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HONDA CRF250X - Honda Owners

1. oooccccccnccccnnnnnnos 100 Appearance Al Cah vasateestnctaccrasraancan nascar tenteuaie 101 ADJUSTMENTS FOR COMPETITION 103 Front Suspension Adjustments cc0008 104 Rear Suspension Adjustments ooooccccncncncnnnnn 118 Suspension Adjustments for Track Condit IONS oes sacecintctosmadasonnatieseenetensessatesaried 122 Suspension Adjustment Guidelines 123 Carburetor Adjustments amp Turning Tips 126 Chassis AdjuStMEN S occccccccnnconnnncnccnnnccnnnnnnnnos 133 on 134 Tire Selection for Track Conditions 135 Personal Fit Adjustments cccccccncccnnnnnnnnnnnnnnnos 136 AA S 137 Transporting Your Motorcycle 138 storing Your HonNda ooccciccncicinnonicinicncc nicanases 139 You amp the PnvViOniie nt sconicninenal aora 141 TYOUDIGSHOOUNG cccocisinionioloniocina nnccino nacion iceniada 142 TAKING CARE OF THE UNEXPECTED curas 143 If a Fuse BlowWS ccccccocccccnonnocccncnanonanoss 144 If Your Battery is Low or Dead 145 TECHNICAL INFORMATION 147 Vehicle Identification erosiones 148 SCOT IC AVION srasni nm 149 Torque Specifications emos roees 151 High Altitude Carburetor Adjustment 154 Emission Control Systems cccccccccnncnnnnnnnnnnnos 155 Oxysenated Fuel Searsin 156 Competition Logbook oocccnnnccccconcninnnnnnnnns 157 Optional Parts List sorcidri psico tiran 159 Spare Parts
2. pe g na 1 engine oil filler cap dipstick 2 engine oil drain bolt 3 sealing washer 6 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 Engine Oil 7 Remove the left engine guard bolt 4 and left engine guard 5 4 left engine guard bolt 5 left engine guard 8 Remove the oil filter cover bolts 6 and oil filter cover 7 9 Remove the oil filter 8 from the cover 10 Check that the oil filter cover O ring 9 is in good condition 6 oil filter cover bolts 7 oil filter cover 8 oil filter 9 oil filter cover O ring 10 11 12 spring rubber seal OUT SIDE mark 11 Apply grease to the seat face of spring 10 12 Position the spring against the engine crankcase and install a new oil filter with the rubber seal 11 facing out away from the engine You should see the OU T SIDE mark 12 on the filter body near the seal Use a new genuine Honda oil filter or a filter of equal quality specified for your model If the oil filter is not installed properly it will cause serious engine damage 13 Install the oil filter cover O ring and oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified forque 9 Ibf ft 12 N m 1 2 kgf m 14 Install the left engine guard and left engine guard bolt 15 Fi
3. 1 trickle charger Servicing Your Honda 99 Headlight amp Taillight Refer to Safety Precaution on page 2 3 To pull the headlight bulb out push and turn the socket 5 counterclockwise Taillight Headlight Bulb The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service 1 Remove the two front visor bolts 1 and pull out the front visor 2 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 4 To install the headlight reverse the removal procedure 1 front visor bolts ae Headlight Aim 2 Disconnect the headlight connector 3 Remove the dust cover 4 The headlight beam can be raised or lowered Turn the adjusting screw 1 clockwise to move 3 the headlight up or turn the adjusting screw OZ S Pa counterclockwise to move the headlight down to On L djustment A j AR proper adjus y if NED A Y ID O y NES EIRA 3 headlight connector 4 dust cover 100 Servicing Your Honda Refer to Safety Precautions on page 2 Frequent cleaning and polishing will keep your Honda looking newer
4. 3 lock nut increase 4 cable adjuster decrease Refer to Safety Precautions on page 2 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 Using spark plugs 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 objects or dirt replace the spark plug with a new one e Use only a wire type feeler gauge to check the spark plug 1f necessary To prevent damaging the iridium tip of the center electrode and platinum tip of the side electrode never use a leaf type feeler gauge 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 page 37 2 Disconnect the spark plug cap 1 3 Clean any dirt from around the spark plug base 4 Remove the spark plug 2 1 spark plug cap 2 spark plug 5 Check t
5. Servicing Your Honda The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD x NO GOOD 5 dust seal 6 guide bushing 7 slider 8 outer tube 3 Pour the fork oil from the outer tube 1 Pour the fork oil from the oil hole 9 of the fork damper TTT SUIT I I ATTN I I l FEAE dl 1 outer tube 9 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 oP MAA i Lo QT N i YZ 1 outer tube Amount of fork oil left in the fork within damper and spring unit cc 0 C 32 F 10 C 50 F K ma 20 C 68 F Meee ne 30 C 86 F ee Fesi Amount of fork oil al 0 20 40 60 80 100 120 140 160 Inverted time minutes Suspension 5 Pour the recommended fork oil page 84 into the outer tube Fork Oil Capacity Standard 0 42 kgf mm Fork Spring lt lt No mark factory products 2 scribe mark O aftermarket parts Standard oil 11 7 US oz capacity 345 cm3 Maximum oil capacity 13 5 US oz 399 cm3 Slightly stiffer as it nears full compression Minimum oil 10 2 US oz Slightly stiffer as
6. 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 tighten the nuts to the specified torque 15 Ibf ft 21 N m 2 1 kgf m 1 exhaust pipe joint nuts 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 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 four bolts 2 spark arrester 3 and gasket 4 from the muffler 3 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 Install the spark arrester
7. 16 Ibf ft 22 N m 2 2 kgf m Tighten the front bolts first 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 1 handlebar 2 handlebar upper holders Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant Be certain that the throttle cables have no kinks or other damage Servicing Your Honda 97 Additional Maintenance Procedures LEFT SIDE Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing Sy 7 AGA Eo 00 ENGINE Cylinder head cover Exhaust pipe joint nuts Water pump cover Crankshaft hole cap Transmission oil check bolt Clutch cover Cylinder bolt Oil filter cover Cylinder head bolts Drive sprocket 1 2 1 1 SONO RUAN QO Soa e MNONOOO oo oO 7 cylinder bolt 8 oil filter cover 9 cylinder head bolts 10 drive sprocket RIGHT SIDE 1 cylinder head cover 2 exhaust pipe joint nuts 3 water pump cover 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover 98 Se
8. Spokes Rim locks Subframe bolts upper lower Fork center bolt Fork center lock nut Disc cover bolts Fork protector bolts Muffler mounting bolts front rear Muffler clamp bolt Sprocket nuts Seat mounting bolts Front brake reservoir JW Nx NWMOCO WRAAH U0 al cap screws Rear brake reservoir cap bolts Fork air pressure release A 40 D screw OD ONN Side stand mounting A J ON bolts upper al Y S s 1 N Q A Y N AJO N a 22 9 PONNY ONNI PN 00 T ou CS lower N 33 AK Pe NOTES 1 Apply Honda Thread Lock or an equivalent to the threads A 2 Apply oil to the threads and flange surfaces EZ NO 3 Stake SILA A oN lt MAID ME 4 U nut J MS f H a 5 UBS nut Y PAR AN 6 SH bolt CO Ya A 7 Alock bolt LOSA Technical Information 153 High Altitude Carburetor Adjustment When operating this motorcycle at high altitude the air fuel mixture becomes overly rich Above 6 500 feet 2 000 m driveability and performance may be reduced and fuel consumption increased The carburetor can be modified to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may caus
9. h h 4 2 3 4 5 6 7 8 9 Na No O N AS i O Po a ENS A ADD 00 Z de Technical Information 151 Torque Specifications Frame box SA SS N ee RNG a EA y EET KAA ROO LA O A D ON a OE 152 Technical Information 000 YO Ol D N 1 1 gt oOo N FRAME Steering stem nut Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut Chain adjuster lock nuts Engine mounting bolts Front engine hanger bracket bolts Mid engine hanger bracket bolt Upper engine hanger plate bolts engine side frame side Shock absorber upper lower Swingarm pivot nut Fork fork damper fork cap Rear shock arm nuts swingarm side shock link side Rear shock link nuts Shock spring lock nut Kickstarter arm bolt CES dl dl 010 o OOUN D OM DN PASITO aD Eeo N ONA RA Onon NOTE 2 4 NOTE 2 4 NOTE 2 4 Apply Honda Thread Lock or an equivalent to the threads Apply oil to the threads and flange surface 1 2 3 Stake 4 U nut 5 UBS nut 6 SH bolt 7 Alock bolt Torque Specifications Frame Torque FRAME 21 Front brake master cylinder holder bolts Brake hose bolts Caliper mounting bolts Front brake disc nuts Rear brake disc nuts Brake pedal pivot bolt
10. ll also find important safety precautions information on oils and tips for keeping your Honda looking good A CDI Capacitive Discharge Ignition 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 164 Before You Service Your Honda The Importance of Maintenance 000 24 Maintenance AAA 2 Important Safety Precauti0ns cccccccnnnn 25 Maintenance Schedule cnsnsnci nacer iicdaia 26 General Competition Maintenance 29 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Component Locations sisiaicocincenacininn tocino tevadisa rss 35 Seal AA de nendau San dnesnmesuaceananecnonees 36 Fuel Tank Removal icscccccoscctsssasecansegeasosssasssatasases 37 Subframe Upright Positi0N cccccccccccncncnnnnc 39 Service Procedures Fluids amp Filters PS e SUC osc e PP PO PE 41 AA a etree ter 43 Transmission Oil e cacocicececesesrccemransaamsnatanesme acess 46 A tas E E EA 48 A ICT epena e A 51 Crankcase Breather acopiar ia 53 Engine BUKSE PEA EE E O E esa 54 Ai A 56 Hot siart Leye orron 60 AA R 61 Exhaust Pipe Muffler ccccccccccccccnnnnnnnnnnnnnnonnns 62 SPAK A IA 65 O A 66 Piston Piston Rings Piston PiD ooonono
11. 1 1 fuel valve The three way fuel valve 1s 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 after stopping the engine 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 S0 F 95 F 1 Pull the choke knob 2 up all the way to fully ON if the engine is cold 2 Keep the throttle fully closed 3 Pull the clutch lever all the way in and press the starter button with the throttle completely closed Or operate the kickstarter to start the engine Starting from the top of the stroke kick through to the bottom with a rapid continuous motion Do not operate the throttle Allowing the kickstarter to snap back freely against the pedal stop can damage the engine case Starting amp Stopping the Engine 4 Warm up the engine don t operate the throttle 5 About 15 seconds after the e
12. 15 100 1 0 Cooling system NGK a capacity Spark plug IMR8C 9H R tire size pressure 100 100 18 59M Anter drani US ida Standard psi kPa kgf cm 15 100 1 0 er draining qt 1 13 DENSO Sinale disc brake After disassembly 1 27 US at 1 20 VUH24D F brake swept area g NGK i 51 8 in 334 5 cm Carburetor For extended high we IMR9C 9H speed riding A brake sweprarea P ease Type Piston valve DENSO 6 inf 391 1 cm Identification number FCRO2A VUH27D Fuel capacity a E Main jet standard 130 Fuel reserve capacity 0 4 US gal 1 52 Jet needle standard NCVT Head light 12V 35 W Caster angle 27 54 Needle clip position 3rd groove Fuse Tel erat panes Fork oil capacity Slow jet standard 40 except fork damper 11 7 US oz Pilot screw opening 2 1 4 turns out er le pan Float level 0 31 in Technical Information 149 Specifications For California Dimension Drive train Overall length 2 174 mm Liquid cooled 4 stroke Clutch type Wet multi plate type Overall width 827 mm Cylinder arrangement Single 10 dal from 5 speed constant mesh Overall height 1 261 mm verica Primary reduction 3 611 Wheelbase 1 483 mm Bore and stroke 3 07 x 2 06 in o ea 2 384 Seal deal 29 mm Displacement 15 22 cu in 249 4 cm Gear fs ue Footpeg height 432 mm 429 4 Gear ratio III 1 833 Ground clearance 346 mm Engine oil capacity Gear ratio IV iva ae ian tw coe enue EE After draining and Final reduction 3 786 0 73 US qt 690
13. 2 1 a l d sji 3 PA N E ly q a 4 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 nuts 12 10 throttle cables 11 throttle cable lock nut 12 adjusting nuts Carburetor Adjustments amp Tuning Tips Carburetor Disassembly 1 Pull up the cable clamp 1 and remove the carburetor top bolts 2 Then remove the carburetor top 3 2 4 ab a me an E e a o AA r eh gt NA og pd To E 7 w F a j i 4 1 cable clamp 2 carburetor top bolts 3 carburetor top 2 Remove the jet needle holder 4 and jet needle 5 from the throttle valve 6 4 jet needle holder 5 jet needle 6 throttle valve 7 link arm set screw 8 throttle valve 3 Remove the link arm set screw 7 When installing the link arm set screw apply a locking agent to the link arm set screw threads Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 9 throttle valve roller 10 floating valve cont d Adjustments for Competition 129 Carburetor Adjustments amp Tuning Tips When installing the floating valve 10 onto the throttle valve 8 make sure the floating valve s flat side faces out and the hole 11 faces down 8 y ie 8 throttle valve 10 floating valve 11 hole 130 Adjustments for Competition
14. amp Wheel Bearings It is not necessary to remove the wheels to See the Honda Service Manual for inspection perform the recommended service in the information Maintenance Schedule pages 27 and 28 However information for wheel removal is 1 Check the axle shaft for runout provided for emergency situations 2 Check the condition of the wheel bearings Wheel Rims amp Spokes 1 rim lock 1 Inspect the wheel rims and spokes for damage 90 Servicing Your Honda Refer to Safety Precautions on page 2 To safely operate your motorcycle the tires must be the proper type off road and size in good condition with adequate tread and correctly inflated A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tire inflation and maintenance The following pages give detailed information on how and when to check your air pressure how to inspect your tires for wear and damage and our recommendations on tire 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 motorcycle ride more harshly are m
15. and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube Crankcase Breather Servicing Your Honda 53 Throttle Refer to Safety Precautions on page 2 Throttle Freeplay 1 freeplay Inspection Check freeplay 1 Freeplay 1 8 3 16 in 3 5 mm If necessary adjust to the specified range Upper Adjustment Minor adjustments are generally made with the upper adjuster 2 3 ri 2 dust cover 3 upper lock nut 4 upper adjuster increase decrease 54 Servicing Your Honda UN Pull the rubber 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 Return the dust cover to 1ts 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 1ts 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 use
16. 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 Honda Thread Lock 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 hand grips controls and footpegs A stiff nylon parts cleaning brush works well e Check tire air pressure e Check spoke tension and rim lock nut security e Check sprocket bolt and nut security e Clean the sides of the drive chain with a stiff nylon parts cleaning brush Lubricate and adjust the chain as necessary Do not perform maintenance while engine is running Injury to your fingers or hands may result e After adjustment check that the chain adjuster index marks 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
17. 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 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 164 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
18. capacity 303 cm3 it nears full compression Optional Softer 0 40 kgf mm Fork Spring 3 scribe mark Standard oil 11 8 US oz capacity 350 cms Maximum oil 13 7 US oz Slightly stiffer as 404 cm3 it nears full compression capacity Minimum oil 10 4 US oz Slightly stiffer as capacity 308 cms it nears full compression Optional Stiffer 0 44 kgf mm Fork Spring C gt 1 scribe mark Standard oil 11 8 US oz capacity 348 cm Maximum oil capacity 13 6 US oz Slightly stiffer as 402 cm it nears full compression Minimum oil 10 3 US oz Slightly stiffer as capacity 306 cm3 it nears full compression Be sure the oil capacity is the same in both fork legs 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 2 fork damper 10 O ring 7 Tighten the fork damper using the lock nut wrench to the specified torque 25 lb ft 84 N m 3 5 kgf m Servicing Your Honda 85 Brakes Refer to Safety Precautions on page 2 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
19. 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 motorcycle 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 motorcycle 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 top of the most rearward point of the subframe down to the machined edge at the rear of the wingarm as illustrated for three different situations unloaded motorcycle on workstand with rear suspension fully extended no rider loaded with rider motorcycle on ground with rider loaded without rider motorcycle on ground without rider 1 Support your motorcycle on a workstand with the rear wheel off the ground 2 Measure the unloaded dimension 120 Adjustments for Competition NLOADED MEASUREMENT without rider edo 3 Measure the loaded with rider dimension Remove the workstand With two helpers available sit as far forward as possible on your motorcycle s seat wearing your riding apparel
20. s handling braking and stability Adding accessories or making modifications that change this motorcycle 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 motorcycle 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 4 we recommended that you do not carry any cargo on this motorcycle However 1f you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines e Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that 1t 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 e Do not attach large or heavy items such as a sleeping bag or tent to the handlebar fork or front fender e Make sure that all cargo is tied down securely e Never exceed the maximum weight limit e Check that both tires are inflated properly Loading Motorcycle Safety 3 A
21. 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 99 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 2 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 11 140 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 e Choose Sensible Cleaners Use a biodegradable detergent when you wash your motorcycle Avoid aerosol spray cleaners that contain chloroflur carbons CFCs which damage the atmosphere s protective ozone layer Don t throw cleaning solvents away see the following guidelines for proper disposal e Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before ch
22. 2 side facing out 2 gt mark Install the drive chain rollers as follows e Upper Greem e Lower Black Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil Pro Honda Chain Lube or an equivalent or SAE 80 or 90 gear oil is recommended Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers More About Drive Chain The master link is the most critical element of drive chain security Master links are reusable as long as they remain in excellent condition We recommend installing a new master link retaining clip when the drive chain 1s reassembled You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets Additional Maintenance Procedures Refer to Safety Precautions on page 2 jery ve Handlebar Inspection Steering Stem Inspection 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from 1 With your CRF on a box or workstand front its proper position by inspecting the punch wheel elevated turn the handlebar to the right and left to check for roughness in the steering head bearings Stand in front of your CRF grab the fork at mark Check the torque of the upper holder 2 bolts
23. 27 oil hole cont d Adjustments for Competition 107 Front Suspension Adjustments 17 Temporarily install the fork damper to the outer tube 18 Set the lower end axle holder 28 of the slider in a vise with a piece of wood or soft jaws to avoid damage Overtightening the vise can damage the axle holder 19 Loosen the center bolt 29 28 axle holder 29 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 30 mm 108 Adjustments for Competition 22 Apply pressure to the fork damper and insert a special tool or mechanic s stopper tool 30 see below between the axle holder 28 and lock nut 31 23 Hold the lock nut and remove the fork center bolt 29 from the fork damper Do not remove the lock nut from the fork damper piston rod If the lock nut is removed the piston rod will fall in the fork damper and you can not reassemble the fork damper 30 stopper tool 31 lock nut 28 axle holder 29 center bolt 24 Remove the push rod 32 from the fork damper 25 Remove the special tool or mechanic s stopper tool between the axle holder 28 and lock nut 31 while applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole 28 axle holder 31
