Honda crf250r 2012, Owner'S Manual

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Page 2: ...2012 Honda CRF250R OWNER S MANUAL COMPETITION HANDBOOK ...

Page 3: ...rmation is intended to help you avoid damage to your CRF other property or the environment Unless you are mechanically qualified and have the proper tools you should see your dealer for the service and adjustment procedures discussed in this manual An official Honda Service Manual for your CRF is available page 160 It is the same manual your dealer uses If you plan to do any service on your CRF be...

Page 4: ...fety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Of course it is not practical or possible to warn you about all hazards associat...

Page 5: ...21 Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 30 Service Preparations Maintenance Component Locations 32 Seat 33 Fuel Tank 34 Subframe 36 Service Procedures Fl...

Page 6: ...ight Angle 136 Wheelbase 136 Gearing 137 Tire Selection for Track Conditions 138 Personal Fit Adjustments 139 Control Positioning 139 Handlebar Position Width Shape 139 TIPS 141 Transporting Your Motorcycle 142 Storing Your Honda 143 Preparation for Storage 143 Removal from Storage 143 You the Environment 144 Troubleshooting 145 TECHNICAL INFORMATION 147 Vehicle Identification 148 Serial Numbers 1...

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Page 8: ...tion and recommendations to help you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Safety Precautions 2 Accessories Modifications 3 Safety Labels 4 ...

Page 9: ...oper protective gear Take Time to Get to Know Your CRF Because every motorcycle is unique take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine and yourself in competition Learn and Respect Your Limits Never ride beyond your personal abilites or faster than conditions warrant Remember that alcohol drugs illness and fatigue can ...

Page 10: ...your CRF in any way that would change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding modifications and accessories ...

Page 11: ...4 Motorcycle Safety Safety Labels Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your dealer for replacement For Canada ...

Page 12: ...s Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 Indicator 7 MIL Blink Pattern 7 Current DTC Freeze DTC 7 Circuit Inspection 8 DTC Index 9 ...

Page 13: ...6 Instruments Controls Operation Component Locations clutch lever MIL front brake lever engine stop button throttle grip fast idle knob engine idle speed shift lever kickstarter rear brake pedal ...

Page 14: ... engine speed is over 5 500 rpm The MIL has two types of blinks a long blink and short blink The long blinking lasts for 1 2 seconds the short blinking lasts for 0 4 seconds One long blink is the equivalent of ten short blinks For example when one long blink is followed by two short blinks the MIL is 12 one long blink 10 blinks plus two short blinks When the ECM stores more than one DTC the MIL wi...

Page 15: ...tem is often related to poorly connected or corroded connections Check the following connections 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 No 1 No 2 CKP sensor connector 7 ECM connector Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system 1 2 5 7 6 3 4 ...

Page 16: ... operates normally Engine does not start Injector fuel pump and ignition shut down Engine does not start Injector fuel pump and ignition shut down Engine does not start Injector fuel pump and ignition shut down Function Failure Symptom Fail safe Function Should be serviced by your dealer unless the owner has proper tools and is technically qualified The series of 12 19 and 69 MIL blinks cannot be ...

Page 17: ...10 Instruments Controls ...

Page 18: ...p get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension steering damper and other adjustments see page 109 Before Riding Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Pre ride Inspection 13 ...

Page 19: ...nd other adjustments see page 109 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not weari...

Page 20: ...105 Steering damper operation 103 Throttle operation 59 Tires for damage or improper inflation pressure 95 Spokes for looseness 94 Rim locks for looseness 94 Front and rear suspension for proper operation 85 86 Front and rear brakes check operation 90 Drive chain for correct slack and adequate lubrication 97 98 Drive chain sliders and drive chain rollers for damage or wear 97 98 Exhaust pipe Muffl...

Page 21: ...14 Before Riding ...

Page 22: ...ll as break in guidelines Safe Riding Precautions 16 Starting Stopping the Engine 17 Fast Idle Knob 17 Preparation 17 Starting Procedure 17 How to Stop the Engine 18 Break in Guidelines 19 Basic Operating Instructions 15 Basic Operating Instructions 15 Basic Operating Instructions ...

Page 23: ...e first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death ...

Page 24: ...e pages 50 53 54 Cold Engine Starting 1 Shift the transmission into neutral 2 If the temperature is 95 F 35 C or below pull the fast idle knob 1 fully out 1 fast idle knob 3 With the throttle closed operate the kickstarter starting from the top of the kickstarter stroke and kick through to the bottom with a rapid continuous motion 4 About a minute after the engine starts push the fast idle knob ba...

Page 25: ... throttle 2 engine stop button Normal Engine Stop 1 Shift the transmission into neutral 2 Lightly open the throttle 1 two or three times and then close it 3 Push and hold the engine stop button 2 until the engine stops completely Emergency Engine Stop To stop the engine in an emergency push and hold the engine stop button ...

Page 26: ...ying extra attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced ...

Page 27: ...20 Basic Operating Instructions ...

Page 28: ...our dealer s parts department Before You Service Your Honda The Importance of Maintenance 22 Maintenance Safety 23 Important Safety Precautions 23 Maintenance Schedule 24 General Competition Maintenance 26 Before After Competition Maintenance 30 Between Motos Practice Maintenance 30 After Competition Maintenance 30 Service Preparations Maintenance Component Locations 32 Seat 33 Fuel Tank 34 Subfra...

Page 29: ...ecause your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section 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 ...

Page 30: ... motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using an optional workstand or a maintenance stand to provide support To reduce ...

Page 31: ...es and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda Genuine Parts or thei...

Page 32: ...7 98 99 99 91 93 90 62 105 100 85 86 86 87 115 106 150 152 94 96 105 R L R I R R R R R R R R I FREQUENCY NOTE Ref Page Each race or about 2 5 hours Every 3 races or about 7 5 hours Every 6 races or about 15 0 hours Every 9 races or about 22 5 hours Every 12 races or about 30 0 hours WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL This maintenance schedule is...

Page 33: ...s or their equivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reas...

Page 34: ... thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda White Lithium Grease or an equivalent is handy for this because any d...

