner after
a few minutes of riding.
NOTICE
(2)
(1)
Servicing Your Honda 103
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 rinse 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 And Muffler Maintenance
The exhaust pipe and muffler are stainless steel,
but may became stained by mud or dust.
To remove mud or dust, use a wet sponge and a
liquid kitchen abrasive, then rinse well with clean
water. Dry with chamois or a soft towel.
If necessary, remove heat stains by using a
commercially available fine texture compound.
Then rins by the same manner as removing mud
or dust.
104 Servicing Your Honda
This section tells you how to fine tune your CRF
for maximum competition performance.
Initial suspension adjustments should be
performed after a minimum of two hours of easy
break-in time.
Optional front and rear suspension springs are
available in both stiffer and softer than standard
rates, in order to tailor your CRF specifically for
your weight, riding style and course conditions.
Follow the instructions given in the rear
suspension sag setting section of
Rear
Suspension Adjustments
to determine if your
combined rider and sprung machine weight (rider
fully dressed for competition and machine
coolant, oil and fuel levels ready for competition)
requires an optional stiffer or softer rear spring.
The need for either optional rear spring may need
to be balanced by installing the optional fork
springs of a similar rate.
Front Suspension Adjustments.........................106
Rear Suspension Adjustments ..........................120
Suspension Adjustments for Track
Conditions ........................................................124
Suspension Adjustment Guidelines..................125
Carburetor Adjustment & Tuning Tips ............128
Chassis Adjustments.........................................135
Gearing .............................................................136
Tire Selection for Track Conditions.................137
Personal Fit Adjustments .................................138
Adjustments for Competition 105
Adjustments for Competition
(2)
(1)
106 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 163)
The inverted fork on your CRF features sealed
damper cartridges with dual (separate air and oil)
chambers to prevent aeration. The design also
isolates the oil in each fork tube/slider, which
may contain air bubbles and/or metal particles,
from the sealed cartridge to provide more
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/cm
2
).
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 your CRF on an optional warkstand or
equivalent support with the front wheel off the
ground.
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 rebound damping adjuster (1) has 16
positions or more. Turning the adjuster screw one
full turn clockwise advances the adjuster four
positions. To adjust the rebound damping to the
standard setting, proceed as follows:
Turn the adjuster clockwise until it will no longer
turn (lightly seats). This is the full hard position.
The adjuster is set in the standard position when
the adjuster is turned counterclockwise 15 clicks.
Make sure that both fork legs are adjusted to the
same position.
Compression Damping
Adjustment
This adjustment affects how quickly the fork
compresses. The fork compression damping
adjuster (2) screw has 16 positions or more.
Turning the adjuster one full turn changes the
adjuster four positions. To adjust the adjuster to
the standard position, proceed as follows:
Turn the adjuster clockwise until it will no longer
turn (lightly seats). This is the full hard position.
The adjuster is set in the standard position when
the adjuster is turned counterclockwise 7 clicks.
Make sure that both fork legs are adjusted to the
same position.
Adjustments for Competition 107
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 compression
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 dealer for this service.
• When disassembling the fork, turn the
rebound (1) and compression (2) damping
adjusters counterclockwise to the softest
position to prevent damaging the adjustment
needle (be sure to record the number of turns
from the starting position).
Fork Springs
The fork springs in CRF’s are about right for
riders weighing between 150 and 160 lb (less
riding gear). So if you're a heavier rider, you
have to go up on the oil level or get a stif fer
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 level.
Minimum oil capacity:
Standard spring:
10.2 US oz (303 cm
3
)
Softer spring: 10.4 US oz (308 cm
3
)
Stiffer spring: 10.3 US oz (306 cm
3
)
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 damping adjuster
(1)
(2)
Force (N)
Stroke (mm)
Oil capacity 13.5 US oz (399 cm
3
)
(MAX)
Oil capacity 11.7 US oz (345 cm
3
)
(STANDARD)
Oil capacity 10.2 US oz (303 cm
3
)
(MIN)
(1) rebound damping (2) compression
adjuster damping adjuster
(1)
(2)
Front Suspension Adjustments
108 Adjustments for Competition
(5) headlight connector
4. Remove the handlebar pad.
Remove the handlebar holder nuts, washers,
mounting rubbers (6) and handlebar (7).
(8) upper pinch bolts
(9) fork damper
(10)
(11)
(10) disc cover
(11) bolts
8. Remove the tripmeter cable (12) and front
axle nut (13) and loosen the axle pinch bolts
(14) on both fork legs.
9. Pull the front axle shaft (15) out of the wheel
hub and remove the front wheel.
(12) tripmeter cable (14) axle pinch bolts
(13) front axle nut (15) front axle shaft
10.Remove the fork protector bolts (16),
tripmeter cable clamp bolts (17) and brake
hose clamp bolts (18) and fork protectors
(19).
Remove the brake caliper bolts (20) and brake
caliper (21).
The fork protector bolts and brake caliper
bolts have a locking agent applied.
(5)
(7)
(6)
(8)
(9)
(14)
(15)
(12)
(14)
(13)
(6) handlebar holder nuts/washers/mounting rubbers
(7) handlebar
5. Loosen the upper pinch bolts (8).
6. Loosen the fork dampers (9) using the lock
nut wrench but do not remove it yet.
• Lock nut wrench 07WMA-KZ30100
Do not use an adjustable wrench to loosen the
fork damper: it may damage them.
NOTICE
1. Place your CRF on the optional workstand or
equivalent support with the front wheel off the
ground.
2. Remove the front visor bolts (3) and front
visor (4).
(3)
(4)
(3) front visor bolts
(4) front visor
3. Disconnect the headlight connector (5).
7. Remove the disc cover (10) by removing the
bolts (11).
Keep the master cylinder upright to prevent air
from entering system.
NOTICE
Front Suspension Adjustments
Adjustments for Competition 109
(22) lower pinch bolts
12.Clean the fork assembly, especially the sliding
surface (23) of the slider and dust seal (24).
13.Record the rebound damping adjuster position
and turn the adjuster counterclockwise until it
stops.
14.Measure the length (25) between the axle
holder and outer tube and record it before
disassembling the fork.
(24) dust seal (30) slider
(26) outer tube (31) guide bushing
16.Drain the fork oil from the outer tube (26).
Drain the fork oil from the oil hole (32) of the
fork damper.
(26) outer tube (32) oil hole
(23) sliding surface (25) length
(24) dust seal
15.Hold the outer tube (26), then remove the fork
damper (27) from the outer tube using the
lock nut wrench (28). Gently slide the outer
tube down onto the lower end of the slider
(29).
• Lock nut wrench 07WMA-KZ30100
(30)
(24)
(31)
(26)
(25)
(24) (23)
(28)
(26)
(29)
(26)
(27)
(26) (32)
(16) fork protector bolts (19) fork protectors
(17) tripmeter cable clamp bolts (20) brake caliper bolts
(18) brake hose clamp bolts (21) brake caliper
11.Loosen the fork leg lower pinch bolts (22),
then pull the fork legs down and out.
(19)
(16)
(20)
(20)
(21)
(18)
(17)
(22)
Do not support the brake caliper by the brake
hose. Do not operate the front brake lever after
the front wheel is removed. To do so will cause
difficulty in fitting the brake disc between the
brake pads.
(cont’d)
The outer tube (26) can drop on the slider (30)
and damage the fork dust seal (24) and guide
bushing (31) when the fork damper is removed.
To avoid damage hold both the outer tube and
slider when removing the fork damper.
NOTICE
(26) outer tube (28) lock nut wrench
(27) fork damper (29) slider, lower end
Front Suspension Adjustments
110 Adjustments for Competition
22.Apply pressure to the fork damper and insert a
piston base (35) or mechanic's stopper tool
(see below) between the axle holder (33) and
lock nut (36).
23.Hold the lock nut and remove the fork center
bolt (34) 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
(33) axle holder (35) piston base
(34) fork center bolt (36) lock nut
24.Remove the push rod (37) from the fork
damper.
25.Remove the piston base or mechanic's stopper
tool between the axle holder (33) and lock nut
(36) while applying pressure to the fork cap.
Be careful not to damage the lock nut and fork
center bolt hole.
NOTICE
(33) axle holder (37) push rod
(36) lock nut
26.Remove the fork damper assembly (38) from
the fork assembly (39).
Remove the fork from the vise.
Remove the fork spring (40) from the fork
assembly.
(38) fork damper assembly (40) fork spring
(39) fork assembly
(33)
(35)
(36)
(34)
(33)
(37)
(36)
(38)
(40)
(39)
17.Temporarily install the fork damper to the
outer tube.
18.Set the lower end (axle holder) (33) of the
slider 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 fork center bolt (34).
NOTICE
(33) axle holder (34) fork center bolt
20.Push out the fork 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 0.08 in (2.0 mm) thick as shown
if you do not have the piston base.
(34)
(33)
2.2 in (55 mm)
1.0 in (25 mm)
1.2 in (30 mm)
0.48 in (12.2 mm)
R0.24 in (6.1 mm)
Front Suspension Adjustments
Adjustments for Competition 111
(1) fork cap assembly (3) lock nut wrench
(2) fork damper
(1) fork cap assembly (2) fork damper
4. Empty the fork oil from the oil hole (3) of the
fork damper (2) by pumping the damper rod
several times.
(2) fork damper (3) oil hole
5. Clean the fork cap and fork damper threads.
(2) fork damper
7. Pump the fork damper piston rod (4) slowly
several times to bleed the air from the fork
damper (2).
(2) fork damper (4) fork damper piston rod
(2)
(3)
(1)
(1)
(2)
(2)
(3)
(2)
(2)
(4)
6. Extend the fork damper piston rod to maximum.
Pour the recommended fork oil into the fork
damper (2).
Recommended Oil:
Pro Honda HP Fork Oil 5 W or equivalent
Recommended Amount:
6.5 US oz (192 cc, 6.8 Imp oz)
3. Remove the fork cap assembly (1) from the
fork damper (2).
Be careful not to damage the fork cap bushing.
Do not disassemble the fork cap assembly.
Replace the fork cap as an assembly if it is
damaged.
Damper Oil Change
1. Place the fork damper (2) in a vise with a
piece of wood or soft jaws to avoid damage.
2. Loosen the fork cap assembly (1) while
holding the fork damper (2) using the lock nut
wrench (3).
• Lock nut wrench 07WMA-KZ30100
(cont’d)
Front Suspension Adjustments
112 Adjustments for Competition
(2) fork damper (4) fork damper piston rod
(2)
(4)
(4) 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 damper 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.
NOTICE
(4)
(7)
12.Screw in the lock nut (7) to the fork damper
piston rod (4) fully.
(1) fork cap assembly (3) lock nut wrench
(2) fork damper
11.Hold the fork damper (2) in an upright
position and pump the fork damper piston rod
(4) to 3.9 in (100 mm) slowly several times.
(2)
(3)
(1)
10.Place the fork damper (2) in a vise with a
piece of wood or soft jaws to avoid damage.
