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1. Upper roller bolt 9 Ibf ft 12 N m 1 2 kgf m Lower roller nut 9 Ibf ft 12 N m 1 2 kgf m 1 chain slider 2 Check the chain guide slider 2 for wear Replace the chian guide slider if it is worn to the bottom of the wear limit groove 3 1 upper drive chain roller 2 lower drive chain roller 2 chain guide slider 3 wear limit groove 96 Servicing Your Honda Refer to Safety Precautions on page 25 Steering Head Bearing Inspection With your CRF on a box or optional workstand front wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings al INR EE Stand in front of your CRF grab the fork at the axle look at the steering head and push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or play is felt but you do not see any movement in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer Additional Maintenance Procedures Handlebar Inspection 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its proper position by inspecting the paint mark 2 3 Check the torque of the handlbar upper holder b
2. HA If the engine is cold start it and warm it up 3 minutes and then shut it off Connect a tachometer to the engine Shift into neutral Start the engine Keep the motorcycle in an upright position Adjust idle speed with the throttle stop screw 1 Idle speed 1 700 100 rpm NAUN MEE IE N RAN 3 Ds 1 throttle stop screw lt 4 Wash PEN NE TT TAS on LY 4 air vent hoses 5 overflow hose 134 Adjustments for Competition The following suggestions may improve a specific concern Subtle changes in overall handling may also be noted Rear End If you have a problem with rear wheel traction raise the rear end of your CRF by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your CRF s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your CRF wants to turn too quickly lower the rear of the motorcycle by reducing the rear spring pre load This will increase fork rake and trail and should improve stability in a straight line The effective suspension travel will be transferred toward the firmer end of wheel travel Keep the race sag adjustment page 122 in the 3 5 4 3 in 90 110 mm r
3. 1 choke knob 2 starter jet 3 air passage 4 throttle valve 5 orifice Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot start lever is pulled back the hot start valve 1 opens allowing air to be supplied to the main bore 2 through the hot start air passage 3 This extra air enters the air fuel mixture from the slow circuit resulting in a lean condition 1 hot start valve 2 main bore 3 hot start air passage Accelerator Pump Circuit The accelerator pump circuit operates when the throttle is opened As the throttle valve 1 opens the pump rod 2 depress the diaphragm 3 At this time the inlet check valve 4 is shut resulting in a sharp increase in pressure in the pump chamber 5 The outlet check valve 6 then opens supplying fuel to the main bore via the accelerator nozzle 7 Lo n aie TTE ea 5 4 throttle valve pump rod diaphragm inlet check valve 5 pump chamber 6 outlet check valve 7 accelerator
4. Lack of fuel in tank P 41 Clogged fuel line P 41 Clogged fuel fill cap breather tube P 41 Clogged fuel valve P 41 Clogged fuel filter P 42 Not cleaned frequently enough P 51 Contaminants in the fuel Cam sprocket not installed properly Faulty carbon or wet fouled spark pulg P 61 Faulty ignition control module Faulty alternator Faulty direct ignition coil Broken or shorted direct ignition coil wire Faulty ignition pulse generator Loose or disconnected ignition system wires Faulty engine stop button Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing Taking Care of the Unexpected This section gives practical advice to help you IE a Fuse BlOWS siese EE SEE DERS BORS ee 146 problems If Your Battery Is Low or Dead esse esse 147 Taking Care of the Unexpected 145 If a Fuse Blows All of the electrical circuits on your CRF have a fuse to protect them from damage caused by excess current flow short circuit or overload If something electrical on your CRF stops working the first thing you should check for is a blown fuse Check the fuse before looking elsewhere for another possible cause of the problem Replace a blown fuse and check component operation The main fuse and spare are located on the starter magnetic switch behind the right side cover Recommended Main Fuse 15A 1 To prevent an accidental short circuit s
5. 2 a 5 bushing 6 O ring 1 fork cap assembly 2 fork damper 112 Adjustments for Competition 10 Tighten the fork cap assembly 1 while holding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 2 1 fork cap assembly 3 lock nut wrench 2 fork damper 11 Hold the fork damper 2 in an upright position and pump the fork damper piston rod 4 to 3 9 in 100 mm slowly several times a ab 7 3 9 in 100 mm N 2 fork damper 4 fork damper piston rod 12 Screw in the lock nut 7 to the fork damper piston rod 4 fully 4 fork damper piston rod 7 lock nut Turn the rebound adjuster and compression adjuster counterclockwise to the softest position Check the fork damper piston rod sliding surface for damage Apply fork oil to the fork damper piston rod sliding surface Cover the fork damper piston rod end with soft jaws to prevent fork damage NOTICE Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 13 Blow the extra oil off to the fork damper spring chamber 8 by pumping the fork damper piston rod to full stroke 8 fork damper spring chamber 14 Drain the extra oil from the oil hole 9 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 caus
6. FRAME Remarks FRAME Remarks Driven sprocket lt gt Drive chain links Shock spring 268 8 Ibf in 4 80 kgf mm Standard iis Aluminum Standard oe No mark Se S factory products Optional 54 Teeth Aluminum lt 116 gt or Orange 52 Teeth Aluminum ES paint lt 116 gt aftermarket parts Drive chain size link DID 520MXV 120ZB Optional 254 8 Ibf in 4 55 kgf mm Handlebar Softer SS Red and Black lower holder NE paint Standard 3 mm offset Optional Elsa Stiffer 280 Ibf in 5 00 kgf mm EES White EE paint TOOLS Remarks 291 2 Ibf in 5 20 kgf mm Pin spanner A To adjust spring pre load E gt Blue gt two spanners required EE paint Workstand PA For maintenance Fork spring 23 52 Ibf in 0 42 kgf mm Standard No mark Air gauge For checking tire air pressure CT factory products or _ 2 scribe marks aftermarket parts Optional 22 4 Ibf in 0 40 kgf mm Softer n 3 scribe marks Stiffer 24 64 Ibf in 0 44 kgf mm ee 1 scribe mark The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked Before replacing the springs be sure to mark them so they can be distinguished from other optional springs Technical Information 163 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
7. ae Ce a 8 fuel line 10 fuel valve bolt 9 fuel valve Servicing Your Honda 37 Fuel Tank Removal Installation 8 Install the shrouds 8 and shroud B bolts 1 Install the fuel tank on the frame collars 9 2 Install the fuel valve 1 and tighten fuel valve Tighten the shroud B bolts to the specified bolt 2 torque 3 Connect the fuel line 3 to the fuel valve 3 7 Ibf ft 5 N m 0 5 kgf m 9 Install the shroud A bolts collars 10 fuel valve 3 fuel line fuel valve bolt 4 Install and tighten the fuel tank bolt 4 8 shroud 5 Hook the air cleaner cover rubber 5 9 shroud B bolts collars 6 Install the fuel tank band 6 10 shroud A bolts collars Put th h in th i 7 oe e breather tube 7 in the steering stem jo Install the seat pase do ie 4 fuel tank bolt 6 fuel tank band 5 air cleaner cover rubber 7 breather tube 38 Servicing Your Honda Refer to Safety Precautions on page 25 The subframe may be adjusted to an upright position to permit servicing of the rear suspension Upright Position 1 Remove the right side cover bolt 1 collar 3 seat mounting bolt 2 and right side cover 4 1 right side cover bolt 3 collar 2 seat mounting bolt 4 right side cover 2 Open the air cleaner housing cover 5 by turning the quick fastener 6 counterclockwise and remove the left side cover bolt 7 collar 9 seat mounting bolt 8 and le
8. API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label Viscosity SAE 10W 30 weight JASO T903 MA standard others without friction modifiers such as molybdenum additives Pro Honda GN4 4 stroke oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label e Your CRF does not need oil additives Use the recommended oil Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance NOT RECOMMENDED OK e Oil is a major factor affecting the performance and service life of the transmission and clutch Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10 20 30 40 50 C 20 0 20 40 60 80 100 120 F 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 MEETI
9. esse see ee ee ee se ee ee ee 2 contacting Honda esse esse esse ee ee se es se ee 171 OUE EE E ee DE De EE De De se 44 appearance Calend sesse see ina Tinea eass 102 controls operating iss see see ee ee ee ee 7 flooded engine starting sesse sesse ee ee ee 16 authorized manual esse se ee ee se ee 168 GOOlANE SEER EERS GE DE De Ee GE Se EE 48 fork cylinder removal iese sesse ese ee ee ee trises 76 front suspension adjustment sesse esse 106 B front suspension inspection ees esse esse 82 D oil recommendation esse ss ss se ee ee 84 basic operation ees esse ese ee ee RA RA ee ee ee 13 front brake lever adjustment esse esse esse ee 86 EES AE N OE EE ONE 99 damping adjustments front suspension disassembly ccceeeeees 107 before riding iese esse ee ee AA Ge AA ee iini 9 de EE EE NE OE EE 106 fuel between motos amp practice maintenance 33 PCat EE Ais tee hie et teed 121 ii EE N EE 41 brakes dealer your Honda esse sesse esse se es see ee se ee ee se ee 172 ed are reer EA EE AEA 42 fluid levels ies SEERDE bee RR Se eke 87 diagram WITINS sees see see ee ee ee ee Re 165 recommendation esse see se ee ee 41 lever front adjustment esse ese se see se 86 drive chali Re AE EE RE etd ties 94 teftielifig hist EE se heii Ge etd oe 41 Dad WEATS id trieste tai eei ENE Ie 89 SYSE OE OE EE 41 pedal height iront nginitian 86 oxygenated AE OE reseni 160 break in guidelines esse se
10. speed riding 7 at draining 1 19 US qt 1 13 2 DENSO F brak Single disc brake VUH27D brake swept area 51 8 in 334 5 cm at disassembly 1 27 US qt 1 20 Spark plug gap 0 03 0 04 in t R brake swept area omgie disc brako Carburetor 0 8 0 9 mm 60 6 in 391 1 cm Type Piston valve Light unleaded gasoline pump Identification number FCRO2B Fuel recommendation Ma RAN ee TE EET Head light 12V 35 W higher ain je Fuse Fuel tank capacity 219USgal 8 32 Jet needs NCAT Main fuse 15A Fuel reserve capacity 0 40 US gal 1 52 oe jet l due Caster angle 27054 Pilot screw opening 2 Ales turns out Trail length 46in 118 mm Float level 0 31 in 8 0 mm Fork oil capacity Idle speed 1 700 100 rpm except fork damper per leg 11 8 US oz 348 cm Technical Information 153 Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Engine ENGINE Torque Item Remarks Ibfeft Nem kgfem 1 Cylinder head cover bolts 7 10 1 0 2 Exhaust pipe joint nuts 15 21 2 1 3 Coolant drain bolt 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 NOTE 1 5 Transmission oil check bolt 9 12 1 2 6 Clutch cover bolts 7 10 1 0 7 Cylinder bolt 7 10 1 0 8 Oil filter cover bolts 9 12 1 2 9 Cylinder head bolts 7 10 1 0 10 Drive sprocket bolt 23 31 3 2 11 Engine oil drain bolt 12 16 1 6 NOTE 2 12 Transmis
11. 157 Emission Control ystems Exhaust Emission Reguirements USA only The U S Environmental Protection Agency EPA and the California Air Resources Board CARB reguire that your motorcycle comply with applicable exhaust emission standards during its useful life when operated and maintained according to the instructions provided The vehicle emission control information label 1 is attached to the rear fender 1 1 vehicle emission control information label Noise Emission Requirements The EPA also requires that motorcycles built after January 1 1983 comply with applicable noise emission standards for one year or 1 865 miles 3 000 km after the time of sale to the ultimate purchaser the time operated and maintained according to the instructions provided USA only 158 Technical Information Noise Emission Control System TEMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED U S federal law prohibits or Canadian provincial laws may prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered in
12. Front Brake Fluid Level Check 1 LWR LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LWR LOWER level mark 1 If the level is at or below the LWR LOWER level mark check the brake pads for wear page 89 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the front brake lever freeplay exceeds 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 Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 89 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the rear brake pedal freeplay exceeds 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 Servicing Your Honda 87 Brakes Adding Front Brake Fluid NOTICE Spilled brake fluid will severely damage instrument lenses and painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap mak
13. 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 CREF 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 CRF on ground without rider 1 Support your motorcycle on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 122 Adjustments for Competition without rider EXAMPLE 23 6 in 600 mm a CHAIN ADJUSTER LOCK NUT
14. Valve Clearance Refer to Safety Precautions on page 25 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule pages 27 28 The checking or adjusting of the valve clearance should be performed while the engine is cold The valve clearance will change as engine temperature rises 66 Servicing Your Honda Cylinder Head Cover Removal Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat page 36 2 Remove the fuel tank page 37 3 Disconnect the breather tube 1 and direct ignition coil 2 1 breather tube 2 direct ignition coil 4 Remove the cylinder head cover bolts rubber seals 3 and cylinder head cover 4 3 cylinder head cover bolts rubber seals 4 cylinder head cover Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 crankshaft hole cap 2 Rotate the crankshaft by turning the primary drive gear bolt 2 clockwise until aligning the punch mark 3 on the primary drive gear with the A mark 4 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the prima
15. 25 Clean the clamping surface of the axle and axle holders Install the front wheel 28 between the fork legs while inserting the disc between the pads and align 29 the tab of the tripmeter gear box as shown Check that the tripmeter gear box O ring 30 is in good condition replace it if necessary Apply a thin layer of grease to the axle 31 and insert the axle from the right side 28 front wheel 29 align 31 axle 26 Install and tighten the axle nut 32 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m Tighten the left axle pinch bolts 33 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m Pad 32 axle nut 33 left axle pinch bolts 27 Install the handlebar 34 mounting rubbers washers and handlebar holder nuts 35 and tighten the handlebar holder nuts to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 34 handlebar 35 mounting rubbers washers handlebar holder nuts 28 Install the front visor by aligning its grommets 30 With the front brake applied pump the fork 36 with the tabs 37 on the steering stem check front brake operation 36 front visor grommets 37 tabs 31 While keeping the forks parallel alternately tighten the right axle pinch bolts 40 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 29 Install and tighten the front visor bolts 38 Install the handlebar pad 39 NOTICE To avoid damage when torquing the axle p
16. 4 and remove by lifting it up at a point just opposite the gap NOTICE Do not damage the piston ring by spreading the ends too far 4 piston ring Piston Piston Rings Piston Pin Piston Piston Pin Piston Ring Inspection Piston Ring Installation EE es top ring re We recommend you consult the Service Manual 1 Remove the carbon deposits from the piston Ad EG ring or your authorized Honda dealer for correct crown and piston ring grooves with the sel Service Limit measurements removed ring 2 Apply engine oil to the piston rings and install them NOTICE Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation ail ring To install the oil ring install the spacer first then install the side rails e Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail Servicing Your Honda 77 Piston Piston Rings Piston Pin Piston Installation 1 Place clean shop towels over the crankcase opening to keep the piston pin clips from falling into the crankcase 2 Apply molybdenum disulfide oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containi
17. 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 Other Inspection e Make sure there are not fluid leaks e Check for deterioration or cracks in the hoses and fittings Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions Generally the pads will wear faster on wet and dirty tracks Inspect the pads at each regular maintenance interval pages 27 and 28 Front Brake Pads Inspect the brake pads 1 through the front wheel to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness 3 indicator 0 04 in 1 mm q ly 1 replace wear indicator grooves 0 04 in 1 mm alias replace 1 brake pads 3 brake disc 2 front brake caliper Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced minimum thickness indicator 4 replace 4 brake pads 6 brake disc 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
18. If you have questions about waranty coverage or the nature of the repair it is best to talk to the service manager of your Honda dealer Sometimes in spite of the best intentions of all concerned a misunderstanding may occur If you aren t satisfied with your dealer s handling of the situation we suggest you discuss your problem with the appropriate member of the dealership s management team If the problem has already been reviewed with the service Manager Parts Manager Sales Manager etc contact the Owner of the dealership or his designated representative 170 Consumer Information Your owner s manual was written to cover most of the guestions you might ask about your Honda Any guestions 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 P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include
19. Valve Clearance ss ee oe en goe ER Ge 68 66 Piston Piston Rings Piston PIN iese sesse esse ee 74 Servicing Your Honda Chassis SUSPENSIONS ie Ee AE GE ee ER oe ke Se ee ee 82 Front Suspension Inspection eee 82 Rear Suspension Inspection ese 83 Recommended Fork Oil sees see se ee 84 Fork Oil Change sesse ieni aia ir 84 Brakes ER RE E Mite vaca 86 MEAN EN ER EN eoe 90 Tires K amp T be Sherret rerent e Ein Ge Ee 91 SIS Stand sie es e E e OE Ge ee Pe 93 Drive Chain rs Ee GE see ee se seg i SEGE bel 94 Additional Maintenance Procedures 97 Electrical Battery cts RE N NE EE 99 Headlight amp Taillight esse ese se ee ee ee ee 101 Appearance Care iese esse esse ee ee ee rasie ee 102 Servicing Your Honda 23 The Importance of Maintenance A well maintained motorcycle is essential for safe economical and trouble free riding It will also help reduce air pollution Careful pre ride inspections and good maintenance are especially important because your CRF is designed to be ridden over rough off road terrain To help you properly care for your CRF this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avo
20. WN e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 5 Remove the radiator cap and coolant drain bolt 1 at the water pump 2 to drain coolant After the coolant has been completely drained reinstall the coolant drain bolt with a new sealing washer and radiator cap Coolant drain bolt 7 Ibf ft 10 N m 1 0 kgf m gt 1 coolant drain bolt 2 water pump 6 Disconnect the siphon tube from the radiator Drain the reserve tank coolant Empty the coolant and rinse the inside of the reserve tank with water 7 Lubricate the drive chain 8 Remove the battery and charge it fully Store in an area protected from freezing temperatures and direct sunlight Slow charge the battery page 100 once a month Storing Your Honda 9 Inflate the tires to their recommended pressures 10 Place your CRF on the optional Honda work stand or equivalent to raise both tires off the ground 11 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 12 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 13 Cover your CRF with a porous material Avoid using plastic or similar non breathing coated materials that restrict air flow and allow heat and moisture to accumulate Tips 141 Storing Your Honda Removal from
21. and size in good condition with adequate tread and correctly inflated WAR Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire replacement Air Pressure Properly inflated tires provide the best combination of handling tread life and riding comfort Generally underinflated tires wear unevenly adversely affect handling and are more likely to fail from being overheated Underinflated tires can also cause wheel damage on hard terrain Overinflated tires make your CRF ride harshly are more prone to damage from surface hazards and wear unevenly Make sure the valve stem caps are secure If necessary install a new cap 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 Front 15 psi 100 kPa 1 0 kgf cm Rear 15 psi 100 kPa 1 0 kgf cm If you decide to
22. e Faulty exciter coil e Broken or shorted direct ignition coil e Faulty engine stop button e Loose or disconnected ignition system wires e Faulty ignition pulse generator LOW gt Valve stuck open ENGINE STARTS BUT SOON STOPS ENGINE DOES NOT FIRE 5 Removed and inspect spark plug DRY e Worn cylinder and piston ring e Leaking damaged cylinder head gasket e Improper valve timing e Seized valve e Improper choke operation Pilot screw incorrectly adjusted e Insulator leaking e Improper ignition timing Faulty direct ignition coil or ignition pulse generator e Fuel contaminated Improper hot start operation P 60 WET PLUG e Carburetor flooded 6 START WITH CHOKE ON 144 Tips e Choke closed e Throttle valve open e Air cleaner dirty P 51 POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK 1 Check if air cleaner is over oiled P 51 CORRECT 2 Check if the intake tube is leaking POSSIBLE CAUSES INCORRECT Over oiled air cleaner LEAKING NOT LEAKING 3 Check carbureator pilot screw adjustment 4 Check carburetor jets and accelerator pump for clogs m Loose insulator clamp e Damaged insulator INCORRECT e Fuel air mixture too lean Turn the pilot screw out e Fuel air mixture
23. right side cover 2 Loosen the muffler clamp bolt 5 3 Remove the muffler A bolt washer 6 muffler B bolt 7 and muffler 8 5 muffler clamp bolt 6 muffler A bolt washer 7 muffler B bolt 8 muffler Muffler Installation 1 Remove the gasket 2 Install a new gasket 1 on to the exhaust pipe 3 Install the muffler clamp 2 by aligning the tab 4 of the muffler clamp with the cut out 5 of the muffler 3 4 Install the muffler 1 gasket 2 muffler clamp 3 muffler 4 tab 5 cut out 5 Tighten the muffler B bolt 6 and muffler A bolt washer 7 to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 6 Tighten the muffler clamp bolt 8 to the specified torque 15 Ibf ft 21 N m 2 1 kgf m n 6 muffler B bolt 8 muffler clamp bolt 7 muffler A bolt washer Exhaust Pipe Muffler 7 Install the right side cover 9 collar 10 and side cover bolt 11 8 Install the seat mounting bolt 12 and tighten it to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 9 right side cover 10 collar 11 side cover bolt 12 seat mounting bolt Servicing Your Honda 63 Exhaust Pipe Muffler Exhaust Pipe Removal Exhaust Pipe Installation 1 Remove the muffler page 62 1 Install a new exhaust pipe gasket 1 exhaust 2 Remove the exhaust pipe joint nuts 1 pipe 2 and exhaust pipe joint nuts 3 and exhaust pipe 2 and exhaust pipe gasket 3
24. the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first 1 control lever mounting bolts As an alternative consider wrapping the handlebar area under the control assemblies with teflon tape Then tighten the assemblies to their normal torque Upon impact the fully tightened assemblies should rotate on the Teflon tape 138 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 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 materia
25. tripmeter cable 15 front axle shaft 13 front axle nut 10 Remove the fork protector bolts 16 tripmeter cable clamp bolts 17 and brake hose clamp bolts 18 and fork protectors 19 Remove the brake caliper bolts 20 and brake caliper 21 The fork protector bolts and brake caliper bolts have a locking agent applied Do not support the brake caliper by the brake hose Do not operate the front brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads a W y et 16 20 af 16 fork protector bolts 19 fork protectors 17 tripmeter cable clamp bolts 20 brake caliper bolts 18 brake hose clamp bolts 21 brake caliper 11 Loosen the fork leg lower pinch bolts 22 then pull the fork legs down and out 22 lower pinch bolts 26 outer tube 27 fork damper 12 Clean the fork assembly especially the sliding surface 23 of the slider and dust seal 24 13 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 14 Measure the length 25 between the axle holder and outer tube and record it before disassembling the fork 24 23 23 sliding surface 24 dust seal 25 length 15 Hold the outer tube 26 then remove the fork damper 27 from the outer tube using the lock nut wrench 28 Gently slide the outer tube down onto t