Page 35: ...ance Disassemble clean and inspect the front fork and replace oil regularly Contamination due to the tiny metal particles produced from the normal action of the fork as well as normal oil breakdown will deteriorate the performance of the suspension Refer to the Honda Service Manual Use only HP Fork Oil SS 19 or equivalent which contains special additives to assure maximum performance of your CRF s...

Page 36: ...ove freely on the caliper bracket pins Check pad thickness periodically and replace the pads when minimum thickness is reached If the brakes fade when they are hot inspect the pads for glazing or damage and replace if necessary Brake Fluid Replacement Refer to the Honda Service Manual page 160 for brake fluid replacement instructions Replace the hydraulic fluid in the brake system every 2 years Re...

Page 37: ... wear 1 2 After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program Right after the event is a good time to begin your next maintenance cycle After Race Lubrication Apply a light coating of rust inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away This will preven...

Page 38: ...bly priced cleaning brushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it off as soon as possible after the event dry it and apply a spray lubri...

Page 39: ...und damping adjuster transmission oil fill cap transmission oil check bolt rear brake pedal front suspension rebound damping adjuster rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster front suspension compression damping adjuster spark plug steering damper adjuster rear suspension spring pre load adjuster rear brake fluid reservoir clutc...

Page 40: ...ckward 1 seat mounting bolts 2 seat Installation 1 Install the seat while aligning the seat front prong 1 with the seat bracket 2 and seat rear prong 3 with the ECM bracket 4 2 Install and tighten the seat mounting bolts to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat front prong 2 seat bracket 3 seat rear prong 4 ECM bracket 2 1 2 1 3 4 ...

Page 41: ...nce between the frame and tank and adjust the cushion rubbers 12 if necessary 1 shroud A bolts and collars 3 shrouds 2 shroud B bolts 4 Install a hose clamp 4 to the breather tube 5 and shut the hose clamp securely 4 hose clamp 5 breather tube 5 Pull the breather tube 5 out of steering stem nut 6 Unhook the fuel tank band 6 5 breather tube 6 fuel tank band 7 fuel tank bolt and collar 8 Unhook the ...

Page 42: ...e hose clamp 8 from the breather tube 6 breather tube 8 hose clamp 7 steering stem nut 7 Install the shrouds 9 by aligning shroud tabs 10 with the air cleaner housing cover tabs 11 3 fuel tank 5 fuel tank band 4 collar and fuel tank bolt 9 12 13 10 11 9 shrouds 10 shroud tabs 11 air cleaner housing cover tabs 12 shroud B bolts 13 collars and shroud A bolts 8 Install the shroud B bolts 12 collars a...

Page 43: ...ffler mounting A bolt 6 muffler mounting B bolt 7 washer A 8 washer B 9 and muffler 10 6 muffler mounting A bolt 9 washer B 7 muffler mounting B bolt 10 muffler 8 washer A 5 Disconnect the IAT sensor connector 11 6 Remove the ECM mounting rubber 12 from the ECM bracket 13 Unhook the fuel tank band 14 12 ECM mounting rubber 13 ECM bracket 14 fuel tank band 7 Loosen the screw 15 on the air cleaner c...

Page 44: ...ng cover tabs 5 4 Loosely attach the upper and lower end of the subframe to the main frame while connecting the air cleaner connecting tube 6 to the throttle body 7 5 Loosely install all subframe bolts Installation 1 Connect the crankcase breather tube 1 2 ECM 5 air cleaner housing cover tabs 3 bracket 6 air cleaner connecting tube 4 shroud tabs 7 throttle body 2 3 7 6 5 4 6 Align the subframe wit...

Page 45: ...ok the fuel tank band 14 Install the ECM mounting rubber 15 to the ECM bracket 16 14 fuel tank band 15 ECM mounting rubber 16 ECM bracket 15 14 16 18 muffler clamp 20 exhaust pipe 19 gasket new 13 Install the muffler 21 14 Install the muffler clamp 18 by aligning the tab 22 of the muffler clamp with the cutout 23 of the muffler 18 19 20 13 screw 13 0 18 0 06 in 4 5 1 5 mm 17 IAT sensor connector 1...

Page 46: ...e muffler mounting B bolt 26 and muffler mounting A bolt 27 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 18 Install the seat 29 19 Install the side covers 30 seat mounting bolts 31 and bolts 32 Then tighten the seat mounting bolts and side cover bolts to the specified torque seat mounting bolts 19 lbf ft 26 N m 2 7 kgf m side cover bolts 7 lbf ft 10 N m 1 0 kgf m 26 muffler mounting B bolt 2...

Page 47: ...ting cover 1 3 Check the fuel line 2 for cracks deterioration damage or leakage Replace the fuel line if necessary 4 Install the fuel quick connect fitting cover 5 Install the fuel tank page 35 Use only unleaded fuel in your Honda If you ride your Honda in a country where leaded fuel might be available take precautions to use only unleaded fuel Your engine is designed to use any unleaded gasoline ...

Page 48: ...fuel tank to the left side of the frame page 34 3 Remove the fuel quick connect fitting cover 1 from the fuel pump 2 4 Check the fuel quick connect fitting 3 for dirt and clean if necessary 1 fuel pump sub harness connector 2 Start the engine and let it idle until the engine stalls 5 4 6 Pull and release the joint rubber 6 of the injector side from the retainer 7 6 joint rubber injector side only ...

Page 49: ...arks and flame away Handle fuel only outdoors Wipe up spills immediately Injector side Fuel Pump side 9 9 10 10 9 To prevent damage and keep foreign matter out cover the disconnected connectors 11 and fuel joints 12 with plastic bags 13 11 disconnected connector 12 fuel joint 13 plastic bags 13 12 11 Connection 1 Insert a new retainer 1 into the connector 2 by aligning its locking pawls 3 with the...

Page 50: ... rubber 5 is in place between the flange 6 and retainer tab 7 5 joint rubber injector side only 6 flange 7 retainer tab 5 Install the rubber 8 clamp 9 and bolt 10 by aligning the clamp tab 11 with the groove 12 of the stay 5 7 6 6 Install the fuel quick connect fitting cover 13 and set the rubber cover tab 14 to the hole 15 of the fuel quick connect fitting cover Be sure the rubber cover 16 is pro...

Page 51: ...l line page 41 3 Remove the fuel pump mounting bolts 1 stopper cable guide 2 stopper cable 3 washers 4 collars 5 conical spring washers 6 and fuel pump plate 7 while holding the fuel tank 4 Remove the fuel tank Be careful not to drop the fuel tank when removing the stopper cable 1 fuel pump mounting bolts 2 stopper cable guide 3 stopper cable 4 washers 5 collars 6 conical spring washers 7 fuel pum...

Page 52: ...5 from the fuel pump base 11 and remove the O ring 16 Wipe the spilled out fuel immediately 11 fuel pump base 15 fuel pump unit holder assembly 16 O ring 10 Remove the fuel pump stopper 17 and damper rubber 18 12 hooks 14 grooves 13 tabs 17 fuel pump stopper 18 damper rubber 11 Remove the fuel pump assembly 19 with fuel pump filter 20 O ring 21 from the fuel pump unit holder 22 19 fuel pump assemb...

Page 53: ... assembly 7 red wire 5 O ring new 8 black wire 6 fuel pump unit holder 9 grooves 4 Install a new damper rubber 10 to the fuel pump filter as shown Install the fuel pump stopper 11 10 new damper rubber 11 fuel pump stopper 5 Apply a small amount of silicone grease to a new O ring 12 Install a new O ring to the fuel pump base 13 6 Install the fuel pump unit holder assembly 14 into the fuel pump base...

Page 54: ...el pump unit 11 Install the fuel pump plate 26 with its identification mark 27 facing toward the front side and facing up 26 fuel pump plate 27 identification mark 12 Install the conical spring washers 28 collars 29 washers 30 stopper cable 31 stopper cable guide 32 and fuel pump mounting bolts 33 13 Install the fuel tank Make sure that the convex surface of the conical spring washers are upside 2...

Page 55: ...ry harness positive cable first then connect the battery harness negative cable to a 12V battery terminals Battery harness 070MZ MEN0100 Battery harness adapter 070MZ KRN0100 1 2 battery harness 3 battery harness adapter 4 Position the fuel tank on the main frame 5 Turn the PUMP selector switch 4 ON The selector switches can be used to change power delivery as follows ECM selector switch ON Power ...

Page 56: ...lar API service label suggested oil Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil viscosity weight SAE 10W 30 JASO T 903 standard MA Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displaying a circular API energy conserving service label on the container They may affect lubricat...

Page 57: ...our the drained oil into a suitable container and dispose of it in an approved manner page 144 Improper disposal of drained fluids is harmful to the environment NOTICE Checking Adding Oil 1 Run the engine at idle for 3 minutes then shut it off 2 Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine 3 Support the CRF in an upright position on a le...

Page 58: ...nment NOTICE NOTICE 6 7 5 4 10 9 8 8 Remove the oil filter cover bolts 4 and oil filter cover 5 9 Remove the oil filter 6 from the oil filter cover 10 Check that the oil filter cover O ring 7 is in good condition 4 oil filter cover bolts 5 oil filter cover 6 oil filter 7 oil filter cover O ring 8 spring 9 rubber seal 10 OUT SIDE mark Using the wrong oil filter may result in leaks or engine damage ...

Page 59: ... higher except oils labeled as energy conserving on the circular API service label SAE 10W 30 MA without friction modifiers as molybdenum additives Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil Canada only or an equivalent motorcycle oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conformi...

Page 60: ...le Allow any excess oil to flow out of the oil check bolt hole If no oil flows out of the oil check bolt hole add oil slowly through the transmission oil filler hole until oil starts to flow out of the oil check bolt hole Install the oil check bolt with a new sealing washer and transmission oil fill cap Repeat step 1 4 5 After inspecting the oil level or adding oil tighten the oil check bolt to th...

Page 61: ...r in this motorcycle This coolant solution is recommended for most operating temperatures and provides good corrosion protection Decreasing the concentration of antifreeze to less than 40 will not provide proper corrosion protection NOTICE Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 shoul...

Page 62: ...p cover 4 for leakage Clean away any clogged dirt or sand if necessary Check for signs of seal leakage A small amount of coolant weeping from the bleed hole is normal If water leaks through the bleed hole the mechanical seal is damaged If oil leaks through the bleed hole the oil seal is damaged See an official Honda Service Manual or consult your dealer for replacing the mechanical seal or oil sea...

Page 63: ...mine the correct service interval for your riding conditions Your CRF s air cleaner has very specific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality Using the wrong air cleaner may result in premature engine wear NOTICE Cleaning 1 Remove the seat page 33 2 Remove the air cleaner retaining bolt 1 and air cleaner assembly 2 Pr...

Page 64: ... water rinse well and allow to dry thoroughly The air cleaner element is made in two pieces inner and outer which cannot be separated 5 Clean the inside of the air cleaner housing 6 Allow the air cleaner to dry thoroughly After drying apply 1 7 oz 50 cm3 of clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil from the inside of the element Place the element into a plastic bag 7 and spr...

Page 65: ...in or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube Draining 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 crankcase breather tube 1 2 ...

Page 66: ...rque 3 0 lbf ft 4 N m 0 4 kgf m 4 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 dealer 5 6 1 Pull the dust cover 2 back 2 Loosen the lock nut 3 3 Turn the upper adjuster 4 Turning the adjuster in direction will decrease freeplay and turning it in direction will increase freeplay 4 Tighten ...

Page 67: ...ables from the throttle grip down to the throttle body 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 3 1 throttle housing 2 paint mark 2 Check for smooth rotation of the throttle 3 from fully open to fully closed in all ...

Page 68: ...When pushed in the fast idle knob acts as the idle adjust screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed Idle Speed Adjustment 1 If the engine is cold start it and warm it up 3 minutes Then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral Start the engine 4 Keep the motorcycle i...

Page 69: ...ut 3 cable end adjuster increase freeplay decrease freeplay 5 Loosen the lock nut 4 and turn the integral cable adjuster 5 to adjust the clutch lever freeplay 3 8 13 16 in 10 20 mm at the tip of lever Tighten the lock nut 1 2 3 4 Turn the cable end adjuster 3 in direction until it seats lightly and then turn it out 5 turns 4 5 4 lock nut 5 integral cable adjuster increase freeplay decrease freepla...

Page 70: ... and accelerate gradually If you can t get proper adjustment or the clutch does not work properly the cable may be kinked or worn or the clutch discs may be worn Inspect the clutch discs and plates page 65 3 4 Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster 2 2 cable end adjuster increase freeplay decrease freeplay Turning the cable end adjuster 2 in di...

Page 71: ...progressive steps 4 Remove the clutch pressure plate 5 4 clutch spring bolts clutch springs 5 clutch pressure plate 5 Remove the clutch lifter 6 and clutch lifter rod 7 6 Turn the lifter bearing plate of the clutch lifter bearing with your finger The bearing plate should turn smoothly and quietly Discard the clutch lifter if the bearing plate does not turn smoothly 3 1 2 5 4 7 6 6 clutch lifter 7 ...

Page 72: ...nd clutch plates as an assembly 1 1 clutch disc 2 2 clutch plate If you feel the clutch slippage when replacing the clutch discs and plates replace the clutch springs Clutch System Check the clutch plate 2 for excessive warpage or discoloration Check the plate warpage on a surface plate using a feeler gauge Measure the thickness of the clutch plates Service Limit 0 004 in 0 10 mm Replace the clutc...

Page 73: ...h lifter 7 onto the clutch lifter rod 6 clutch lifter rod 7 clutch lifter 8 Install the clutch pressure plate 8 9 Install the five clutch springs and clutch spring bolts 9 8 clutch pressure plate 9 clutch spring bolts clutch springs 10 O ring new 11 clutch cover 4 1 2 5 3 6 7 8 9 10 11 11 Apply oil to a new O ring 10 and install in the groove of the clutch cover 11 12 Install the cover by tighteni...

Page 74: ... clutch by pulling the lever in Coast to a stop then remove and inspect the spark plug The porcelain insulator around the center electrode should appear tan or medium gray If you re using a new plug ride for at least 10 minutes before taking a plug reading a brand new plug will not show color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes an...

Page 75: ...e rises Valve Clearance 68 Servicing Your Honda Cylinder Head Cover Removal Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and hang the fuel tank to the left of the frame pages 33 34 2 Disconnect the breather tube 1 and spark plug cap 2 Positioning At Top Dead Center On The Compression Stroke 1 Remove the crankshaft hole cap 1 1 breather tube ...

Page 76: ...turning the primary drive gear bolt 2 crankshaft clockwise until aligning the punch mark 3 on the primary drive gear with the mark 4 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear bolt clockwise again and align the punch mark with the mark The inspection must be made w...

Page 77: ...se the tensioner stopper tool Tensioner stopper 070MG 0010100 07AMG 001A100 3 Turn the tensioner shaft clockwise with the tensioner stopper 3 until it stops in order to retract the tensioner fully Then insert the tensioner stopper fully to hold the stopper in the fully retracted position 3 tensioner stopper 2 1 3 2 Remove the cam chain tensioner lifter cover bolt 1 and sealing washer 2 ...

Page 78: ...lifters 10 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left Do not let the valve lifters or shims fall into the crankcase NOTICE 9 8 7 5 Slide the left camshaft bearing 7 and remove the camshaft 8 and cam chain 9 then attach a piece of wire to the cam chain to prevent it from falling into the crankcase 4 Make sure the piston is ...

Page 79: ...the thickest 2 900 mm thickness in intervals of 0 025 mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with a micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm ...

Page 80: ... on the valve retainers 2 Do not let the shims fall into the crankcase NOTICE 1 shims 2 valve retainers 2 Apply molybdenum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive to the outer surface of the each the valve lifters 3 Install the valve lifters to the proper position 3 Rotate the primary drive gear bolt 4 crank...

Page 81: ... crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 14 14 18 17 22 8 Remove the tensioner stopper 19 from the cam chain tensioner lifter 19 19 tensioner stopper 9 Install a new sealing washer 20 and tighten the cam chain tensioner lifter cover bolt 21 20 sealing washer 21 cam chain tensioner lifter cover bolt 20 21 16 identifi...

Page 82: ...eplace them if necessary Install the rubber seals onto the cylinder head cover with the UP marks 5 facing up 4 rubber seal 5 UP marks 4 5 5 Cylinder Head Cover Installation 1 Check that the spark plug hole packing 1 is in good condition and replace it if necessary Apply engine oil to the spark plug hole packing and install it to the cylinder head cover 2 2 Check that the cylinder head cover packin...

Page 83: ...cover page 68 8 Set the piston at TDC on the compression stroke page 68 9 Remove the camshaft holder camshaft valve lifters and shims page 70 1 ECT sensor connector 11 Loosen the radiator hose clamp screw 2 and disconnect the radiator hose 3 2 radiator hose clamp screw 3 radiator hose 3 2 10 Disconnect the ECT sensor connector 1 1 4 shock absorber upper nut 5 bolt 13 Loosen the insulator band scre...

Page 84: ...left cylinder head hanger plate 12 right cylinder head hanger plate 9 12 10 9 11 10 15 Remove the cylinder head bolts 13 16 Loosen the cylinder bolt 14 13 cylinder head bolts 14 cylinder bolt 15 cylinder head stud bolts washers 16 cylinder head 13 14 16 15 17 Remove the cylinder head stud bolts washers 15 and cylinder head 16 Loosen the nuts in a crisscross pattern in two or three steps Do not let...

Page 85: ...iston Rings Piston Pin 18 Remove the dowel pins 17 cylinder head gasket 18 and cam chain guide 19 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 17 dowel pins 19 cam chain guide 18 cylinder head gasket 19 18 17 ...

Page 86: ...ep the piston pin clips or other parts from falling into the crankcase 2 Remove the piston pin clips 1 using a pair of needle nose pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston and rings should be replaced every 6 races or about every 15 0 hours of running Replace the piston pin every 6 races or about every 15 0 hours of running Piston...

Page 87: ...he side rails Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between the top ring and the upper side rail Space the ring end gaps 90 degrees apart between the upper side rail spacer and the lower side rail NOTICE top ring oil ring mark top ring oil ring side rail si...