Tighten the fork cap assembly (1) while
holding the cut out of the fork damper using
the lock nut wrench (3) to the specified
torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m)
(2) fork damper
9. Apply fork oil to the bushing (5) and new O-
rings (6) on the fork cap assembly (1).
Extend the fork damper piston rod to
maximum, holding it, install the fork cap
assembly to the fork damper (2).
Be careful not to damage the fork cap bushing.
If it is difficult to install the fork cap assembly,
the fork damper oil level might be higher than
standard oil level. Inspect the fork damper oil
level again.
(1) fork cap assembly (5) bushing
(2) fork damper (6) O-rings
1.65 – 1.85 in
(42 – 47 mm)
(2)
(2)
(6)
(1)
(5)
8. Extend the fork damper piston rod to
maximum. Adjust the oil level of the fork
damper (2) as shown.
Oil Level:
1.65 – 1.85 in (42 – 47 mm)
Front Suspension Adjustments
Adjustments for Competition 113
(8) fork damper spring chamber
(10) pressure release screw (11) fork cap
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 143).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
(9) oil hole
(8)
(9)
(10)
(11)
14.Drain the extra oil from the oil hole (9).
By doing this procedure, about 0.6 US oz (17 cm
3
)
of fork fluid will be drained from the damper
spring chamber through the oil hole and cause
5.9 US oz (175 cm
3
) of fork fluid to be left in the
chamber.
13.Blow the extra oil off to the fork damper
spring chamber (8) by pumping the fork
damper piston rod to full stroke.
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
(11).
Hold the fork damper up side down for 10
minutes and drain the oil from the fork
damper spring chamber.
Front Suspension Adjustments
114 Adjustments for Competition
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)
(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. Using compressed air, blow all oil off the fork
spring (3).
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)
(2)
(A)
(4)
(3)
(1)
Adjustments for Competition 115
Front Suspension Adjustments
4. Place the lower end (axle holder) of the slider
in a vise with a piece of 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 piston base (5) or mechanic's stopper tool
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 fork damper
piston rod until it stops.
Check the push rod installation by turning the
push rod right and left.
7. Apply fork oil to a new O-ring (7) and install
it to the fork center bolt (8). Install the fork
center bolt to the fork damper piston rod
aligning the fork center bolt adjusting rod (9)
with the push rod. Tighten the fork center bolt
fully by hand.
NOTICE
(2) lock nut (7) O-ring
(5) piston base (8) fork center bolt
(6) push rod (9) adjusting rod
8. Measure the length of the lock nut (2) and
fork center bolt (8) clearance.
Standard
: 0.06 – 0.08 in (1.5 – 2.0 mm)
If the clearance is out of specification, check the
lock nut and center bolt installation.
(2) lock nut (8) fork center bolt
9. Tighten the lock nut (2) to the fork center bolt
(8) closely by hand. Tighten the lock nut to
the specified torque:
16 Ibf·ft (22 N·m, 2.2 kgf·m)
(2) lock nut
(8) fork center bolt
10.Remove the piston base or mechanic's stopper
tool while applying pressure to the fork
damper.
Install the fork center bolt (8) to the axle
holder and tighten it to the specified torque:
51 Ibf·ft (69 N·m, 7.0 kgf·m)
(8) fork center bolt
11.Measure the length between the axle holder
and outer tube.
Standard:
12.5 in ± 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 fork center bolt and lock
nut installation.
(10) length
(cont’d)
(8)
(7)
(9)
(5)
(2)
(6)
(2)
(8)
(8)
(2)
(8)
(10)
116 Adjustments for Competition
Front Suspension Adjustments
13.Pour the recommended fork oil (11) into the
outer tube/slider (1).
Recommended Oil:
Pro Honda HP Fork Oil 5 W or equivalent.
(1) outer tube/slider (11) fork oil
(1)
(11)
()
Fork Oil Capacity:
Standard 23.53 lbf/in (4.12 N/mm) Fork Spring
Standard oil
capacity
11.7 US oz
(345 cm
3
)
Maximum oil
capacity
13.5 US oz
(399 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.2 US oz
(303 cm
3
)
()
Optional Softer 22.38 lbf/in (3.92 N/mm) Fork Spring
Standard oil
capacity
11.8 US oz
(350 cm
3
)
Maximum oil
capacity
13.7 US oz
(404 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.4 US oz
(308 cm
3
)
No mark
(factory products)
3 scribe marks
2 scribe marks
(aftermarket parts)
or
()
Optional Stiffer 24.61 lbf/in (4.31 N/mm) Fork Spring
Standard oil
capacity
11.8 US oz
(348 cm
3
)
Maximum oil
capacity
13.6 US oz
(402 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.3 US oz
(306 cm
3
)
1 scribe mark
Be sure the oil capacity is the same in both fork
legs.
(17)
(13)
Adjustments for Competition 117
Front Suspension Adjustments
14.Install a new O-ring (12) on the fork damper
assembly (4). Apply the recommended fork
oil to the O-ring.
15.Pull up the outer tube/slider (1) slowly and
install the fork damper assembly (4) into the
outer tube.
(1) outer tube/slider (12) O-ring
(4) fork damper assembly
16.Insert both fork legs into the fork clamps.
Tighten the fork lower pinch bolts (13) to the
specified torque.
15 Ibf·ft (20 N·m, 2.0 kgf·m)
(1) outer tube (16) upper fork clamp
(15) align
19.Tighten the fork lower pinch bolts (13) to the
specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m)
20.Tighten the fork upper pinch bolts (17) to the
specified torque:
16 Ibf·ft (22 N·m, 2.2 kgf·m)
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
(12)
(4)
(1)
(cont’d)
(13) lower pinch bolts
(13)
(4)
(14)
(16)
(15)
(1)
(4) fork damper assembly (14) lock nut wrench
18.For ease of releasing air pressure after the
forks are installed, Loosen the lower pinch
bolts and position the outer tubes so that the
pressure release screws are in front of the
rebound damping adjusters.
Align (15) the top surface of the upper fork
clamp (16) with the outer tube (1) upper
surface as shown.
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.
• Lock nut wrench 07WMA-KZ30100
When using the lock nut wrench, use a 20 in
(50 cm) long deflecting beam type torque
wrench. The lock nut wrench increases the
torque wrench’s leverage, so the torque
wrench reading will be less than the torque
actually applied to the fork damper.
118 Adjustments for Competition
(35)
(34)
Front Suspension Adjustments
21.Clean the threads of the fork protector bolts
(18) and axle holder thoroughly.
Apply locking agent to the fork protector bolt
threads.
Install the fork protectors (19), fork protector
bolts, brake hose clamp bolts (20) and
tripmeter cable clamp bolts (21).
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 (23) and hose with the
left fork leg, making sure that the brake hose
is not twisted. An improperly routed brake
hose may rupture and cause a loss of braking
efficiency. Route the hose carefully.
23.Clean the threads of the caliper mounting
bolts (22) and brake caliper thoroughly.
Apply locking agent to the bolt threads.
Install the brake caliper (23) on the slider and
tighten the caliper mounting bolts to the
specified torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m)
(19)
(18)
(22)
(22)
(23)
(20)
(21)
(24)
(25)
(26)
(27)
(18) fork protector bolts
(19) fork protectors
(20) brake hose clamp bolts
(21) tripmeter cable clamp bolts
(22) caliper mounting bolts
(23) brake caliper
26.Install and tighten the axle nut (32) to the
specified torque.
65 Ibf·ft (88 N·m, 9.0 kgf·m)
Tighten the left axle pinch bolts (33) to the
specified torque.
15 Ibf·ft (20 N·m, 2.0 kgf·m)
(32) axle nut
(33) left axle pinch bolts
27.Install the handlebar (34), mounting rubbers,
washers and handlebar holder nuts (35) and
tighten the handlebar holder nuts to the
specified torque:
32 Ibf·ft (44 N·m, 4.5 kgf·m)
(30)
(31)
(29)
(28)
(32)
(33)
(24) left side collar (26) tabs
(25) tripmeter gear box (27) grooves
25.Clean the clamping surface of the axle and
axle holders.
Install the front wheel (28) between the fork
legs while inserting the disc between the pads,
and align (29) the tab of the tripmeter gear
box as shown.
Check that the tripmeter gear box O-ring (30)
is in good condition, replace it if necessary.
Apply a thin layer of grease to the axle (31)
and insert the axle from the right side.
(28) front wheel (30) O-ring
(29) align (31) axle
(34) handlebar
(35) mounting rubbers/washers/handlebar holder nuts
24.Check the left side collar (24) and tripmeter
gear box (25) for wear or damage.
Install the left side collar to the left wheel hub.
Install the tripmeter gear box while aligning
its tabs (26) of the tripmeter gear box with the
grooves (27) on the right wheel hub.
Adjustments for Competition 119
Front Suspension Adjustments
28.Install the front visor by aligning its grommets
(36) with the tabs (37) on the steering stem.
29.Connect the headlight connector (38).
(36) front visor grommets (38) headlight connector
(37) tabs
30.Install and tighten the front visor bolts (39).
Install the handlebar pad (40).
31.With the front brake applied, pump the fork
up and down several times to seat the axle and
check front brake operation.
32.While keeping the forks parallel, alternately
tighten the right axle pinch bolts (41) to the
specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m)
To avoid damage when torquing the axle pinch
bolts, be sure the axle is seated firmly onto the
left fork leg clamp inner surface.
33.Install the tripmeter cable (42) and tighten the
lock nut securely.
NOTICE
34.Install the disc cover (43) and tighten the bolts
(44) to the specified torque:
10 Ibf·ft (13 N·m, 1.3 kgf·m)
(43) disc cover (44) bolts
35.Turn the rebound damping (45) and
compression damping (46) adjuster back to
their original setting.
(37)
(36)
(38)
(40)
(39)
(42)
(41)
(43)
(44)
(39) front visor bolts (40) handlebar pad
(41) right axle pinch bolts (42) tripmeter cable
(45) rebound damping (46) compression
adjuster damping adjuster
(45)
(46)
120 Adjustments for Competition
Rear Suspension Adjustments
Pin spanners should be used for turning the lock
nut and adjusting nut. See page 163 for optional
pin spanners.
Spring pre-load length (Standard spring)
Standard:
10.10 in (256.6 mm)
Min. : 9.6 in (243 mm)
Spring pre-load length (Optional spring)
Min. (Softer, 254.7 lbf/in (44.6 N/mm)):
9.7 in (246 mm)
Min. (Stiffer, 279.8 lbf/in (49.0 N/mm)):
9.7 in (246 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 dealer. The
instructions found in this owner’s manual are
limited to adjustments of the shock assembly
only.
Puncture or exposure to flame may also result in
an explosion, causing serious injury.
Service or disposal should only be done by your
dealer or a qualified mechanic, equipped with the
proper tools, safety equipment and the Honda
Service Manual.
If your CRF is new, put enough part-throttle
break-in time (about one hour) on it to ensure
that the suspension has worked in.
Rear Suspension Spring Pre-Load
Pre-load should be adjusted when the engine is
cold because it is necessary to remove the
muffler (page 62).