24. Ask one helper to steady your motorcycle perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the loaded with rider dimension Example Unloaded 23 6 in 600 mm 2 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 loaded without rider dimension Do this with your motorcycle set at the standard race sag IO IKE LOADED LN amp without rider Op Es EXAMPLE 21 7 in 550 mm 5 W e DNS Serie SLI aunty Example Unloaded 23 6 in 600 mm Lo
25. Inspecti0N cccccccccnnnnnm 83 Recommended Fork Oil occcccccnn 84 Fork OIl CWA A 84 PE AG CS sateen stale O A 86 A AE TET 90 TES MIDES ondas sous 91 MM 93 Dive CIA orinar aE 94 Additional Maintenance Procedures 97 Electrical A R ER 99 Headlight amp Taillight ooooccccccccccconncnnn 100 Appearance Cane dot NEn ENS 101 ADJUSTMENTS FOR COMPETITION 103 Front Suspension AdjustmentS ccccccccononccnncs 104 Rear Suspension Adjustment ooooooocccncnnnnccs 118 Suspension Adjustments for Track Bs A Eara 122 Suspension Adjustments Guidelines 123 Carburetor Adjustments amp Tuning Tips 126 Chassis ACJUStMenttS cssssesssseececceeeeeeeeees 133 A E sent EE E 134 Tire Selection for Track Conditions 135 Personal Fit Adjustments cccccccccncnnnnnnnnnnnnnnnns 136 TAKING CARE OF THE UNA PRECIO nica dana 143 2 Puse OWS cumiaresiiisbata 144 If Your Battery is Low or Dead 145 TECHNICAL INFORMATION o ccccccccccccons 147 Vehicle Identification escasas cora 148 AMA Aoneoseannsass 149 Torque Specifications sscresetassinsdosonsittlcicabic nd 151 High Altitude Carburetor Adjustment 154 Emission Control Systems cccccccccccncncnnnnnos 155 Oxygenated Fuel soriire 156 Competition Logbook ooocccccccccccncnnnnnnnn 157 Optional Parts List is aicuisccnusesnsandndnesstexbecatee
26. Pin spanners should be used for turning the lock nut and adjusting nut See page 159 for optional pin spanners Spring pre load length Standard spring Standard 10 02 in 254 4 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 kef 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 1s 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 until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 7 12 2 1 12 turns and the punch marks are aligned
27. ROLLER O O O O T O O y O O oRvespRockET cs DRIVEN SPROGKET cs y BRAKE FLUIDO o COW Hr BRAKE PADS WEAR o II BRAKE SYSTEM as woes 1 O AA O OYO ES e CONTROL CABLES O O OOOO O U U I S O e S O Oooo Oo y y EXHAUST PIPE MUFFLER fF O Oooo d S 2 ETT 88 SWINGARM SHOOK LINKAGE O OoOo y OS IA III O E O E DO NOTES Ao ss PDAMPER As NUTS BOLTS FASTENERS O O O O O OOOO TOO T O O OT O OS O O e waeesmRes O O OOOO A A O O O E E 80 857 STEERING HEAD BEARINGS O O O OOOO O T O T O O T O O S T a S S 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 N QO Servicing Your Honda Perform maintenance on firm level ground using the side stand a workstand or equivalent support Use genuine Honda parts or their equivalent when servicing your motorcycle Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin
28. 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 135 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 Adjust the mounting bolt torque of the clutch and brake lever assemblies so that they can rotate on the handlebar in a fall If an assembly does not rotate 1t may bend or break a control lever Make sure that the bolts are torqued securely enough to prevent slippage during normal operation Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained Tighten the top bolts first 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 t
29. 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 156 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 tank Wipe up any spills immediately Oxygenated fuels can damage paint and plastic Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events The best way to organize the many bits of information is to record them in a logbook Your logbook can include such information as suspension adjustments 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
30. Your Honda Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster Cable end adjuster 2 cable end adjuster increase free play decrease free play 1 Turn the cable end adjuster 2 to obtain the specified freeplay 2 Check the freeplay again 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 Y e YA Qed AE PIN 3 lock nut 4 integral cable adjuster increase decrease 1 Turn the cable end adjuster counterclockwise to provide maximum freeplay 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 motorcycle should move smoothly and accelerate gradually If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn See your Honda dealer or refer to the official Honda Service Manual page 164 Other Inspections amp Lubrication e Check that the clutch lever assembly is positioned properly and the securing bolts are tight e Check th
31. and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compression and rebound If you run softer rebound damping the wheel will follow the rough ground and small bumps much better and you will hook up better With a lot of rebound damping the wheel returns very slowly and doesn t contact the ground quickly enough after each bump The result is a loss of traction and slower lap times 122 Adjustments for Competition Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF using the methods described on pages 104 119 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 harder position at this time Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Turn the compression damping adjuster to a stiffer setting Install the optional stiff spring Adjustments for Too Soft Stiff
32. 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 General Competition Maintenance Servicing Your Honda 29 General Competition Maintenance Spark Plug Spark Plug Cap Air Cleaner Some non resistor plugs may cause ignition problems Refer Install a small plastic tie wrap around the spark plug cap to Clean and oil your air cleaner regularly because the volume to the recommendations elsewhere in this manual for specific reduce any possibility of it loosening or of water of air able to pass through it has a great effect on types so you will be sure to use the proper reach and heat penetration i performance Both engine performance and long term range Replace periodically as specified in the Maintenance Schedule pages 27 28 durability may be affected by an air cleaner that has deteriorated and allows dirt to pass Inspect the air cleaner closely each time it s serviced for evidence of small tears or seam separation Keep a spare air cleaner oiled and ready to install sealed in a plastic bag Riding in dusty conditions may require servicing the air cleaner or replacing 1t 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
33. cm Telescopic fork After disassembly 0 90 US at system 1 N 2 3 4 5 F suspension travel 11 0 in 280 mm Tranemiccion il NE al EMAL capacity Battery 12V 4 Ah a 3 F tire size pressure 30 100 21 51M debe disassembly 0 79 US at Starting system Startermotor Kickstarter psi kPa kgf cm 15 100 1 0 cool eye Spark plug R tire size pressure 100 100 18 59M a ene iS Standard IMR8C 9H psi kPa kgf cm 15 100 1 0 er draining 3 qt 1 13 DENSO After disassembly 1 27 US at 1 20 VUH24D F brake swept area Single disc brake l P 51 8 in 334 5 cm Carburetor Porexicnded high NGK Single disc brake Type Piston valve Speco ing NSO 60 6 in 391 1 cm Identification number FCRO2A VUH27D Fuelcacacty 21USGa 830 ain jet sandra ae Fuel reserve capacity 0 4 US gal 1 52 Jet needle standard NCYV Head light 12V 35 W ret erat anar IMR9C 9H R brake swept area Fork oil capacity Slow jet standard 40 except fork damper 11 7 US oz Pilot screw opening 2 turns out er le dis Float leve 0 31 in 150 Technical Information Torque Specifications Nuts Bolts Fasteners Check and tighten nuts bolts and fasteners before every outing A a a ENGINE Engine Cylinder head cover Clutch cover Water pump cover Transmission oil check bolt Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolt Exhaust pipe joint nut Drive Sprocket h hb bh N NNN N 00NUuUO COO
34. e Faulty alternator e Faulty ignition coil e Broken or shorted spark plug wire e Faulty ignition pulse generator 6 Check for e Ring worn low compression e Cylinder worn or damaged CORRECT e Piston worn or damaged e Head gasket not sealing 142 Tips POOR PERFORMANCE AT HIGH SPEED CHECK Disconnect fuel line at carburetor and check for clogging P 41 UNRESTRICTED FUEL FLOW 2 Remove air cleaner P 51 AIR FILTER NOT DIRTY Check carbureator jets for clogging NOT CLOGGED 4 Check valve timing 5 Try spark test GOOD SPARK 6 Check for low compression CORRECT FUEL FLOW RESTRICTED D INCORRECT WEAK OR INTERMITTENT SPARK LOW POSSIBLE CAUSES 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 41 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 ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing Taking Care of the Unexpected This section gives practical advice to help you SA ninais inako 144 problems If Your Battery is Low or Dead 145 Ta
35. eS q wA SAN a Pa 7 M J ONE q Aa SS ow Y kes A Le O ONE E aN g V P D S AS I A i s Y IKEN NUS E fuel valve shift lever side stand rear brake pedal 8 Operating Controls Before each ride you need to make sure you and your Honda are both ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your motorcycle For information about suspension carburetion and other adjustment see page 103 Are You Ready to Ride Muacacinsanna nad 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection Before Riding 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 motorcycle are both ready to ride For information about suspension carburetor and other adjustments see page 103 Whether you re preparing for competition or for practice always make sure you are e In good physical and mental condition e Free of alcohol and drugs e Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury whe
36. flames away from all fuel related precautions in this owner s manual parts Important Safety Precautions e Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Servicing YourHonda 25 Maintenance Schedule To maintain the safety and reliability of your motorcycle regular inspection and service is required as shown in the Maintenance Schedules Regular OFF ROAD non competition Use and Competition Use that follow The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools Procedures for these items are provided in this manual The Maintenance Schedule also includes items that involve more extensive procedures and may require special training tools and equipment Therefore we recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools Procedures for items in this schedule are provided in a service manual available for purchase from your dealer page 166 Because your motorcycle does not have an odometer service intervals in the maintenance sche
37. lock nut 26 Remove the fork damper assembly 33 from the fork assembly 34 32 push rod Remove the fork from the vise Remove the fork spring 35 from the fork 34 33 fork damper assembly 34 fork assembly 33 35 spring Damper Oil Change 1 fork cap 3 lock nut wrench 2 fork damper 1 Loosen the fork cap 1 by turning the fork damper 2 using the lock nut wrench 3 Front Suspension Adjustments 2 Remove the fork cap assembly 4 from the 5 Extend the fork damper piston rod to maximum fork damper Pour the recommended fork oil into the fork damper Be careful not to damage the fork cap bushing Recommended Oil Do not disassemble the fork cap assembly A A 9 W or equivalent pi i fork cap as an assembly if it is 6 6 US oz 195 cc 6 9 Imp oz 2 fork damper 6 Pump the fork damper piston rod 6 slowly 2 fork damper 4 fork cap assembly several times to bleed the air from the fork damper 2 3 Empty the fork oil from the fork damper 2 by pumping the damper rod several times ion 2 fork damper 5 oil hole cont d 4 Clean the fork cap and fork damper threads Adjustments for Competition 109 Front Suspension Adjustments 7 Extend the fork damper piston rod to maximum Adjust the oil level of the fork damper as shown Oil Level 1 65 1 85 in 42 47 mm 1 65 1 85 in 42 47 mm 2 fork damper 8 Apply fork oil to t
38. longer Frequent cleaning also identifies you as an owner who values his motorcycle A clean CRF is also easier to inspect and service While you re cleaning be sure to look for damage wear and gasoline or oil leaks General Recommendations e To clean your CRF you may use water a mild neutral detergent and water a mild spray and wipe cleaner polisher a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your CRF or discolor the seat and decals If your motorcycle 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 motorcycle High pressure washers like those at coin operated car washes can damage certain parts of your CRF The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings driving dirt inside and needed lubrication out If you use a high pressure washer avoid spraying the following areas wheel hubs muffler outlet under seat engine stop button brake master cylinder under fuel tank drive chain front fork dust seals steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your motorcycle You may
39. of deterioration or dirt penetration 30 Servicing Your Honda Handgrips Always use Honda Hand Grip Cement U S A only or Honda Bond A 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 punch mark on the handlebar Refer to the Honda Service Manual page 164 for installation instructions For added security you may choose to safety wire the hand grips to the handlebar and throttle to prevent the possibility of them loosening Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the grip rubber so they will not snag your glove Throttle Control Remove the throttle control every few rides clean the inside of the drum and the handlebar thoroughly and apply a light coating of silicone lubricant Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way Move the handlebar from lock to lock to be sure there is no cable interference Check to be sure the top of the carburetor is screwed on tight Make certain the throttle operation is perfect after servicing and inspecting General Competition Maintenance Fuel Filter Periodically drain the fuel from the tank remove and clean the fuel valve filter Replace the fuel valve O ring if there are any signs of damage or deterioration page 4
40. off road motorcycle When you own a Honda you re part of a worldwide family of satisfied customers people who appreciate Honda s reputation for building quality into every product Your Honda was designed as a recreational motorcycle for off road use by one rider only Before riding take time to get acquainted with your motorcycle and how 1t works To protect your investment we urge you to take responsibility for keeping your motorcycle well maintained Scheduled service 1s 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 We also recommend that you read the owner s manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your Honda other property or the environment Unless you are mechanically qualified and have the proper tools you should see your Honda dealer for the service and adjustment procedures discussed in this manual Introduction The official Honda Service Manual for your motorcycle is available page 164 It is the same manual your dealer uses If yo
41. range while riding check the brake pads If they are not worn beyond the recommended limit page 89 there 1s probably air in the brake system Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system Front Brake Lever Adjustment 1 lock nut 2 adjuster 3 piston 86 Servicing Your Honda Loosen the lock nut 1 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise Tighten the lock nut Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay 3 8 13 16 in 10 20 mm Apply grease to the contacting faces of the adjuster and piston 3 Brake Pedal Height The brake pedal height should be approximately level with the right footpeg 1 Loosen the lock nut 1 and turn the adjusting bolt 2 in direction to raise the pedal 3 or in direction to lower it 2 Tighten the lock nut at the desired pedal height 1 lock nut 2 adjusting bolt 3 rear brake pedal raise the pedal height lower the pedal height Fluid Level Inspection Front Brake Fluid Level Check 1 LOWER level mark With the motorcycle in an upright posit
42. 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 123 Suspension Adjustment Guidelines Stiff suspension 124 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 Middle travel too stiff e Stiff on bumps when cornering e Front end wanders when cornering e Stiff suspension on bumps especially downhill bumps While braking front end dives during initial travel then feels stiff Final travel too stiff e Doesn t bottom on landings but feels stiff e Stiff on large bumps especially downhill bumps e Stiff on large bumps when cornering Entire travel too stiff e Stiff suspension on any type of terrain Adjustments for Competition 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 soring makes the suspension too stiff
43. sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly worn drive chain Both chain and sprockets must be in good condition or the new replacement chain or sprocket s will wear rapidly Excessively worn sprocket teeth have a hooked worn appearance Replace any sprocket which is damaged or excessively worn Damaged Sprocket wom Sprocket Teeth Teeth REPLACE Normal Sprocket Teeth GOOD Drive Chain 4 Lubricate the drive chain 5 Recheck chain slack and adjust if necessary Servicing Your Honda 95 Drive Chain Drive Chain Sliders 1 Check the chain slider 1 for wear If the wear 1s 3 16 in 5 mm or more replace it 1 Koi AA eo CX O Wo SSS A Xo C 1 chain slider 2 Check the chain guide slider 2 for wear Replace the chian guide slider 1f it is worn to the bottom of the wear limit groove 3 2 chain guide slider 3 wear limit groove 96 Servicing Your Honda Drive Chain Rollers 1 Measure the diameter of the drive chain rollers 1 Replace them if below the service limit SERVICE LIMIT UPPER ROLLER 1 1 in 29 mm LOWER ROLLER 1 5 in 39 mm p ur 4 P j E i Y Ja Pi et e Te o A 7 ie i a e E 1 drive chain rollers 2 If the drive chain roller removed install the drive chain roller with its gt mark
44. suspension Make all compression and rebound damping adjustments in the specified increment or turns described in pages 119 and 120 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 119 After adjusting the adjusters simultaneously suspension may be 1 rear shock absorber fine tuned by turning one of the compression and rebound damping adjusters in one click or 5 Push the rear wheel sideways to check for in 1 12 turn increments worn or loose swingarm bearings There If you have a problem finding an acceptable should be no movement If there is have the adjustment return to the standard position and bearings replaced by your Honda dealer begin again Servicing Your Honda 83 Suspension Recommended Fork Oil suggested oil Pro Honda HP Fork Oil or equivalent Fork Oil Change Refer to Suspension Removal on page 105 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
45. the air cleaner to dry thoroughly After drying soak the air cleaner 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 cont d Servicing YourHonda 51 Air Cleaner 10 Apply a thin coat of Honda White Lithium Grease to the sealing surface Assemble the air cleaner and holder Install the tab 7 of the holder in the hole 8 of the air cleaner tab 9 Install the 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 with the A mark 11 of the air cleaner housing by rotating the air cleaner 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 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 Refer to Safety Precautions on page 2 Crankcase Breather Service more frequently 1f your motorcycle 1s ridden in the rain or often at full throttle Service the breather 1f you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2
46. the frame surface Muffler stain remover Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only This section tells you how to fine tune your CRF for maximum competition performance Initial suspension adjustments should be performed after a minimum of two hours of easy break in time Optional front and rear suspension springs are available in both firmer and softer than standard rates in order to tailor your CRF specifically for your weight riding style and course conditions Follow the instructions given in the rear suspension sag setting section of Rear Suspension Adjustments to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 00000008 104 Rear Suspension Adjustments cccccceeeees 118 Suspension Adjustments for Track Conditions A A 122 Suspension Adjustments Guidelines 123 Carburetor Adjustments amp Tuning Tips 126 Chassis ACJUSHMEMIS sosisini 133 E PN E E E eaeven seasgavveuavace 134 Tire Selection for Track Conditions 135 Personal Fit Adjustments occccccccccncnnncnncnnnnnnss 136 Adjustments fo