Page 88: ...on pin and new piston pin clips 5 Use new piston pin clips Never reuse old piston pin clips Do not let the piston pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 6 NOTICE 1 piston 4 piston pin 2 O mark 5 piston pin clip 3 large valve recess 6 piston cut out Cylinder Installation 1 Place clean shop towels over the crankcase opening to prevent dust ...

Page 89: ...e piston rings and cylinder walls NOTICE 3 cam chain 5 piston rings 4 cylinder 7 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankcase guide hole 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs Cylinder Head Installation 1 Install the dowel pins 1 and a new cylinder head gasket 2 Do not let the dowe...

Page 90: ...and cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 3 cylinder head 4 cylinder head stud bolts washers 5 cylinder bolt 6 cylinder head bolts 3 4 6 5 7 left cylinder head hanger plate 8 right cylinder head hanger plate 9 cylinder head hanger plate bolts 10 cylinder head hanger bolts 10 7 9 5 Install the left cylinder head hanger plate 7 and right cylinder he...

Page 91: ...nnect the ECT sensor connector 20 20 ECT sensor connector 11 Install the shims valve lifters camshaft and camshaft holder page 73 12 Install the crankshaft hole cap page 74 13 Install the cylinder head cover page 75 14 Install the spark plug page 67 15 Install the exhaust pipe page 102 16 Install the subframe page 37 and muffler page 101 17 Install the fuel tank and seat pages 33 35 18 Fill and bl...

Page 92: ... Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension Adjustment Guidelines page 130 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 ...

Page 93: ...crement or turns described in page 126 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 126 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the compression and rebound damping adjusters in one click or in 1 12 turn incremen...

Page 94: ...er NOTICE 1 outer tube 6 dust seal 5 slider 3 Drain the fork oil from the outer tube 1 Drain the fork oil from the oil hole 7 of the fork damper 1 outer tube 7 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 0 4 US oz 12 cm3 of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 C 68 F 1 outer tube Pour the drained oil into a suit...

Page 95: ...in 4 2 N mm Fork Spring Standard oil capacity 12 8 US oz 377 cm3 Maximum oil capacity 13 0 US oz 385 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 2 US oz 301 cm3 1 scribe mark Optional Stiffer 26 20 lbf in 4 59 N mm Fork Spring Standard oil capacity 12 7 US oz 375 cm3 Maximum oil capacity 12 9 US oz 382 cm3 Slightly stiffer ...

Page 96: ...alling the fork leg page 112 tighten the fork damper to the specified torque Actual 25 lbf ft 34 N m 3 5 kgf m Torque wrench scale reading 23 lbf ft 31 N m 3 2 kgf m using a 20 in 500 mm long torque wrench When using the lock nut wrench use a 20 in 500 mm long deflecting beam type torque wrench The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less tha...

Page 97: ...rom the system 1 lock nut 2 adjuster 1 Loosen the lock nut 1 2 To position the brake lever farther away from the handgrip turn the adjuster 2 clockwise To position the brake lever closer to the handgrip turn the adjuster counterclockwise 3 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 4 Apply silicone grease to the contacting faces of the adju...

Page 98: ... equivalent Other Checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings 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 93 Worn brake pads should be replaced If ...

Page 99: ...voir cap 4 Tighten the screws to the specified torque 0 7 lbf ft 1 0 N m 0 1 kgf m Adding Rear Brake Fluid Spilled brake fluid will severely damage the painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first Always use fresh DOT4 brake fluid from a sealed container when servicing the system Do not mix dif...

Page 100: ...r 3 brake disc 2 brake pads Rear Brake Pads Inspect the brake pads 5 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 4 rear brake caliper 6 brake disc 5 brake pads Other Inspections Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight Make sure th...

Page 101: ...to perform the recommended service in the Maintenance Schedule page 25 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 wheel rim 3 rim lock 2 spoke 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Front Spoke 2 7 lbf ft 3 7 N m 0 4 kgf m Rear Spoke 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Lo...

Page 102: ...rds and wear unevenly Make sure the valve stem caps are secure If necessary install new caps Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your CRF has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold t...

Page 103: ... same size construction speed rating and load range as the originals Replace the tube any time you replace a tire The old tube will probably be stretched and if installed in a new tire could fail Front Rear Type 80 100 21 51M DUNLOP 100 90 19 57M DUNLOP MX51F MX51 bias ply tube Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be...

Page 104: ... sprocket 2 drive sprocket 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked or bindin...

Page 105: ...ces of the link plates and rollers Adjustment 1 Loosen the rear axle nut 1 2 Loosen both lock nuts 2 and turn the adjusting bolts 3 counterclockwise to decrease slack or clockwise to increase slack Align the index marks 4 of the axle plates 5 with the same reference marks 6 on both sides of the swingarm Drive Chain Rollers 1 Check the upper drive chain roller 1 and lower drive chain roller 2 for w...

Page 106: ... master link For ease of assembly hold the chain ends against adjacent rear sprocket teeth while inserting the master link Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation 8 Recheck chain slack and adjust as necessary More About Drive Chain The master link is the most critical element of drive chain security Master links ar...

Page 107: ...ler may reduce engine performance 1 seat mounting bolt 3 right side cover 2 side cover bolt 2 Loosen the muffler clamp bolt 4 5 muffler mounting A bolt 8 washer B 6 muffler mounting B bolt 9 muffler 7 washer A 2 1 3 5 6 7 8 9 Muffler Removal 1 Remove the seat mounting bolt 1 side cover bolt 2 and right side cover 3 4 muffler clamp bolt 3 Remove the muffler mounting A bolt 5 muffler mounting B bolt...

Page 108: ... the muffler 2 muffler clamp 5 tab 4 muffler 6 cutout 5 Install the washer A 7 washer B 8 muffler mounting B bolt 9 and muffler mounting A bolt 10 7 washer A 8 washer B 9 muffler mounting B bolt 10 muffler mounting A bolt 6 Tighten the muffler clamp bolt 11 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 9 muffler mounting B bolt 10 muffler mounting A bolt 3 2 1 6 4 5 2 10 9 7 8 10 9 7 Tighten ...

