Home

Front Suspension Adjustments

1. eee 2 Important Safety Precautions ccccceeee Z Accessories amp Modifications 00000s0seseees 3 Safety LADES peraosane rE 4 OPERATING CONTROLS eeeeeeeeeeeooosssssesss000 5 Operation Component Locations 0000008 6 BEFORE RIDING sscsssssisesssissisenssssssosissosssssssss 7 Are You Ready to Ride cccssssesssseeeeeeeeees 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection s scnnvsnccnastavsansanesecenccacsnas 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding Precautions i j5 ssseesessesenavseceencseezerss 12 Starting amp Stopping the Engine eee 13 Prpa AUIOM eE 13 Starting Procedure cssissreeirsosireesrcrrsiesnissss 13 Flooded Engine oconssesecsecacsusnesbsaansastecsnauseyotes 13 How to Stop the EMG icc cscscocssesvevsaceraniaves 14 Break in Guidelines 1 555 yoveansiaconsseawsrmncenntberernes 15 160 Table of contents SERVICING YOUR Honda cssssssssees 17 Before You Service Your Honda The Importance of Maintenance eees 18 Maintenance Safety os iyisacinunroevsainnicacciinanatacsnassdee 19 Important Safety Precautions ccccccee 19 Maintenance Schedule o on 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 6 26 Service Preparations M
2. ne OK a l j om ee amp Mn P 3 float bowl plug 2 drain screw 7 Change the main jet 4 and slow jet 5 as required Carburetor Adjustments amp Tuning Tips 9 Rotate the carburetor and align the lug 6 on the carburetor with the slot 7 on the insulator 7 slot 6 lug 4 main jet 5 slow jet 10 Tighten the connecting and insulator band Screws 8 Reinstall the float bowl plug 11 Remove the fuel tank page 30 12 If you ve determined that the jet needle or clip position of jet needle must be changed you must remove the carburetor top Remove the carburetor top bolts 8 and carburetor top 9 If you ve determind that the jet needle or clip position of jet needle must be changed you must remove the carburetor top 8 carburetor top bolts 9 carburetor top 13 Remove the jet needle holder 10 and jet needle 11 from the throttle valve 12 14 Change the clip position of jet needle or jet needle as required 15 Reinstall the jet needle jet needle holder carburetor top and carburetor top bolts 16 Install the fuel tank page 31 e 10 jet needle holder 12 throttle valve 11 jet needle 17 Start the engine If the engine idle speed is too high or too low or engine is not idling adjust the engine idle speed page 48 18 Repeat steps 4 16 until the engine gives maximum power with the correct spark plug reading It is always
3. Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Honda Dielectoric Grease on all electrical connections Suspension Linkage Lubrication Disassemble clean inspect and lubricate all pivot bearings after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Use Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive FH S Swingarm Pivot Lubrication Clean inspect and lubricate when servicing suspension linkage pivots Be sure all of the suspension pivot seals are in good condition Use Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Swingarm Do not attempt to weld or otherwise repair a damaged swingarm Welding will weaken the swingarm Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file Be aware that filing them too sharp will 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 General Competition Maintenan
4. 8 Remove the stopper tool 15 from the cam chain tensioner lifter ee lt 5 i 3 k wie ay a an E 15 15 stopper tool 9 Rotate the primary drive gear bolt crankshaft clockwise two turns and align the punch mark 8 with the index mark 9 Make sure that the timing marks 11 on the sprocket align with the A mark 12 on the camshaft holder assembly If the timing mark doesn t align with the A mark remove the cam sprocket Then realign the valve timing punch mark timing marks 8 9 index mark 11 12 A mark 62 Servicing Your Honda 10 Measure the intake valve clearance and exhaust valve clearance Valve Clearance IN 0 006 0 001 in 0 EX 0 011 0 001 in 0 16 feeler gauge 11 Install the new sealing washer 17 and cam chain tensioner lifter cover bolt 18 sealing washer 7 8 cam chain tensioner lifter cover bolt 12 Measure the decompressor arm clearance by inserting a feeler gauge 16 between the decompressor arm adjusting screw 19 and right side rocker arm 20 DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor clearance is 0 011 in 0 28 mm 0 014 in 0 35 mm 0 025 in 0 63 mm 16 feeler gauge 19 decompressor arm adjusting screw 20 right side rocker arm Decomp
5. 133 Personal Fit Adjustments ccccicdescssvecetesuereccienss 134 Control Positioning 201 cssosniseticatceriesosatanteicece 134 Handlebar Position Width amp Shape 134 Adjustments for Competition Adjustments for Competition 97 Front Suspension Adjustments The front suspension can be adjusted for the rider s weight and riding conditions by using one or more of the following methods e Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel e Compression damping Turning the compression damping screw adjusts how quickly the fork compresses e Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends e Fork springs Optional springs are available in softer and stiffer types than the standard rate page 151 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 98 Adjustments for Competition Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork trave
6. 5 for wear Replace the guide slider if it is worn to the bottom of the wear limit 6 6 wear limit Measure the diameter of the upper 7 and lower drive chain rollers 8 Replace them if below the service limit SERVICE LIMIT upper roller 1 5 in 39 mm lower roller 1 4 in 35 mm Replace the roller if necessary as follows Install the upper drive chain roller Green with the gt mark 9 facing toward the frame and lower drive chain rollar Black with the gt mark 9 side facing out 7 upper drive chain roller 8 lower drive chain roller 9 gt mark 8 Check the driven sprocket nut torque values after each race 24 Ibf ft 82 N m 3 3 kgf m Adjustment 1 Loosen the rear axle nut 1 2 Loosen both the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm Ti 1 rear axle nut 4 index mark 2 lock nut 5 axle plate 3 adjusting bolt 6 reference mark 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Loosen the adjusting bolt counterclockwise lightly until it touches the axle plate Then while holding the adjusting bolt with a wrench tighten the lock nut to the specified torque 20 Ibf ft 27 N
7. Example Turn the compression damping adjuster to a stiffer position Install the optional stiff spring Adjust compression damping to a softer position and rebound damping to a harder position at this time Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Turn the compression damping adjuster to a stiffer setting Install the optional stiff spring Adjustments for Too Soft Stiff Damping a S a Soft Initial travel too soft Test stiffer compression damping adjustments in one click increments suspension e Steering is too quick Test stiffer rebound damping in one click increments e Front end darts while cornering or riding in a straight line Middle travel too soft If suspension isn t stiff in initial travel e Front end dives when cornering Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring Final travel too soft If initial and middle travel aren t stiff e Bottoms on landings Test stiffer compression damping adjustments in one click increments e Bottoms on large bumps especially downhill bumps If initial and middle travel are stiff Install the optional stiff s
8. Maximum oil 13 9 US oz Slightly stiffer as capacity 412 cms it nears full compression Minimum oil capacity Slightly softer as it nears full compression Suspension Optional Stiffer 0 48 kgf mm Fork Spring CJ scribe marks Standard oil 12 5 US oz capacity 369 cm3 13 6 US oz 401 cm3 Slightly stiffer as it nears full compression Maximum oil Capacity 10 3 US oz 305 cm3 Minimum oil Capacity Slightly softer as it nears full compression Be sure the oil capacity is the same in both fork legs cont d Servicing Your Honda 77 Suspension T Check that the O ring 10 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring Temporarily install the fork damper 2 to the outer tube 1 After installing the fork leg page 119 tighten the fork damper to the specified torque 25 Ibf ft 84 N m 3 5 kgf m 1 outer tube 2 fork damper 10 O ring 78 Servicing Your Honda Refer to Safety Precautions on page 19 Both the front and rear brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently 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
9. PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the Club There are hundreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Specialty Vehicle Institute of America for ATV owners One full year of the Honda Red Rider magazine or Honda Red Rider ATV for ATV purchasers Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner Racing contingency programs and assistance at selected dual sport off road and motocross events Contact your Honda dealer for more information or call 1 800 847 HRCA or log on to www hrca honda com The Honda Rider s Club USA only Consumer Information 159 Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETY eessssseeees 1 Important Safety Information
10. air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear Air Cleaner Cleaning Remove the seat page 29 Loosen the air cleaner retaining bolt 1 Align the two access top tabs 2 of the air cleaner 3 and A mark 4 of the air cleaner housing by rotating the air cleaner counterclockwise 4 Remove the air cleaner 3 with the retaining bolt keeping the two access top tabs up NO m oS 1 air cleaner retaining bolt 2 two access top tabs 3 air cleaner 4 A mark cont d Servicing YourHonda 43 Air Cleaner 5 Remove the air cleaner 3 from the air 9 Apply a thin coat of Honda White Lithium cleaner holder 5 Grease to the sealing surface 10 Assemble the air cleaner and holder Improper installation of the air cleaner assembly Install the tab 6 of the holder in the hole 7 may allow dirt and dust to enter the engine and of the air cleaner tab 8 and the air cleaner cause rapid wear of the piston rings and cylinder retaining bolt through the assembly 11 Install the assembly into the air cleaner 14 Reinstall the seat making sure it is securely housing keeping the two access top tabs 2 attached up 12 Carefully position the sealing f
11. decrease freeplay and in direction to increase freeplay 4 Tighten the lock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 31 If you can t get the freeplay within the specified range contact your Honda dealer 2 dust cover increase 3 lock nut decrease 4 adjuster 46 Servicing Your Honda Throttle Inspection p Ter NK a Ae k 1 throttle 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle 1 from fully open to fully closed in all steering positions If there is a problem see your Honda 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 Throttle Servicing Your Honda 47 Engine Idle Speed Refer to Safety Precautions on page 19 Remember idle speed adjustment in not a cure all for other problems in your engine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere The engine must be at normal operating temperature for accurate idle speed adjustment For information about high altit
12. e f after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustments until the correct settings are obtained as described a 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Stiff suspension Suspension feels stiff on small bumps Suspension feels stiff on large bumps 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings Soft suspension Entire travel too soft 1 Test stiffer high and low speed compression adjustments simultaneously 2 If it still feels soft replace the spring with a harder spring optional and begin with the standard settings to stiffer setting Rear end sways 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing 1 Test stiffer high speed compression adjustment after jumping 2 If it still bottoms test stiffer high and low speed compression
13. 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 Tires amp 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 A WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual 80 100 21 51M Front DUNLOP D742F 110 90 19 62M Rear DUNLOP D756 e Use a replacement tire equivalent to the original e Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Servicing YourHonda 85 Drive Chain Refer to Safety Precautions on page 19 The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets When the motorcycle is ridden on unusually dusty or muddy tracks more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF and check that your transmission is in neutral It is not necessary
14. the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the loaded without rider dimension Do this with your CRF set at the standard race sag BIKE LOADED without rider a EXAMPLE 21 7 in 550 mm ES eso HPS NOE Example Unloaded 23 6 in 600 mm Loaded 21 6 in 550 mm Sag 2 0 in 50 mm Without Rider cont d Adjustments for Competition 113 Rear Suspension Adjustments 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your CRF With the spring pre load set to obtain the proper race sag the rear suspension should sag 0 4 to 1 0 in 10 to 25 mm If the rear of your CRF sags more than 1 0 in 25 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will 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 you
15. tub 4 screw 12 muffler clamp 14 cut out 19 side cover bolts 5 air cleaner connecting tube clamp l 6 air cleaner case cover 10 Tighten the muffler B bolt washers 15 and 7 fuel tank band muffler A bolt 16 to the specified torque 8 crankcase breather tube 15 Ibf ft 21 N m 2 1 kgf m Be E O 11 Tighten the muffler clamp bolt 17 to the 7 Install the muffler clamp 9 and new gasket specified torque 10 to the exhaust pipe 15 Ibf ft 21 N m 2 1 kgf m i E _ m D 15 muffler B bolt washers 9 muffler clamp 10 gasket 16 muffler A bolt 17 muffler clamp bolt Servicing Your Honda 33 Fuel System Refer to Safety Precautions on page 19 Fuel Recommendation Type Unleaded Pump Octane Number 91 or higher We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Your engine is designed to use any gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 148 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
16. 19 Ibf ft 26 N m 2 7 kgf m 1 seat bolts 2 seat seat front prong seat bracket seat rear prong 3 4 5 6 frame Servicing YourHonda 29 Fuel Tank Removal Refer to Safety Precautions on page 19 5 Pull the breather tube 4 out of steering stem 9 Disconnect the fuel line 8 from the fuel nut valve 9 The fuel line leading to the Removal 6 Unhook and remove the fuel tank band 5 carburetor must be disconnected not the fuel 1 Turn the fuel valve OFF 7 Unhook the air cleaner case cover 6 line leading to the fuel tank 2 Remove the seat page 29 8 Remove the fuel tank bolt 7 10 Remove the fuel valve bolt 10 and fuel 3 Remove the shroud A bolts collars 1 pe valve 4 Remove the shroud B bolts 2 and shrouds BERTE e Li 11 Remove the fuel tank 3 5 4 oa A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 4 breather tube 5 fuel tank band 6 7 air cleaner case cover fuel tank bolt 1 shroud A bolts collars 2 shroud B bolts 3 shrouds 8 fuel line 10 fuel valve bolt 9 fuel valve 30 Servicing Your Honda Installation 1 Install the fuel tank on the frame 2 Install the fuel valve 1 and tighten the bolt 2 3 Connect the fuel lin
17. 28 27 axle holder 28 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 1 0 mm thick as shown if you do not have the special tool 55 mm 33 mm cont d Adjustments for Competition 101 Front Suspension Adjustments 22 Apply pressure to the fork damper and insert a special tool or mechanic s stopper tool 29 see below between the axle holder 27 and lock nut 30 23 Hold the lock nut and remove the fork center bolt 28 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 cannot reassemble the fork damper 27 axle holder 30 lock nut r 29 stopper tool 31 push rod Damper Oil Change 1 Set the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage 2 Loosen the fork cap assembly 2 while holding the fork damper 1 using the lock nut wrench 3 26 Remove the fork damper assembly 32 from the fork assembly 33 Remove the fork from the vise Remove the fork spring 34 from the fork 1 fork cap 3 lock nut wrench 2 fork damper 27 axle holder 29 stopper tool 28 fork center bolt 30 lock nut 24 Remove the push rod 31 from the fork damper 25 Remove the special tool or mechanic s stopper tool 29 be
18. 4 left engine guard bolt 5 left engine guard 9 Remove the oil filter cover bolts 6 and oil filter cover 7 10 Remove the oil filter 8 from the oil filter cover 11 Check that the oil filter cover O ring 9 is in good condition Ex 6 oil filter cover bolts 7 oil filter cover 8 oil filter 9 oil filter cover O ring 10 11 12 spring rubber seal OUT SIDE mark 38 Servicing Your Honda 12 Apply grease to the filter side of the spring end then install the spring 10 into the new oil filter 8 13 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 seal Use a new genuine Honda oil filter or a filter of equal quality specified for your model If the oil filter is not installed properly it will cause serious engine damage 14 Apply engine oil to the O ring and install it to the oil filter cover 15 Install the oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 16 Install the left engine guard and tighten the left engine guard bolt 17 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69 at oil and filter change 0 70 US qt 0 66 at oil change 18 Install the engine oil filler cap 19 Ch
19. Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 12 Basic Operating Instructions Always follow the proper starting procedure described below Your CRF can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Starting Procedure Always follow the proper starting procedure described as follow i 1 fuel valve 2 choke knob Starting amp Stopping the Engine Check the engine oil transmission oil and coolant levels before starting the engine pages 37 40 41 Cold Engine Starting 1 Turn the fuel valve 1 ON 2 Shift the transmission into neutral 3 If the temperature is 95 F 35 C or below pull the choke knob 2 fully out 4 If the temperature is below 32 F 0 C open the throttle two or three times The engine requires a richer mixture for starting in cold weather When the throttle is so opened the accelerator pump will feed extra fuel to the cylinder thereby facilitating starting in cold weather 5 With the throttle closed operate the kickstarter starting from the top of the kickstarter
20. S S NS sR Gason OOOO OS 8 eansmissoNoL O OO OOOO S S to Ccoounesystem O OO oOo Oe Coawechan OOOO S o a S aa T T T CoRvechansoeR O OO oS a O88 DRIVE CHAIN ROLLER o S T T T o DRIVE SPROCKET I G T T T o DRIVEN SPROCKET a a O O a a BRAKE FLUID notes 80 BRAKE PADS WEAR Ce O e a o BRAKE SYSTEM I 8 CLUTCH SYSTEM a a T T T o CONTROL CABLES S CS EXHAUST PIPE MUFFLER ooo G T S T o SUSPENSION a a a A A A C a a a S S a a Eo o E a a E E E wwa it NUTS BOLTS FASTENERS o S T T T o WHEELSTIRES o G T T T o STEERING HEAD BEARINGS S S a n T o This maintenance schedule is based upon average riding condition Machine subjected to severe use require more frequent servicing NOTE 1 Clean after every moto for dusty riding condition 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride 4 Inspect after the first break in ride Servicing Your Honda 21 General Competition Maintenance Perform maintenance on firm level ground using optional workstand or equivalent support When tightening bolts nuts or screws start with the larger diameter or inner fasteners and tighten them to the specified torque using a crisscross pattern Use genuine Honda parts or their equivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coat
21. SAE OME OUON saeir En EN 128 r EEE E E EE 131 control freeplay ssssssiseseriosniiorriesiiiieras 49 fOr competit OT sseni 97 O eE E 132 high altitude carburetor ccccccceeeeees 147 personal Tii seccstueacccsey treroseneacteersceaurarceesecas 134 suspension front 2 52 ssviesawacansenseesdenderscsetomncces 98 SUSPENSION TEAT vncnssexesonsaxananssnteennsnadacbessees 111 suspension track conditions ccc0e 115 HreselechioOn sopisi ier Ea 85 after competition maintenance eeseesssesssssee 26 dir VE AM CT eimi 43 air pressure front SUS DCIS OU seoncpteedcuosesdusgeieccotetnacsasticses 98 UMS E A E E NE E 84 apparel prol ciVe a sejesscrerosauessaesbeteceniatcensuentelaust 2 appearance CANE ee rsen nh ere ee EESE 94 authorized THANWALS 25255 0 hnesanndaconasenessaversecbosas 156 Dasic Operatorin r 11 Db fore Tidiness ran nr era ires 7 between motos amp practice maintenance 26 brakes MITC VGC E E EE 80 lever front adjustment ccccceceeeeeeees 19 DAC WEA opereren enre errr AEA 82 pedal belg ME has asvcedneeeadincie nvoecstessevsasssaniauen 19 break in guidelines 5 incsnueicccanensentenensessuenssGeriess 15 162 Index capacity Uel nescrise ninien sacle 34 carburetor I SUC BIE serierne nnie iA erR 126 circuit TMC MONS ccc cuteecectosanesevacseeawerenuscncces 121 COMM POMCINS sce coscoswwctyavdenanenonsdeeadentverseratossed 119 disassembly assembly c