47. the lock nuts 2 and turn the adjusting bolt 3 counterclockwise to decreace slack or clockwise to increase slack Align the index mark 4 of the plates with same reference marks 5 on both sides of the swingarm 1 rear axle nut 4 index mark 2 lock nut 5 reference marks 3 adjusting bolt 3 Tighten and torque the rear axle nut to the specified torque 94 Ibf ft 127 N m 13 0 kgf m 4 Recheck chain slack and adjust if necessary 5 Turn the adjusting bolt counterclockwise lightly until it touches the axle plate Then tighten the lock nut to the specified torque by holding the adjusting bolt with a wrench 20 Ibf ft 27 N m 2 8 kgf m Removal Cleaning amp Replacement For maximum service life the drive chain should be cleaned lubricated and adjusted before each outing Your motorcycle 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 l 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 Replace the drive chain 1f it has damaged rollers loose fitting links damaged O rings or other wise appears unserviceable Replacement Chain DID520MXV REPLACE Inspect the
48. the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water pump 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 pump seal or the engine oil seal Both seals should be replaced left side cover 8 collars at the same time quick fastener 9 reserve tank cap left side cover bolt 10 air cleaner box cover seat bolt 1 water hoses 2 siphon hose 3 water leakage check hole 4 water pump cover Servicing Your Honda 49 Coolant Coolant Replacement Refer to Safety Precautions on page 2 L 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 164 A WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap Ze To properly dispose of drained coolant refer to You amp the Environment page 141 50 Servicing Your Honda Coolant System Bleed Air Remove the radiator cap 1 lt Q 1 radiator cap Fill the system with the
49. the transmission oil filler cap 1 and oil check bolt 2 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 Install the oil check bolt and transmission oil filler cap Repeat step 14 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m Install the transmission oil filler cap securely Transmission Oil Replacing Transmission Oil 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil filler cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch the oil Then remove the transmission oil drain bolt 2 and sealing washer 3 5 After the oil has drained install the transmission oil drain bolt with a new sealing washer to the specified torque 16 Ibf ft 22 N m 2 2 kgf m 6 Fill the crankcase with recommended oil Capacity 0 71 US at 0 67 at oil change 7 Check the transmission oil level by following the steps in Checking amp Adding Oil this page 1 transmission oil filler cap 2 transmission oil drain bolt 3 se
50. to full stroke 2 fork damper 8 spring chamber 13 Drain the extra oil from the fork damper spring chamber 8 oil hole 9 By doing this procedure about 17 cm of fork fluid will be drained from the damper spring chamber through the oil hole and cause 178 cm of fork fluid to be left in the chamber TT rr AM HI ALA MO AMY i TMM TE 8 spring chamber 9 oil hole Front Suspension Adjustments 14 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 15 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 pressure release screw 11 fork cap Adjustments for Competition 111 Front Suspension Adjustments Fork Assembly 1 Drain the fork oil from the outer tube slider by placing it upside down About 7 cc of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 20 C Wy 1 outer tube slider Hi 112 Adjustments for Competition Amount of fork oil left in the fork without damper and spring unit cc STs ofa i o El ie 0 C 32 F 10 C 50 F 14 12 Fo J r 30 C 86 F 20 C 68 F Amount of fork oil Inverted time minutes 1 outer tube slider 3 spring 2 Tight
51. 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 motorcycle s air cleaner has very specific performance requirements Use a new genuine Honda air cleaner specified for your model or an air cleaner of equal quality Using the wrong air cleaner can result in premature engine damage Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear Cleaning 1 To open the air cleaner cover 1 turn the quick fastener 2 counterclockwise 1 air cleaner cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 and air cleaner 4 as shown 4 3 air cleaner retaining bolt 4 air cleaner 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 is made in two pieces inner and outer which cannot be separated 5 Clean the inside of the air cleaner housing 6 Allow
52. use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Hondabrite and rinse with a garden horse at full pressure Stubborn deposits may require a quick wipe with a sponge Appearance Care Washing Your Motorcycle with a Mild Detergent 1 Rinse your CRF thoroughly with cool water to remove loose dirt 2 Fill a bucket with cool water Mix in a mild neutral detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your CRF with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime 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 Servicing Your Honda 101 Appearance Care Condensat
53. valve 2 main bore 3 hot start air passage 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 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 1s 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 AA AAA p E MM ie A cl L i oo EE m li l id 3 SIE A AA ll throttle valve pump rod diaphragm inlet check valve 5 pump chamber 6 outlet check valve 7 accelerator nozzle N a ar ar 1 2 3 4 Carburetor Adjustments 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 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 1s 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
54. valve 7 operate to maintain a constant level of fuel in the float bowl 1 main jet 5 baffle plate 2 jet needle 6 float 3 needle jet 7 float valve 4 air jet Adjustments for Competition 127 Carburetor Adjustments amp Tuning Tips Carburetor Removal 1 Turn the fuel valve OFF 2 Drain the remaining fuel in the float bowl by removing the float bowl plug 1 A WARNING Gasoline is highly flammable and explosive You can be burmed or seriously injured when handing fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately qa y SEIS E SS a 1 float bowl plug 3 Install the float bowl plug 128 Adjustments for Competition 4 Remove the fuel tank page 37 5 Remove the band 2 and rear suspension upper mounting nut 3 and pull out the rear suspension upper mounting bolt 4 2 N S N Sa M 2 band 3 upper mounting nut 4 upper mounting bolt lt gt A B SN Y R A w 4 6 Lift the sub frame to the upright position page 39 7 Loosen the intake band screw 5 5 intake band screw 8 Disconnect the throttle sensor connector 6 Remove the carburetor 6 throttle sensor connector 9 Remove the hot start cable holder 7 7 hot start cable holder 10 Remove the throttle drum cover bolt 8 and throttle drum cover 9 x i m a
55. with the top surface of the cylinder head 9 Install the cam chain 10 over the sprocket without rotating the sprocket 2 Apply molybdenum disulfide oil solution a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to outer surface of the each valve lifters Install the valve lifters 3 7 cam sprocket 9 cylinder head 8 timing marks 10 cam chain 3 valve lifters Valve Clearance 5 Apply grease to the set rings and install it onto the camshaft holders 11 Install the camshaft holder bolts 12 TORQUE 12 Ibf ft 16 N m 1 6 kgf m Tighten the camshaft holder bolts in a criss cross pattern in 2 or 3 steps a 11 camshaft holders 12 camshaft holder bolts 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 8 Install a new sealing washer 15 and cam valve lifter and cam lobe chain tensioner lifter chain tensioner lifter cover bolt 16 If the feeler gauge 13 cannot be inserted the shim is caught between the valve lifter and the valve retainer Remove the camshaft holders A to place the shim correctly and reinstall the a camshaft holders CI VALVE CLEARANCES IN 0 005 0 001 in 0 12 0 03 mm B EX 0 011 0 001 in 0 28 0 03 mm n 4 A 14 stopper tool 15 sealing washer 16 camchain tensioner lift
56. 0 2400 to 1 Service more frequently when ridden in wet oa or dusty conditions 3 Replace every 2 years Replacement requires S ca mi km NOTE Month x FUEL LINE FUEL STRAINER SCREEN THROTTLE OPERATION AIR CLEANER CRANKCASE BREATHER SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER DECOMPRESSOR SYSTEM ENGINE IDLE SPEED RADIATOR COOLANT COOLING SYSTEM A SECONDARY AIR SUPPLY SYSTEM TRANSMISSION OIL o DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND O MAS E A MS SUSPENSION A A MN ne 10 x gt gt EMISSION REALATED ITEMS L every 300 mi 500 km or 3 months L every 300 mi 500 km or 3 months x SPARK ARRESTER C every 1 000 mi 1 600 km or every 100 operating hours o a a a a oa slsr nna neose OOO O a o oo 7 Should be serviced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Service Manual page 164 In the interest of safety we recommended these items be serviced only by your Honda dealer NON EMISSION REALATED ITEMS NUTS BOLTS FASTENERS omi om z Month FUELLING 3 3 3 3 O SO FUEL STRAINER SCREEN THROTTLE OPERATION 7 Ls AIRCLEANER ooo ss _ CRANKCASE BREATHER SS SPARKPLUG ooo EA Y VALVE CLEARANCE EA m EA ENGINE OILFILTER DECOMPRE
57. 168 Table of Contents SERVICING YOUR HONDA cocccccccccccccccccos 23 Before You Service Your Honda The Importance of Maintenance e 24 Maintenance Safety iis sssciacscccctahcasssctcossatenendaiaes 25 Important Safety Precautions mmo 23 Maintenance Schedule eercrinacstoororoiai agas 26 General Competition Maintenance 30 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Component Locations cccccecceeeeeseesseeeeees 35 A R R 36 Fuel Tank Removal is cac asecsisacccenatecennasieccaxcerents 37 Subframe Upright Positi0N oocooccccnccccnnnon 39 Service Procedures Fluids amp Filters AAA e ENN 41 Pone Oil AAN A PP tee 43 Transmission Ollanta slabuesi 46 COO eere onnu eee ede seats E calera lisa 48 Ps CS ANC ot antics E T 51 Crankease BIC ar cscccsecescesrenssgcssecossasasscoumiese 53 Engine INTO disc EE 54 CIC SV SUC Ul xceccosnca a 56 Hot Start CV CF sce secsnnsesdcspdenesesevecsarsasoscaeceecaes 60 Jn piei 61 Exhaust Pipe Muffler ccccccccccccnncnnnnnnnnnnnnnnnnos 62 ss A anan 65 Valve Claros nociones iana 66 Piston Piston Rings Piston PIN ooooooconanoooo 74 Chassis SUSPENSO sos snatas carantesoraaseosmanceonardascatteb racecars 82 Front Suspension Inspecti0N cccccccnnn 82 Rear Suspension
58. 2 Cylinder Removal Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals The tolerances are quite tight so it s important to keep these dowels absolutely clean page 76 Engine Mounting Bolts Make sure the engine mounting bolts are tightened to the proper torque specification For added peace of mind remove the nuts clean the threads and apply Honda Thread Lock or an equivalent prior to torquing the nuts Pressure Vacuum Leak Down Test Perform this test at regular intervals to minimize the possibility of engine damage from air leaks Fuel Contamination Refer to Fuel System in your Owner s Manual page 41 and in this supplement Fuel System page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel valve and fuel strainer screen Replace the fuel valve O ring if there are any signs of damage or deterioration page 41 Loosen the exterior 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 129 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
59. 5 Remove the accelerator pump cover screws 12 and accelerator pump cover 13 13 12 accelerator pump cover screws 13 accelerator pump cover 6 Remove the D ring 14 O ring 15 spring 16 and diaphragm 17 Clean the diaphragm When installing the D ring into the accelerator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 13 accelerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube guides 8 Remove the pump rod 23 Clean the pump rod and rod passage 24 Install the pump rod into the link lever 25 Push the rod forcibly into the link lever until it snaps into place K 24 23 pump rod 24 rod passage 25 link lever Carburetor Adjustments amp Tuning Tips 9 Measure the float level 26 with the float level gauge 27 during float tab just Carburetor Assembly contacting the float valve and the carburetor intake 28 facing up The float level should To assemble reverse the disassembly procedures be 0 31 in 8 0 mm To install the carburetor reverse the removal Adjust the float level by bending the float tab procedures carefully e After installing the ca
60. 9C 9H NGK or VUH27D DENSO Drive Chain D I D 520DMXV
61. Connect the radiator hose 10 to the cylinder 9 Install the cylinder head cover page 73 10 Install the exhaust pipe page 64 head and tighten the radiator hose clamp 11 Connect the spark plug cap 12 11 Install the carburetor securely 12 Install the subframe and muffler page 40 13 Install the fuel tank and the seat page 38 14 Fill the cooling system with the recommended radiator coolant page 48 i ia Uy a ee Ws NN ICO 4 CIN N D a saa h ARS NA ANA as N Na ZA ANS KX ee OO IG f S k dy ka as 10 10 radiator hose 12 spark plug cap 11 radiator hose clamp 7 Install the shims and cam shaft page 71 8 Install the spark plug page 61 Servicing Your Honda 81 Suspension Refer to Safety Precautions on page 2 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 1s qualified to determine whether or not replacement parts or repairs are needed Front Suspension Inspection When your CRF is new break it in for approximately one hour to ensure that the suspension has worked in page 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 disassemb
62. Damping a O AN 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 soft compression damping adjustments in one click increments If initial travel is still soft after installing the optional stiff spring Test stiffer compression damping adjustments in one click increments If final travel is still soft after installing the optional stiff spring Increase the fork oil capacity in increments of 0 2 oz 5 cc Entire travel too
63. HONDA CRF250X OWNER S MANUAL amp COMPETITION HANDBOOK 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 and operation on public streets roads or highways is illegal 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 relaed 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 Honda Motor Co Ltd 2004 Honda CRF250X OWNER S MANUAL amp COMPETITION HANDBOOK Introduction Congratulations on choosing your Honda
64. 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 8 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 13 16 clicks with the punch marks on the adjuster and the shock absorber aligned Adjustments for Competition 119 Rear Suspension Adjustments Rear Suspension Race Sag Setting the proper race sag ride height is very important for competition use Race sag refers to the amount of rear wheel travel used by your motorcycle at rest ready to
65. NO E TN rear brake pedal front wheel axle Servicing Your Honda 35 Seat Removal Refer to Safety Precautions on page 2 Installation 1 Slide the seat front prong 4 onto the seat Removal bracket 5 and the seat rear prong 6 onto 1 Remove the seat bolts 1 and collars 2 the tab 7 by pushing down and forward on 2 Slide the seat 3 back the seat in each of these areas 2 Install the collars and tighten the seat bolts 19 Ibf ft 26 Nm 2 7 kgf m 1 seat bolts 3 seat 2 collars seat front prong seat rear prong seat bracket tab 36 Servicing Your Honda Fuel Tank Removal Refer to Safety Precautions on page 2 5 Pull the breather tube 4 out of steering stem 9 Disconnect the fuel line 8 from the fuel nut valve 9 The fuel line leading to the Removal 6 Unhook and remove the fuel tank band 5 carburetor must be disconnected not the fuel 1 Turn the fuel valve OFF 7 Unhook the air cleaner cover rubber 6 line leading to the fuel tank 2 Remove the seat page 36 8 Remove the fuel tank bolt 7 10 Remove the fuel valve bolt 10 and fuel 3 Remove the shroud A bolts collars 1 TOT valve 4 Remove the shroud B bolts collars 2 and ee de aff jo 11 Remove the fuel tank shrouds 3 si Ly ELO 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
66. OsenessS ccccccccooonooocccnonononnos 90 Rim locks for looseness ws ss sssasecicascacecccecioone 90 Front and rear suspension for proper OL ALOU sesans oases piane aisnean ae 82 83 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication ca icriad 94 Drive chain guide sliders and guide rollers for damage OF WEA sis cessnuassesasssccuvavasavanenecunces 96 Exhaust pipe Muffler inspection removal and installati0n occccccnnnommo 64 Every possible part for looseness such as cylinder head nuts engine mounting bolts axle nuts handlebar holder bolts fork triple clamp bolts drive chain adjuster drive chain guide wire harness connectors kickstarter mounting bolt etc oooooonncnnnnnnnnn 151 153 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 lt secewsaseacwsnescivcvccatnnnasseveas 14 Starting amp Stopping the Engine cccccccnnnncnoc 15 Prepara ON esseeri aA E 15 E Way e e ncinsccesstepens tase teceausncenceetieoces 15 Startmo Procedure seins 15 Flooded Engine iccscisssrszesesaasomnaatactonnsaatomarsacss 16 How to Stop the Engln ooooonnnnncccnccccnnnnnos 16 SOL no GCIS eccepire apenn aE 17 BERI e e e O OO 18 AA E AS 19 Post ride InspectiON ooooocccccnnnnnnnnonnnnnnnnnnnnnnnos 20 Break in Guidelines a
67. R 4 Remove the handlebar pad Remove the handlebar holder nuts 4 washers mounting rubbers and handlebar 5 Keep the master cylinder upright to prevent air from entering system R Mi Reninal Ud A ul 4 handlebar holder nuts 5 handlebar 106 Adjustments for Competition 5 Loosen the upper pinch bolts 6 6 Loosen the fork damper 7 using the lock nut wrench but do not remove it yet Do not use an adjustable wrench to loosen the fork damper it may damage them Loosen the upper pinch bolts before loosening the fork damper to avoid damaging the fork cap 6 upper pinch bolts 7 fork damper 7 Remove the disc cover 8 by removing the two bolts 9 8 disc cover 9 bolts 8 Remove the tripmeter cable 10 and front axle nut 11 and loosen the axle pinch bolts 12 on both fork legs 9 Pull the front axle shaft 13 out of the wheel hub and remove the front wheel 12 axle pinch bolts 13 front axle shaft 10 trip meter cable 11 front axle nut 10 Remove the fork protector bolts 14 tripmeter cable clamp bolt 15 and brake hose clamp bolts 16 and fork protectors 17 Remove the brake caliper bolts 18 and brake caliper 19 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 brake lever after the front wheel is removed To do so will cause difficulty i
68. Remove the carburetor page 128 7 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 ia A 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 74 Servicing Your Honda 8 Disconnect the spark plug cap 4 9 Remove any dirt around the spark plug base PZR AN O UN AS oa y VN 4 spark plug cap 10 Remove the cylinder head cover page 66 11 Remove the spark plug 5 5 spark plug 12 Position the piston to top dead center on the compression stroke page 66 Remove the cam shaft page 68 13 Loosen the radiator hose clamp 6 and disconnect the radiator hose 7 6 radiator hose clamp 7 radiator hose Piston Piston Rings Piston Pin 14 Remove the engine hanger nuts 8 and engine 15 Remove the cylinder head bolts 10 18 Remove the dowel pins 14 cylinder head hanger plates 9 16 Loosen the cylinder bolt 11 gasket 15 and cam chain guide 16 Do not let the dowel pins and cam chain fall into the crankcase 8 engine hanger nuts 10 cylinder head bolts 9 engine hanger plates 11 cylinder bolt 17 Remove the cylinder head nuts washers 12 and cylinder head 13 Loosen the nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase 14 dowel pins 16 cam chain guide 15 cylinder head gasket 12 cylinder head nuts was
69. SSOR SYSTEM EA EA ENGINE DE SEED T RADIATOR COOLANT oa COOLING SYSTEM _____ EA SECONDARY AIR SUPPLY SYSTEM EA TRANSMISSION OIL ETA DRIVECHAIN y o a DRIVE CHAIN SLIDER Ss BRAKEFLUID o o EA BRAKEPADWEAR a BRAKESYSTEM 3 7 A Y HEADLIGHTAIM O EA E a SIDESTAND o o i inten a A NUTS BOLTS FASTENERS EA a Servicing Your Honda Zi 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 at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace MS About About About About About mr NOTE every every every every every Ref Page 2 5 hours 7 5 hours 15 0 hours 22 5 hours 30 0 hours THROTTLE OPERATION posos ss CIC A IO E E E O A II fC O E S O O CRANKCASE BREATHER SS posos ss SPARKPLUG A AI E E E E IA RADIATOR COOLANT NOTE SS posa VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTES SS posos ss ENGINE QM NOTES PR a OS PENGINEOILFILTER NOTES a ENGINE IDLE SPEED sa PISTON AND PISTON RINGS A PRISTON PIN A TRANSMISSION OIL E A COOLING sYsTtEM 8 DRIVE HAIR DRIVE CHAIN SLIDER O O OCO O o TSS n S O O y O O O DRIVE CHAIN
70. TUTE 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 Motorcycle Dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance drive ability and poor fuel economy ON E UN rR Emission Control Systems Source of Emission The combustion process produces carbon monoxide CO and hydrocarbons HC Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd Utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydrocarbons Exhaust Emission Control System California only The exhaust emission control system consists of a secondary air injection system No adjustments to this system should be made although periodic inspection of the com