An optional pin spanner is available for turning
the lock nut and adjusting nut to adjust spring
pre-load.
1. Place your CRF on an optional workstand or
equivalent support with the rear wheel off the
ground.
2. Loosen the connecting tube clamp screw and
subframe mounting upper bolt, and remove
the rear subframe mounting lower bolts, then
lift the subframe. See page 39.
3. Check that the spring pre-load is adjusted to
the standard length. Adjust as necessary by
loosening the lock nut (1) and turning the
adjusting nut (2).
Each complete turn of the adjusting nut
changes the spring length by 0.06 in (1.5 mm).
4. After adjustment, hold the adjusting nut and
tighten the lock nut to the specified torque:
32 lbf·ft (44 N·m, 4.5 kgf·m)
(1) lock nut (3) pin spanners
(2) adjusting nut (4) spring length
T
o increase spring pre-load:
Loosen the lock nut with the optional pin spanner
(3) and turn the adjusting nut to shorten the
spring length (4). Do not shorten to less than:
9.6 in (243 mm)
To decrease spring pre-load:
Loosen the lock nut with the optional pin spanner
(3) and turn the adjusting nut to increase the
spring length (4). Do not increase to more than:
10.14 in (257.6 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) / 15.9 lbf (70.6 N)
(1)
(2)
(4)
(3)
Adjustments for Competition 121
Rear Suspension Adjustments
(3) rebound damping adjuster
To adjust to the standard position:
1. Turn the adjuster clockwise until it will no
longer turn (lightly seat). This is the full hard
position.
2. Turn the adjuster counterclockwise 11 – 14
clicks with the punch marks on the adjuster
and the shock absorber aligned.
Rear Suspension Damping
Compression Damping
Compression damping may be adjusted in two
stages with separate adjusters.
The high speed damping adjuster (1) is ef fective
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 compression
damping can be increased by turning the
appropriate adjuster clockwise.
• Adjust the high speed compression adjuster in
1/12 turn increments.
• Be sure the low speed compression adjuster is
firmly located in a detent, and not between
positions.
(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.
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 compression 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 12 clicks
and the punch marks are aligned.
Rebound Damping
The rebound damping adjuster (3) is located at
the lower end of the shock absorber.
It has 17 positions or more. Turning the adjuster
one full turn advances the adjuster 4 positions.
• Rebound damping can be increased by turning
the adjuster clockwise.
• Be sure that the rebound adjuster is firmly
located in a detent, and not between positions.
(1)
(2)
1
(3)
122 Adjustments for Competition
Rear Suspension Adjustments
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 about one-third
of the maximum travel.
On your CRF, ride height is changed by
adjusting the rear suspension spring pre-load.
Spring Pre-load & 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 workstand with rear
suspension fully extended, no rider.
loaded with rider: motorcycle on ground, with
rider.
loaded without rider: CRF on ground, without
rider.
1. Support your motorcycle 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.
Ask 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
REAR FENDER MOUNTING BOLT
CHAIN ADJUSTER LOCK NUT
LOADED
(with rider)
EXAMPLE: 19.7 in (500 mm)
BIKE LOADED
(without rider)
EXAMPLE: 21.7 in (550 mm)
Example:
Unloaded
= 23.6 in (600 mm)
– Loaded = 21.7 in (550 mm)
Sag = 2.0 in (50 mm)
(Without Rider)
Adjustments for Competition 123
Rear Suspension Adjustments
Because of the great absorption quality of the
shock bumper rubber, it may be difficult for you
to notice when your CRF’s suspension is
bottoming. Some riders may think the damping
or perhaps the leverage ratio is too harsh. In
reality, the problem is most likely insufficient
spring pre-load or a spring that is too soft. Either
situation prevents utilizing the full travel.
Keep in mind that a properly adjusted suspension
system may bottom slightly every few minutes at
full speed. Adjusting the suspension to avoid this
occasional bottoming may cost more in overall
suspension performance than it is worth.
A spring that is too stiff for your weight will not
allow the rear tire to hook up under acceleration
and will pass more bumps on to you.
6. Calculate the
free sag dimension.
To do this, subtract the
loaded without rider
dimension (step 5) from the unloaded
dimension (step 2).
Free sag indicates the distance your rear
suspension should sag from the weight of the
sprung portion of your CRF.
With the spring pre-load set to obtain the
proper race sag, the rear suspension should
sag 0.4 to 1.0 in (10 to 25 mm).
If the rear of your CRF sags less than 0.4 in
(10 mm) from its own weight, the spring is
too stiff for your weight. It is not compressed
enough, 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.
124 Adjustments for Competition
Suspension Adjustments for Track Conditions
Soft Surface
On soft ground, sand, and especially mud,
consider increasing compression damping front
and rear.
Sand often requires a bit more rebound damping
to minimize rear end kick. Although sand bumps
are usually larger, there’s more distance between
them, giving the shock more time to recover.
You may want a little bit stiffer front suspension
for sand tracks to help keep the front end up and
improve straight-line stability.
In a muddy event, stiffer aftermarket springs
front and rear may help, especially if you are
heavier than the average rider. Your CRF may be
undersprung because of the added weight of the
clinging mud. This additional weight may
compress the suspension too much and affect
traction.
Hard Surface
For a fast, hard track with no lar ge 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.
Adjustments for Competition 125
Suspension Adjustment Guidelines
Follow the procedures described below to accurately adjust your CRF , using the methods described on pages 106 – 124. Remember to make all adjustments in
one click or 1/12 turn increments. Test ride after each adjustment.
Front Suspension Adjustment
Adjustments for Type of Track
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 char t below.
Adjust to a stiffer position.
Example: – Turn the compression damping adjuster to a stiffer position.
– Install the optional stiff spr ing. (Adjust compression damping to a softer position and rebound damping to a stiff 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 spr ing.
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 abo ve adjustment:
– Reduce the rebound damping in one-click increments.
– Test softer compression damping adjustments in one-click increments.
If that doesn’t solve the problem, install the optional stiff spr ing.
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 spr ing.
If initial travel is stiff after installing the optional stiff spr ing:
– Test softer compression damping adjustments in one-click increments.
If initial travel is still soft after installing the optional stiff spr ing:
– Test stiffer compression damping adjustments in one-click increments.
If final travel is still soft after installing the optional stiff spr ing:
– Increase the fork oil capacity in increments of 0.2 oz (5 cc).
– Install the optional stiff spr ing.
– Test stiffer compression damping adjustments in one-click increments.
– Increase rebound damping in one-click increments.
126 Adjustments for Competition
Suspension Adjustment Guidelines
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 str aight line.
Middle travel too stiff:
• Stiff on bumps when cornering.
• Front end wanders when cornering.
• Stiff suspension on bumps, especially downhill 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-clic k 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 clic k
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
desire 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 travel.)
If final travel is still stiff after the abo ve adjustment, or
If initial and middle travel becomes stiff:
– Install the optional soft spr ing.
– Test softer compression damping adjustments in one-click increments.
If the entire travel feels stiff after the above adjustment:
– Test softer compression damping adjustments in one-click increments until the
desired initial travel compression damping is obtained.
– Lower the oil capacity by 0.2 oz (5 cc).
– Test softer compression damping adjustments in one-click increments.
– Reduce the rebound damping in one-click increments.
– Lower the oil capacity by 0.2 oz (5 cc).
Adjustments for Competition 127
Suspension Adjustment Guidelines
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-clic k increments, and the high speed compression adjuster in 1/12 t urn 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 tab le and test stiffer or softer compression and/or rebound damping adjustments until
the correct settings are obtained as descr ibed.
Hard-surfaced track
Sand track
Mud track
Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the char t below.
Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spr ing 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 stiff er settings.
– Install the optional stiff spr ing.
– 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 sim ultaneously.
1. Test softer high speed compression adjustment.
2. If it still feels stiff, further test softer low and high speed compression adjustments sim ultaneously.
1. Test softer high and low speed compression adjustments and rebound adjustment sim ultaneously.
2. If it still feels stiff, replace the spring with a softer spring (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 stiff er 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 spr ing 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 spr ing with a
stiffer spring (optional) if necessary.
1. Test softer rebound damping 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.
128 Adjustments for Competition
Carburetor Adjustment & Tuning Tips
The carburetor used on your CRF will seldom
experience trouble with the standard settings
under average load, and average climatic and
barometric conditions. However, to fine-tune the
engine’s power output, the carburetor may
require specific adjustments for competition use.
However, in order to comply with emission
regulations, we recommend that you make no
carburetor changes unless you use your CRF for
competition only.
Carburetor Components
Cold Start Circuit
A very rich mixture must be delivered to the
cylinder when a cold engine is being started.
When the choke knob (1) is pulled out, fuel is
metered by the starter jet (2) and is mixed with
air from the air passage (3) (located above the
throttle valve (4)) to provide a rich mixture for
starting. The mixture discharges through the
orifice (5) into the cylinder.
(1) choke knob (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)
Carburetor Adjustment & Tuning Tips
Adjustments for Competition 129
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 valve (4) is shut
resulting in a sharp increase in pressure in the
pump chamber (5). The outlet check valve (6)
then opens, supplying fuel to the main bore via
the accelerator nozzle (7).
(1) throttle valve (5) pump chamber
(2) pump rod (6) outlet check valve
(3) diaphragm (7) accelerator nozzle
(4) inlet check valve
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.
Baf
fle Plate
The baffle plate (5) prevents foaming of fuel or
abnormal fuel level around the main jet.
Float Bowl
The float (6) and float valve (7) operate to
maintain a constant level of fuel in the float
bowl.
(1) main jet (5) baffle plate
(2) jet needle (6) float
(3) needle jet (7) float valve
(4) air jet
(3)
(1)
(7)
(6)
(2)
(5)
(4)
(3)
(2)
(1)
(5)
(4)
(2)
(4)
(7)
(6)
(5)
(1)
(3)
Carburetor Adjustment & Tuning Tips
Carburetor Removal
1. Turn the fuel valve OFF.
2. Drain the remaining fuel in the float bowl into
an approved gasoline container by loosening
the carburetor drain screw (1).
(1) carburetor drain screw
Drain the carburetor into an approved gasoline
container and dispose of it in an approved
manner (page 143).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
(1)
130 Adjustments for Competition
(2) band
(3) rear suspension upper mounting nut
(4) rear suspension upper mounting bolt
6. Lift the subframe to the upright position (page
39).
7. Loosen the intake band screw (5) and remove
the clip (6).
(5) intake band screw
(6) clip
8. Disconnect the throttle position sensor
connector (7). Remove the carburetor.
(7) throttle position sensor connector
9. Remove the hot start cable holder (8).
(8) hot start cable holder
(2)
(3)
(4)
(5)
(6)
(7)
(8)
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.
3. Tighten the carburetor drain screw after drain
the fuel.
4. Remove the fuel tank (page 37).
5. Remove the band (2) and rear suspension
upper mounting nut (3), and pull out the rear
suspension upper mounting bolt (4).