22. Servicing Your Honda 51 Clutch System Clutch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 1 72 in 43 7 mm Replace the clutch springs as a set if any one of them is below the service limit or if the clutch plates have been burnt heat discolored Clutch Disc Plate Installation 1 Coat the clutch plates 1 with transmission oil 2 Install the eight clutch discs 2 and seven clutch plates 1 alternately starting with a disc or V AR N Tr NK UM Eig OS SAW RY Q G NWA O EN BIR S amp els A Y S 1 seven clutch plates 2 eight clutch discs 52 Servicing Your Honda Apply grease to the clutch lifter rod 3 Insert the clutch lifter rod into the mainshaft Apply engine oil to the needle bearing 4 and washer 5 and install them onto the clutch lifter 6 6 Install the clutch lifter onto the rod n A OW 3 clutch lifter rod 4 needle bearing 5 wahe 6 clutch lifter Install the clutch pressure plate 7 Install the six clutch springs and bolts 8 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 9 Ibf ft 12 N m 1 2 kgf m VO o0 N Z 7 clutch pressure plate 8 clutch springs and bolts 10 Install a new O ring 9 in the groove of the clutch cover 10 11 Install the clutch cover by tightening the six cover bolts to the s
23. adjustments and replace the spring with a harder spring optional if necessary Suspension bottoms after landing 1 Test stiffer low speed compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a harder spring optional if necessary Suspension bottoms after end of 1 Test softer rebound dumping adjustment continuous bumps 2 If it still bottoms test stiffer high and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a harder spring optional if necessary 118 Adjustments for Competition The carburetor on your CRF should perform suitably with the standard recommended settings under average load climatic and barometric conditions However to fine tune the engine s power output the carburetor may require adjustments for specific competition needs Optional main jets and slow jets are available for your CRF See your Honda dealer Any engine or air cleaner modifications or the use of an aftermarket exhaust system may require jetting changes Carburetor Adjustments amp Tuning Tips Carburetor Components Cold Start Circuit A very rich mixture must be delivered to the cylinder when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a ric
24. amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your CRF purchased from your Honda dealer e Tensioner stopper e Lock Nut Wrench e Spoke Wrench e Spoke Wrench e Piston base O7OMG 0010100 O7WMA KZ30100 O7JMA MR60100 O7VOMA KZ30100 07958 2500001 Chemical Products Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke Oil Engine Oil Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives only 4 stroke Oil Engine Oil Honda thread Lock Pro Honda HP Fork Oil 5W Honda Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite cleaner Honda Contact Cleaner Honda Dielectric Compound Honda Hand Grip Cement Honda Hondalock Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive White Lithium Grease Wheel Bearing Grease Silicone Sealer high temperature grease antifreeze Pro Honda HP Coolant Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape
25. as Standard oil 12 5 US oz capacity 369 cm3 Maximum oil 13 6 US oz Slightly stiffer as capacity 401 cm3 it nears full compression Minimum oil 10 3 US oz Slightly softer as capacity 305 cm3 it nears full compression capacity 407 cm3 it nears full compression Minimum oil 10 5 US oz Slightly softer as capacity 311 cm3 it nears full compression or Be sure the oil capacity is the same in both fork Optional Softer 0 44 kgf mm Fork Spring legs Cy 3 scribe marks Standard oil 12 9 US oz capacity 380 cm Maximum oil 13 9 US oz Slightly stiffer as capacity 412 cm3 it nears full compression Minimum oil 10 7 US oz Slightly softer as capacity 316 cm3 it nears full compression cont d Adjustments for Competition 107 Front Suspension Adjustments 14 Check that the O ring 12 on the fork damper 17 Tighten the fork damper 4 to the specified assembly 4 is in good condition Apply the torque using the lock nut wrench 14 recommended fork oil to the O ring Actual 15 Pull up the outer tube 1 slowly and install 25 Ibf ft 84 N m 3 5 kgf m the fork damper assembly 4 into the outer Torque wrench scale reading tube 23 Ibf ft 81 N m 3 2 kgf m using a 20 in 50 cm long torque wrench When using the lock nut wrench use a 20 inches long deflecting beam type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be
26. better to jet a little rich than a little lean It is advisable to record the settings course conditions lap times and climatic and barometric conditions for future reference 129 Adjustments for Competition Carburetor Adjustments amp Tuning Tips Spark Plug Reading Using spark plugs with an improper heat range Refer to Spark Plug on page 54 or incorrect reach can cause engine damage Check any jetting change by reading the spark Before removing the spark plug clean the spark plug The following procedure is recommended plug area thoroughly to prevent dirt from You may not get an accurate reading if you entering the cylinder simply turn off the engine and pull the plug for inspection Ride for 10 15 minutes before taking a plug reading A new plug will not color immediately Use a new spark plug Inspect the plug before installing it To obtain an accurate reading of a new spark plug 1 Accelerate at full throttle on a straight 2 Push the engine stop button and pull the clutch lever in to release the clutch 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain indicate rich jetting 13
27. bolt 2 number plate 3 handlebar pad cont d Adjustments for Competition 99 Front Suspension Adjustments 4 Remove the handlebar holder nuts 3 washers mounting rubbers and handlebar 4 Keep the master cylinder upright to prevent air from entering system 7 Remove the disc cover 7 by removing the two bolts 8 7 disc cover 8 bolts front axle pinch bolts 10 on both forks 3 T holder nuts hub and remove the front wheel 4 handlebar 5 Loosen the upper pinch bolts 5 6 Loosen the fork damper 6 but do not remove them yet Do not use an adjustable wrench to loosen the fork damper it may damage them 11 front axle shaft 9 axle nut 10 axle pinch bolts hose clamp bolts 13 and fork protectors 14 caliper 16 5 upper pinch bolts 6 fork damper 100 Adjustments for Competition 8 Remove the front axle nut 9 and loosen the Pull the front axle shaft 11 out of the wheel 9 Remove the fork protector bolts 12 brake 10 Remove the brake caliper bolts 15 and brake Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads 12 A 12 fork protector bolts 15 brake caliper bolts 13 brake hose clamp bolts 16 brake caliper 14 fork protectors 11 Loosen the fork leg lower pinch bolts 1
28. change yoxeconsesscenctosscavattiosonctetsaies 102 Fork Assembly oe aac vpacaeyienaenavertsnude a enide wees con 105 Rear Suspension Adjustments seeeeeeees 111 Rear Suspension Spring Pre Load 111 Rear Suspension Damping eeeeseesss000e 112 Rear Suspension Race Sag sseseesseeeee 113 Suspension Adjustments for Track Conditions sae coseacesd ierann naneo riari 115 Suspension Adjustment Guidelines 116 Carburetor Adjustments amp Tuning Tips 119 Carburetor Components orssers ssiccedeoesssevedaives 119 Carburetor Circuit Functions ccc0e 121 Carburetor Removal 121 Carburetor Disassembly ccccccceeeeeees 123 Carburetor Assembly ccccceeeeeeeeeees 125 Standard Tuning Recommendation 126 Adjustments for Altitude amp Temperature 126 Special Tuning Conditions ccccccee 127 Pre Adjustment Checks jccisssisveicesssadnenteneeers 127 Carburetor Minor Adjustments 128 Spark Plug Reading 2 ssasevscivencrowvavenceervores 130 Chassis ACjJUStMent cccceeeeeseceeeeeeeeeeeeeees 131 Ko Eidean EET 131 Fork Height Angle cccccccccccccccccseeeeees 131 WV CCN AG 6 srani 131 RG A TD arcs e serr ace ERE E EEES weenie 132 Tire Selection for Track Conditions 133 Personal Fit Adjustments cccccccccsssssseeees 134 Control Positioning ye srassencnesdesczswsesace
29. compression damping adjustments in one click increments Reduce the rebound damping adjustments in one click increments Check for dirt in the dust seals Check the fork oil for any contamination If the front end dives while cornering reduce the rebound damping in one click increments If that doesn t solve the problem install the optional stiff spring If the stiff spring makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel becomes stiff Install the optional soft spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer compression damping adjustments in one cl
30. counterclockwise 5 8 clicks with the punch marks on the adjuster and the shock absorber aligned Rear Suspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel travel used by your CRF at rest ready to ride with you on the seat As a general rule of thumb the race sag dimension should be about one third of the maximum travel On your CRF ride height is changed by adjusting the rear suspension spring pre load Spring Pre load amp Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the center of the rear fender mounting bolt to the center of the 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 motorcycle on ground without rider 1 Support your CRF on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension REAR FENDER
31. for play in the steering head bearings If any roughness or play is felt but you do not see any movement in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer 92 Servicing Your Honda Handlebar Inspection 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 3 Check the torque of the upper holder 2 bolts 16 Ibf ft 22 N m 2 2 kgf m Tighten the front bolts first 1 handlebar 2 handlebar upper holders Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant Be certain that the throttle cables have no kinks or other damage Additional Maintenance Procedures LEFT SIDE Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing ENGINE J S O Cylinder head cover bolts 7 10 1 0 Clutch cover bolts 7 10 1 0 Water pump cover bolts 7 10 1 0 4 Transmission oil check bolt 7 10 1 0 5 Crankshaftholecap 11 15 1 5 Oil filter cover 9 12 12 7 Cylinderbolt i 7 10 10 8 Cylinderheadbots 7 10 10 9 Exhaust pipe joint nuts 15 RIGHT SIDE 1 cylinder head cover bolts 6 oil filte
32. from entering Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation Cover your CRF with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Storing Your Honda Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with the recommended fuel page 34 4 Pour a fresh recommended coolant mixture page 41 slowly into the radiator filler hole up to the filler neck Capacity 1 18 US qt 1 12 at disassembly 1 09 US qt 1 03 at draining Lean your CRF slightly right and left several times to bleed trapped air in the cooling system If the coolant level lowers add coolant and repeat the above procedure Install the radiator cap securely 5 Perform all maintenance checks page 9 Tips 137 You amp the Environment Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environmentally responsible motorcycle owner e Choose Sensible Cleaners Use a biod
33. less than the torque actually applied to the fork GJ outertibe 16 upper fork clamp damper 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 lbf ft 22 N m 2 2 kgf m 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 Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced 4 fork damper 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 of the outer tube 1 with the top surface of the upper fork clamp 16 13 fork lower pinch bolts 13 lower pinch bolts 17 upper pinch bolts 108 Adjustments for Competition Front Suspension Adjustments 21 Clean the threads of the fork protector bolts 24 Clean the surfaces where the axle and axle 25 Install the handlebar 25 mounting rubbers 18 and axle holder thoroughly clamps contact each other 26 washers and handlebar holder nuts 27 Apply locking agent to the bolt threads Install the left and right side collars into the and tigh
34. 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 113 in the 3 5 3 9 in 90 100 mm range Fork Height Angle The position of the fork tubes in the clamps is adjustable Standard Position The standard position 1 align the top of the outer tube 2 not the top of the fork cap with the top of the upper fork clamp 3 1 standard position 2 O in 0 mm f 2 top of outer tube 3 upper fork clamp Chassis Adjustments Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to 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 position
35. parts and tools may be ordered from your authorized Honda dealer Driven sprocket lt gt Drive chain links Shock spring 308 0 Ibf in 5 50 kgf mm factory products Main jet 158 178 in increments of Optional 47 Teeth Aluminum Standard 168 2 or 3 lt 114 gt or Red CD gt 49 Teeth Aluminum paint pm Slee ns Handlebar Slow jet 38 48 lower holder Optional 296 8 Ibf in 5 30 kgf mm Standard 42 in increments of 2 or 3 Standard 3 mm offset softer Ss Blue Jet Needles Optional paint Standard needle NCYQ Stiffer 319 2 Ibf in 5 70 kgf mm a o Numper Pin spanner A To adjust spring preload E palo AN two spanners required 330 4 Ibf in 5 90 kgf mm Silver Straight diameter 2 745 mm Workstand BA For maintenance eS _ paint Jet needle number Jet needle number standard series 1 2 clip position Fork spring 25 76 lbf in 0 46 kgf mm leaner than Standard No mark standard series factory products leaner only at 1 8 to 3 4 throttle 9 2 scribe marks Sp om aftermarket parts en en Creat ee BO O2 725 mm O2 725 mm om NCYP NCVP 02 735 mm 02 735 mm Stiffer 26 88 Ibf in 0 48 kgf mm standard needle _ __ 4 scribe marks NCYQ NCVQ CY 02 745 mm 02 745 mm NCYR NCVR The standard fork spring and shock spring Pe eos mounted on the motorcycle when it leaves the NCYS NCVS factory are not marked Before replacing the 2 765 mm 2 765 mm springs be sure to mark them so the
36. 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 30 2 Drain the fuel from the fuel tank into an approved gasoline container Disconnect the fuel valve and fuel line 3 Remove the fuel filter 1 from fuel tank by removing the bolts 2 Wash the fuel filter in high flash point cleaning solvent 4 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 3 is in place Install the fuel filter in the fuel tank Refill the fuel tank Attach the fuel valve and fuel line and turn the fuel valve to ON check for leaks 1 fuel filter 3 O ring 2 bolts Servicing Your Honda 35 Engine Oil Refer to Safety Precautions on page 19 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the engine Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine 36 Servicing Your Honda Oil Recommendation API SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 40 classification viscosity weight JASO T 903 standard MA or MB suggested oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with moly
37. skills Special Honda tools are necessary for some procedures Publication Item No Description Price Each 61MEN51 2006 CRF450R Service Manual 48 00 61CMO002 Common Manual 48 00 31MEN620 2006 CRF450R Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form Canada See your Honda dealer to order authorized manuals Publication Item No Sub Total Prices are subject to change without notice and Purchaser s Sales without incurring obligation Tax Mich Add 6 Calif Add 8 25 Orders are mailed within 10 days Please allow adequate time for delivery Grand Total 156 Consumer Information NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation Customer Name Attention Street Address No P O Box Number 9 _______ __ Apt City State Zip Code Daytime Telephone Number Check or money order enclose
38. standard position when the adjuster is turned counterclockwise 9 clicks Make sure that both fork legs are adjusted to the same position Compression Damping Adjustment This adjustment affects how quickly the fork compresses The fork compression damping adjuster 2 screw has 16 positions or more Turning the adjuster screw one full turn changes the adjuster four positions To adjust the adjuster to the standard position proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 8 clicks Make sure that both fork legs are adjusted to the same position Both compression and rebound damping can be increased by turning the adjuster clockwise Always start with full hard when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the rebound and compression adjusters are firmly located in a detent and not between positions 1 rebound damping adjuster screw 2 compression damping adjuster screw Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of r
39. stroke kick through to the bottom with a rapid continuous motion Do not open the throttle As the carburetor is equipped with an accelerator pump excessive fuel will be charged into the engine and the spark plug will be fouled 1f the throttle is opened and closed repeatedly Excessive fuel in the engine makes kickstarting difficult 6 About a minute after the engine starts push the choke knob back all the way to fully OFF If idling is unstable open the throttle slightly Warm Engine Starting 1 Turn the fuel valve ON 2 Shift the transmission into neutral 3 Pull the hot start lever 3 and kick start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 3 hot start lever Starting the engine after a stall during riding or after a fall 1 Shift the transmission into neutral 2 Pull the hot start lever and kick start the engine Do not open the throttle 3 As soon as the engine starts release the hot start lever Flooded Engine If the engine fails to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine 1 Shift the transmission into neutral 2 With the throttle fully opened repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine 3 With the throttle closed pull the hot start lever and kick start the engine Do not open the throttle 4 As soon as
40. the book Introduction 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 Honda dealer for the service and adjustment procedures discussed in this manual The official Honda Service Manual for your CRF is available page 156 It is the same manual your dealer uses If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility To help you make informed decisions about safety this manual contai
41. the engine starts release the hot start lever Basic Operating Instructions 13 Starting amp Stopping the Engine How to Stop the Engine 1 throttle grip 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle 1 2 3 times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow result in hard starting Emergency Engine Stop To stop the engine in an emergency press the engine stop button 14 Basic Operating Instructions Break in Guidelines Help assure your CRF s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when e piston is replaced e piston rings are replaced e cylinder is replaced crankshaft or crank bearings are replaced Basic Operating Instructions 15 16 Basic Operating Instructions Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CRF in good shape this section includes a Maintenance Schedule for required servicing and step by s
42. to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule Drive Chain Inspection 1 Turn the engine off raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm 86 Servicing Your Honda 1 drive chain slack 2 drive sprocket 3 driven sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for e damaged rollers e loose pins e dry or rusted links e kinked or binding links e excessive wear Replace the drive chain page 87 if it has damaged rollers loose pins or kinks that cannot be freed Lubricate the drive chain page 87 if it appears dry or shows signs of rust Lubricate any kinked or binding links and work them free Adjust chain slack if needed 5 Check the chain slider 4 for wear If the wear is 0 2 in 5 mm or more replace it 4 chain slider 6 5 chain guide slider 7 Check the chain guide slider
43. 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 Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments carburetor adjustments gearing and tire selection This detailed information along with your comments can prove valuable when you compete at the same track or on similar terrain Your logbook can also tell you when maintenance was performed and when it will be necessary again Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components If you choose to sell your CRF the accurate maintenance records in your logbook might be the deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black jetting changes
44. 0 62 US qt 590 cm DENSO ee etic After disassembly 0 71 US qt 670 cm wean Tire pressure front cold 15 psi 100 kPa 1 0 kgf cm Carbure a For extended high NGK EEN l l 5 ag Tire pressure rear cold 15 psi 100 kPa 1 0 kgf cm Type Bion wAe speed riding Single disc brake DENSO F brake swept area 51 8 in 334 5 cm oer number FCROOE VK27PRZ11 er Single disc brake Main jet standard 168 Spark plug gap oad Oren pega aa 60 6 in 391 1 cm Jet needle standard NCYQ salle Fuel capacity 1 90 US gal Needle clip position 4th groove Caster angle 26 47 standard Trail length 109 3 mm Slow jet standard 42 Fork oil capacity Pilot screw opening 1 1 2 turns out except fork damper 12 7 US oz Float level 0 31 in 8 0 mm per leg Idle speed 1 700 100 rpm Technical Information 143 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Engine De ya y SS 144 Technical Information _ ENGINE FF 1 Cylinderheadcoverbolts 7 10 10 2 Clutch cover bolts 7 10 10 3 Water pump cover bolts 7 10 1 0 4 Transmission oil check bolt 7 10 1 0 5 Oilfiltercover st 9 12 12 7 Cylinder bot 7 10 10 Cylinder head bolts 7 10 10 9 Exhaust pipe jointnut 15 21 21 10 Drive sprocketboit 23 31 32 Torque Specifications _Ibfeft FRAME o Steerin