Page 109: ... pipe joint nuts 1 exhaust pipe 2 and gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket Exhaust Pipe Installation 1 Install a new exhaust pipe gasket 1 as shown 2 Install the exhaust pipe 2 and exhaust pipe joint nuts 3 1 exhaust pipe gasket new 2 exhaust pipe 3 exhaust pipe joint nuts 3 Install the muffler page 101 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to...

Page 110: ...ng two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you have a problem finding an acceptable adjustment return to the standard position and begin again 1 Unlock the number plate tab 1 from the handlebar pad Remove the bolts 2 and number plate 3 4 steering damper 5 damper rod 6 steering damper mounting bolts 3 With your CRF on a box or a...

Page 111: ...heck that the steering moves smoothly from side to side Steering Damper 3 2 1 1 2 3 4 5 2 1 Removal 1 Remove the number plate page 103 2 Remove the steering damper mounting bolts 1 collar 2 and steering damper 3 1 steering damper mounting bolts 2 collar 3 steering damper Inspection 1 Check the damper rod 1 operation The damper rod is fully extended and compressed by hand Release the damper rod the...

Page 112: ...lts first 1 handlebar 2 handlebar holders 3 paint mark 4 handlebar upper holder bolts Control Cables Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate the cable pivot points with a commercially available cable lubricant If the clutch lever hot start lever and throttle operation is not smooth replace the cable Be sure the throttle returns free...

Page 113: ...head bolts Drive sprocket bolt Transmission oil drain bolt Cylinder head stud bolts Torque lbf ft N m kgf m 7 15 7 11 9 7 7 12 7 9 7 23 12 33 10 21 10 15 12 10 10 16 10 12 10 31 16 45 1 0 2 1 1 0 1 5 1 2 1 0 1 0 1 6 1 0 1 2 1 0 3 2 1 6 4 6 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover bolts 7 coolan...

Page 114: ... head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on the Pro Honda Hondabrite and rinse...

Page 115: ... Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes par...

Page 116: ...bined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional stiffer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 110 Rear Suspension Adjustments 125 Suspension Adjustments fo...

Page 117: ...using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pressure re...

Page 118: ...d 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 click and lower the oil capacity in increments of 0 2 US oz 5 cm3 in both fork legs until the desired performance is obtained Do not however lower the oil capacity below the minimum oil capacity Minimum oil capacity Standard spri...

Page 119: ...mpression damping 2 rebound damping adjuster adjuster 2 1 Front Suspension Adjustments 4 3 4 Loosen the fork bridge upper pinch bolts 5 5 Loosen the fork damper 6 using a lock nut wrench 7 but do not remove them yet Lock nut wrench 07WMA KZ30100 Do not use an adjustable wrench to loosen the fork damper it may damage them NOTICE 5 fork bridge upper pinch bolts 6 fork damper 7 lock nut wrench 6 Remo...

Page 120: ...e caliper 10 Remove the fork protector socket bolts 17 and fork protectors 18 11 9 10 10 16 14 13 12 15 7 Remove the front axle nut 9 and loosen the axle pinch bolts 10 on both forks Pull the front axle shaft 11 out of the wheel hub and remove the front wheel with disc cover collar 17 fork protector socket bolts 18 fork protectors 18 17 17 22 21 20 19 fork bridge lower pinch bolts 12 Clean the for...

Page 121: ... nut wrench 7 Gently slide the outer tube down onto the lower end axle holder 23 15 Drain the fork oil from the outer tube slider 26 and oil holes 27 of the fork damper 19 Push the fork center bolt 28 out from the axle holder 23 of the slider by pushing the fork damper While the fork center bolt is pushed out install the piston base 29 or a mechanic s stopper tool between the axle holder and fork ...

Page 122: ...k assembly Remove the O ring 37 Do not attempt to separate the fork assembly and drop the axle holder out from the outer tube which can damage the guide bushings 38 To avoid damage hold both the outer tube and silder NOTICE Damper Oil Change 1 Place the fork damper 1 in a vise with a piece of wood or soft jaws to avoid damage Over tighten the vise can damage the fork damper 2 Loosen the fork cap a...

Page 123: ...the fork cap assembly 2 2 4 5 1 1 4 6 fork cap and fork damper threads 7 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper 1 Recommended Oil HP Fork Oil SS 19 Recommended Amount 8 3 US oz 245 cm3 3 Remove the fork cap assembly 2 from the fork damper threads and then pop it out by pumping the fork damper piston rod 4 slowly 4 Remove the fork cap ...

Page 124: ...age Cover the oil holes with shop towel 11 to prevent blow out of fork oil Blow the extra oil off from the fork damper oil chamber 5 by pumping the fork damper piston rod to full stroke Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked NOTICE 4 10 5 11 11 1 fork damper 3 lock nut wrench 2 fork cap assembly 12 Completely screw in the fork center bolt lock nu...

Page 125: ...e oil completely off the fork damper 2 fork center bolt lock nut A thread length 1 A 2 5 fork damper oil chamber 12 oil holes Pour the drained oil into a suitable container and dispose of it in an approved manner page 144 Improper disposal of drained fluids is harmful to the environment NOTICE 5 12 15 Drain the extra oil from the oil holes 12 of the fork damper oil chamber 5 By doing this procedur...

Page 126: ...oil to new O ring 11 and install it to the fork center bolt 12 Install the fork center bolt to the fork damper piston rod Tighten the fork center bolt fully by hand NOTICE 2 fork center bolt lock nut 11 O ring new 9 piston base 12 fork center bolt 10 push rod 9 2 10 12 11 3 Install the collar 3 to the C ring 4 of the fork damper assembly 5 as shown Install the washer 6 and spring retainer 7 to the...

Page 127: ...piston base or mechanic s stopper tool while pushing the fork damper Apply locking agent to the fork center bolt threads Install the fork center bolt 12 to the axle holder and tighten it to the specified torque 51 Ibf ft 69 N m 7 0 kgf m 12 fork center bolt 12 Measure the length between the axle holder and outer tube Standard 12 5 0 1 in 316 5 2 mm 13 Compare the length 13 at assembly and at disas...