Carburetor Adjustment & Tuning Tips
Adjustments for Competition 131
Carburetor Disassembly
1. Pull up the cable clamp (1) and remove the
carburetor top cover bolts (2).
Then remove the carburetor top cover (3).
(1) cable clamp
(2) carburetor top cover bolts
(3) carburetor top cover
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 set torx screw (6).
When installing the link arm set torx screw,
apply a locking agent to the link arm set torx
screw threads.
4. Remove the throttle valve (7), throttle valve
roller (8) and floating valve (9).
(6) link arm set torx screw (8) throttle valve roller
(7) throttle valve (9) floating valve
(2)
(1)
(3)
(5)
(4)
(6)
(7)
(9)
(7)
(8)
10.Remove the throttle drum cover bolt (9) and
throttle drum cover (10).
(9) throttle drum cover bolt
(10) throttle drum cover
11.Remove the throttle cables (11) by looseing
the throttle cable lock nut (12) and adjusting
nuts (13).
(11) throttle cables
(12) throttle cable lock nut
(13) adjusting nuts
(cont’d)
(9)
(10)
(12)
(11)
(13)
Carburetor Adjustment & Tuning Tips
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 down.
(7) throttle valve
(9) floating valve
(10) hole
(10)
(7)
(9)
132 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-ring ’s
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
(11)
(12)
(13)
(17)
(13)
(12)
(15)
(16)
(14)
(21)
(20)
(18)
(19)
(17)
(24)
(23)
(24)
(22)
(22)
Carburetor Adjustment & Tuning Tips
(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 float tab is just
contacting the float valve with the carburetor
intake (27) facing up. The float level should
be 0.31 in (8.0 mm).
If the float level is out of specification, adjust
it by bending the float tab carefully.
(17) float bowl (28) leak jet
(25)
(26)
(27)
(17)
(28)
Adjustments for Competition 133
Carburetor Assembly
To assemble, reverse the disassembly procedures.
To install the carburetor, reverse the removal
procedures.
Tighten the following parts to the specified
torque.
float bowl screws:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
accelerator pump cover screws:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
carburetor top cover bolts:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
jet needle/holder assembly:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
leak jet:
0.2 lbf·ft (0.3 N·m, 0.03 kgf·m)
link arm set torx screw:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
throttle drum cover bolt:
2.5 lbf·ft (3.4 N·m, 0.3 kgf·m)
hot start cable nut:
1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)
throttle cable lock nut:
3.0 lbf·ft (4 N·m, 0.4 kgf·m)
throttle cable bolt:
3.0 lbf·ft (4 N·m, 0.4 kgf·m)
shock absorber upper mounting nut:
32 lbf·ft (44 N·m, 4.5 kgf·m)
• Tighten the insulator band screw (1) so the
insulator band distance is 0.4 ± 0.04 in
(11 ± 1 mm).
(1) band screw
(1)
0.4 ± 0.04 in
(11 ± 1 mm)
Carburetor Adjustment & Tuning Tips
(2) throttle cables
(3) hot start cable
(4) throttle position sensor connector
(3)
(4)
(2)
134 Adjustments for Competition
Idle Speed Adjustment
1. If the engine is cold, start it and warm it up 3
minutes and then shut it off.
2. Connect a tachometer to the engine.
3. Shift into neutral. Start the engine.
4. Keep the motorcycle in an upright position.
5. Adjust idle speed with the throttle stop screw
(1).
Idle speed:
1,700 ± 100 rpm
(1) throttle stop screw
(1)
(5) air vent hoses
(6) overflow hose
(5)
(5)
(5)
(6)
• Route the throttle cables (2), hot start cable
(3) and throttle sensor wire correctly.
• After installing the carburetor, adjust the
throttle cable freeplay and hot start cable
freeplay.
• After installing the carburetor, check the
throttle position sensor connector (4) for
correct routing.
• After installing the carburetor, check the air
vent hoses (5) and overflow hose (6) for
kinking or pinching and correct routing.
• Check that the U-ring and O-ring are in good
condition. Replace them if necessary.
Chassis Adjustments
Adjustments for Competition 135
The following suggestions may improve a
specific concern. Subtle changes in overall
handling may also be noted.
Rear End
If you have a problem with rear wheel traction,
raise the rear end of your CRF by increasing the
rear spring pre-load. Instead of running 3.9 in
(100 mm) of sag, you can run 3.5 in (90 mm) so
the rear of the bike will sit a little higher . This
should produce more traction because of the
change to the swingarm and the location of your
CRF’s center of gravity.
If you have a problem with the steering head
shaking when you use the front brake hard or if
your CRF wants to turn too quickly, lower the
rear of the motorcycle by reducing the rear spring
pre-load. This will increase fork rake and trail
and should improve stability in a straight line.
The effective suspension travel will be
transferred toward the firmer end of wheel travel.
Keep the race sag adjustment (page 122) in the
3.5 – 4.3 in (90 – 110 mm) range.
Fork Height/Angle
Standard Position
The position of the outer tubes in the clamps is
not adjustable. Align the top of the outer tube (1)
with the top of the upper fork clamp (2).
(STANDARD POSITON)
Wheelbase
Adjusting your CRF’s wheelbase can offer subtle
changes in overall handling. You may adjust
wheelbase by adding or removing links on the
drive chain. If you change the wheelbase, be
sure to re-check race sag and adjust, if necessary.
In the past, a general rule was lengthen the
wheelbase to add straight line stability, shorten
the wheelbase to improve turning. However, we
suggest you do not lengthen the wheelbase of
your CRF unless you are racing on a track with
more fast sections than normal.
As a general recommendation, keep the
wheelbase as short as possible. This positions
the wheels closer together, improves turning
response, increase 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 of fer
more overall benefits.
(1)
(2)
(3)
(1) top of outer tube
(2) upper fork clamp
(3) standard position
0 in (0 mm)
Gearing
136 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 driven sprockets.
Gearing changes allow you to more closely
match the type of terrain and the available
traction. Normally, a change of one tooth on the
rear sprocket will be sufficient.
There is a choice of both higher and lower final
drive ratios with two optional aluminum driven
sprockets. Like the optional springs and these
sprockets are listed in the
Optional Parts List
section (page 160) of this manual.
Unless you have the required mechanical
knowhow, tools, and a Honda Service Manual,
sprocket changing should be done by your 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 rear 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 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 overall
time. Your goal is the fastest overall lap time,
even if the trade-off is gearing that feels wrong in
some sections.
If you decide to try a gearing change, have
someone check your times with a stopwatch
(before and after the change) to get an accurate
appraisal of the 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.
Tire Selection for Track Conditions
Adjustments for Competition 137
Choosing the correct tire tread pattern and rubber
compound can affect your placing in competition.
The tires on your CRF offer a “happy medium”
for the variety of soil conditions the majority of
riders are likely to encounter.
Experienced competitors often switch to tires
developed for specific terrain conditions. If you
do switch, stay with the factory recommended
sizes. Other tires may affect handling or
acceleration.
Be aware that tire sizes (width and aspect ratio)
do vary from manufacturer to manufacturer or
even among tires made by the same
manufacturer. Variations in tires, especially the
sidewall profile, can change the attitude of your
CRF and its handling. Tire variations that raise
or lower the rear of your CRF have a more
significant effect on handling than variations in
front tires which, generally, don’t vary as much.
Often, you can see or feel the change in tire size.
Another way to check is to measure the rolling
circumference of the old and new tires. A higher
profile tire will have a larger rolling
circumference.
If you do switch to tires designed for special
terrain use, remember they will be less
acceptable in other circumstances. For example,
an aggressive mud tire will give excellent grip on
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 lar gest
possible contact patch on the surface. The rubber
compound needs to be softer for hard ground in
order to hook up, but not so soft that the knobs
roll over easily and affect holding a straight line.
These tires tend to wear more quickly than
standard tires because of the combination of soft
rubber and hard terrain.
Muddy Soil
Use a more open tread pattern to avoid clogging.
For these conditions, the relatively long knobs
will probably be made from a harder rubber
compound to reduce any tendency to bend back
under acceleration or wear quickly.
Loose, Sandy Soil
Use a tire that is similar in construction to those
needed for tacky soil and mud, but with a few
more knobs.
Personal Fit Adjustments
138 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 front 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 and rear 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 & 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
forward either 0.12 in (3 mm) (using optional
handlebar lower holders) or 0.24 in (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.
Tips
Tips 139
Here’s helpful advice on how to transport and
store your Honda, as well as three troubleshooting
flow charts.
Transporting Your Motorcycle .........................140
Storing Your Honda..........................................141
You & the Environment ...................................143
Troubleshooting................................................144
Transporting Your Motorcycle
140 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 to the upper
ends of the straps to the handlebar (one on the
right side, the other on the left), close to the fork.
Check that the tie-down straps do not contact any
control cables or electrical wiring.
Tighten both straps until the front suspension is
compressed about half-way. Too much pressure
is unnecessary and could damage the fork seals.
Use another tie-down strap to keep the rear of the
motorcycle from moving.
We recommend that you do not transport your
CRF on its side. This can damage the
motorcycle, and leaking gasoline could be a
hazard.
Storing Your Honda
Tips 141
5. Remove the radiator cap and coolant drain bolt
(1) at the water pump (2) to drain coolant.
After the coolant has been completely
drained, reinstall the coolant drain bolt with a
new sealing washer and radiator cap.
Coolant drain bolt:
7 lbf·ft (10 N·m, 1.0 kgf·m)
9. Inflate the tires to their recommended
pressures (page 91).
10.Place your CRF on the optional Honda work-
stand or equivalent to raise both tires of f the
ground.
11.Stuff a rag into the muffler outlet. Then tie a
plastic bag over the end of the muf fler to
prevent moisture from entering.
12.Store your CRF in an unheated area, free of
dampness, away from sunlight, with a
minimum of daily temperature variation.
13.Cover your CRF with a porous material.
Avoid using plastic or similar non-breathing,
coated materials that restrict air flow and
allow heat and moisture to accumulate.
(2)
(1)
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 44).
3. Change the transmission oil (page 47).
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 carburetor
drain screw to the specified torque:
1.1 lbf·ft (1.5 N·m, 0.2 kgf·m)
(1) coolant drain bolt (2) water pump
6. Disconnect the siphon tube from the radiator.
Drain the reserve tank coolant. Empty the
coolant and rinse the inside of the reserve tank
with water.
7. Lubricate the drive chain.
8. Remove the battery and charge it fully. Store
in an area protected from freezing
temperatures and direct sunlight. Slow charge
the battery (page 100) once a month.
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.
Storing Your Honda
142 Tips
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 (page 44, 47).
2. Uncover the end of the muffler and remove
the rag from the muffler outlet.
3. Fill the fuel tank with recommended fuel
(page 41).
4. Charge the battery (page 100) as required.
Install the battery.
5. Pour a fresh recommended coolant mixture
(page 48) slowly into the radiator filler hole
up to the filler neck.