45. 0 Adjustments for Competition An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 1 insulator 3 side electrode 2 center electrode Spark Plug Coloring Guidelines Condition Spark Plug Appearance Normal Dark brown to light tan correct color with dry electrode Overheating Light gray or white color lean Lean Wet Wet or sooty rich Rich Remember that in addition to improper jetting e A lean condition can be caused by air leaks in the inlet tract or exhaust system the passage of too much air because of the use of the wrong air cleaner use of a less restrictive aftermarket exhaust system or a hole or holes deliberate or uninterna in the air cleaner A rich condition can be caused by a plugged or dirty air cleaner use of a more restrictive aftermarket exhaust system a clogged spark arrester or excessive oil on the air cleaner Excessive smoking will occur 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
46. 0 degrees apart between upper side rail spacer and lower side rail Piston Piston Rings Piston Pin Yj top ring LASS ae oil ring Knnn oil ring Servicing Your Honda 69 Piston Piston Rings Piston Pin 1 2 Piston Installation a T Cylinder Installation 1 Place clean shop towels over the crankcase 4 fu 1 Clean off any gasket material from the gasket opening to keep the piston pin clips from surface of the crankcase being careful not to falling into the crankcase let any material fall into the crankcase 2 Apply molybdenum disulfide oil a mixture of Be careful not to remove any metal from the 1 2 engine oil and 1 2 molybdenum disulfide gasket surface grease containing more than 3 2 Remove the shop towel Do not let any gasket debris fall into the crankcase 3 Install the cylinder gasket 1 A dowel pins 2 and B dowel pin 3 Do not let the dowel pins fall into the crankcase 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 flesh engine oil to the piston pin 4 Install the piston pin and new piston pin clips 5 Use new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out k a m4 ae a A 1 cyl
47. 2006 Honda CRF450R OWNER S MANUAL amp COMPETITION HANDBOOK ea oe i Introduction Congratulations on choosing your Honda CRF motocross motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your CRF is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned closed course events by experienced riders only Be aware that motocross is a physically demanding sport that requires more than just a fine motorcycle To do well you must be in excellent physical condition and be a skillful rider For the best results work diligently on your physical conditioning and practice frequently Before riding take time to get acquainted with your CRF and how it works To protect your investment we urge you to take responsibility for keeping your CRF well maintained Scheduled service is a must of course But it s just as important to observe the break in guidelines and perform all the pre ride and other periodic checks detailed in this manual You should also read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of
48. 7 then pull the fork legs down and out 17 lower pinch bolts 12 Clean the fork assembly especially the sliding surface of the slider 18 and dust seal 19 13 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it Stops 14 Measure the length 22 between the axle holder and outer tube and record it before disassembling the fork 22 length 15 Hold the outer tube then remove the fork damper 23 from the outer tube using a lock nut wrench 24 Gently slide the outer tube down onto the lower end of the slider 25 23 23 fork damper 24 lock nut wrench 25 slider lower end The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD 18 NO GOOD 20 18 slider 20 outer tube 19 dust seal 21 guide bushing 16 Drain the fork oil from the outer tube 20 Drain the fork oil from the oil hole 26 of the fork damper ee titi yA Ti AATAL ein 20 outer tube 26 oil hole Front Suspension Adjustments 17 Temporarily install the fork damper to the outer tube 18 Set the lower end axle holder 27 of the slider in a vise with a piece of wood or soft jaws to avoid to damage Overtightening the vice can damage the axle holder 19 Loosen the center bolt
49. ENGINE STOP BUTTON BIW BI G BIW gt L BI w BI G 1__Kt BI G BL BLACK _ Br BROWN YELLOW O ORANGE Bu BLUE __ Lb LIGHT BLUE P_ PINK WHITE _ Gr GRAY COLOR COMB GROUND MARKING G GREEN Lg LIGHT GREEN R RED _ P PINK_ ENGINE STOP BUTTON CONTINUIT FRAME BODY GROUND BI Y Wiring Diagram IGNITION CONTROL MODULE 2 gt m a 5 35 03a 2P 2P BI arn Sa a ALTERNATOR THROTTLE SENSOR IGNITION PULSE GENERATOR Technical Information 153 154 Technical Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals sis vicvsscsssrscexenscovevevsonervecesens 156 Contacting TOMO A515 5s2ionctanesnatoceaiadontarnssence 157 Your Honda DOAN Cl cecerexaconsst ouncsrccseediconviaricess 158 The Honda Rider s Club USA only 159 Consumer Information Consumer Information 155 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm Inc Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and
50. MOUNTING BOLT UNLOADED MEASUREMENT without rider EXAMPLE 23 6 in 600 mm CHAIN ADJUSTER LOCK NUT 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your CRF s seat wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the loaded with rider dimension REAR FENDER MOUNTING BOLT LOADED with rider EXAMPLE 19 7 in 500 mm ALPA KA Me WWE ors Hes CHAIN ADJUSTER LOCK NUT Example Unloaded 23 6 in 600 mm Loaded 19 7 in 500 mm Race Sag 3 9 in 100 mm 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
51. SOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor clearance is 0 011 in 0 28 mm 0 014 in 0 35 mm 0 025 in 0 63 mm If only decompressor arm clearance needs adjustment see Decompressor Arm Clearance Adjustment page 63 If intake valve clearance exhaust valve Clearance and decompressor arm clearance don t need adjustment see Spark Plug Installation page 64 Camshaft Holder Assembly Removal 1 Record the intake valve clearance exhaust valve clearance and decompressor arm clearance Make sure the piston is at TDC Top Dead Center on the compression stroke page 55 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 BET an i 4 h B 1 cam chain tensioner lifter cover bolt 2 sealing washer Valve Clearance Use the tensioner stopper tool e Tensioner stopper O7OMG 0010100 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 cont d Servicing Your Honda 57 Valve Clearance 4 Remove the cam sprocket bolt 4 Rotate the primary drive gear bolt crankshaft clockwise one turn and remove the other sprocket bolt and cam sprocket 5 Then attach a p
52. T CLOGGED 5 Check valve INCORRECT e Cam sprocket not timing installed properly CORRECT 6 Try spark test WEAK OR e Faulty carbon or wet INTERMITTENT fouled spark pulg COOR SPANK Jj SPARK P 130 e Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Loose or disconnected ignition system wires Faulty engine stop button 7 Check for LOW e Ring worn low compression Cylinder worn or damaged CORRECT Piston worn or damaged Head gasket not sealing Improper valve timing Valve stick open Troubleshooting Tips 139 140 Tips This section contains dimensions capacities and other technical data Vehicle Identification 23 1 ssssescarevonceorerescenesceesnce 142 SpecilicaNoNS ereere n O Eai 143 Torque Specifications cccccccsssssssssseeeseeeeeees 144 High Altitude Carburetor Adjustment 147 Oxygenated UC IS oar cccasetacin ven untevaeeratarastnerietcaes 148 Competition Logbook ccccccceeeeeeseseseeeeees 149 Optional Parts List 3 ssssesacdnvascerecsesensauanoeesvess 151 Spare Parts amp Equipment 1 i06s x dexesnenecsdesenuads 152 Wiring DA STAM csieecsssvernasavenentovanccuneenssutestevveees 153 Technical Information Technical Information 141 Vehicle Identification Serial Numbers The frame VIN and engine serial numbers are required when you register your CRF They may also b
53. Teeth REPLACE Normal Sprocket Teeth GOOD Use of a new chain with worn sprockets will cause rapid chain wear 88 Servicing Your Honda REPLACE Measure a section of the drive chain to determine whether the chain is worn beyond its service limit Put the transmission in gear and then turn the rear wheel forward until the lower section of the chain is pulled taut With the chain held taut and any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service Replacement chain D I D 520DMA2 Service limit 10 20 in 259 0 mm MEASURE A SPAN OF 17 PINS 16 PITCHES Lubricate the drive chain Pass the chain over the sprockets and join the ends of the chain with the master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation Recheck chain slack and adjust as necessary More About Drive Chain e The master link is the most critical element of drive chain security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining cl
54. UR HONDA ccc cccceeeees 17 Before You Service Your Honda The Importance of Maintenance ceeeeees 18 Maintenance Safety cs nsedsasiesssaiapsevsdeneansasencnveces 19 Important Safety Precautions c 000 19 Maintenance Schedule ossee 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 6 26 Service Preparations Maintenance Component Location 28 Seal REMOVAL ee eee ne oe 29 Fuel Tank Removal decades cicwecisdacewssccessscseeesoeeenes 30 Subframe REMOV Al cc cocsacvsaswsaniceavcaesgessewsesdaeeiio 32 Contents Service Procedures Fluids amp Filters Fuel Syse eee oe ee ee en oe 34 PASC EE E EE E E 36 Transmission Oil ba stcnaseistuoetsesvcteassvoreroetadecuit sate 39 3 510 E EE E nen eee P eee 4 PAT VG ACM eer E E EEEE Ea 43 C rankcas Breather is ssncsev oscssbaxsareneceiacaicetaraevons 45 Engine BATEE i e EA T ETE ENE E E 46 Engine TONS Speed esecsasscitsnasocencncanetonsauanessieansss 48 Cuh Syste enrere Erria 49 Hot start LEVET renra E 53 SPAK PIDO xo stiecccteseaseevensadavondevedvaiewucesvoacioereanseee 54 VON i AI E eceran 55 Piston Piston Rings Piston Pin 000000008 66 Chassis USP STS TOM eieiei EE 74 PT ANS a E E E E ventas 19 MY MAC E EE A E E T 83 Tires amp TUDES esseere keder nEn eas 84 Drine C Doi
55. WEA 16 ignition coil bolts 17 and ignition coil 15 Ibf ft 21 N m 2 1 kgf m With 3 nut 18 Connect the primary wire 19 and spark plug 13 radiator hose 14 radiator hose clamp screw 21 exhaust pipe gasket 22 exhaust pipe 23 exhaust pipe joint nuts 7 Install the camshaft holder assembly page 60 2 Onion 13 Install the carburetor page 125 8 Install the spark plug page 64 He Dae pat ae 14 Install the subframe ioe 90 and muffler 18 ignition coil nut page 32 19 primary wire 15 Install the fuel tank and the seat page 31 20 spark plug cap 16 Add the coolant up to the filler neck page 41 Servicing Your Honda 73 Suspension Refer to Safety Precautions on page 19 Loose worn or damaged suspension components may adversely affect the handling and stability of your CRF If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection 74 When your CRF is new break it in for approximately one hour to ensure that the suspension has worked in page 15 After break in test run your CRF with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CRF for three hours See page 99 for fork disass
56. aintenance Component Locations 28 Seal REMOVAL erreser reniri aa ei 29 Fuel Tank Rm all tassecenasccasesiraciessstemsapousentes 30 Subframe REMMOV Al accsiozace scwadewicennsvacsnaoetacesionatee 32 Service Procedures Fluids amp Filters Puel ysi Miera A 34 Eng foe 1 errare ain ir 36 Transmission OM iesene a nr Nn 39 COO eee ean EE E AEE 41 ACICE ae E E E 43 Crankcase Breather eis cocussecoseteseessieth cot eimentou 45 Engine METRE OTE VS EREE EPE EEA TEE 46 Engine Idle Speed asssiresirrsrersesninnnr ny meee 48 Cuich Syste eaeoe NTE 49 Hot Start LEVET ierra ee AA kaan 53 SPE PI a 54 Nalve Clearance suiran snin ea 55 Piston Piston Rings Piston Pin 0 0000008 66 Chassis SUSPENSION sessio ronan rr era EEEN ERRE 74 Front Suspension Inspection ccceeeeees 74 Rear Suspension Inspection cccceeeeeeees 75 PTI 8 EE EEEE A E T E 79 IVY NAS 1S a A E E E ET A T 83 Tires e TUDES earen ruen E ERR nants 84 Drive C Hain eorr tnererE snr raS EE SA 86 Exhaust Pipe Muffler ssaxiconcsstsoncaerasececnieusacveiied 89 Additional Maintenance Procedures 92 Appearance Cale sosscsorirrron iee een eia 94 ADJUSTMENTS FOR COMPETITION 97 Front Suspension Adjustments 00000008 98 Front Suspension Air Pressure 0008 98 Front Suspension Damping cccseseeees 98 POT DUS A EEAS 99 Front suspension Disassembly 005 99 Damper oil
57. ake fluid be sure the reservoir is When adding brake fluid be sure the reservoir is and fittings horizontal before the cap is removed or brake horizontal before the cap is removed or brake fluid may spill out fluid may spill out 1 screws 3 diaphragm 2 reservoir cap 4 upper level mark 5 6 reservoir cap 7 set plate 8 diaphragm 9 1 Remove the screws 1 reservoir cap 2 and upper level mark diaphragm 3 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 4 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 0 7 Ibf ft 1 0 N m 0 1 kgf m 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 9 Do not overfill 3 Reinstall the diaphragm set plate and reservoir cap 4 Tighten the bolts to the specified torque 0 7 Ibf ft 1 0 N m 0 1 kgf m Servicing Your Honda 81 Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval page 21 Front Brake Pads Inspect the pads 1 through the front wheel to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness indicator wear indicator gr
58. ase 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay Tighten the lock nut Check the adjustment Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CRF should move smoothly and accelerate gradually Mn P If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the Honda Service Manual page 156 Other Inspections amp Lubrication e Check that the clutch lever assembly is positioned properly and the securing bolts are tight e Check the clutch cable for kinks or signs of wear If necessary have it replaced e Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Clutch Operation 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 40 2 Remove the rear brake pedal 1 by removing its pivot bolt 2 1 rear brake pedal 2 pivot bolt 3 Remov
59. aust 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 Servicing YourHonda 19 Maintenance Schedule To maintain the safety and reliability of your CRF regular inspection and service is required as shown in the Maintenance Schedule that follows The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purchase from your Honda dealer page 158 Service intervals in the maintenance schedule are expressed in terms of races and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenanc
60. bdenum additives 4 stroke engine oil or an equivalent Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label e Your CRF does not need oil additives Use the recommended oil e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication Ses XEN ed NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10 20 30 40 50C 20 O 20 40 60 80 100 120F JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification Checking amp Adding Oil 1 engine oil filler cap 2 upper level H mark 3 lower level L mark NO e Run the engine for 3 minutes then shut it off Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine Support the CRF in an upright position on a level surface Remove the engine oil fill
61. brake pads If they are not worn beyond the recommended limit page 82 there is probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system Front Brake Lever Adjustment LZ LESS lt THAN 0 8 in 20 mm 1 lock nut 2 adjuster 3 piston 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 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm 6 Apply grease to the contacting faces of the adjuster and piston 3 Brakes 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 pedal 3 or in direction to lower it 2 Tighten the lock nut at the desired pedal height raise the pedal height lower the pedal height 1 lock nut 2 adjusting bolt 3 rear brake pedal Servicing YourHonda 79 Brakes Fluid Level Inspection Front Brake Fluid Level Check 1 LOWER lev
62. breather tube plug 2 tube Servicing Your Honda 45 Throttle Refer to Safety Precautions on page 19 1 Pull the dust cover 2 back Lower Adjustment 2 Loosen the lock nut 3 The lower adjuster is used for major freeplay 3 Turn the adjuster 4 adjustment such as after replacing the throttle Throttle Freeplay Turning the adjuster in direction will cables or removing the carburetor It is also used decrease freeplay and turning it in direction if you can not get the proper adjustment with the 1 will increase freeplay upper adjuster 4 Tighten the lock nut Return the dust cover to B a its normal position lt l i 5 After adjustment check for smooth rotation of h TEE A U the throttle grip from fully closed to fully A c open in all steering positions 6 If the adjuster is threaded out near its limit or S SESS la the correct freeplay cannot be reached turn the adjuster all the way in and back out one 4 1 freeplay turn Tighten the lock nut install the dust imp cover and make the adjustment with the F Inspection lower adjuster 5 P Check freeplay 1 aa Freeplay 1 8 3 16 in 3 5 mm a If necessary adjust to the specified range 5 lock nut increase 6 adjuster decrease Upper Adjustment Minor adjustments are generally made with the upper adjuster 1 Remove the fuel tank page 30 2 Loosen the lock nut 5 3 Turn the adjuster 6 in direction to
63. cause wheel damage on hard terrain Overinflated tires make your CRF ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap 84 Servicing Your Honda 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 15 psi 100 KPa 1 0 kor 15 psi 100 KPa 1 0 kor If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Inspection Take time to inspect your tires and wheels before you ride 1 tire tread depth e Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 mm or any time you notice a reduction in traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the
64. ccccceeeeeeees 123 high altitude adjustment ccccceeeeeees 147 DOSS CC Ol E E eeroaneeeuset 48 minor adjustments seessseeeeeeesssssseeeeereses 128 TONY Al E E EE E EEE 121 EE E eC me tee 94 OI 9 sa apices E E T 86 chassis adjustment for track conditions 133 INO KTV OD eeii 13 Cleaner aii serseri rie RENREN 43 cleaning appearance care seeeesssssseeseeresse 94 clutch system adjustment ccceeseseeeeeeees 49 consumer information x ssczencsicancncidescncsinarcetanecc 155 competition LOgbOOK ccccecececeeeeeeseeeeeees 149 contacting Honda ssssssssrersrsinsinisrrsrnisenricen 157 controls operating eesssssssesseeeesssssssssseeressss 5 COOL aE E E 41 Customer SOrV iOO ciseus aineina nE 158 cylinder System serisinin rna 68 er damping adjustments DEO 1i AE EEEE A A 98 TC i E E E EEEO E E E T 112 dealer your Honda ius sssesesessevseniaratarcesiortncnianiee vd 158 VAT Ns WIDE pirosra tsesa rne nanasa 153 drive chall aeresreirrs ennie inicie EERE 86 engine ood era 13 Idle speedier re eE 48 AUO T oser E EOE 142 PIOC TN oo ee sereectes toanaicewe ne eN AE EErEE ESEE 34 Sr EMM og ate Se a E E A E E 13 BLO OOM se stsipne aren get reastas ai 14 BE ONS aE A EO 14 Won SUAN vo sctecote tas osneeneestsen gecesi sa uieii 13 environment protecting o5o c20icensssesicerderiventunese 138 filter T A A 43 Oe E E E E E 31 flooded engine Starting cecccccceccessst
65. ce Brake Fluid Replacement Refer to Brake Pad Wear in your Owner s Manual page 82 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper pin and caliper bracket pins Check pad thickness periodically and replace when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Replace the hydraulic fluid in the brake system every two years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid Water Leakage Check Hole After every race check the leakage check hole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced b m e e e e e e e e o e e ee ee ee ee e Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Fork Oil Performance Disassemble clean and i
66. ce should be performed while the engine is cold The valve clearance will change as engine temperature rises Cylinder Head Cover Removal Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat page 29 2 Remove the fuel tank page 30 3 Disconnect the breather tube 1 and spark plug cap 2 2 spark plug cap 1 breather tube 4 Remove the cylinder head cover A bolt 3 cylinder head cover B bolts 4 and cylinder head cover 5 sfa LA 3 cylinder head cover A bolt 4 cylinder head cover B bolts 5 cylinder head cover Valve Clearance Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 a i l Des j AY ba A ral i w bgo A p DEn NS l E 1 crankshaft hole cap 2 Remove the spark plug 2 2 spark plug cont d Servicing Your Honda 55 Valve Clearance 3 Rotate the crankshaft by turning the primary 2 Measure the exhaust valve clearance by drive gear bolt 3 clockwise until aligning the Valve Clearance And Decompressor Arm inserting a feeler gauge 1 between the punch mark 4 on the primary drive gear Clearance Inspection exhaust rocker arm 4 and shims 5 with the index mark 5 on the right crankcase cover In this position the piston may either be 1 Measure the intake valve clearance by on the compre
67. d payable to Helm Inc U S funds only Do not send cash Check here if your billing Master a Hi address is different from the Card VISA E Discover shipping address shown above Account Number Se ee eee eee Expiration Date Mo Yr o5 Customer Signature These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order HELM P O BOX 07280 DETROIT MICHIGAN 48207 Your Owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc RO Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following information in your letter e name address and telephone number e produc