Page 128: ...01 cm3 1 scribe mark Optional Stiffer 26 20 lbf in 4 59 N mm Fork Spring Standard oil capacity 12 7 US oz 375 cm3 Maximum oil capacity 12 9 US oz 382 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 1 US oz 299 cm3 2 scribe marks Be sure the oil capacity is the same in both fork legs cont d 16 Install a new O ring 15 on the fork...

Page 129: ...eading will be less than the torque actually applied to the fork damper 18 17 17 fork damper 18 lock nut wrench 20 For ease of releasing air pressure after the forks are installed loosen the fork bridge lower pinch bolts and position the outer tubes so that the fork air pressure release screws are in front of the compression damping adjusters Align the top of the outer tube 19 with the top surface...

Page 130: ... 30 disc cover collar 31 right side collar 28 Install the front wheel between the fork legs while inserting the disc between the pads being careful not to damage the pads 29 Insert the front axle shaft through the forks and wheel hub from the right side Make sure that the front axle shaft is seated firmly onto the left fork leg clamp inner surface Tighten the front axle nut 32 to the specified tor...

Page 131: ...5 Ibf ft 20 N m 2 0 kgf m 34 Install and tighten the disc cover socket bolt 37 to the specified torque 10 Ibf ft 13 N m 1 3 kgf m 37 disc cover socket bolt 35 Turn the rebound damping 38 and compression damping 39 adjuster screws back to their original settings 36 37 38 rebound damping adjuster 39 compression damping adjuster 38 39 36 right axle pinch bolts To avoid damage when torquing the axle p...

Page 132: ...he connecting tube clamp screw and remove the subframe s three mounting bolts then remove the subframe See page 36 3 Check that the spring preload is adjusted to the standard length Adjust as necessary by loosening the lock nut 1 and turning the adjusting nut 2 Each complete turn of the adjusting nut changes the spring length by 0 06 in 1 5 mm 4 After adjustment hold the adjusting nut and tighten ...

Page 133: ...Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster The high speed damping adjuster has 3 1 2 turn or more To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 3 4 turns and the punch marks are aligned Low Speed Damping ...

Page 134: ...g adjustment procedure establishes the correct starting point for any suspension tuning the proper rear suspension spring pre load adjustment for your specific needs Your CRF should be at normal racing weight including fuel oil and coolant 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 fix...

Page 135: ...n to you 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 rear shock 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 t...

Page 136: ...iffer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compre...

Page 137: ...t Front end shakes Fork bottoms over any type of terrain Action Test stiffer compression damping adjustments in one click increments Test stiffer rebound damping in one click increments If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in one click increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in one cli...

Page 138: ...ravel test softer compression damping adjustments in one click increments until the desired compression damping for initial travel is obtained If initial travel isn t stiff Test stiffer compression damping adjustments in one click increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in one ...

Page 139: ...s Suspension bottoms at landing after jumping Suspension bottoms after landing Suspension bottoms after end of continuous bumps Action 1 Test softer low speed compression adjustment 2 If it still feels stiff further test softer low and high speed compression adjustments simultaneously 1 Test softer high speed compression adjustment 2 If it still feels stiff further test softer low and high speed c...

Page 140: ...ain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Light gray or white color streaks the porcelain insulator and center electrode indicate lean air fuel mixture Wet or black sooty streaks on the porcelain indicate rich air fuel mixture NOTICE Condition Normal Overheating Lean Wet Rich Spark Plug ...

Page 141: ...x positions To adjust the adjuster to the standard setting proceed as follows Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard position The adjuster is set in the standard position when the adjuster is turned counterclockwise 9 12 clicks Damping can be increased by turning the adjuster clockwise Always start with full hard when adjusting damping Do not t...

Page 142: ...ering damper adjuster in one click increments at a time Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment Symptom Steering is wobbling on large bumps Adjust the steering damper adjuster to stiffer setting Steering is wobbling at sand track Adjust the steering damper adjuster to stiffer setting Steering is heavy when cornering Adju...

Page 143: ...k tubes in the clamps is not adjustable Align the groove in the outer tube with the top surface of the upper fork clamp Standard Position The standard position 1 align the top of the outer tube 2 not the top of the fork cap with the top surface of the upper fork clamp 3 The following suggestions may improve a specific concern Subtle changes in overall handling may also be noted Rear End If you hav...

Page 144: ...at and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too drastic a change in s...

Page 145: ...y will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands...

Page 146: ...essed when sitting or standing comfortably on your CRF Handlebar Position Width Shape Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first The handlebar position may be moved rearward either 0 12 in 3 mm using optional handlebar lower holders or 0 24 in 6...

Page 147: ...140 Adjustments for Competition ...

Page 148: ...ips Here s helpful advice on how to transport and store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 142 Storing Your Honda 143 You the Environment 144 Troubleshooting 145 ...

Page 149: ... trailer rail Attach the lower ends of two straps to the tie down hooks on your CRF Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and co...

Page 150: ...ner 7 Inflate the tires to their recommended pressures 8 Place your CRF on an optional workstand or equivalent to raise both tires off the ground 9 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 10 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 11 Cover yo...

Page 151: ...ning solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and ...

Page 152: ...Faulty valve core Punctured tire Clutch slipping Improperly adjusted clutch lever freeplay p 58 Worn clutch discs plates p 61 Warped clutch discs plates p 61 Weak clutch springs p 61 Sticking clutch lifter Additive in engine oil Dirty air cleaner element Clogged muffler Fast idle knob stuck open or damaged Restricted fuel fill cap breather tube Restricted fuel flow Worn piston and cylinder Use of ...

Page 153: ... the air cleaner P 52 AIR CLEANER NOT DIRTY DIRTY WEAK OR INTERMITTENT SPARK GOOD SPARK 6 Try spark test Faulty ECM Faulty CKP sensor Not cleaned frequently enough Faulty camshaft Faulty valve springs Faulty carbon or wet fouled spark plug P 67 Faulty ECM Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty CKP sensor Loose or disconnected ignition system wires Faulty en...

Page 154: ...her technical data Vehicle Identification 148 Specifications 149 Torque Specifications 150 Oxygenated Fuels 153 Competition Logbook 154 Optional Parts List 156 Spare Parts Equipment 157 Wiring Diagram 158 Technical Information Technical Information 147 ...