Capacity:
1.27 US qt (1.20R)
after disassembly
1.19 US qt (1.13R)
after draining
Remove the radiator reserve tank cap and fill
the reserve tank to the upper level line.
Bleed air from the system (page 50).
6. Perform all maintenance checks (page 11).
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 non-
recyclable wastes.
Tips 143
You & the Environment
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
144 Tips
Troubleshooting
The items that are serviceable using this Manual
are followed by the page number reference in
parenthesis. The items that require use of the
Honda Service Manual are followed by an
asterisk (*).
POOR PERFORMANCE AT LOW AND UNSTABLE
IDLE SPEED
CHECK POSSIBLE CAUSES
1. Check if air
cleaner is over-
oiled (P.51)
CORRECT
INCORRECT
INCORRECT
LEAKING
CLOGGED
WEAK OR
INTERMITTENT
SPARK
CORRECT
NOT LEAKING
NOT CLOGGED
GOOD SPARK
2. Check if the intake
tube is leaking
3. Check carbureator
pilot screw
adjustment*
4. Check carburetor
jets and accelerator
pump for clogs
5. Try spark test
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)*
• Fuel-air mixture too rich
(Turn the pilot screw in)*
• Contaminants in the
fuel
• Not cleaned frequently
enough (P.131)
• Faulty, carbon or wet
fouled spark pulg (P.61)
• Faulty ignition control
module*
• Faulty alternator*
• Faulty direct ignition coil*
• Broken or shorted
direct ignition coil wire.
• Faulty ignition pulse
generator*.
• Faulty throttle position
sensor*
• Ring worn
• Cylinder worn or
damaged*
• Piston worn or
damaged*
• Head gasket not
sealing
INCORRECT
CORRECT
6. Check the throttle
position sensor*
POOR PERFORMANCE AT HIGH SPEED
CHECK POSSIBLE CAUSES
1. Disconnect fuel
line at carburetor
and check for
clogging (P.41)
UNRESTRICTED
FUEL FLOW
FUEL FLOW
RESTRICTED
DIRTY
2. Remove air
cleaner (P.51)
AIR CLEANER
NOT DIRTY
• Lack of fuel in tank
(P.41)
• Clogged fuel line
(P.41)
• Clogged fuel fill
cap breather tube
(P.41)
• Clogged fuel valve
(P.41)
• Clogged fuel filter
(P.42)
• Not cleaned
frequently enough
(P.51)
CLOGGED
INCORRECT
LOW
WEAK OR
INTERMITTENT
SPARK
NOT CLOGGED
CORRECT
CORRECT
GOOD SPARK
3. Check carbureator
jets for clogging
4. Check valve
timing
5. Try spark test
6. Test cylinder
compression*
• Contaminants in
the fuel
• Cam sprocket not
installed properly
• Faulty, carbon or wet
fouled spark pulg
(P.61)
• Faulty ignition control
module*
• Faulty alternator*
• Faulty direct ignition coil*
• Broken or shorted
direct ignition coil wire.
• Faulty ignition pulse
generator*.
• Loose or disconnected
ignition system wires
• Faulty engine stop button
• Ring worn
• Cylinder worn or
damaged
• Piston worn or
damaged
• Head gasket not
sealing
ENGINE DOES NOT START OR IS HAND 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
compression*
CORRECT
LOW
1. Check the fuel
flow to carburetor
REACHING
CARBURETOR
• No fuel in fuel tank
• Clogged fuel line or fuel
filter (P.41, 42)
• Sticking float valve*
• Clogged fuel fill cap
breather tube (P.41)
• Faulty spark plug (P.61)
• Fouled spark plug
(P.61)
• Faulty ignition control
module*
• Faulty exciter coil
• Broken or shorted direct
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 direct ignition
coil or ignition pulse
generator)*
• Fuel contaminated
• Improper hot start
operation (P.60)
• Carburetor flooded
• Choke opened
• Throttle valve open
• Air cleaner dirty (P.51)
5. Removed and
inspect spark plug
6. START WITH CHOKE ON
DRY
WET PLUG
Taking Care of the Unexpected
Taking Care of the Unexpected 145
This section gives practical advice to help you
problems.
If a Fuse Blows ................................................146
If Your Battery Is Low (or Dead).....................147
If You Crash .....................................................148
146 Taking Care of the Unexpected
If a Fuse Blows
All of the electrical circuits on your CRF have a
fuse to protect them from damage caused by
excess current flow (short circuit or overload).
If something electrical on your CRF stops
working, the first thing you should check for is a
blown fuse (1). Check the fuse before looking
elsewhere for another possible cause of the
problem. Replace a blown fuse and check
component operation.
• The main fuse (and spare) are located on the
starter magnetic switch behind the right side
cover.
(2) seat mounting bolt (4) collar
(3) right side cover bolt (5) right side cover
3. Disconnect the wire connector (6) of the
starter magnetic switch (7).
4. Pull out the main fuse (8). If it is blown,
install the spare main fuse (9).
(6) wire connector (8) main fuse
(7) starter magnetic switch (9) spare main fuse
5. Reconnect the wire connector.
If you do not have a replacement fuse with the
proper rating for the circuit, install one with a
lower rating.
Replacing a fuse with one that has a higher
rating greatly increases the chance of damage to
the electrical system.
If you replace a blown fuse with a spare fuse that
has a lower rating, replace the fuse with the
correct rating as soon as you can. Also remember
to replace the spare fuse that was installed.
If the replacement fuse of the same rating burns
out in a short time, there is probably a serious
electrical problem on your CRF.
Leave the blown fuse in that circuit and have
your CRF checked by your dealer.
6. Install the right side cover, collar and right
side cover bolt.
7. Install the seat mounting bolt and tighten it to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
NOTICE
(1)
(9)
(6)
(8)
(7)
(2)
(4)
(3)
(5)
(1) blown fuse
Recommended Main Fuse:
15A
1. To prevent an accidental short circuit, stop the
engine.
2. Remove the seat mounting bolt (2), right side
cover bolt (3), collar (4) and right side cover
(5).
If Your Battery Is Low (or Dead)
Jump-starting is not recommended, especially if
you use an automobile battery.
The greater amperage of an automobile battery
when the car engine is running can damage your
CRF’s electrical system.
Bump starting is also not recommended.
If you can’t charge the battery or it appears
unable to hold a charge, contact your dealer.
Taking Care of the Unexpected 147
If You Crash
Personal safety is your first priority after a crash.
If you or anyone else has been injured, take time
to assess the severity of the injuries and whether
it is safe to continue riding. If you cannot ride
safety, send someone for help. Do not ride if you
will risk further injury.
If you decide that you are capable of riding
safety, first evaluate the condition of your
motorcycle. If the engine is still running, turn it
off and look it over carefully; inspect it for fluid
leaks, check the tightness of critical nuts and
bolts, and secure such parts as the handlebar,
control levers, brakes, and wheels.
If there is minor damage, or you are unsure about
possible damage but decide to try riding the
motorcycle back to your base, ride slowly and
cautiously.
Sometimes, crash damage is hidden or not
immediately apparent. When you get home,
throughly check your motorcycle and correct any
problems you find. Also, be sure to have your
dealer check the frame and suspension after any
serious crash.
148 Taking Care of Unexpected
This section contains dimensions, capacities, and
other technical data.
Vehicle Identification .......................................150
Specifications ...................................................151
Torque Specifications.......................................154
High Altitude Carburetor Adjustment ..............157
Emission Control Systems ...............................158
Oxygenated Fuels.............................................160
Competition Logbook ......................................161
Optional Parts List ...........................................163
Spare Parts & Equipment .................................164
Wiring Diagram................................................165
Technical Information 149
Technical Information
150 Technical Information
Vehicle Identification
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)
Technical Information 151
Specifications
Single disc brake
60.6 in
2
(391.1 cm
2
)
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Item English
85.5 in
32.6 in
49.6 in
58.3 in
37.7 in
17.0 in
13.6 in
Metric
Type
Dimension
Frame
Fork oil capacity
(except fork damper per leg)
F. suspension
R. suspension
Tire size, front
Tire size, rear
F. brake, swept area
Tire pressure, front (cold)
R. brake, swept area
unleaded gasoline, pump
octane number of 91 or
higher
Fuel recommendation
Fuel tank capacity
Caster angle
Trail length
Twin tube
Telescopic fork,
travel 11.0 in (280 mm)
stroke 12.4 in (315 mm)
Pro-link,
travel 12.3 in (312 mm)
80/100 – 21 51M
DUNLOP D742FA
DUNLOP D756
100/100 – 18 59M
Single disc brake
51.8 in
2
(334.5 cm
2
)
27 54
1.9 US gal
4.6 in
15 psi (100kPa, 1.0 kgf/cm
2
)
Tire type
bias-ply, tube
Tire pressure, rear (cold)
15 psi (100kPa, 1.0 kgf/cm
2
)
11.7 US oz
345 cm
3
118 mm
7.3R
Fuel reserve capacity 0.4 US gal 1.6R
Item English
3.07 x 2.06 in
0.31 in
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve clearance
(cold)
Intake: 0.005 ± 0.001 in
(0.12 ± 0.03 mm)
Exhaust: 0.011 ± 0.001 in
(0.28 ± 0.03 mm)
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