68. da 1 2 3 4 PN MACS y TNA x YO OIA water hoses overflow tube water leakage check hole water pump cover Coolant Replacement Refer to Safety Precautions on page 19 Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the Honda Service Manual page 156 A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap To properly dispose of drained coolant refer to You amp the Environment page 138 Improper disposal of drained fluids is harmful to the environment Refer to Safety Precautions on page 19 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your CRF s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an
69. dalock or an equivalent on the attaching studs Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration Servicing YourHonda 23 General Competition Maintenance Handgrips Always use Honda Handgrip Cement U S A only or Honda Bond A when replacing handgrips Throttle Grip Align the index mark on the throttle grip with the index mark of the throttle cable guide Left handlebar grip Align the A mark on the left handlebar grip with the paint mark on the handlebar Refer to the Service Manual for installation instructions For added security you may choose to safety wire the hand grips to the handlebar and throttle to prevent the possibility of them loosening Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the grip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the drum and handlebar thoroughly and apply a light coating of silicone lubricant Inspect the cable carefully for kinks or other damage that may restrict throttle control in anyway Move the handlebar from lock to lock to be sure there is no cable interference Check to be sure the top of the carburetor is screwed on tight Make certain the throttle operation is perfect after servicing and inspecting 24 Servicing Your Honda Gaskets Always use new gaskets when reassembling components Cy
70. damage Replace the wear ring if it is 0 06 in 1 5 mm or flat with the outer tube 4 Install the wear ring with its end gap facing rearward 0 06 in 1 5 mm 4 f 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 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 preload and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 115 Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the shock assembly only e When your CRF is new break it in for approximately one hour with the standard suspension settings before attempting to adjust the rear suspension Make all compression and rebound damping adjustments in the specified increment or turns described in page 112 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the
71. djustment TB ON eat vaste A T I E E AE 98 IG T OEE E TE T N ET 111 for track conditions ccceccccceeeeeeeeeeeeeees 115 golde NEE oss eee Ce ee ee ee re ere 116 iransmiission Oll ssiri aTi 39 UONE APS stake e eioi Ea 119 throttle DECC D x E A TEATA 46 SPECON sereen EE 47 tires ON ONC 6 SUC E E E 84 IGA ettae cea guages haeg avecsen E E 84 Be LC ON poss conc EA EEE 85 TOONS eet eniect recuse e ve 152 torque specifications isi cascnasmncsrescvansscdetens 144 146 PANS POMS oc crcvacvesanseussaencdnmsiendsanoantweneaesdvessedes 136 troubleshooting ccs asasnct one norsiesdaneimterconuieceedannccs 139 mbes TPA CNG x soewesnsticy enn senewsyotevsee sensetecteverncies 84 LS o e E T A A EEA 13 vehicle identification y 2 xa vinsacsssensscewicacesntedeeeauencs 142 Washing your motorcycle eceeceeeeeseeeeeeeeeees 94 WS ONS E E EEE EE EE E ET 83 wanne diarani goss outers eu bdenaeacaxntotecneateecssathece 153 164 Index Memo 165 166 Memo Memo 167 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 e Transmission oil amp engine
72. e 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter page 37 3 Change the transmission oil page 40 4 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and loosen the drain screw Drain gasoline into an approved container Retighten the drain screw A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 5 Remove the bolt 1 and right engine guard 2 1 bolt 3 coolant drain bolt 2 right engine guard 7 8 9 10 11 12 Remove the radiator cap and coolant drain bolt 3 at the water pump 4 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washer is in good condition and reinstall the radiator cap and drain bolt alt U 4 f ko N Fi 4 i i N T P a T b g A a a i i J 4 water pump Lubricate the drive chain Inflate the tires to their recommended pressures Place your CRF on the optional Honda workstand or equivalent to raise both tires off the ground Stuff a rag into the silencer outlet Then tie a plastic bag over the end of the silencer to prevent moisture
73. e 23 Remove the engine hanger B bolts 14 left NOTICE engine hanger plate 15 and right engine hanger plate 16 i Do not let the dowel pins and cam chain fall into the crankcase pi gh 2 17 cylinder head bolts 18 cylinder bolt 16 Remove the cylinder head nuts washers 19 and the cylinder head 20 21 dowel pins 23 cam chain guide 22 cylinder head gasket Loosen the nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase 1 engine hanger nut 2 engine hanger A bolt 3 fuel hose guide 4 engine hanger B bolts 5 left engine hanger plate 6 right engine hanger plate h ee ee ee ee 19 cylinder head nuts washers 20 cylinder head Servicing Your Honda 67 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 De A B iil E 3 2 cylinder 1 evindet bolt 2 Remove the A dowel pins 3 B dowel pin 4 and cylinder gasket 5 Do not let the dowel pins fall into the crankcase TA f 3 A dowel pins 4 B dowel pin 5 cylinder gasket 68 Servicing Your Honda 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 Re
74. e 3 to the fuel valve r A 2 i e MAJK MN Se A a T i 1 3 i t i TE gq We i i oo a t ewe hi Z EN i 1 a x Y y ie 4 i F j t i pr Pe a 1 fuel valve 3 fuel line 2 fuel valve bolt 4 Install and tighten the fuel tank bolt 4 5 Hook the air cleaner case cover 5 6 Install and hook the fuel tank band 6 4 4 fuel tank bolt 5 air cleaner case cover 6 fuel tank band Fuel Tank Removal 7 Put the breather tube 7 in the steering stem 9 Install the shroud B bolts 11 and A bolts nut collars 12 7 breather tube 11 shroud B bolts 12 shroud A bolts collars 8 Install the shroud 8 by aligning it s tab 9 with subframe 10 10 Install the seat page 29 8 shroud 10 subframe Servicing Your Honda 31 Subframe Removal Refer to Safety Precautions on page 19 5 Disconnect the crankcase breather tube 7 Installation 6 Unhook the fuel tank band 8 and remove it 1 Loosely attach the upper and lower ends of Removal 7 Unhook the air cleaner case cover 9 the subframe 1 to the mainframe while 1 Remove the seat page 29 8 Loosen the screw 10 on the air cleaner connecting the air cleaner connecting tube to 2 Remove the side covers 1 by removing the connecting tube clamp 11 the carburetor Then align the subframe with bolts 2 the rear whe
75. e use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability 20 Servicing Your Honda Perform the pre ride inspection page 9 at each scheduled maintenance period Summary of Maintenance Schedule Notes and Procedures Notes 1 Clean after every moto for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride 4 Inspect after the first break in ride Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean L lubricate R replace Maintenance Schedule Perform the Pre ride Inspection page 9 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace Each race Every 3 races Every 6 races Every 9 races Every 12 races NOTE or about or about or about or about or about Ref Page 2 5 hours 7 5 hours 15 0 hours 22 5 hours 30 0 hours THROTTLE OPERATION O O O O OOOO S S a ND sO Chorstaarsystem O O OZ O oS S S n SS aRar OOOO o oe G S S T S T CeRankcasE BREER O O OOOO S S T T sakea OoOO S a G a e PRADIATOR coon O O O oes O S S S o o VALVE CLEARANCE DECOMPRESSOR SYSTEM wora D Ooo o S S T naneo OOOO o oe S o a OPO nene orme OOOO o oe S o o S T T enene esee OOOO S a G WS ts PPISTONANDPISTONRINGS O OOOO S
76. e a chance to make additional checks and adjustments e Clean accumulated dirt from under the fenders and off the wheels suspension components hand grips controls and footpegs A stiff nylon parts cleaning brush works well e Check tire air pressure e Check spoke tension and rim lock nut security e Check sprocket bolt and nut security e Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result e After adjustment check that the chain adjuster 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 26 Servicing Your Honda 1 chain adjuster index marks e Suspend the front wheel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi 0 kPa 0 kgf cm2 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 screws After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent
77. e 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 15 in 257 7 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length 1 16 in 1 5 mm Rear Suspension Adjustments Pin spanners should be used for turning the lock nut and adjusting nut See page 151 for optional pin spanners Spring preload length Standard spring Standard 10 11 in 256 7 mm Min 9 8 in 249 0 mm Spring preload length Optional spring Min Softer 5 3 kgf mm 9 88 in 251 mm Min Stiffer 5 7 kgf mm 9 88 in 251 mm Min Stiffer 5 9 kgf mm 9 84 in 250 mm Adjustments for Competition 111 Rear Suspension Adjustments Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters The high speed damping adjuster 1 is effective when damping adjustment is desired for high speed operation The low speed damping adjuster 2 should be used when damping adjustment is desired at relatively low speeds e Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise e Adjust the high speed compression adjuster in 1 2 turn increments e 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 adjus
78. e required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of the manual The Vin vehicle identification number 1 appears on the Safety Certification Label attached to the right side of the frame RIGHT SIDE 142 Technical Information The frame number 2 is stamped on the right side of the steering head RIGHT SIDE as N D A a 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE ko 3 engine number Specifications Overall length 2 191 mm Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width Cylinder arrangement Single 8 inclined from 5 speed constant mesh Overall height 1 262 mm vertical Primary reduction 2 739 Wheelbase 1 492 mm 3 78 x2 44 in 96 0 62 1 800 Seat height pate aaen Gear ratio Il 1 470 Footpeg height 120 4 Gear ratio III 1 235 Frame Goal 0 16 0 03 mm 0 909 T Exhaust 0 011 0 001 in l I Telescopic fork Left foot operated return Engine oil capacit p F suspension travel 11 0 in 280 mm ene ona y 0 70 US qt 660 cm Gear shift pattern system 1 N 2 3 4 5 Pro link After draining and travel 12 6 in 320 mm oil filter change 0 73 US qt 690 cm g i ee 80 100 21 51M After disassembly 0 90 US qt 850 cm Starting system Kickstarter ire size fron icsi i DUNLOP D742F Halismilesionvel Spark plug De capacity Standard 110 90 19 62M After draining
79. e the six clutch cover bolts 3 and clutch cover 4 3 Y i m f A s N 3 clutch cover bolts 4 clutch cover 4 Remove the six clutch spring bolts and springs 5 Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 5 Remove the clutch pressure plate 6 aj i f d 4 o A aff uf g 5 clutch spring bolts springs 6 clutch pressure plate 6 Remove the washer 7 needle bearing 8 clutch lifter 9 and clutch lifter rod 10 7 Remove the eight clutch discs and seven clutch plates 11 Assemble the clutch lifter needle bearing and washer Turn the needle bearing with your finger The needle bearing should turn smoothly and quietly Replace the needle bearing and washer if the needle bearing does not turn smoothly 7 washer 8 needle bearing 9 clutch lifter Clutch System Clutch Disc Plate Inspection Replace the clutch discs 1 if they show signs of scoring or discoloration Measure the thickness of each clutch disc Service Limit 0 112 in 2 85 mm Replace the clutch discs and clutch plates as an assembly Sa 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 006 in 0 15 mm Replace the clutch discs and plates as a set 2 clutch plate
80. e the spark plug hole packing 1 from e If the old plug is good it onto the crankshaft hole cap 2 the cylinder head cover 1 8 turn after it seats Apply grease to the crankshaft hole cap threads Install the spark plug hole packing to the If installing a new plug tighten it twice to Install and tighten the crankshaft hole cap to the spark plug hole 2 prevent loosening specified torque a First tighten the plug 11 lbf ft 15 N m 1 5 kgf m NGK 3 4 turn after it seats DENSO 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats 1 spark plug hole packing 2 spark plug hole 1 O ring 2 crankshaft hole cap 2 Install the cylinder head cover packing 3 into the groove of the cylinder head cover 4 k 1 spark plug 3 cylinder head cover packing 4 cylinder head cover 64 Servicing Your Honda 3 Install the cylinder head cover 5 4 Tighten the cylinder head cover A bolt 6 and cylinder head cover B bolts 7 to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover A bolt 7 cylinder head cover B bolts 5 Connect the spark plug cap 8 and breather tube 9 8 spark plug cap 9 breather tube Valve Clearance 6 Install the fuel tank and seat page 31 Servicing Your Honda 65 Piston Piston Rings Piston Pin 7 Disconnect the spark plug cap 4 and rem
81. ean 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 Appearance Care Exhaust Pipe Maintenance The exhaust pipe is stainless steel but may became stained by oil or mud Remove heat stains with a liquid kitchen abrasive Servicing YourHonda 95 96 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 firmer 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 firmer 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 0000000008 98 Front Suspension Air Press
82. ebound 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 5 US oz 311 cm Softer spring 10 7 US oz 816 cm Stiffer spring 10 3 US oz 805 cm When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork Oil capacity 13 8 US oz 407 cm3 MAX Oil capacity 12 7 US oz 375 cm3 STANDARD Oil capacity 10 5 US oz 311 cm3 MIN 120 160 200 240 280 Stroke mm Front Suspension Adjustments Front Suspension Disassembly e If your CRF is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for this service 1 Place your CRF on the optional workstand or equivalent support with the front wheel off the ground 2 Remove the number plate bolt 1 and number plate 2 3 Remove the handlebar pad 1 number plate
83. eck the engine oil level by following the steps in Checking amp Adding oil page 37 Refer to Safety Precautions on page 19 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the transmission and clutch Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission Oil Recommendation type transmission oil or 4 stroke engine oil API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label viscosity SAE 10W 40 weight JASO T903 MA standard others without friction modifiers as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molyodenum additives 4 stroke engine oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Transmission Oil e Your CRF does not need oil additives Use the recommended oil e Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lub
84. educes frequency of shifting wider gear ratios e reduces engine rpm at a given throttle setting or ground speed which may allow better rear wheel traction on slippery or loose terrain However e the engine may not pull the higher gearing e the spacing between gears may be too wide e engine rpm may be too low Lower Gearing more rear sprocket teeth e decrease top speed in each gear 132 Adjustments for Competition e increases frequency of shifting narrower gear ratios e increases engine rpm at a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However e spacing between gears may be too narrow e engine rpm may be too high Some tracks may be watered heavily prior to the first race then lightly or not at all during the day This results in a track surface that is slippery during the first few races then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions e Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth t
85. egradable detergent when you wash your CRF Avoid aerosol spray cleaners that contain chloroflur carbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal e Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wastes in separate sealed containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in your area and get instructions on how to dispose of non recyclable wastes 138 Tips Improper disposal of drained fluids is harmful to the environment 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 INCORRECT e Over oiled air cleaner cleaner is over oiled P 43 CORRECT d 2 Check if the insulator LEAKING e Loose insulator clamp is leaking e Damaged insulator NOT LEAKING 3 Check carburetor INCORRECT e Fu
86. el air mixture too pilot screw lean Turn the pilot adjustment P 128 screw out P 128 e Fuel air mixture too rich CORRECT Turn the pilot screw in P 128 4 4 Check carburetor CLOGGED e Contaminants in the jets and accelerator fuel pump for clogs e Not cleaned frequently NOT CLOGGED enough P 123 L 5 Try spark test WAKE OR e Faulty carbon or wet INTERMITTENT fouled spark pulg P 130 SPARK e Faulty ignition control module e Faulty alternator e Faulty ignition coil e Broken or shorted spark plug wire e Faulty ignition pulse generator e Loose or disconnected ignition system wires e Faulty engine stop button 6 Check for LOW e Ring worn low compression e Cylinder worn or damaged CORRECT e Piston worn or damaged e Head gasket not sealing e Valve stick open POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel FUEL FLOW Lack of fuel in tank line at carburetor RESTRICTED P 34 and check for Clogged fuel line clogging P 34 P 34 UNRESTRICTED Aes il Cap breatner tube FUEL FLOW oe Clogged fuel valve P 34 e Clogged fuel filter P 35 2 Remove air DIRTY _ Not cleaned cleaner P 43 frequently enough AIR FILTER P 43 NOT DIRTY 3 Install a larger CONDITION Jet size wrong rejet carburetor main WORSE in the opposite jet p 126 direction P 128 CORRECT 4 Check carbureator CLOGGED e Contaminants in jets for clogging the fuel NO
87. el and tighten the subframe mounting B bolts 2 and subframe mounting A bolts 3 to the specified torque B bolts 22 lbf ft 80 N m 3 1 kgf m A bolts 36 Ibf ft 49 N m 5 0 kgf m BPA fa 7 EEn breather tube 8 fuel tank band 1 side covers 9 air cleaner case cover 2 bolts 10 screw 11 air cleaner connecting tube clamp 3 Loosen the muffler clamp bolt 3 4 Remove the muffler A bolt 4 muffler B 9 Remove the subframe mounting A bolts 12 1 subframe bolt washers 5 and muffler 6 and subframe mounting B bolts 13 Then 2 subframe mounting B bolts remove the subframe 14 by pulling it 3 subframe mounting A bolts straight backward 3 muffler clamp bolt O 4 muffler A bolt 5 muffler B bolt washers 12 subframe mounting A bolts 6 muffler 13 subframe mounting B bolts 14 subframe 32 Servicing Your Honda Subframe Removal 2 Tighten the screw 4 on the air cleaner 8 Install the muffler 11 12 Install the side covers 18 side cover bolts connecting tube clamp 5 9 Install the muffler clamp 12 by aligning the 19 3 Hook the air cleaner case cover 6 tab 13 of the muffler clamp with the cut out 13 Install the seat page 29 4 Install and hook the fuel tank band 7 14 of the muffler 5 Connect the crankcase breather tube 8 11 18 L a gt a ee o Nie WR eS A 18 side covers 11 muffler 13
88. el mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 1 If the level is at or below the LOWER level mark check the brake pads for wear page 82 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 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding 80 Servicing Your Honda Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 82 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 0 8 in 20 mm there is probably air in the brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Brakes Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 e Make sure there are no fluid leaks brake fluid or an equivalent brake fluid or an equivalent e Check for deterioration or cracks in the hoses When adding br
89. embly Replace the fork oil every 3 races or 7 5 hours of running See page 77 for oil level adjustment after changing the fork oil Replace the damper oil every 9 races or 22 5 hours of running See page 102 for damper fork oil replacement Use Pro Honda HP Fork Oil SW 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 Servicing Your Honda Refer to Suspension Adjustment Guidelines page 116 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt Check for signs of oil leakage Damaged or 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
90. engine and radiator cool down before removing the radiator cap 2 Add coolant up to the filler neck if the level is low Inspect the coolant level before each outing A coolant loss of 0 7 2 0 US oz 20 60 cm through the over flow tube is normal If coolant loss is more than this inspect the cooling system Capacity 1 18 US qt 1 12 at disassembly 1 09 US qt 1 03 at coolant change 3 Install the radiator cap securely If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage Servicing YourHonda 41 Coolant Cooling System Inspection SY NN 42 Check the cooling system for leaks see the Honda Service Manual for troubleshooting of leaks Check the water hoses 1 for cracks deterioration and clamp bands for looseness Check the radiator mount for looseness Make sure the overflow tube 2 1s connected and not clogged Check the radiator fins for clogging Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water pump seal is damaged If oil leaks through the check hole the transmission oil seal is damaged See the Honda Service Manual or consult your Honda dealer for replacing the water seal or the transmission oil seal Both seals should be replaced at the same time Servicing Your Hon