71. accnnossaconacolcooDemandss 21 SERVICING YOUR HONDA ssssosssssssssse 23 Before You Service Your Honda The Importance of Maintenance ccccccccnnnnnos 24 Maintenance Safety aeisriai an iaa 25 Important Safety Precautions ooocccccnnonos 25 Maintenance Schedule memorando 26 General Competition Maintenance 30 Before amp After Competition Maintenance 33 Between Motos amp Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Component Locations seissctanarsceersssiactactinntiseeess 35 Seal ROMO srncfarenecedercsueseumivanpwesvessausuaresiacencene 36 Fuel lank Removal sssaicaniscc entorno rola pisas an Subframe Upright Positi0N ooooonnnnccccncncnnnnnns 39 Contents Service Procedures Fluids amp Filters A II menrcncsernena 41 A A 43 Transmission Olano 46 A lal PP ee PE OO A 48 AE E E In 51 Crankcase Breather eeeeeeeeesssssssssssssssssssese 2 Engine Ms A iuteeencetunousaasuonesart 54 Ae 56 Hot Stat Loi 60 OD PG IPP Ree EOI E 61 Exhaust Pipe Muffler vastas 62 Spare AOSTO osorno pelle 65 Vilve Ele AMO osorno errar 66 Piston Piston Rings Piston PiN oooooconaooooo 74 Chassis SUSPENSION assores rne na a rE aESNESEn EENE NA 82 PSA CS E E E T S 86 A A E A 90 ASA niai 91 TG e 93 DA AAA e A 94 Additional Maintenance Procedures 97 Electrical PAULI A o O O 99 Headlight amp Taillight
72. acing contingency programs and assistance at selected dual sport off road and motocross events Contact your Honda dealer for more information or call 1 800 847 HRCA or log on to www hrca honda com The Honda Rider s Club USA only Consumer Information 167 Table of Contents The following presents the contents of each section of your owner s manual MOTORCYCLE SAFETY ooooocccccccccccccccccconcnonss 1 Important Safety Precautions cccccccccnccncnoncnos 2 Me OANA AAA uo a 3 Accessories amp Modifications cccccccccnnnonccnnnnnnnnss 4 Safety LaDe a 5 OPERATING CONTROLS eeeeeoeeeseocsssssssssss 7 Component Locations cccccconncnocnccnnncnnnnnnnnnnnnnnss 8 BEFORE RIDING sisi ci sissisisdl 9 Are You Ready to Ride ccscsesssssesacorsseacsessenecaess 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection a smcnstaniconincitoracicorogiinaees 11 BASIC OPERATING INSTRUCTIONS 13 Safe Riding Precautions oooooooonooooocnccnnnnnnnnnnnnos 14 Starting amp Stopping the Engine eee 15 PPS PAGAL OM APP 5 rE 15 Pae E A a 15 Staring Procedur aacionma liada 15 Flogpded Ence asesinan piola 16 How to Stop the Ene tonic iii 16 PEGA GC AUS sea ccserncccencncatastansenstorsaiodoasatnsecnattas 17 A E O 18 DATO scoprine ios apa eaea O A 19 Post ride Inspection ssessseseeeenssesssssseeeesssss 20 Brake in Guidelines s scscsiczcosossasnasacaccstscateremactea 21
73. aded 21 7 in 550 mm Sag 2 0 in 50 mm Without Rider 6 Calculate the free sag dimension To do this subtract the loaded without rider dimension step 5 from the unloaded dimension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your motorcycle With the spring pre load set to obtain the proper race sag the rear suspension should sag 10 to 25 mm 0 4 to 1 0 in If the rear of your motorcycle sags more than 25 mm 1 0 in from its own weight the spring is too stiff for your weight It is not compressed enough even though you have the proper race sag adjustment As a result the rear suspension will not extend as far as it should Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre load consider an aftermarket shock absorber spring A spring that is too soft for your weight forces you to add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top out when you dismount your motorcycle Because of the great absorption quality of the shock bumper rubber it may be difficult for you to notice when your motorc
74. 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 Front Suspension Adjustments 17 Tighten the fork lower pinch bolts 13 to the specified torque 14 Ibf ft 20 N m 2 0 kgf m 18 Tighten the fork upper pinch bolts 14 to the specified torque 16 lbf ft 22 Nm 2 2 kgf m Over tightening the pinch bolts can deform the outer tubes Deformed outer tubes must be replaced 4 fork damper 13 lower pinch bolts 14 upper pinch bolts cont d Adjustments for Competition 115 Front Suspension Adjustments 19 Clean the threads of the fork protector bolts 20 Clean the surfaces where the axle and axle 15 and axle holder thoroughly clamps contact each other Apply locking agent to the bolt threads Install the left and right side collars into the Install the fork protectors 16 fork protector wheel hub Insert the front axle shaft through bolts brake hose clamp bolts 17 and the wheel hub from the right side Make sure tripmeter cable clamp bolt 18 the front axle shaft 1s seated firmly onto the Tighten the fork protector bolts to the left fork leg clamp inner surface Tighten the specified torque front axle nut 19 to the specified torque 5 Ibf ft 7 N m 0 7 kgf m 65 lbf ft 88 Nm 9 0 kgf m fork protector bolts 19 front axle nut fork protectors brake hose clamp bolts tripme
75. aling washer Servicing YourHonda 47 Coolant Your motorcycle s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and corrosion Coolant Recommendation Use Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines Check the antifreeze container label Use only distilled water as a part of the coolant solution Water that is high in mineral content or salt may be harmful to the aluminum engine Using coolant with silicate inhibitors may cause premature wear of radiator pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and water in this motorcycle This coolant solution is recommended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection 48 Servicing Your Honda Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequen
76. amp BQuIpMe Nl sins 160 Aaa MAP 161 CONSUMER INFORMATION ccce008 163 Authorized Manuals cccccccccnncnnnnnncnnnnnnnnnnos 164 Contacting Hond c5s 2ss0s0asesssnsnncsanaaaasinceiaatameds 165 Your Honda Delle linacos 166 The Honda Rider s Club USA only 167 TABLE OF CONTENTS oooccccccccccccccoccccccononos 168 INDEXA crnina 170 QUICK REFERENCE This section presents some of the most important information and recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Motorcycle Safety Motorcycle Safety 1 Important Safety Information Important Safety Precautions Your motorcycle can provide many years of pleasure 1f you take responsibility for your own safety and understand the challenges you can meet in competitive racing There is much that you can do to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider 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 motorcycle 1s designed for one person only There are no
77. ance venis 2120 Sas si aa 148 service ELTI AETS TA AE TET 163 anA a sosvascosenseaeuansasester 164 Spare D e e E 160 24d a AA E E S 41 PAE PIO ornoen anna E 6l MAMMA S P E E E E su nseeeeaioes 6l SPECILCACIONS ena ip nn ena 149 150 spring pre load rear suspension occocncnncccn 118 starting TNS E TOO E A AA 15 AI A 16 steering stem IMSPECUON scaosnssnerscnsncanceaccnescedcoveas 97 109 AAA A 16 ORAS O A 139 lod I AA o A 39 Index 171 Index suspension PP E o ea 82 IG I OPA A E AE AET TET 83 suspension adjustment E 0 5 Pe No Po E A A 104 PO er O 118 for track COMA ILIONS wi sensssiscsdnonedenchasaeanaebeneess 135 AM o A 123 transmission Oil eeeeeeessessssssssssssssessssseeerrereeee 46 amne ODS seresa arin eR EE aaa 126 throttle D A A ese 54 o A A 55 tires Gilt pre E ceper e EE 91 A E 91 SA T A OL EOS COn PORRO A A sates 160 torque SPECHICATIONS csessracsnsezaspnsanasyoacencees 151 153 PE US OTN cca canoes dente II seven 138 AAA 142 tubes replaCing ositos tri 91 VAIO UE arias 15 vehicle identification soseisuoien eco ciaciancndc 148 Washing your motorcycle ooooccccncnnnnnns 101 welo Di NAN osaera Nane AEA dada dolo sis 3 e A T E TE 90 writing AAA danauaeeeNeedacatsdnctense 161 172 Index Memo 173 Quick Reference The following is a brief but important collection of information you need to know about your Honda You ll also find space to record important no
78. and use the pressure release screws to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of O at sea level will increase as elevation increases s J 7 d f j 1 pressure release screws After Competition Maintenance It is important to the long term performance of your motorcycle 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 disc brakes or the disc rotors Remove the drive chain clean it and lubricate the chain and sprockets Be sure the chain is wiped clean and is dry before applying the chain lube Take care to prevent catching your fingers between the chain and sprocket Servicing Your Honda 33 Before Y After Competition Maintenance Routine Cleaning If your motorcycle 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 pr
79. and gasket in the muffler 1 and tighten the four bolts 2 to the specified torque 9 Ibf ft 12 N m 1 2 kgf m va 1 muffler 2 bolts Spark Arrester Servicing YourHonda 65 Valve Clearance Refer to Safety Precautions on page 2 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule The checking or adjusting of the clearance should be performed while the engine is cold The 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 spark plug cap 2 a 4 ESA ONIN QA un 3 Ae a A W 1 SAK lt 1 breather tube 2 spark plug cap 4 Remove the cylinder head cover bolts 3 and cylinder head cover 4 3 cylinder head cover bolts 4 cylinder head cover Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 i g 1 crankshaft hole cap e 1 Lal 1e b h i E AB A A e E 2 Rotate the crankshaft by turning the primary drive gear l
80. and low speed compression adjustments and softer rebound damping adjustment and replace the spring with a harder spring optional if necessary Adjustments for Competition 125 Carburetor Adjustments 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 require specific adjustments for competition use However in order to comply with emission regulations we recommend that you make no carburetor changes unless you use your CRF for competition only 126 Adjustments for Competition Hot Start Circuit Carburetor Components A lean mixture must be delivered to the cylinder when a hot engine is being started When the hot Cold Start Circuit start lever is pulled back the hot start valve 1 A very rich mixture must be delivered to the opens allowing air to be supplied to the main cylinder when cold engine is being started When bore 2 through the hot start air passage 3 This the choke knob 1 is pulled out fuel is metered extra air enters the air fuel mixture from the slow by the starter jet 2 and is mixed with air from circuit resulting in a lean condition the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 hot start
81. anging 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 Improper disposal of drained fluids is harmful to the environment You amp the Environment Tips 141 Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis The items that require use of the Honda Service Manual are followed by an asterisk POOR PERFORMANCE AT LOW AND UNSTABLE IDLE SPEED CHECK POSSIBLE CAUSES 1 Check if air e Over oiled air cleaner cleaner is over oiled P 51 CORRECT A 2 Check if the intake LEAKING e Loose insulator clamp e Damaged insulator NOT LEAKING o 49 10 HH pad x Q e Fuel air mixture too lean Turn the pilot screw out P 132 e Fuel air mixture too rich Turn the pilot screw in P 132 3 Check carbureator INCORRECT pilot screw adjustment P 132 CORRECT A 4 Check carburetor CLOGGED e Contaminants in the jets and accelerator fuel pump for clogs e Not cleaned frequently NOT CLOGGED ansugnibales 5 Try spark test WAKE OR e Faulty carbon or wet INTERMITTENT fouled spark pulg P 61 ADO PISRA SPARK e Faulty ignition control module
82. ankcase guide hole head gasket 2 Do not let the dowel pins fall into the crankcase 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs 1 dowel pins 2 cylinder head gasket cont d Servicing Your Honda 79 Piston Piston Rings Piston Pin 2 Route the cam chain through the cylinder 4 Install the cylinder bolt 5 and cylinder head 5 Install the engine hanger plates 7 engine head 3 bolts 6 and tighten them to the specified hanger nuts 8 of the frame side and engine Install the cylinder head torque hanger nut 9 of the engine side 7 lbf ft 10 Nm 1 0 kgf m Tighten the engine hanger nut to the specified e o torque frame side 25 lbf ft 34 N m 3 5 kgf m Do not damage mating surfaces when installing engine side 40 lbf ft 54 N m 5 5 kgf m 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 5 cylinder bolt 6 cylinder head bolts Wh 8 Do not let the washers and nuts fall into the crankcase 7 engine hanger plate 8 engine hanger nuts of the frame side 9 engine hanger nut of the engine side Tighten the cylinder head nuts in a criss cross pattern in 2 or 3 steps 3 cylinder head 4 cylinder head nuts washers 80 Servicing Your Honda Piston Piston Rings Piston Pin 6
83. anuals The Service Manual used by your authorized Honda dealer is available from NOTE Dealers and Companies please provide dealer or company name and also Helm Inc the name of the person to whose attention the shipment should be sent For purchases outside U S A please write to the address shown below for a quotation 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 Customer Name scooters and ATVs Attention These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper Street Address No P O Box Number SSA tools and skills Special Honda tools are necessary for some procedures City OOOO State Zip Code Publication Item No Description 61KSCO1 2005 CRF250X Service Manual 48 00 61CM002 Common Manual 48 00 Daytime Telephone Number 31KSC610 2005 CRF250X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Order On Line www helminc com Check or money order enclosed payable to Helm Inc U S funds only Do not Order Toll Free 1 888 CYCLE93 1 888 292 5393 send cash 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 p
84. away e Handle fuel only outdoors e Wipe up spills immediately breather tube fuel tank band air cleaner cover rubber fuel tank bolt 4 5 6 4 1 shroud A bolts collars 2 shroud B bolts collars 3 shrouds 8 fuel line 10 fuel valve bolt 9 fuel valve Servicing Your Honda 37 Fuel Tank Removal Installation 7 Put the breather tube 7 in the steering stem 1 Install the fuel tank on the frame nut 2 Install the fuel valve 1 and fuel valve bolt 2 3 Connect the fuel line 3 to the fuel valve W breather 7 breather tube 1 3 8 Install the shrouds 8 and shroud B bolts 1 fuel valve 3 fuel line collars 9 2 fuel valve bolt 9 Install the shroud A bolts collars 10 4 Install the fuel tank bolt 4 5 Hook the air cleaner cover rubber 5 6 Install the fuel tank band 6 A AOS l A ae SD V a AL 8 shrouds 9 shroud B bolts collars 10 shroud A bolts collars 4 fuel tank bolt 6 fuel tank band 10 Install the seat page 36 5 air cleaner cover rubber 38 Servicing Your Honda Refer to Safety Precautions on page 2 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 seat bolt 2 collars 3 and right side cover 4 1 right side cover bolt 3 collars 2 seat bolt 4 right
85. ay by check or money order or charge to your credit card Mail to Helm Incorporated at the address shown on this order form Canada See your Honda dealer to order authorized manuals Publication D mm Q Price Total Item No tem Description ly Each Price Sub Total Check here if your billing Master wn address is different from the Card VISA Discover shipping address shown above Account Number PLE T ILE PILE EEE ET Expiration Date Mo Yr Poe Customer Signature 3Z2M lt gt U 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 Prices are subject to change without notice and without incurring obligation AU O PO BOX 07280 DETROIT MI 48207 Orders are mailed within 10 days Please allow hagas adequate time for delivery Grand Total 164 Consumer Information Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If he doesn t have the answer right away he will get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If you wish to comme
86. cccnccnnccnnncnnnnonns 86 PPP PP o 89 A 86 break in guidelines ac ccveurassusacatensesatssomainceatanasaunas 21 170 Index capaciiy A aE 41 carburetor a UI cooler ecards 132 Circuit TNC ONS corrigen coleiases 126 COMPONEN rotas 126 disassembly assembly occcccccccococc 129 high altitude adjustment cccccccccnncccncnnnos 154 AE EE eevee rca ATOA 132 care FA PC Al AACS acosada estan 101 CUA CIN o AE T A E E 94 chassis adjustment for track conditions 135 SN O e 15 O E our wancasensnesencessanntaen 51 cleaning appearance care ccccccnnnnnnnccnnnnnnnnnnnnnn 101 clutch system AC JUSTMENL e erporisaaccarss 56 consumer information ccceseeeeseeeeeceeeeeees 163 controls A I component locations MAMENANG sesers i sieri 50 35 op rating COMMONS sccrssssassacapsacesesossasesearaneneonei 8 competition logbook oooooononocconcccnnncnnnos 157 contacting Honda wccsstinsceancecwenderessciesmialaorsianieese 165 controls operating eeseessssseeeereessssssseceeeesssssse 8 O e 48 Ao o lt eee anrr eee 163 cylinder AA 76 C damping adjustments HODE eae E ase 104 E EE PEO 118 dealer your Honda cronistas 166 diagram A A 161 TVS CHAIN ciecen Ne 94 engine Hood e o EEE 43 Il DECO rollo E 132 o E eso E N 148 A A S ETA E AT 41 SII EE OO T 15 BOD 0188 10 0 saa t 16 BOD UN ss A o eenn RA ana 16 ONL SUI E EE EE E 16 environment protecting vsssicccacecccacd
87. ccessories amp Modifications Accessories amp Modifications Modifying your motorcycle or using non Honda accessories can make your motorcycle 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 motorcycle 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 alter your riding position or interfere with operating any controls Modifications We strongly advise you not to remove any original equipment or modify your motorcycle in any way that would change its design or operation Such changes could seriously impair your motorcycle 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 arrest
88. ch lifter rod Install the clutch pressure plate 8 Install the five clutch springs and bolts 9 Tighten the bolts in a crisscross pattern in 2 or 3 steps to the specified torque 9 lbf ft 12 Nm 1 2 kgf m CaS bagi e PS 8 clutch pressure plate 9 clutch spring bolts springs 9 Install a new O ring 10 in the groove of the clutch cover 11 10 Install the cover by tightening the five cover bolts 11 clutch cover Clutch System 11 Lubricate the O rings 12 rear brake pedal 13 pivot and pivot bolt 14 with Honda Lithium Grease Tighten the pivot bolt to the specified torque 19 Ibf ft 26 N m 2 7 kgf m Connect the brake pedal return spring 15 if 1t was removed 12 Insert the pin 16 12 O rings 15 return spring 13 brake pedal 16 pin 14 pivot bolt 13 Fill the crankcase with transmission oil page 47 Servicing Your Honda 59 Hot Start Lever Refer to Safety Precautions on page 2 Hot Start Lever Freeplay left handlebar 1 hot start lever 2 freeplay Inspection Check freeplay 1 16 1 8 in 2 3 mm If necessary adjust to the specified range 60 Servicing Your Honda Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster in will increase free play and turning out will decrease free play After adjustment tighten the lock nut
89. coasseasnssaanates 141 filter IE a E A E 5I O o A O E E 44 flooded engine starting suso sso sscasdavbevasentaonsddnerncs 16 fork front suspension adjustment cccccccccccco 104 front suspension inspection cccccccccncncnnnnnos 82 oil recommendation csc cnccnacsxeseneasnonesavnssendanes 84 frame BAM AST AAA PPP 148 front brake lever adjustment ooooonnnnnnnnccnnnnn s 86 front suspension Maintenance oooooooncnnnocnnnnnnnnss 104 fuel A a ES UE EE E EEO E 41 o A eo UA A EE 41 recommenda ON sessooenisorccen coreo cian 41 MAA E santos 41 SIS cocotero E TANE 41 OX y Sena dossi ani N EEE 156 tank Capac screen rencac latas pss 41 A aeeeacee anaseae oesnaes seen E 15 gap spark ONO escusar II 6l PASCO A nirp enen eni erain 41 SAS MING eA 41 A E 134 guidelines suspension adjustment 123 handlebar inspection esencias 97 high altitude carburetor adjustment 154 Honda E E E E Te 165 Kide 6 C Doen a 167 Service Manya leistinas 164 WOU E e E 166 identification vehicle arcaica 148 idle speed enge sroine ana 132 inspection pre Tide sissies eii 11 labels Saloi y cercan 5 locations component seesesssseeereressssssseeereesss 8 logbook competition iccicnsacenendwcssrwncenexpnilnsdanddns 157 maintenance after COM CULO a sa csacsacotacesassiecssascanecasceosies 33 before amp after competition cccccccncnnnnonnnnnno 34 between motos amp practice oocccccccnocmom