26. 3 Remove the engine oil filler cap dipstick 1 from the left crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the engine oil drain bolt 2 and sealing washer 3 5 With the engine stop button pushed repeat kickstarter operation approximately 5 times to drain the engine oil completely 6 After the oil has drained apply fresh engine oil to the engine oil drain bolt threads and tighten it with a new sealing washer to the specified torque 12 Ibf ft 16 N m 1 6 kgf m 1 engine oil filler cap dipstick 2 engine oil drain bolt 3 sealing washer 7 It is recommended to replace the oil and filter about every 15 0 hours However if you replace only the oil before the recommended interval see page 28 8 Remove the left engine guard bolt 4 and left engine guard 5 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 Replace it if necessary 6 oil filter cover bolts 7 oil filter cover 8 oil filter 9 oil filter cover O ring 10 spring 11 rubber seal 12 OUT SIDE mark 12 Apply grease to the filter side of the spring end then install the spring 10 into the new oil filter 13 Position the spring against the engine crankcase and install a new oil filter with
27. Ltd 2006 2007 Honda CRF250X OWNER S MANUAL amp COMPETITION HANDBOOK FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only USA only If conforms to US EPA Noise Emission regulations but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester Obey local laws and regulations It conforms to US EPA and California exhaust emission regulations for off road motorcycles Introduction Congratulations on choosing your Honda CRF off road motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your Honda was designed as a recreational CRF for off road use by one rider only Before riding take time to get acquainted with your motorcycle 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 man
28. Refer to Safety Precautions on page 25 Loose worn or damaged suspension components may adversely affect the handling and stability of your motorcycle If any suspension components appear worn or damaged see your Honda dealer for further inspection Your dealer is qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection e When your CRF is new break it in for approximately one hour to ensure that the suspension has worked in page 21 After break in test run your CRF with the front suspension at the standard setting before attempting any adjustments For optimum fork performance we recommend that you disassemble and clean the fork after riding your CRF for 3 hours See page 107 for fork disassembly Replace the fork oil every 7 5 hours of running See page 84 for oil level adjustment after changing the fork oil Replace the damper oil every 22 5 hours of running See page 111 for oil level adjustment after changing the damper oil Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination 82 Servicing Your Honda e Refer to Suspension Adjustment Guidelines page 125 Make all rebound and compression damping adj
29. Valve Cleatanc se esels clathrate se ee 66 Piston Piston Rings Piston PIN esse see sesse ee 74 Chassis SUSPENSION assieta ien ienis oi eas 82 Brake Seo eean RE EE de ee 86 MAAR AR AA EES 90 Tires GCs TUDES iese se BE oe Re eia 91 Side Stand ER EE se EE lh ev ge Ee 93 Driver Chain 40 00 Wives SE Bek Se bee Ee LE ete 94 Additional Maintenance Procedures 97 Electrical Batter io hee os tases Ge tees tes vate 99 Headlight amp Taillight 2 0 see se ee ee ee 101 Appearance Care ut esse ees Se Re se gee 102 ADJUSTMENTS FOR COMPETITION 105 Front Suspension AdjustmentS esse eee 106 Rear Suspension Adjustments uses sesse esse 120 Suspension Adjustments for Track Conditions is Ee EE ee ee gee ted 124 Suspension Adjustment Guidelines 125 Carburetor Adjustment amp Turning Tips 128 Chassis Adjustments esse see see ee ee ee ee 135 ear ing ES ER EE ee S 136 Tire Selection for Track Conditions 137 Personal Fit Adjustments 0 eee see see see 138 TIP EE EE ee Ge GR ED GE De 139 Transporting Your Motorcycle iese sesse 140 Storing Your Honda sesse esse esse ees see ee ee 141 You amp the Environment iese ese esse esse ee see ese 143 Troubleshooting esse ss se ee Ge ee ee 144 TAKING CARE OF THE UNEXPECTED ee ese ssesseese sees oes see sees sees 145 Tf a Fuse BlOWS eers seges eene gee beds Ge Eise dee 146 If Your Battery Is Low
30. When installing the link arm set torx screw apply a locking agent to the link arm set torx 1 Pull up the cable clamp 1 and remove the screw threads carburetor top cover bolts 2 4 Remove the throttle valve 7 throttle valve Then remove the carburetor top cover 3 roller 8 and floating valve 9 8 throttle drum cover bolt 9 throttle drum cover 11 Remove the throttle cables 10 by looseing the throttle cable lock nut 11 and adjusting 1 cable clamp nuts 12 2 carburetor top cover bolts 3 carburetor top cover 2 Remove the jet needle holder assembly 4 from the throttle valve 5 4 ye 8 6 link arm set torx screw 8 throttle valve roller 7 throttle valve 9 floating valve 10 throttle cables 11 throttle cable lock nut 12 adjusting nuts 4 jet needle holder assembly 5 throttle valve cont d Adjustments for Competition 131 Carburetor Adjustment amp Tuning Tips When installing the floating valve 9 onto the 5 Remove the accelerator pump cover screws throttle valve 7 make sure the floating valve s 11 and accelerator pump cover 12 flat side faces out and the hole 10 faces down 7 11 A J S fi FT SR MG IL yo sk a 12 11 accelerator pump cover screws 12 accelerator pump cover A 7 throttle valve 6 Remove the U ring 1
31. alter your riding position or interfere with operating any controls Modifications We strongly advise you not to remove any original equipment or modify your CRF in any way that would change its design or operation Such changes could seriously impair your CRF s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your area Safety Labels This page shows the locations of safety labels on your CRF Some labels warn you of potential hazards that could cause serious injury Othere provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement IMPORTANT INFORMATION This vehicle is designed and manufactured for off road use only It does not conform to Federal motor vehicle safety standards and operation on public streets roads or highways is illegal For your protection always wear your helmet while riding Operator only No passengers Read the owner s manual carefully This Honda motorcycle is sold as is without warranty and the entire risk as to quality and performance is with the buyer D gt NEVER OPEN WHEN HOT Hot coolant will burn you D gt NE JAMAIS OUVRIR A CHAUD Le liquide risque d
32. available for purchase from your Honda dealer page 168 Because your CRF does not have an odometer service intervals in the maintenance schedules are expressed in terms of riding days as well as miles To avoid overlooking required service we urge you to develop a convenient way to record the number of days and or distance traveled USA miles Canada kilometers you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or replacement to ensure the best quality and reliability 26 Servicing Your Honda Perform the pre ride inspection page 11 at each scheduled maintenance period Each item on the maintenance schedule requires some mechanical knowledge Certain items particularly those marked and may require more technical information and tools Consult your Honda dealer Should be serviced by your Honda dealer unless the owner has proper tools and service data and is mechanically qualified Refer to the official Honda Service Manual page 168 In the interest of safety we recommend these items be serviced only by your Honda dealer Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary clean replace adjust lubricate TPA MAINT
33. bolt 1 and sealing washer 2 Tensioner stopper 070MG 0010100 1 Record the intake valve clearance and exhaust valve clearance 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 2 sealing washer 3 stopper tool 68 Servicing Your Honda Valve Clearance 4 Remove the camshaft holder bolts 4 and camshaft holders 5 Loosen the camshaft holder bolts in a criss cross pattern in two or three steps 5 Remove the camshaft 6 and then attach a piece of wire to the cam chain to prevent it from falling into the crankcase Be careful not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6 Remove the valve lifters 7 7 Remove the shims 8 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left NOTICE Do not let the valve lifters and shims fall into the crankcase 8 shims 7 valve lifters Servicing YourHonda 69 Valve Clearance Shim Selection 1 Clean the valve shim contact area in the valve lifter 1 with compressed air 1 valve lifter 70 Servicing Your Honda Measure the shim thickness with a micrometer an
34. 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 NOTICE Improper disposal of drained fluids is harmful to the environment You amp the Environment Tips 143 Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that reguire use of the Honda Service Manual are followed by an asterisk ENGINE DOES NOT START OR IS HAND TO START CHECK 1 Check the fuel flow to carburetor NOT REACHING CARBURETOR REACHING CARBURETOR y 2 Try spark test GOOD SPARK POSSIBLE CAUSES m gt e No fuel in fuel tank e Clogged fuel line or fuel filter P 41 42 e Sticking float valve e Clogged fuel fill cap breather tube P 41 WEAK OR NO s e Faulty spark plug P 61 SPARK y 3 Test cylinder compression CORRECT 4 Start by following normal starting procedure e Fouled spark plug P 61 e Faulty ignition control module
35. cornering e Stiff suspension on bumps especially downhill bumps e While braking front end dives during initial travel then feels stiff If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Final travel too stiff e Doesn t bottom on landings but feels stiff e Stiff on large bumps especially downhill bumps e Stiff on large bumps when cornering If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel becomes stiff Install the optional soft spring Test softer compression damping adjustments in one click increments If the entire travel feels stiff after the above adjustment Test softer compression damping adjustments in one click increments until the desired initial travel compression damping is obtained Lower the oil capacity by 0 2 oz 5 cc Entire travel too stiff e Stiff suspension on any type of terrain Test softer compression damping adjustments in one click increment
36. cover 2 6 seat mounting bolt 3 7 left side cover 4 left side cover bolt 8 reserve tank cap 5 9 collar UPPER level line 6 Bleed air front the system as follows e Shift the transmission into neutral Start the engine and let it idle 2 3 minutes e Snap the throttle three four times to bleed air from the system e Stop the engine and if necessary add coolant up to the proper level Reinstall the radiator cap e Check the level of coolant in the reserve tank and fill to the UPPER level if it is low NOTICE If the radiator cap is not installed properly it will cause excessive coolant loss and may result in overheating and engine damage 7 Install the radiator reserve tank cap and left side cover and close the air cleaner housing cover Refer to Safety Precautions on page 25 The air cleaner uses polyurethane inner and outer pieces which can t be separated A dirty air cleaner will reduce engine power Proper air cleaner maintenance is very important for off road vehicles A dirty water soaked worn out or defective air cleaner will allow dirt dust mud and other impurities to pass into the engine Service the air cleaner more frequently if you ride in unusually wet or dusty areas Your 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 cle
37. degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Washing Your Motorcycle with a Mild Detergent 1 Rinse your CRF thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover is for removing stains on the non coated aluminum frame only 4 After washing rinse your CRF thoroughly with plenty of clean water to remove any residue 5 Dry your CRF with a chamois or a soft towel 6 Lubricate the drive chain to prevent rusting 7 Start the engine and let it idle for several minutes The engine heat will help dry moist areas 8 As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance If the inside of the headlight lens appears clouded immediately after washing it should cleaner after a few minute
38. dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 76 Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Pro Honda Hondalock or an equivalent prior to torquing the nuts Fuel Contamination Refer to Fuel System in your Owner s Manual page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the fuel tank remove and clean the fuel valve and fuel filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 42 Loosen the carburetor drain screw and examine the fuel that flows out of the float bowl If you notice anything in the fuel such as water or dirt remove the float bowl and inspect its contents page 131 For maximum efficiency drain and replace fuel that has remained in your fuel tank for more than a month Gaskets Always use new gaskets when reassembling components Battery Electrical accessories use current from the battery even when the engine is off Limited operation also allows the battery to discharge If you have electrical accessories on your CRF or do not ride frequently we recommend that you charge the battery frequently see Battery Charging page 100 If you do
39. ee ee ee 21 Fi delete AO EE 41 tank removal sesse see see ee ee ee 37 EI EE MO IE HA 15 176 Index G M R gap spark plug sesse sees see see ee aa 61 maintenance rear SUSPENSION INSPECTION iese esse sees se se 83 ERENS AR N OR N EE EE 41 after COMPCtItION eee see see ee ee ee ee 33 Rider s Club Honda esse esse esse se ee see Ge 173 GOALIE sesse SEE E ee Ek og 136 before amp after competition esse see sees 33 riding guidelines suspension adjustment 125 between motos amp practice ee see se see 33 Apparel Ee Ee N ie alate 2 component locations sees se ee ee ee 35 basic OperatON esse esse esse ee ee ee ee ee 13 H general competition iese esse see ee ee ee 29 as ies N HR EE OE ER 9 importane Ese geed gede ES ese 24 important safety information sesse sesse ee 2 handlebar inspection sesse ee ee ee 97 saltetV RE ee e 25 Safety precautions sees sesse see se ee ee ee ee 2 high altitude carburetor adjustment 157 Schedules res inh Mi Ee Se Ee tones 27 28 Honda manual Sef VlC sie GELE ses insignier ae eed 168 S contacting ESE ee EE Ge GE ed ate 171 Modifications ie RES VD esse n ese Gee be spe 4 Rider s Club se Es Seated 173 muffler safety service manual sesse esse ees ee ee ee ee 168 ie OE ER N OR EN 62 a few words abott 0 Safety Messages your dealer ss see
40. hot start lever 3 Basic Operating Instructions 15 Starting amp Stopping the Engine Flooded Engine How to Stop the Engine Starting the engine after a stall during riding or after a fall 1 Shift the transmission into neutral 2 Pull the hot start lever all the way in and start the engine Do not open the throttle 3 As soon as the engine starts release the hot start lever Starting a flooded engine Using the start button 1 Do not use the choke 2 Shift the transmission into neutral with the 1 throttle 2 engine stop button throttle fully opened 3 Pull the hot start lever and clutch lever all the Normal Engine Stop way in and depress the start button for 5 1 Shift the transmission into neutral seconds 2 Turn the fuel valve OFF If the engine starts quickly close the throttle 3 Lightly open the throttle 1 two or three then open it slightly if idling is unstable If the times and then close it engine does not start wait 10 seconds and 4 Depress and hold the engine stop button 2 then follow the regular starting procedure until the engine stops completely 4 As soon as the engine starts release the hot start lever Failure to close the fuel valve may cause the carburetor to overflow result in hard starting ae the kickstarter Do not use the choke Emergency Engine Stop Shift the transmission into neutral with the To stop the engine in an emergency depress and throttle fully opened re
41. in 257 6 mm Each turn of the adjuster changes spring length and spring pre load One turn equals spring length spring pre load 0 06 in 1 5 mm 15 9 Ibs 7 2 kg Pin spanners should be used for turning the lock nut and adjusting nut See page 163 for optional pin spanners Spring pre load length Standard spring Standard 10 10 in 256 6 mm Min 9 6 in 243 mm Spring pre load length Optional spring Min Softer 4 55 kgf mm 9 7 in 246 mm Min Stiffer 5 00 kgf mm 9 7 in 246 mm Min Stiffer 5 20 kgf mm 9 8 in 248 mm 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 12 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 adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster To adjust to the standard position 1 Turn the adjuster clockwise
42. manuals Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems common to all Honda motorcycles motor scooters and ATVs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Publication Item No Description Price Each 61KSCO3 2007 CRF250X Service Manual 48 00 61CM002 Common Manual 48 00 31KSC630 2007 CRF250X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Order Toll Free 1 888 CYCLE93 1 888 292 5393 NOTE For Credit Card Orders Only Monday Friday 8 00 AM 6 00 PM EST OR By completing this form you can order the materials desired You can pay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form USA only Canada See your Honda dealer to order authorized manuals Price Total Each Price Publication item No Item Description Qty Sub Total Purchaser s Sales Tax Mich Add 6 Calif Add 8 25 Prices are subject to change without notice and without incurring obligation Orders are mailed within 10 days Ple
43. no fluid leaks Check for deterioration or cracks in the hoses and fittings Brakes Servicing Your Honda 89 Wheels Refer to Safety Precautions on page 25 Maintenance of spoke tension and wheel trueness roundness is critical to safe motorcycle operation During the first few rides spokes will loosen more rapidly due to the initial seating of the parts Excessively loose spokes may result in instability at high speeds and the possible loss of control It s also important that the rim locks are secure to prevent tire slippage It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims amp Spokes 1 wheel rims 2 spokes 3 rim lock 1 Inspect the wheel rims 1 and spokes 2 for damage 90 Servicing Your Honda 2 Tighten any loose spokes and rim locks 3 to the specified torque Spoke 2 7 Ibf ft 3 68 N m 0 4 kgf m Rim Lock 9 Ibf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see the Honda Service Manual for inspection instructions Axles amp Wheel Bearings See the Honda Service Manual for inspection information 1 Check the axle shaft for runout 2 Check the condition of the wheel bearings Refer to Safety Precautions on page 25 To safely operate your CRF the tires must be the proper type off road
44. not expect to ride your CRF for at least two weeks we recommend you remove the battery or at least disconnect the battery cables negative cable first Electrical Connectors Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections water shorts or corrosion Additional corrosion protection is offered by using Pro Honda Dielectric Grease on all electrical connections Servicing Your Honda 31 General Competition Maintenance Suspension Linkage Lubrication Disassemble clean inspect and lubricate all suspension linkage pivots with grease after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Swingarm Pivot Lubrication Clean inspect and lubricate the swingarm and suspension linkage pivots with grease Be sure all of the dust seals are in good condition Swingarm N life of brake fluid Fuse Check the fuse before looking elsewhere for the cause of an electrical problem Brake Fluid Replacement Refer to Brake Pad Wear in your Owner s Manual page 89 Brake Caliper Inspection Be sure both the front and rear calipers are able to move freely on the caliper bracket pins Check pad thickness periodically and replace the pads when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replaceme
45. nozzle TESE 1 2 3 4 Carburetor Adjustment amp Tuning Tips Slow Circuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 O 3 J ad AE N 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 m
46. oil solution to the camshaft journals and cam lobes 1 shims 2 valve retainers Place the cam sprocket 7 and align the o es i timing marks 8 on the cam sprocket with the 2 EE iB solution a top surface of the cylinder head 9 11 camshaft holders 12 camshaft holder bolts molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to outer surface of the each valve lifters Install the valve lifters 3 Install the cam chain 10 over the sprocket without rotating the sprocket 7 cam sprocket 9 cylinder head 8 timing marks 10 cam chain cont d Servicing Your Honda 71 Valve Clearance 6 Insert the feeler gauge between the intake 7 Remove the stopper tool 14 from the cam 3 valve lifter and cam lobe chain tensioner lifter Crankshaft Hole Cap Installation If the feeler gauge 13 cannot be inserted the shim is caught between the valve lifter and the valve retainer Remove the camshaft holders to place the shim correctly and reinstall the camshaft holders Coat a new O ring 1 with engine oil and install it onto the crankshaft hole cap 2 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 Ibf ft 15 N m 1 5 kgf m Valve Clearance IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 14 stopper tool 8 Install a new sealing washer 15 and tighten the c
47. penetration Handgrips Always use Pro Honda Handgrip Cement U S A only or equivalent when replacing handgrips Throttle grip Align the index mark on the throttle grip with the edge of the throttle cable guide Left handlebar grip Align the A mark on the left handlebar grip with the paint mark on the handlebar Refer to the Honda Service Manual page 168 for installation instructions For added security you may choose to bind the handgrips to the handlebar and throttle pipe with safety wires to prevent the possibility of them loosening Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the handgrip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the throttle pipe and handlebar thoroughly and apply a light coating of oil Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way Move the handlebar from lock to lock to be sure there is no cable interference Make certain the throttle operation is perfect after servicing and inspecting General Competition Maintenance Fuel Filter Periodically drain the fuel from the fuel tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 42 Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from
48. plug will not color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere Check the carburetor fuel system and ignition timing 8 With the plug washer attached Thread the spark plug in by hand to prevent cross threading 9 Tighten the spark plug e If the old plug is good 1 8 turn after it seats e If installing a new plug tighten it twise to prevent loosening a First tighten the plug NGK 1 2 turn after it seats DENSO 1 tum after it seats b Then loosen the plug c Next tighten the plug again 1 8 tum after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too light the threads may be damaged 10 Connect the direct ignition coil Take care to avoid pinching any cables or wires 11 Install the fuel tank and seat pages 36 38 Servicing Your Honda 61 Exhaust Pipe Muffler Exhaust Pipe Muffler Inspection Check the flange bolts for tightness Check the exhaust pipe and muffler for cracks or deformation A damaged exhaust pipe and muffler may reduce engine performance 62 Servicing Your Honda Muffler Removal 1 Remove the seat mounting bolt 1 side cover bolt 2 collar 3 and right side cover 4 1 seat mounting bolt 2 side cover bolt 3 collar 4
49. 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 10 Before Riding A WARNING Not wearing a helmet increases the chance of serious injury or death ina crash Be sure you always wear a helmet eye protection and other protective apparel when you ride Competitive riding can be tough on a motorcycle so it s important to inspect your CRF and correct any problems you find before each ride Check the following items page numbers are at the right A WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems Is Your Motorcycle Ready to Ride Pre ride Inspection Check the following before each ride Engine oil level oo cece see see ee se ee ee 44 Transmission oil level sesse se se ee ee 47 Coolant for proper level eee see se 48 Cooling system and hoses for condition 49 Spark plug for proper heat range carbon fouling and direct ignition coil connector for LOOSENESS rasse second KEER rk get ERG GEEL SEDES cous 61 Air cleaner for condition an
50. responsibility for your own safety and understand the challenges you can meet in competitive racing There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider most important Always Wear a Helmet It s a proven fact helmets significantly reduce the number and severity of head injuries So always wear an approved motorcycle helmet We also recommended that you wear eye protection sturdy boots gloves and other protective gear Never Carry a Passenger Your CRF is designed for one person only There are no handholds footrests or seat for a second person so never carry a passenger A passenger could interfere with your ability to move around to maintain your balance and control of the motorcycle Ride Off Road Only Your CRF is designed and manufactured for off road use only The tires are not made for pavement and the CRF does not have turn signals and other features required for use on public roads If you need to cross a paved or public road get off and walk your CRF across Always Wear Protective Gear We recommend that you wear sturdy boots gloves and other protective gear The exhaust system becomes very hot during operation and it remains hot after operation Never touch any part of the hot exhaust system Wear clothing that fully covers your legs 2 Motorcycle Safety Do not wear loose clothing wh