91. er turn the pilot screw counter clockwise to richen the mixture The minimum to maximum range of pilot screw adjustments is 1 to 3 turns out from the lightly seated position If you exceed 3 turns out the next larger slow jet is needed If you are under 1 turn out the next smaller slow jet is needed 128 Adjustments for Competition 1 pilot screw Adjustment Procedure 1 Warm up the engine 2 Make 2 3 laps of a course with the standard setting or corrected jetting page 126 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and reading its firing end page 130 It may take more than two or three laps to get a good spark plug reading with a new spark plug 3 Change carburetor settings or select suitable carburetor jets taking into consideration the engine conditions and factors for temperature and altitude page 126 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Turn the fuel valve OFF Drain the remaining fuel in the float bowl by loosening the drain screw 2 and disconnect the fuel line from the fuel valve 6 Loosen the connecting and insulator band screws Rotate the carburetor Remove the float bowl plug 3
92. er 1 with compressed air thickness in intervals of 0 025 mm 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 the micrometer e Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3 000 mm 1 valve lifter 1 80 mm 1 825 mm 1 85 mm 1 875 mm Servicing YourHonda 59 Valve Clearance 3 Install the valve lifters into the camshaft 4 Install the camshaft holder assembly onto the Camshaft Holder Assembly holder assembly 4 cylinder head with the intake cam lobes 5 facing up as illustrated below Apply the oil to the camshaft holder assembly bolt threads and seating surface Tighen the camshaft holder assembly bolts 6 to the specified torque 10 Ibf ft 14 N m 1 4 kgf m 1 Install the newly selected shims 1 on the valve spring retainers 2 Do not let the shims fall into the crankcase Tighten the camshaft holder assembly bolts in a criss cross pattern in 2 or 3 steps 3 valve lifters 4 camshaft holder assembly 1 shims 2 valve spring retainers 2 Apply molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the camshaft and outer sur
93. er cap 1 Check that the oil level is between the upper 2 and lower 3 level marks in the inspection window e If the oil is at or near the upper level mark you do not have to add oil e If the oil is below or near the lower level mark add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap Repeat steps 1 4 Reinsert the engine oil filler cap Check for oil leaks Engine Oil Changing Engine Oil amp Filter 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil filler cap 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 tighten the engine oil drain bolt with a new sealing washer to the specified torque 12 Ibf ft 16 N m 1 6 kgf m 1 engine oil filler cap 2 engine oil drain bolt 3 sealing washer 7 It is recommended to replace the oil and filter every 6 races or about every 15 0 hours However if you replace only the oil before the recommended interval see page 21 cont d Servicing Your Honda 37 Engine Oil 8 Remove the left engine guard bolt 4 and left engine guard 5
94. er s Club Honda sss scceieeancnatenctaanecerssnensese 159 riding COON E sa stasena A E E 2 basic operation woecedeaseuedeerececwns sevacuaheesceartaveres 11 DO a e A E d important safety information cccccee 2 safety precautions sxisonsscrpanctrtactartedcroaviansewans 2 safety a few words about 00 Safety Message important information ssscccecieyessassssevnssavercasavess 2 important precautionS sssseereeesssssseeeeeesss 2 DE eE E R R E E 4 Mane ACS sssaaa eei 19 riding precautionS ssssssseeeeessesssssseeereresss 12 Schedule maintenance cee eecesecescescesceecees 20 Serial UMD CUS sademneteteoiedonrseasenctetcaensosiaasnacteranel 142 Service US OMIT A A 158 ATON e E A 156 spare Par ea E 152 Spark KNOCK sssrripsrnreredenrerice rretara rar rnat 34 spark plug maintenan GE sssrin eissa 54 Pe e RE 130 specifications seeeeesssssssssssssssssseesseeeeeererseeee 143 spring pre load rear suspension 0008 111 starting SU Ne PE E E EE A muacueencane 13 troubleshooting cccccccccessssseeeeeeeeeeeeees 139 steering stem Inspection vicierscnctesernererancocateronceels 92 Stopping engine sep recwaatrotanasvatuneevousteewaneteeeerewses 14 TA A e A EE E E E E E 137 SUDANIE ee drecses ikir eserse seucteaseeetesssesesenaanesendae 32 cont d Index 163 Index suspension TOME II O E vende A E EEE T 74 IS AREE EEE EET N A I E A ET 75 suspension a
95. face of the each valve eS lifters 3 4 camshaft holder assembly 5 intake cam lobes 6 camshaft holder assembly bolts 60 Servicing Your Honda 5 Rotate the primary drive gear bolt 7 crankshaft clockwise and align the punch mark 8 with the index mark 9 Make sure the piston is at TDC Top Dead Center on the compression stroke 7 Doy YA x 7 en 7 primary drive gear bolt 8 punch mark 9 index mark 6 Place the cam sprocket 10 and align the timing mark 11 on the cam sprocket with the A mark 12 on the camshaft holder assembly Install the cam chain 13 over the sprocket without rotating the sprocket a 7 10 cam sprocket 11 timing mark 12 A mark 13 cam chain Valve Clearance 7 Clean and apply a locking agent to the cam sprocket bolt threads coating width 0 26 in 6 5 mm from tip Temporarily install the cam sprocket bolt 14 by aligning the bolt holes of the cam sprocket and camshaft Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the sprocket bolt 14 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Rotate the primary drive gear bolt crankshaft clockwise one turn and tighten the other sprocket bolt to the specified torque see above Do not let the bolts and sprocket fall into the crankcase 10 cam sprocket 14 cam sprocket bolts cont d Servicing Your Honda 61 Valve Clearance
96. ffect on performance Both engine performance and long term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the cleaner Closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 43 Use the Honda genuine air cleaner or an equivalent air cleaner specified for your model Using the wrong Honda air cleaner or a non Honda air cleaner which is not of equivalent quality may cause premature engine wear or performance problems Air Cleaner Housing Sealing Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with silicone sealer if there is any doubt to its sealing integrity Use Hon
97. g a passenger can cause an accident in which you and others can be hurt Wear Protective Gear Whether you re practicing to improve your skills or riding in competition always wear an approved helmet eye protection and proper protective gear Take Time to Get to Know Your CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilites or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safety 2 Motorcycle 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 Maintaining your CRF properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured Accessories amp Modifications Accessories amp Modifications Installing non Honda accessories removing original equipment or modifying your CRF in any way that would change its design or operation could seriously impair your CRF s handling stability and braking makin
98. g it unsafe to ride A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories Motorcycle Safety 3 Safety Labels Read this label carefully and don t remove it If the label comes off or becomes hard to read contact your Honda dealer for replacement IMPORTANT INFORMATION Operator only No passengers This Honda Motorcycle is sold as is wihtout warranty and the entire risk as to quality and performance is with the buyer Read owner s manual A DYANNI T This vehicle is designed manufactured and sold NEVER OPEN WHEN HOT for competition use only It does not conform to Federal Motor Vehicle Safety Standards or OL COMAn aN DUN yon U S EPA Noise and Emissions Standards Ss OY Operation on public streets roads highways or for off road recreation is illegal State and Federal laws prohibit operation of this vehicle except in an organized racing or competitive event on a closed course Or by permit issued by the local governmental agency having jurisdiction 4 Motorcycle Safety Operating Controls Read this section carefully before you ride It Operation Component Locations 000008 6 presents the location of the basic controls on your CRF Operating Controls 5 Operation Component Locations hot start lever clutch lever front bra
99. g stemnut 80 1 2 Fork bridge upper pinch Tie a N bolts 3 a Fork bridge lower pinch las a f bolts 4 Handlebar upper rr Leh ee holder bolts 16 5 Handlebar holder nuts 32 6 7 Frontaxlenut 65 Lyo BOS 7 Front axle pinch bolts 15 RSA KX eneet MOE ront engine e Upper engine hanger plate bolts engine side Sio frame side S E E T A Shock absorber upper 32 44 45 NOTE1 lower 32 44 45 NOTE Swingarm pivot nut te o NOTE T Fork fork damper 25 34 35 fork cap rea e E Rear shock arm nuts swingarm side NOTE 1 3 39 shock link side 5 4 54 Rear shock Hs nuts Ei 45 as D o1 O NO IW 8 Shock m lock nut EN 19 Kickstarter arm bolt 1 U nut 2 UBS nut 3 Apply oil to the threads and flange surface 4 Alock bolt 5 SH bolt O cont d Technical Information 145 Torque Specifications Frame 40 k we 38 20 21 SAN 40 33 ON ZY ae Ne 2 5 E Noe N OK D Wk A v3 oS A Sas J 146 Technical Information O N 20 Front brake master cylinder holder bolts mounting bolts Rear brake disc nuts 5 Brake pedal pivot bolt Spokes R 00 9 Subframe bolts Q Q9 D Q GO amp w CO N _ NOTES im locks Drive chain roller O Forkcenterbolt 2 Disc cover bolts 3 Fo
100. gap 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 ten minutes before taking a plug reading a brand new plug will not color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere page 130 Check the carburetor fuel system and ignition timing 8 Tighten the spark plug e If the old plug is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening a First tighten the plug NGK 3 4 turn after it seats DENSO 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats 9 Connect the spark plug cap 10 Install the fuel tank and seat page 31 Refer to Safety Precautions on page 19 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule page 21 The checking or adjusting of the valve clearan
101. ge or other cause freshness of fuel owner modifications such as exhaust system holes in the air cleaner etc ignition timing compression If the above check out then adjust the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition Refer to the list on page 151 for the optional carburetor parts To prevent engine damage always adjust the main jet before adjusting the jet needle If there is any doubt always choose the next richer Jet so there is a margin for safety Adjustments for Competition 127 Carburetor Adjustments amp Tuning Tips Carburetor Minor Adjustments The standard carburetor settings are ideal for the following conditions sea level altitude and 68 F 20 C air temperature If your conditions are different you may need to adjust the carburetor settings using the tuning information on pages 126 and 127 Confirm your settings are correct before proceeding Minor Adjustments 1 Adjust the carburetor setting using the tuning information on pages 126 and 127 2 When the engine is warm enough to run without the choke push the choke knob down to its off position 3 Adjust the pilot screw 1 to obtain the best off idle performance If the engine blubbers rich exiting a corner turn the pilot screw clockwise to lean the mixture If the engine surges lean exiting a corn
102. 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 radiator pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and water in this motorcycle This coolant solution is recommended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 19 1 With the engine cold remove the radiator cap 1 and check coolant level The coolant level is correct when it is at the bottom of the 1 radiator cap 2 filler neck Coolant A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the
103. going slower when in reality you ve decreased your time by increasing your speed with better traction These gearing recommendations should be evaluated by considering your ability your riding style and the track Choosing the correct tire tread pattern and rubber compound can affect your placing in competition The tires on your CRF offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in 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 g
104. h 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 the center electrode and a platinum tip in the side electrode Be sure to observe the following when servicing the spark plug e Do not clean the spark plug If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one Use only a wire type feeler gauge to check the spark plug gap if necessary To prevent damaging the iridium tip of the center electrode and platinum tip of the side electrode never use a leaf type feeler gauge Do not adjust the spark plug gap If the gap is out of specification replace the spark plug with a new one 54 Servicing Your Honda Spark Plug Replacement amp Inspection 1 Remove the seat and fuel tank page 30 2 Disconnect the spark plug cap 1 3 Clean any dirt from around the spark plug base 4 Remove the spark plug 2 _ 1 spark plug cap 2 spark plug 5 Check the electrode for wear or deposits the sealing gasket 3 for damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 039 0 043 in 1 0 1 1 mm 3 sealing gasket 4 spark plug
105. h lever freeplay 3 8 13 16 in 10 20 mm at the tip of lever Tighten the lock nut lock nut integral cable adjuster increase freeplay 6 Adjust the cable end adjuster for minor adjustement Clutch System Clutch Lever Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected cont d Servicing Your Honda 49 Clutch System Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster 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 50 Servicing Your Honda Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained T D KG RNK Ea a Ll FT he aaa SRA 3 3 lock nut increase 4 integral cable adjuster decre
106. h mixture for starting The mixture discharges through the orifice 5 into the cylinder gt i So o I 1 choke knob 2 starter jet 3 air passage 4 throttle valve 5 orifice Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot start lever is pulled back the hot start valve 1 opens allowing air to be supplied to the main bore 2 through the hot start air passage 3 This extra air enters the air fuel mixture from the slow circuit resulting in a lean condition 1 hot start valve 2 main bore 3 hot start air passage Adjustments for Competition 119 Carburetor Adjustments amp Tuning Tips Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened As the throttle valve 1 opens the pump rod 2 depresses 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 _ a TTS if bot Aa Il FOTRA S 7 5 1 throttle valve 2 pump rod 3 diaphragm 4 inlet check valve 5 pump chamber 6 outlet check valve 7 accelerator nozzle 120 Adjustments for Competition Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture e
107. hamber 5 oil hole NOTICE 15 Blow out the oil from the fork damper spring 2 i l l chamber using compressed air to the oil hole Be careful not to bend or damage the fork Wipe the oil completely off the fork damper damper piston rod when the piston rod is stroked 16 If you can not use compressed air remove the 13 Blow the extra oil off to the fork damper 2 a bean aL pana a a ouvert Damm me ror minutes and drain the oil from the fork 6 _t damper piston rod to full stroke F i kamt amper spring chamber 3 9 in 100 mm is 2 fork damper 6 piston rod SS 10 13 2 fork damper 11 spring chamber 12 pressure release screw 13 fork cap 10 soft jaws 104 Adjustments for Competition Fork Assembly 1 Drain the fork oil from the outer tube slider by placing it upside down About 7 cc of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 20 C 1 oP Q NA ddd 1 outer tube slider Front Suspension Adjustments Amount of fork oil left in the fork 2 Tighten the lock nut 2 fully and measure the without damper and spring unit cc thread length A as shown ey 9 0 3 ss esias sandara 0 43 0 51 in 14 19 mm Wipe the oil completely off the fork damper 16 0 C 32 F 14 F 10 C 50 F 12 S9 20 C 68 F AP Se 30 C 86 F Amount of fork oil Inverted time minutes 2 lock nut A thread leng
108. ick increments until the desired initial travel compression damping is obtained Lower the oil level by 0 2 oz 5 cc Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil level by 0 2 oz 5 cc Adjustments for Competition 117 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard settings If the suspension is too stiff soft adjust according to the chart below Sand track Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring preload Example Turn the compression damping adjuster and especially rebound damping adjuster to a stiffer setting Increase standard Race Sag 0 2 to 0 4 in 5 to 10 mm Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Adjust the compression and rebound damping adjusters to stiffer settings Install the optional stiff spring Reduce standard Race Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment e Always begin with the standard settings e Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 6 turn increments at a time Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment
109. ie E Teese Terr itt rete 86 Exhaust Pipe Muffler ccccceccsssssssssseeeeeeees 89 Additional Maintenance Procedures 92 Appearance Care eeeeessssssseseereesssssssseeeeessss 94 ADJUSTMENTS FOR COMPETITION 97 Front Suspension Adjustments 0000000008 98 Rear Suspension Adjustments sseeee 111 Suspension Adjustments for Track Conditions occ venvactsesscoevgeecsevens vasemeeveteussteacen 115 Suspension Adjustment Guidelines 116 Carburetor Adjustments amp Tuning Tips 119 Chassis AC USHMEIING 54cs 00208vesacesvenaxesexecdnbenerse 131 RS AIDS E E AE E E A S S 132 Tire Selection for Track Conditions 133 Personal Fit Adjustment cceeeeeeeeeeeees 134 MD E E TE E E E E E 135 Transporting Your Motorcycle ccccceees 136 Storing Your Honda eeeessseeceeeeeeeeeeeeees 137 You amp the Env iOniMen t esccesecedsessnsaioveorntseotenenee 138 TP OUDIE SMOOUIIG assesses sar ccneservesausnecetsetedeuacseeatl 139 TECHNICAL INFORMATION 0008 141 Vehicle Identification 33 ss5cassniaanasssederndsencnsionsans 142 DS CIC AU ONS scissor neern RE 143 TORQUE Specifications Sse csncsseesaedenentaowersaceevens 144 High Altitude Carburetor Adjustment 147 Oxygenaled SIG ooo ccdacecsnateresstaseeteaaretaseseaee 148 Competition Logbook cceecceceeeeeeeeeeeeeeees 149 Optional Parts List ssicosos2cosssnuns
110. iece of wire to the cam chain to prevent it from falling into the crankcase Do not let the bolts sprocket and cam chain 7 fall into the crankcase i i eas T t aoe 4 cam sprocket bolts 5 cam sprocket 6 cam chain 58 Servicing Your Honda Make sure the piston is at TDC Top Dead Center on the compression stroke Loosen the camshaft holder assembly bolts 7 in a crisscross pattern in 2 3 steps Remove the camshaft holder assembly bolts camshaft holder assembly 8 intake valve lifters 9 and shims 10 As you remove the camshaft holder assembly the intake valve lifter and the intake valve shim may be sticking in the camshaft holder assembly Keep the intake valve lifters and the shims so as to allow identification of the originally installed location such as intake or exhaust right or left 7 camshaft holder assembly bolts 8 camshaft holder assembly Do not let the valve lifters and shims fall into the crankcase iE N 2 i 8 camshaft holder assembly 9 intake valve lifters 10 shims 6 Remove the valve shims Valve Clearance j 2 Measure the shim thickness and record it 3 Calculate the new shim thickness using the Shim Selection Seventy three different thickness shims 2 are equation below available from the thinnest 1 200 mm 1 Clean the valve shim contact area in the valve thickness shim to the thickest 3 000 mm B C D A lift
111. immediately 1 drain screw 3 Tighten the drain screw cont d Adjustments for Competition 121 Carburetor Adjustments amp Tuning Tips 4 Disconnect the fuel line 2 from the fuel 10 Remove the hot start cable holder 6 12 Remove the throttle cables 9 by loosening valve 3 5 Remove the fuel tank page 30 6 Remove the subframe page 32 7 Loosen the insulator band screw 4 the throttle cable lock nut 10 9 6 hot start cable holder 9 throttle cables 11 Remove the throttle drum cover bolt 7 and 10 throttle cable lock nut throttle drum cover 8 2 fuel line 3 fuel valve 4 insulator band screw 8 Disconnect the throttle position sensor connector 5 9 Remove the carburetor 7 throttle drum cover bolt 8 throttle drum cover 5 throttle position sensor connector 122 Adjustments for Competition Carburetor Adjustments amp Tuning Tips 3 Remove the link arm set screw 6 When installing the floating valve 8 onto the Carburetor Disassembly When installing the link arm set screw apply a throttle valve 5 make sure the floating locking agent to the link arm set screw threads valve s flat side faces out and the hole 9 1 Remove the carbretor top bolts 1 and 4 Remove the throttle valve 5 throttle valve faces down carburetor top 2 roller 7 and floating valve 8 ku 5 ae e Q A as y 2 1 carburetor top bo