90. d if you can not get the proper adjustment with the upper adjuster 5 lock nut 6 adjuster increase decrease 1 Remove the fuel tank page 37 2 Loosen the lock nut 5 3 Turn the adjuster 6 in direction to decrease freeplay and in direction to increase freeplay 4 Tighten the lock nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your Honda dealer Throttle Throttle Inspection 1 Check that the throttle assembly is positioned properly and the securing screws 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 Your Honda 55 Clutch System Refer to Safety Precautions on page 2 Clutch Freeplay 1 EA 1 clutch lever Inspection Check freeplay Freeplay 3 8 3 4 in 10 20 mm If necessary adjust to the specified range Improper freeplay adjustment can cause premature clutch wear 56 Servicing
91. dules 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 miles you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your motorcycle 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 ower has the proper tools and service date and is mechanically qualified Refer to the official Honda Service Manual page 164 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 lubricate replace ARO Maintenance Schedule MAINTENANCE SCHEDULE REGULAR OFF ROAD USE NON COMPETITION Summary of Maintenance Schedule Notes and Procedures ee First Maint Refer NOTES too 600 1200 180
92. e 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 O in 0 mm Chassis Adjustments Wheelbase Adjusting your motorcycle 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 motorcycle 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 motorcycle you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits Adjustments for Competition 133 Gearing You can adjust the power delivery of the standard engine to suit track conditions by changing gearing This allows you to utilize a different portion of the engine s power range at a given throttle setting New gearing may provide the change you are looking for without the need to consider further modifications The portion
93. e 1f necessary Check for interference between the frame and tank and adjust 1f 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 service the fuel filter 1 Drain the fuel from the fuel tank into an approved gasoline container 2 Remove the fuel tank page 37 3 Remove the fuel filter 1 from fuel tank by removing the screws 2 Wash the fuel filter in high flash point cleaning solvent 4 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 3 is in place Install the fuel filter in the fuel tank Refill the fuel tank Attach the fuel valve and fuel line and turn the fuel valve to ON or RES check for leaks 1 fuel filter 2 screws 42 Servicing Your Honda Refer to Safety Precautions on page 2 Using the proper oil and regularly checking adding and changing oil will help extend the service life of the engine s life Even the best oil wears out Changing oil helps get rid of dirt and deposits Operating the engine with old or dirty oil can damage your engine Running the engine with insufficient oil can cause serious damage to the engine Oil Recommendation API SG or higher except oils labeled as energy conserving on the circular API service label SAE 10W 40 classification viscosity wei
94. e clutch cable for kinks or signs of wear If necessary have it replaced e Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion Clutch Operation 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Clutch Cover Disc Plate Removal 1 Drain the transmission oil page 47 2 Remove the rear brake pedal 1 by removing the pin 2 and pivot bolt 3 1 rear brake pedal 2 pin 3 pivot bolt 3 Remove the five clutch cover bolts 4 and clutch cover 5 e Br 4 a MK e OS O ad 7 r P 7 Ps f W m e a O z y KS la E J Mal dd r que j 4 clutch cover bolts 5 clutch cover 4 Remove the five clutch spring bolts and clutch springs 6 Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps Clutch System 5 Remove the clutch pressure plate 7 e Y ey 6 clutch spring bolts clutch springs 7 clutch pressure plate 6 Remove the clutch lifter 8 and clutch lifter rod 9 7 Remove the eight clutch discs seven clutch plates judder spring and spring seat 10 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 doe
95. e engine overheating and damage 154 Technical Information Exhaust Emission Requirements The California Air Resources Board CARB requires that your motorcycle comply with applicable exhaust emissions 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 frame below the seat SN Y AR DI a 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 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 inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTI
96. e results from removing the battery and slow trickle charging it every 30 days see Battery Charging 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 1 Remove the seat page 36 2 Remove the battery band 1 and screws 2 negative cable 3 first 1 battery band 2 screws 3 negative cable 4 positive cable 3 Install the screws positive cable 4 first and battery band 1 4 Install the seat page 36 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
97. ed 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 motorcycle were designed to provide a good combination of handling braking durability and comfort across a broad range of riding conditions A WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual 100 100 18 59M bias ply tube type 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 Refer to Safety Precautions on page 2 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 clean engine oil Side Stand Servicing Your Honda 93 Drive Chain Refer to Safety Precautions on page 2 An endless riveted master link chain connects the countershaft and rear wheel sprockets The O ring chain us
98. ed Honda dealer for correct Service Limit measurements Piston Ring Installation 1 Clean the piston ring groove 2 Apply engine oil to the piston rings and install them Do not damage the piston ring by spreading the ends too far Do not damage the piston during piston ring installation e To install the oil ring install the spacer first then install the side rails e Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail Piston Piston Rings Piston Pin a top ring i aes omnes e oil ring El Servicing Your Honda 77 Piston Piston Rings Piston Pin Piston Installation 1 3 Cylinder Installation 1 Place clean shop towels in the crankcase to A S 1 Clean off any gasket material from the gasket keep the piston pin clips from falling into the LS EQ A surface of the crankcase being careful not to crankcase let any material fall into the crankcase 2 Apply molybdenum disulfide oil solution a Be careful not to remove any metal from the mixture of 1 2 engine oil and 1 2 gasket surface molybdenum disulfide grease containing 2 Remove the shop towel Do not let any gasket debris fall into the crankcase 3 Install the dowel pins 1 and cylinde
99. emperature grease antifreeze Other Products pliers safety wire safety wire mechanic s wire duct tape plastic tie wraps hose clamps drop light electrical tape Wiring Diagram REGULATOR RECTIFIER STARTER RELAY SWITCH ENGINE STOP SWITCH MAIN RELAY IGNITION CONTROL MODULE STARTER SWITCH CLUTCH SWITCH BATTERY 12V4AH Smarr BI Br BI R FL co Zo a nom m sono eee EL coor LE Ooo r BEU 0m te C a NEO i IE la es VEA IES o E EE E Ao E Bi Sl Si ARA Al gt gt Aek pel E O o 9 A H Bl BI Ue acai E E S E A E HEADLIGHT Lo 12V35W O3_ 35x m 3 m gt a F gt 333 5 Om aa OPTION a G SF 5 gt 3 BI Y gn 133 53 a m IGNITION COIL ALTERNATOR NA SPARK PLUG TP SENSOR IGNITION PULSE GENERATOR BI BLACK Br BROWN ENGINE STOP SWITCH STARTER SWITCH Y YELLOW O ORANGE E IG BAT3 ST Bu BLUE Lb LIGHT BLUE ee MEA G GREEN Lg LIGHT GREEN puss OJO R RED P PINK ret e Ww WHITE Gr GRAY CORD CORD Technical Information 161 162 Technical Information Consumer Information This section contains information about Authorized Manuals c occncccnccnnccnccnncnnoconccnnins 164 contacting Honda and how to get an official Contacting TIONG Aiiscascsnceescacsnsssscassacaseimecoagezsaiss 165 Honda service manual Your Honda Dealer acconinanonca acota opacar 166 The Honda Rider s Club USA only 167 Consumer Information 163 Authorized M
100. en the lock nut 2 fully and measure the thread length A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Wipe the oil completely off the fork spring 3 Install the fork spring Install the fork damper 4 to the outer tube slider 1 4 fork damper assembly 4 Set the lower end axle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage Overtightening the vise can damage the axle 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 Measure the thread length again Standard 0 43 0 51 in 11 13 mm 6 Install the push rod 6 into the piston rod until it stops Check the push rod installation by turning the push rod right and left 7 Install a new O ring 7 to the fork center bolt 8 Install the center bolt to the fork damper piston rod aligning the center bolt adjusting rod 9 with the push rod Tighten the center bolt fully by hand 2 lock nut 5 stopper tool 6 push rod 7 O ring 8 center bolt 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 m
101. er caver bolt 13 feeler gauge T2 Servicing Your Honda Valve Clearance 3 Install the cylinder head cover 5 and tighten Cylinder Head Cover Installation the cylinder head cover bolts 6 to the specified torque 1 Remove the spark plug hole packing 1 from 7 lbf ft 10 Nm 1 0 kgf m the cylinder head cover AY x y Install the spark plug hole packing to the s fe spark plug hole 2 W 5 cylinder head cover 6 cylinder head cover bolts a i a ns j J T sl gt a a a a i a F E a i ae r g y i A aa Pi baai ay j Ey F pe a a ll A y at A ba j 3 i F j E B O k y gt e y Y 2 io a F T d Pa a le a y f f e P 1 spark plug hole packing 2 spark plug hole 4 Connect the spark plug cap 7 and breather tube 8 2 Install the cylinder head cover packing 3 into the groove of the cylinder head cover 4 l 7 spark plug cap 3 cylinder head cover packing 8 breather tube 4 cylinder head cover 5 Install the fuel tank and the seat page 38 Servicing Your Honda 73 Piston Piston Rings Piston Pin Cylinder Head Removal 1 Clean the area above the engine before disassembly to prevent dirt falling into the engine 2 Drain the engine oil page 44 3 Drain the radiator coolant after cooling the motorcycle page 139 4 Remove the seat and fuel tank page 37 5 Lift the subframe to the upright position page 39 6
102. er 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 motorcycle 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 11N streets roads or highways is illegal For your protection always wear your helmet while A DINN G E R riding Operator only No passengers O NEVER OPEN WHEN HOT Read the owner s manual carefully l This Honda motorcycle is sold as is without warranty 3 Hot coolant will burn you and the entire risk as to quality and performance is f wth the Buyer SoZ Y N e V a Motorcycle Safety 5 6 Motorcycle Safety Operating Controls Read this section carefully before you ride It Component Locations sucorrniosion cios oasis 8 presents the location of the basic controls on your motorcycle Operating Controls 7 Component Locations hot start lever tripmeter clutch lever ASS front brake lever engine stop button start button throttle grip fuel fill cap choke knob kickstarter Ba N SA ORR Lae Se
103. es 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 and check that your transmission is in neutral It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule 94 Servicing Your Honda Drive Chain Inspection 1 Turn the engine off raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral 2 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 1 drive chain plate inner 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
104. even when the engine is off Limited operation also allows the battery to discharge If you have electrical accessories on your motorcycle or do not ride frequently we recommend that you charge the battery frequently see Battery charging page 99 If you do not expect to ride your motorcycle 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 Honda Dielectric Grease on all electrical connections Servicing Your Honda 31 General Competition Maintenance Suspension Linkage Lubrication Disassemble clean inspect and lubricate all pivot bearings after each 7 5 hours of running time in order to maintain proper suspension performance and minimize component wear Use Honda Moly 60 paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Swingarm Pivot Lubrication Clean inspect and lubricate when servicing suspension linkage pivots Be sure all of the suspension pivot seals are in good condition Use Honda Moly 60 paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive Swingarm Do not attempt to weld or otherwise repair a damaged s
105. event 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 motorcycle Avoid using stiff abrasive brushes on the plastic or rubber parts If your motorcycle was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts If you decide to wash your motorcycle or use cleaners refer to Appearance Care page 101 34 Servicing Your Honda hot start lever clutch lever 7 engine stop button fuel fill cap clutch lever choke knob Da front brake ZAS fuel tank hose LRR FAA S steering ya AT front gt suspension air cleaner housing cover carburetor rear suspension gt EA Z gt T taillight Y St left side cover chain slipper E rear wheel axle gt DO je LN engine oil transmission oil drain bolt drain bolt fuel valve MOE iV a chain slider side stand WA y lane chain chain adjuster Component Locations tripmeter front brake lever 5 starter button throttle grip radiator cap throttle grip front brake lever Ne kickstarter right side cover Os IRA O PES tripmeter cable 75 NI AS
106. ge the attitude of your motorcycle and its handling Tire variations that raise or lower the rear of your motorcycle 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 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
107. ght MA or MB Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent JASO T 903 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 Engine Oil e Your motorcycle 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 Oe Sermo ie NOT RECOMMENDED OK e Oil is a major factor affecting the peformance and service life of the engine Do not use non detergent vegetable or castor based racing oils Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range SAE 20W 50 SAE 20W 40 SAE 10W 40 SAE 10W 30 0 20 40 60 80 100 F Servicing Your Honda 43 Engine Oil JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification 44 Servicing Your Honda Checking amp Add
108. 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 motorcycle is designed and manufactured for off road use only The tires are not made for pavement and the motorcycle 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 motorcycle 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 2 Motorcycle Safety exhaust system Wear clothing that fully covers your legs Do not wear loose clothing which could catch on the control levers kickstarter footpegs drive chain or wheels Take Time to Learn and Practice Developing off road riding skills is a gradual step by step process Start by practicing at low speed in a safe area and slowly build your skills Personal instruction from an experienced rider can also be valuable If you need assistance ask your dealer about riding groups in your area Also be sure to read the Tips Practice Guide for the Off Highway Motorcyclist booklet that came with your motorcycle USA only Be Alert for Off Road Hazards The terrain can present a variet
109. he bushing and new O ring on the fork cap 1 assembly 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 2 fork damper 1 fork cap 110 Adjustments for Competition 9 Tighten the fork cap 1 while holding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 bf ft 80 N m 3 1 kgf m 3 lock nut wrench 1 fork cap 2 fork damper 10 Hold the fork damper 2 in an upright position and pump the fork piston rod 6 to 3 9 in 100 mm slowly several times A 0 3 9 in 100 mm i 2 fork damper 6 piston rod 11 Screw in the lock nut 7 to the fork damper piston rod 6 fully 7 lock nut 6 piston rod Turn the rebound adjuster and compression adjuster counterclockwise to the softest position Check the fork damper piston rod sliding surface for damage Apply fork oil to the fork damper piston rod sliding surface Cover the fork piston rod end with soft jaws to prevent fork damage Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked 12 Blow the extra oil off to the fork damper 2 spring chamber 8 by pumping the fork damper piston rod
110. he electrode for wear or deposits the gasket 3 for damage and the insulator for cracks Replace 1f you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 031 0 035 in 0 8 0 9 mm 3 sealing gasket 4 spark plug gap 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 ten minutes before taking a plug reading a brand new plug will not color initially If the electrodes appear burnt or the insulator 1s 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 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 tur
111. he forks parallel alternately tighten the right axle pinch bolts to the specified torque 14 Ibf ft 20 N m 2 0 kgf m 26 tabs Front Suspension Adjustments To avoid damage when torquing the axle pinch bolts be sure the axle is seated firmly onto the left fork leg clamp inner surface 28 Install the trip meter cable 30 30 gt a j L_ i 29 axle pinch bolts 30 tripmeter cable 29 Clean the threads of the disk cover bolts and axle holder thoroughly Install the disc cover 31 and tighten the bolts 32 to the specified torque 9 Ibf ft 13 Nm 1 3 kgf m 31 disc cover 32 bolts 30 Turn the rebound damping adjusters back to their original settings 117 Adjustments for Competition 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 eq
112. hers 13 cylinder head Servicing Your Honda 75 Piston Piston Rings Piston Pin 2 Remove the dowel pins 3 and cylinder Cylinder Removal gasket 4 Piston Removal 1 Remove the cylinder bolt 1 and cylinder 2 NOTICE 1 Place clean shop towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase NOTICE Do not let the dowel pins fall into the crankcase aen e a a needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Do not damage the piston Always support the piston when pressing out the pin Do not let the clips fall into the crankcase Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder 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 A B n 7 5 1 ih y fins i ee A 1 a 3 me if E Wh i j 3 dowel pins 4 cylinder gasket 1 cylinder bolt 2 cylinder 1 piston pin clip 3 piston 2 piston pin 4 piston rings 4 Spread each piston ring 4 and remove by lifting it up at a point just opposite the gap Do not damage the piston ring by spreading the ends too far 76 Servicing Your Honda Cam Shaft Holders Cylinder Head C ylinder Piston Piston Pin Piston Ring Inspection We recommend you consult the Service Manual or your authoriz
113. ightened assemblies should rotate on the Teflon tape 136 Adjustments for Competition e Position the shift lever and brake pedal so they are close to your boot for rapid access but not so close that either is depressed when sitting or standing comfortably on your motorcycle 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 Handlebar width can be trimmed with a hacksaw to better suit your particular shoulder width and riding preference Think this through carefully and cut off just a small amount at a time from both sides equally It is obviously much easier to make the handlebar narrower than it is to add material Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar An alternate handlebar shape through varying rise or rearward sweep dimensions will provide further adjustment to riding position and may better suit your particular body size or riding style Each of the ergonomic dimensions of the
114. il e Do not use oils with graphite or molybdenum additives They may adversely affect clutch operation e Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance area NOT RECOMMENDED OK e Oil is a major factor affecting the performance and service life of the transmission and clutch Do not use non detergent vegetable or castor based racing oils Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range BIZ 20W 50 PSN EE 20W 40 stern 10W 40 a ae ee SAE 10W 30 0 20 40 60 80 100 F JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard has the following classification on the oil container PRODUCT MEETING JASO T 903 COMPANY GUARANTEEING THIS MA PERFORMANCE 1 code number of the sales company of the oil 2 oil classification Checking amp Adding Oil 1 transmission oil filler cap 2 oil check bolt L 2 Wait 3 minutes after shutting off the engine to Run the engine for 3 minutes then shut it off allow the oil to properly distribute itself in the clutch and transmission Support the CRF in an upright position on a level surface Remove