Jet needle
Piston valve
FCR02C
# 130
NLAT
Slow jet
Pilot screw opening
Float level
Idle speed
Liquid cooled, 4-stroke
# 42
1 3/4 turns out
1,700 ± 100 rpm
Type
Metric
0.66 R
0.69 R
0.85 R
0.67 R
0.75 R
78.0 x 52.2
mm
8.0 mm
Engine
Carburetor
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
3.611
2.384
1.750
1.333
1.041
0.814
3.786
NGK
DENSO
NGK
DENSO
Gear shift pattern
Ignition
Starting system
Spark plug :
Standard
Spark plug gap 0.031 – 0.035 in
(0.8 – 0.9 mm)
For extended high
speed riding
ICM
Electric, Kickstarter
Battery YTX5L-BS 12V-4Ah (10HR)
Light
Head light 12V-35 W
Fuse
Main fuse 15 A
Left foot-operated return
system 1-N-2-3-4-5
IMR8C-9H
VUH24D
IMR9C-9H
VUH27D
2,172 mm
827 mm
1,261 mm
1,481 mm
958 mm
432 mm
346 mm
15.2 cu-in
0.70 US qt
0.73 US qt
0.90 US qt
0.70 US qt
0.79 US qt
1.13 R
1.20 R
1.19 US qt
1.27 US qt
249 cm
3
after disassembly
Cooling system,
capacity
after draining
For USA (except California)
152 Technical Information
Specifications
Spark plug gap 0.031 – 0.035 in
(0.8 – 0.9 mm)
Valve clearance
(cold)
Intake: 0.005 ± 0.001 in
(0.12 ± 0.03 mm)
Exhaust: 0.011 ± 0.001 in
(0.28 ± 0.03 mm)
Item English
3.07 x 2.06 in
0.31 in
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
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
Jet needle
Piston valve
FCR03C
# 132
NLBU
Needle clip position
(standard)
Slow jet
Pilot screw opening
Float level
Idle speed
Liquid cooled, 4-stroke
2nd groove
# 42
2 turns out
1,700 ± 100 rpm
Type
Metric
0.66 R
0.69 R
0.85 R
0.67 R
0.75 R
1.13 R
1.20 R
78.0 x 52.2
mm
8.0 mm
Engine
Carburetor
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
3.611
2.384
1.750
1.333
1.041
0.814
3.786
NGK
DENSO
NGK
DENSO
Gear shift pattern
Ignition
Starting system
Spark plug :
Standard
For extended high
speed riding
ICM
Electric, Kickstarter
Battery YTX5L-BS 12V-4Ah (10HR)
Light
Head light 12V-35 W
Fuse
Main fuse 15 A
Left foot-operated return
system 1-N-2-3-4-5
IMR8C-9H
VUH24D
IMR9C-9H
VUH27D
15.2 cu-in
0.70 US qt
0.73 US qt
0.90 US qt
0.70 US qt
0.79 US qt
249 cm
3
after disassembly
Cooling system,
capacity
after draining 1.19 US qt
1.27 US qt
Single disc brake
60.6 in
2
(391.1 cm
2
)
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Item English
85.5 in
32.6 in
49.6 in
58.3 in
37.7 in
17.0 in
13.6 in
Metric
Type
Dimension
Frame
Fork oil capacity
(except fork damper per leg)
F. suspension
R. suspension
Tire size, front
Tire size, rear
F. brake, swept area
Tire pressure, front (cold)
R. brake, swept area
unleaded gasoline, pump
octane number of 91 or
higher
Fuel recommendation
Fuel tank capacity
Caster angle
Trail length
Twin tube
Telescopic fork,
travel 11.0 in (280 mm)
stroke 12.4 in (315 mm)
Pro-link,
travel 12.3 in (312 mm)
80/100 – 21 51M
DUNLOP D742FA
DUNLOP D756
100/100 – 18 59M
Single disc brake
51.8 in
2
(334.5 cm
2
)
27 54
1.9 US gal
4.6 in
15 psi (100kPa, 1.0 kgf/cm
2
)
Tire type
bias-ply, tube
Tire pressure, rear (cold)
15 psi (100kPa, 1.0 kgf/cm
2
)
11.7 US oz
345 cm
3
118 mm
7.3R
Fuel reserve capacity 0.4 US gal 1.6R
2,172 mm
827 mm
1,261 mm
1,481 mm
958 mm
432 mm
346 mm
For California
Technical Information 153
Single disc brake
60.6 in
2
(391.1 cm
2
)
Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Item English
85.5 in
32.6 in
49.6 in
58.3 in
37.7 in
17.0 in
13.6 in
Metric
Type
Dimension
Frame
Fork oil capacity
(except fork damper per leg)
F. suspension
R. suspension
Tire size, front
Tire size, rear
F. brake, swept area
Tire pressure, front (cold)
R. brake, swept area
unleaded gasoline, pump
octane number of 91 or
higher
Fuel recommendation
Fuel tank capacity
Caster angle
Trail length
Twin tube
Telescopic fork,
travel 11.0 in (280 mm)
stroke 12.4 in (315 mm)
Pro-link,
travel 12.3 in (312 mm)
80/100 – 21 51M
DUNLOP D742FA
DUNLOP D756
100/100 – 18 59M
Single disc brake
51.8 in
2
(334.5 cm
2
)
27 54
1.9 US gal
4.6 in
15 psi (100kPa, 1.0 kgf/cm
2
)
Tire type
bias-ply, tube
Tire pressure, rear (cold)
15 psi (100kPa, 1.0 kgf/cm
2
)
11.7 US oz
345 cm
3
118 mm
7.3R
Fuel reserve capacity 0.4 US gal 1.6R
Item English
3.07 x 2.06 in
0.31 in
Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve clearance
(cold)
Intake: 0.005 ± 0.001 in
(0.12 ± 0.03 mm)
Exhaust: 0.011 ± 0.001 in
(0.28 ± 0.03 mm)
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
Jet needle
Piston valve
FCR02C
# 130
NLAT
Slow jet
Pilot screw opening
Float level
Idle speed
Liquid cooled, 4-stroke
# 42
1 3/4 turns out
1,700 ± 100 rpm
Type
Metric
0.66 R
0.69 R
0.85 R
0.67 R
0.75 R
78.0 x 52.2
mm
8.0 mm
Engine
Carburetor
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
3.611
2.384
1.750
1.333
1.041
0.814
3.786
NGK
DENSO
NGK
DENSO
Gear shift pattern
Ignition
Starting system
Spark plug :
Standard
Spark plug gap 0.031 – 0.035 in
(0.8 – 0.9 mm)
For extended high
speed riding
ICM
Electric, Kickstarter
Battery YTX5L-BS 12V-4Ah (10HR)
Light
Head light 12V-35 W
Fuse
Main fuse 15 A
Left foot-operated return
system 1-N-2-3-4-5
IMR8C-9H
VUH24D
IMR9C-9H
VUH27D
2,172 mm
827 mm
1,261 mm
1,481 mm
958 mm
432 mm
346 mm
15.2 cu-in
0.70 US qt
0.73 US qt
0.90 US qt
0.70 US qt
0.79 US qt
1.13 R
1.20 R
1.19 US qt
1.27 US qt
249 cm
3
after disassembly
Cooling system,
capacity
after draining
For Canada
154 Technical Information
Torque Specifications
Nuts, Bolts, Fasteners
Check and tighten nuts, bolts, and fasteners before every outing.
Engine
Item
ENGINE
1
2
3
4
6
7
8
9
10
11
12
13
NOTE: 1. Apply grease to the threads.
2. Apply engine oil to the threads.
Cylinder head cover bolts
Exhaust pipe joint nuts
Coolant drain bolt
Crankshaft hole cap
Clutch cover bolts
Cylinder bolt
Oil filter cover bolts
Cylinder head bolts
Drive sprocket bolt
Engine oil drain bolt
Transmission oil drain bolt
Air supply pipe bolt
Torque
Remarks
lbf
•
ft N
•
m kgf
•
m
7
15
7
11
9
7
7
9
7
23
12
12
7
10
21
10
15
12
10
10
12
10
31
16
16
10
1.0
2.1
1.0
1.5
1.2
1.0
1.0
1.2
1.0
3.2
1.6
1.6
1.0
NOTE 1
NOTE 2
NOTE 2
Transmission oil check
bolt
5
(2)
(3)
(5)
(4)
(6)
(13)
(1)
(7)
(10)
(11)
(12)
(8)
(9)
Technical Information 155
Torque Specifications
Frame
Item
14
15
16
17
18
19
Swingarm pivot nut
Fork (fork damper)
(fork cap)
Rear shock arm nuts
(swingarm side)
(shock link side)
Rear shock link nuts
Shock spring lock nut
Kickstarter arm bolt
Torque
Remarks
lbf
•
ft N
•
m kgf
•
m
65
25
22
39
39
39
32
28
88
34
30
53
53
53
44
38
9.0
3.5
3.1
5.4
5.4
5.4
4.5
3.9
12 Upper engine hanger
plate nuts
(engine side)
(frame side)
40
25
54
34
5.5
3.5
11 Middle engine hanger
bracket nut
47 64 6.5
10 Front engine hanger
bracket nut
40 54 5.5
8 Rear axle nut
94 127 13.0
7 Front axle pinch bolts
15 20 2.0
6 Front axle nut
65 88 9.0
NOTE 2
NOTE 1, 2
NOTE 1, 2
NOTE 1, 2
13 Shock absorber (upper)
nuts
(lower)
32
32
44
44
4.5
4.5
NOTE 2
NOTE 2
9 Chain adjuster lock nuts
20 27 2.8 NOTE 3
NOTE 2
5
Handlebar holder nuts
32 44 4.5
4 Handlebar upper
holder bolts
16 22 2.2
3 Fork lower pinch bolts
15 20 2.0
2 Fork upper pinch bolts
16 22 2.2
1 Steering stem nut
80 108 11.0
FRAME
1. Apply engine oil to the threads and flange surface.
2. U-nut.
3. UBS nut.
4. Alock bolt : Replace with a new one.
NOTES:
21
22
Brake hose bolts
Caliper mounting bolts
25
22
34
30
3.5
3.1
NOTE 4
20 Front brake master
cylinder holder bolts
7.3 9.9 1.0
(6)
(3)
(1)
(2)
(4)
(12)
(10)
(19)
(15)
(5)
(7)
(11)
(17)
(9)
(8)
(14)
(13)
(9)
(13)
(22)
(20)
(21)
(18)
(16)
156 Technical Information
Torque Specifications
Item
FRAME
Torque
Remarks
lbf
•
ft N
•
m kgf
•
m
23
24
25
26
27
28
29
30
31
32
Front brake disc nuts
Rear brake disc nuts
Rear brake pedal pivot bolt
Spokes
Rim locks
Subframe (upper)
mounting bolts
(Iower)
Fork center bolt
Fork center bolt lock nut
Disc cover bolts
Fork protector bolts
12
12
27
2.7
9
22
36
51
16
10
5.2
16
16
36
3.68
12
30
49
69
22
13
7
1.6
1.6
3.7
0.4
1.2
3.1
5.0
7.0
2.2
1.3
0.7
NOTE 2
NOTE 2
NOTE 4
34
35
36
Muffler clamp bolt
Driven sprocket nuts
Seat mounting bolts
15
24
19
21
32
26
2.1
3.3
2.7
NOTE 2
40 Side stand mounting
bolts (upper)
(lower)
41
42
43
44
Shroud B bolts
Fuel joint bolts
Brake lever adjuster lock nut
Brake pedal adjuster lock nut
40
29
54
39
5.5
4.0
39 Fork air pressure release
screw
0.9 1.2 0.1
3.7
7
4.4
4.4
5
10
5.9
5.9
0.5
1.0
0.6
0.6
38 Rear brake reservoir
cap bolts
0.7 1.0 0.1
37 Front brake reservoir
cap screws
0.7 1.0 0.1
33 Muffler mounting
bolts (front)
(rear)
19
19
26
26
2.7
2.7
1. Apply engine oil to the threads and flange surfaces.
2. U-nut.
3. UBS nut.
4. Alock bolt: Replace with a new one.
NOTES:
Frame
(23)
(39)
(28)
(42)
(36)
(35)
(40)
(37)
(43)
(39)
(32)
(27)
(26)
(25)
(26)
(44)
(27)
(24)
(38)
(36)
(33)
(34)
(41)
(29) (30)
(31)
Technical Information 157
At high altitude, the standard carburetor air-fuel
mixture will be too rich. Performance will
decrease, and fuel consumption will increase. A
very rich mixture will also foul the spark plug
and cause hard starting. Operation at an altitude
that differs from that at which this engine was
certified, for extended periods of time, may
increase emissions.
High altitude performance can be improved by
specific modifications to the carburetor. If you
always operate your engine at altitudes above
6,500 feet (2,000 meters), have your servicing
dealer perform this carburetor modification.