51. tighten the nuts to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 1 exhaust pipe joint nuts a 2 exhaust pipe 1 exhaust pipe gasket 3 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 63 64 Servicing Your Honda Spark Arrester Inspection The spark arrester must be serviced every 1 000 mi 1 600 km of running or 100 operating hours to maintain its efficiency Regular servicing prevents carbon buildup which can diminish engine performance and also complies with USDA regulations for regular maintenance to assure proper function The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment 1 Allow the engine and muffler 1 to cool 2 Remove the bolts 2 spark arrester 3 and gasket 4 from the muffler 1 muffler 3 spark arrester 2 bolts 4 gasket Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of brakes and holes Replace if necessary Check the gasket Replace if necessary Apply a seizure inhibitor Three Bond 1901 or equivalent to the bolts threads Install the spark arrester and gasket in the muffler 1 and tighten the bolts 2 to the specified torque 4 4 Ibf ft 6 N m 0 6 kgf m 1 muffler 2 bolts Spark Arrester Servicing Your Honda 65
52. 3 O ring 14 spring 9 floating valve 15 and diaphragm 16 10 hole Clean the diaphragm When installing the U ring into the accelerator pump cover 12 make sure the U ring s flatside faces down away from the float bowl 17 12 accelerator pump cover 15 spring 13 U ring 16 diaphragm 14 O ring 17 float bowl 132 Adjustments for Competition 7 Remove the holder screw 18 throttle stop screw holder 19 float bowl screws 20 tube guides 21 and float bowl 17 7 float bowl 8 holder screw 9 throttle stop screw holder 0 float bowl screws 1 1 1 1 2 21 tube guides 8 Remove the pump rod 22 Clean the pump rod and rod passage 23 Install the pump rod into the link lever 24 Push the rod forcibly into the link lever until it snaps into place r 7 23 22 pump rod 24 link lever 23 rod passage 9 Measure the float level 25 with the float level gauge 26 while the float tab is just contacting the float valve with the carburetor intake 27 facing up The float level should be 0 31 in 8 0 mm If the float level is out of specification adjust it by bending the float tab carefully 26 25 float level 26 float level gauge 27 carburetor intake 10 Remove the leak jet 28 from the float bowl 17 Clean the leak jet 17 oo 17 float bowl 28 leak jet Carburetor Adjustment amp Tunin
53. 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 bY LOADED with rider EXAMPLE 19 7 in 500 mm CHAIN ADJUSTER LOCK NUT Example Unloaded 23 6 in 600 mm Loaded 19 7 in 500 mm Race Sag 3 9 in 100 mm 4 Calculate the race sag dimension To do this subtract the loaded with rider dimension step 3 from the unloaded dimension step 2 Standard Race Sag 3 9 in 100 mm Adjust spring pre load as necessary to obtain the desired handling results Decreasing the race sag dimension example 3 5 in 90 mm improves turning ability for tight terrain at the cost of slightly reduced straight line stability Increasing the race sag dimension example 4 3 in 110 mm may improve stability on faster terrain with less turns but will reduce turning performance slightly and may upset the balance between the front and rear suspension producing a harsher ride This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range 5 Measure the lo
54. 4 Starting amp Stopping the Engine ee 15 Prepatation iese EE ee SEGE Ee RS Ses bee 15 Fuel VAVE sis ee Ee EE ee ve ge Re 15 Starting Procedure eee se see see ee ee 15 Flooded Engine is siese deere eg REKE Eseg Ede 16 How to Stop the Engine iese esse esse ese ee see ee 16 Shif ng Gears Es SE Re Ee RE Se N Ek aes 17 Braking fests cases teeta ve Ed EE EER ER Ee ahs dae se 18 Parke ee RE AE AO GE N 19 Post ride InspecCHONn esse esse esse ese ee ee ee ee 20 Break in Guidelines 00 eee se se ee ee ee 21 Basic Operating Instructions Basic Operating Instructions 13 Basic Operating Instructions Safe Riding Precautions Side Stand Tripmeter Before riding your CRF for the first time please The side stand 1 is used to support your CRF The tripmeter 1 is used to record the distance review the Important Safety Precautions while parked page 19 To operate use your foot traveled USA miles Canada kilometers per beginning on page 2 and the previous section to lower the side stand until it is fully extended trip or section of route titled Before Riding Before riding raise the side stand To operate pull the tripmeter reset knob 2 out OFF and turn it until the meter shows all zeros For your safety avoid starting or operating the 0 then push the knob in ON engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area an
55. Clean the battery box after removing the battery for storage Dry the battery box 8 Slow charge the battery see page 100 once every 30 days Installation 1 Reinstall in the reverse order of removal Be sure to connect the positive terminal first then the negative terminal 2 Check all bolts and other fasteners are secure Servicing Your Honda 99 Battery Battery Charging Be sure to read the information that came with your battery charger and follow the instructions on the battery Improper charging may damage the battery We recommended using a trickle charger 1 for home charging These units can be left connected for long periods without risking damage to the battery However do not intentionally leave the charge connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a motorcycle battery and cause permanent damage 1 trickle charger 100 Servicing Your Honda Refer to Safety Precaution on page 25 Headlight Bulb 1 Remove the front visor bolts 1 and pull out the front visor 2 1 front visor bolts 2 front visor 2 Disconnect the headlight connector 3 Remove the dust cover 4 3 headlight connector 4 dust cover 3 To pull the headlight bulb out push and turn the headlight bulb socket 5 counterclockwise f 5 headlight bu
56. Contents SERVICING YOUR HONDA sesse sesse ese 23 Before You Service Your Honda The Importance of Maintenance sesse esse 24 Maintenance Safety sesse ses se ee ed ee 25 Important Safety PrecautionsS esse esse esse 25 Maintenance Schedule eee see se ese see 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal poen EE Ee EE Gee RE ge gee Keehn 36 Fuel Tank Removal esse esse esse see ee se ee ee 37 Subframe Upright Position sees see se esse ese ee 39 Service Procedures Fluids amp Filters Fuel Systemi sei Ee EE De ee De se EE oe Es ENS 41 Enzime Oils As ee de e lots 43 Transmission Oil esse sees ee se ee ee Re Re ee 46 Bere ER N N ER EE EE HE 48 Air Cl aner ts eee oe ee TAS 51 Crankcase Breather sesse esse se ee ee ee ee 53 Engine died ae AA EE NEE RT HEEN 54 Clutch Systeme is fee tain ancien eens 56 Hot Start Lever esse sees esse ee ee ee ee ER ee ee 60 Spark di AAR AN EE 61 Exhaust Pipe Muffler esse esse see ee se ee ese 62 Spark Arreste nsec EE ER ae ee ee ee See 65 Valve Clearance sesse sesse se ee eo Re Re ee 66 Piston Piston Rings Piston PIN esse sesse sees 74 Chassis SUSPENSIOIT Eise Pe keu N ee a 82 Front Suspens
57. EM l 49 DRIVE CHAIN LL R 94 96 DRIVE CHAIN SLIDER l 96 DRIVE CHAIN ROLLER l 96 DRIVE SPROCKET l 95 DRIVEN SPROCKET l 95 BRAKE FLUID NOTE 2 l 87 BRAKE PADS WEAR l 89 BRAKE SYSTEM l 86 CLUTCH SYSTEM NOTE 5 l 56 CONTROL CABLES LL 97 EXHAUST PIPE MUFFLER l 62 SUSPENSION l 82 83 SWINGARM SHOCK LINKAGE L 32 FORK OIL FORK TUBE SLIDER NOTE 3 R 84 DAMPER R 111 NUTS BOLTS FASTENERS l 98 154 156 WHEELS TIRES l 90 91 STEERING HEAD BEARINGS l 97 This maintenance schedule is based upon average riding condition Machine subjected to severe use require more frequent servicing NOTE 1 Clean after every heat for dusty riding conditions 2 Replace every 2 years Replacement requires mechanical skill 3 Replace after the first break in ride 4 Inspect after the first break in ride 5 Replace the transmission oil if the clutch discs and plates are replaced 28 Servicing Your Honda General Competition Maintenance Perform maintenance on firm level ground using the side stand a workstand or eguivalent 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
58. ENANCE SCHEDULE REGULAR OFF ROAD USE NON COMPETITION FREQUENCY Whichever vi Regular Maintenance Interval a First Maintenance Refer mi 100 600 1 200 1 800 2 400 to km 150 1 000 2 000 3 000 4 000 Page ITEMS NOTE Month 1 6 12 18 24 FUEL LINE l l 41 x FUEL STRAINER SCREEN C C 42 THROTTLE OPERATION l l 55 AIR CLEANER NOTE 1 C C Cc C 51 CRANKCASE BREATHER l l I l 53 SPARK PLUG l l I l 61 VALVE CLEARANCE l l I I 66 ENGINE OIL R R R R R 44 ENGINE OIL FILTER R R R R R 44 DECOMPRESSOR SYSTEM I l l I l ENGINE IDLE SPEED I l l I I 134 RADIATOR COOLANT NOTE 3 l R 48 50 COOLING SYSTEM l l I I 49 SECONDARY AIR SUPPLY SYSTEM NOTE 2 l l TRANSMISSION OIL R R R R R 47 DRIVE CHAIN NOTE 1 Lb I L every 300 mi 500 km or 3 months 94 96 DRIVE CHAIN SLIDER I l I l 96 BRAKE FLUID NOTE 3 l l I I 87 BRAKE PADS WEAR l l I I 89 BRAKE SYSTEM I I l I l 87 HEADLIGHT AIM l l 101 CLUTCH SYSTEM l l I l 56 SIDE STAND l l 93 SUSPENSION l l 82 83 SPARK ARRESTER C every 1 000 mi 1 600 km or 65 every 100 operating hours NUTS BOLTS FASTENERS l l 98 154 156 x WHEELS TIRES I l l I I 90 91 x STEERING HEAD BEARINGS I l l 97 Should be serviced by your Honda dealer unless the owner has proper tools and service data and is mechanically qualified Refer to the of
59. GNITION CONTROL MODULE REGULATOR RECTIFIER STARTER MAGNETIC SWITCH hd HO qt af MAIN FUSE 154 amp B 2 BATTERY ENGINE STOP ag STARTER BUTTON EE OP CLUTCH SWITCH z 9 i 12V4AH G RE oh ae z355 a 94 9 o BEER EBEES E fora ol o ol io ee e w i STARTER MOTOR g gt m S gt g3c VEER SE SEE gogg GE B gt go be B GP 6P mE Er 2 y co azr VEER na sEEBEE 35383 Ede 20a non B BI Kt BI BL ap V HT x Gr Gr aoa eo coll Bu a Bu e Ee 8 wW TAILLIGHT G d G f ind tot ed HEADLIGHT 12V35W a 35 of S z a gt z Bi GP 33 gt ass BI BL 4P U 2p G BIY x3 as ENGINE STOP BUTTON STARTER BUTTON a gt B EES eoi g ALTERNATOR BI BLACK Br BROWN CONTINUITY CONTINUITY J Y YELLOW O ORANGE E G BAT3 ST Bu BLUE Lb LIGHT BLUE y SPARK PLUG G GREEN Lg LIGHT GREEN Puss OTO ruse OTO al R RED P PINK FREE cee W WHITE Gr GRAY sone aus Byw eon vin Byer THROTTLE POSITION IGNITION PULSE GENERATOR SENSOR Technical Information 165 166 Technical Information Authorized Manuals Warranty Coverage Warranty Service Contacting Honda Your Honda Dealer This section contains information about contacting Honda and how to get an official Honda service manual Consumer Information Consumer Information 167 Authorized Manuals The Service Manual used by your authorized Honda dealer is available from Helm Inc USA only Canada See your Honda dealer to order authorized
60. Gear sesse sesse ds ede ee ee SE ee 17 Braking AO OE OO N EE 18 Te dir WE DE OER 19 Post ride Inspection ce esse esse ese ee sede ee ee ee 20 Break in Guidelines esse sesse se se ge ee ee 21 SERVICING YOUR HONDA sesse sesse ees 23 Before You Service Your Honda The Importance of Maintenance eee eee 24 Maintenance Safety esse esse see ee 25 Important Safety PrecautiOnsS iese esse see see 25 Maintenance Schedule ees ee se se ee se 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal si Ee RR Ee GE KE EE Kies 36 Fuel Tank Removal sees sees sees se se se ee se 37 Subframe Upright Position 39 Contents Service Procedures Fluids amp Filters DiE n MEE SEE 41 Engine Oil EE OE RE IE ets 43 Transmission Oil esse esse ee ee ee ee ee ee 46 Coolant ME RE RE ene aeea Ee Ge 48 Arr OE AE AR EE ste 51 Crankcase Breather 0 0 0 0 eeeceseecsseceseceeeeeeeeenees 53 Engine Throttle EE OE EE eS 54 ClutchSVStemM sissies DE SeSe Ge castes se anceesessdeenaae 56 Hot Start Lever iese ese esse esse ee ee ee ee ee ee 60 Spark Plug EE EE ean tas 61 Exhaust Pipe Muffler iese esse see ee se ee ee 62 Spark ATrester ses ds see ees eg ees ke 65
61. IMPORTANT NOTICES FOR RECREATIONAL OFF ROAD OR COMPETITION USE ONLY This motorcycle is designed and manufactured for recreational off road use or competition only and is covered by noise control warranty It does not conform to federal motor vehicle safety standards or US EPA On Highway Exhaust Emission regulations and operation on public streets roads or highways is illegal The vehicle is equipped with a USDA qualified spark arrester If you need to cross a paved or public road get off and walk your motorcycle across Do not modify any emission related items except for competition use Any emission related modifications should be restored to standard factory specifications before resuming recreational off road use NO PASSENGERS This motorcycle is designed and constructed as an operator only model The motorcycle load limit and seating configuration do not safety permit the carrying of a passenger This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured on the front cover may not match your vehicle Honda Motor Co
62. ION ee eseesee see 149 Vehicle Identification esse ese se ee ee ee 150 Specifications esse see ee Se de AG AA ee ee 151 Torque Specifications 154 High Altitude Carburetor Adjustment 157 Emission Control Systems sesse see see se see 158 Oxygenated Fuels esse ese se ee ee ee 160 Competition Logbook s es 161 Optional Parts List ees esse esse se ed ee ee ee 163 Spare Parts amp Equipment sesse esse ese esse 164 Wiring DiagrAM esse esse ses se de ee ee 165 CONSUMER INFORMATION esse eseesees 167 Authorized Manuals iese esse ese se ee ee ee 168 Warranty COVErage ese ss sede se ee ee ee 169 Warranty Service sesse askese EER gede 170 Contacting Honda esse esse esse ese ee eed ee ee 171 Your Honda Dealer esse esse esse esse see see ee 172 The Honda Rider s Club USA only 173 TABLE OF CONTENTS ccscssssseseeeeerees 174 led DO EE OE N He 176 OUICK REFERENCE Table of Contents Table of Contents 175 Index A C E ACCESSOMIES ses se Ge se ER hs DE gee gee Deed 4 Capacity Mel o vices sete ssa OER De Re ee se Ee ee 41 engine adjustments carburetor flooded oxceecsscccccasececonshecciasesvecsassvoseranpesvavateese 16 CHASSIS vei cet RE AE EE OE 135 assembly ero EER has GR ER ER EE eyes 133 idl speed sesse RED Ge S 134 control freeplay 54 56 60 86 Circuit FUNCTIONS cece eee rriei
63. Improper freeplay adjustment can cause premature clutch wear Make sure to adjust the clutch lever 1 freeplay after the clutch cable is disconnected 56 Servicing Your Honda Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in direction will increase freeplay and turning it in direction will decrease freeplay If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn and make the adjustment with the integral cable adjuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained 3 lock nut 4 integral cable adjuster increase decrease 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out 5 turns 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your CRF should move smoothly and accelerate gradually I
64. NG 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 o NI 1 transmission oil filler cap 3 sealing washer 2 oil check bolt 1 2 Run the engine at idle for 3 minutes then shut it off Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission Support the CRF in an upright position on a level surface Remove the transmission oil filler cap 1 oil check bolt 2 and sealing washer 3 from the right crankcase cover A small amount of oil should flow out of the oil check bolt hole Allow any excess oil to flow out of the oil check bolt hole If no oil flows out of the oil check bolt hole add oil slowly through the transmission oil filler hole until oil start 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 step 1 4 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 9 Ibf ft 12 N m 1 2 kgf m 6 Install the transmission oil filler cap securely Transmission Oil Replacing Transmission Oil 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1 from the right cr
65. S at 0 85 Starting system Electric Kickstarter Transmission oil NGK ie 100 100 18 59M capacity Spark plug IMR8C 9H elek DUNLOP D756 at draining 0 71 US qt 0 67 Standard GEES Tire type bias ply tube at disassembly 0 79 US at 0 75 VUH24D Tire pressure front cold 15 psi 100kPa 1 0 kgf cm Cooling system For extended high NGK nee ee Tire pressure rear cold 15 psi 100kPa 1 0 kgf cm capacity speed riding at draining 1 19 US qt 1 13 4 DENSO F brake swept area Single dis brake i VUH27D 51 8 in 334 5 cm at disassembly 1 27 US qt 1 20 2 F Spark plug gap 0 03 0 04 in R brake swept area Single de prake Carburetor 0 8 0 9 mm 60 6 in 391 1 cm Type Piston valve Light unleaded gasoline pump Identification number FCRO2B Fuel recommendation octane number of 91 or Head light 12V 35 W higher Main jet 130 Eise Fuel tank capacity 2 19 US gal 8 3 Jel ropade NEAT Main fuse 15A Fuel reserve capacity 0 40 US gal 1 52 alow jet jies Caster angle 27054 Pilot screw opening 2 di turns out Trail length 4 6 in 118 mm Float level 0 31 in 8 0 mm Fork oil capacity Idle speed 1 700 100 rpm except fork damper per leg 11 8 US oz 348 cm Technical Information 151 Specifications For California Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall l
66. Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage 2 Uncover the end of the muffler and remove the rag from the muffler outlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the battery page 100 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 27 US qt 1 20 at disassembly 1 19 US qt 1 13 at draining Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from the system 6 Perform all maintenance checks page 11 142 Tips Owning and riding a motorcycle can be enjoyable but you must do your part to protect nature When you show respect for the land wildlife and other people you also help preserve the sport of off road riding Following are tips on how you can be an environmentally responsible motorcycle owner Choose Sensible Cleaners Use a biodegradable detergent when you wash your CRF Avoid aerosol spray cleaners that contain chlorofluorocarbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and
67. a Hondalock or an equivalent and tighten to the specified torque Between Motos amp Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments e Clean accumulated dirt from under the fenders and off the wheels suspension components handgrips controls and footpegs A stiff nylon parts cleaning brush works well e Check tire air pressure e Check spoke tension and rim lock security e Check sprocket 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 Before amp After Competition Maintenance 1 chain adjuster index marks e Suspend the front wheel above the ground and use the pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi 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 elevatio
68. ack Bel ale AR EE DO HOK 124 Suspension Adjustment Guidelines 125 Carburetor Adjustment amp Tuning Tips 128 Chassis AdjustmentS esse esse ese ee ee ee ee 135 Gearing RE EE OE 136 Tire Selection for Track Conditions 137 Personal Fit Adjustments ee see see se ee 138 Adjustments for Competition Adjustments for Competition 105 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 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 163 The inverted fork on your CRF features sealed damper cartridges with dual separate air and oil chambers to prevent aeration The design also isolates the oil in each fork tube slider which may contain air bubbles and or metal particles from the sealed cartridge to provide more consistent damping 1 compression damping adjuster 2 rebound damping adjuster 106 Adjustments for Competition Front Suspension Air Pressure Air is an unstabl
69. aded without rider dimension Do this with your CRF set at the standard race sag BIKE LOADED without rider EXAMPLE 21 7 in 550 mm Example Unloaded 23 6 in 600 mm Loaded 21 7 in 550 mm Sag 2 0 in 50 mm Without Rider 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 less than 0 4 in 10 mm from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sidewa
70. 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 i aK Ze YN KY 1 tire tread depth Tires amp Tubes Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects Measure tread depth 1 Replace the tire before depth at the center reaches 0 12 in 3 mm or any time you notice a reduction in traction Check the position of both valve stems A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim Tube Replacement If a tube is punctured or damaged you should replace it as soon as possible A repaired tube may not have the same reliability as a new one and it may fail while you are riding Use a replacement tube equivalent to the original Servicing Your Honda 91 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 seriousl
71. age the fork cap bushing Do not disassemble the fork cap assembly Replace the fork cap as an assembly if it is damaged 1 fork cap assembly 2 fork damper 4 Empty the fork oil from the fork damper 2 by pumping the damper rod several times 5 Clean the fork cap and fork damper threads TULL 2 fork damper Front Suspension Adjustments 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 5 US oz 192 cc 6 8 Imp oz 2 fork damper 7 Pump the fork damper piston rod 4 slowly several times to bleed the air from the fork damper 2 Ps 2 fork damper 4 fork damper piston rod cont d Adjustments for Competition 111 Front Suspension Adjustments 8 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper 2 as shown Oil Level 1 65 1 85 in 42 47 mm 1 65 1 85 in 42 47 mm 2 fork damper 9 Apply fork oil to the bushing 5 and new O ring 6 on the fork cap assembly 1 Extend the fork damper piston rod to maximum holding it install the fork cap assembly to the fork damper 2 Be careful not to damage the fork cap bushing If it is difficult to install the fork cap assembly the fork damper oil level might be higher than standard oil level Inspect the fork damper oil level again
72. ain jet 5 baffle plate 2 jet needle 6 float 3 needle jet 7 float valve 4 air jet Adjustments for Competition 129 Carburetor Adjustment amp Tuning Tips Carburetor Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by loosening the carburetor drain screw 1 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 1 carburetor drain screw 3 Tighten the carburetor drain screw after drain the fuel 130 Adjustments for Competition Remove the fuel tank page 37 Remove the band 2 and rear suspension upper mounting nut 3 and pull out the rear suspension upper mounting bolt 4 2 band 3 rear suspension upper mounting nut 4 rear suspension upper mounting bolt 6 Lift the subframe to the upright position page 39 7 Loosen the intake band screw 5 ibs TN 5 intake band screw 8 Disconnect the throttle position sensor connector 6 Remove the carburetor 6 throttle position sensor connector 9 Remove the hot start cable holder 7 7 hot start cable holder Carburetor Adjustment amp Tuning Tips 10 Remove the throttle drum cover bolt 8 and 3 3 Remove the link arm set torx screw 6 throttle drum cover 9 Carburetor Disassembly
73. air cleaner clean amp oiled sealed in a plastic bag chain amp masterlinks chain guide slider chain guide chain rollers inner tubes front amp rear fenders footpegs front visor amp side covers handlebar grips levers brake clutch amp hot start clutch lever handlebar mount clutch cable hot start cable throttle assembly throttle cable shift lever rear brake pedal spokes front amp rear each side sprockets smaller than standard for gearing changes amp collision damage replacement assorted nuts bolts washers screws cotter pins headlight bulbs battery fuses Additional Spares front brake assembly rear brake assembly wheels amp tires front amp rear mounted clutch discs and plates engine amp transmission oil 164 Technical Information seat ignition components radiator hoses radiator shrouds L amp R brake hoses front amp rear General Tools sockets 3 8 in drive screwdrivers blade amp Phillips No 1 2 3 wrench large adjustable wrenches open end amp box wrenches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your motorcycle p
74. ak 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 e crankshaft or crank bearings are replaced Basic Operating Instructions 21 22 Basic Operating Instructions Keeping your CRF well maintained is absolutely essential to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun To help keep your CRF in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on oils and tips for keeping your Honda looking good The ICM Ignition Control Module system is used on this motorcycle consequently routine ignition timing adjustment is unnecessary If you want to check the ignition timing refer to the Honda Service Manual page 168 For information about the exhaust emission and noise emission requirements of the U S Environmental Protection Agency EPA and the California Air Resources Board CARB see page 158 USA only Maintenance replacement or repair of the emission control devices and sy
75. altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 6 500 feet 2 000 meters have your servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications High Altitude Carburetor Adjustment California only Technical Information