112. in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include e basic track conditions altitude and temperature e carburetion changes e suspension settings e chassis adjustments tested and selected e gearing e tire selection e air pressure Competition Records e your placings e thoughts to improve performance next time both yours and your CRF s e strategy notes Maintenance Records e regular interval maintenance e repairs e running time on engine e running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft operators do but without the benefit of an electrical hourmeter All running time is broken down into hours and tenths of an hour each six minutes represents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include e Your placing in each moto and overall finishi
113. inder gasket 3 B dowel pin 2 A dowel pins 4 Clean the any gasket material off the cylinder 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out 70 Servicing Your Honda Piston Piston Rings Piston Pin 5 Apply fresh engine oil to the cylinder wall 6 Install the cam chain guide 7 and fit the cam piston outer surface and piston rings chain guide tab 8 in the cylinder cut out 9 Cylinder Head Installation Route the cam chain 4 through the cylinder Push the guide until it bottoms in the 5 crankcase guide hole 1 Install the dowel pins 1 and new cylinder Install the cylinder over the piston rings by hand while compressing the piston rings 6 Do not damage the piston rings and cylinder walls head gasket 2 Do not let the dowel pins fall into the crankcase 7 cam chain guide 8 cam chain guide tab 9 cylinder cut out 1 dowel pins 2 cylinder head gasket 4 cam chain 6 piston rings 5 cylinder cont d Servicing YourHonda 71 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 4 Install the washers and cylinder head nuts and tighten to the specified torque 44 Ibf ft 59 N m 6 0 kgf m Do not let the washers and nuts fall into
114. ing or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride Inspection Items Refer to Pre ride Inspection page 9 22 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 page 21 S Engine Oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston cylinder and crankshaft Also replace engine oil filter often to ensure the greatest service life Frequent changes will also assure consistent performance of power and response page 37 General Competition Maintenance Spark Plug Cap Install a small plastic tie wrap around the spark plug cap to reduce any possibility of it loosening or of water penetration Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 40 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great e
115. ip when the drive chain is reassembled You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets 2 Loosen the muffler clamp bolt 4 Exhaust Pipe Muffler Inspection 3 Remove the muffler A bolt 5 muffler B 1 Check the flange bolts and exhaust pipe joint bolt washers 6 and muffler 7 nuts for tightness 2 Check the exhaust pipe and muffler for cracks or deformation A damaged exhaust pipe and muffler may reduce engine performance Muffler Removal 1 Remove the seat bolt 1 side cover bolt 2 and right side cover 3 4 muffler clamp bolt 6 muffler B bolt washers 5 muffler A bolt 7 muffler 1 seat bolt 3 right side cover 2 side cover bolt Exhaust Pipe Muffler Servicing Your Honda 89 Exhaust Pipe Muffler Muffler Installation 1 Remove the gasket 1 2 Install the muffler clamp 2 and new gasket onto the exhaust pipe 3 1 gasket 2 muffler clamp 3 Install the muffler 4 4 Install the muffler clamp 5 by aligning the tab 6 of the muffler clamp with the cut out 7 of the muffler 4 muffler 6 tab 5 muffler clamp 7 cut out 90 Servicing Your Honda 5 Tighten the muffler B bolt washers 8 and muffler A bolt 9 to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 6 Tighten the muffler clamp bolt 10 to the specified tor
116. ke lever engine stop button throttle grip choke knob fuel valve shift lever rear brake pedal 6 Operating Controls Before each ride you need to make sure you and your Honda are both ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustment see page 97 Are You Ready to Ride cccessesseeeeeeeeeeees 8 Is Your Motorcycle Ready to Ride 4 9 Pre ride Inspection Before Riding Before Riding 7 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 97 Whether you re preparing for competition or for practice always make sure you are e In good physical and mental condition e Free of alcohol and drugs e Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride 8 Before Riding A WARNING Not wearing a helmet increases the chance of serious i
117. l 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 O psi 0 kPa 0 kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings Remove the pressure release screw 1 Check that the O ring 2 is in good condition Install and tighten the pressure release screw to the specified torque 0 9 Ibf ft 1 2 N m 0 1 kgf m a z 4 5 AA W i va N K i WN 1 pressure release screw 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
118. lange of the element to prevent dirt intrusion 13 Align the set tab 9 of the air cleaner with the A mark 4 of the air cleaner housing by rotating the air cleaner 3 clockwise Tighten the retaining bolt 1 securely 1 air cleaner retaining bolt 3 air cleaner 7 hole 5 air cleaner holder 8 air cleaner tab 6 holder tab 6 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 is made in two pieces inner and outer which cannot be separated 7 Clean the inside of the air cleaner housing 8 Allow the air cleaner to dry thoroughly After drying soak the air cleaner in clean Pro er Honda Foam Filter Oil or an equivalent air gt 4 9 retaining bolt two access top tabs air cleaner A mark set tab cleaner oil Apply air cleaner oil to the entire surface inner and outer and rub it with both hands to saturate the air cleaner with oil Squeeze out excess oil 44 Servicing Your Honda Crankcase Breather Refer to Safety Precautions on page 19 Service more frequently if your CRF is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube Draining 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits 2 Reinstall the crankcase breather tube plug EZKE 1 crankcase
119. lean the leak jet 12 O rings 14 diaphragm 13 spring 20 pump rod 22 link lever 21 rod passage 19 float bowl 26 leak jet 124 Adjustments for Competition 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 top cover bolts 1 5 lbf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 Ibf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 lbf ft 2 1 N m 0 2 kgf m e After installing the carburetor adjust the throttle cable 1 free play and hot start cable 2 free play e After installing the carburetor check the throttle sensor connector 3 for correct routing as necessary e After installing the carburetor check the air vent hoses 4 and overflow hose 5 for kinking or pinching and correct routing as necessary 1 throttle cables 2 hot start cable 3 throttle position sensor connector Carburetor Adjustments amp Tuning Tips 4 air vent hoses 5 overflow hose Adjustments for Competition 125 Carburetor Adjustments amp Tuning Tips k All jetting is based on Standard Tuning Recommendations e Standard jetting e Unmodified Engine For the following recommendations to be TEMPERATURE accurate y
120. linder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 68 iA CA A i o C 3 Y an we A oF ZARN A Wp A K Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Honda Thread Lock or an equivalent prior to torquing the nuts Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace the fuel valve O ring 1f there are any signs of damage or deterioration page 35 Fuel Contamination Refer to Fuel System in your Owner s Manual page 34 and in this supplement Fuel System page 34 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 35 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 121 For maximum efficiency drain and replace fuel that has remained in your fuel tank for more than a month
121. locks for looseness cece eeeceeeeeeeeeeeeees 83 Front and rear suspension for proper OP Al OU ceirnin EE EREE 74 75 Front and rear brakes check operation 79 Drive chain for correct slack and adequate IUDr AUT ON sti cacscoteose rentet 86 Drive chain guide sliders and guide rollers for damage OF WEAL sccccseeseeeeeeeeees 86 87 Exhaust pipe Muffler inspection removal and installation 89 90 91 Every possible part for looseness such as cylinder head nuts engine mounting bolts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt wcccccnscsdsnrcnicsendesednerancceeroness 92 93 Before Riding 9 10 Before Riding This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions ccccccccceeeeeeeeeeeeeees 12 Starting amp Stopping the Engine ceeeeeee 13 Prepara ON cus sccrasspavuasesacpaneedebecetienucsceeesese 13 Starine Procedure sospressa 13 Flooded Eng INE sererai 13 How to Stop the Engine is csaseccrsenesevenssavenncanus 14 Break in Guidelines cecessesssssssececeeeeeeeeeeees 15 Basic Operating Instructions Basic Operating Instructions 11 Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time please review the Important Safety
122. lts 2 carburetor top 5 throttle valve 8 floating valve 2 Remove the jet needle holder 3 and jet 9 hole needle 4 from the throttle valve 5 5 throttle valve 7 throttle valve roller 6 link arm set screw 8 floating valve 3 jet needle holder 4 jet needle 5 throttle valve cont d Adjustments for Competition 123 Carburetor Adjustments amp Tuning Tips 5 Remove the accelerator pump cover screws 7 Remove the holder screw 15 throttle stop 9 Measure the float level 23 with the float 10 and accelerator pump cover 11 screw holder 16 float bowl screws 17 level gauge 24 during float tab just tube guides 18 and float bowl 19 contacting the float valve and the carburetor intake 25 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 10 accelerator pump cover screws 11 accelerator pump cover 15 holder screw 16 throttle stop screw holder 6 Remove the O rings 12 spring 13 and 17 float bowl screws diaphragm 14 T a ete oat bow Clean the diaphragm 23 float level 24 float level gauge 8 Remove the pump rod 20 25 carburetor intake Clean the pump rod and rod passage 21 Install the pump rod into the link lever 22 Push the rod forcibly into the link lever until it snaps into place 10 Remove the leak jet 26 from the float bowl 19 C
123. m 2 8 kgf m Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers Drive Chain Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing 1 Remove the master link retaining clip 1 with pliers Do not bend or twist the clip Remove the master link 2 Remove the drive chain 1 retaining clip 2 master link 2 Clean the drive chain in high flash point solvent and allow it to dry 3 Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceable Replacement chain D I D 520DMA2 cont d Servicing Your Honda 87 Drive Chain 4 Inspect the sprocket teeth for wear or damage We recommend replacing the sprocket whenever a new chain is installed Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket goU Worn Sprocket Teeth
124. 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 Take care to prevent catching your fingers between the chain and sprocket Remove the drive chain clean it and lubricate the chain and sprockets Be sure the chain is wiped clean and is dry before applying the chain lube Before amp After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash yo
125. mbly 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 2 fork damper 7 bushing 8 O ring cont d Adjustments for Competition 103 Front Suspension Adjustments 10 Tighten the fork cap 1 while holding the cut 12 Screw in the lock nut 9 to the fork damper 14 Drain the extra oil from the fork damper out of the fork damper 2 using the lock nut piston rod 6 fully spring chamber 11 oil hole 5 wrench 3 to the specified torque 22 bf ft 30 N m 3 1 kgf m By doing this procedure about 0 6 US oz 17 cm of fork fluid will be drained from the damper spring chamber through the oil hole and cause 5 9 US oz 173 cm of fork fluid to be left in the chamber 6 piston rod 9 lock nut Turn the rebound adjuster and compression adjuster counterclockwise to the softest position Check the fork damper piston rod sliding surface 1 fork cap 3 lock nut wrench for damage VUPRARAAA al a Apply fork oil to the fork damper piston rod f eDi aiani Arr Er a l z 11 Hold the fork 2 j igh sliding surface oe pled AR ees oat fae Cover the fork piston rod end with soft jaws 10 FFIEC position and pump the fork piston rod 6 to 3 9 in 100 mm slowly several times to prevent fork damage 11 spring c
126. move 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 30 0 hours of running i i EA i 1 J a _ N 1 m f s E N fe i ia DOTT l ih agi i i gt a 1 piston pin clip 2 piston pin 3 piston 4 Spread each piston ring 4 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 4 piston ring Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your authorized Honda dealer for correct Service Limit measurements Piston Ring Installation 1 Remove the carbon deposits from the piston head and piston ring grooves with the removed ring 2 Apply engine oil to the piston rings and install the piston rings Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation e To install the oil ring install the spacer first then install the side rails e Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 9
127. naawseresanienosebotoon 151 Spare Parts amp Equipment ccccceecceeeeeees 152 Wiring PAG ssa ccd stesenncainctowehseabeenosieeom 153 CONSUMER INFORMATION cce0e8 155 Authorized Manuals ccccccccccceseeeeeeeeeeeeees 156 Contacting THOM as is5siersccssscaisesancelattaveagnsbovese 157 Your Honda Dealer eeeneeennnseesssesssssssseeee 158 The Honda Rider s Club USA only 159 TABLE OF CONTENTS csscssssssssssees 160 INDE A ororena E E 162 QUICK REFERENCE 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 the safety labels on your CRF Important Safety Information eceeeeees Important Safety Precautions cc0eee Accessories amp Modifications 00eeeeeeereees Safety Labels Motorcycle Safety 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 As an experienced rider you know there is much you can do to protect yourself when you ride The following are a few precautions we consider most important Never Carry a Passenger Your CRF is designed for one operator only Carryin
128. ng position e Thoughts on what you could do to improve your performance next time e Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events e Any places on the course where you chose the wrong line and were passed too easily e Notes on strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular maintenance items you ll want to record in your logbook should include e Dates and results of cylinder piston and ring examinations 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 l remember to keep a close eye on these areas in the future Technical Information 149 O 5 T S E re a a Date Running Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use j 50 Technical Information Optional Parts List These
129. njury or death ina crash Be sure you always wear a helmet eye protection and other protective apparel when you ride Competitive riding can be tough on a motorcycle so it s important to inspect your CRF and correct any problems you find before each ride Check the following items page numbers are at the right A WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems Is Your Motorcycle Ready to Ride Pre ride Inspection Check the following before each ride STIG oil ley lera af Transmission oil level ccceeesessseeeeeeeeeees 40 Coolant for proper level cncsex dessevedswcsseseesienes 41 Cooling system and hoses for condition 42 Spark plug for proper heat range carbon fouling and high tension cord terminal for OOREEN 54 Air cleaner for condition and Contamina Oisein a 43 Clutch lever adjustment and freeplay 49 Hot starter operation and freeplay 53 Breather drain for cleaning ccccceeeees 45 Steering head bearing and related parts for condition s ssessssscessssssiersrerssoreescsersesisrsves 92 Carburetor throttle operation ccc08 46 Tires for damage or improper inflation B SM e E A 84 Spokes for lOOSeNESS sssssseeeeeeeeeeeeeees 83 Rim
130. ns a section devoted to Motorcycle Safety as well as a number of Safety Messages throughout the manual Safety Messages are preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions PANN You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION You CAN be HURT if you don t follow instructions Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgement Safety Messages Contents MOTORCYCLE SAFETY cescssceeeees 1 Important Safety Information eeees 2 Important Safety PrecautionS cceeeeeees 2 Accessories amp Modifications cccccccccccccceceeees 3 A IASG eenn 4 OPERATING CONTROLS cc cccccssseeees 5 Operation Component Locations 00cccc0e 6 BEFORE RIDING siccssstsserevsssescnsssousssdsaecsccesesane 7 Are You Ready to Ride ccesssesssseeeeeeeeees 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection sc seissetaseisceconee versace vasnteneesnsss 9 BASIC OPERATING INSTRUCTIONS 11 Safe Riding PreCautiOms osicis cctevehasesessessdoroovs 12 Starting amp Stopping the Engine ee 13 Break in Guidelines up csnssserctpzecnntsvescrseredsnagarsenes 15 SERVICING YO
131. nspect 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 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 83 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Honda Thread Lock or an equivalent and tighten to the specified torque Servicing YourHonda 25 Before amp After Competition Maintenance Between Motos amp Practice Maintenance After practice or between motos you hav
132. nters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 air passage 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters the venturi past the needle jet Baffle 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 Carburetor Circuit Functions The carburetor has several major circuits each providing the fuel air mixture over a given portion of throttle valve opening These major circuits overlap as shown below MAIN JET JET NEEDLE TAPERED SECTION JET NEEDLE STRAIGHT SECTION SLOW JET PILOT SCREW 1 8 1 4 1 2 3 4 FULLY FULLY CLOSED OPEN Main jet The main jet affects fuel air ratio from half 1 2 to full throttle 4 4 The size should be reduced at higher altitudes Honda carburetor jet sizes are numbered in increments of 2 or 3 When changing the main jet size increase or decrease it gradually until the desired jetting is obtained Because Honda jet size numbers do not correspond with other carburetor manufacturer s jet size numbers use
133. o adjustments of the shock assembly only Puncture or exposure to flame may also result in an explosion causing serious injury Service or disposal should only be done by your Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the official 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 89 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and remove the rear subframe s three mounting bolts then remove the subframe See page 32 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 mm 1 lock nut 2 adjusting nut 3 pin spanners 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 8 in 249 0 mm To decrease spring pre load Loosen th
134. o 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 cost is some sections where the gearing feels wrong If you decide to try a gearing change have someone check your times with a stopwatch before and after the change to get an accurate appraisal of the change Seat of the pants feelings can t be trusted Eliminating wheelspin with a gearing change can make you feel like you re
135. oil filler hole until oil starts to flow out of the oil check bolt hole Tighten the oil check bolt with a new sealing washer and transmission oil filler cap Repeat steps 1 4 After inspecting the oil level or adding oil tighten the oil check bolt to the specified torque 7 Ibf ft 10 N m 1 0 kgf m Replacing Transmission Oil 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil has drained tighten the transmission oil drain bolt with a new sealing washer to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 6 Fill the crankcase with recommended oil Capacity 0 62 US qt 0 59 at oil change 7 Check the transmission oil level by following the steps in Checking amp Adding Oil this page 1 transmission oil filler cap 2 transmission oil drain bolt 3 sealing washer 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
136. oil insufficient quantity improper oil e Air cleaner dirty leaking because of Quick Reference Record important information here ameno SyS neo S SS Owner s Name adiess SSCSC SSSSSCSSS Prone Dealer s a e Phone Service Mgr Maintenance The maintenance schedule page 21 lists service frequencies for each race or about 2 5 hours every 3 races or about 7 5 hours and every 9 races or about 22 5 hours unleaded gasoline pump octane number of 91 or higher Pre ride Inspection Check the items listed on the Pre Ride inspection checklist each time before you ride page 9 Fuel Capacity Engine oil Transmission oil Tires Tire Pressure cold Spark Plug Drive Chain tank 1 90 US gal 7 2 2 Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke engine oil or an equivalent Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdem additives 4 stroke engine oil or an equivalent 80 100 21 51M 110 90 19 62M Front Rear DUNLOP D742F DUNLOP D756 Type bias ply tube type Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm standard IFR8H11 NGK or VK24PRZ11 DENSO optional IFR9H11 NGK or VK27PRZ11 DENSO D I D 520DMA2