115. in bolts 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 spark plug and pour a tablespoon 0 51 0 68 US oz 15 20 cm of clean engine oil into the cylinder With the spark plug grounded or the engine stop button pressed in crank the engine several times to distribute the oil then reinstall the spark plug 9 Remove the battery and charge itfully Store in an area protected from freezing temperatures and direct sunlight Slow charge the battery page 99 once a month Storing Your Honda 10 Inflate the tires to their recommended pressures 11 Place your CRF on the optional Honda work stand or equivalent to raise both tires off the ground 12 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 13 Store your motorcycle in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 14 Cover your motorcycle 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 139 Storing Your Honda Removal from Storage 1 Uncover and clean your CRF Change the engine and transmission oil if more than 4 months have passed since the start of storage
116. ing Oil 1 engine oil filler cap dipstick 2 upper level mark 3 lower level mark 1 Run the engine 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 If the oil is at or near the upper level mark you do not have to add oil e If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 15 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil filler cap 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 After the oil has drained tighten the engine oil drain bolt with a new sealing washer to the specified torque 16 Ibf ft 22 N m 2 2 kgf m
117. ing Your Honda 2 Tighten the screw 4 on the air cleaner connecting tube clamp 5 4 screw 5 air cleaner connecting tube clamp 3 Install the rear suspension upper mounting bolt 6 nut 7 and band 8 Tighten the rear suspension upper mounting bolt to the specified torque 32 lbf ft 44 N m 4 5 kgf m 6 rear Suspension upper mounting bolt 7 nut 8 band Nm E Install the muffler page 63 Install the seat 9 page 36 Install the left side cover 10 collars 11 seat bolt 12 and left side cover bolt 13 Close the air cleaner box cover 14 and turn the quick fastener 15 clockwise 9 seat 13 left side cover bolt 10 left side cover 14 air cleaner box cover 11 collars 15 quick fastener 12 seat bolt 7 Install the right side cover 16 collars 17 seat bolt 18 and right side cover bolt 19 16 right side cover 17 collars 18 seat bolt 19 right side cover bolt Refer to Safety Precautions on page 2 Fuel Recommendation Type Unleaded Pump Octane Number 91 or higher We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components Your engine is designed to use any gasoline that has a pump octane number of 91 or higher Gasoline pumps at service stations normally display the pump octane number For information on the use of oxygenated fuels see page 156 Use of lowe
118. ing 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 whoop to the next Generally with higher gearing it is easier to maintain that perfect attitude maximum rear wheel traction and a light front end because you remain in the powerband longer in each gear The higher gearing allows you to steer more efficiently with throttle control and body English If you are riding a track with sections where you ch
119. ion check the fluid level It should be above the LOWER level mark 1 If the level 1s 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 brake level 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 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 The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 1 screws 2 reservoir cap 3 upper level mark 1 Remove the screws 1 reservoir cap 2 and diaphragm 2 Fill the reservo
120. ion 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 102 Servicing Your Honda Aluminum Frame Maintenance Exhaust Pipe Maintenance Aluminum corrodes when it comes in contact The exhaust pipe is stainless steel but may with dust mud and road salt became stained by oil or mud To remove stains use Scotch Brite Hand Pad Remove heat stains with a liquid kitchen 7447 maroon or an equivalent abrasive Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame Do not use steel wool to clean the frame as it could damage or discolor
121. ir with DOT 4 brake fluid to the upper level mark 3 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the screws to the specified torque 1 1 lbf ft 1 5 N m 0 15 kgf m 88 Servicing Your Honda Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 4 bolts 5 reservoir cap 6 diaphragm 7 upper level mark 1 Remove the bolts 4 reservoir cap 5 and diaphragm Check the diaphragm 6 installation as shown 2 Fill the reservoir with DOT 4 brake fluid to the upper level mark 7 Do not overfill 3 Reinstall the diaphragm and reservoir cap 4 Tighten the bolts to the specified torque 1 1 lbf ft 1 5 N m 0 15 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 indicator 0 04 in 1 mm replace wear indicator gro
122. keep track of the running time on the engine and suspension components If you choose to sell your motorcycle 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 in red suspension chassis settings in blue and gearing selections in green Color codes will help you identify the information you want with a glance Tuning amp Adjustment Records Keep track of the settings and adjustments that worked best at a particular location These items include e basic track conditions altitude and temperature e suspension settings e chassis adjustments tested and selected e gearing e tire selection e air pressure Competition Records e your placings e thoughts to improve performance next time both yours and your motorcycle 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 races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft ope
123. king Care of the Unexpected 143 If a Fuse Blows All of the electrical circuits on your motorcycle have a fuse to protect them from damage caused by excess current flow short circuit or overload If something electrical on your motorcycle 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 e The main fuse and spare are located on the starter motor magnetic switch behind the right side cover Recommended Main Fuse 15A 1 To prevent an accidental short circuit stop the engine 2 Remove the seat bolt 1 right side cover bolt 2 collars 3 and right side cover 4 1 seat bolt 2 right side cover bolt 3 collars 4 right side cover 144 Taking Care of the Unexpected Disconnect the wire connector 5 of the starter magnetic switch 6 Pull main fuse 7 out If it is blown 8 install the spare main fuse 9 wire connector starter magnetic switch main fuse blown fuse Spare main fuse 5 Reconnect the wire connector If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a fuse with one that has a higher rating greatly increases the chance of damage to the electrical system If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse
124. l A and one of three signal words DANGER WARNING or CAUTION These signal words mean WDC BN You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WIN NINE You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions NE o7 N00 E 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 SAFETY oooooccccccccccccccccccccconoss 1 Important Safety Precautions oooccccccncnnnos 2 E a tesecasacta san E 3 Accessories amp Modifications cccccccceeees 4 ale LD are 5 OPERATING CONTROLS onnnmnccccccccoccccccccccocos 7 Component Locations ccccccoooooocnncnnncncnnnonnnonnnnss 8 BEFORE RIDING iii iman 9 Are You Ready to Ride oonocccnncccccnnnonmms omo 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection sisi casi 11 BASIC OPERATING INSTRUCTIONS 13 Safe Riding Precautions 000eseeeeeees 14 Starting amp Stopping the Engine occccccccnn 15 Odo dls sete cececxdnncnontaneamsenitorsstodoasatnsecnaaect 17 A O 18 A 19 Post ride IMS PC CHOM ueno oiiene aaa 20 Break in Guidelines ascrani
125. le and clean the fork after riding your CRF for three hours Refer to Suspension adjustment information page 104 for make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If the fork is still too stiff soft after adjusting compression damping determine which portion of the travel is still too stiff soft This is an important step that will help you solve suspension problems Make sure that the fork protectors 1 and dust seals 2 are clean and not packed with mud and dirt Check for signs of oil leakage Damaged or leaking fork seals should be replaced before your CRF is ridden 4 T 0 06 in 1 5 mm 3 3 3 wear ring See page 105 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 109 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 mate
126. lifters Servicing Your Honda 69 Valve Clearance Shim Selection 1 Clean the valve shim contact area in the valve lifter 1 with compressed air SALE T 1 valve lifter 70 Servicing Your Honda Measure the shim thickness and record it Twenty 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 Pan 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness e Make sure of the correct shim thickness by measuring the shim with the micrometer e Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2 900 mm 1 80 mm 1 825 mm 1 85 mm 1 875 mm 3 Rotate the primary drive gear lock bolt 4 Camshaft Installation crankshaft clockwise and align the punch mark 5 with the index mark 6 1 Install the newly selected shims 1 on the valve retainers 2 Do not let the shims fall into the crankcase 4 primary drive gear lock bolt 5 punch mark 6 index mark 4 Apply molybdenum oil solution to the cam journals and cam lobes 1 shims 2 valve retainers Place the cam sprocket 7 and align the timing mark 8 on the cam sprocket
127. ll also find that your dealer is a source of information USA only the Honda Rider s Club of America We re sure you ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda One of the best ways to get the most enjoyment from owning and riding your Honda is through the Honda Rider s Club of America Your purchase of a new motorcycle scooter ATV or 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 24 hour emergency roadside assistance for your new Honda includes roodside assistance for your transport vehicles as long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Speialty Vehicle Institute of America for ATV owners One full year of the Honda Red Rider magazine or Honda Red Rider ATV for ATV purchasers Discounts from HRCA partners for experienced rider courses Discounted vehicle insurance from the HRCA s insurance partner R
128. ll the crankcase with the recommended oil Capacity 0 73 US qt 0 69 at oil and filter change 0 70 US at 0 66 at oil change 16 Install the engine oil filler cap dipstick 17 Check the engine oil level by following the steps in Checking amp Adding Oil page 44 Servicing Your Honda 45 Transmission Oil Refer to Safety Precautions on page 2 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 Type transmission oil or 4 stroke engine oil API classification SG or higher except oils 4 stroke engine oil labeled as energy only conserving on the circular API service label Viscosity SAE 10W 40 weight JASO T903 MA standard others without friction modifiers such as molybdenum additives Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molyodenum additives 4 stroke engine oil or an equivalent suggested oil Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label e Your motorcycle does not need oil additives Use the recommended o
129. ll the hot start lever and clutch lever in and press the starter button for 3 seconds If the engine starts quickly close the throttle then open it slightly if idling is unstable If the engine does not start wait 10 seconds and then follow the starting the engine 4 As soon as the engine starts release the hot start lever Using the kickstarter 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter Operation approximately 10 times very slowly to discharge excessive fuel from the engine 3 Pull the hot start lever and start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 16 Basic Operating Instructions How to Stop the Engine 1 throttle grip 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Turn the fuel valve OFF 3 Lightly open the throttle 1 2 3 times and then close it 4 Depress and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow result in hard starting Emergency Engine Stop To stop the engine in an emergency press and hold the engine stop button 23 49 gt 1 Your motorcycle has five forward gears To start riding after the engine has been warmed and the side stand raised l Za 3 Close the throttle and pull the front brake le
130. m If the clearance is out of specification check the lock nut and center bolt installation 2 A 0 06 0 08 in 1 5 2 0 mm A 1 68 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten the lock nut to the specified torque 16 lbf ft 22 Nm 2 2 kgf m 2 lock nut 8 center bolt Front Suspension Adjustments 10 Apply fork oil to the center bolt 8 O ring Remove the special tool or mechanic s stopper tool while applying pressure to the fork damper Install the center bolt to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 8 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 center bolt and lock nut installation 10 length cont d Adjustments for Competition 113 Front Suspension Adjustments 13 Pour the recommended fork oil 11 into the Fork Oil Capacity Optional Stiffer 0 44 kgf mm Fork Spring OUE areca CL Standard 0 42 kgf mm Fork Spring Recommended Oil No mark 1 b k Pro Honda HP Fork Oil 5 W or equivalent A UE Q Sarie mar 2 scribe mark Co aftermarket parts Standard oil 11 7 US oz capacity 345 cms Maximum oil 13 5 US oz Slightly s
131. machine were determined to suit the greatest possible number of riders based on an average size rider Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle oooo 138 Storing Your Motorcycle oooccccccccccnnnonomo 139 You amp the Environment s es 141 TPOUDICSHOOUNG on ccpssssaceoaccediaevaacesaecaannasecncasasatas 142 Tips Tips 137 Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your motorcycle brace the front wheel transport your Honda we recommend that you against the front of the truck bed or trailer rail follow these guidelines Attach the lower ends of two straps to the tie e Use a loading ramp down hooks on your vehicle Attach to the upper e Make sure the fuel valve is off ends of the straps to the handlebar one on the e Secure the motorcycle in an upright position right side the other on the left close to the fork using motorcycle tie down straps Avoid using rope which can loosen and allow the Check that the tie down straps do not contact any motorcycle to fall over control cables or electrical wiring Tighten both straps until the front suspension 1s 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 y
132. mage An optional cooling fan is available and is recommended 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 motorcycle 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 A Few Words About Safety Your safety and the safety of others is very important And operating this motorcycle safely 1s an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You will find important safety information in a variety of forms including e Safety Labels on the motorcycle e Safety Messages preceded by a safety alert symbo
133. mms gt 33 general competition ssssssssseeerssssssssserersse 29 TE OILANC xccarat ocsonsanessacinncseasobeisned ccecetcccasia 24 SALLY OPEP PO POE EE 25 UN O EEEE 27 28 manoal NIC teria 164 AA coe sssaneasasecdecatesecosonesiee 4 oil A E E EE 82 A poet 46 operating CONOIS 2225 22302 osssesssoataceesscecsesteencceiapaccononthee 7 optional PP EE 159 POC S e oeo lao ette 159 oxygenated Ue Suesicriciossalc ciedad caricdiciona 156 pads DRAKE cascercomand cocacnecsetccnesteasaoereactesecnt tesco ae 89 parts OPO Ma sasssa inan Ei 159 personal fit adjustments oooccccccccnnnnnnnnnnnnnnnss 136 pingine EN IO rien hopsennatneds 41 AR A sesaszatestaudcseonmes 61 pre load rear SUSPENSION coccccccccnonnnnncnnnnnnnnnss 118 preside 1S ECU ON esscononrcsrionan osito sentida ca nina 11 prolechive appar eae eee eee isis 2 rear SUSPENSION maintenance oooooccccccnnnnnnnnnnnn 83 Riders Club Honda ciciciccscscccosssstetieacnestaandavoasse 167 riding A 2 DASIC OD CTAL OM AA one 13 DOLOT O AE e NEU E E iSSi eaa aei 9 important safety information cccccccccnnnnnnns 2 safety precautions seseeeeeessssssssssssssssssseee 2 safety a few words about Safety Messages important Informatl0N cooccccccnnnnnnonononononinnnnss 2 important precautions vsusosnincanniiacin cria 2 DEI euge E R 5 mantenan A 25 riding precautions estos icionicaneconaniccces dorados 14 schedule mainten
134. n after it seats 10 Connect the spark plug cap 11 Install the fuel tank and seat page 38 Servicing Your Honda 61 Exhaust Pipe Muffler 2 Loosen the muffler clamp bolt 5 Exhaust Pipe Muffler Inspection Muffler Removal 3 Remove the muffler A bolt 6 muffler B bolt washer 7 and muffler 8 Check the flange bolts for tightness Check the exhaust pipe and muffler for cracks or deformation A damaged exhaust pipe and muffler may reduce engine performance 1 Remove the seat bolt 1 collar 2 side cover bolt 3 collar 2 and right side cover 4 5 muffler clamp bolt 7 muffler B bolt washer 6 muffler A bolt 8 muffler 1 seat bolt 3 side cover bolt 2 collars 4 right side cover 62 Servicing Your Honda Muffler Installation 1 Remove the gasket 2 Install a new gasket 1 and muffler 2 2 muffler Exhaust Pipe Muffler 3 Tighten the muffler B bolt 3 and muffler A 5 Install the right side cover 6 collar 7 and bolt 4 to the specified torque side cover bolt 8 19 lbf ft 26 N m 2 7 kgf m 6 Install the collar 7 and seat bolt 9 tighten the bolt to the specified torque 4 Tighten the muffler clamp bolt 5 to the 20 Ibf ft 26 N m 2 7 kgf m specified torque 15 Ibf ft 21 Nm 2 1 kgf m 6 right side cover 8 side cover bolt 7 collars 9 seat bolt 3 muffler B bolt 5 muffler clamp bolt 4 muffler A bolt Servicing Your Honda 63
135. n fitting the brake disc between the brake pads 14 18 14 fork protector bolts 17 fork protectors 15 tripmeter cable clamp bolt 18 brake caliper bolts 16 brake hose clamp bolts 19 brake caliper 11 Loosen the fork leg lower pinch bolts 20 na pull the fork legs down and out 78 y 20 lower pinch bolts 12 Clean the fork assembly especially the sliding surface of the slider 21 and dust seal 22 The outer tube can drop on the slider and damage the fork dust seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NO GOOD 21 slider 23 outer tube 22 dust seal 24 guide bushing 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 25 length Front Suspension Adjustments 15 Hold the outer tube 23 then remove the fork damper 24 from the outer tube using the lock nut wrench 25 Gently slide the outer tube down onto the lower end of the slider 26 25 23 23 outer tube 24 fork damper 25 lock nut wrench 26 slider lower end 16 Pour the fork oil from the outer tube 23 Pour the fork oil from the oil hole 27 of the fork damper 23 27 RHH PTT DAMA 23 outer tube
136. n 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 NS A T 44 Transmission oil level ssscscsevacscswstwsasexsadenenneds 4 Coolant for proper level 48 Cooling system and hoses for condition 49 Spark plug for proper heat range carbon fouling and high tension cord terminal for A one a a 61 Air cleaner for condition and COMA MTNA VOM so tcseccatnseacaneccseestansaestaavonnassaues 5I Clutch operation and free play 56 Steering head bearings and related parts Oo AAA 97 Carburetor throttle operation occmomoo 39 Engine idle speed for stable and proper Andi e E seer re try tr 132 Tires for damage or improper inflation no E E E ATS 91 Spokes for lo
137. nce and exhaust valve clearance need adjustment see Camshaft Removal page 68 and select the correct shim for each valve Servicing Your Honda 67 Valve Clearance CamShaft Removal 1 Record the intake valve clearance and exhaust 68 valve clearance Servicing Your Honda 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool e Tensioner stopper O70MG 0010100 3 Turn the tensioner shaft clockwise with the stopper tool 3 until it stops in order to retract the tensioner fully Then insert the stopper tool fully to hold the stopper in the fully retracted position 3 stopper tool 4 Remove the camshaft holder bolts 4 and camshaft holders 5 Loosen the camshaft holder bolts in a criss cross pattern in 2 or 3 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 Valve Clearance 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 Do not let the valve lifters and shims fall into the crankcase 8 shims 7 valve
138. ng improper heat range or other cause freshness of fuel owner modifications such as exhaust system holes in the air box etc ignition timing compression If the above check out then adjust the carburetor for your specific racing conditions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition 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 motorcycle by increasing the rear spring pre load Instead of running 3 9 in 100 mm of sag you can run 3 5 in 90 mm so the rear of the bike will sit a little higher This should produce more traction because of the change to the swingarm and the location of your motorcycle s center of gravity If you have a problem with the steering head shaking when you use the front brake hard or if your motorcycle 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 120 in the 90 100 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the fork tub