76. am chain tensioner lifter cover bolt 16 1 O ring 2 crankshaft hole cap a SS 13 feeler gauge oa 15 sealing washer 16 cam chain tensioner lifter cover bolt 72 Servicing Your Honda Valve Clearance 5 3 Check the rubber seals 5 are in good 5 Connect the direct ignition coil 8 and Cylinder Head Cover Installation condition replace them if necessary breather tube 9 Install the rubber seals onto the cylinder head 1 Check the spark plug hole packing 1 is in cover with the UP marks 6 facing up good condition replace it if necessary Apply engine oil to the spark plug hole packing a and install it to the spark plug hole 2 5 is SN 6 6 5 rubber seal 8 direct ignition coil 6 UP marks 9 breather tube 4 Install the cylinder head cover 4 and tighten 6 Install the fuel tank and the seat pages 36 1 spark plug hole packing the cylinder head cover bolts 7 to the 38 2 spark plug hole specified torque 2 Inspect the cylinder head cover packing 3 PIOREO NMT O kyin for damage or deterioration replace it if necessary Install the cylinder head cover packing into the groove of the cylinder head cover 4 P A 4 cylinder head cover 7 cylinder head cover bolts 3 cylinder head cover packing 4 cylinder head cover Servicing Your Honda 73 Piston Piston Rings Piston Pin 10 Disconnect the direct ignition coil 5 14 Positio
77. amping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil capacity in increments of 0 2 oz 5 cc Entire travel too soft 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 Adjustments for Competition 125 Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff e Stiff on small bumps while riding at full throttle in a straight line e Stiff on small cornering bumps e Front end wanders while riding at full throttle in a straight line Test softer compression damping 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 desire compression damping for initial travel is obtained Middle travel too stiff e Stiff on bumps when cornering e Front end wanders when
78. aner specified for your model or an air cleaner of equal quality Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear Cleaning 1 To open the air cleaner housing cover 1 turn the quick fastener 2 counterclockwise 1 air cleaner housing cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 and air cleaner assembly 4 as shown 3 air cleaner retaining bolt 4 air cleaner assembly Air Cleaner 3 Pull the air cleaner element 5 out from the air cleaner holder 6 5 air cleaner element 6 air cleaner holder 7 tab 8 hole 9 air cleaner tab 4 Wash the air cleaner in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner element is made in two pieces inner and outer which cannot be separated Clean the inside of the air cleaner housing Allow the air cleaner to dry thoroughly After drying soak the air cleaner element in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil Apply air cleaner oil to the entire surface inner and outer and rub it with both hands to saturate the air cleaner with oil Squeeze out excess oil NN cont d S
79. ange Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the outer tube 1 with the top of the upper fork clamp 2 STANDARD POSITON 1 top of outer tube 1 2 upper fork clamp 3 standard position 3 0 in 0 mm Chassis Adjustments Wheelbase Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase be sure to re check race sag and adjust if necessary In the past a general rule was lengthen the wheelbase to add straight line stability shorten the wheelbase to improve turning However we suggest you do not lengthen the wheelbase of your CRF unless you are racing on a track with more fast sections than normal As a general recommendation keep the wheelbase as short as possible This positions the wheels closer together improves turning response increase weighting traction on the rear wheel and lightens weighting on the front wheel With your CRF you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 135 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 a
80. ank Wipe up any spills immediately NOTICE Oxygenated fuels can damage paint and plastic Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments gearing and tire selection This detailed information along with your comments can prove valuable when you compete at the same track or on similar terrain Your logbook can also tell you when maintenance was performed and when it will be necessary again Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components If you choose to sell your CRF the accurate maintenance records in your logbook might be the deciding deal maker for a potential buyer Consider using different color pens or pencils to record important information on specific subjects For example record results in black 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 suspension settings e chassis adjustments tested and selected e gearin
81. ankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil has drained apply fresh engine oil to the transmission oil drain bolt threads and tighten it with a new sealing washer to the specified torque 12 Ibf ft 16 N m 1 6 kgf m 6 Fill the crankcase with recommended oil Capacity 0 71 US qt 0 67 at oil change 7 Check the transmission oil level by following the steps in Checking amp Adding Oil this page ff 1 transmission oil filler cap 2 transmission oil drain bolt 3 sealing washer Servicing Your Honda 47 Coolant Your CRF s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine NOTICE Using coolant with silicate inhibitors may cause premature wear of water seals or blockage of radiator passages Using tap w
82. ankcase with transmission oil page 47 Clutch System Servicing Your Honda 59 Hot Start Lever Refer to Safety Precautions on page 25 Adjustment Adjustments can be made with the cable end adjuster Hot Start Lever Freeplay Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster in direction will increase freeplay and turning it in direction will decrease freeplay After adjustment tighten the lock nut 1 hot start lever 2 freeplay Inspection Check freeplay 1 16 1 8 in 2 3 mm 3 lock nut increase If necessary adjust to the specified range 4 adjuster decrease 60 Servicing Your Honda Refer to Safety Precautions on page 25 Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions Standard IMR8C 9H NGK or VUH24D DENSO Optional IMR9C 9H NGK or VUH27D DENSO Use only the recommended type of spark plugs in the recommended heat range NOTICE Using a spark plug with an improper heat range or incorrect reach can cause engine damage Using a non resistor spark plug may cause ignition problems This motorcycle uses spark plug that have an iridium tip in center electrode and a platinum tip in side electrode Be sure to observe the following when servicing the spark plug e Do not clean the spark plug If an electrode is contaminated with accumulated obj
83. ase allow adequate time for delivery Handling Charge 5 00 Grand Total 168 Consumer Information oda N de AdzZMEKPY NOTE Dealers and Companies please provide dealer or company name and also the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a guotation Customer Name Attention Street Address No P O Box Number Apt City State Zip Code Daytime Telephone Number Check or money order enclosed payable to Helm Inc U S funds only Do not send cash Check here if your billing ME VISA Di address is different from the al Iscover shipping address shown above Account Number Expiration Date Mo Yr Customer Signature Date These Publications cannot be returned for credit without receiving advance authorization within 14 days of delivery On returns a restocking fee may be applied against the original order HELM P O BOX 07280 DETROIT MICHIGAN 48207 Your new Honda is covered by these warranties e Motorcycle Limited Warranty e Exhaust Emission Warranty USA only e Noise Control Warranty USA only There are responsibilities restrictions and exclusions which apply to these warranties Please read the Honda Motorcycle Warranties Booklet given to you
84. ases 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 Symptom Action Soft Initial travel too soft Test stiffer compression damping adjustments in one click increments suspension e Steering is too quick Test stiffer rebound damping in one click increments e Front end darts while cornering or riding in a straight line Middle travel too soft If suspension isn t stiff in initial travel e Front end dives when cornering Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one click increments Test softer compression damping adjustments in one click increments If that doesn t solve the problem install the optional stiff spring Final travel too soft If initial and middle travel aren t stiff 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 spring If initial travel is stiff after installing the optional stiff spring Test softer compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression d
85. ater 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 48 Servicing Your Honda Increasing the concentration of antifreeze is not 2 Open the air cleaner housing cover 4 by recommended because it decreases cooling turning the quick fastener 5 system performance Higher concentrations of counterclockwise and remove the left side antifreeze up to 60 should only be used to cover bolt 6 collar 7 seat mounting bolt provide additional protection against freezing 8 and left side cover 9 Check the cooling system frequently during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 25 1 With the engine at normal operating temperature check the coolant level in the reserve tank It should be between the UPPER 1 and LOWER 2 level marks If the reserve tank 3 is empty or if coolant loss is excessive check for leaks and see your Honda dealer for repair 4 air cleaner housing cover 7 collar 5 quick fastener 8 seat mounting bolt 6 left side cover bolt 9 left side cover 3 Remove the reserve tank cap 10 Always add coolant to the reserve tank Do not attempt to add coolant by removing the radi
86. ator cap 1 UPPER level mark 2 LOWER level mark 3 reserve tank 10 reserve tank cap 4 Add coolant to the reserve tank as reguire to bring the coolant level to the UPPER level mark Install the reserve tank cap 10 Install the left side cover 9 collar 7 seat mounting bolt 8 and left side cover bolt 6 Close the air cleaner housing cover 4 and turn the quick fastener 5 clockwise Tighten the seat mounting bolt to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 7 4 air cleaner housing cover 5 quick fastener 6 left side cover bolt 7 collar 8 seat mounting bolt 9 left side cover 10 reserve tank cap Cooling System Inspection 1 Check the cooling system for leaks see the Honda Service Manual for troubleshooting of leaks Check the water hoses 1 for cracks deterioration and radiator hose clamp for looseness Check the radiator mount for looseness Make sure the siphon hose 2 is connected and not clogged Check the radiator fins for clogging Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water seal is damaged If oil leaks through the check hole the engine oil seal is damaged See the Honda Service Manual or consult your Honda dealer for replacing the water seal or the engine oil seal Both seals should be replaced at th
87. automobile battery when the car engine is running can damage your CRF s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer Taking Care of the Unexpected 147 148 Taking Care of Unexpected This section contains dimensions capacities and other technical data Vehicle Identification esse ese ee ee ee ee 150 Specifications si ese EE ag ese SE SR EE 151 Torque SpecificatlONnS esse esse esse ee se ee ee 154 High Altitude Carburetor Adjustment 157 Emission Control Systems i e sesse see se ee 158 Oxygenated Fuels esse esse ee se ee ee 160 Competition Logbook sesse esse se ee ee ee 161 Optional Parts LISE esse esse se ee ee ee 163 Spare Parts amp Equipment esse esse see se ee 164 Wiring Diagram esse esse ds sed ee AG Ee eee 165 Technical Information Technical Information 149 Vehicle Identification Sarsal Nanhers hari n number 2 is stamped on the left The VIN and engine serial numbers are required LEFT SIDE when you register your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the streering head RIGHT SIDE 2 engine number 150 Technical Information For USA except California Spec
88. by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly check all parts for proper installation and operation All Pre ride Inspection Items Refer to Pre ride Inspection page 11 Servicing Your Honda 29 General Competition Maintenance Spark Plug Some non resistor plugs may cause ignition problems Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range Replace periodically as specified in the Maintenance Schedule pages 27 28 N Engine oil and Filter Drain and replace engine oil often to ensure the greatest service life of the piston cylinder and crankshaft Also replace engine oil filter often to ensure the greatest service life Frequent changes will also assure consistent performance of power and response page 44 30 Servicing Your Honda Transmission Oil Drain and replace transmission oil often to ensure the greatest service life of the transmission and clutch Frequent changes will also assure consistent performance of both shifting and clutch action page 47 Air Cleaner Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance Both engine performance and long term durability may be affected by an air cleaner that
89. by your Honda dealer at the time of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle Your warranty coverage will not be voided if you choose to perform your own maintenance However you should have the prope tools and service information and be mechanically qualified Failures that occur due directly to improper maintenance or lack of maintenance are not covered Almost all of your warranty coverage can be extended through the Honda Protection Plan USA only For more information see your Honda dealer Warranty Coverage Consumer Information 169 Warranty Service Please remember taht recommended maintenance interval servicing is not included in your warranty coverage Additionally your warranty does not apply to the normal wear of items such as brakes tires etc If you belive you have a problem with your Honda call the service department of your Honda dealer Make an appointment for an inspection and diagnosis Remember as the owner of the motorcycle you will be asked to authorize that inspection Your dealer will give you the results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you
90. d contamination esse esse see see ee ee ee ee ee 51 Clutch operation and freeplay eee 56 Hot start lever freeplay esse sesse esse ee ee 60 Breather drain for cleaning ss ss sesse 53 Steering head bearings and related parts for condition soisin se Re ee ee ee ee 97 Carburetor throttle operation 0 0 0 0 see ses 55 Engine idle speed for stable and proper REM cosets EE Ge Ge ed ge ed 134 Tires for damage or improper inflation PICSSULE ie EE PR sesse ees Ie gee Poes sd ee NG 91 Spokes for looseness 90 Rim locks for loosenesS ee se ee see 90 Front and rear suspension for proper OpeTAHON sesse ae see ee De ee gee eg Des 82 83 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 94 Drive chain guide sliders and guide rollers for damage OF Wear i e ese see ee ee ee 96 Exhaust pipe Muffler inspection 62 Every possible part for looseness such as cylinder head nuts engine mounting bolts axle nuts handlebar holder bolts fork bridge pinch bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt etc ees see ee 98 154 156 Before Riding 11 12 Before Riding This section gives basic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions sesse esse se ee ee 14 Side Stand ii ages EA Eer Ge e ee 14 Ti1pmeter EER EE ORE ete bee eb ds 1
91. d cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob 14 Basic Operating Instructions Always follow the proper starting procedure described below Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Fuel Valve ON OFF RES 1 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor OFF Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor RES Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor Starting Procedure Always follow the proper starting procedure described as follow 1 fuel valve 2 choke knob Check the engine oil transmission oil and coolant levels before starting the engine pages 44 47 48 To restart a warm engine follow the procedure for High Air Temperature Normal Air Temperature 10 C 35 C 50 F 95 F 1 Turn the fuel valve 1 ON 2 Pull the choke knob 2 fully ON if the engine is cold 3 Keep the throttle fully closed 4 Pull the clutch lever all the way i
92. d compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after end of 1 Test softer rebound damping adjustment continuous bumps 2 If it still bottoms test stiffer high and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a stiffer spring optional if necessary 127 Adjustments for Competition Carburetor Adjustment amp Tuning Tips The carburetor used on your CRF will seldom experience trouble with the standard settings under average load and average climatic and barometric conditions However to fine tune the engine s power output the carburetor may reguire specific adjustments for competition use However in order to comply with emission regulations we recommend that you make no carburetor changes unless you use your CRF for competition only 128 Adjustments for Competition Carburetor Components Cold Start Circuit A very rich mixture must be delivered to the cylinder when a cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder
93. d record it Sixty nine different thickness shims 2 are available from the thinnest 1 200 mm thickness shim to the thickest 2 900 mm thickness in intervals of 0 025 mm 2 shim 3 A A B C D Calculate the new shim thickness using the equation below B C D New shim thickness Recorded valve clearance Specified valve clearance Old shim thickness Make sure of the correct shim thickness by measuring the shim with a micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2 900 mm 1 80 mm 1 825 mm 1 85 mm 1 875 mm Valve Clearance 7 3 Rotate the primary drive gear bolt 4 5 Apply grease to the set rings and install it Camshaft Installation crankshaft clockwise and align the punch onto the camshaft holders 11 mark 5 with the A mark 6 Apply oil to the camshaft holder bolt threads 1 Install the newly selected shims 1 on the and seating surface Install the camshaft holder bolts 12 and tighten it to the specified to torque 12 Ibf ft 16 N m 1 6 kgf m valve retainers 2 NOTICE Tighten the camshaft holder bolts in a criss cross Do not let the shims fall into the crankcase P 7 pattern in two or three steps AS 4 primary drive gear bolt 5 punch mark 6 A mark 4 Apply molybdenum
94. damaging the adjustment needle be sure to record the number of turns from the starting position 1 2 compression damping adjuster 1 rebound damping adjuster Adjustments for Competition 107 Front Suspension Adjustments 1 Place your CRF on the optional workstand or equivalent support with the front wheel off the ground 2 Remove the front visor bolts 3 and front visor 4 3 front visor bolts 4 front visor 3 Disconnect the headlight connector 5 5 headlight connector 4 Remove the handlebar pad Remove the handlebar holder nuts washers mounting rubbers 6 and handlebar 7 108 Adjustments for Competition NOTICE Keep the master cylinder upright to prevent air from entering system Gea 6 handlebar holder nuts washers mounting rubbers 7 handlebar 5 Loosen the upper pinch bolts 8 6 Loosen the fork damper 9 using the lock nut wrench but do not remove it yet NOTICE Do not use an adjustable wrench to loosen the fork damper it may damage them 8 upper pinch bolts 9 fork damper 7 Remove the disc cover 10 by removing the bolts 11 10 disc cover 11 bolts 8 Remove the tripmeter cable 12 and front axle nut 13 and loosen the axle pinch bolts 14 on both fork legs 9 Pull the front axle shaft 15 out of the wheel hub and remove the front wheel wis SAAG 14 axle pinch bolts k k 12
95. damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 124 Do not attempt to disassemble service or 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 pages 121 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 121 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound damping adjusters in one click or in 1 12 turn increments If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Bounce the rear of the motorcycle up and down and check for smooth suspension action 2 Lift the subframe to the upright position page 39 3 Check for a broken or collapsed spring 4 Check the rear shock absorber 1 for a bent rod or oil leaks 1 rear shock absorber 5 P
96. e 9 engine hanger nuts bolts 11 cylinder head bolts 10 engine hanger plates 12 cylinder bolt 19 Remove the cylinder head nuts washers 13 and cylinder head 14 Loosen the nuts in a criss cross pattern in two or three steps 15 dowel pins 17 cam chain guide 16 cylinder head gasket NOTICE Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase 13 cylinder head nuts washers 14 cylinder head Servicing Your Honda 75 Piston Piston Rings Piston Pin Cylinder Removal 1 Remove the cylinder bolt 1 and cylinder 2 NOTICE Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder 1 cylinder bolt 2 cylinder 2 Remove the dowel pins 3 and cylinder gasket 4 NOTICE Do not let the dowel pins fall into the crankcase 3 dowel pins 4 cylinder gasket 76 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 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hours of running 1 piston pin clip 2 piston pin 4 Spread each piston ring
97. e break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load Pre load should be adjusted when the engine is cold because it is necessary to remove the muffler page 62 An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place your CRF on an optional workstand or equivalent support with the rear wheel off the ground 2 Loosen the connecting tube clamp screw and subframe mounting upper bolt and remove the rear subframe mounting lower bolts then lift the subframe See page 39 120 Adjustments for Competition 3 Check that the spring pre load is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjusting nut changes the spring length by 0 06 in 1 5 mm 4 After adjustment hold the adjusting nut and tighten the lock nut to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 1 lock nut 2 adjusting nut 3 pin spanners 4 spring length To increase spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 9 6 in 243 mm To decrease spring pre load Loosen the lock nut with the optional pin spanner 3 and turn the adjusting nut to increase the spring length 4 Do not increase to more than 10 14
98. e same time 1 water hoses 2 siphon hose 3 water leakage check hole 4 water pump cover Coolant Servicing Your Honda 49 Coolant Coolant Replacement Refer to Safety Precautions on page 25 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 168 A WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap To properly dispose of drained coolant refer to You amp the Environment page 143 NOTICE Improper disposal of drained fluids is harmful to the environment 50 Servicing Your Honda Coolant System Bleed Air 1 Remove the radiator cap 1 Fill the system with the recommended coolant through the filler opening up to filler neck Use a fresh recommended coolant mixture 1 27 US at 1 20 at disassembly 1 19 US qt 1 13 at coolant change 3 Turn the quick fastener 2 counterclockwise and open the air cleaner housing cover 3 4 Remove the left side cover bolt 4 collar 5 seat mounting bolt 6 and left side cover 7 5 Remove the reserve tank cap 8 and fill the reserve tank to the UPPER level line 9 OY a e 8 i quick fastener air cleaner housing
99. e sure the reservoir is horizontal first e Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible e The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent 1 screws 2 reservoir cap 3 diaphragm 4 upper level mark 1 Remove the screws 1 reservoir cap 2 and diaphragm 3 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 4 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 0 7 Ibf ft 1 0 N m 0 1 kgf m 88 Servicing Your Honda Adding Rear Brake Fluid NOTICE Spilled brake fluid will severely damage instrument lenses and painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first e Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible e The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent 5 bolts 6 reservoir cap 7 set plate 8 diaphragm 9 upper level mark 1 Remove the bolts 5 reservoir cap 6 set plate 7 and diaphragm 8 Check the diaphragm installation as shown 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark
100. e 5 9 US oz 175 cm of fork fluid to be left in the chamber FENN 9 oil hole Front Suspension Adjustments 15 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 16 If you can not use compressed air remove the pressure release screw 10 on the fork cap 11 Hold the fork damper up side down for 10 minutes and drain the oil from the fork damper spring chamber 10 10 pressure release screw 11 fork cap Adjustments for Competition 113 Front Suspension Adjustments Fork Assembly Drain the fork oil from the outer tube slider 1 by placing it upside down About 7 cc of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 20 C 1 outer tube slider 114 Adjustments for Competition Amount of fork oil left in the fork without damper and spring unit cc minute 5 10 20 35 55 85 145 OPF 30 86 7 1 59 4 7 42 35 35 3 5 20 68 10 6 8 2 7 1 5 9 5 6 4 7 4 7 10 50 11 8 83 7 2 6 2 5 8 4 9 4 8 0 32 12 9 10 6 9 4 8 2 7 9 7 1 5 9 cc 16 0 C 32 F ME 10 C 50 F 12 FAK 20 C 68 F 10 i 30 C 86 F Amount of fork oil Inverted time minutes 2 Tighten the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the
101. e gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure is 0 psi 0 kPa 0 kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place your CRF on an optional warkstand or equivalent support with the front wheel off the ground 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 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 adjust