137. omfortable and more responsive to your control input Control Positioning e Position the control levers so that you can use them comfortably when seated and standing e 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 Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first q 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 134 Adjustments for Competition e 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 amp Shape e Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved forward either 3 mm using
138. ondition Main Jet Adjustment long straights next larger uphill sections high humidity next smaller raining hotter than 113 F 45 C Carburetor Adjustments amp Tuning Tips Once you ve adjusted the carburetor for temperature and altitude it shouldn t need major readjustment unless race conditions change drastically However there are some unique atmospheric conditions or race day situations that may require additional adjustments They are as follows To prevent engine damage always adjust the main jet before adjusting the jet needle Always choose the next richer jet if there is any doubt so there is a margin for safety Main Jet Go richer on the main jet by one number when the track has a very long straightaway or uphill section a high percentage of sand or the track is muddy e Go leaner on the main jet by one number when it is very humid or raining or it is hotter than 113 degrees F After using the chart and making any adjustments for special conditions it shouldn t be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting changes are necessary check for worn crankshaft seals air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner air leaks float level clogged carburetor jets spark plug fouling improper heat ran
139. only Honda jets Carburetor Adjustments amp Tuning Tips Jet Needle The jet needle controls fuel air mixture over fully closed to 3 4 throttle The straight section 1 affects throttle response at smaller throttle openings By changing the position of the clip 2 in its groove you can improve acceleration at medium low and medium speed 9 1st LEANER 2nd 3rd 2 4th 5th 6th 7th RICHER r4 1 1 straght section 2 clip Slow Jet and Pilot Screw The slow jet and pilot screw affects fuel air ratio over fully closed to 1 4 throttle Adjust the pilot screw to obtain the best off idle performance e Ifthe engine blubbers rich exiting a corner turn the pilot screw clockwise to lean the mixture e Ifthe engine surges lean exiting a corner turn the pilot screw counterclockwise to richen the mixture The minimum to maximum range of pilot screw adjustment is 1 3 8 to 2 1 8 turns out from the lightly seated position If you exceed 2 1 8 turns out the next larger slow jet is needed If you are under 1 3 8 turns out the next smaller slow jet is needed Carburetor Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by loosening the drain screw 1 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills
140. ooves 1 brake pads 2 front brake caliper 3 brake disc 82 Servicing Your Honda Rear Brake Pads Inspect the 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 5 pitza any dag minimum thickness indicator C7 g P W I 6 brake disc 4 brake pads 5 rear brake caliper 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 Wheels Refer to Safety Precautions on page 19 2 Tighten any loose spokes and rim locks 3 to the specified torque Maintenance of spoke tension and wheel trueness Spoke roundness is critical to safe motorcycle front 2 7 lbf ft 3 68 N m 0 4 kgf m operation During the first few rides spokes will rear 2 7 lbf ft 8 7 N m 0 4 kgf m loosen more rapidly due to the initial seating of Rim Lock 9 Ibf ft 12 N m 1 2 kgf m the parts Excessively loose spokes may result in 3 Check wheel rim runout If runout is instability at high speeds and the possible loss of noticeable see the Honda Service Manual for control It s also important that the rim locks are inspection instructions secure to prevent tire slippage It is not necessary to remove the wheel
141. optional handlebar lower holders or 6 mm by rotating the standard holders 180 degrees Refer to the Service Manual for installation instructions Be sure to check control cable and wiring harness routing after the adjustment e Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your particular body size or riding style Each of the ergonomic dimensions of the machine were determined to suit the greatest possible number of riders based on an average size rider Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle cccceeeees 136 Storing Your TON in sssecsnctcccesnnceavennsntexesepiensies 137 Preparation for Storage ccccccceeeeeeeeeeeeeees 137 Removal from Storage ccccccccccssseeetsees 137 You amp the Environment cccccccssseeseeeeeees 138 Troubleshooting sisrate 139 Tips Tips 135 Transporting You
142. ore 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 I8 Servicing Your Honda Maintenance Safety This section includes instructions on how to e Read the instructions before you begin and perform some important maintenance tasks make sure you have the tools and skills Some of the most important safety precautions required follow However we cannot warn you of every conceivable hazard that can arise in performing To help prevent the motorcycle from falling maintenance Only you can decide whether or over park it on a firm level surface using the not you should perform a given task optional work stand or a maintenance stand to provide support A WARNING To reduce the possibility of a fire or Failure to properly follow maintenance explosion be careful when working around instructions and precautions can cause gasoline Use only a non flammable high you to be seriously hurt or killed flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes Always follow the procedures and sparks and flames away from all fuel related precautions in this owner s manual parts Important Safety Precautions e Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exh
143. ou must use the standard settings as a baseline Also don t change any of the settings until you ve determined what changes are necessary Standard settings 1 1 2 turns out Adjustment Pilot screw opening Nova Adjustments for Altitude amp Temperature All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture 10 000 ft 3 050 m to 7 500 ft 2 300 m 7 499 ft 2 299 m to 5 000 ft 1 500 m 4 999 ft 1 499 m to 2 500 ft 750 m 2 499 ft 749 m to 1 000 ft 300 m 999 ft 299 m to Sea level CENT FAHR PS SJ JN CLIP JN MJ PS SJ JN CLIP JN MJ PS SJ JN CLIP JN MJ PS SJ JN CLIP JN MJ PS SJ JN CLIP JN MJ 4 16 39 60 STANDARD 15 27 59 80 26 38 79 100 37 49 99 120 Legend PS Pilot Screw opening from fully seated SJ Slow Jet JN CLIP Needle Clip position JN Jet Needle MJ Main Jet 126 Adjustments for Competition Special Tuning Conditions There are some unique atmospheric conditions or situations that may require additional adjustments It should not be necessary to go more than one jet size richer or leaner to fine tune your CRF If larger jetting changes are necessary check for air leaks blocked or restricted exhaust or fuel systems or a dirty air cleaner C
144. ove 11 Position the piston at top dead center on the Cylinder Head Removal the ignition coil nut 5 ignition coil bolts 6 compression stroke page 55 and ignition coil 7 Remove the camshaft holder assembly page 1 Clean the area above the engine before 8 Remove any dirt from around the spark plug 57 disassembly to prevent dirt falling into the base 12 Loosen the radiator hose clamp screw 9 and engine Ei disconnect the radiator hose 10 2 Drain the radiator coolant after cooling the ae l motorcycle page 42 3 Remove the seat and fuel tank page 29 4 Remove the muffler page 89 and subframe page 32 5 Remove the carburetor page 121 6 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 4 3 41 a a Pis A aA i on ei n 4 spark plug cap 6 ignition coil bolts 5 ignition coil nut 7 ignition coil 9 radiator hose clamp screw 10 radiator hose 9 Remove the cylinder head cover page 55 10 Remove the spark plug 8 F oop 7 A f i i i j f 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 8 spark plug 66 Servicing Your Honda Piston Piston Rings Piston Pin 13 Remove the engine hanger nut 11 engine 14 Remove the cylinder head bolts 17 17 Remove the dowel pins 21 cylinder head hanger A bolt 12 and fuel hose guide 13 15 Loosen the cylinder bolt 18 gasket 22 and cam chain guid
145. pecified torque 7 Ibf ft 10 N m 1 0 kgf m T 9 O ring 10 clutch cover 12 Lubricate the O ring 11 rear brake pedal 12 pivot and pivot bolt 13 with Honda Lithium Grease and tighten the pivot bolt to the specified torque 27 Ibf ft 36 N m 3 7 kgf m Connect the brake pedal return spring 14 if it was removed 13 pivot bolt 14 return spring 11 O ring 12 brake pedal 13 Add the transmission oil page 40 Refer to Safety Precautions on page 19 Hot Start Lever Freeplay left handlebar 1 hot start lever 2 hot start lever freeplay Inspection Check freeplay 1 16 1 8 in 2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster clockwise will increase free play and turning it counterclockwise will decrease free play After adjustment tighten the lock nut 3 lock nut increase 4 cable adjuster decrease Hot Start Lever Servicing Your Honda 53 Spark Plug Refer to Safety Precautions on page 19 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions IFR8H11 NGK or VK24PRZ11 DENSO IFR9H11 NGK or VK27PRZ11 DENSO Optional Use only the recommended type of spark plugs in the recommended heat range Using a spark plug wit
146. per mounting bolts 22 brake caliper cont d Adjustments for Competition 109 Front Suspension Adjustments 27 Install and tighten the number plate bolt 30 Install the handlebar pad 31 g Ae 5 Pr A A TRK A y A N 32 axle pinch bolts i 30 number plate bolt 31 handlebar pad To avoid damage when torquing the axle pinch l l bolts be sure the axle is seated firmly onto the 28 With the front brake applied pump the fork left fork leg clamp inner surface up and down several times to seat the axle and check front brake operation 30 Clean the threads of the disk cover bolts and axle holder thoroughly Apply locking agent to the bolt threads Install the disc cover 33 and tighten the bolts 34 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m tighten the right fork pinch bolts 32 to the specified torque 33 disc cover 34 bolts 15 Ibf ft 20 N m 2 0 kgf m 31 Turn the rebound damping adjusters back to their original settings 110 Adjustments for Competition The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited t
147. pring If initial travel is stiff after installing the optional stiff spring Test soft compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil level in increments of 0 2 oz 5 cc Entire travel too soft Install the optional stiff spring e Front end shakes Test stiffer compression damping adjustments in one click increments e Fork bottoms over any type of terrain Increase rebound damping in one click increments 116 Adjustments for Competition Suspension Adjustment Guidelines D S a Stiff Initial travel too stiff suspension e Stiff on small bumps while riding at full throttle in a straight line e Stiff on small cornering bumps e Front end wanders while riding at full throttle in a straight line Middle travel too stiff e Stiff on bumps when cornering e Front end wanders when cornering e Stiff suspension on bumps especially downhill bumps e While braking front end dives during initial travel then feels stiff Final travel too stiff e Doesn t bottom on landings but feels stiff e Stiff on large bumps especially downhill bumps e Stiff on large bumps when cornering Entire travel too stiff e Stiff suspension on any type of terrain Test softer
148. procedures described in page 112 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 2 turn increments If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Bounce the rear of the motorcycle up and down and check for smooth suspension action 2 Remove the subframe page 32 3 Check for a broken or collapsed spring 4 Check the rear shock absorber 1 for a bent 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 Honda dealer Suspension Servicing Your Honda 75 Suspension Recommended Fork Oil suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change Refer to front suspension removal on page 99 1 Clean the fork assembly especially the sliding surface of the slider and dust seal 2 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 3 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 F CK 27 LZ Z 1 outer tube 2 fork damper 3 lock nut wrench 4 slider lower end 76 Servicing Yo
149. que 15 Ibf ft 21 N m 2 1 kgf m aie ji 3 i r j aa ak 2E ae a a 8 muffler B bolt washers 10 muffler clamp bolt 9 muffler A bolt 7 Install the right side cover 11 and side cover bolt 12 8 Install the seat bolt 13 and tighten the bolt to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 11 right side cover 13 seat bolt 12 side cover bolt Exhaust Pipe Removal Remove the muffler page 89 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 W 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket Exhaust Pipe Installation 1 Install a new exhaust pipe gasket 1 exhaust pipe 2 and exhaust pipe joint nuts 3 and tighten to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 90 Exhaust Pipe Muffler Servicing Your Honda 91 Additional Maintenance Procedures Refer to Safety Precautions on page 19 Steering Head Bearing Inspection 1 With your CRF on a box or workstand front wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings ae EF wey ue q i ha i T k i i J k T oo a i 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
150. r Motorcycle If you use a truck or motorcycle trailer to To secure your CRF brace the front wheel transport your Honda we recommend that against the front of the truck bed or trailer rail you follow these guidelines Attach the lower ends of two straps to the tie down e Use a loading ramp hooks on your vehicle Attach the upper ends of e Make sure the fuel valve is off the straps to the handlebar one on the right side e Secure the motorcycle in an upright position the other on the left close to the fork using motorcycle tie down straps Avoid using rope which can loosen and allow the Check that the tie down straps do not contact any motorcycle to fall over 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 136 Tips 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 Storag
151. r cover bolts 7 cylinder bolt 8 cylinder head bolts cylinder head cover bolts clutch cover bolts water pump cover bolts transmission oil check bolt crankshaft hole cap exhaust pipe joint nuts N Nr S ST Sa S 1 2 3 4 5 9 Servicing Your Honda 93 Appearance Care Refer to Safety Precautions on page 19 Frequent cleaning and polishing will keep your Honda looking newer longer Frequent cleaning also identifies you as an owner who values his motorcycle A clean CRF is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations e To clean your CRF you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CRF or discolor the seat and decals If your CRF is still warm from recent operation give the engine and exhaust system time to cool off We recommend the use of a garden hose to wash your CRF High pressure washers like those at coin operated car washes can damage certain parts of your CRF The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings driving dirt inside and needed lubrication out 94 Ser
152. r 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 114 Adjustments for Competition Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too firm for your weight will not allow the rear tire to hook up under acceleration and will pass more bumps on to you 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
153. ressor Arm Clearance Adjustment 1 Make sure that the piston is at top dead center on the compression stroke page 55 Measure the right exhaust valve clearance by inserting a feeler gauge 1 between the right side rocker arm 2 and shim 3 Right Exhaust Valve Clearance EX 0 011 0 001 in 0 28 0 03 mm 3 shim 1 feeler gauge 2 right side rocker arm 2 Pull out the feeler gauge between the right side rocker arm and shim Valve Clearance 3 Loosen the lock nut 4 and decompressor arm adjusting screw 5 Insert the feeler gauge 1 between the adjusting screw and right side rocker arm 6 DECOMPRESSOR CLEARANCE RIGHT EXHAUST VALVE CLEARANCE 0 014 IN 0 35 mm Example If measured right exhaust valve clearance is 0 011 in 0 28 mm decompressor clearance is 0 011 in 0 28 mm 0 014 in 0 85 mm 0 025 in 0 63 mm Turn the adjusting screw until there is a slight drag on the feeler gauge Hold the adjusting screw and tighten the lock nut to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 1 feeler gauge 4 lock nut 5 decompressor arm adjusting screw 6 right side rocker arm Recheck the clearance between the adjusting screw and right side rocker arm Servicing YourHonda 63 Valve Clearance Spark Plug Installation Crankshaft Hole Cap Installation Cylinder Head Cover Installation Tighten the spark plug 1 Coat a new O ring 1 with engine oil and install 1 Remov
154. rication and clutch performance arya lan NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10 20 30 40 50C 20 O 20 40 60 80 100 120F cont d Servicing Your Honda 39 Transmission Oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard is labeled on the oil container For example the following label shows the MA classification PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification 40 Servicing Your Honda Checking amp Adding Oil 1 2 l pA transmission oil filler cap 3 sealing washer oil check bolt Run the engine for 3 minutes then shut it off Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CRF in an upright position on a level surface Remove the transmission oil filler cap 1 and 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
155. rip on wet loamy terrain but less impressive grip on a hard surface Tire Selection for Track Conditions If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on the transmission Complete consumer information can be obtained from the various tire manufacturer representatives and dealers Some general recommendations for specific terrain follow Hard Slick Soil Use tires with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface The rubber compound needs to be softer for hard ground in order to hook up but not so soft that the knobs roll over easily and 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 Adjustments for Competition 133 Personal Fit Adjustments The following suggestions may make your ride both more c
156. rk protector bolts 4 Muffler mounting bolts A B 5 Muffler clamp bolt Driven sprocket nuts Seat mounting bolts Front brake reservoir 9 Rear brake reservoir O Fork air pressure release akRWNM Torque kgfem ee E 30 3 1 NOTE 4 16 1 6 NOTE 1 16 1 6 NOTE 1 36 37 04 fo 04 fo O1 O Go Q s ie No N O1 G Q 2 12 12 27 2 2 3 68 3 7 front rear N 12 o S O 1 2 NOTES 1 2 NOTE1 1 o ne 12 gt upper lower upper lower _J Ae i 22 36 CQ i 1 O SSS ee eS NJol 4 Niwlrmlolo O1 MDIOIOJ O1 21 15 15 N co Nd 2 P Po sl InNia alw I N WINO o o p Po O N i 1 0 1 0 0 1 2 0 1 U nut UBS nut Apply oil to the threads and flange surface Alock bolt SH bolt When operating this motorcycle at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifica
157. s the wheels closer together improves turning response increases weighting traction on the rear wheel and lightens weighting on the front wheel With your CRF you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 131 Gearing You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional driven sprockets Like the optional springs these sprockets are listed in the Optional Parts List section of this manual page 151 Unless you have the required mechanical knowhow tools and an official Honda Service Manual sprocket changing should be done by your Honda dealer Higher Gearing less driven sprocket teeth e increases top speed in each gear provided the engine will pull the higher gearing e r
158. s to Axles amp Wheel Bearings perform the recommended service in the Maintenance Schedule page 21 However See the Honda Service Manual for inspection information for wheel removal is provided for information emergency situations 1 Check the axle shaft for runout 2 Check the condition of the wheel bearings Wheel Rims amp Spokes j N j po g Yr a Br i il oe DN BT y l a______ 2 1 wheel rim 3 rim lock 2 spoke 1 Inspect the wheel rims 1 and spokes 2 for damages Servicing Your Honda 83 Tires amp Tubes Refer to Safety Precautions on page 19 To safely operate your CRF the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire repair and replacement Air Pressure Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also
159. sonvoscs 134 Handlebar Position Width amp Shape 134 FIPS se Re 135 Transporting Your Motorcycle scceceees 136 Storing Your Honda sseseeeeessssssssererrsssssse 137 Preparation for Storage ccccceseeeeeeeeeees 137 Removal frrom Storage cccccccccseeccssssees 137 You amp the Environment cccccssssseeeeeeees 138 Troubleshooting sxc sasavorhonctoierenarsecenaattecnseeiecancs 139 TECHNICAL INFORMATION 141 Vehicle Identification serssnesiervniseverncseversscaanenzeoe 142 SCO CAINS orsin Aari 143 Torque Specifications ccccccscccsssssssssssseeeeees 144 High Altitude Carburetor Adjustment 147 Oxygenated CIS oe ose varsetn eevee avveteuseeacacst aie 148 Competition Logbook ceseeeseecceeeeeeeeeeeees 149 Optional Parts List 0 0 200saceaassacerencsacrsnnneees 151 Spare Parts amp Equipment cccccccccsecssseees 152 Wiring DA STAM ox caeresiaseaslsncervasatatvcsevemnsterenereven 153 CONSUMER INFORMATION ccce008 155 Authorized Manuals visssesvciaxeccrcseocsecessbresveisees 156 Contacting Honda eeeeeeeeeeeeessssssssesssssseee 157 Your Honda De ASC isicsosssssaccesansavacersuwecsotsnvenenes 158 The Honda Rider s Club USA only 159 Table of Contents Table of contents 161 Index ICCC 58 ONS A EEE E E 3 adjustments altitude and temperature eeeeeeessessseee 126
160. ssion or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 6 If it is free it is an indication that the valves are closed and that the piston is on the compression stroke If it is tight and the valves are open rotate the primary drive gear bolt 360 and realign the punch mark to the index mark inserting a feeler gauge 1 between the valve lifters 2 and cam lobe 3 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shim w 1 feeler gauge Valve Clearances 2 valve lifters IN 0 006 0 001 in 0 16 0 03 mm 3 cam lobe EX 0 011 0 001 in 0 28 0 03 mm If intake valve clearance and exhaust valve Jey clearance need adjustment see Camshaft Holder eS Assembly Removal page 57 and select the correct shim for each valve 3 primary drive gear nat 5 index mark a punch mark 6 exhaust rocker arm 56 Servicing Your Honda Measure the decompressor arm clearance by inserting a feeler gauge 1 between the decompressor arm adjusting screw 6 and right side rocker arm 7 1 feeler gauge 6 decompressor arm adjusting screw 7 right side rocker arm DECOMPRES
161. stssees 13 fork front suspension adjustment ccccceees 98 front SUSPENSION INSPCCTION ccccceeeeees 74 oil TECOMMENAATION cccceceeeeessessseeeeees 76 frame MUD CL sssi srin ninina 142 front brake lever adjustment ccsisascsecasienensazinnvarncees 79 front suspension maintenance sesssse0000000 98 fuel IN aE E teveseendee 34 Ni E E E E E E 33 HE COMME MC ALIGN ccnp ierenascucstaarrcrsrvesomtekeuten 34 TTC MAS fs sisenaisnivncetenntetndsiewgentorretecsaguvadeaxsteseons 34 BS ON EE E E EE 34 DA IT e a eon oe ee E ene 148 tank CAPAC sstcsernctwsonsreiaasehtuvewsmaiseriaaieeedaen 34 VS AEE E EE EEEE 13 gap spark plug siconsancoseteigeatexayenteiadondscicenntendectes 54 PAS OMION sea E EE 148 O ea a Ar O 34 US AE E E EE E 132 guidelines suspension adjustment 116 handlebar INspectiOn cccccccceeeeeeeeeesseeeeees J2 high altitude carburetor adjustment 147 Honda COMUAC LIED soie rE NEE 157 Rid r 5 scien ctsavocwcocaenustecrtuetetsesnesceoeaencees 159 Service Manual seisseen i n 156 your d al ft sssrinin rierien 158 identification vehicle niccccessunwiavssvensencssnievsasvces 142 TONG speed OS uss ysrterercternnescenyeceen senses 48 inspection pre ride eesssssseeeeeersssssseseeeerssss 9 labels Safely asics ee r Ei 4 logbook competition eeeseessseeeeeeesssssseeeeeee 149 maintenance after COMIPCUUOM 4 ia
162. t 8 center bolt Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten the lock nut to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 2 lock nut 8 center bolt 2 lock nut 5 stopper tool 6 push rod 7 O ring 8 center bolt 9 adjusting rod 106 Adjustments for Competition 10 Apply fork oil to the center bolt 8 O ring Remove the special tool or mechanic s stopper tool while applying pressure to the fork damper Install the center bolt to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m T Wa A WZ a 8 N 8 center bolt 11 Measure the length between the axle holder and outer tube Standard 12 5 0 1 in 317 2 mm 12 Compare the length 10 at assembly and at disassembly They should be the same length If the length at assembly is longer than at disassembly check the center bolt and lock nut installation 10 length 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 11 fork oil Front Suspension Adjustments Fork Oil Capacity Optional Stiffer 0 48 kgf mm Fork Spring Standard 0 46 kgf mm Fork Spring No mark factory products Cy 4 scribe marks 2 scribe marks aftermarket parts Standard oil 12 7 US oz capacity 375 cm3 Maximum oil 13 8 US oz Slightly stiffer
163. t model year and frame VIN serial number e date of purchase e dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 157 Your Honda Dealer Once you purchase your new Honda get familiar with the organization of your Honda dealer so you can utilize the full range of services available The service department is there to perform regular maintenance and unexpected repairs It has the latest available service information from Honda The parts department offers Genuine Honda parts Pro Honda products Hondaline accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department 158 Consumer Information Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or
164. ten the handlebar holder nuts to the Install the fork protectors 19 fork protector wheel hub Insert the front axle shaft through specified torque bolts and brake hose clamp bolts 20 the wheel hub from the right side Make sure 32 Ibf ft 44 N m 4 5 kgf m Tighten the fork protector bolts to the the front axle shaft is seated firmly onto the specified torque left fork leg clamp inner surface Tighten the 5 2 lbf ft 7 N m 0 7 kgf m front axle nut 23 to the specified torque 25 65 lbf ft 88 N m 9 0 kgf m _ gt 22 Align the brake caliper 22 and hose with the F oS UV A _ left fork leg making sure that the brake hose Tighten the left axle pinch bolts 24 to the a is not twisted An improperly routed brake specified torque A 29 hose may rupture and cause a loss of braking 15 Ibf ft 20 N m 2 0 kgf m efficiency 23 Clean the threads of the caliper mounting Vp bolts 21 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper 22 on the slider and tighten the caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 25 handlebar 26 mounting rubbers 27 washers handlebar holder nuts 26 Install the number plate 28 by aligning its hole with the tab 29 on the steering stem 23 front axle nut 24 left axle pinch bolts 18 fork protector bolts 19 fork protectors 20 brake hose clamp bolts 28 number plate 29 tab 21 cali
165. tep instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good An ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 156 An optional tool kit may be available Check with your Honda dealer s parts depertment Before You Service Your Honda The Importance of Maintenance e 18 Maintenance Safety sscssessivercsasiassanscsestescnnveatenesee 19 Important Safety Precautions 0008 19 Maintenance Schedule c cssaiecaninsenccreendecedersavesea ser 20 General Competition Maintenance 22 Before amp After Competition Maintenance 26 Between Motos amp Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat ede 0 01072 ee ee Keien 29 Fuel Tank Removal sovscnccsnncantcnnicsadomucsecoovbondwacses 30 Subframe REMIOV Aho ic coenscsarcsiesoscatseisisdacesienaverees 32 Service Procedures Fluids amp Filters allio boy Alle 4 E E mercer arte teeter 34 Eao mne eee setae wees A 36 Transmission Oil occcunsonecsnacuneceatesadomuctecoowboedswacns 39 Ox 076 1 1 eee EE 41 AN CICCANTI ee ee ee we 43 Crankcase Breather sis
166. ter 112 Adjustments for Competition 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 1 2 2 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 9 clicks and the punch marks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 17 positions or more Turning the adjuster one full turn advances the adjuster 4 positions e Rebound damping can be increased by turning the adjuster clockwise e Be sure that the rebound adjuster is firmly located in a detent and not between positions 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
167. th 3 Blow out the oil completely off the fork spring 3 using the compressed air Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 spring cont d Adjustments for Competition 105 Front Suspension Adjustments 4 Set 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 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation holder 5 Temporarily install the fork damper to the Pa 2 ork l Push out the fork damper piston rod from the t R n axle holder of the slider by pushing the fork o damper Apply pressure to the fork damper and insert the special tool or mechanic s stopper tool 5 between the axle holder and lock nut Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the piston rod until it stops Check the push rod installation by turning the push rod right and left 9 7 Install a new O ring 7 to the center bolt 8 Install the fork center bolt to the fork damper piston rod aligning the center bolt adjusting rod 9 to the push rod Tighten the center bolt fully by hand 2 lock nu
168. th a chamois or a soft towel Lubricate the drive chain to prevent rusting Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance THAN 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 cl
169. the crankcase Tighten the cylinder head nuts in a criss cross pattern in 2 or 3 steps 3 cylinder head 4 cylinder head nuts washers T2 Servicing Your Honda 4 Install the cylinder bolt 5 and cylinder head bolts 6 to the specified torque 7 Srn o N m 1 0 ach 5 cylinder bolt 6 cylinder head bolts 5 Install the left engine hanger plate 7 right engine hanger plate 8 and engine hanger B bolts 9 and tighten the engine hanger B bolts until lightly contact the frame Install the engine hanger A bolt 10 fuel hose guide 11 and engine hanger nut 12 and tighten the engine hanger nut until it lightly contacts the engine hanger plates Tighten the engine hanger B bolts to the specified torque 19 Ibf ft 26 N m 2 7 kgf m Tighten the engine hanger nut to the specified torque 40 lbf ft 54 N m 5 5 kgf m 7 8 9 10 11 12 left engine hanger plate right engine hanger plate engine hanger B bolts engine hanger A bolt fuel hose guide engine hanger nut Piston Piston Rings Piston Pin 6 Connect the radiator hose 13 to the cylinder 9 Install the crankshaft hole cap page 64 12 Install a new exhaust pipe gasket 21 head and tighten the radiator hose clamp 10 Install the cylinder head cover page 64 exhaust pipe 22 and exhaust pipe joint nuts screw 14 securely 11 Install the ignition coil 15 ground terminal 23 and tighten to the specified torque i
170. ticucscsessescseisecsctinwsecorancnnssecens 45 Engine AME OLS EEEE P AE E EE EE E 46 Engine Idle Speed ness savsonssseuataverstueeteivtacceesdedvet 48 Chah Sy EM ea E RE 49 Hot siar LEVE esra nN EE 53 PE EIO iaa E EEEE 54 Valve Gl 1 6 1 6 lt a ee ee ere ea 55 Piston Piston Rings Piston Pin cccseeeeeee 66 Servicing Your Honda Chassis DUES le MS TON eiro 74 Front Suspension Inspection cc0006 74 Rear Suspension Inspection cccceee8 75 Recommended Fork Oil ceeeeeeeeeeeeeeees 76 Fork Coil C Dange xs x coctoussonanceiaranctavarnttenenceed 76 BOSS EEEE ETE IEE EA T 79 RO E EE A E EEE A ES 83 Trese OOpa eE 84 Diye CHa eese E 86 Exhaust Pipe Muffler ccccccccssssessssseseeseees 89 Additional Maintenance Procedures 92 Appearance CATE aironctareccoonisasnancnwenaaiodenteewencoe 94 Servicing Your Honda 17 The Importance of Maintenance Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to get maximum performance during each moto Careful pre ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section A WARNING Improperly maintaining this motorcycle or failing to correct a problem bef
171. tions may cause engine overheating and damage High Altitude Carburetor Adjustment Technical Information 147 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 148 Technical Information If you notice any
172. to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a loss of traction and slower lap times Suspension Adjustments for Track Conditions Adjustments for Competition 115 Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF using the methods described on pages 98 115 Remember to make all adjustments in one click increments Test ride after each adjustment Front Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below Sand track Adjust to a stiffer position
173. tween the axle holder 27 and lock nut 30 while applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole 32 fork damper assembly 34 spring 33 fork assembly 102 Adjustments for Competition 3 Remove the fork cap assembly 4 from the fork damper 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 2 fork damper 4 fork cap assembly 4 Empty the fork oil from the fork damper 2 by pumping the damper rod several times 2 fork damper 5 oil hole 5 Clean the fork cap and fork damper threads 6 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 4 US oz 190 cc 6 7 Imp oz 2 fork damper 7 Pump the fork damper piston rod 6 slowly several times to bleed the air from the fork damper 2 2 fork damper 6 piston rod Front Suspension Adjustments 8 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper as shown Oil Level 1 65 1 85 in 42 47 mm 1 65 1 85 in 42 47 mm 2 fork damper 9 Apply fork oil to the bushing 7 and new O ring 8 on the fork cap 1 assembly Extend the fork damper piston rod to maximum holding it install the fork cap asse
174. ude carburetor adjustment see page 147 Idle Speed Adjustment 1 Turn the pilot screw 1 in until it is lightly seated and record the number of turns Turn the pilot screw out the same number of turns pr 1 pilot screw 2 If the engine is cold start it and warm it up 3 minutes Then shut it off 3 Connect a tachometer to the engine 4 Shift the transmission into neutral Start the engine 5 Keep the motorcycle in an upright position 6 Adjust idle speed with the throttle stop screw 2 Idle speed 1 700 100 rpm 48 Servicing Your Honda aa 2 throttle stop screw Refer to Safety Precautions on page 19 Clutch Lever Adjustment The distance between the tip of the clutch lever and the grip may be adjusted Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected 1 lock nut 2 adjuster 1 Loosen the lock nut 1 2 To position the clutch lever farther away from the handgrip turn the adjuster 2 counterclockwise To position the brake lever closer to the handgrip turn the adjuster clockwise 3 Tighten the lock nut 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns Cable end adjuster 3 cable end adjuster increase freeplay decrease freeplay N Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutc
175. under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank 34 Servicing Your Honda Refueling Procedure Fuel Tank Capacity 1 90 US gal 7 2 2 Ate 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube in the steering stem nut A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Fuel Valve and Hose 3 fuel line 1 fuel valve 2 fuel filter 1 Check the fuel valve 1 and fuel filter 2 for contamination 2 Check for leaks 3 Check the fuel line 3 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Check for interference between the frame and tank and adjust if necessary Fuel System Fuel Filter The fuel filter is mounted on the bottom the fuel tank Dirt accumulated in the filter will
176. ur CRF or use cleaners refer to Appearance Care page 94 Servicing Your Honda 27 Maintenance Component Locations hot start lever clutch lever fd front brake fluid reservoir front brake lever Po De coisa i AES fuel fill cap spark plug choke knob rear suspension air cleaner spring pre load engine idle adjuster speed a p Eg a front brake breather caliper BO tube K gt N P A D QA i gt SU x engine oil inspection window transmission oil drain bolt engine oil drain bolt engine oil filler cap drive chain 28 Servicing Your Honda J w UF SAS SZ rear Suspension high speed rear Suspension low speed o GSA Z N mp throttle grip front Suspension compression damping adjuster rear suspension rebound damping adjuster damping adjuster damping adjuster rear brake pedal rear brake fluid reservoir front suspension rebound damping adjuster transmission oil check bolt transmission oil filler cap rear brake caliper Seat Removal Refer to Safety Precautions on page 19 Installation 1 Install the seat 2 while aligning the seat Removal front prong 3 with the seat bracket 4 and 1 Remove the seat bolts 1 seat rear prong 5 with the frame 6 2 Remove the seat 2 by sliding it backward 2 Install and tighten the seat bolts to the specified torque
177. ur Honda The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD 7 NO GOOD 1 1 outer tube 5 dust seal 6 guide bushing 7 slider 4 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 9 of the fork damper 1 outer tube 9 oil hole 5 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 1s left inverted for about 20 minutes at 20 C 68 F 1 oP Y J H L Ai J wp 1 outer tube Amount of fork oil left in the fork within damper and spring unit Cc 0 C 32 F 10 C 50 F N aa 20 C 68 F wee nn 30 C 86 F 0 20 40 60 80 100 120 140 160 Inverted time mimites 6 Pour the recommended fork oil into the outer tube Fork Oil Capacity Standard 0 46 kgf mm Fork Spring No mark factory products or 2 scribe marks CJ aftermarket parts Slightly stiffer as it nears full compression Standard oil 12 7 US oz capacity 375 cm3 13 8 US oz 407 cms Maximum oil capacity 10 5 US oz 311 cms Minimum oil Capacity Slightly softer as it nears full compression Optional Softer 0 44 kgf mm Fork Spring CS 3 scribe marks Standard oil 12 9 US oz capacity 380 cms
178. ure 98 Front Suspension Damping ccceeeeees 98 Fork SPENE Secere neninn E 99 Front Suspension DisassembDly 0 99 Damper CG ANG Ca scstossccesnncectosenosawseemsnise 102 FOLK AASS COI DY enara 105 Rear Suspension Adjustment seecceeeeees 111 Rear Suspension Spring Pre Load 111 Rear Suspension DampiIn cccceceees 112 Rear Suspension Race Sag cseeesseeeeees 113 Suspension Adjustments for Track Conditions EEE EE ER I ET E ate 115 Suspension Adjustment Guidelines 116 Carburetor Adjustments amp Tuning Tips 119 Carburetor Components cccccceseeeeees 119 Carburetor Circuit Functions w c isesvacmacivonesss 121 Cat DUretor KK CMO allxccscossccssonssst siasexgutancers 121 Carburetor DIsassem BLY sssseccsesccuessecesenes 123 Carburetor Assembly cccccscriscrsswssdessonduabacscate 125 Standard Tuning Recommendations 126 Adjustments for Altitude amp Temperature 126 Special Tuning Conditions eccseeeeees 127 Pre Adjustment Checks cisiciscsveensssssazeleciees 127 Carburetor Minor Adjustments 128 Spark plug R ading sce ccaaiesndecscelicsonessecoscice 130 Chassis AAC USEC os cctsenccstsessanssesondlaseusiieenese 131 Por Eod ooe E 131 Fork Peis it Ane les cnsceacsnraciiesvvedactiniedesietedes 131 Wore IDIS erani R 131 E A EE E E E 132 Tire Selection for Track Conditions
179. vecisdwectnsssaconsadesdaesteeigeeans 26 before amp after competition cccceeeeeees 26 between Motos amp PLractiCe cccseeeeeeeeeees 26 component locations ssssseeeesssssssseeeresss 28 general competition sssseeeeesssssssseeeresss 22 TAR OTA AUG reeter aer Rra 18 SAG EY ye pan chenst oussuascsouronsgul dice A 19 BC I oc ce estes Seas eedeagaeeteen sone cndenee enke 20 manoal Sel V1CO p ccusaaminceondasaneaceritneaniebioes 156 modifications occasesventensneaues edt ecsnnd weeeromedersavieeoeres 3 oil TOU Ke E E E AA A E 76 transmission ssssssssseeeesssssssseeeeesssssssseeeeesssss 39 operating COMTO eer N E 5 TRIG ECUICTIONS aeiiae iorri ERr a E a l1 operation component locations sssssssesseeee 6 optional pa cocns ce yewoee eden sevessenexcseverntieus se ooe 151 O KC e E 132 oxygenated TUCIS si cunnsseveseevavndsanenadsesconsnniieaneces 148 pads DRAG je ia ciee vane eavoenencsereetenoasstee ogee EF NEESER 82 parts OPUOM al ices iystaneies cesetanternsmsersetos anes eae 151 personal fit adjustments cccesseeeeseeeeeeees 134 poginge cd 4028 1 cee ere nee ene eet 34 Ps SO E E E E E EEE T 54 pre load rear SUSPENSION sssssssssseeeressss 111 pre ride 1S DE CH OM ctien nerves stivvaiorevectevstvestossunetandees 9 DEOLE CEN 6 appare ericscasuecensesanerastenemaueradesanreroennnes 2 rear SUSPENSION maintenance cceeeeeeeeeeees 111 Rid
180. vicing Your Honda 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 motorcycle You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Washing Your Motorcycle with a Mild Detergent 1 Rinse your CRF thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover is for removing stains on the non coated aluminum frame only 4 After washing rinse your CRF thoroughly with plenty of clean water to remove any residue Dry your CRF wi
181. y can be distinguished from other optional springs 1 Richer at 1 16 to 1 4 throttle General flow characteristics Leaner Technical Information 151 Spare Parts amp Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding In addition to the usual nuts and bolts consider the following Spare Parts spark plugs air cleaner clean amp oiled sealed in a plastic bag optional carburetor jets needles chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front visor amp covers handlebar grips levers brake clutch amp hot start clutch lever handlebar mount clutch cable hot start cable throttle assembly throttle cable shift lever rear brake pedal spokes front amp rear each side sprockets larger amp smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins Additional Spares front brake master cylinder rear brake assembly wheels amp tires front amp rear mounted clutch plates amp transmission oil seat ignition components 152 Technical Information radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end

Front Suspension Adjustments

Contents

Download Pdf Manuals

Related Search

Related Contents