139. ngine startes push the choke knob back all the way to fully OFF If idling is unstable open the throttle slightly Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine 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 3 under Normal Air Temperature Low Air Temperature 10 C 50 or below 1 Follow steps 1 4 under Normal Air Temperature 2 Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine Hot Engine Starting 1 Pull the hot start lever 3 and start the engine following step 3 under Normal Air Temperature 2 As soon as the engine starts release the hot start lever 3 hot start lever 3 Basic Operating Instructions 15 Starting amp Stopping the Engine Flooded Engine Starting the engine after a stall during riding or after a fall 1 Shift the transmission into neutral 2 Pull the hot start lever and start the engine Do not open the throttle 3 As soon as the engine starts release the hot start lever Starting a flooded engine Using the start button 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened 3 Pu
140. nnnanannno 74 Servicing Your Honda Chassis SUSPEN O A 5 AEE E AR 82 Front Suspension Inspecti0N oooomooooo 82 Rear Suspension Inspecti0N oooocccnonncos 83 Recommended Fork Oil oooo 84 Fork OIC DANTE ase cen rer renee 84 BD ECS acti o seunGovageuees 86 O SEE T 90 Tres S AAA 91 SG SLAC AAA oo E 93 Dive Ma re sentir nsn aE NNR E 94 Additional Maintenance Procedures 97 Electrical A A sean seadions sanaacnsanancen sank sogoaeenes 99 Headlight amp Taillight cccccnnnnnnnnnnnnnnnnnno 100 NA AAA 101 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 motorcycle is designed to be ridden over rough off road terrain To help you properly care for your motorcycle 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 motorcycle to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair If your motorcycle overturns or is involved in a crash be sure your Honda dealer inspects all major parts e
141. nsion feels stiff on large bumps 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression adjustments and rebound adjustment simultaneously 2 If it still feels stiff replace the spring with a softer spring optional and begin with the standard settings to softer settings Soft suspension Entire travel too soft 1 Test stiffer high and low speed compression adjustments simultaneously 2 If it still feels soft replace the spring with a harder spring optional and begin with the standard settings to stiffer setting Rear end sways 1 Test stiffer high and low speed compression adjustments and rebound adjustment to stiffer settings simultaneously Suspension bottoms Suspension bottoms at landing 1 Test stiffer high soeed compression adjustment after jumping 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a harder spring optional if necessary Suspension bottoms after landing 1 Test stiffer low speed compression adjustment 2 If it still bottoms test stiffer high and low speed compression adjustments and replace the spring with a harder spring optional if necessary Suspension bottoms after end of 1 Test softer rebound dumping adjustment continuous bumps 2 If it still bottoms test stiffer high
142. nt on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc RO Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following information in your letter e name address and telephone number e product model year and frame VIN serial number e date of purchase e dealer name and address We will likely ask your Honda dealer to respond or possibly acknowledge your comments directly Contacting Honda Consumer Information 165 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 166 Consumer Information Your dealer can inform you about competition events in your area You
143. 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 Oe AA 1600 O 1400 Oil capacity 11 7 US oz 345 cm3 j 2 1200 STANDARD I 1000 800 600 400 200 0 S AL SH Y gt RY OS AS gt hs ES Stroke mm Front Suspension Adjustments Front Suspension Disassembly e If your CRF is brand new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in For optimum performance and extended fork life the fork should be completely disassembled and cleaned after the first three hours of riding See the Service Manual or your Honda dealer for this service 1 Place your CRF on the optional workstand or equivalent support with the front wheel off the ground 2 Remove the front visor bolts 1 and front visor 2 1 front visor bolts 2 front visor cont d Adjustments for Competition 105 Front Suspension Adjustments 3 Disconnect the head light connector 3 O IA gt ee AR w Y VII S A O lt 2 A 3 headlight connector NI SS PIA
144. ock bolt 3 clockwise until aligning the punch mark 4 on the primary drive gear with the index mark 5 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear lock bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed This condition can be determined by moving the exhaust rocker arm 6 If it is free it is an indication that the valves are closed and that the piston is on the compression stroke If it is tight and the valves are open rotate the primary drive gear lock bolt 360 and realign the punch mark to the index mark 3 primary drive gear lock bolt 4 punch mark 5 index mark Valve Clearance Inspection Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cam lobe 3 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 shim 5 1 feeler gauge 4 exhaust rocker arm 5 exhaust vakve shim 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 cleara
145. of your engine s power range you use can be adjusted by changing the final drive ratio with different sized rear sprockets Gearing changes allow you to more closely match the type of terrain and the available traction Normally a change of one tooth on the rear sprocket will be sufficient There are two higher gearing choices with two optional aluminum driven sprockets For muddy or sandy courses there is a more durable steel driven sprocket with the standard number of teeth Like the optional springs and these sprockets are listed in the Optional Parts List section 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 rear 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 134 Adjustments for Competition However e 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 dur
146. off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 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 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 Transmission Oil Airbox Sealing Drain and replace transmission oil often to ensure the Remove and reseal the air cleaner housing boot where it greatest service life of the transmission and clutch Frequent connects to the air cleaner housing with silicone sealer if changes will also assure consistent performance of both there is any doubt to its sealing integrity Use Hondalock or shifting and clutch action page 47 an equivalent on the attaching studs Inspect the air cleaner and air intake tract regularly for signs
147. oose 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 motorcycle offer a happy medium for the variety of soil conditions the majority of riders are likely to encounter Experienced competitors often switch to tires developed for specific terrain conditions If you do switch stay with the factory recommended sizes Other tires may affect handling or acceleration Be aware that tire sizes width and aspect ratio do vary from manufacturer to manufacturer or even among tires made by the same manufacturer Variations in tires especially the sidewall profile can chan
148. ore 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 motorcycle has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are 15 psi 100 kPa 1 0 kgf cm 15 psi 100 kPa 1 0 kgf cm If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Inspection Take time to inspect your tires and wheels before you ride Nes gt g E A 1 tire tread depth Tires amp Tubes e Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for cuts slits or cracks in the tires Replace a tire if you can see fabric or cord Check for rocks or other objects embedded in the tire or tread Remove any objects 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 damag
149. our motorcycle on its side This can damage the motorcycle and leaking gasoline could be a hazard 138 Tips If you won t be riding for an extended period such as during the winter thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your motorcycle running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water wash it down with fresh water and wipe dry 2 Change the engine oil and filter page 44 Change the transmission oil page 47 4 Drain the fuel tank and carburetor into an approved gasoline container Turn the fuel valve OFF and remove the carburetor drain bolt Drain gasoline into an approved container Reinstall the drain bolt A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel W 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 bolts 1 at the water pump 2 to drain coolant After the coolant has been completely drained ensure that the drain bolt sealing washers are in good condition and reinstall the drain bolt and radiator cap 1 dra
150. our 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 For maximum braking close the throttle and firmly apply the brake lever and pedal controls Applying the brakes too hard may cause the wheels to lock and slide reducing control of your motorcycle If this happens release the brake controls steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your speed or complate 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 motorcycle 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 Ba
151. over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments If initial and middle travel aren t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If final travel is still stiff after the above adjustment or If initial and middle travel becomes stiff Install the optional stiff 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 Test softer compression damping adjustments in one click increments Reduce the rebound damping in one click increments Lower the oil capacity by 0 2 oz 5 cc Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard surfaced t
152. oves 0 04 in 1 mm E 1 F l i F l F 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 i Gears thickness indicator LA Me V VY k i 1 ye ly replace 4 brake pads 6 brake disc 5 rear brake caliper Ss wit T Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Brakes Servicing Your Honda 89 Wheels Refer to Safety Precautions on page 2 2 Tighten any loose spokes and rim locks 1 to the specified torque Maintenance of spoke tension and wheel trueness Spoke 2 7 lbf ft 3 68 N m 0 38 kgf m roundness is critical to safe motorcycle Rim Lock 9 4 lbf ft 13 N m 1 3 kgf m operation During the first 100 miles 150 km 3 Check wheel rim runout If runout is spokes will loosen more rapidly due to the initial noticeable see the Honda Service Manual for seating of the parts Excessively loose spokes inspection instructions 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 Axles
153. ponents is recommended 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 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 Technical Information 155 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by Volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume
154. r Competition Adjustments for Competition 103 Front Suspension Adjustments The front suspension can be adjusted for the rider s weight and riding conditions by using one or more of the following methods e Oil volume The effects of higher or lower fork oil level are only felt during the final 3 9 in 100 mm of fork travel e Compression damping Turning the compression damping screw adjusts how quickly the fork compresses e Rebound damping Turning the rebound damping screw adjusts how quickly the fork extends e Fork springs Optional springs are available in softer and stiffer types than the standard rate page 159 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 104 Adjustments for Competition Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked such as in a fork Air pressure acts as a progressive spring and affects the entire range of fork 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 f
155. r gasket 2 Do not let the dowel pins fall into the crankcase 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 Use new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out p e di MEE wr te de hi 5 a e y y b h adi d ng 1 dowel pins 2 cylinder gasket 4 Clean the any gasket material off the cylinder 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out 78 Servicing Your Honda N Apply clean engine oil to the cylinder wall piston outer surface and piston rings Route the cam chain 3 through the cylinder 4 Install the cylinder over the piston rings by hand while compressing the piston rings 5 Do not damage the piston rings and cylinder walls K Ca 3 cam chain 5 piston rings 4 cylinder Piston Piston Rings Piston Pin 6 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs Cylinder Head Installation 8 Push the guide until it bottoms in the 1 Install the dowel pins 1 and new cylinder cr
156. r 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 2 1 fuel fill cap 3 steering stem nut 2 breather tube l 2 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 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 A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately Fuel System Fuel Valve and Line aS fuel valve 3 fuel line fuel filter Check the fuel valve 1 and fuel filter 2 for contamination Check for leaks Check the fuel line 3 for cracks deterioration damage or leakage Replace the fuel lin
157. r 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 purchased from your Honda dealer e Clutch Center Holder 07724 0050001 or 07724 0050002 O7WMA KZ30100 070MG 0010100 O7JMA MR60100 e Lock Nut Wrench e Tensioner Stopper e Nipple Wrench Chemical Products Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke Oil Engine Oil Pro Honda HP Trans Oil or Pro Honda GN4 or HP4 without molybdenum additives only 4 stroke Oil Transmission Oil Honda thread Lock Pro Honda HP Fork Oil 5W Honda Brake Fluid Pro Honda Chain Lube Pro Honda Foam Filter Oil Honda brite cleaner Honda Contact Cleaner Honda Dielectric Compound Honda Hand Grip Cement Honda Hondalock Honda Moly 60 Paste U S A only or molybdenum disulfide paste containing more than 40 molybdenum disulfide additive White Lithium Grease Wheel Bearing Grease Silicone Sealer high t
158. rack Begin with the standard settings If the suspension is too stiff soft adjust according to the chart below Sand track Lower the rear end to improve front wheel stability by increasing Race Sag reduce spring preload Example Turn the compression damping adjuster and especially rebound damping adjuster to a stiffer setting Increase standard Race Sag 0 2 to 0 4 in 5 to 10 mm Mud track Adjust to a stiffer position because mud build up increases your CRF s weight Example Adjust the compression and rebound damping adjusters to stiffer settings Install the optional stiff spring Reduce standard Race Sag 0 2 to 0 4 in 5 to 10 mm Symptoms and Adjustment e Always begin with the standard settings e Turn the low speed compression and rebound adjusters in one click increments and the high speed compression adjuster in 1 6 turn increments at a time Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment 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 adjustments until the correct settings are obtained as described 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 Suspe
159. rators do but without the benefit of an electrical hourmeter All running time is broken down into hours and tenths of an hour each six minutes represents one tenth of an hour Competition Logbook Racing Records Information worth recording for this section of your logbook may include e Your placing in each moto and overall finishing position e Thoughts on what you could do to improve your performance next time e Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events e Any places on the course where you chose the wrong line and were passed too easily e Notes on strategy used by your competition or by riders in another event that are worth remembering Maintenance Records Regular maintenance items you ll want to record in your logbook should include e Dates and results of cylinder piston and ring examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance Engine transmission and suspension oil changes chain sprocket chain guide and slider replacements coolant changes and related component replacements Spark plug brake pad and control cable replacements In addition you should record any irregularities noted in component wear so you ll remember to keep a close eye on these areas in the future Con
160. rburetor adjust the throttle cable 1 free play and hot start cable 2 free play 26 e After installing the carburetor check the throttle sensor connector 3 for correct routing as necessary e After installing the carburetor check the air vent hoses 4 and overflow hose 5 for kinking or pinching and correct routing as a El necessary 26 float level 27 float level gauge 28 carburetor intake 10 Remove the leak jet 29 from the float bowl 18 Clean the leak jet 4 air vent hoses 5 overflow hose 1 throttle cables US 2 hot start cable 18 float bow AS CAR El 3 throttle sensor connector Adjustments for Competition 131 Carburetor Adjustments amp Tuning Tips Adjustment Procedure 1 Turn the pilot screw in until it is lightly seated and record the number of turns Turn the pilot screw 1 out the same number of turns 1 pilot screw N If the engine is cold start it and warm it up three minutes 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 2 Idle speed 1 700 100 rom NM B YW 2 throttle stop screw 132 Adjustments for Competition Pre Adjustment Checks Before adjusting carburetor settings check the following air cleaner e air leaks float level clogged carburetor jets spark plug fouli
161. recommended coolant through the filler opening up to filler neck Use a fresh recommended coolant mixture page 48 Capacity 1 19 US qt 1 132 3 Turn the quick fastener 2 counter clockwise 4 Remove the left side cover bolt 3 seat bolt 4 collars 5 and left side cover 6 5 Remove the radiator reserve tank cap 7 and fill the reserve tank to the UPPER level line 8 ie a 7 gt SAA SS Z i e ERTQIHIAS KEY 4 j ES fa ON rf j e VAL aN 6 S oe aN e 2 quick fastener 3 left side cover bolt 4 seat bolt 5 6 left side cover 7 radiator reserve tank cap 8 UPPER level line collars 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 3 4 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 1s low 7 Install the radiator reserve tank cap and left side cover Refer to Safety Precautions on page 2 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
162. rials Check the oil for any contamination 3 wear rings 4 Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times 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 Install the wear ring with its end gap facing rearward 82 Servicing Your Honda Suspension 1 Bounce the rear of the motorcycle up and down Rear Suspension Inspection and check for smooth suspension action 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 1s contained within a rubber 7 bladder i eth MA f The shock absorber s spring preload and damping adjustments compression and rebound should be adjusted for the rider s weight and track conditions page 122 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 2 Lift the subframe to the upright position page 39 3 Check for a broken or collapsed spring 4 Check the shock 1 for a bent shaft or oil e When your CRF is new break it in for leaks approximately one hour with the standard suspension settings before attempting to adjust the rear
163. rk compression damping adjuster 2 screw has 16 positions or more Turning the adjuster screw one full turn changes the adjuster four positions To adjust the adjuster to the standard position proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 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 Always start with full hard when adjusting damping Do not turn the adjuster screw more than the glven positions or the adjuster may be damaged Be sure that the rebound and compression adjusters are firmly located in a detent and not between positions 1 rebound damping adjuster screw 2 compression damping adjuster screw Fork Springs The fork springs in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of 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