102. e piston rings and cylinder walls i Si oe 5 piston rings cylinder AU Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankcase guide hole 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs Piston Piston Rings Piston Pin Cylinder Head Installation 1 Install the dowel pins 1 and new cylinder head gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 1 dowel pins 2 cylinder head gasket cont d Servicing YourHonda 79 Piston Piston Rings Piston Pin 2 Route the cam chain through the cylinder head 3 Install the cylinder head NOTICE Do not damage mating surfaces when installing the cylinder head 3 Apply engine oil to all cylinder head nut threads Install the washers and cylinder head nuts 4 Tighten the cylinder head nuts to the specified torque 29 Ibf ft 39 N m 4 0 kgf m NOTICE Do not let the washers and nuts fall into the crankcase Tighten the cylinder head nuts in a criss cross pattern in two or three steps EE ao N 3 cylinder head 4 cylinder head nuts washers 80 Servicing Your Honda 4 Install the cylinder bolt 5 cylinder head bolts 6 and tighten them to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 5 cylinder bolt 6 cylinder head bolts 5 In
103. e vous bruler DRL HITS D Motorcycle Safety 5 6 Motorcycle Safety Operating Controls Read this section carefully before you ride It Operation Component Locations iese esse esse 8 presents the location of the basic controls on your CRE Operating Controls 7 Operation Component Locations hot start lever tripmeter clutch lever front brake lever engine stop button throttle grip kickstarter fuel valve shift lever rear brake pedal 8 Operating Controls Before Riding Before each ride you need to make sure you and Are You Ready to Ride esse esse esse ese see 10 your Honda are both ready to ride To help get Is Your Motorcycle Ready to Ride ee 11 you prepared this section discusses how to Pre ride Inspection esse esse see ee ee ee ee ee 11 evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustment for competition see page 105 Before Riding 9 Are You Ready to Ride Before riding your CRF for the first time we recommend that you read this owner s manual make sure you understand the safety messages and know how to operate the controls Before each ride it s also important to make sure you and your CRF are both ready to ride For information about suspension carburetor and other adjustments see page 105 Whether you re preparing for competition or for
104. eavier 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 retums very slowly and doesn t contact the ground guickly enough after each bump The result is a loss of traction and slower lap times 124 Adjustments for Competition Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF using the methods described on pages 106 124 Remember to make all adjustments in one click increments Test ride after each adjustment Front Suspension Adjustment Adjustments for Type of Track Hard surfaced track Begin with the standard setting If the suspension is too stiff soft adjust according to the chart below Sand track Adjust to a stiffer position Example Turn the compression damping adjuster to a stiffer position Install the optional stiff spring Adjust compression damping to a softer position and rebound damping to a stiff position at this time Mud track Adjust to a stiffer position because mud build up incre
105. ects or dirt replace the spark plug with a new one e To check the spark plug gap use only a wire type feeler gauge To prevent damaging the iridium tip of the center electrode and platinum tip of the side electrode never use a leaf type feeler gauge e Do not adjust the spark plug gap If the gap is out of specification replace the spark plug with a new one Spark Plug Replacement amp Inspection 1 Remove the seat and fuel tank pages 36 37 2 Disconnect the direct ignition coil 1 3 Clean any dirt from around the spark plug base 4 Remove the spark plug 2 1 direct ignition coil 2 spark plug 5 Check the electrodes for wear or deposits the sealing gasket 3 for damage and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 03 0 04 in 0 8 0 9 mm 3 sealing gasket 4 spark plug gap Spark Plug 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Push the engine stop button and disengage the clutch by pulling the lever in Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If you re using a new plug ride for at least 10 minutes before taking a plug reading a brand new
106. ed for units that will be operated in conditions with high engine load and low vehicle speed Whenever you ride tread lightly By staying on established trails and riding only in approved areas you help protect the environment and keep off road riding areas open for the future If you have any questions or if you ever need a special service or repairs remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important production information You may also want to visit our website at www honda com Happy riding California Proposition 65 Warning WARNING This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You will find important safety information in a variet
107. elines e Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability e Place weight as close to the center of the motorcycle as possible Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front fender e Check that both tires are inflated properly Loading Motorcycle Safety 3 Accessories amp Modifications Accessories amp Modifications Modifying your CRF or using non Honda accessories can make your CRF unsafe Before you consider making any modifications or adding an accessory be sure to read the following information A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories 4 Motorcycle Safety Accessories We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your CRF Because Honda cannot test all other accessories you must be personally responsible for proper selection installation and use of non Honda accessories Check with your dealer for assistance and always follow this guideline e Make sure the accessory does not reduce ground clearance and lean angle limit suspension travel or steering travel
108. ely before shifting NOTICE Improper shifting may damage the engine transmission and drive train Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Downshift to a lower gear before you feel the engine laboring lugging at low rpm NOTICE Downshifting can help slow your motorcycle especially on downhills However downshifting when engine rpm is too high can cause engine damage NOTICE To prevent transmission damage do not coast or tow the motorcycle for long distances with the engine off Shifting Gears Basic Operating Instructions 17 Braking To slow or stop apply the front brake lever and rear brake pedal smoothly while downshifting to match your speed Gradually increase braking as you feel the brakes slowing your speed To prevent stalling the engine pull the clutch lever in before coming to a complete stop For support put your left foot down first then your right foot when you are through using the rear brake pedal For maximum braking close the throttle and firmly apply the front brake lever and rear brake pedal controls Applying the brakes too hard may cause the wheels to lock and slide reducing control of your CRE If this happens release the brake controls steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your s
109. 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 160 Technical Information If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel 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 t
110. emove the clutch lifter assembly 10 and clutch lifter rod 11 7 Remove the eight clutch discs seven clutch plates judder spring and spring seat 12 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 10 clutch lifter assembly 11 clutch lifter rod 12 clutch discs clutch plates judder spring and spring seat Servicing YourHonda 57 Clutch ystem Clutch Disc Plate Inspection Replace the clutch discs 1 if they show signs of scoring or discoloration Measure the thickness of each clutch disc Service Limit 0 112 in 2 85 mm Replace the clutch discs and clutch plates as a set 1 clutch disc Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 004 in 0 10 mm Replace the clutch discs and plates as a set 2 clutch plate 58 Servicing Your Honda Clutch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 1 50 in 38 0 mm Replace the clutch springs as a set if any one of them is beyond the service limit or if the clutch plates have been burn heat discolored Clutch Disc Plate Installation 1 Install the spring seat 1 and judder spring 2 onto the clutc
111. ength 85 5 in 2 172 mm Type Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 32 6 in 827 mm Cylinder arrangement Single 10 inclined from Transmission 5 speed constant mesh Overall height 49 6 in 1 261 mm vertical Primary reduction 3 611 Wheelbase 58 3 in 1 481 mm Bore and stroke 3 07 x 2 06 in Cees Gear ratio 2 384 Seat height 37 7 in 958 mm Displacement 152 cu in 249 cm Gear ratio II 1 750 Footpeg height 17 0 in 432 mm Compression ratio 129 1 Gear ratio III 1 333 Ground clearance 13 6 in 346 mm Vae die r nce Intake 0 005 0 001 in Gear ratio IV 1 041 Frame cold 0 12 0 03 mm Gear ratio V 0 814 Type Twin tube Exhaust 0 011 0 001 in Final reduction 3 786 Telescopic fork 0 28 0 03 mm Left foot operated return F suspension travel 11 0 in 280 mm Engine oil capacity Pear shi pantern system 1 N 2 3 4 5 stroke 12 4 in 315 mm at draining 0 70 US at 0 66 2 Electrical Pro link at draining and R suspension i Battery 12V 4 Ah P travel 12 3 in 312 mm oil filter change 0 73 US at 0 69 E 80 100 21 51M rep IEM Tire size front DUNLOP D742F at disassembly 0 90 US qt 0 85 Starting system Electric Kickstarter Transmission oil NGK Ester 100 100 18 59M capacity Spark plug IMR8C 9H eer Al DUNLOP D756 at draining 0 71 US at 0 67 S
112. ents until the correct settings are obtained as described Symptom Action Stiff suspension Suspension feels stiff on small 1 Test softer low speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Suspension feels stiff on large 1 Test softer high speed compression adjustment bumps 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings Soft suspension Entire travel too soft 1 Test stiffer high and low speed compression adjustments simultaneously 2 If it still feels soft replace the spring with a stiffer spring optional and begin with the standard settings to stiffer setting Rear end sways 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing 1 Test stiffer high speed compression adjustment after jumping 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a stiffer spring optional if necessary Suspension bottoms after landing 1 Test stiffer low spee
113. er is set in the standard position when the adjuster is turned counterclockwise 14 clicks Make sure that both fork legs are adjusted to the same position Compression Damping Adjustment This adjustment affects how quickly the fork compresses The fork compression damping adjuster 2 screw has 16 positions or more Turning the adjuster one full turn changes the adjuster four positions To adjust the adjuster to the standard position proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 7 clicks Make sure that both fork legs are adjusted to the same position Both compression and rebound damping can be increased by turning the adjuster clockwise NOTICE Always start with full hard when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the rebound and compression adjusters are firmly located in a detent and not between positions 1 2 compression damping adjuster 1 rebound damping adjuster Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 Ibs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each
114. ervicing YourHonda 51 Air Cleaner 7 10 Apply a thin coat of Pro Honda White Lithium Grease or equivalent to the sealing surface Assemble the air cleaner element and holder Install the tab 7 of the holder in the hole 8 of the air cleaner tab 9 Install the air cleaner assembly into the air cleaner housing Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner element with the A mark 11 of the air cleaner housing by rotating the air cleaner assembly counterclockwise Install and tighten the air cleaner retaining bolt 3 securely 3 air cleaner retaining bolt 10 access tab 11 A mark 52 Servicing Your Honda NOTICE Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 11 Close the air cleaner housing cover 1 and turn the quick fastener 2 clockwise 1 air cleaner housing cover 2 quick fastener Refer to Safety Precautions on page 25 Crankcase Breather Service more frequently if your CRF is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather
115. es of the swingarm 1 rear axle nut 2 lock nut 3 adjusting bolt 4 index mark 5 axle plate 6 reference marks 3 Tighten the rear axle nut to the specified torque 94 Ibf ft 127 N m 13 0 kgf m Recheck chain slack and adjust if necessary Turn the adjusting bolt counterclockwise lightly until it touches the axle plate Then tighten the lock nut to the specified torque by holding the adjusting bolt with a wrench 20 Ibf ft 27 N m 2 8 kgf m ye Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing Your CRF has an endless riveted master link type chain It should only be removed or replaced by your Honda dealer The O rings can be damaged by steam cleaning high pressure washers and certain solvents 1 Clean the side surfaces of the chain with a dry cloth Use a high flash point solvent such as kerosene not gasoline Do not brush the rubber O rings Brushing will damage them Use of a solvent may also damage the O rings 2 Replace the drive chain if it has damaged rollers loose fitting links damaged O rings or other wise appears unserviceable 3 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced Replacement Chain Size link DID520MXV 116 1 drive chain plate inner 4 Inspect the sp
116. extend the service life of the engine Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine Oil Recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label viscosity SAE 10W 30 weight JASO T 903 standard MA suggested oil Pro Honda GN4 4 stroke oil or an equivalent x Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label Engine Oil e Your CRF does not need oil additives Use the recommended oil e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication NOT RECOMMENDED OK e Oil is a major factor affecting the peformance and service life of the engine Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 10W 40 10W 30 10 20 30 40 50 C 20 0 20 40 60 80 100 120 Servicing YourHonda 43 Engine Oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conformin
117. f you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn Inspect the clutch discs and plates page 58 Other Inspections amp Lubrication e Check that the clutch lever assembly is positioned properly the end of the holder 1 aligned with the paint mark 2 on the handlebar and the securing bolts are tight ie 1 holder ad 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 2 paint mark 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 47 2 Remove the rear brake pedal 1 by removing the pin 2 and pivot bolt 3 washer 4 and dust seals 5 1 rear brake pedal 2 pin 3 pivot bolt 4 washer 5 dust seals 3 Remove the five clutch cover bolts 6 and clutch cover 7 6 clutch cover bolts 4 Remove the five clutch spring bolts and clutch springs 8 Loosen the bolts in a crisscross pattern in two or three progressive steps Clutch System 5 Remove the clutch pressure plate 9 4 A do 9 clutch pressure plate 6 R
118. ficia Honda Service Manual page 168 In the interest of safety we recommended these items be serviced only by your Honda dealer Maintenance Schedule Summary of Maintenance Schedule Notes and Procedures NOTES 1 Service more freguently when ridden in wet or dusty conditions 2 USA and Canada type only 3 Replace every 2 years Replacement reguires mechanical skill Servicing Your Honda 27 Maintenance Schedule MAINTENANCE SCHEDULE COMPETITION USE All items should be checked before each competition event See your Honda dealer unless you are mechanically qualified and have the proper tools Damage from competition use is not covered by the Distributor s Limited Warranty on your Honda Perform the Pre ride Inspection page 11 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace FREQUENCY NOTE os rs bie ED rs ee een es ae Ref Page ITEMS THROTTLE OPERATION l 55 HOT START SYSTEM l 60 AIR FILTER NOTE 1 C 51 CRANKCASE BREATHER l 53 SPARK PLUG l 61 RADIATOR COOLANT NOTE 2 l 48 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 66 ENGINE OIL NOTE 3 l R 44 ENGINE OIL FILTER NOTE 3 R 44 ENGINE IDLE SPEED l 134 PISTON AND PISTON RINGS R 76 PISTON PIN R 76 TRANSMISSION OIL NOTE 5 l R 47 COOLING SYST
119. flame away e Handle fuel only outdoors e Wipe up spills immediately Fuel System Fuel Line 1 fuel line 1 Check for leaks 2 Check the fuel line 1 for cracks deterioration damage or leakage Replace the fuel line if necessary 3 Check for interference between the frame and tank and adjust if necessary Servicing Your Honda 41 Fuel System Fuel Filter The fuel filter is mounted on the bottom left side of the fuel tank Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor To 1 2 3 1 42 service the fuel filter Drain the fuel from the fuel tank into an approved gasoline container Remove the fuel tank page 37 Remove the fuel joint 1 from fuel tank by removing the bolts 2 fuel joint 2 bolts Servicing Your Honda 3 fuel filter Wash the fuel filter 3 in high flash point cleaning solvent Check that the O ring 4 is in good condition and install it onto the fuel joint Install the fuel filter in the fuel tank by tightening the bolts to the specified torque 7 Ibf ft 10 N m 1 0 kgf m Refill the fuel tank Attach the fuel valve and fuel line and turn the fuel valve to ON or RES check for fuel leaks e df 3 Oo 4 4 O ring Refer to Safety Precautions on page 25 Using the proper oil and regularly checking adding and changing oil will help
120. for more information from owning and riding your Honda is through or call 1 800 847 4722 or log on to the Honda Rider s Club of America Your www hrca honda com purchase of a new motorcycle scooter ATV or PWC from a participating U S Honda dealer entitles you to a complimentary one year membership in the Club There are handreds of HRCA Chapter sponsoring dealers across the USA with events and activities almost every weekend Membership benefits include e 24 hour toll free roadside assistance for your new Honda includes roadside assistance for your transport vehicle up to one ton as long as your Honda is aboard or in tow For street legal motorcycles and scooters only e An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more e Reimbursement up to 75 for successful completion of a Motorcycle Safety Foundation training course Separate complimentary training from the Specialty Vehicle Institute of America for purchasers of new ATVs e One full year of Honda Red Rider magazine Six issues Discounts from HRCA partners for experienced rider courses e Discounted vehicle insurance from the HRCA s insurance partner e Racing contingency programs and assistance at selected dual sport off road and motocross events for off road motorcycles and selected ATVs If you purchased an off road motorcycle ATV or PWC your benefits do not incl
121. ft side cover 10 3 Remove the seat 11 page 36 5 air cleaner housing cover 9 collar 6 quick fastener 10 left side cover 7 left side cover bolt 11 seat 8 seat mounting bolt Subframe Upright Position 4 Remove the muffler page 62 7 Loosen the subframe mounting upper bolt 5 Remove the wire band 12 rear suspension 17 and remove the subframe mounting lower upper mounting nut 13 and bolt 14 bolts 18 17 E 18 12 wire band 13 rear suspension upper mounting nut 14 rear suspension upper mounting bolt 17 subframe mounting upper bolt 18 subframe mounting lower bolts 6 L h 15 he air cl 8 Lift the subframe 19 as shown er Ine Screw 15 on the air cleaner Tighten the subframe mounting upper bolt to connecting tube clamp 16 the specified torque 22 Ibf ft 30 N m 3 1 kgf m 15 screw 16 air cleaner connecting tube clamp 19 subframe Servicing Your Honda 39 Subframe Upright Position Installation 1 Loosen the subframe mounting upper bolt 1 2 Loosely attach the lower ends of the subframe 2 to the mainframe while connecting the air cleaner connecting tube to the carburetor Then align the subframe with the rear wheel and tighten the subframe mounting lower bolts 3 and subframe mounting upper bolt to the specified torgue upper bolts 22 Ibf ft 30 N m 3 1 kgf m lower bolt 36 Ibf ft 49 N m 5 0 kgf m 1 subframe mounting u
122. g 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 running time on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many hours of running The most effective way to schedule maintenance is by the hours you have run your CRF An official guesstimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft operators do but without the benefit of an electrical hourmeter All running time is broken down into hours and tenths of an hour each 6 minutes represents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include e Your placing in each moto and overall finishing position e Thoughts on what you could do to improve your performance next time e Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events 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
123. g Tips 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 Ibf ft 2 1 N m 0 2 kgf m accelerator pump cover screws 1 5 Ibf ft 2 1 N m 0 2 kgf m carburetor top cover bolts 1 5 Ibf ft 2 1 N m 0 2 kgf m jet needle holder assembly 1 5 Ibf ft 2 1 N m 0 2 kgf m leak jet 0 2 Ibf ft 0 3 N m 0 03 kgf m rink arm set torx screw 1 5 Ibf ft 2 1 N m 0 2 kgf m throttle drum cover bolt 2 5 Ibf ft 3 4 N m 0 3 kgf m hot start cable nut 1 5 Ibf ft 2 1 N m 0 2 kgf m throttle cable lock nut 3 0 Ibf ft 4 N m 0 4 kgf m throttle cable bolt 3 0 Ibf ft 4 N m 0 4 kgf m shock absorber upper mounting nut 32 Ibf ft 44 N m 4 5 kgf m e Route the throttle cables 1 hot start cable 2 and throttle sensor wire correctly e After installing the carburetor adjust the throttle cable freeplay and hot start cable freeplay e After installing the carburetor check the throttle position sensor connector 3 for correct routing e After installing the carburetor check the air vent hoses 4 and overflow hose 5 for kinking or pinching and correct routing 1 throttle cables 2 hot start cable 3 throttle position sensor connector Adjustments for Competition 133 Carburetor Adjustment amp Tuning Tips Idle Speed Adjustment
124. g to the standard is labeled on the oil container For example the following label shows the MA classification MA e PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 1 code number of the sales company of the oil 2 oil classification 44 Servicing Your Honda Checking amp Adding Oil N 3 1 engine oil filler cap dipstick 2 upper level mark 3 lower level mark 1 Run the engine at idle for 3 minutes then shut it off 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine 3 Support the CRF in an upright position on a level surface 4 Remove the engine oil filler cap dipstick 1 wipe it clean and insert the engine oil filler cap dipstick without screwing it in Remove the engine oil filler cap dipstick 5 Check that the oil level is between the upper 2 and lower 3 level marks on the engine oil filler cap dipstick e Ifthe oil is at or near the upper level mark you do not have to add oil e Ifthe oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil amp Filter 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface
125. ghten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 13 lower pinch bolts 17 Tighten the fork damper assembly 4 to the specified torque using the lock nut wrench 14 Actual 25 Ibf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m using a 20 in 50 cm long torque wrench When using the lock nut wrench use a 20 inch long deflecting been type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper 14 4 fork damper assembly 14 lock nut wrench 18 For ease of releasing air pressure after the forks are installed Loosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters Align 15 the top surface of the upper fork clamp 16 with the outer tube slider 1 upper surface as shown Front Suspension Adjustments 1 outer tube slider 15 align 16 upper fork clamp 19 Tighten the fork lower pinch bolts 13 to the specified torque 15 Ibf ft 20 N m 2 0 kgf m 20 Tighten the fork upper pinch bolts 17 to the specified torque 16 Ibf ft 22 N m 2 2 kgf m NOTICE Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced EE a 13 13 lower pinch bolts 17
126. h center as shown Coat the clutch discs 3 and plates 4 with clean engine oil 2 Install the clutch disc A larger I D disc 5 onto the clutch outer Stack the seven clutch plates and seven clutch discs alternately 1 spring seat 2 judder spring 3 clutch discs 4 clutch plates 5 clutch disc A 3 Insert the clutch lifter rod into the mainshaft 4 Install the clutch lifter assembly 6 onto the rod 6 clutch lifter assembly 5 Install the clutch pressure plate 7 6 Install the five clutch springs and clutch spring bolts 8 7 Tighten the bolts in a crisscross pattern in two or three steps to the specified torque 9 Ibf ft 12 N m 1 2 kgf m 7 clutch pressure plate 8 clutch spring bolts clutch springs 8 Install a new O ring 9 in the groove of the clutch cover 10 9 Install the clutch cover by tightening the clutch cover bolts to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 9 O ring 10 clutch cover 10 Apply grease to the rear brake pedal pivot bolt sliding surface 11 Install the rear brake pedal 12 dust seals 11 washer 15 and pivot bolt 13 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 12 Insert the pin 16 Ce ve Nin 15 11 dust seals 14 return spring 12 rear brake pedal 15 washer 13 pivot bolt 16 pin 13 Fill the cr
127. has r deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 51 Use the Honda genuine air cleaner or an equivalent 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 Pro Honda Handgrip Cement or equivalent if there is any doubt to its sealing integrity Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt
128. he lower end of the slider 29 28 lock nut wrench 29 slider lower end Front Suspension Adjustments NOTICE The outer tube 26 can drop on the slider 30 and damage the fork dust seal 24 and guide bushing 31 when the fork damper is removed To avoid damage hold both the outer tube and Slider when removing the fork damper NO GOOD x 24 31 ie TES A II Hyr 30 NO GOOD 26 24 dust seal 26 outer tube 30 slider 31 guide bushing 16 Drain the fork oil from the outer tube 26 Drain the fork oil from the oil hole 32 of the fork damper A 26 32 EE HE STL 26 outer tube 32 oil hole cont d Adjustments for Competition 109 Front Suspension Adjustments 17 Temporarily install the fork damper to the outer tube 18 Set the lower end axle holder 33 of the slider in a vise with a piece of wood or soft jaws to avoid damage NOTICE Overtightening the vise can damage the axle holder 19 Loosen the fork center bolt 34 33 33 axle holder 34 fork center bolt 20 Push out the fork center bolt from the axle holder of the slider by pushing the fork damper 21 Make the mechanic s stopper tool out of a thin piece of steel 1 0 mm thick as shown if you do not have the special tool 55 mm 25 mm end ae A ami 30 mm 110 Adjustments for Co
129. 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 CRE 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 102 Servicing 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 NOTICE High pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi surface cleaner
130. ich could catch on the control levers kickstarter footpegs drive chain or wheels Take Time to Learn and Practice Developing off road riding skills is a gradual step by step process Start by practicing at low speed in a safe area and slowly build your skills Personal instruction from an experienced rider can also be valuable If you need assistance ask your dealer about riding groups in your area Also be sure to read the Tips amp Practice Guide for the Off Highway Motorcyclist booklet that came with your CRF USA only Be Alert for Off Road Hazards The terrain can present a variety of challenges when you ride off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Ride within Your Limits Pushing limits is another major cause of motorcycle accidents Never ride beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and ride safety Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let your friends drink and ride either Keep Your Honda In Safe Condition It s important to keep you
131. id a possible costly engine repair If your CRF overturns or is involved in a crash be sure your Honda dealer inspects all major parts even if you are able to make some repairs Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section 24 Servicing Your Honda A WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual Maintenance Safety This section includes instructions on how to perform some important maintenance tasks Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owner s manual Important Safety Precautions e Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Bu
132. iesene 128 NUMBER Hi ed ER ee Ge AE ie 150 for competition iese see ee AA 105 COMPONENS ee ee AA ee ee 128 PIN SIDE E GELE BREED GE ee tesa 41 eie AA N OE TN 136 disassembly en sede ERF ee ed Gee ES eetehi 131 Ee EE EE eben 15 high altitude carburetor iese esse see ee 157 high altitude adjustment sesse see ee 157 StOP DUON sees see ee RA AA ee ee 16 IIS speed ac EE RR ek Re a 134 IDS Speed aie ER TE eet RD Ge ee 134 SLOPPINS SE N EE cca trates EE ie 16 personal fit si ieke ER SEED se tint ei be 138 vol IE AE 130 RE EE 144 suspension TONE ee ee ee 106 CALE appeatanCe seeks SE ien GEE See rischi 102 exhaust pipe SUSPENSION TEAT esse esse ese ee RA ee ee 120 Chat drive ses ese ee ON SEE Rek see Dee 94 TEMOVAl winched hehe tien Ee se 64 suspension track conditions sesse sees 124 Chassis adjustments sesse ese ee ee ee ee ee 135 installation i e ee esse eg heed ee EE ee 64 tire seleCHON sesse sees ee ee AA ee ee 92 CHOKE ai RE EE eies eins 15 environment protecting esse sesse ee see see 143 after competition maintenance sesse sesse 33 cleaner Ii EE EA NG 51 air cleanen narenn i ai ea 51 cleaning appearance care see ee ee 102 F air pressure clutch system adjustment sesse sees see ee ee 56 front SUSPENSION sesse see see ee Se ee ee 106 consumer information sesse see see ee ee ee 167 filter El AE EE AR AE 91 competition logbook esse se ee ee ee 161 EN RE KO EE 51 apparel protectiVe
133. ifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85 5 in 2 172 mm Type Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 32 6 in 827 mm Cylinder arrangement Single 10 inclined from Transmission 5 speed constant mesh Overall height 49 6 in 1 261 mm vertical Primary reduction 3 611 Wheelbase 58 3 in 1 481 mm Bore and stroke 3 07 x 2 06 in es Gear ratio 2 384 Seat gigi 37 7 L 958 mm Displacement 152 cuin 249 cm Gear ratie Il 1 750 Footpeg height 17 0 L 432 mm Compression ratio 129 1 Gear rao III 1 333 Ground clearance 13 6 in 346 mm VaWeclearance Intake 0 005 0 001 in Gear ratio IV 1 041 Frame cold 0 12 0 03 mm Gear ratio V 0 814 Type Twin tube Exhaust 0 011 0 001 in Final reduction 3 786 i 0 28 0 03 mm l Telescopic fork l Gear shift pattern Left foot operated return F suspension travel 11 0 in 280 mm Engine oil capacity system 1 N 2 3 4 5 stroke 12 4 in 315 mm at draining 0 70 US qt 0 66 Electrical Pro link at draining and R suspension Batter 12V 4 Ah R travel 12 3 in 312 mm oil filter change 0 73 US qt 0 69 x 80 100 21 51M i a cid Tire size front DUNLOP D742F es 0 90 U
134. il to the threads and flange surface 2 U nut 3 UBS nut 4 Alock bolt Replace with a new one Technical Information 155 Torque Specifications Frame FRAME Torque Item Ibfeft Nem kgfem Remarks 23 Front brake disc nuts 12 16 1 6 NOTE 2 24 Rear brake disc nuts 12 16 1 6 NOTE 2 25 Rear brake pedal pivot bolt 27 36 3 7 26 Spokes 2 7 3 68 0 4 27 Rim locks 9 12 1 2 28 Subframe upper 22 30 3 1 23 mounting bolts ower 36 49 5 0 N 29 Fork center bolt 51 69 7 0 30 Fork center bolt lock nut 16 22 2 2 31 Disc cover bolts 10 13 1 3 32 Fork protector bolts 5 2 7 0 7 NOTE 4 33 Muffler mounting bolts front 19 26 2 7 rear 19 26 2 7 34 Muffler clamp bolt 15 21 2 1 35 Driven sprocket nuts 24 32 3 3 NOTE 2 36 Seat mounting bolts 19 26 2 7 37 Front brake reservoir cap screws 0 7 1 0 0 1 38 Rear brake reservoir cap bolts 0 7 1 0 0 1 39 Fork air pressure release screw 0 9 1 2 0 1 40 Side stand mounting 32 bolts upper 40 54 5 5 27 lower 29 39 4 0 41 Shroud B bolts 3 7 5 0 5 42 Fuel joint bolts 7 10 1 0 43 Brake lever adjuster lock nut 4 4 5 9 0 6 Brake pedal adjuster lock nut 4 4 5 9 0 6 29 30 156 Technical Information 44 26 NOTES 3 UBS nut 1 Apply oil to the threads and flange surfaces 2 U nut 4 Alock bolt Replace with a new one At high
135. inch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 32 Install the tripmeter cable 41 and tighten the lock nut securely 39 handlebar pad 38 front visor bolts up and down several times to seat the axle and Front Suspension Adjustments 33 Install the disc cover 42 and tighten the bolts 43 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m 42 disc cover 43 bolts 34 Turn the rebound damping 44 and compression damping 45 adjuster back to their original setting 44 45 compression 44 rebound damping damping adjuster adjuster Adjustments for Competition 119 Rear Suspension Adjustments The rear suspension can be adjusted for the rider s weight and riding conditions by changing the spring pre load and the rebound and compression damping The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your Honda dealer The instructions found in this owner s manual are limited to adjustments of the 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 authorized Honda dealer or a qualified mechanic equipped with the proper tools safety equipment and the Honda Service Manual If your CRF is new put enough part throttl
136. ion Inspection cece 82 Rear Suspension Inspection eeeee eee 83 Recommended Fork Oil esse esse esse see ee 84 Fork Oil Change sesse ss se se ee ee 84 Brakes Re E Gas test aves ae Ge eg 86 ER RE N en iiet stee eoe rren 90 Tires se TUDES Ee ese anie eainnt 91 Side Stand ine einen AE OE RE iea 93 Drive Chaitss EA ER EK 94 Additional Maintenance Procedures iese 97 Electrical et oo EE EE EG 99 Headlight amp Taillight 2 0 0 se se see se Ge ee 101 Appearance Cate iiir see ses ee se ee ee E 102 ADJUSTMENTS FOR COMPETITION 105 Front Suspension Adjustments eee 106 Rear Suspension Adjustments essen 120 Suspension Adjustments for Track Conditions 32 EE EO eks 124 Suspension Adjustment Guidelines 125 Carburetor Adjustment amp Tuning Tips 128 Chassis Adjustments 135 ET i aT OS OE OE eee eee 136 Tire Selection for Track Conditions 137 Personal Fit Adjustments 2 0 0 0 ee see see see 138 TIP Soe bose EE ee N EG GR De oe 139 Transporting Your Motorcycle ees esse esse 140 Storing Your Honda sesse esse esse ees see ee ee 141 You amp the Environment iese ese esse esse ee see ese 143 Troubleshooting esse se ee ee AA Ge ee 144 TAKING CARE OF THE UNEXPECTED ese esee see sees se esse see sees se ee ese ee ee 145 Ifa Fuse BION S Deer SE EE ER SE GESE Dee 146 If Your Battery Is Low or Dead sesse esse 147 TECHNICAL INFORMAT
137. ith the tab 6 of the frame 2 Remove the seat 2 by sliding it backward 2 Install and tighten the seat mounting bolts to the specified torque 19 Ibf ft 26 N m 2 7 kgf m 1 seat mounting bolts 2 seat 3 seat front prong 4 seat bracket 5 seat rear prong 6 tab 36 Servicing Your Honda Refer to Safety Precautions on page 25 Removal 1 Turn the fuel valve OFF 2 Remove the seat page 36 3 Remove the shroud A bolts collars 1 4 Remove the shroud B bolts collars 2 and shrouds 3 1 shroud A bolts collars 2 shroud B bolts collars 3 shroud 5 Pull the breather tube 4 out of steering stem nut 6 Unhook and remove the fuel tank band 5 7 Unhook the air cleaner cover rubber 6 8 Remove the fuel tank bolt 7 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt 4 breather tube a Fuel Tank Removal 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank Remove the fuel valve bolt 10 and fuel valve 11 Remove the fuel tank 10 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 TOETER I ea TRES Ta Fli zee
138. k oil by turning the outer tube 1 upside down About 12 cc of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F fi S N W SS SEASONS 1 outer tube Amount of fork oil left in the fork within damper and spring minute unit cc 5 10 20 35 55 85 145 C F 30 86 27 15 3 106 94 83 7 9 7 9 20 68 29 4 16 5 11 8 10 6 9 4 8 2 82 10 50 28 2 21 2 16 5 15 3 12 9 11 8 11 8 0 32 30 6 22 4 18 8 16 5 16 5 15 3 14 1 0 C 32 F 10 C 50 F oe 20 C 68 F 30 C 86 F 0 20 40 60 80 100 120 140 160 Inverted time minutes 5 Pour the recommended fork oil page 84 into the outer tube Optional Softer 0 40 kgf mm Fork Spring 3 scribe marks Standard oil 11 9 US oz capacity 353 cm3 Maximum oil 13 7 US oz Slightly stiffer as capacity 404 cm3 it nears full compression Minimum oil 10 4 US oz Slightly softer as capacity 308 cm3 it nears full compression Fork Oil Capacity Standard 0 42 kgf mm Fork Spring g_______ No mark factory products as 2 scribe marks Ce aftermarket parts Optional Stiffer 0 44 kgf mm Fork Spring gt 1 scribe mark Standard oil 11 8 US oz Standard oil 11 9 US oz capacity 348 cm3 capacity 351 cm3 Maximum oil 13 5 US oz S
139. l 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 Tips Here s helpful advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 0 0 0 0 cece 140 Storing Your Honda esse esse sesse sees se ee se ee ee 141 You amp the Environment sesse sees ses ese esse see 143 Troubleshooting sesse esse se ee ee ee ee 144 Tips 139 Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport your Honda we recommend that you follow these guidelines e Use a loading ramp e Make sure the fuel valve is off e Secure the motorcycle in an upright position using motorcycle tie down straps Avoid using rope which can loosen and allow the motorcycle to fall over 140 Tips To secure your CRF brace the front wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on your CRF Attach to the upper ends of the straps to the handlebar one on the right side the other on the left close t
140. lb socket 4 To install a new headlight bulb push and turn the headlight bulb socket clockwise If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to prevent early bulb failure 5 Install the dust cover 4 tightly against the headlight unit with its TOP mark 6 facing up ARR 4 dust cover 6 TOP mark 6 To install the headlight reverse the removal procedure Headlight amp Taillight Headlight Aim The headlight aim can be raised or lowered Turn the adjusting screw 1 clockwise to move the headlight up or turn the adjusting screw counterclockwise to move the headlight down to proper adjustment 1 adjusting screw Taillight The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibility of damage to the lighting system if the battery is carelessly removed Never kick start the engine without the battery connected If it becomes necessary to kick start the engine with the battery removed remove the relays to the battery to prevent damage to the lighting Servicing Your Honda 101 Appearance Care Refer to Safety Precautions on page 25 Frequent cleaning and polishing will keep your Honda looking newer longer Frequent cleaning also identifies you as an owner who values
141. lightly stiffer as Maximum oil 13 6 US oz Slightly stiffer as capacity 399 cm3 it nears full capacity 402 cm3 it nears full compression compression Minimum oil 10 2 US oz Slightly softer as Minimum oil 10 3 US oz Slightly softer as capacity 303 cm3 it nears full capacity 306 cm3 it nears full compression compression Be sure the oil capacity is the same in both fork legs Suspension 6 Check taht the O ring 10 on the fork damper 2 is in good condition Apply the recommended fork oil to the O ring 10 EA 1 r Ng f ill 10 O ring 1 outer tube 2 fork damper 7 Temporarily install the fork damper 2 to the outer tube 1 After installing the fork leg page 117 tighten the fork damper to the specified torque Actual 25 Ibf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 Ibf ft 31 N m 3 2 kgf m Servicing Your Honda 85 Brakes Refer to Safety Precautions on page 25 Both the front and rear brakes are the hydraulic disc type As the brake pads wear the brake fluid level will drop A leak in the system will also cause the level to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding check the brake pads If they are not worn beyond the recommended limit page 89 there is probab
142. lt 2 3 4 5 6 13 98 Servicing Your Honda LEFT SIDE 8 1 i 1 cylinder head cover bolts 7 cylinder bolt 8 oil filter cover bolts 9 cylinder head bolts 10 drive sprocket bolt 11 engine oil drain bolt 12 transmission oil drain bolt Refer to Safety Precautions on page 25 Your CRF has a maintenance free type battery You do not have to check the battery electrolyte level or add distilled water as you would with a conventional type battery NOTICE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed Electrical accessories use current from the battery even when the engine is stopping Limited operation also allows the battery to discharge If you have electrical accessories on your motorcycle or do not ride frequently we recommended that you charge the battery frequently see Battery Charging on page 100 If you do not expect to ride your CRF for at least two weeks we recommended you remove the battery or at least disconnect the battery cables negative cable first If you plan to store your CRF see Battery Storage this page If your battery seems weak and or is leaking electrolyte cause slow starting or other electrical problems see your Honda dealer WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Battery Storage If you plan t
143. ly air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system 86 Servicing Your Honda Front Brake Lever Adjustment _ LESS T T N THAN lt 18 16 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 While holding the adjuster tighten the lock nut to the specified torque 4 4 IDf ft 5 9 N m 0 6 kgf m 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay LESS THAN 13 16 in 20 mm 6 Apply grease to the contacting faces of the adjuster and piston 3 Rear Brake Pedal Height The rear brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in direction to raise the rear brake pedal 3 or in direction to lower it 2 Tighten the lock nut to the specified torque at the desired pedal height 4 4 Ibf ft 5 9 N m 0 6 kgf m 1 lock nut 2 adjusting bolt 3 rear brake pedal raise the pedal height lower the pedal height Fluid Level Inspection
144. m frame only Appearance Care Exhaust Pipe And Muffler Maintenance The exhaust pipe and muffler are stainless steel but may became stained by oil or mud To remove mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well with clean water Dry with chamois or a soft towel If necessary remove heat stains by using a commercially available fine texture compound Then rins by the same manner as removing mud or dust Servicing YourHonda 103 104 Servicing Your Honda This section tells you how to fine tune your CRF for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both stiffer and softer than standard rates in order to tailor your CRF specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments cece 106 Rear Suspension Adjustments iese sesse sees 120 Suspension Adjustments for Tr
145. monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons Exhaust Emission Control System The exhaust emission control system is composed of appropriate carburetor settings No adjustments should be made except for an idle speed adjustment with the throttle stop screw The exhaust emission control system is separate from the crankcase emission control system Secondary Air Injection System The exhaust emission control system consists of a secondary air injection system The secondary air injection system introduces filtered air into the exhaust gases in the exhaust port The secondary air injection system helps improve emission performance No adjustments to this system should be made although periodic inspection of the components is recommended Crankcase Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion muffler through the air cleaner and the carburetor Emission Control Systems Technical Information 159 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
146. mpetition 22 Apply pressure to the fork damper and insert a special tool or mechanic s stopper tool 35 see below between the axle holder 33 and lock nut 36 23 Hold the lock nut and remove the fork center bolt 34 from the fork damper NOTICE Do not remove the lock nut from the fork damper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you can not reassemble the fork damper 33 axle holder 34 fork center bolt 35 stopper tool 36 lock nut 24 Remove the push rod 37 from the fork damper 25 Remove the special tool or mechanic s stopper tool between the axle holder 33 and lock nut 36 while applying pressure to the fork cap NOTICE Be careful not to damage the lock nut and fork center bolt hole 33 axle holder 36 lock nut 37 push rod 26 Remove the fork damper assembly 38 from the fork assembly 39 Remove the fork from the vise Remove the fork spring 40 from the fork 38 39 38 fork damper assembly 40 fork spring 39 fork assembly Damper Oil Change 1 Place the fork damper 2 in a vise with a piece of wood or soft jaws to avoid damage 2 Loosen the fork cap assembly 1 while holding the fork damper 2 using the lock nut wrench 3 3 lock nut wrench 1 fork cap assembly 2 fork damper 3 Remove the fork cap assembly 1 from the fork damper 2 Be careful not to dam
147. n and depress the start button Or operate the kickstarter to start the engine Starting from the top of the stroke kick through to the bottom with a rapid continuous motion Do not operate the throttle NOTICE Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case Starting amp Stopping the Engine 5 Warm up the engine don t operate the throttle 6 About 15 seconds after the engine starts push the choke knob all the way to fully OFF If idling is unstable open the throttle slightly NOTICE Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine High Air Temperature 35 C 95 F or above 1 Do not use the choke 2 Keep the throttle fully closed 3 Start the engine following step 4 under Normal Air Temperature Low Air Temperature 10 C 50 F or below 1 Follow steps 1 4 under Normal Air Temperature 2 Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF NOTICE Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine Hot Engine Starting 1 Pull the hot start lever 3 all the way in and start the engine following step 4 under Normal Air Temperature 2 As soon as the engine starts release the hot start lever 3
148. n increases 2 pressure release screw After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will prevent rusting of the exposed metal Apply rust inhibiting oil more heavily if the event was particularly wet or muddy Take care to avoid spraying any oil near the brake pads or the brake discs Clean and lubricate the drive chain page 96 Be sure the chain is wiped clean and is dry before lubricating the chain Take care to prevent catching your fingers between the chain and sprocket Servicing Your Honda 33 Before 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 ex
149. n the piston to top dead center on the 11 Remove any dirt around the spark plug base compression stroke page 66 Remove the camshaft page 68 15 Loosen the radiator hose clamp 7 and disconnect the radiator hose 8 Cylinder Head Removal 1 Clean the area above the engine before disassembly to prevent dirt falling into the engine 2 Drain the engine oil page 44 3 Drain the radiator coolant after cooling the motorcycle page 141 4 Remove the seat and fuel tank pages 36 37 5 Lift the subframe to the upright position page 39 6 Remove the carburetor page 130 7 Remove the exhaust pipe page 64 8 Disconnect the air suction 1 and vacuum hoses 2 5 direct ignition coil 9 Remove the air supply pipe bolt 3 PAIR control valve bolts nuts 4 and PAIR control 12 Remove the cylinder head cover page 66 7 radiator hose clamp valve 5 13 Remove the spark plug 6 8 radiator hose 1 air suction hose 4 PAIR control valve bolts nuts 2 vacuum hose 5 PAIR control valve 6 spark plug 3 air supply pipe bolt 74 Servicing Your Honda Piston Piston Rings Piston Pin 16 Remove the engine hanger nuts bolts 9 and 17 Remove the cylinder head bolts 11 20 Remove the dowel pins 15 cylinder head engine hanger plates 10 18 Loosen the cylinder bolt 12 gasket 16 and cam chain guide 17 x NOTICE Do not let the dowel pins and cam chain fall into the crankcas
150. ng more than 3 molybdenum disulfide additive to the connecting rod small end 3 Install the piston 1 with the IN mark 2 and or the large valve recesses 3 facing the intake side of the engine 4 Apply clean engine oil to the piston pin 4 Install the piston pin and new piston pin clips 5 NOTICE Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 6 78 Servicing Your Honda 1 piston 2 IN mark 3 large valve recesses 4 piston pin 5 piston pin clip 6 piston cut out Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust or dirt from entire the engine 2 Clean off any gasket material from the gasket surface of the crankcase 3 Remove the shop towel Do not let any gasket debris fall into the crankcase 4 Install the dowel pins 1 and new cylinder gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 1 dowel pins 2 cylinder gasket 5 Clean the any gasket material off the cylinder 6 Apply clean engine oil to the cylinder wall piston outer surface and piston rings Route the cam chain 3 through the cylinder 4 Install the cylinder over the piston rings by hand while compressing the piston rings 5 NOTICE Do not damage th
151. no VIND esse esse sees 150 W warranty COVETA QC ss NE N EO EES 169 SEFVICE EE ER Ee Ge 170 washing your Motorcycle esse sesse esse se ee 102 Wer Sht LMit sr EE OE secant taboos 3 WEEMS A fd E ED ve ee ee Ged tees 90 wiring diagraM 0 ese ese ee see see Ge ee ee ee ee 165 178 Index Memo 179 Ouick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important notes How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of costly engine repairs are e Transmission oil amp engine oil insufficient quantity improper oil e Air cleaner dirty leaking because of improper installation poor seal Quick Reference Record important information here VIN Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr Maintenance The maintenance schedule pages 27 28 lists service frequencies for about 2 5 hours about 7 5 hours about 15 0 hours about 22 5 hours and about 30 0 hours Pre ride Inspection Check the items listed on the Pre ride Inspection checklist each time before you ride page 11 Fuel
152. nt Replace the hydraulic fluid in the brake system every 2 years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service 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 32 Servicing Your Honda 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 Steering Head Bearings Periodically clean inspect and regrease the steering head bearings especially if wet muddy or extremely dusty courses are encountered often Use urea based multi purpose g
153. o store your CRF we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the battery we recommend disconnecting the battery cables negative cable first You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging on page 100 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label A WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery maintenance The battery is located under the seat Removal 1 Remove the seat page 36 2 Remove the battery band 1 3 Remove the positive terminal cover 2 Battery 4 Disconnect the negative terminal 3 first then the positive terminal 4 and remove the battery 5 M 1 battery band 2 positive terminal cover 3 negative terminal 4 positive terminal 5 battery 5 Unless you have been riding regulary charge the battery see page 100 6 Store your battery in an easy to reach location off the floor in an area protected from freezing temperatures and direct sunlight 7
154. o the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damage the fork seals Use another tie down strap to keep the rear of the motorcycle from moving We recommend that you do not transport your CRE on its side This can damage the motorcycle and leaking gasoline could be a hazard If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your CRF running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRE If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry Change the engine oil and filter page 44 Change the transmission oil page 47 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and loosen the carburetor drain screw Drain gasoline into an approved container Tighten the carburetor drain screw to the specified torque 1 1 Ibf ft 1 5 N m 0 2 kgf m A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel
155. oil completely off the fork damper N4 f ZAK A N 2 lock nut A thread length 3 Using compressed air blow all oil off the fork spring 3 Install the fork spring Install the fork damper assembly 4 to the outer tube slider 1 mm 4 S i a MA m yy TA 1 outer tube slider 3 fork spring 4 fork damper assembly 4 Place the lower end axle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage NOTICE Overtightening the vise can damage the axle holder 5 Temporarily install the fork damper to the fork Push out the fork damper piston rod from the axle holder of the slider by pushing the fork damper Apply pressure to the fork damper and insert the special tool or mechanic s stopper tool 5 between the axle holder and lock nut 2 Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the fork damper piston rod until it stops Check the push rod installation by turning the push rod right and left 7 Apply fork oil to a new O ring 7 and install it to the fork center bolt 8 Apply locking agent to the fork center bolt threads Install the fork center bolt to the fork damper piston rod aligning the fork center bolt adjusting rod 9 with the push rod Tighten the fork center bolt fully by hand 2 lock nut 5 stopper tool 6 push rod 7 O ring 8 fork center bol
156. olts 3 16 Ibf ft 22 N m 2 2 kgf m Tighten the front bolts first 1 handlebar 3 handlebar upper holder bolts 2 paint mark Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable Be sure the throttle returns freely from fully open to fully closed automatically in all steering positions Servicing Your Honda 97 Additional Maintenance Procedures Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing ENGINE Torque item Ibfeft Nem kgfem 1 Cylinder head cover bolts 7 10 1 0 2 Exhaust pipe joint nuts 15 21 2 1 3 Coolant drain bolt 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 5 Transmission oil check bolt 9 12 1 2 6 Clutch cover bolts 7 10 1 0 7 Cylinder bolt 7 10 1 0 8 Oil filter cover bolts 9 12 1 2 9 Cylinder head bolts 7 10 1 0 10 Drive sprocket bolt 23 31 3 2 11 Engine oil drain bolt 12 16 1 6 12 Transmission oil drain bolt 12 16 1 6 13 Air supply pipe bolt 7 10 1 0 RIGHT SIDE exhaust pipe joint nuts coolant drain bolt crankshaft hole cap transmission oil check bolt clutch cover bolts air supply pipe bo
157. oop 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 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 fo
158. operative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles reader pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by your Honda dealer 1 Hard starting or stalling after starting 2 Rough idle 3 Misfiring or backfiring during acceleration 4 After burning backfiring 5 Poor performance drive ability and poor fuel economy Federal regulations prohibit removing or disabling a device or element of design that may affect your engins s emission performance unless your CRF will be used exclusively in competition If you modify your engine for use in sanctinoed competition events you must deface or destroy the emission control information label Source of Emission The combustion process produces carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon
159. or Dead sesse esse 147 TECHNICAL INFORMATION esse see sees 149 Vehicle Identification ees sesse see se ee 150 Specifications sesse se ee En is et 151 Torque SpecificatHOnS esse sesse see se se ee 154 High Altitude Carburetor Adjustment 157 Emission Control Systems iss see ss sees se see 158 Oxygenated Fuels ioin esse esse ss see se ee ee 160 Competition Logbook n se 161 Optional Parts LISE esse sesse see ee ee ee 163 Spare Parts amp Equipment sesse esse esse se ee 164 Wiring Diagram esse esse esse esse ae se ee AA ee ee 165 CONSUMER INFORMATION esse sesse 167 Authorized Manuals ees se se see se se ee 168 Warranty Coverage esse esse se se ee ee ee 169 Warranty Service ees esse see se ee AA ee ee 170 Contacting Honda esse sees sees see ee ee ee ee 171 Your Honda Dealer esse esse ese ee se ee see se ee 172 The Honda Rider s Club USA only 173 TABLE OF CONTENTS sesse sesse esse ese ese 174 INDEX esse ee ee ee ee gee Gees Ge ee GN ee 176 OUICK 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 safety labels on your CRF Motorcycle Safety Motorcycle Safety 1 Important Safety Information Important Safety Precautions Your CRF can provide many years of pleasure if you take
160. pacity Standard 0 42 kgf mm Fork Spring O No mark factory products or aftermarket parts OQ 2 scribe marks Standard oil 11 8 US oz capacity 348 cm3 Maximum oil 13 5 US oz Slightly stiffer as capacity 399 cm3 it nears full compression Minimum oil 10 2 US oz Slightly softer as capacity 303 cm3 it nears full compression Optional Softer 0 40 kgf mm Fork Spring 3 scribe marks Standard oil 11 9 US oz capacity 353 cm3 Maximum oil 13 7 US oz Slightly stiffer as capacity 404 cm3 it nears full compression Minimum oil 10 4 US oz Slightly softer as capacity 308 cm3 it nears full compression Optional Stiffer 0 44 kgf mm Fork Spring C gt 1 scribe mark Standard oil 11 9 US oz capacity 351 cm3 Maximum oil 13 6 US oz Slightly stiffer as capacity 402 cm3 it nears full compression Minimum oil 10 3 US oz Slightly softer as capacity 306 cm3 it nears full compression Be sure the oil capacity is the same in both fork legs 14 Check that the O ring 12 on the fork damper assembly 4 is in good condition Apply the recommended fork oil to the O ring 15 Pull up the outer tube slider 1 slowly and install the fork damper assembly 4 into the outer tube 12 4 12 1 el 1 outer tube slider 4 fork damper assembly 12 O ring 16 Insert both fork legs into the fork clamps Ti
161. peat kickstarter hold the engine stop button operation approximately ten times very slowly to discharge excessive fuel from the engine Close the throttle 3 Pull the hot start lever all the way in and start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 16 Basic Operating Instructions eN 1 Your CRF has five forward gears in a one down four up shift pattern To start riding after the engine has been warmed and the side stand raised 1 Close the throttle and pull the front brake lever in 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the front brake Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will stall If the engine rpm speed is too high or you release the clutch lever too quickly your CRF may lurch forward 5 When you attain a moderate speed close the throttle pull the clutch lever in and raise the shift lever After shifting release the clutch lever and apply the throttle 6 To continue shifting up to each higher gear repeat step 5 7 To shift down to a lower gear close the throttle pull the clutch lever in and depress the shift lever After shifting release the clutch lever and apply the throttle Remember to close the throttle and pull the clutch lever in complet
162. peed or complete braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your CRF When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking accelerating or turning When descending a long steep grade use engine compression braking by downshifting with intermittent use of both brakes When you brake to a stop pull the clutch lever in before stopping completely to prevent stalling the engine For support put your left foot on the ground first then your right foot when you re through braking 18 Basic Operating Instructions Parking Lower the side stand to support your CRF If you re through riding for the day turn the fuel valve OFF Always choose a level surface to park Basic Operating Instructions 19 Post ride Inspection When you return home after riding thoroughly clean your CRF and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your CRF for leaks or damage Be sure to lubricate the drive chain page 96 to prevent rusting 20 Basic Operating Instructions Bre
163. posed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your CRF or use cleaners refer to Appearance Care page 102 34 Servicing Your Honda engine oil filter engine oil filler hot start lever clutch lever fuel fill cap engine idle choke knob coolant reserve tank ir rs rear suspension al cleaner i spring pre load battery adjuster spark arrester ha SP crankcase breather GEEN Gara ol HI 4 LSS ST i S NA YS transmissions oil drain bolt cap dipstick i f engine oil drain drive chain bolt Maintenance Component Locations front brake fluid reservoir front brake lever throttle grip radiator cap front suspension compression damping adjuster rear suspension rebound damping rear suspension high speed adjuster damping adjuster rear suspension low speed damping adjuster oe aA EE transmission oil check bolt y rear brake transmission oil pedal filler cap front suspension rebound damping adjuster rear brake fluid reservoir rear brake caliper Servicing Your Honda 35 Seat Removal Refer to Safety Precautions on page 25 Installation 1 Install the seat while aligning the seat front Removal prong 3 with the seat bracket 4 and seat 1 Remove the seat mounting bolts 1 rear prong 5 w
164. pper bolt 2 subframe 3 subframe mounting lower bolts 40 Servicing Your Honda 3 Tighten the screw 4 on the air cleaner connecting tube clamp 5 4 screw 5 air cleaner connecting tube clamp 4 Install the rear suspension upper mounting bolt 6 nut 7 and wire band 8 Tighten the rear suspension upper mounting nut to the specified torque 32 Ibf ft 44 N m 4 5 kgf m 6 rear Suspension upper mounting bolt 7 rear suspension upper mounting nut 8 wire band 5 Install the muffler page 63 Install the seat 9 page 36 Install the left side cover 10 seat mounting bolt 11 collar 12 and left side cover bolt 13 Close the air cleaner housing cover 14 and turn the quick fastener 15 clockwise ON 9 seat 13 left side cover bolt 10 left side cover 14 air cleaner housing cover 11 seat mounting bolt 15 quick fastener 12 collar 8 Install the right side cover 16 seat mounting bolt 17 collar 18 and right side cover bolt 19 16 right side cover 17 seat mounting bolt 18 collar 19 right side cover bolt 9 Tighten the seat mounting bolts to the specified torque 19 Ibf ft 26 N m 2 7 kgf m Refer to Safety Precautions on page 25 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 exhau
165. r CRF properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your CRF before every ride and perform all recommended maintenance Your CRF was designed as a rider only motorcycle It was not designed to carry a passenger or cargo A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the CRF In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your CRF s handling braking and stability Adding accessories or making modifications that change this CRF s design and performance can also make it unsafe Also the weight of any accessories will reduce the maximum load the motorcycle can carry More specific information on load limits accessories and modifications follows Loading How much weight you put on your CRF and how you load it are important to your safety If you decide to carry cargo you should be aware of the following information A WARNING Overloading or carrying a passenger can cause a crash and you can be seriously hurt or killed Follow all loading guidelines in this manual Loading Guidelines As discussed on page 2 we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guid
166. r specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tires especially the sidewall profile can change the attitude of your CRF and its handling Tire variations that raise or lower the rear of your CRF have a more significant effect on handling than variations in front tires which generally don t vary as much Often you can see or feel the change in tire size Another way to check is to measure the rolling circumference of the old and new tires A higher profile tire will have a larger rolling circumference If you do switch to tires designed for special terrain use remember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface 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
167. rear wheel off the ground by placing an optional workstand or equivalent support under the engine and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Regular off road Use Maintenance Schedule page 27 94 Servicing Your Honda Drive Chain Inspection 1 Stop the engine and raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 Check slack 1 in the upper drive chain run midway between the sprockets 2 3 Drive chain slack should allow the following vertical movement by hand 1 1 3 8 in 25 35 mm NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 1 drive chain slack 2 drive sprocket 3 driven sprocket If the chain is found to be slack in one segment of its length and taut in another this indicates that some of the links are either worn kinked or binding Kinking and binding can frequently be eliminated by thorough cleaning and lubrication If the drive chain requires adjustment procedure is as follows Adjustment 1 Loosen the rear axle nut 1 2 Loosen the lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decreace slack or clockwise to increase slack Align the index mark 4 of the axle plates 5 with same reference marks 6 on both sid
168. rease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent Fork Oil Performance Disassemble clean and inspect the fork and replace the oil regularly Contamination due to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performance of the suspension Refer to the Honda Service Manual page 168 Use only Pro Honda HP Fork Oil 5W U S A only or equivalent which contains special additives to assure maximum performance of your CRF s front suspension Frame Because your CRF is a high performance machine the frame should not be overlooked as part of your overall competition maintenance program Periodically inspect the frame closely for possible cracking or other damage It makes good racing sense Spokes Check spoke tension frequently between the first few rides As the spokes spoke nuts and rim contact points seat in the spokes may need to be retightened Once past this initial seating in period the spokes should hold their tension Still be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis page 90 Nuts Bolts Etc Application of a thread locking agent to essential fasteners offers added assurance and security Remove the nuts clean the threads of both the nuts and bolts apply Pro Hond
169. 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 e When you last performed shock linkage and swingarm pivot bearing maintenance Engine transmission and suspension oil changes chain sprocket chain guide and slider replacements coolant changes and related component replacements Spark plug brake pad and control cable replacements In addition you should record any irregularities noted in component wear so you ll remember to keep a close eye on these areas in the future Technical Information 161 Competition Logbook Date Running Time Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use 162 Technical Information These parts and tools may be ordered from your authorized Honda dealer Optional Parts List ENGINE Remarks Cooling system assembly Thermo switch An optional cooling fan is availabe for competition use The fan will help avoid the engine damage if the engine is kept idling too long when hot or when riding in mud or sand or any condition that causes high engine load at low vehicle speed
170. rns from hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using a side stand or an optional workstand to provide support To reduce the possibility of a fire or explosion be careful when working around gasoline Use only a non flammable high flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Servicing Your Honda 25 Maintenance Schedule To maintain the safety and reliability of your CRF regular inspection and service is required as shown in the Maintenance Schedules Regular OFF ROAD Use non competition and Competition Use that follow The Maintenance Schedule list items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in these schedules are provided in a service manual
171. rocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly worn drive chain Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket ivan Worn Sprocket Teeth Teeth REPLACE REPLACE Normal Sprocket Teeth GOOD NOTICE Use of a new chain with worn sprockets will cause rapid chain wear Drive Chain 5 Lubricate the drive chain 6 Recheck chain slack and adjust if necessary Servicing Your Honda 95 Drive Chain Drive Chain Sliders Drive Chain Rollers Lubrication 1 Check the chain slider 1 for wear 1 Measure the diameter of the drive chain Lubricate the drive chain with 80 90 gear oil If the wear is 3 16 in 5 mm or more replace rollers Replace them if below the service or drive chain lubricant designed specifically for it limit use with O ring chains Wipe off the excess oil or Service Limit chain lubricant UPPER ROLLER 1 1 in 29 mm LOWER ROLLER 1 2 in 31 mm 2 Replace the roller if necessary as follows Install the upper drive chain roller Green 1 and lower drive chain roller Black 2 as shown Tighten the drive chain roller bolt and nut to the specified torque
172. ry drive gear bolt clockwise again and align the punch mark with the A mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 5 If it is free it is an indication that the valves are closed and that the piston is on the compression stroke If it is tight and the valves are open rotate the primary drive gear lock bolt 360 and realign the punch mark to the A mark ON 2 primary drive gear bolt 4 A mark 3 punch mark 5 exhaust rocker arm Valve Clearance Inspection 1 Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cam lobe 3 A 1 feeler gauge 2 valve lifters 3 intake cam lobe Valve Clearance 2 Measure the exhaust valve clearance by inserting a feeler gauge 1 between the exhaust rocker arm 4 and shims 5 1 feeler gauge 4 exhaust rocker arm 5 exhaust valve shims Valve Clearances IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm If intake valve clearance and exhaust valve clearance need adjustment see Camshaft Removal page 68 and select the correct shim for each valve Servicing YourHonda 67 Valve Clearance 2 Remove the cam chain tensioner lifter cover Use the tensioner stopper tool Camshaft Removal
173. s Reduce the rebound damping in one click increments Lower the oil capacity by 0 2 oz 5 cc 126 Adjustments for Competition Rear Suspension Adjustment Adjustments for Type of Track Suspension Adjustment Guidelines Hard surfaced track Begin with the standard settings If the suspension is too stiff soft adjust according to the chart below Sand track Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring pre load Example Turn the compression damping adjuster and especially rebound damping adjuster to a stiffer setting Increase standard Race Sag 0 2 to 0 4 in 5 to 10 mm Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Adjust the compression and rebound damping adjusters to stiffer settings Install the optional stiff spring Reduce standard Race Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment e Always begin with the standard settings e Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 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 e If after setting the suspension feels unusual find the corresponding symptom in the table and test stiffer or softer compression and or rebound damping adjustm
174. s of riding Condensation Control Some condensation can form within the transmission cavity as well This is natural and just one more reason you should change the engine and transmission oil often After Cleaning Lubrication There are some things you should do just after washing your CRF to help prevent rust and corrosion Once your CRF is clean and dry you should protect any bare steel from rusting by applying a light coating of a rust inhibitor Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent Be sure the chain is wiped clean and is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage or discolor the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminu
175. se ee He ge ee ie eg tel axe 172 EENDE LEG OG RE EE AE EE 63 important infOrmatON e sesse sesse se se ee ee 2 important precautions cece se see se se 2 I O labels ESE sets EL EE donuts de Siek 5 maintenance esse esse ee ee RA ee ee ee 25 identification vehicle iese sesse ses ee ee ee 150 oil riding precautions 2 0 0 sesse see se ee ee ee ee 14 idle speed engine ees see ee Se ee se 134 air AA AR EE RE 43 schedule maintenance sesse se ee ee ee 27 28 inspection pre ride oe eels ee ee ee ee ee 11 LOT SE sige E eee Ee ae 84 Seat removal ee GE cel alot aa Ese eg 36 TFANSMISSION esse see se see ee Ge GR ee ee ee 46 serial numbers sesse see se se ee ee Se Ge ee ee 150 L Operating controls esse ee ee ee ee 7 service MANUALS esse esse esse inen 168 operation component locatiOnS ees see see 8 SIME EE EE EA LE NE 14 labelsisafety uc ER ee Ge ee De ee Gah ese 5 Optional parts IS sesse ee ee ee ee 163 spare Parts EN EE EE en es 164 logbook Competition esse sesse se se ee se 161 Sproekets EE setae Rest el 163 Sparksarresterss EE RE Er es Ge Ee NR eerste 65 oxygenated fuels oe eee ee ee ee ee ee ee 160 Spark KNOCK EE EN ER NE 41 dou EE 61 P sp cificati ns ae Se GE St eee 151 153 spring pre load rear SUSPENSION esse see see 120 Pads Brake ie He ses ee eean Been bees be EDE ing ee be 89 starting parts Optional sees eee ee ee ee RA ee ee ee 163 engine EED EE OE EE EIE 15 personal fit adjustmen
176. sion oil drain bolt 12 16 1 6 NOTE 2 13 Air supply pipe bolt 7 10 1 0 154 Technical Information NOTE 1 Apply grease to the threads 2 Apply engine oil to the threads Torque Specifications Frame FRAME Torque Item Ibfeft_ Nem kgfem Remarks 1 Steering stem nut 80 108 11 0 2 Fork upper pinch bolts 16 22 2 2 3 Fork lower pinch bolts 15 20 2 0 4 Handlebar upper holder bolts 16 22 2 2 5 Handlebar holder nuts 32 44 4 5 6 Front axle nut 65 88 9 0 7 Front axle pinch bolts 15 20 2 0 8 Rear axle nut 94 127 13 0 NOTE 2 9 Chain adjuster lock nuts 20 27 2 8 NOTE 3 10 Front engine hanger bracket nut 40 54 5 5 11 Mid engine hanger bracket nut 47 64 6 5 12 Upper engine hanger plate nuts engine side 40 54 5 5 frame side 25 34 3 5 13 Shock absorber upper 32 44 4 5 NOTE 2 nuts lower 32 aa 45 NOTE2 14 Swingarm pivot nut 65 88 9 0 NOTE 2 15 Fork fork damper 25 34 3 5 fork cap 22 30 3 1 16 Rear shock arm nuts swingarm side 39 53 5 4 NOTE 1 2 shock link side 39 53 5 4 NOTE 1 2 17 Rear shock link nuts 39 53 5 4 NOTE 1 2 18 Shock spring lock nut 32 44 4 5 19 Kickstarter arm bolt 28 38 3 9 20 Front brake master cylinder holder bolts 7 3 9 9 1 0 21 Brake hose bolts 25 34 3 5 22 Caliper mounting bolts 22 30 3 1 NOTE 4 NOTES 1 Apply o
177. spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn and lower the oil level in increments of 0 2 oz 5 cc in both fork legs until the desired performance is obtained Do not however lower the oil level below the minimum oil level Minimum oil capacity Standard spring 10 2 US oz 303 cm Softer spring 10 4 US oz 308 cm Stiffer spring 10 3 US oz 306 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 5 US oz 399 cm3 MAX gt 1800 p Sa 1600 j 1400 F Oil capacity 11 8 US oz 348 cm3 j iP 1200 STANDARD 1000 800 600 400 200 0 TH PAP PS wo MP 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 e When disassembling the fork turn the rebound 1 and compression 2 damping adjusters counterclockwise to the softest position to prevent
178. st 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 160 Use of lower octane gasoline can cause persistent pinging or spark knock a louder rapping noise which if severe can lead to engine damage Light pinging experienced while operating under a heavy load such as climbing a hill is no cause for concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank Refueling Procedure Fuel Tank Capacity 2 19 US gal 8 3 1 fuel fill cap 2 breather tube 3 steering stem nut 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and insert the breather tube in the steering stem nut A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and
179. stall the engine hanger plates 7 engine hanger nuts bolts 8 of the frame side and engine hanger nut bolt 9 of the engine side Tighten the engine hanger nut to the specified torque frame side 25 IDf ft 34 N m 3 5 kgf m engine side 40 Ibf ft 54 N m 5 5 kgf m 7 engine hanger plate 8 engine hanger nuts bolts of the frame side 9 engine hanger nut bolt of the engine side Piston Piston Rings Piston Pin 6 Connect the radiator hose 10 to the cylinder 9 Install the cylinder head cover page 73 13 Install the exhaust pipe page 64 head and tighten the radiator hose clamp 11 Connect the direct ignition coil 12 14 Install the carburetor page 133 securely 15 Install the subframe and muffler pages 40 63 16 Install the fuel tank and the seat pages 36 38 17 Fill the cooling system with the recommended radiator coolant page 48 ws 40 radiator Hose 12 direct ignition coil 11 radiator Res amp 10 Install the PAIR control valve 13 PAIR 7 Install the shims and camshaft page 71 ee oe daad alt supply 8 Instal the spark plug page Ol 11 Tighten the PAIR control valve nuts and air supply pipe bolt to the specified torque 7 Ibf ft 10 N m 1 0 kgf m 12 Connect the vacuum 16 and air suction 17 hoses 13 PAIR control valve 14 PAIR control valve bolts nuts 15 air supply pipe bolt 16 vacuum hose 17 air suction hose Servicing Your Honda 81 Suspension
180. stems may be performed by any motorcycle repair establishment or individual using parts that are certified to EPA standards An optional tool kit may be available Check with your Honda dealer s parts department Before You Service Your Honda The Importance of Maintenance sesse esse ese 24 Maintenance Safety esse esse see se ee ee 25 Important Safety Precautions sesse 25 Maintenance Schedule iese esse ee ee ee 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Maintenance Component Locations 35 Seat Removal sesse es vee eie ee eke N ei 36 Fuel Tank Removal esse sees sees se ese ee ee ee 37 Subframe Upright Position ese esse ee se ee ee 39 Service Procedures Fluids amp Filters Fuel System ve ccchssfezensitetcttseststetiletes souetonsssachece sa 41 Engine Olkoon ea E a 43 Transmission Oil ees sesse ee ee ee RR ee 46 Coolants ort sari ea EE EE ET 48 Gade Ek AE EE NEE 51 Crankcase Breather iese ese ee ee ee ee 53 Engine Throttle N OE OR NA 54 Clutch System ccc see see se AG AA ee ee 56 Hot Start Lever ER ieee Seb Sets Be SE 60 Spark PIU sc aches RE a a ea atisi 61 Exhaust Pipe Muffler esc sesse ee ee ee 62 Spark ATrestefs iseer Ee Re SE Se see ee die 65
181. t 0 0 see se ee ee ee 138 troubleshooting sees esse see se se ee ee 144 pinging Engine sees see ee se se ee Ge Ge GR ee 41 steering head bearing inspection esse esse esse 97 PLUG ie RE EE EE N 61 StOPpiNg Engine se ee AA ee ee ee 16 pre load rear SUSPENSION esse see ee ee ee 120 NA HE EER 141 pre ride inspection iese sesse ese se ee ee ee 11 Subfam En Ascent wake tae ia i 39 protective apparel sees se ee Ge AG ee ee 2 cont d Index 177 Index suspension TOME ER EEE EAE esas 82 TERT oe tt este Eie Re DR De Ee Es 83 suspension adjustment for track conditions 124 TONE EED GE RE ee EE 106 Siidelines EER SE DE en san 125 e AE EE AR N 120 T transmission oil esse ese ee Re RA Ge ee ee 46 tang EDS Ee Ee oe EN GE Ge erais 128 throttle freeplay a EE RE ED GE be RE Re Re Re ieee 54 1NSPECUOR ousie ers MERE erea ee EN Eb soles 55 tires AIP PLESSUTC Se RE ee ee ed Ee Ge Re Gee 91 INSPCCHON os n na e pete Eo ian 91 teplacement sarius eee SEDEER RE igst 92 TOOLS ss es EE EE EEE E 164 torque specificatiOns esse sesse eee 98 154 156 transpoOrting 00 eee eee ese ese ee see Se GR ee Se ee Ge 140 trIpmeters diese isdie ees bie see ee sd ee ede oie 14 troubleshooting iese sesse se ee ee ee 144 tubes replacing si ESE ER ee ee Ee ge 91 V valve Teli RE EE Ee Ge RE EE 15 Valve Clearance esse sesse ese es se ee ee Ge Gee ee 66 vehicle identification
182. t 9 adjusting rod 8 Measure the length of the lock nut 2 and fork center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 Es 0 06 0 08 in 1 5 2 0 mm 2 lock nut 8 fork center bolt 9 Tighten the lock nut 2 to the fork center bolt 8 closely by hand Tighten the lock nut to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 2 lock nut 8 fork center bolt Front Suspension Adjustments 10 Remove the special tool or mechanic s stopper tool while applying pressure to the fork damper Install the fork center bolt 8 to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 8 fork center bolt 11 Measure the length between the axle holder and outer tube Standard 317 2mm 12 Compare the length 10 at assembly and at disassembly They should be the same length If the length at assembly is longer than at disassembly check the fork center bolt and lock nut installation 10 length cont d Adjustments for Competition 115 Front Suspension Adjustments 13 Pour the recommended fork oil 11 into the outer tube slider 1 Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent 1 outer tube slider 116 Adjustments for Competition 11 fork oil Fork Oil Ca
183. t 49 6 in 1 261 mm vertical Primary reduction 3 611 Wheelbase 58 4 in 1 483 mm Bore and stroke 3 07 x 2 06 in oe Gear ratio 2 384 Seat height StL m sk Displacement 15 2 cu in 249 cm Sear el i 1 30 Footpeg height 17 0 h 432 mm Compression ratio 129 1 Gear lb N 1 333 Ground clearance 13 6 in 346 mm TERA Intake 0 005 0 001 in Gear lie IV 1 041 Frame cold 0 12 0 03 mm Gear ratio V 0 814 Type Twin tube Exhaust 0 011 0 001 in Final reduction 3 786 Telescopic fork 0 28 0 03 mm Left foot operated return F suspension travel 11 0 in 280 mm Engine oil capacity eer dt patter system 1 N 2 3 4 5 stroke 12 4 in 315 mm at draining 0 70 US at 0 66 2 Electrical R suspension Prolink at draining and Battery 12V 4 Ah travel 12 3 in 312 mm oil filter change 0 73 US qt 0 69 z 80 100 21 51M i gamon Si Tire size front EE oe at disassembly 0 90USqt 0 85 4 Starting system Electric Kickstarter Transmission oil NGK Ten 100 100 18 59M capacity Spark plug IMR8C 9H ol ob DUNLOP D756 at draining 0 71 US qt 0 67 2 Standard DENSO Tire type bias ply tube at disassembly 0 79 US qt 0 75 VUH24D Tire pressure front cold 15 psi 100kPa 1 0 kgf cm Cooling system For extended high ars IMR9C 9H Tire pressure rear cold 15 psi 100kPa 1 0 kgf cm capacity
184. t a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion of your engine s power range you use can be adjusted by changing the final drive ratio with different sized driven sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There is a choice of both higher and lower final drive ratios with two optional aluminum driven sprockets Like the optional springs and these sprockets are listed in the Optional Parts List section page 163 of this manual Unless you have the required mechanical knowhow tools and a Honda Service Manual sprocket changing should be done by your Honda dealer Higher Gearing less driven sprocket teeth e increases top speed in each gear provided the engine will pull the higher gearing e reduces frequency of shifting wider gear ratios e reduces engine rpm at a given throttle setting or ground speed which may allow better rear 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 engine rpm may be too low 136 Adjustments for Competition Lower Gearing more rear sprocket teeth e decrease top speed in each gear e increases frequency of shifting narrower gear ratios increases engine rpm a
185. t a given throttle setting or ground speed which may provide more power to the ground on good traction surfaces However spacing between gears may be too narrow engine rpm may be too high Some tracks may be watered heavily prior to the first race then lightly or not at all during the day This results in a track surface that is slippery during the first few races then changes from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions e Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in speed Average conditions use the standard sprocket Hard but not slippery track conditions use lower gearing more teeth to keep the engine rpm high where the engine produces the most power This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer For tight tracks consider lower gearing to avoid having to slip the clutch frequently Repeated fanning or pulling of the clutch lever in a turn to raise engine rpm may eventually damage the clutch system A gearing change may help for riding in sand where you want to keep the front end light so it can float from the peak of one sand wh
186. tandard DENSO Tire type bias ply tube at disassembly 0 79 US at 0 75 VUH24D Tire pressure front cold 15 psi 100kPa 1 0 kgf cm Cooling system For extended high Nef IMR9C 9H Tire pressure rear cold 15 psi 100kPa 1 0 kgf cm capacity speed riding at draining 1 19 US at 1 13 DENSO F brake swept area ng disc Drake VUH27D Single disc brake Carburetor park plug gap 03 0 04 In R brake swept area f 0 8 0 9 mm 60 6 in 391 1 com Type Piston valve TR i unleaded gasoline pump Identification number FCRO3B E Fuel recommendation Setane number of 91 or Head light 12V 35 W high Main jet 132 gner Fuse Fuel capacity 2 19 US gal 8 32 di a F PERY Main fuse 15A eedle clip position Fuel reserve capacity 0 40 US gal 1 52 era p 2nd groove Caster angle 27 54 Slow jet 42 Trail length 4 6 in 118 mm Pilot screw opening 2 1 4 turns out Fork ed MES 7 Float level 0 31 in 8 0 mm except fork damper per le oz ee per Per led eats Idle speed 1 700 100 rpm 152 Technical Information Specifications For CANADA Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85 5 in 2 172 mm Type Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 32 6 in 827 mm Cylinder arrangement Single 10 inclined from Transmission 5 speed constant mesh Overall heigh
187. tank Capacity unleaded gasoline pump octane number of 91 or higher tank 2 19 US gal 8 3 reserve 0 40 US gal 1 5 2 Engine oil Pro Honda GN4 4 stroke oil or an equivalent Transmission oil Pro Honda GN4 4 stroke oil or an equivalent Tires 80 100 21 51M 100 100 18 59M Front Rear DUNLOP D742F DUNLOP D756 Type bias ply tube Tire Pressure cold Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm Spark Plug standard IMR8C 9H NGK or VUH24D DENSO optional IMR9C 9H NGK or VUH27D DENSO Coolant ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or equivalent distilled water Drive Chain Size link DID 520MXV 116
188. 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 137 Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input Control Positioning e Position the control levers so that you can use them comfortably when seated and standing 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 Pro Honda Hondalock or an equivalent to
189. the rubber seal 11 facing out away from the engine You should see the OUT SIDE mark 12 on the filter body near the rubber seal Use a new genuine Honda oil filter or a filter of equal quality specified for your model NOTICE If the oil filter is not installed properly it will cause serious engine damage 14 Apply engine oil to a new 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 bolt then tighten them 17 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69 2 at oil and filter change 0 70 US at 0 66 at oil change 18 Install the engine oil filler cap dipstick 19 Check the engine oil level by following the steps in Checking amp Adding Oil page 44 Engine Oil Servicing Your Honda 45 Transmission Oil Refer to Safety Precautions on page 25 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the transmission and clutch Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine and transmission 46 Servicing Your Honda Oil Recommendation
190. the upper adjuster 5 lower lock nut 6 lower adjuster increase decrease Remove the fuel tank page 37 Loosen the lower lock nut 5 Turn the lower adjuster 6 in direction to decrease freeplay and in direction to increase freeplay 4 Tighten the lock nut to the specified torque 3 0 Ibf ft 4 N m 0 4 kgf m 5 Operate the throttle grip to ensure that it functions smoothly and returns completely 6 Install the fuel tank page 38 PD If you can t get the freeplay within the specified range contact your Honda dealer Throttle Throttle Inspection 1 throttle 1 Check that the throttle assembly is positioned properly and the securing bolts are tight 2 Check for smooth rotation of the throttle 1 from fully open to fully closed in all steering positions If there is a problem see your Honda 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 Servicing YourHonda 55 Clutch System Refer to Safety Precautions on page 25 Clutch Freeplay 1 clutch lever Inspection Check freeplay Freeplay 3 8 13 16 in 10 20 mm If necessary adjust to the specified range
191. the following information in your letter name address and telephone number e product model year and VIN e date of purchase e dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 171 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 172 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 The Honda Rider s Club USA only One of the best ways to get the most enjoyment Contact your Honda dealer
192. too rich Turn the pilot screw in CLOGGED Contaminants in the NOT CLOGGED 5 Try Spark test GOOD SPARK Y 6 Check the throttle position sensor CORRECT 7 Test cylinder compression CORRECT WEAK OR INTERMITTENT SPARK fuel e Not cleaned frequently enough P 131 gt e Faulty carbon or wet fouled spark pulg P 61 e Faulty ignition control module e Faulty alternator e Faulty direct ignition coil e Broken or shorted direct ignition coil wire e Faulty ignition pulse generator INCORRECT se Faulty throttle position LOW sensor Ring worn e Cylinder worn or damaged e Piston worn or damaged e Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED POSSIBLE CAUSES CHECK 1 Disconnect fuel line at carburetor and check for clogging P 41 FUEL FLOW RESTRICTED UNRESTRICTED FUEL FLOW 2 Remove air cleaner P 51 AIR CLEANER NOT DIRTY 3 Check carbureator jets for clogging DIRTY CLOGGED ___ gt NOT CLOGGED 4 Check valve timing CORRECT 5 Try spalk test INCORRECT gt GOOD SPARK T 6 Test cylinder compression CORRECT WEAK OR INTERMITTENT SPARK LOW _ gt
193. top the engine 2 Remove the seat mounting bolt 1 right side cover bolt 2 collar 3 and right side cover 4 1 seat mounting bolt 2 right side cover bolt 3 collar 4 right side cover 146 Taking Care of the Unexpected 3 Disconnect the wire connector 5 of the starter magnetic switch 6 4 Pull main fuse 7 out If it is blown 8 install the spare main fuse 9 5 wire connector 6 starter magnetic switch 7 main fuse 8 blown fuse 9 spare main fuse 5 Reconnect the wire connector If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace the spare fuse that was installed If the replacement fuse of the same rating burns out in a short time there is probably a serious electrical problem on your CRF Leave the blown fuse in that circuit and have your CRF checked by your Honda dealer If Your Battery Is Low or Dead Jump starting is not recommended especially if you use an automobile battery The greater amperage of an
194. tube plug 1 crankcase breather tube plug 2 tube Crankcase Breather Servicing Your Honda 53 Throttle Refer to Safety Precautions on page 25 Throttle Freeplay 1 R ER Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range 1 freeplay Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 dust cover 3 upper lock nut 4 upper adjuster increase decrease 54 Servicing Your Honda PD Pull the dust cover 2 back Loosen the upper lock nut 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay Tighten the lock nut to the specified torque 3 0 Ibf ft 4 N m 0 4 kgf m Return the dust cover to its normal position After adjustment check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions If the adjuster is threaded out near its limit or the correct freeplay cannot be reached turn the adjuster all the way in and back out one turn Tighten the lock nut install the dust cover and make the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you can not get the proper adjustment with
195. ual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a NOTICE symbol This information is intended to help you avoid damage to your Honda other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual Introduction The official Honda Service Manual for your CRF is available page 168 It is the same manual your dealer uses If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference Read the Warranties Booklet page 169 throughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities This motorcycle has no cooling fan For this reason engine overheating and coolant loss will occur if the engine is kept idling too long when hot Additionally when riding in mud or sand or any condition that causes high engine load at low vehicle speed the time it takes for the engine to overheat will be shortened especially when the ambient temperature is high Continuing to operate the unit in these conditions will result in engine damage An optional cooling fan is available and is recommend
196. ude roadside assistance or trip interruption protection Consumer Information 173 Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETV ee sees sesse esse esse see 1 Important Safety Information 0 esse sees see see 2 Important Safety Precautions cece 2 Loader nests cess aa ate aia 3 Accessories amp Modifications sesse esse ese se ee 4 Safety Labels ese ese ee es se ER Re se ee 5 OPERATING CONTROLS sesse sesse sesse ese see 7 Operation Component Locations iese sesse 8 BEFORE RIDING esse elees tasse iese de seke ves ie 9 Are You Ready to Ride eseese 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection ee sees sees see eke ee see 11 BASIC OPERATING INSTRUCTIONS 13 Safe Riding Precautions ses se se see 14 SIDS Stand ER Rivet cas GEES gese Gesk ee 14 Tiipmeter ER EE EE ee N k 14 Starting amp Stopping the Engine 15 PrEParatwon sesine entasse eaa 15 Fuel Valver si ie ese neg ees Re EEE EEN 15 Starting Procedure sesers 15 Flooded Engin esse see ss se ses se se ee se ee ee ee 16 How to Stop the Engine esse esse ee ses see ee 16 Shifting Gears recs esse SEE ee Re be ee ed ees 17 Braking ss RE GE N ee GAS ee 18 Parking ER whan Ee ee eg bee EE enters 19 Post ride Inspection ce esse esse ese ee see ee ee ee 20 Brake in Guidelines 0 0 0 see se se se ee ee 21 174 Table of
197. until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 3 4 2 1 4 turns and the punch marks are aligned Low Speed Damping The low speed damping can be adjusted by turning the center screw of the compression adjuster The low speed compression adjuster has 13 positions or more Turning the adjuster one full turn clockwise advances the adjuster 4 positions To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seat This is the full hard setting 2 Turn the adjuster counterclockwise 12 clicks and the punch marks are aligned Rebound Damping The rebound damping adjuster 3 is located at the lower end of the shock absorber It has 17 positions or more Turning the adjuster one full turn advances the adjuster 4 positions 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 Rear Suspension Adjustments 3 rebound damping adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seat This is the full hard position 2 Turn the adjuster counterclockwise 11 14 clicks with the punch marks on the adjuster and the shock absorber aligned Adjustments for Competition 121 Rear Suspension Adjustments Rear Suspension Race Sag
198. upper pinch bolts cont d Adjustments for Competition 117 Front Suspension Adjustments 21 Clean the threads of the fork protector bolts 18 and axle holder thoroughly Apply locking agent to the fork protector bolt threads Install the fork protectors 19 fork protector bolts brake hose clamp bolts 20 and tripmeter cable clamp bolts 21 Tighten the fork protector bolts to the specified torque 5 2 Ibf ft 7 N m 0 7 kgf m 22 Align the brake caliper 23 and hose with the left fork leg making sure that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency Route the hose carefully 23 Clean the threads of the caliper mounting bolts 22 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper 23 on the slider and tighten the caliper mounting bolts to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 21 18 18 fork protector bolts 19 fork protectors 20 brake hose clamp bolts 21 tripmeter cable clamp bolts 22 caliper mounting bolts 23 brake caliper 118 Adjustments for Competition 24 Check the left side collar 24 and tripmeter gear box 25 for wear or damage Install the left side collar to the left wheel hub Install the tripmeter gear box while aligning its tabs 26 of the tripmeter gear box with the 26 tabs 27 grooves 24 left side collar 25 tripmeter gear box
199. urchased from your Honda dealer e Clutch Center Holder 07724 0050001 or 07724 0050002 O7WMA KZ30100 070MG 0010100 O7JMA MR60100 07958 2500001 e Lock Nut Wrench e Tensioner Stopper e Spoke Wrench e Piston base Chemical Products Pro Honda GN4 4 stroke Oil Engine and Transmission Oil Pro Honda HP Fork Oil 5W Pro Honda DOT 4 Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Pro Hondabrite cleaner Pro Honda Dielectric Grease Pro Honda Handgrip Cement Pro Honda Hondalock Molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Pro Honda White Lithium Grease Multi purpes Grease Rust inhibiting oil cable lubricant Pro Honda HP Coolant Urea based mult purpose grease designed for high temperature high pressure performance example EXCELITE EP2 manufactured by KYODO YUSHI Japan or Shell Stamina EP2 or equivalent Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape Wiring Diagram I
200. ush 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 83 Suspension Recommended Fork Oil viscosity weight 5 W Pro Honda HP Fork Oil or equivalent suggested oil Fork Oil Change Refer to Front Suspension Disassembly on page 107 1 Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops 2 Hold the outer tube 1 then remove the fork damper 2 from the outer tube using the lock nut wrench 3 Gently slide the outer tube down onto the lower end of the slider 4 1 outer tube 2 fork damper 3 lock nut wrench 4 slider lower end 84 Servicing Your Honda NOTICE The outer tube 1 can drop on the slider 7 and damage the fork dust seal 5 and guide bushing 6 when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD 1 outer tube 5 dust seal 6 guide bushing 7 slider 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 9 of the fork damper 1 TEEEEEEKEKKNNN SEENEEEEEEEEIE I I SOATTTTUTTI i H H A amp E annann H 1 outer tube 9 oil hole 4 Drain the for
201. ustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems 1 Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt 2 Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CRF is ridden 1 fork protector 2 dust seal 3 Inspect the wear rings 3 for wear or damage Replace the wear ring if it is 0 06 in 1 5 mm or flat with the outer tube 4 When replacing the wear ring remove the fork leg page 107 Install the wear ring with its end gap facing rearward 4 I 0 06 in 1 5 mm 3 3 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 pre load and
202. y hurt or killed Always use the size and type of tires recommended in this owner s manual 80 100 21 51M DUNLOP D742F 100 100 18 59M Rear DUNLOP D756 Type bias ply tube Front 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 92 Servicing Your Honda Side Stand Refer to Safety Precautions on page 25 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with grease Servicing Your Honda 93 Drive Chain Refer to Safety Precautions on page 25 An endless riveted master link chain connects the drive and driven sprockets The O ring chain uses rubber between the side plates of the pin and roller links to seal in the manufacturer installed lubricating grease and keep out moisture and dirt The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when the motorcycle is ridden in unusually dusty or muddy areas more frequent maintenance will be necessary Before servicing your drive chain turn the engine OFF raise the
203. y of forms including e Safety Labels on the motorcycle e Safety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean Es Ted You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions ET IISTER You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions Der dle Ed You CAN be HURT if you don t follow instructions e Safety Headings such as Important Safety Reminders or Important Safety Precautions e Safety Section such as Motorcycle Safety e Instructions how to use this motorcycle correctly and safety This entire book is filled with important safety information please read it carefully Safety Messages Contents MOTORCYCLE SAFETV ee sees sesse esse esse see 1 Important Safety InformatON eee see ee 2 Important Safety PrecautiOnS iese esse sesse 2 ES GE OE EE NE N N OE N 3 Accessories amp Modifications sesse esse ese se ee 4 Dabety Labels AE RE testes Meee ED 5 OPERATING CONTROLS 1 esse see sees se esse 7 Operation Component Locations iese sesse 8 BEFORE RIDING uuu sees se esse ese sees sees see ee ae 9 Are You Ready to Ride oo eee se se see see 10 Is Your Motorcycle Ready to Ride 0 11 Pre ride Inspection iese sesse se ese se Rd ee 11 BASIC OPERATING INSTRUCTIONS 13 Safe Riding Precautions 14 Starting amp Stopping the Engine 15 Shifting
204. ys over lips and square edged terrain It may even top out when you dismount your CRF Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your CRF s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too stiff for your weight will not allow the rear tire to hook up under acceleration and will pass more bumps on to you Adjustments for Competition 123 Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often reguires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are h

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