This engine, when operated at high altitude with
the carburetor modifications for high altitude use,
will meet each emission standard throughout its
useful life.
Even with carburetor modification, engine
horsepower will decrease about 3.5% for each
1,000-foot (300-meter) increase in altitude. The
effect of altitude on horsepower will be greater
than this if no carburetor modification is made.
When the carburetor has been modified for high
altitude operation, the air-fuel mixture will be too
lean for low altitude use. Operation at altitudes
below 5,000 feet (1,500 meters) with a modified
carburetor may cause the engine to overheat and
result in serious engine damage. For use at low
altitudes, have your servicing dealer return the
carburetor to original factory specifications.
NOTICE
High Altitude Carburetor Adjustment (California only)
158 Tips
Emission Control Systems
Exhaust Emission Requirements
The U.S. Environmental Protection Agency
(EPA), the California Air Resources Board
(CARB), and Environment Canada (EC) require
that your motorcycle comply with applicable
exhaust emission standards during its useful life,
when operated and maintained according to the
instructions provided.
The vehicle emission control information label
(1) (2) is attached to the left side of the frame.
(1) vehicle emission control information label
(2) vehicle emission control information label
(Canada only)
Noise Emission Requirements
The EPA also requires that motorcycles built
after January 1,1983 comply with applicable
noise emission standards for one year or 1,865
miles (3,000 km) after the time of sale to the
ultimate purchaser, the time operated and
maintained according to the instructions
provided. (USA only)
Noise Emission Control System
TAMPERING WITH THE NOISE CONTROL
SYSTEM IS PROHIBITED: U.S. federal law
prohibits, or Canadian provincial laws may
prohibit the following acts or the causing thereof.
(1) The removal or rendering inoperative by any
person, other than for purposes of maintenance,
repair or replacement, of any device or element
of design incorporated into any new vehicle for
the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in
use; or (2) the use of the vehicle after such
device or element of design has been removed or
rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO
CONSTITUTE TAMPERING ARE THE
ACTS LISTED BELOW:
1. Removal of, or puncturing the muffler,
baffles, reader pipes, or any other component
which conducts exhaust gases.
2. Removal of, or puncturing of any part of the
intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or
parts of the exhaust or intake system, with
parts other those specified by the
manufacturer.
(1)
(2)
Problems that May Affect Motorcycle
Emissions
If you are aware of any of the following
symptoms, have the vehicle inspected and
repaired by your Honda dealer.
1. Hard starting or stalling after starting.
2. Rough idle.
3. Misfiring or backfiring during acceleration.
4. After-burning (backfiring).
5. Poor performance (drive ability) and poor fuel
economy.
Federal regulations prohibit removing or
disabling a device or element of design that may
affect your engins’s emission performance unless
your CRF will be used exclusively in
competition. If you modify your engine for use
in sanctinoed competition events, you must
deface or destroy the emission control
information label.
Fuel Permeation Emission Control System
This vehicle complies with the Fuel Permeation
Emission Control regulations of the U.S.
Environmental Protection Agency (EPA), the
California Air Resources Board (CARB), and
Environment Canada (EC).
The fuel tank, fuel hoses, and fuel vapor char ge
hoses used on this vehicle incorporate fuel
permeation control technologies.
Tampering with the fuel tank, fuel hoses, or fuel
vapor charge hoses to reduce or defeat the
effectiveness of the fuel permeation technologies
is prohibited by federal regulations.
Technical Information 159
Emission Control Systems
Source of Emission
The combustion process produces carbon
monoxide (CO), oxides of nitrogen (NOx), and
hydrocarbons (HC).
Control of hydrocarbons and oxides of nitrogen
is very important because, under certain
conditions, they react to form photochemical
smog when subjected to sunlight. Carbon
monoxide does not react in the same way, but it
is toxic.
Honda Motor Co., Ltd. utilizes various systems
to reduce carbon monoxide, oxides of nitrogen
and hydrocarbons.
Exhaust Emission Control System
The exhaust emission control system is
composed of appropriate carburetor settings.
No adjustments should be made except for an
idle speed adjustment with the throttle stop
screw.
The exhaust emission control system is separate
from the crankcase emission control system.
Secondary Air Injection System
The exhaust emission control system consists of
a secondary air injection system.
The secondary air injection system introduces
filtered air into the exhaust gases in the exhaust
port. The secondary air injection system helps
improve emission control performance.
No adjustments to this system should be made
although periodic inspection of the components is
recommended.
Crankcase Emission Control System
The engine is equipped with a closed crankcase
system to prevent discharging crankcase
emissions into the atmosphere.
Blow-by gas is returned to the combustion
muffler through the air cleaner and the
carburetor.
160 Technical Information
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 and Canada use
oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is
unleaded and meets the minimum octane rating
requirement.
Before using an oxygenated fuel, try to confirm
the fuel’s contents. Some states/provinces
require this information to be posted on the
pump.
The following are the EPA-approved percentages
of oxygenates:
ETHANOL (ethyl or grain alcohol) 10% by
Volume
You may use gasoline containing up to 10%
ethanol by volume. Gasoline containing ethanol
may be marketed under the name “Gasohol”.
MTBE (Methyl Tertiary Butyl Ether) 15% by
Volume
You may use gasoline containing up to 15%
MTBE by volume.
METHANOL (methyl or wood alcohol) 5% by
Volume
You may use gasoline containing methanol
containing up to 15% methanol by volume as
long as it contains cosolvents and corrosion
inhibitors to protect the fuel system. Gasoline
containing more than 5% methanol by volume
may cause starting and/or performance problems.
It may also damage metal, rubber, and plastic
parts of your fuel system.
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 the 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
Technical Information 161
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, gearing, and tire
selection. This detailed information, along with
your comments, can prove valuable when you
compete at the same track or on similar terrain.
Your logbook can also tell you when
maintenance was performed and when it will be
necessary again. Your logbook also lets you
record any repairs and lets you keep track of the
running time on the engine and suspension
components.
If you choose to sell your CRF, the accurate
maintenance records in your logbook might be
the deciding deal-maker for a potential buyer.
Consider using different color pens or pencils to
record important information on specific
subjects. For example, record results in black,
suspension/chassis settings in blue, and gearing
selections in green. Color codes will help you
identify the information you want with a glance.
Tuning & 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
• 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’s
• 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 hours of running.
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 6 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 and 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.
Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance
Time Performed, etc.)
(Make several photocopies of this page for future use)
162 Technical Information
Competition Logbook
Technical Information 163
Optional Parts List
FRAME Remarks
Driven sprocket
Standard
< >: Drive chain links
53 Teeth, Aluminum.
<116>
Optional 54 Teeth, Aluminum
<116>
Optional no offset
52 Teeth, Aluminum
<116>
Handlebar
lower holder
Drive chain
size/link
Standard
3 mm offset
DID 520MXV – 120ZB
TOOLS Remarks
For checking tire air pressure.
Pin spanner A
Workstand
To adjust spring pre-load.
(two spanners required)
For maintenance
Air gauge
These parts and tools may be ordered from your
dealer.
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.
268.9 lbf/in (47.1 N/mm)
No mark
(factory products)
Red
paint
(aftermarket parts)
or
254.7 lbf/in (44.6 N/mm)
23.53 lbf/in (4.12 N/mm)
22.38 lbf/in (3.92 N/mm)
24.61 lbf/in (4.31 N/mm)
Orange
Red and Black
279.8 lbf/in (49.0 N/mm)
White
2 scribe marks
(aftermarket parts)
3 scribe marks
1 scribe mark
164 Technical Information
Spare Parts & Equipment
There are numerous spare parts you can take to
an event to help ensure you get in a full day of
riding. In addition to the usual nuts and bolts,
consider the following:
Spare Parts
spark plugs
air cleaner (clean & oiled, sealed in a plastic bag)
chain & masterlinks
chain guide slider
chain guide
chain rollers
inner tubes (front & rear)
fenders
footpegs
front visor & side covers
handlebar
grips
levers (brake, clutch & hot start)
clutch lever handlebar mount
clutch cable
hot start cable
throttle assembly
throttle cable
shift lever
rear brake pedal
spokes (front & rear, each side)
sprockets (smaller than standard, for gearing
changes & collision damage replacement)
assorted nuts, bolts, washers, screws, cotter pins
headlight bulbs
battery
fuses
Additional Spares
front brake assembly
rear brake assembly
wheels & tires (front & rear, mounted)
clutch discs and plates
engine & transmission oil
seat
ignition components
radiator hoses
radiator shrouds (L & R)
brake hoses (front & rear)
General Tools
sockets (3/8 in drive)
screwdrivers: blade & Phillips No. 1, 2, 3
wrench, large adjustable
wrenches: open end & 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 CRF purchased from
your dealer.
• Clutch Center Holder 07724-0050001 or
07724-0050002
• Lock Nut Wrench 07WMA-KZ30100
• Tensioner stopper 070MG-0010100
07AMG-001A100
(USA only)
• Spoke Wrench 07JMA-MR60100
• Piston base 07958-2500001
Chemical Products
Pro Honda GN4 4-stroke oil, or an equivalent.
(Engine and Transmission Oil)
Pro Honda HP Fork Oil 5W
Pro Honda DOT 4 Brake Fluid
Pro Honda Chain Lube
Pro Honda Foam Filter Oil
Pro Hondabrite cleaner
Pro Honda Dielectric Grease
Pro Honda Handgrip Cement
Pro Honda Hondalock
Molybdenum disulfide grease (containing more
than 3% molybdenum disulfide additive)
Pro Honda White Lithium Grease
Multi-purpes Grease
Rust-inhibiting oil
Cable lubricant
Pro Honda HP Coolant
Urea based mult-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)
Teflon tape
Technical Information 165
Wiring Diagram
166 Technical Information
Consumer Information 167
Consumer Information
This section contains information about
contacting Honda and how to get an of ficial
Honda Service Manual.
Authorized Manuals .........................................168
Warranty Coverage...........................................169
Warranty Service .............................................170
Contacting Honda.............................................171
Your Honda Dealer...........................................172
The Honda Rider’s Club (USA only) ..............173
The Service Manual used by your authorized dealer is available from your
dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized
manuals)
Also available but not necessary to service your model is the Honda Common
Service Manual which explains theory of operation and basic service
information for various systems on Honda motorcycles, scooters, ATVs,
MUVs, and PWCs.
These Honda manuals are written for the professional technician, but most
mechanically-capable owners should find them helpful if they have the proper
tools and skills. Special Honda tools are necessary for some procedures.
168 Consumer Information
Authorized Manuals
Publication Item No. Description
61KSC07 2012 CRF250X Service Manual
61CM002 Common Service Manual
31KSC670 2012 CRF250X Owner’s Manual
Order On-Line: www.helminc.com
Order Toll Free: 1-888-CYCLE93 (1-888-292-5393)
(NOTE: For Credit Card Orders Only)
Monday - Friday 8:00 AM - 6:00 PM EST
Consumer Information 169
Your new Honda is covered by these warranties:
• Emissions Control Warranty
• Noise Control Warranty (USA only)
There are responsibilities, restrictions, and
exclusions which apply to these warranties.