164. ront tire off the ground when you release the pressure The standard air pressure is O psi 0 kPa 0 kgf cm You may relieve accumulated air pressure in the fork legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings Remove the pressure release screw 1 Check that the O ring 2 is in good condition Install the pressure release screw to the specified torque 0 9 lbf ft 1 2 N m 1 2 kgf m pa PUN 1 pressure release screws 2 O ring Front Suspension Damping Rebound Damping Adjustment The fork rebound damping adjuster 1 has 16 positions or more Turning the adjuster screw one full turn clockwise advances the adjuster four positions To adjust the rebound damping to the standard setting proceed as follows Turn the adjuster clockwise until 1t 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 10 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 fo
165. rvicing Your Honda Refer to Safety Precautions on page 2 Your motorcycle has a maintenance free type battery You do not have to check the battery electrolyte level or add distilled water as you would with a conventional type battery Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed Electrical accessories use current from the battery even when the engine 1s 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 Charge If you do not expect to ride your motorcycle 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 motorcycle see Battery Storage If your battery seems weak and or is leaking electrolyte cause slow starting or other electrical problems see your Honda dealer WARING Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling Battery Storage If you plan to store your motorcycle 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 storag
166. s O 24 64 lbf in 0 44 kgf mm 1 scribe mark and O 2 scribe marks aftermarket parts 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 159 Spare Parts amp Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding In addition to the usual nuts and bolts consider the following Spare Parts spark plugs air cleaner clean amp oiled sealed in a plastic bag 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 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 disc and plates engine amp transmission oil 160 Technical Information seat ignition components top end complete radiator hoses radiato
167. s ci0 ccacssostadseandencsessosteastanves 21 Basic Operating Instructions Basic Operating Instructions 13 Basic Operating Instructions Safe Riding Precautions Before riding your motorcycle for the first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your motorcycle s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 14 Basic Operating Instructions Side Stand Tripmeter The side stand 1 is used to support your The tripmeter 1 1s used to record the distance motorcycle while parked page 19 To operate traveled USA miles Canada kilometers per use your foot to lower the side stand until it is trip or section of route fully extended 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 0 then push the knob in ON 1 side stand 1 tripmeter 2 tripmeter reset knob Always follow the proper starting procedure described below Your motorcycle can be kickstarted wirh the transmission in gear by pulling in the clutch lever before operating the kickstarter Preparation Make sure that the transmission is in neutral Turn the fuel valve ON Fuel Valve ON OFF RES i E OFF ES
168. s not turn smoothly 8 clutch lifter 9 clutch lifter rod 10 clutch discs clutch plates judder spring and spring seat Servicing Your Honda 57 Clutch System Clutch Disc Inspection Replace the clutch discs 1 1f 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 Clutch Spring Inspection 1 clutch spring Measure the free length of each spring Service Limit 1 50 in 38 0 mm If one or more springs are beyond the service limit replace the springs as a set 58 Servicing Your Honda Clutch Disc Plate Installation 1 Install the spring seat 1 and judder spring 2 onto the clutch center as shown Coat the clutch discs 3 and plates 4 with clean transmission 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 Y ty Q S a A Sm do a ANA Oe WRE JIN Gp QX Na NS AN MO N E NE G RRN ENa E AAMT N ARIAS EN NJ NS S Els JS RY o S Q o S 2a RN N eN Ris 1 spring seat 2 judder spring 3 clutch discs 4 clutch plates 5 clutch disc A 3 Apply grease to the clutch lifter rod 6 4 Insert the clutch lifter rod into the mainshaft 5 Install the clutch lifter 7 onto the rod 5 7 clutch lifter 6 clut
169. sic Operating Instructions Parking Lower the side stand to support your motorcycle If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park Basic Operating Instructions 19 Post ride Inspection When you return home after riding thoroughly clean your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to lubricate the drive chain page 96 to prevent rusting 20 Basic Operating Instructions Break in Guidelines Help assure your CRF s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when e piston is replaced e piston rings are replaced e cylinder is replaced crankshaft or crank bearings are replaced Basic Operating Instructions 21 22 Basic Operating Instructions Keeping your motorcycle 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 motorcycle in good shape this section includes a Maintenance Schedule for required servicing and step by step instructions for specific maintenance tasks You
170. side cover 2 Turn the quick fastener 5 counterclockwise and remove the left side cover bolt 6 seat bolt 7 collars 8 and left side cover 9 3 Remove the seat 10 page 36 wey IO O BV 4 S 6 e 5 quick fastener 8 collars 6 left side cover bolt 9 left side cover 7 seat bolt 10 seat Subframe Upright Position 4 Remove the muffler page 62 7 Loosen the subframe mounting A bolt 16 5 Remove the band 11 rear suspension upper and remove the subframe mounting B bolts mounting nut 12 and bolt 13 17 AE NON 11 lt gt 3 Y S TOA X ata Ss Pe 1 11 band 12 rear suspension upper mounting nut 16 13 bolt 17 subframe mounting B bolts 6 Loosen the screw 14 on the air cleaner 8 Lift the subframe 18 as shown connecting tube clamp 15 14 screw 18 subframe 15 air cleaner connecting tube clamp Servicing Your Honda 39 Subframe Upright Position Installation 1 Loosely attach the lower ends of the subframe 1 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 B bolts 2 and subframe mounting A bolt 3 to the specified torque B bolts 22 lbf ft 30 N m 3 1 kgf m A bolt 36 Ibf ft 49 N m 5 0 kgf m tS a LESS ew i 1 subframe 2 subframe mounting B bolts 3 subframe mounting A bolt 40 Servic
171. sumer Information 157 Competition Logbook Date Running Location E vent Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use 58 Consumer Information These parts and tools may be ordered from your authorized Honda dealer 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 Driven sprocket lt gt Drive chain links Standard 53 Teeth Aluminum lt 114 gt 50 Teeth Aluminum lt 114 gt 52 Teeth Aluminum lt 114 gt 3 mm offset Pin spanner A To adjust spring preload N two spanners required For checking tire air pressure Optional Handlebar lower holder Standard Optional Shock spring Standard Optional Softer Stiffer Fork spring Standard Optional Softer Stiffer Optional Parts List 268 8 lbf in 4 80 kgf mm No mark og factory products Orange paint E aftermarket parts 254 8 Ibf in 4 55 kgf mm Red and Black paint 280 Ibf in 5 00 kgf mm Wite paint 291 2 Ibf in 5 20 kgf mm Blue 23 52 lbf in 0 42 kgf mm No mark O factory products or Q 22 4 lbf in 0 40 kgf mm _ 3 scribe mark
172. ter cable clamp bolt 1 1 1 1 116 Adjustments for Competition 21 Align the brake caliper 20 and hose with the left fork leg making sure that the brake hose is not twisted 22 Clean the threads of the caliper mounting bolts 21 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slider and tighten the caliper mounting bolts to the specified torque 22 bf ft 80 N m 3 1 kgf m An improperly routed brake hose may rupture and cause a loss of braking efficiency Route the hose carefully Fit the brake caliper over the disc taking care not to damage the brake pads 20 caliper 21 caliper mounting bolts 23 Install the handlebar 22 mounting rubbers 23 washers and handlebar holder nuts 24 and tighten the handlebar holder nuts to the specified torque 33 Ibf ft 44 N m 4 5 kgf m 25 Install and tighten the front visor bolts 27 Install the handlebar pad 28 27 front visor bolts 28 handle bar pad 26 With the front brake applied pump the fork up and down several times to seat the axle and check front brake operation 22 handlebar 23 mounting rubbers 24 washers handlebar holder nuts 24 Install the front visor by aligning its grommets 25 with the tabs 26 on the steering stem INR O i j Ge a y VEO YY 25 front visor grommets 27 Tighten the left axle pinch bolts 29 alternately first While keeping t
173. tes 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 premix oil insufficient quantity improper oil e Air cleaner dirty leaking because of improper installation poor seal 174 Quick Reference Record important information here Service Mar Maintenance Pre ride Inspection Fuel Capacity Engine oil Transmission oil Tire Pressure cold Spark Plug Owner s The maintenance schedule pages 27 28 lists service frequencies for about every 2 5 hours about every 7 5 hours about every 22 5 hours and about every 30 0 hours Check the items listed on the Pre Ride inspection checklist each time before you ride page 11 unleaded gasoline pump octane number of 91 or higher tank 2 19 US gal 8 3 seufence is same as transmission oil Pro Honda GN4 or HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent Pro Honda HP Trans oil Pro Honda GN4 or HP4 without molybdem additives 4 stroke oil or an equivalent Front 80 100 21 51M Rear 100 100 18 59M Type bias ply tube type Front 15 psi 100 kPa 1 0kgf cm Rear 15 psi 100 kPa 1 0kgf cm standard IMR8C 9H NGK or VUH24D DENSO optional IMR
174. tiffer as capacity 399 cm3 it nears full compression Standard oil 11 8 US oz capacity 348 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 Minimum oil 10 2 US oz Slightly softer as capacity 303 cm3 it nears full compression Optional Softer 0 40 kgf mm Fork Spring 1 outer tube 11 fork oil 14 Install the fork damper as described in Fork 3 scribe mark oil change page 84 85 Standard oil 11 8 US oz capacity 350 cm3 Maximum oil 13 6 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 114 Adjustments for Competition 15 Check that the O ring 12 on the fork damper assembly 4 is in good condition Apply the recommended fork oil to the O ring 1 outer tube slider 4 fork damper assembly 12 O ring 16 Temporarily thread the fork damper 4 into the outer tube Insert both fork legs into the fork clamps Align the groove in the outer tube with the top surface of the upper fork clamp Temporarily tighten the fork lower pinch bolts 13 and then tighten the fork damper 4 to the specified torque using a special tool 25 lbf ft 84 N m 3 5 kgf m For ease of releasing air pressure
175. tification Serial Numbers The VIN frame and engine serial numbers are required when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of the manual The Vin vehicle identification number 1 appears on the Safety Certification Label attached to the left side of the frame LEFT SIDE 1 vin 148 Technical Information The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number Specifications For USA except California amp CANADA 2 174 mm Liquid cooled 4 stroke Clutch type Wet multi plate type 827 mm Single 10 inclined from Transmission 5 speed constant mesh 1 261 mm vertical Primary reduction 3 611 1 483 mm Bore and stroke 8 07x206in 78 0x 52 2 Gear ratio 2 384 107 kg After draining 0 70USqt 660 cm Frame After draining and Gear shift pattern Left foot operated return Telescopic fork After disassembly 0 90 US at system 1 N 2 3 4 5 F suspension travel 11 0 in 280 mm Transmission oil stroke 12 4 af 315 mm capacity Battery 12V 4 Ah R suspension Pro link After draining 0 71 US at 670 cm Ignition Se After disassemb 0 79 US qt F tire size pressure 80 100 21 51M o y q Starting system Startermotor Kickstarter psi kPa kgf cm
176. tly during freezing weather Checking amp Adding Coolant Refer to Safety Precautions on page 2 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 1 UPPER level mark 3 reserve tank 2 LOWER level mark 4 left side cover 5 quick fastener To remove the left side cover 4 turn the quick fastener 5 counterclockwise and remove the left side cover bolt 6 seat bolt 7 and collars 8 7 seat bolt 8 collars 6 left side cover bolt 3 9 Remove the reserve tank cap 9 Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap reserve tank cap Coolant Add coolant to the reserve tank as require to bring the coolant level to the UPPER level Cooling System Inspection mark Install the reserve tank cap 9 1 Check the cooling system for leaks see the Install the left side cover 4 collars 8 seat Honda Service Manual for troubleshooting of bolt 7 and left side cover bolt 6 Close the leaks air cleaner box cover 10 and turn the quick 2 Check water hoses 1 for cracks fastener 5 clockwise deterioration and clamp bands for looseness 3 Check the radiator mount for looseness 4 Make sure
177. u plan to do any service on your motorcycle beyond the standard maintenance procedures in this manual you will find the Service Manual a valuable reference Your new Honda is covered by Noise Control Warranty USA only There are responsibilities restrictions and exclusions which apply to this warranty Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the line 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 proper tools and service information and be mechanically qualified Failures that occur due directly to improper maintenance or lack of maintenance are not covered 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 da
178. uipment and the Honda Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and remove the rear subframe s three mounting bolts then lift the subframe See page 39 118 Adjustments for Competition 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjuster nut changes the spring length by 1 16 in 1 5 mm _ 2 Sn FS F R EN INEA 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 4 in 265 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 lbs 7 2 kg
179. vasses 159 Spare Parts amp EquipMent ooooooccncncncncnnnonnno 160 Wiring Did OAM oscars calco sorarni crias 161 CONSUMER INFORMATION o ooccccccccoconns 163 Authorized Manuals sc scceccscessaspouasasictscrssayeenaecs 164 Contacting Honda salsas 165 Your Honda Dealer scusiaisoicconsrecindcsiiscio cani 166 The Honda Rider s Club USA only 167 Table of Contents Table of Contents 169 Index AEE E EE E E 4 adjustments altitude and temperature ooccccccnccnononononnns 154 CD O An aa E E 132 E E PR O 133 control free play oocooommmmm o 54 56 60 86 for competition AAA 103 PP E E 134 high altitude carburetor ccccccccccncccnnnnn 154 personal Tiesiai erain 136 suspension OM aureus 104 SUSPENSION TE dl icsceazasnetasccnatceoeastecteuntenouaes 118 suspension track CconditiONS oooocccncnncos 135 O SOLO CHO sisse ii inei 91 after competition Maintenance cccccceeeeeees 33 PM CNC INCU CA Po oe Jl air pressure front SUsSpension ssesssssessssssseeeeseetteereeesee 104 o EE e 91 American Honda contacting ooooccccccccnnnnnnns 165 apparel PLOLSCUVE interina ica 2 COO op aa a E Sa 48 appearance Car certain coladas 101 authorized manuals s2cc cssssessa2ecsccascovemaraawencatonss 164 Dasic OCT A OM 0 COPOOOPAE OA A 13 AAA a A dandansees 9 between motos amp practice maintenance 33 brakes aA 8 Ne ATE 87 lever front adjustment occcc
180. ven if you are able to make some repairs Remember proper maintenance is your responsibility Be sure to inspect your motorcycle before each ride and follow the Maintenance Schedule in this section 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 24 Servicing Your Honda Maintenance Safety This section includes instructions on how to e Read the instructions before you begin and perform some important maintenance tasks make sure you have the tools and skills Some of the most important safety precautions required follow However we cannot warn you of every conceivable hazard that can arise in performing To help prevent the motorcycle from falling maintenance Only you can decide whether or over park it on a firm level surface using the not you should perform a given task side stand or a maintenance stand to provide support A WARNING To reduce the possibility of a fire or Failure to properly follow maintenance explosion be careful when working around instructions and precautions can cause gasoline Use only a non flammable high you to be seriously hurt or killed flash point solvent such as kerosene not gasoline to clean parts Keep cigarettes Always follow the procedures and sparks and
181. ver in Pull the clutch lever all the way in Depress the shift lever from neutral down to first gear 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 motorcycle may lurch forward 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 To continue shifting up to each higher gear repeat step 5 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 completely before shifting Improper shifting may damage the engine transmission and drive train Learning when to shift gears comes with experience Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Downshift to a lower gear before you feel the engine laboring lugging at low rpm Shifting Gears Basic Operating Instructions 17 Braking To slow or stop apply the front brake and rear brake smoothly while down shifting to match your speed Gradually increase braking as you feel the brakes slowing y
182. wingarm 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 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 when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Replace the hydraulic fluid in the brake system every two years Replace the fluid more frequently if you subject your brakes to severe use Heavy braking heats the brake fluid and it may deteriorate sooner than expected Any type of riding that requires frequent use of the brakes such as in tight woods can shorten the service life of brake fluid a 4 EN y 4 lame le US l SA LAW Water Pump Inspection Hole After every race check the inspection hole located just
183. 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 motorcycle Leave the blown fuse in that circuit and have your motorcycle 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 automobile battery when the car engine 1s running can damage your motorcycle 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 145 146 Taking Care of Unexpected This section contains dimensions capacities and other technical data Vehicle Identification endoscopia norton 148 SPEC IICALIONS speriene rapaces 149 Torque Specifications vecescincocaniaiddasianencaceniacaccad 151 High Altitude Carburetor Adjustment 154 Emission Control Systems cccccccccnnnncnnnnnnnnnnos 155 Oxy genated PUCIS 2 2 ssssasransactestaeetiacasessotoopuaseast 156 Competition Logbook ccccccccccccnnnnnnnnnnnnnnno 157 Optional Parts List occcccccccncncnnnnnnnnononmo 159 Spare Parts amp EquipMent oooooonnccnnnncnnnnonnnocos 160 AD AA 161 Technical Information Technical Information 147 Vehicle Iden
184. y 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 1s 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 your motorcycle 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 motorcycle before every ride and perform all recommended maintenance Your Honda was designed as a rider only motorcycle It was not designed to carry a passenger or cargo passenger or cargo could interfere with your ability to move around to maintain your balance and control of the motorcycle In addition exceeding the weight limits or carrying an unbalanced load can seriously affect your motorcycle
185. ycle s suspension is bottoming Some riders may think the damping or perhaps the leverage ratio is too harsh In reality the problem is most likely insufficient spring pre load or a spring that is too soft Either situation prevents utilizing the full travel Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth A spring that is too firm for your weight will not allow the rear tire to hook up under acceleration and will pass more bumps on to you Rear Suspension Adjustments Adjustments for Competition 121 Suspension Adjustments for Track Conditions Soft Surface On soft ground sand and especially mud consider increasing compression damping front and rear Sand often requires a bit more rebound damping to minimize rear end kick Although sand bumps are usually larger there s more distance between them giving the shock more time to recover You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight line stability In a muddy event stiffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your motorcycle may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much

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