Page 155: ...F They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head RIGHT SIDE 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE 2 engine number 1 2 ...

Page 156: ... Displacement Compression ratio Valve clearance cold Intake Exhaust 0 005 0 001 in 0 12 0 03 mm 0 011 0 001 in 0 28 0 03 mm Engine oil capacity After draining After draining and oil filter change After disassembly After disassembly Transmission oil capacity After draining Identification number Idle speed GQ26A 2 000 100 rpm Liquid cooled 4 stroke Single 5 inclined from vertical 0 70 US qt 0 73 US ...

Page 157: ...rain bolt Engine oil drain bolt Cylinder bolt Oil filter cover bolts Cylinder head bolts Drive sprocket bolt Transmission oil drain bolt Cylinder head stud bolts Torque Remarks lbf ft N m kgf m 7 15 7 11 9 7 7 12 7 9 7 23 12 33 10 21 10 15 12 10 10 16 10 12 10 31 16 45 1 0 2 1 1 0 1 5 1 2 1 0 1 0 1 6 1 0 1 2 1 0 3 2 1 6 4 6 NOTE 1 NOTE 2 NOTE 2 NOTE 2 Transmission oil check bolt 5 1 Apply grease t...

Page 158: ... 1 5 Handlebar lower holder nuts 32 44 4 5 4 Handlebar upper holder bolts 16 22 2 2 3 Fork bridge lower pinch bolts 15 20 2 0 2 Fork bridge upper pinch bolts 16 22 2 2 1 Steering stem nut 80 108 11 0 FRAME 1 U nut 2 UBS nut 3 Apply molybdenum oil to the threads and flange surface 4 Alock bolt replace with a new one 5 Apply locking agent to the threads 6 SH bolt NOTES 19 20 Shock spring lock nut Ki...

Page 159: ...per mounting bolts Brake lever adjuster lock nut Brake pedal adjuster lock nut Mud guard screws Side cover bolts Fuel pump mounting bolts 22 12 12 27 2 7 2 7 9 24 24 36 51 16 10 5 2 15 19 19 24 19 0 7 0 7 1 0 3 7 9 9 3 0 15 4 4 4 4 0 8 7 8 30 16 16 36 3 7 3 7 12 33 33 49 69 22 13 7 21 26 26 32 26 1 0 1 0 1 3 5 12 12 4 20 5 9 5 9 1 1 10 11 3 1 1 6 1 6 3 7 0 4 0 4 1 2 3 4 3 4 5 0 7 0 2 2 1 3 0 7 2 1...

Page 160: ...ohol MTBE Methyl Tertiary Butyl Ether 15 by Volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by Volume You may use gasoline containing methanol containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or perfor...

Page 161: ...intenance 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 guesstimate is close enough for our timekeeping purposes You may choose to reco...

Page 162: ...on 155 Competition Logbook Date Running Location Event Comments Suspension Settings Steering Damper Settings Gearing Chassis Adjustments Time Maintenance Performed etc Make several photocopies of this page for future use ...

Page 163: ...r authorized dealer FRAME Remarks Shock spring Standard Optional Softer Stiffer Fork spring Standard The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked Before replacing the springs be sure to mark them so they can be distinguished from other optional springs 296 9 lbf in 52 0 N mm No mark factory products Red paint aftermarket parts or 285...

Page 164: ...e 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 dealer Lock Nut Wrench 07WMA KZ30100 Spoke Wrench 07JMA MR60100 070MA KZ30100 Tensioner Stopper 070MG 0010100 07A...

Page 165: ...158 Technical Information Wiring Diagram ...

Page 166: ...information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 160 Contacting Honda 161 Your Dealer 162 The Honda Rider s Club USA only 163 Consumer Information 159 Consumer Information ...

Page 167: ...ers ATVs MUVs PWCs These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures 160 Consumer Information Authorized Manuals Publication Item No Description 61KRN52 2012 CRF250R Service Manual 61CM002 Common Service Manual 31KRN680 2012 CRF2...

Page 168: ...evel If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 9...

Page 169: ...uine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area as well as provide you with information about the Honda Rider s Clu...

Page 170: ...a HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country You can log on to the HRCA Clubhouse website for more information at www hrca honda com Consumer Information 163 The Honda Rider s Club USA only ...

Page 171: ... drive 97 chassis adjustments 136 cleaner air 56 cleaning appearance care 107 clutch system adjustment 62 competition logbook 154 consumer information 159 contacting Honda 161 controls 5 coolant 54 customer service 162 cylinder system 79 damping adjustments front 110 rear 126 steering damper 134 dealer your 162 diagram wiring 158 drive chain 97 engine idle speed 61 lacks power 145 number 148 oil 4...

Page 172: ...tional parts list 156 sprockets 137 oxygenated fuels 153 pads brake 93 parts optional 156 personal fit adjustments 139 pinging engine 40 plug spark 67 pre load rear suspension 125 pre ride inspection 13 protective apparel 2 rear suspension maintenance 125 Rider s Club Honda USA only 163 riding apparel 2 basic operation 15 before 11 important safety information 2 safety precautions 2 safety a few w...

Page 173: ...uidelines 130 transmission oil 52 tuning tips 133 throttle freeplay 59 inspection 60 tires air pressure 95 flat 95 selection 138 tools 157 torque specifications engine 150 frame 151 152 transporting 142 troubleshooting 145 tubes replacing 95 vale clearance 68 vehicle identification no VIN 148 washing your motorcycle 107 wheels 94 wiring diagram 158 W V T ...

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Page 177: ...m2 Rear 15 psi 100 kPa 1 0kgf cm2 standard R0451B 8 NGK DID520DMA4 116RB RK520TXZ 116RJ Tires Tire Pressure cold Spark ethylene glycol antifreeze silicate free for aluminum engines in 50 50 solution with Pro Honda HP Coolant or equivalent distilled water Coolant Plug Drive Chain link Front Type bias ply tube 80 100 21 51M DUNLOP MX51F Rear 100 90 19 57M DUNLOP MX51 Quick Reference Quick Reference ...