Please read the Honda Motorcycle Warranties
Booklet given to you by your Honda dealer at the
time of purchase. Be sure to keep your Honda
owner’s card with your Warranties Booklet.
Canada: Please refer to the Warranty Booklet
posted on our website at www.honda.ca.
It is important to realize that your warranty for
your Honda applies to defects in material or
factory workmanship. Your warranty coverage
does not apply to normal wear or deterioration
associated with using the motorcycle.
Your warranty coverage will not be voided if you
choose to perform your own maintenance.
However, you should have the prope tools and
service information and be mechanically
qualified. Failures that occur due directly to
improper maintenance or lack of maintenance are
not covered.
Warranty Coverage
170 Consumer Information
Warranty Service
Please remember that recommended maintenance
interval servicing is not included in your
warranty coverage. Additionally, your warranty
does not apply to the normal wear of items (such
as brakes, tires etc.).
If you believe you have a problem with your
Honda, call the service department of your
Honda dealer. Make an appointment for an
inspection and diagnosis. Remember, as the
owner of the motorcycle, you will be asked to
authorize that inspection. Your dealer will give
you the results of the inspection. If the problem
is covered under warranty, your dealer will
perform the warranty repairs for you.
If you have questions about warranty coverage or
the nature of the repair, it is best to talk to the
Service Manager of your Honda dealer.
Sometimes, in spite of the best intentions of all
concerned, a misunderstanding may occur. If you
aren’t satisfied with your dealer ’s handling of the
situation, we suggest you discuss your problem
with the appropriate member of the dealership ’s
management team. If the problem has already
been reviewed with the Service Manager, Parts
Manager, Sales Manager, etc., contact the Owner
of the dealership or his designated representative.
Consumer Information 171
Contacting Honda
Your owner’s manual was written to cover most
of the questions you might ask about your Honda.
Any questions not answered in the owner ’s
manual can be answered by your dealer. If he
doesn’t have the answer right away, he will get it
for you.
If you have a difference of opinion with your
dealer, please remember that each dealership is
independently owned and operated. That’s why
it’s important to work to resolve any dif ferences
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 2200, Torrance, CA
90509-2200, mailstop: 100-4C-7B,
Telephone: (866) 784-1870.
Canada: Honda Canada Inc., Customer Relations
Dept, 180 Honda Boulevard, Markham, Ontario
L6C 0H9, telephone: (888) 946-6329,
facsimile: (877) 939-0909.
Please include the following information in your
letter:
• name, address, and telephone number
• product model, year, and VIN
• date of purchase
• dealer name and address
We will likely ask your dealer to respond, or
possibly acknowledge your comments directly.
172 Consumer Information
Your Honda Dealer
Once you purchase your new Honda, get familiar
with the organization of your Honda dealer so
you can utilize the full range of services
available.
The service department is there to perform
regular maintenance and unexpected repairs. It
has the latest available service information from
Honda.
The parts department offers Honda Genuine
Parts, Pro Honda products, Honda Genuine
Accessories (USA only), and Honda accessories
and products (Canada only). The same quality
that went into your Honda can be found in Honda
Genuine replacement parts. You’ll also find
comparable quality in the accessories and
products available from the parts department.
Your dealer can inform you about competition
events in your area, as well as provide with
information about the Honda Rider’s Club of
America (USA only).
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.
Consumer Information 173
The Honda Rider’s Club (USA only)
The Honda Rider’s Club of America (HRCA)
sponsors local riding chapters at Authorized
Honda Dealerships across the country. You can
log on to the HRCA Clubhouse website for more
information at
www.hrca.honda.com.
174 Index
accessories ...........................................................4
adjustments,
chassis.........................................................135
control freeplay..............................54,56,60,86
for competition ...........................................105
gearing ........................................................136
high altitude carburetor ..............................157
idle speed ....................................................134
personal fit ..................................................138
suspension, front.........................................106
suspension, rear ..........................................120
suspension, track conditions.......................124
tire selection..................................................92
after competition maintenance...........................33
air cleaner...........................................................51
air pressure,
front suspension..........................................106
tires ...............................................................91
apparel, protective................................................2
appearance care................................................102
authorized manuals ..........................................168
basic operation ...................................................13
battery ................................................................99
before riding.........................................................9
between motos & practice maintenance ............33
brakes,
fluid level......................................................87
lever, front adjustment..................................86
pad wear........................................................89
pedal height ..................................................86
break-in guidelines.............................................21
capacity, fuel ......................................................41
carburetor,
assembly .....................................................133
circuit functions ..........................................128
components.................................................128
disassembly.................................................131
high altitude adjustment .............................157
idle speed ....................................................134
removal .......................................................130
care, appearance...............................................102
chain drive .........................................................94
chassis adjustments..........................................135
choke knob.........................................................15
cleaner, air..........................................................51
cleaning, appearance care ................................102
clutch system, adjustment..................................56
consumer information......................................167
competition logbook ........................................161
contacting Honda .............................................171
controls, operating ...............................................7
coolant................................................................48
cylinder removal ................................................76
damping adjustments,
front ............................................................106
rear ..............................................................121
dealer, your Honda...........................................172
diagram, wiring................................................165
drive chain .........................................................94
engine,
flooded ..........................................................16
idle speed ....................................................134
number ........................................................150
pinging ..........................................................41
starting ..........................................................15
stop button ....................................................16
stopping ........................................................16
won’t start...................................................144
exhaust pipe,
removal .........................................................64
installation ....................................................64
environment, protecting..............................143
filter,
air .................................................................51
oil .................................................................44
flooded engine, starting .....................................16
fork,
front suspension adjustment .......................106
front suspension inspection ..........................82
oil recommendation ......................................84
front brake lever adjustment ..............................86
front suspension disassembly ..........................107
fuel,
line ................................................................42
filter ..............................................................42
recommendation ...........................................41
refueling........................................................41
system ...........................................................41
oxygenated..................................................160
tank capacity.................................................41
tank removal .................................................37
valve..............................................................15
F
E
D
C
B
A
Index
Index 175
Index
gap, spark plug...................................................61
gasoline ..............................................................41
gearing .............................................................136
guidelines, suspension adjustment...................125
handlebar inspection ..........................................97
high altitude carburetor adjustment .................157
Honda,
contacting....................................................171
Rider’s Club................................................173
service manual ............................................168
your dealer ..................................................172
identification, vehicle ......................................150
idle speed, engine ............................................134
inspection, pre-ride ............................................11
labels, safety ........................................................5
logbook, competition .......................................161
maintenance,
after competition...........................................33
before & after competition ...........................33
between motos & practice ............................33
component locations.....................................35
general competition ......................................29
importance ....................................................24
safety.............................................................25
schedule ...................................................27,28
manual, service ................................................168
modifications .......................................................4
muffler,
removal .........................................................62
installation ....................................................63
oil,
engine............................................................43
fork................................................................84
transmission ..................................................46
operating controls ................................................7
operation component locations ............................8
optional parts list .............................................163
sprockets .....................................................163
oxygenated fuels ..............................................160
pads, brake .........................................................89
parts, optional ..................................................163
personal fit adjustments ...................................138
pinging, engine ..................................................41
plug, spark..........................................................61
pre-load, rear suspension .................................120
pre-ride inspection .............................................11
protective apparel.................................................2
rear suspension inspection .................................83
Rider’s Club Honda .........................................173
riding,
apparel ............................................................2
basic operation..............................................13
before ..............................................................9
important safety information ..........................2
safety precautions ...........................................2
safety,
a few words about..................Safety Messages
important information.....................................2
important precautions .....................................2
labels...............................................................5
maintenance ..................................................25
riding precautions .........................................14
schedule, maintenance ..................................27,28
seat removal .......................................................36
serial numbers..................................................150
service manuals................................................168
side stand ...........................................................14
spare parts ........................................................164
spark arrester......................................................65
spark knock........................................................41
spark plug...........................................................61
specifications ............................................151-153
spring pre-load, rear suspension ......................120
starting,
engine............................................................15
troubleshooting ...........................................144
steering head bearing inspection .......................97
stopping engine..................................................16
storage..............................................................141
subframe.............................................................39
(cont’d)
S
R
P
O
M
L
I
H
G
176 Index
Index
suspension,
front ..............................................................82
rear ................................................................83
suspension adjustment,
for track conditions.....................................124
front ............................................................106
guidelines....................................................125
rear ..............................................................120
transmission oil..................................................46
tuning tips ........................................................128
throttle,
freeplay .........................................................54
inspection......................................................55
tires,
air pressure....................................................91
inspection......................................................91
replacement...................................................92
tools..................................................................164
torque specifications............................98,154-156
transporting ......................................................140
tripmeter.............................................................14
troubleshooting ................................................144
tubes, replacing ..................................................91
valve, fuel ..........................................................15
valve clearance...................................................66
vehicle identification no. (VIN) ......................150
warranty,
coverage......................................................169
service.........................................................170
washing your motorcycle.................................102
weight limit..........................................................3
wheels ................................................................90
wiring diagram.................................................165
W
V
T
Front: 15 psi (100 kPa, 1.0kgf/cm
2
)
Rear: 15 psi (100 kPa, 1.0kgf/cm
2
)
standard: IMR8C-9H (NGK) or VUH24D (DENSO)
optional: IMR9C-9H (NGK) or VUH27D (DENSO)
Tires 80/100 – 21 51 M
DUNLOP
bias-ply, tube
D742FA
Front
Type
100/100 – 18 59 M
DUNLOP D756
Rear
Tire Pressure (cold)
Spark Plug
Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil.Transmission oil
Pro Honda GN4 4-stroke oil, or an equivalent motorcycle oil.
The maintenance schedule (pages 27-28) lists ser vice frequencies for:
about 2.5 hours,
about 7.5 hours,
about 22.5 hours, and about 30.0 hours.
about 15.0 hours,
Check the items listed on the Pre-ride Inspection checklist each time before you ride
(page 11).
unleaded gasoline, pump octane number of 91 or higher
tank: 1.93 US gal (7.3R), reserve: 0.42 US gal (1.6R)
main: 15 A
Maintenance
Pre-ride Inspection
Fuel tank Capacity
Engine oil
Fuse
DID 520MXV – 116LE
Drive Chain Size/link
Record important information here:
VIN
Engine No.
Owner’s:
Name
Address
City/State
Phone
Dealer’s:
Name
Address
City/State
Phone
Service Mgr.
ethylene glycol antifreeze (silicate-free) for aluminum engines in 50/50 solution with Pro
Honda HP Coolant or equivalent distilled water.
Coolant
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 & engine oil: insufficient
quantity, improper oil.
• Air cleaner: dirty, leaking because of
improper installation (poor seal).
Quick Reference
Quick Reference
SYMBOL COMPONENT SEE PAGE
choke knob 8, 15
START button 8, 15
These symbols are used in Operating Controls and Basic Operating Instructions sections:
