Honda CRF250R 2018, Owner'S Manual

Page 1: ...G YOUR HONDA 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 31 Service Preparations Maintenance Component Locations 32 Seat 33 Fuel Tank 34 Subframe 37 Service ...

Page 2: ...Fit Adjustments 142 Control Positioning 142 Handlebar Position Width Shape 142 TIPS 143 Transporting Your Motorcycle 144 Storing Your Honda 145 Preparation for Storage 145 Removal from Storage 145 You the Environment 146 Troubleshooting 147 TAKING CARE OF THE UNEXPECTED 149 If a Fuse Blows 150 If Your Battery Is Low or Dead 151 TECHNICAL INFORMATION 153 Vehicle Identification 154 Serial Numbers 15...

Page 3: ...2018 Honda CRF250R OWNER S MANUAL COMPETITION HANDBOOK ...

Page 4: ...ck 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 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...

Page 5: ...out the manual Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 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 be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED o...

Page 6: ...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 7: ...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 abilities or faster than conditions warrant Remember that alcohol drugs illness and fatigue can reduce your ability to perform well and ride safely Don t Drink and Ride Alcohol and riding don t mix Even one drink can reduce your a...

Page 8: ...ould change its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride Accessories Modifications 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 9: ...Safety Labels 4 Motorcycle Safety Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact your dealer for replacement For Canada ...

Page 10: ... section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 MIL Malfunction Indicator Lamp 7 MIL Blink Pattern 7 Current DTC Freeze DTC 7 Circuit Inspection 8 DTC Index 9 Mode Indicator 10 ...

Page 11: ...nt Locations 6 Instruments Controls clutch lever engine stop button front brake lever throttle grip MIL mode indicator engine mode select button start button fast idle knob engine idle speed shift lever rear brake pedal ...

Page 12: ...linking 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 will indicate them by blinking in the order from the lowest number to highest number The DTC is indicated in two ways according to the failure sta...

Page 13: ... is often related to poorly connected or corroded connections Check the following connections Remember circuit inspection is not a cure all for other problems in your engine s PGM FI system Circuit Inspection 1 MAP sensor connector 2 ECT sensor connector 3 TP sensor connector 4 IAT sensor connector 5 Injector connector 6 CKP sensor connector 7 ECM connector 4 5 7 2 6 1 3 ...

Page 14: ... an official Honda Service Manual page 166 for troubleshooting of the PGM FI symptom DTC Index MIL blinks Function Failure Symptom Fail safe function 1 MAP sensor circuit malfunction Poor performance drivability 2 MAP sensor performance problem Poor performance drivability 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IA...

Page 15: ...cates the currently selected mode by blinking the mode number once when the engine is started The mode indicator indicates a selected mode when you operate the engine mode select button page 126 If the mode indicator stays on or does not come on when it should have your dealer check it for problems 1 mode indicator blue 2 engine mode select button 2 1 ...

Page 16: ... ready to ride To help get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension and other adjustments see page 125 Are You Ready to Ride 12 Is Your Motorcycle Ready to Ride 13 Pre ride Inspection 13 ...

Page 17: ...n and other adjustments see page 125 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 we...

Page 18: ...for damage or improper inflation pressure 110 Spokes for looseness 109 Rim locks for looseness 109 Front and rear suspension for proper operation 88 104 Front and rear brakes check operation 105 Drive chain for correct slack and adequate lubrication 112 113 Drive chain sliders and drive chain rollers for damage or wear 112 113 Exhaust pipe Muffler for looseness 115 Every possible part for loosenes...

Page 19: ...14 Before Riding 1 3 ...

Page 20: ...is section gives basic information on how to start and stop your engine as well 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 ...

Page 21: ...closed 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 Safe Riding Precautions WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsci...

Page 22: ... on page 61 Make sure that the transmission is in neutral Always follow the proper starting procedure described as follows Check the engine oil and coolant levels before starting the engine pages 52 54 Cold Engine Starting 1 Shift the transmission into neutral 2 If the temperature is 50 F 10 C or below pull the fast idle knob 1 fully out 3 With the throttle closed Pull the clutch lever all the way...

Page 23: ...the start button Do not open the throttle Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe and muffler discolorations When starting the engine the MIL amber will stay on for 2 seconds then go off And then the mode indicator blue indicates the current engine mode for 0 8 seconds then goes off If the MIL mode indicator 1 does not come on or go off when it sho...

Page 24: ...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 25: ...20 Basic Operating Instructions 1 3 ...

Page 26: ...al page 166 An optional tool kit may be available Check with your 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 31 Service Preparations ...

Page 27: ...lly important because your CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section 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 ...

Page 28: ...ine 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 the possibility of a fire or ...

Page 29: ...n terms of races and riding hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda Genuine...

Page 30: ...very 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 Ref Page FUEL LINE NOTE 6 I R 41 FUEL PUMP FILTER NOTE 6 R 45 49 THROTTLE OPERATION I 60 AIR FILTER NOTE 1 C 56 CRANKCASE BREATHER I 58 SPARK PLUG I 67 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 68 78 ENGINE OIL NOTE 3 NOTE 5 I R 51 ENGINE OIL FILTER NOTE 3 R 52 ...

Page 31: ... Genuine Parts or their equivalents when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surfaces 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 reassemb...

Page 32: ...rviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Air Filter Oil or an equivalent Be sure to grease the air cleaner flan...

Page 33: ...r an equivalent and tighten to the specified torque 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 an official Honda Service Manual page 166 Use only Pro Honda HP Fork Oil SS ...

Page 34: ... performance and minimize component wear Swingarm Do not attempt to weld or otherwise repair a damaged swingarm Welding will weaken the swingarm Swingarm Pivot Lubrication Clean inspect and lubricate the swingarm and suspension linkage pivots with molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 after each 7 5 hours of running time in order to maintain...

Page 35: ...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 After adjustment check that the chain adjuster index marks 1 are in the same position on each side This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake Maintaining p...

Page 36: ... drive chain clean and lubricate it pages 113 114 Be sure the chain is wiped clean and is dry before lubricating the chain Routine Cleaning If your CRF is only slightly dirty it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags Take care to prevent catching your fingers between the chain and sprocket A variety of reasonably priced cleaning brushes are ava...

Page 37: ...iper front suspension compression damping adjuster both left and right rear suspension rebound damping adjuster rear suspension high speed compression damping adjuster rear suspension low speed compression damping adjuster engine oil fill cap front suspension rebound damping adjuster both left and right engine oil filter rear brake pedal rear brake fluid reservoir battery engine oil drain bolt rea...

Page 38: ...all the seat while aligning the seat front prong 1 with the slot 2 of the fuel tank and seat center prongs 3 with the seat support base slots 4 2 Install and tighten the seat mounting bolts 5 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat mounting bolts 2 seat 2 1 1 1 seat front prong 4 seat support base slots 2 slot 5 seat mounting bolts 3 seat center prongs 1 3 2 4 5 5 ...

Page 39: ...deterioration kinks or other damage Do not support the fuel tank by the fuel feed hose 16 NOTICE The fuel tank is made of titanium material Since the fuel tank has not been painted it might be discolored with mud and dust To remove mud or dust use a sponge or soft cloth and a stainless steel kitchen detergent then rinse well clean water After washing rinse with plenty of water and dry with a clean...

Page 40: ... frame 2 Install the washers 2 fuel tank A bolt 3 and B bolts 4 and then tighten the fuel tank A bolt and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m 3 Put the breather tube 5 in the steering stem nut 6 4 Remove the hose clamp 7 from the breather tube 5 Connect the overflow hose 8 to the clamp 9 17 cushion rubbers 3 35 0 10 in 85 0 2 5 mm 1 10 0 10 in 28 0 2 5 mm 17 1 fuel tank 3 fue...

Page 41: ...nd shroud A bolt 16 Tighten the shroud A and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Tighten the shroud C bolt to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m The right and left shrouds can be installed in the same manner 8 Install the seat page 33 10 shroud 14 shroud C bolt 11 shroud tab 15 shroud B bolt 12 slot 16 shroud A bolt 13 air cleaner housing cover 10 14 15 16 13 1...

Page 42: ...rter ignition relay connector 8 and remove the seat support base 9 7 Lift the seat support base 9 and hang it to the left of the subframe 10 8 Disconnect the breather tube 11 and IAT sensor connector 12 9 Loosen the air cleaner connecting tube clamp screw 13 10 Disconnect the negative terminal 14 from the battery 15 1 shroud A bolt 2 shroud B bolt 3 shroud C bolt 4 shroud 5 air cleaner housing cov...

Page 43: ...osely attach the upper and lower ends of the subframe to the main frame and loosely install all subframe bolts 2 Tighten the subframe upper bolts 1 first and then tighten the lower bolts 2 to the specified torque subframe upper bolts 24 lbf ft 32 N m 3 3 kgf m subframe lower bolts 36 lbf ft 49 N m 5 0 kgf m 16 starter relay switch stay bolt 17 plastic wire band 18 starter relay switch 19 starter r...

Page 44: ...bolt 12 to the specified torque 1 5 lbf ft 2 0 N m 0 2 kgf m 5 Connect the air cleaner box 13 to the air cleaner connecting tube 14 and tighten the air cleaner connecting tube clamp screw 15 so the distance between the clamp ends is 0 30 0 06 in 7 5 1 5 mm 6 Connect the breather tube 16 and IAT sensor connector 17 3 starter motor terminal 4 starter relay switch 5 starter motor terminal bolt 6 star...

Page 45: ...housing cover 25 is aligned 11 Install the shroud C bolt 26 B bolt 27 and shroud A bolt 28 Tighten the shroud A and B bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Tighten the shroud C bolt to the specified torque 3 8 lbf ft 5 2 N m 0 5 kgf m The right and left shrouds can be installed in the same manner 12 Install the seat page 33 18 starter ignition relay connector 19 seat support base...

Page 46: ...he fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck 4 Fuel Tank Capacity 1 66 US gal 6 3 ℓ Be careful not to damage the fuel pump while filling the fuel tank Avoid overfilling the tank There should be no fuel in the filler neck 3 Close the fuel fill cap and ...

Page 47: ...age 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 5 Remove the bolt 4 clamp 5 and setting rubber 6 6 Place a shop towels 7 over the each fuel quick connect fitting Fuel Pressure Relieving 1 fuel pump connector 1 Fuel Line Replacement 1 fuel quick connect fitting cover 2 fuel pump 3 fuel quick connect...

Page 48: ...h plastic bags 13 Connection 1 Install the rubber cover 1 onto the fuel joint 2 of the fuel pump as shown 2 Be sure that the slide retainer 3 is completely pulled up before connecting the quick connect fitting Do not bend or twist the fuel feed hose Do not reuse the kinked or damaged fuel hose Do not use gloves or a shop towel while installing the quick connect fitting WARNING Gasoline is highly f...

Page 49: ...l the setting rubber 5 toward the recess 6 of the setting rubber to the fuel joint 2 6 Install the clamp 7 and bolt 8 by aligning the clamp tab 9 with the groove 10 of the stay Tighten the bolt securely 7 Install the fuel quick connect fitting cover 11 Be sure the rubber cover 1 is properly installed between the fuel quick connect fitting cover and fuel pump 8 Increase the fuel pressure page 50 9 ...

Page 50: ... and disconnect it 5 Remove the fuel pump mounting nuts 5 fuel pump mounting cap nut 6 stopper cable guide 7 stopper cable 2 washer 8 collars 9 conical spring washers 10 and fuel pump plate 11 while holding the fuel tank Fuel Pump Filter Replacement WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and ...

Page 51: ...n assembly 9 Release the hooks of the fuel pump unit holder from the grooves 19 in the fuel pump base tabs while pushing the holder against the base and slightly spreading the base tabs Be careful not to damage the hooks and tabs 10 Remove the fuel pump unit holder assembly 20 from the fuel pump base 16 and remove the O ring 21 Wipe the spilled out fuel immediately 11 Remove the fuel pump stopper ...

Page 52: ...unt of engine oil to a new O ring 5 Install the new O ring to the fuel pump assembly 2 3 Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder 6 while routing the fuel pump yellow 7 and green 8 wires through the holder grooves 9 as shown 4 Install a new damper rubber 10 to the fuel pump filter as shown Install fuel pump stopper 11 24 fuel pump assembly 25 fuel pump un...

Page 53: ...abs 22 with the fuel pump unit grooves 23 Check the dust seal lug 24 which is located the index mark 25 of the fuel pump base 13 9 Apply small amount of engine oil to a new O ring 26 Install the new O ring into the between the collar A 27 and collar B 28 of the fuel pump unit 29 10 Install the fuel pump unit 29 into the fuel tank 30 with its hose joint 31 facing forward Be careful not to damage th...

Page 54: ...e specified sequence as shown 8 lbf ft 11 N m 1 1 kgf m 14 Install the harness band clip 43 to the stopper cable guide 39 15 Install the stopper cable 38 to the frame hook 44 of the frame while holding the fuel tank 30 16 Connect the fuel line page 43 17 Increase the fuel pressure page 50 18 Install the fuel tank page 35 24 dust seal lug 32 fuel pump plate 33 groove 34 fuel pump unit lug 24 33 34 ...

Page 55: ...sing fuel pressure With the throttle closed Pull the clutch lever all the way in and depress the start button The engine will start up by increasing the fuel pressure If the engine does not start check all connector connections and or refer to an official Honda Service Manual page 166 for troubleshooting of the PGM FI symptom Fuel Pressure Increasing ...

Page 56: ...s displaying a circular API energy conserving or resource conserving service label on the container They may affect lubrication Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range 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 M...

Page 57: ...rk remove the oil fill cap 4 and add the recommended oil until it reaches the upper level mark Do not overfill 5 Check that the O ring 5 is in good condition and replace it if necessary 6 Reinstall the engine oil fill cap 4 7 Check for oil leaks 1 Remove the engine guard A bolts washers 1 B bolt washer 2 and engine guard 3 2 Run the engine at idle for 3 minutes then shut it off 3 Support the CRF i...

Page 58: ...he spring end then install the spring into a new oil filter 13 Position the spring against the engine crankcase and install a new oil filter with the rubber seal 12 facing out away from the engine You should see the OUT SIDE mark 13 on the filter body near the seal Use a new Honda Genuine oil filter or a filter of equal quality specified for your model NOTICE If the oil filter is not installed pro...

Page 59: ...freeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to Important Safety Precautions on page 23 1 Position your CRF on an optional workstand or equivalent support so that it is securely held in plac...

Page 60: ...d at the same time 7 Check the radiator air passages for clogging or damage Straighten bent fins 6 and remove insects mud or other obstructions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Radiator should be replaced by your dealer unless you have the proper tools and service data and are mechanically qualif...

Page 61: ...pecific performance requirements Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality NOTICE Using the wrong air cleaner may result in premature engine wear Proper air cleaner maintenance can prevent premature engine wear or damage expensive repairs low engine power poor gas mileage and spark plug fouling NOTICE Improper or lack of proper air cleaner main...

Page 62: ...element and holder Install the holder tab in the hole of the air cleaner element 8 Apply 0 05 0 19 oz 1 5 5 5 g of Pro Honda Foam Air Filter Sealer or equivalent to the air cleaner element contact area of the air cleaner housing 9 Install the air cleaner assembly 2 into the air cleaner housing stay 8 with the UP mark tab 9 facing up 10 Carefully position the sealing flange of the element to preven...

Page 63: ...n see deposits in the transparent section of the crankcase breather tubes If the drain tube overflows the air filter may become contaminated with engine oil causing poor engine performance 1 Remove the crankcase breather tube plug 1 from the crankcase breather tube 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug Draining 1 crankcase breather tube plug 2 ...

Page 64: ...the adjuster all the way in and back out one turn Tighten the lock nut securely 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 throttle body It is also used if you cannot get the proper adjustment with the upper adjuster 1 Loosen the lock nut 1 2 Turn the adjuster 2 in...

Page 65: ...move the throttle housing bolts 2 3 Remove the throttle housing 3 from the throttle pipe 4 4 Thoroughly lubricate the throttle cable ends 5 with multi purpose grease 5 Install the throttle housing to the throttle pipe Check that the throttle assembly is positioned properly the end of the throttle housing is aligned with the paint mark 6 on the handlebar and tighten the throttle housing bolts to th...

Page 66: ...urate idle speed adjustment When pushed in the fast idle knob acts as the idle adjustment screw Turning it counterclockwise results in a faster higher idle speed Turning it clockwise results in a slower lower idle speed 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 Adjust idle...

Page 67: ...e 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 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out five turns 2 Loosen the lock nut 1 3 Turn the integral cable adjuster 2 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engin...

Page 68: ...se to sliding surface of the clutch cable ends 1 Release the dust cover 1 2 Turn the adjuster 2 and remove the clutch cable 3 3 Disconnect the clutch cable end 4 from the clutch lever 5 4 Thoroughly lubricate the clutch cable end 4 with multi purpose grease 5 Connect the clutch cable end to the lever 6 Install the clutch cable and turn the adjuster 7 Remove the clutch cable end adjuster 6 8 Apply ...

Page 69: ...ould turn smoothly and quietly If the operation is not smooth refer to an official Honda Service Manual page 166 for bearing disassembly or see your dealer 6 Remove the clutch lifter 8 first then remove the clutch lifter rod 9 7 Remove the eight clutch discs seven clutch plates judder spring and spring seat 10 Clutch Disc Plate Removal 1 clutch cover A bolts 3 clutch cover B bolts 2 washer 4 clutc...

Page 70: ...ch springs as a set If you feel the clutch slippage when replacing the clutch discs and plates replace the clutch springs 1 Install the spring seat 1 and judder spring 2 onto the clutch center as shown Coat the clutch discs with engine oil 2 Install the clutch disc A larger I D disc and green painted to the clutch disc lug surface 3 onto the clutch outer Stack the seven clutch plates 4 six clutch ...

Page 71: ... m 1 2 kgf m 8 Apply engine oil to a new O ring 11 and install it in the groove of the clutch cover 12 9 Install the cover by tightening a new washer 13 four clutch cover A bolts 14 and two clutch cover B bolts 15 in a crisscross pattern in two or three steps to the specified torque 7 lbf ft 10 N m 1 0 kgf m 10 Fill the crankcase with the recommended engine oil page 52 7 clutch lifter rod 8 clutch...

Page 72: ...r gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 024 0 028 in 0 60 0 70 mm 7 To obtain accurate spark plug readings accelerate up to speed on a straightaway Press and hold 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 cen...

Page 73: ...s 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 3 Disconnect the ignition coil A connector 3 and B connector 4 Remove the ignition coil 5 by removing the ignition coil bolts 6 4 Remove the cylinder head cover socket bolts rubber s...

Page 74: ...compressor weight 6 is in the lower position Check the timing marks 7 on each cam sprocket are aligned with the cylinder head mating surface 8 1 Set the piston at TDC on the compression stroke this page 2 Measure the valve clearances of each intake valve by inserting a feeler gauge 1 between the intake rocker arms 2 slipper surface and camshaft cam lobes 3 NOTICE Be careful not to damage the intak...

Page 75: ... crankcase 2 Rotate the crankshaft by turning the flywheel 3 counterclockwise until the decompressor weight 4 faces up as illustrated below 3 Remove the cam sprocket bolt 5 of the intake camshaft NOTICE Do not let the cam sprocket bolt fall into the crankcase 4 Rotate the camshaft by turning the flywheel and make sure the piston is at TDC on the compression stroke page 69 5 Remove the cam chain te...

Page 76: ...bolt fall into the crankcase 8 Remove the cam sprocket bolt 5 of the intake camshaft NOTICE Do not let the cam sprocket bolt fall into the crankcase 9 Remove the intake camshaft 16 from the intake cam sprocket 17 Remove the intake cam sprocket and exhaust camshaft 18 by removing the cam chain 19 Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase NOTICE ...

Page 77: ...est 2 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 exhaust valve seat if carbon deposits result in a calculated dimension of over 3 000 mm NOTICE Do not lap the valves They are titanium and h...

Page 78: ... and 1 2 molybdenum disulfide grease containing more than 3 molybdenum disulfide additive Moly Paste 77 to the following parts camshaft cam lobes 7 journal surfaces 8 decompressor weight 5 plunger 4 5 Remove the sealing bolt 9 and sealing washer 10 6 Insert the rocker arm shaft stopper bolt 11 aligning the cut out of the rocker arm shaft 12 with the rocker arm shaft stopper bolt by rotating a suit...

Page 79: ... on the cam sprockets align with the cylinder head mating surface 22 Make sure that the intake camshaft cam lobe 7 is in position as shown 12 Clean the threads of the cam sprocket bolt 23 and intake cam sprocket 17 thoroughly Install and temporarily tighten the cam sprocket bolt 13 Remove the rocker arm shaft stopper bolt 11 NOTICE Do not let the cam sprocket bolt and rocker arm shaft stopper bolt...

Page 80: ...bolts B bolts washers and rocker arm shaft stopper bolt fall into the crankcase 16 Remove the tensioner stopper 30 from the cam chain tensioner lifter 31 Tensioner stopper 07AMG 001A100 17 Make sure that the piston is at TDC on the compression stroke page 69 Check that the timing marks 21 on the cam sprockets aligns with the cylinder head mating surface 22 18 Install a new sealing washer 32 and th...

Page 81: ...et bolt to the specified torque 15 lbf ft 20 N m 2 0 kgf m NOTICE Do not let the cam sprocket bolt fall into the crankcase 22 Install the cam chain guide 35 with the mark 36 facing forward Install and tighten the cam chain guide bolts 37 to the specified torque 7 lbf ft 10 N m 1 0 kgf m NOTICE Do not let the cam chain guide bolts fall into the crankcase 23 Rotate the camshaft by rotating the flywh...

Page 82: ...ed torque 4 4 lbf ft 6 0 N m 0 6 kgf m 1 Apply liquid sealant TB1207B or equivalent to the cylinder head semi circular cut outs 1 as shown after cleaning these area 2 Apply liquid sealant TB5211B or equivalent to the cylinder head cover groove 2 as shown after degreasing the groove and install the cylinder head cover packing 3 into it Crankshaft Timing Hole Cap Installation 1 O rings new 3 timing ...

Page 83: ...oil bolts 9 to the specified torque 7 lbf ft 10 N m 1 0 kgf m Connect the ignition coil A connector 10 to the blue terminal 11 Connect the ignition coil B connector 12 to the black terminal 13 6 Install the spark plug page 67 7 Connect the spark plug cap 14 and breather tube 15 8 Install the fuel tank and seat page 33 35 4 rubber seals 5 UP marks 4 rubber seals 6 cylinder head cover 7 cylinder hea...

Page 84: ...ve the cam chain guide camshaft holder intake cam sprocket camshafts and shims page 70 11 Disconnect the ECT sensor connector 1 12 Pull the harness band clip 2 while pressing both side of the anchor and disconnect it 13 Loosen the left radiator hose clamp screw 3 and disconnect the left radiator hose 4 14 Loosen the right radiator hose clamp screw 5 and disconnect the right radiator hose 6 15 Loos...

Page 85: ... bolts in a crisscross pattern in two or three steps NOTICE Do not let the washers and cam chain fall into the crankcase 20 Remove the dowel pins 19 and cylinder head gasket 20 NOTICE Do not let the dowel pins and cam chain fall into the crankcase 10 cylinder head hanger bolts 11 cylinder head hanger plate bolts 12 left cylinder head hanger plate 13 right cylinder head hanger plate Left side 11 12...

Page 86: ...ing the piston 4 NOTICE Do not let the cam chain fall into the crankcase Do not pry on or strike the cylinder 3 Remove the dowel pins 5 and cylinder gasket 6 NOTICE Do not let the cam chain and dowel pins fall into the crankcase Cylinder Removal 1 cylinder bolt 2 sealing washer 2 1 3 cylinder 4 piston 4 3 5 dowel pins 6 cylinder gasket 6 5 ...

Page 87: ...s or about every 15 0 hours of running NOTICE Be careful not to damage or give a shock to the piston pin Do not clean the piston pin using a commercially available compound cleaner Spread each piston ring 1 and remove by lifting it up at a point just opposite the gap NOTICE Do not damage the piston ring by spreading the ends too far We recommend you consult an official Honda Service Manual or your...

Page 88: ...installing the piston 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 1 Place a clean shop towel 1 over the crankcase opening to keep the piston pin clips from falling into the crankcase 2 Apply molybdenum disulfide oil a mixtur...

Page 89: ...NOTICE Be careful not to damage or give a shock to the piston pin 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 cutout 8 1 Clean the cylinder mating surfaces 1 of the crankcase being careful not to let any material fall into the crankcase 2 Remove the shop towels 3 Install the dowel pins 2 and a new cyl...

Page 90: ...l pins fall into the crankcase 3 Route the cam chain 3 through the cylinder head and install the cylinder head 4 NOTICE Do not damage mating surfaces when installing the cylinder head Do not let the cam chain fall into the crankcase 4 Apply engine oil to all cylinder head B bolt threads and seating surface Install the washers 5 and cylinder head B bolts 6 and tighten them to the specified torque i...

Page 91: ...te bolts to the specified torque cylinder head hanger bolts 40 lbf ft 54 N m 5 5 kgf m cylinder head hanger plate bolts 24 lbf ft 32 N m 3 3 kgf m 8 Install the throttle body 13 to the insulator 14 by aligning the tab of the throttle body with the groove of the insulator and tighten the insulator band screw 15 so the distance between the band ends is 0 43 0 04 in 11 0 1 0 mm 7 cylinder head A bolt...

Page 92: ...16 Install the crankshaft hole cap and timing hole cap page 77 17 Install the cylinder head cover page 77 18 Install the spark plug page 67 19 Install the left and right exhaust pipes page 118 20 Install the subframe page 38 and left and right mufflers page 116 21 Install the fuel tank and seat pages 33 35 22 Fill and bleed the cooling system page 145 Check for the following compression leaks abno...

Page 93: ...ormance of your CRF s front suspension Periodically check and clean all front suspension parts to assure top performance Check the dust seals for dust dirt and foreign materials Check the oil for any contamination Refer to Suspension Adjustment Guidelines page 135 Make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pa...

Page 94: ...ion 1 Unlock the number plate tab 3 from the handlebar pad Remove the number plate bolts 4 and number plate 5 2 Place your CRF on an optional workstand or equivalent support with the front wheel off the ground 3 Remove the handlebar lower holder nuts washers mounting rubbers 6 and handlebar 7 NOTICE Keep the master cylinder upright to prevent air from entering system Front Suspension Removal 1 com...

Page 95: ... wheel with collars 17 9 Remove the brake hose clamp bolts 18 stay A 19 and stay B 20 10 Remove the front brake caliper mounting bolts 21 and brake caliper 22 Do not support the brake caliper by the brake hose Do not operate the brake lever after the front wheel is removed To do so will cause difficulty in fitting the brake disc between the brake pads 11 Remove the fork protector socket bolts 23 a...

Page 96: ...Gently slide the outer tube down onto the lower end axle holder 4 Lock nut wrench 07WMA KZ30100 NOTICE The outer tube 1 can drop on the axle holder 4 and damage the fork dust seal 5 To avoid damage hold both the outer tube and slider when removing the fork damper 3 Drain the fork oil from the outer tube 1 and oil holes 6 of the fork damper assembly 2 Remove the O ring 7 from the fork damper assemb...

Page 97: ... the remaining oil in the fork from the recommended standard fork oil capacity Refer to Front Suspension Air Pressure on page 127 2 Apply the recommended fork oil to a new O ring 2 Install the O ring on the fork damper assembly 3 3 Pull up the outer tube 1 slowly and temporarily tighten the fork damper assembly 3 using the lock nut wrench 4 Lock nut wrench 07WMA KZ30100 1 outer tube Amount of fork...

Page 98: ...leverage so the torque wrench reading will be less than the torque actually applied to the fork damper assembly 3 Tighten the fork bolt assembly 4 to the specified torque 22 lbf ft 30 N m 3 1 kgf m 4 For ease of releasing air pressure after the fork legs are installed loosen the fork bridge lower pinch bolts 1 and position the outer tubes so that the fork air pressure release screw 5 is in front o...

Page 99: ...ith the left fork leg making sure that the brake hose is not twisted An improperly routed brake hose may rupture and cause a loss of braking efficiency 10 Align the lower surface of the brake hose protector 14 stay A 15 and stay B 16 and assemble them Install and tighten them to the left fork protector securely using the brake hose clamp bolts 17 11 Clean the threads of the front brake caliper mou...

Page 100: ...ebar 23 mounting rubbers washers and handlebar lower holder nuts 24 and tighten the handlebar lower holder nuts to the specified torque 32 lbf ft 44 N m 4 5 kgf m 16 Install the number plate 25 by aligning its tab 26 with the slit 27 on the front fender Install the number plate bolts 28 then tighten the number plate bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m Route the number plate tab...

Page 101: ...pension Damping on page 128 1 Remove the front suspension page 89 2 Disassemble the fork outer tube page 91 3 Place the lower end axle holder 1 of the slider in a vise with a piece of wood or soft jaws to avoid damage NOTICE Over tightening the vise can damage the axle holder 4 Loosen the fork center bolt 2 5 Pull up the fork outer tube slowly and temporarily tighten the fork damper assembly page ...

Page 102: ...r tube NOTICE Be careful not to damage the lock nut and fork center bolt hole 10 Remove the fork damper assembly 6 from the fork assembly 7 Remove the fork from the vise Remove the fork spring 8 spring seat collar 9 and back up ring seat stopper 10 from the fork assembly NOTICE Do not attempt to separate the fork assembly and drop the axle holder out from the outer tube which can damage the guide ...

Page 103: ...e fork bolt bushings Do not disassemble the fork bolt assembly Replace the fork bolt as an assembly if it is damaged 5 Empty the fork oil from the fork damper assembly 4 by pumping the damper rod several times 6 Clean the fork bolt and fork damper assembly threads 5 7 Extend the fork damper piston rod to maximum length Pour the recommended fork oil into the fork damper assembly 4 Recommended Oil P...

Page 104: ...rk bolt assembly in slowly while pulling the piston rod out NOTICE Be careful not to damage the fork bolt piston ring 11 Temporarily tighten the fork bolt assembly 3 to the fork damper assembly 4 12 Completely screw in the fork center bolt lock nut 1 to the fork damper piston rod 2 13 Check the fork damper piston rod sliding surface and threads for damage 2 fork damper piston rod 4 fork damper ass...

Page 105: ...ork damper assembly 4 by pumping the fork damper piston rod to full stroke 16 Drain the extra oil from the oil holes 9 of the fork damper assembly 4 By doing above procedure about 0 2 US oz 5 cm3 of fork oil will be drained from the fork damper through the oil hole and cause 8 2 US oz 243 cm3 of fork oil to be left in the fork damper assembly Pour the drained oil into a suitable container and disp...

Page 106: ...ton rod for smooth operation If the piston rod operation is not smooth check the piston rod for bends or damage 1 Turn the fork assembly 1 by placing it upside down About 0 2 US oz 5 4 cm3 of fork oil will be left in the outer tube slider when it is left inverted for about 20 minutes at 68 F 20 C To properly dispose of drained fluids refer to You the Environment on page 146 NOTICE Improper disposa...

Page 107: ... damper assembly 9 to the outer tube 10 using the lock nut wrench 11 Lock nut wrench 07WMA KZ30100 6 Place the lower end axle holder 12 of the slider in a vise with a piece of wood or soft jaws to avoid to damage NOTICE Over tightening the vise can damage the axle holder 7 Push the outer tube until the fork center bolt lock nut 2 is fully exposed and install the piston base 13 or mechanic s stoppe...

Page 108: ...r bolt installation 11 Tighten the fork center bolt lock nut 2 to the fork center bolt 17 closely by hand Tighten the fork center bolt lock nut to the specified torque 21 lbf ft 28 N m 2 9 kgf m 12 Apply locking agent to the fork center bolt threads Remove the piston base or mechanic s stopper tool while pushing the fork damper Install the fork center bolt 17 to the axle holder and tighten it to t...

Page 109: ...uspension settings before attempting to adjust the rear suspension Refer to Suspension Adjustment Guidelines page 137 for making all rebound and compression damping adjustments in one click or 1 12 turn increments Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turni...

Page 110: ...nut 2 3 To position the front brake lever farther away from the handgrip turn the adjuster 3 clockwise To position the front brake lever closer to the handgrip turn the adjuster counterclockwise 4 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 5 Apply silicone grease to the contacting areas of the adjuster and knocker arm 4 6 Install the front ...

Page 111: ... Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Rear Brake Fluid Level Check With the motorcycle in an upright position check the fluid level It should be above the LOWER mark 1 If the level is at or below the LOWER mark check the brake pads for wear page 108 Worn brake pads should be replaced If the pads are not worn have your brake system inspected...

Page 112: ... m 0 1 kgf m Adding Rear Brake Fluid NOTICE Spilled brake fluid will severely damage 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 DOT 4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended b...

Page 113: ...s 1 from the rear side of the caliper to determine the brake pad wear If either brake pad is worn anywhere to a thickness of 0 04 in 1 0 mm both brake pads must be replaced Check that the front brake lever and rear brake pedal assemblies are positioned properly page 105 and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings B...

Page 114: ... s also important that the rim locks are secure to prevent tire slippage 1 Inspect the wheel rim 1 and spokes 2 for damage 2 Tighten any loose spokes and rim lock 3 to the specified torque Spokes 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Lock 9 lbf ft 12 N m 1 2 kgf m 3 Check wheel rim runout If runout is noticeable see an official Honda Service Manual for inspection instructions See an official Honda Serv...

Page 115: ...t air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Take time to inspect your tires and wheels before you ride Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a b...

Page 116: ...speed rating and load range as the original 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 Tire Replacement 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...

Page 117: ...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 NOTICE 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 binding links excessive wear Replace the drive chain page 114 i...

Page 118: ...e 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 3 Tighten the rear axle nut to the specified torque 94 lbf ft 128 N m 13 1 kgf m 4 Recheck chain slack and adjust as necessary 5 Turn the adjusting bolt counterclockwise until it touches the axle plates lightly Then tighten the chain adjuster lock nuts to the specified tor...

Page 119: ...nd any kinked joints straightened measure the distance between a span of 17 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service 8 Lubricate the drive chain page 113 9 Pass the chain over the sprockets and join the ends of the chain with t...

Page 120: ...r cleaner housing cover 2 by removing the side cover air cleaner housing cover bolts 3 The procedure is the same for the both right and left side 3 Loosen the right muffler clamp bolt 4 and washer 5 4 Remove the right muffler mounting A bolt 6 B bolt 7 washer 8 and right muffler 9 Exhaust Pipe Muffler Inspection Muffler Removal 1 side cover 2 air cleaner housing cover 3 side cover air cleaner hous...

Page 121: ...pecified torque 15 lbf ft 20 N m 2 0 kgf m 7 Remove the gasket 1 8 Install a new gasket onto the exhaust pipe 2 9 Align the cutout 3 of the right muffler 12 with the tab 5 of the right muffler clamp 13 10 Install the right muffler 12 10 left muffler clamp bolt 11 washer 12 left muffler mounting A bolt 13 left muffler mounting B bolt 14 washer 15 left muffler 10 11 13 14 12 15 Muffler Installation ...

Page 122: ...ng cover 19 and side cover 20 while air cleaner housing cover tab 21 insert to the seat support base slot 22 and then tighten the side cover air cleaner housing cover bolts 23 to the specified torque 7 lbf ft 10 N m 1 0 kgf m The procedure is the same for the both right and left side 16 Install the seat page 33 14 washer 15 right muffler mounting B bolt 16 right muffler mounting A bolt 17 right mu...

Page 123: ...116 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 5 Tighten the left muffler clamp bolt left muffler mounting A bolt and B bolt page 116 6 Tighten the right muffler clamp bolt right muffler mounting A bolt and B bolt page 117 Exhaust Pipe Removal 1 exhaust pipe joint nuts 2 left exhaust pipe 3 right exhaust pipe 4 exhaust ...

Page 124: ...ent procedures or see your dealer 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its original position where the end of the right handlebar holders 2 is aligned with the paint mark 3 3 Check the torque of the handlebar upper holder bolts 4 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first Periodically disconnect the throttle and clutch cables at th...

Page 125: ...utch cover A bolts 7 10 1 0 8 Clutch cover B bolts 7 10 1 0 9 Cylinder bolt 7 10 1 0 10 Cylinder head A bolts 7 10 1 0 11 Cylinder head B bolts 35 48 4 9 12 Drive sprocket bolt 23 31 3 2 13 Crankshaft hole cap 11 15 1 5 14 Timing hole cap 4 4 6 0 6 1 cylinder head cover socket bolts 2 exhaust pipe joint nuts 3 water pump cover bolts 4 coolant drain bolt 5 oil filter cover bolts 6 engine oil drain ...

Page 126: ...ment The voltage may read above 12V even with a blown battery fuse when the battery is unmounted page 151 Before you remove the battery be sure to read all the information that follows as well as the information on the battery label If you do not remove the battery we recommend disconnecting the battery cables negative cable first The battery is located under the seat Removal 1 Remove the seat pag...

Page 127: ... may damage the battery We recommend using a charger recommended by your lithium ion li ion battery manufacturer which can be purchased from your dealer These units can be left connected for long periods without risking damage to the battery However the lithium ion li ion battery may degrade if stored with a charger connected Do not intentionally leave the charger connected longer than the time pe...

Page 128: ...abrite 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 Pro Honda Hondabrite and rinse with a low pressure garden hose at full pressure Stubborn deposits may require a quick wipe with a sponge Allow the engine muffler brakes and other high temperature parts to cool befo...

Page 129: ...nd a mild detergent then rinse well with clean water Dry the frame with a soft clean cloth using strokes parallel to the length of the frame NOTICE Do not use steel wool to clean the frame as it could damage or discolor the frame surface Scotch Brite Hand Pad 7447 maroon is for removing stains on the non coated aluminum frame only The fuel tank is made of titanium material To remove mud or dust us...

Page 130: ...mpetition 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 Engine Mode Select Button 126 Current Mode 126 Mode Selection 126 Front Suspension Adjustments 127 Front Suspension Air Pressure 127 Front Suspension Damping 128 Fork Springs 128 Fork Oil Adjustment 129 Rear Suspensi...

Page 131: ...Start the engine 2 With your CRF stopped and the throttle closed push and hold the engine mode select button for 1 or more second Make sure that the fast idle knob is pushed in page 17 If the fast idle knob is pulled out the engine mode will not change 3 Release the engine mode select button The mode indicator will indicate a selected mode by the number of times the indicator blue blinks 4 Repeat ...

Page 132: ...and affects the entire range of fork travel This means the fork action on your CRF will get stiffer during a race For this reason release built up air pressure in the fork legs between motos Be sure the fork is fully extended with the front tire off the ground when you release the pressure The standard air pressure is 0 psi 0 kPa 0 kgf cm2 You may relieve accumulated air pressure in the fork legs ...

Page 133: ...l hard when adjusting damping Do not turn the adjuster screw more than the given positions or the adjuster may be damaged Be sure that the compression and rebound damping adjusters are firmly located in a detent and not between positions Both compression and rebound damping can be increased by turning the adjuster clockwise The fork springs in CRF s are about right for riders weighing between 170 ...

Page 134: ...fter as it nears full compression Standard 26 3 lbf in 4 6 N mm Fork Spring 1 scribe mark Force N Stroke mm Oil capacity 13 3 US oz 392 cm3 MAX Oil capacity 12 0 US oz 356 cm3 STANDARD Oil capacity 10 4 US oz 307 cm3 MIN Standard oil capacity 12 2 US oz 361 cm3 Maximum oil capacity 13 4 US oz 397 cm3 Slightly stiffer as it nears full compression Minimum oil capacity 10 6 US oz 312 cm3 Slightly sof...

Page 135: ...g 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 After adjustment hold the adjusting nut and tighten the shock spring lock nut to the specified torque 32 lbf ft 44 N m 4 5 kgf m Refer to the following pages for the installation procedure of the removed parts subframe page 38 To increase spring pre load Loosen the shock...

Page 136: ... or more To adjust to the standard position 1 Turn the adjuster clockwise harder until it will no longer turn lightly seats 2 Turn the adjuster counterclockwise softer 3 1 4 3 3 4 turns and adjust it until the punch mark 3 on the adjuster and the punch mark 4 on the adjuster body are aligned Low Speed Damping The low speed damping can be adjusted by turning the center screw of the compression damp...

Page 137: ... with you on the seat As a general rule of thumb the race sag dimension should be about one third of the maximum travel On your CRF ride height is changed by adjusting the rear suspension spring pre load Spring Pre load Race Sag Adjustment The following adjustment procedure establishes the correct starting point for any suspension tuning the proper rear suspension spring preload adjustment for you...

Page 138: ...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 to unload too much in t...

Page 139: ...ty In a muddy event stiffer optional springs front and rear may help especially if you are heavier than the average rider Your CRF may be under sprung 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 setting as normal but run softer dam...

Page 140: ...ing in one click increments Middle travel too soft Front end dives when cornering 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 click increments Test softer compression damping adjustments in one click increments If that doesn t solve ...

Page 141: ...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 adjustment in one click increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on ...

Page 142: ...high speed compression damping adjustments simultaneously Suspension feels stiff on large bumps 1 Test softer high speed compression damping adjustment 2 If it still feels stiff further test softer low and high speed compression damping adjustments simultaneously Entire travel too stiff 1 Test softer high and low speed compression damping adjustments and rebound damping adjustment simultaneously 2...

Page 143: ... 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 An improperly tightened spark plug can damage the engine If a plug is too loose the piston may be damaged If a plug is too tight the threa...

Page 144: ...ce sag adjustment page 132 in the 3 7 4 5 in 95 115 mm range The position of the fork in the clamp is not adjustable Standard Position The groove 1 in the outer tube is aligned with the top surface of the upper fork bridge 2 Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the wheelbase...

Page 145: ... 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 up...

Page 146: ...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 147: ... CRF Position the handlebar so that both gripping the bar and operating the controls are comfortable while both seated and standing while riding straight ahead and turning Tighten the forward handlebar upper holder bolts first The handlebar position may be moved rearward either 0 1 in 3 mm using optional handlebar lower holders or 0 2 in 6 mm by rotating the standard holders 180 degrees Refer to a...

Page 148: ... on how to transport and store your CRF as well as three troubleshooting flow charts Transporting Your Motorcycle 144 Storing Your Honda 145 Preparation for Storage 145 Removal from Storage 145 You the Environment 146 Troubleshooting 147 ...

Page 149: ...wheel against the front of the truck bed or trailer rail Attach the lower ends of two straps to the tie down hooks on truck bed or trailer rail 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 compr...

Page 150: ...e 122 once a month 9 Inflate the tires to their recommended pressures 10 Place your CRF on an optional workstand or equivalent to raise both tires off the ground 11 Stuff a rags into the muffler outlets Then tie a plastic bags over the ends of the mufflers to prevent moisture from entering 12 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature...

Page 151: ...w cleaning solvents away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline coolant 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 container...

Page 152: ...uel contaminated ENGINE LACKS POWER CHECK POSSIBLE CAUSES 1 Check the wheel spin smoothness Brake dragging Worn or damaged wheel bearings Bent axle shaft Drive chain too tight 2 Check the tire pressure P 110 Faulty valve core Punctured tire 3 Check the engine speed change accordingly when clutch is engaged Clutch slipping Improperly adjusted clutch lever freeplay P 62 Worn clutch discs plates P 65...

Page 153: ...k plug wire Faulty CKP sensor Loose or disconnected ignition system wires Faulty engine stop button Faulty regulator rectifier Faulty battery CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT CORRECT INCORRECT WEAK OR INTERMITTENT SPARK POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Check the ignition timing Faulty ECM Faulty CKP sensor 2 Check the a...

Page 154: ...Taking Care of the Unexpected Taking Care of the Unexpected 149 This section gives practical advice to help you solve problems If a Fuse Blows 150 If Your Battery Is Low or Dead 151 ...

Page 155: ...e spare main fuse 7 8 Install the starter relay switch cover 4 9 Install the starter relay switch 3 Install and tighten the starter relay switch stay bolt 1 to the specified torque 9 lbf ft 12 N m 1 2 kgf m 10 Install the plastic wire band 2 If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating NOTICE Replacing a fuse with one that has a highe...

Page 156: ... damage your CRF s electrical system and battery Bump starting is not recommended Check the battery voltage using a digital multi meter with the cable connected Below 1V The battery has failed replace the battery Between1V and 8V The battery may have failed charge the battery and then recheck If you can t charge the battery or it appears unable to hold a charge see your dealer ...

Page 157: ...152 Taking Care of the Unexpected 1 3 ...

Page 158: ...le Identification 154 Serial Numbers 154 Specifications 155 Torque Specifications 156 Nuts Bolts Fasteners 156 Oxygenated Fuels 159 Competition Logbook 160 Optional Parts List 162 Spare Parts Equipment 163 Spare Parts 163 General Tools 163 Honda Special Tools 163 Chemical Products 163 Other Products 163 Wiring Diagram 164 ...

Page 159: ...your CRF They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head The engine number 2 is stamped on the left crankcase Serial Numbers 1 VIN 1 2 engine number 2 ...

Page 160: ...amper 8 2 US oz 243 cm3 Item English Metric Engine Type Liquid cooled 4 stroke Cylinder arrangement Single 9 inclined from vertical Bore and stroke 3 1102 x 2 003 in 79 000 x 50 887 mm Displacement 15 215 cu in 249 43 cm3 Compression ratio 13 9 1 Valve clearance cold Intake 0 004 0 001 in 0 11 0 03 mm Exhaust 0 007 0 001 in 0 19 0 03 mm Engine oil capacity 1 14 US qt 1 08 ℓ after draining after dr...

Page 161: ...t nuts 15 21 2 1 3 Water pump cover bolts 7 10 1 0 4 Coolant drain bolt 7 10 1 0 5 Oil filter cover bolts 7 10 1 0 6 Engine oil drain bolt 12 16 1 6 NOTE 1 7 Clutch cover A bolts 7 10 1 0 8 Clutch cover B bolts 7 10 1 0 9 Cylinder bolt 7 10 1 0 10 Cylinder head A bolts 7 10 1 0 11 Cylinder head B bolts 35 48 4 9 NOTE 1 12 Drive sprocket bolt 23 31 3 2 13 Crankshaft hole cap 11 15 1 5 NOTE 2 14 Tim...

Page 162: ...7 12 Driven sprocket nuts 24 32 3 3 NOTE 1 13 Spokes front 2 7 3 7 0 4 rear 2 7 3 7 0 4 14 Chain adjuster lock nuts 20 27 2 8 NOTE 2 15 Cylinder head hanger plate bolts 24 32 3 3 16 Cylinder head hanger bolts 40 54 5 5 17 Engine guard B bolt washer 7 10 1 0 18 Front engine hanger nut 40 54 5 5 19 Engine guard A bolts washers 7 10 1 0 20 Front engine hanger plate nuts 19 26 2 7 21 Disc cover socket...

Page 163: ...3 Rear shock arm nut swingarm side 38 52 5 3 NOTE 1 4 44 Rear axle nut 94 128 13 1 NOTE 1 45 Rear brake disc nuts 12 16 1 6 NOTE 1 46 Rim locks 9 12 1 2 47 Rear shock arm nut shock link side 38 52 5 3 NOTE 1 4 48 Rear suspension nut lower 32 44 4 5 NOTE 1 49 Rear shock link nuts 27 37 3 8 NOTE 1 4 50 Rear brake reservoir cap bolts 0 7 1 0 0 1 51 Rear master cylinder push rod lock nut 4 4 5 9 0 6 5...

Page 164: ...ol by volume Gasoline containing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by Volume You may use gasoline containing up to 5 methanol by volume as long as it also 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 met...

Page 165: ...airs 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 record your time ...

Page 166: ...Logbook Technical Information 161 Date Running Time Location Event Comments Suspension Settings Engine mode Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use ...

Page 167: ...th Aluminum 114 Standard Optional 49 Teeth Aluminum Drive chain size link D I D 520 DMA4K 120RB Handlebar lower holder Standard 0 1 in 3 mm offset Optional no offset TOOLS Remarks Pin spanner A To adjust spring preload two spanners required Workstand For maintenance Air gauge For checking tire air pressure FRAME Remarks Fork spring Standard 26 3 lbf in 4 6 N mm Optional Soft 25 1 lbf in 4 4 N mm S...

Page 168: ...tandard needle nose channel lock set hammer plastic head syringe with adjustable stop air pressure gauge tire irons tire pump or air tank feeler gauge set Vernier caliper metric pressure vacuum testing equipment Any special tools for your CRF purchased from your dealer Tensioner Stopper 07AMG 001A100 Lock Nut Wrench 07WMA KZ30100 Spoke Wrench 07JMA MR60100 Spoke Wrench 070MA KZ30100 Piston Base 07...

Page 169: ... Brown O Orange Lg Light Green P Pink Gr Gray Bl Y Bl R G Bl Y Bl R Bl R Bl R G O Bu Bl G Lg Bl W O O G Bl Bl G G G W Y Bu G G R P G R R Y Y G G R R Y G Y Bl G Y Bl G Bl R W W Bl Bl Y R W Bl G Bl Y Y Y Y G G Bl Bl G R Gr Bu Y Y Y Bu Y W Y Y Y Y Bu Y W Y Bl Bu Bl G W Bu Lg G Bu Bl G Lg Bl W Bl W G Bl O Bl G W Bl W W Bl Lg Br G P W O G Bu Bl G Y G R G R G R G R G R G R R Y R Y R Y Bl Y Bl Y Bl Y Y G...

Page 170: ...umer Information 165 This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 166 Contacting Honda 167 Your Honda Dealer 168 The Honda Rider s Club USA only 169 ...

Page 171: ...ide in conjunction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage 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 Order On Line www helminc com Order...

Page 172: ...dealership level If you wish to comment on your experiences with your CRF or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 Mailstop 100 4C 7B Telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 ...

Page 173: ... Honda Genuine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your Honda dealer can inform you about competition events in your area You ll also find that your dealer is a source of in...

Page 174: ...The Honda Rider s Club USA only Consumer Information 169 The Honda Rider s Club of America HRCA sponsors local riding chapters at Authorized Honda Dealerships across the country ...

Page 175: ... 112 chassis adjustments 139 cleaner air 56 cleaning appearance care 123 clutch system adjustment 62 competition logbook 160 consumer information 165 contacting Honda 167 controls 5 coolant 54 customer service 165 cylinder system 81 damping adjustments front 127 rear 131 dealer your Honda 168 diagram wiring 164 drive chain 112 R engine does not start 147 idle speed 61 lacks power 147 mode select b...

Page 176: ...mponent locations 6 optional parts list 162 sprockets 140 oxygenated fuels 159 pads brake 108 parts optional 162 personal fit adjustments 142 pinging engine 41 piston piston rings piston pin 79 plug spark 67 pre load rear suspension 130 pre ride inspection 13 protective apparel 2 rear suspension adjustment 130 Rider s Club Honda USA only 169 riding apparel 2 basic operation 15 before 11 important ...

Page 177: ...e freeplay 59 inspection 60 lubrication 60 tires air pressure 110 flat 110 selection 111 tools 163 torque specifications engine 156 frame 157 158 transporting 144 troubleshooting 147 tubes replacing 110 tuning tips 138 valve clearance 68 vehicle identification no VIN 154 washing your motorcycle 123 wheels 109 wiring diagram 164 T V W ...

Page 178: ...r 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 and every 12 races or about 30 0 hours Pre ride Inspection Check the items listed on the Pre ride Inspection checklist each time before you ride page 13 Fuel Tank Capacity unleaded gasoline pump octane number of 91 or higher tank 1 66 US gal 6 3 ℓ Engine Oil Capacity Pro Honda GN4...

Page 179: ...ates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle ...