Honda CRF250X, Owner'S Manual & Competition Handbook

Page 1: ...HONDA CRF250X OWNER S MANUAL COMPETITION HANDBOOK ...

Page 2: ... ONLY This motorcycle is designed and manufactured for recreational off road use or competition only and is covered by noise control warranty It does not conform to federal motor vehicle safety standards and operation on public streets roads or highways is illegal If you need to cross a paved or public road get off and walk your motorcycle across Do not modify any emission related items except for...

Page 3: ...2005 Honda CRF250X OWNER S MANUAL COMPETITION HANDBOOK ...

Page 4: ... exclusions which apply to this warranty Please read the Honda Motorcycle Warranties Booklet given to you by your Honda dealer at the line of purchase Be sure to keep your Honda owner s card USA only with your Warranties Booklet It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship Your warranty coverage does not apply to normal wear or ...

Page 5: ... will find important safety information in a variety of forms including Safety Labels on the motorcycle Safety Messages 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 ...

Page 6: ... Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74 Chassis Suspension 82 Brakes 86 Wheels 90 Tires Tubes 91 Side Stand 93 Drive Chain 94 Additional Maintenance Procedures 97 Electrical Battery 99 Headlight Taillight 100 Appearance Care 101 ADJUSTMENTS FOR COMPETITION 103 Front Suspension Adjustments 104 Rear Suspension Adjustments 118 Suspension Adjustments for...

Page 7: ...dations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Important Safety Precautions 2 Loading 3 Accessories Modifications 4 Safety Labels 5 Motorcycle Safety 1 ...

Page 8: ...ep your motorcycle properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from your base To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance 2 Motorcycle Safety exhaust system Wear clothing that fully covers your legs Do not wear loose clothing which could catch on the con...

Page 9: ...our safety If you decide to carry cargo you should be aware of the following information Loading Guidelines As discussed on page 4 we recommended that you do not carry any cargo on this motorcycle However if you decide to carry cargo ride at reduced speeds and follow these commonsense guidelines Keep cargo small and light Make sure it cannot easily be caught on brush or other objects and that it d...

Page 10: ...quipment or modify your motorcycle in any way that would change its design or operation Such changes could seriously impair your motorcycle s handling stability and braking making it unsafe to ride We also advice you not to make any modifications or remove any equipment such as the USDA qualified spark arrester or emission control system components that would make the motorcycle illegal in your ar...

Page 11: ...els on your motorcycle Some labels warn you of potential hazards that could cause serious injury Othere provide important safety information Read these labels carefully and don t remove them If the label comes off or becomes hard to read contact your Honda dealer for replacement ...

Page 12: ...6 Motorcycle Safety ...

Page 13: ...Operating Controls 7 Operating Controls Read this section carefully before you ride It presents the location of the basic controls on your motorcycle Component Locations 8 ...

Page 14: ...trols Component Locations clutch lever hot start lever front brake lever engine stop button fuel fill cap throttle grip tripmeter start button choke knob fuel valve shift lever side stand kickstarter rear brake pedal ...

Page 15: ... get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your motorcycle For information about suspension carburetion and other adjustment see page 103 Before Riding Are You Ready to Ride 10 Is Your Motorcycle Ready to Ride 11 Pre ride Inspection 11 ...

Page 16: ...ther adjustments see page 103 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 wearing a...

Page 17: ...e speed for stable and proper RPM 132 Tires for damage or improper inflation pressure 91 Spokes for looseness 90 Rim locks for looseness 90 Front and rear suspension for proper operation 82 83 Front and rear brakes check operation 87 Drive chain for wear or damage and adequate lubrication 94 Drive chain guide sliders and guide rollers for damage or wear 96 Exhaust pipe Muffler inspection removal a...

Page 18: ...12 Before Riding ...

Page 19: ...information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 14 Starting Stopping the Engine 15 Preparation 15 Fuel Valve 15 Starting Procedure 15 Flooded Engine 16 How to Stop the Engine 16 Shifting Gears 17 Braking 18 Parking 19 Post ride Inspection 20 Break in Guidelines 21 ...

Page 20: ...first time please review the Important Safety Precaution beginning on page 2 and the previous section titled Before Riding For your safety avoid starting or operating the engine in an enclosed area such as a garage Your motorcycle s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death 1 side stand 1 tripmeter 2 tripmeter reset knob...

Page 21: ...ot start lever 3 and start the engine following step 3 under Normal Air Temperature 2 As soon as the engine starts release the hot start lever NOTICE NOTICE Basic Operating Instructions 15 1 fuel valve The three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel...

Page 22: ...he engine starts release the hot start lever Using the kickstarter 1 Do not use the choke 2 Shift the transmission into neutral with the throttle fully opened repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine 3 Pull the hot start lever and start the engine Do not open the throttle 4 As soon as the engine starts release the hot start lever 1...

Page 23: ... 2 Pull the clutch lever all the way in 3 Depress the shift lever from neutral down to first gear 4 Release the front brake Gradually open the throttle while you slowly release the clutch lever If the engine rpm speed is too low when you release the clutch lever the engine will stall If the engine rpm speed is too high or you release the clutch lever too quickly your motorcycle may lurch forward 5...

Page 24: ... reduce your speed or complate braking before beginning a turn Avoid braking or closing the throttle quickly while turning Either action may cause one or both wheels to slip Any wheel slip will reduce your control of your motorcycle When riding in wet or raining conditions or on loose surfaces the ability to maneuver and stop will be reduced All of your actions should be smooth under these conditi...

Page 25: ...Parking Lower the side stand to support your motorcycle If you re through riding for the day also turn the fuel valve OFF Always choose a level place to park Basic Operating Instructions 19 ...

Page 26: ...n your motorcycle and remove any dirt mud brush rocks or other objects you may have picked up along the way After cleaning carefully inspect your motorcycle for leaks or damage Be sure to lubricate the drive chain page 96 to prevent rusting 20 Basic Operating Instructions ...

Page 27: ...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 28: ...22 Basic Operating Instructions ...

Page 29: ...nda The Importance of Maintenance 24 Maintenance Safety 25 Important Safety Precautions 25 Maintenance Schedule 26 General Competition Maintenance 29 Before After Competition Maintenance 33 Between Motos Practice Maintenance 33 After Competition Maintenance 33 Service Preparations Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Fil...

Page 30: ...e ridden over rough off road terrain To help you properly care for your motorcycle this section of the manual provides a Maintenance Schedule The service intervals in this schedule are based on average riding conditions More frequent service is needed if you subject your motorcycle to severe use or ride in unusually wet or dusty areas Frequent servicing of the air cleaner is especially important t...

Page 31: ...hot motorcycle parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side stand or a maintenance stand to provide support To reduce the ...

Page 32: ... days as well as miles To avoid overlooking required service we urge you to develop a convenient way to record the number of days and or miles you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda part...

Page 33: ... I I I R I L I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I I I I R I I I I I I I I I I C I I I R R I I I R I I I I I I C I C I I I R R I I R I I R I I I I I I I I I I 41 42 55 51 53 61 66 44 44 132 49 50 49 47 94 96 96 87 89 87 100 56 93 82 83 65 98 90 91 97 FREQUENCY ITEMS EMISSION REALATED ITEMS NON EMISSION REALATED ITEMS NOTE mi km Month 100 150 1 600 1 000 6 1 200 2 000 12 I...

Page 34: ...SPROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE MUFFLER SUSPENSION SWINGARM SHOCK LINKAGE FORK OIL NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS NOTE 1 NOTE 2 NOTE 4 NOTE 3 NOTE 3 NOTE 5 NOTE 2 NOTE 5 NOTE 3 55 60 51 53 61 48 66 44 44 132 76 76 46 48 94 96 96 95 95 87 89 86 56 97 62 82 83 32 84 109 98 90 91 97 I I C I I I I I I I I L I I I I I...

Page 35: ...le 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 reassembly check all parts for proper installation and operation All Pre rid...

Page 36: ... replacing it with a pre serviced air cleaner between motos Be careful not to over oil the air cleaner While it is important to oil the air cleaner thoroughly over oiling will cause an overall rich running condition probably more noticeable off idle and in low rpm performance Follow the servicing instructions in the Maintenance section Use Pro Honda Foam Filter Oil or an equivalent Be sure to grea...

Page 37: ...age 41 and in this supplement Fuel System page 41 Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary Periodically drain the fuel from the tank remove and clean the fuel valve and fuel strainer screen Replace the fuel valve O ring if there are any signs of damage or deterioration page 41 Loosen the exterior drain screw and examine the fuel that flows out of...

Page 38: ...ole located just below the water pump cover on the right crankcase cover Clean away any clogged dirt or sand if necessary Look for coolant or oil leakage Leaking coolant indicates a worn or damaged water seal Leaking oil indicates a bad transmission oil seal If replacement is necessary both seals should be replaced Fork Oil Performance Disassemble clean and inspect the fork and replace the oil reg...

Page 39: ... above the ground and use the pressure release screws to release the built up pressure in excess of normal atmospheric pressure 0 psi in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases 1 pressure release screws 1 1 After Competition Maintenance It is important ...

Page 40: ...re available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your motorcycle Avoid using stiff abrasive brushes on the plastic or rubber parts If your motorcycle was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal p...

Page 41: ...steering head front brake hose clutch lever shift lever transmission oil drain bolt engine oil drain bolt side stand chain slider kickstarter throttle grip front brake lever tripmeter cable right side cover rear brake pedal spark plug front wheel axle clutch lever hot start lever front brake lever engine stop button fuel fill cap throttle grip radiator cap tripmeter starter button Servicing Your H...

Page 42: ...rs Installation 1 Slide the seat front prong 4 onto the seat bracket 5 and the seat rear prong 6 onto the tab 7 by pushing down and forward on the seat in each of these areas 2 Install the collars and tighten the seat bolts 19 lbf ft 26 N m 2 7 kgf m 4 seat front prong 5 seat bracket 6 seat rear prong 7 tab 3 1 2 4 6 7 5 1 1 2 36 Servicing Your Honda ...

Page 43: ...tank bolt 7 4 breather tube 5 fuel tank band 6 air cleaner cover rubber 7 fuel tank bolt 9 Disconnect the fuel line 8 from the fuel valve 9 The fuel line leading to the carburetor must be disconnected not the fuel line leading to the fuel tank 8 fuel line 10 fuel valve bolt 9 fuel valve WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Sto...

Page 44: ... the fuel tank bolt 4 5 Hook the air cleaner cover rubber 5 6 Install the fuel tank band 6 7 Put the breather tube 7 in the steering stem nut 7 breather tube 8 Install the shrouds 8 and shroud B bolts collars 9 9 Install the shroud A bolts collars 10 8 shrouds 9 shroud B bolts collars 10 shroud A bolts collars 4 fuel tank bolt 6 fuel tank band 5 air cleaner cover rubber 38 Servicing Your Honda 4 6...

Page 45: ...leaner connecting tube clamp 15 14 screw 15 air cleaner connecting tube clamp Servicing Your Honda 39 7 Loosen the subframe mounting A bolt 16 and remove the subframe mounting B bolts 17 16 subframe mounting A bolt 17 subframe mounting B bolts 8 Lift the subframe 18 as shown 1 right side cover bolt 3 collars 2 seat bolt 4 right side cover 2 Turn the quick fastener 5 counterclockwise and remove the...

Page 46: ...me 2 subframe mounting B bolts 3 subframe mounting A bolt Installation 1 Loosely attach the lower ends of the subframe 1 to the mainframe while connecting the air cleaner connecting tube to the carburetor Then align the subframe with the rear wheel and tighten the subframe mounting B bolts 2 and subframe mounting A bolt 3 to the specified torque B bolts 22 lbf ft 30 N m 3 1 kgf m A bolt 36 lbf ft ...

Page 47: ...minated gasoline Avoid getting dirt dust or water in the fuel tank Type Unleaded Pump Octane Number 91 or higher Refueling Procedure Fuel Tank Capacity 2 19 US gal 8 3R 1 fuel fill cap 3 steering stem nut 2 breather tube 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the ...

Page 48: ...iner 2 Remove the fuel tank page 37 3 Remove the fuel filter 1 from fuel tank by removing the screws 2 Wash the fuel filter in high flash point cleaning solvent 4 Reassemble the fuel filter in the reverse order of removal Make sure the O ring 3 is in place Install the fuel filter in the fuel tank Refill the fuel tank Attach the fuel valve and fuel line and turn the fuel valve to ON or RES check fo...

Page 49: ...xcept oils labeled as energy conserving on the circular API service label suggested oil Pro Honda GN4 HP4 without molybdenum additives or HP4M with molybdenum additives 4 stroke oil or an equivalent viscosity weight SAE 10W 40 JASO T 903 MA or MB Your motorcycle 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 con...

Page 50: ...ler cap dipstick If the oil is at or near the upper level mark you do not have to add oil If the oil is below or near the lower level mark and add the recommended oil until the upper level mark Do not overfill Reinstall the engine oil filler cap dipstick Repeat steps 1 5 6 Reinsert the engine oil filler cap dipstick 7 Check for oil leaks Changing Engine Oil Filter 1 Run the engine for 3 minutes th...

Page 51: ...hen tighten the oil filter cover bolts to the specified forque 9 lbf ft 12 N m 1 2 kgf m 14 Install the left engine guard and left engine guard bolt 15 Fill the crankcase with the recommended oil Capacity 0 73 US qt 0 69R at oil and filter change 0 70 US qt 0 66R at oil change 16 Install the engine oil filler cap dipstick 17 Check the engine oil level by following the steps in Checking Adding Oil ...

Page 52: ...gine oils displaying a circular API energy conserving service label on the container They may affect lubrication and clutch performance Suggested 4 stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving on the circular API service label transmission oil or 4 stroke engine oil SG or higher except oils labeled as energy conserving on the circular API service la...

Page 53: ... hole until oil start to flow out of the oil check bolt hole Install the oil check bolt and transmission oil filler cap Repeat step 1 4 5 After inspection the oil level or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil filler cap securely Replacing Transmission Oil 1 Run the engine for 3 minutes then shut it off...

Page 54: ...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 should only be used to provide additional protection against freezing Check the cooling system frequently du...

Page 55: ...bleshooting of leaks 2 Check water hoses 1 for cracks deterioration and clamp bands for looseness 3 Check the radiator mount for looseness 4 Make sure the siphon hose 2 is connected and not clogged 5 Check the radiator fins for clogging 6 Check the water leakage check hole 3 below the water pump cover 4 for leakage Make sure the hole remains open If water leaks through the check hole the water pum...

Page 56: ...up to filler neck Use a fresh recommended coolant mixture page 48 Capacity 1 19 US qt 1 13R 3 Turn the quick fastener 2 counter clockwise 4 Remove the left side cover bolt 3 seat bolt 4 collars 5 and left side cover 6 5 Remove the radiator reserve tank cap 7 and fill the reserve tank to the UPPER level line 8 2 quick fastener 6 left side cover 3 left side cover bolt 7 radiator reserve tank cap 4 s...

Page 57: ...e and spark plug fouling Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear NOTICE NOTICE Cleaning 1 To open the air cleaner cover 1 turn the quick fastener 2 counterclockwise 3 Pull the air cleaner element 5 out from the air cleaner holder 6 1 air cleaner cover 2 quick fastener 2 Remove the air cleaner retaining bolt 3 and air cleaner 4 as show...

Page 58: ...nstall the tab 7 of the holder in the hole 8 of the air cleaner tab 9 9 Install the assembly into the air cleaner housing 3 air cleaner retaining bolt 10 access tab 11 mark 52 Servicing Your Honda 10 11 3 10 Carefully position the sealing flange of the element to prevent dirt intrusion Align the access tab 10 of the air cleaner with the mark 11 of the air cleaner housing by rotating the air cleane...

Page 59: ...cycle is ridden in the rain or often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain the deposits into a suitable container 2 Reinstall the crankcase breather tube plug 1 crankcase breather tube plug 2 tube 2 1 ...

Page 60: ...nut 5 Operate the throttle grip to ensure that it functions smoothly and returns completely If you can t get the freeplay within the specified range contact your Honda dealer 5 6 1 Pull the rubber dust cover 2 back 2 Loosen the upper 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 the lock ...

Page 61: ...n all steering positions If there is a problem see your Honda dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion 1 Servicing ...

Page 62: ...freeplay 2 Loosen the lock nut 3 3 Turn the integral cable adjuster 4 to obtain the specified freeplay 4 Tighten the lock nut Check the freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually If...

Page 63: ...t bolt 3 Servicing Your Honda 57 1 rear brake pedal 3 pivot bolt 2 pin 3 Remove the five clutch cover bolts 4 and clutch cover 5 4 clutch cover bolts 5 clutch cover 4 Remove the five clutch spring bolts and clutch springs 6 Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps 5 Remove the clutch pressure plate 7 6 clutch spring bolts clutch springs 7 clutch pressure plate 6 Remove ...

Page 64: ...nstall the clutch disc A larger I D disc 5 onto the clutch outer Stack the seven clutch plates and seven clutch discs alternately 1 spring seat 4 clutch plates 2 judder spring 5 clutch disc A 3 clutch discs 3 Apply grease to the clutch lifter rod 6 4 Insert the clutch lifter rod into the mainshaft 5 Install the clutch lifter 7 onto the rod 6 clutch lifter rod 7 clutch lifter 6 Install the clutch p...

Page 65: ...se Tighten the pivot bolt to the specified torque 19 lbf ft 26 N m 2 7 kgf m Connect the brake pedal return spring 15 if it was removed 12 Insert the pin 16 12 O rings 15 return spring 13 brake pedal 16 pin 14 pivot bolt 13 Fill the crankcase with transmission oil page 47 Servicing Your Honda 59 16 13 14 15 12 ...

Page 66: ...2 3 mm If necessary adjust to the specified range Adjustment Adjustments can be made with the cable end adjuster Loosen the lock nut 3 and turn the adjuster 4 Turning the adjuster in will increase free play and turning out will decrease free play After adjustment tighten the lock nut 3 lock nut increase 4 cable adjuster decrease 60 Servicing Your Honda 1 2 4 3 ...

Page 67: ...and the insulator for cracks Replace if you detect them 6 Check the spark plug gap 4 using a wire type feeler gauge If the gap is out of specifications replace the plug with a new one The recommended spark plug gap is 0 031 0 035 in 0 8 0 9 mm 3 sealing gasket 4 spark plug gap 3 4 Servicing Your Honda 61 Standard IMR8C 9H NGK or VUH24D DENSO Optional IMR9C 9H NGK or VUH27D DENSO 7 To obtain accura...

Page 68: ...ce engine performance 1 seat bolt 3 side cover bolt 2 collars 4 right side cover 2 Loosen the muffler clamp bolt 5 3 Remove the muffler A bolt 6 muffler B bolt washer 7 and muffler 8 5 muffler clamp bolt 7 muffler B bolt washer 6 muffler A bolt 8 muffler 1 4 3 2 2 6 8 7 5 Muffler Removal 1 Remove the seat bolt 1 collar 2 side cover bolt 3 collar 2 and right side cover 4 62 Servicing Your Honda ...

Page 69: ...gf m 4 Tighten the muffler clamp bolt 5 to the specified torque 15 lbf ft 21 N m 2 1 kgf m 3 muffler B bolt 5 muffler clamp bolt 4 muffler A bolt 6 right side cover 8 side cover bolt 7 collars 9 seat bolt 5 Install the right side cover 6 collar 7 and side cover bolt 8 6 Install the collar 7 and seat bolt 9 tighten the bolt to the specified torque 20 lbf ft 26 N m 2 7 kgf m Servicing Your Honda 63 ...

Page 70: ...hten the nuts to the specified torque 15 lbf ft 21 N m 2 1 kgf m 1 exhaust pipe gasket 2 exhaust pipe 3 exhaust pipe joint nuts 2 Install the muffler page 63 Exhaust Pipe Removal 1 Remove the muffler page 62 2 Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 1 2 3 1 2 3 ...

Page 71: ...ur engine from reaching the environment 1 Allow the engine and muffler 1 to cool 2 Remove the four bolts 2 spark arrester 3 and gasket 4 from the muffler 1 muffler 3 spark arrester 2 bolts 4 gasket 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the spark arrester screen The spark arrester must be free of brakes and holes Replace if necessary Che...

Page 72: ...ver bolts 3 and cylinder head cover 4 3 cylinder head cover bolts 4 cylinder head cover 1 crankshaft hole cap 1 2 3 4 1 Refer to Safety Precautions on page 2 Excessive valve clearance will cause noise and eventual engine damage Little or no clearance will prevent the valve from closing and cause valve damage and power loss Check the valve clearance when the engine is cold at the intervals specifie...

Page 73: ...lockwise until aligning the punch mark 4 on the primary drive gear with the index mark 5 on the right crankcase cover In this position the piston may either be on the compression or exhaust stroke If the crankshaft passed the punch mark rotate the primary drive gear lock bolt clockwise again and align the punch mark with the index mark The inspection must be made when the piston is at the top of t...

Page 74: ...2 1 cam chain tensioner lifter cover bolt 2 sealing washer Use the tensioner stopper tool Tensioner stopper 070MG 0010100 3 Turn the tensioner shaft clockwise with the stopper tool 3 until it stops in order to retract the tensioner fully Then insert the stopper tool fully to hold the stopper in the fully retracted position 3 stopper tool 1 2 3 3 68 Servicing Your Honda ...

Page 75: ...nto the crankcase Be careful not let the set rings of the camshaft holders fall into the crankcase 4 camshaft holder bolts 6 camshaft 5 camshaft holders 6 Remove the valve lifters 7 Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust right or left Do not let the valve lifters and shims fall into the crankcase NOTICE 7 valve lifters 7 Remove the ...

Page 76: ... 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 the micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposit...

Page 77: ...6 7 cam sprocket 9 cylinder head 8 timing marks 10 cam chain 5 Apply grease to the set rings and install it onto the camshaft holders 11 Install the camshaft holder bolts 12 TORQUE 12 lbf ft 16 N m 1 6 kgf m Tighten the camshaft holder bolts in a criss cross pattern in 2 or 3 steps 11 camshaft holders 12 camshaft holder bolts 2 2 1 4 5 6 12 12 11 Servicing Your Honda 71 3 valve lifters 4 primary d...

Page 78: ...r Remove the camshaft holders to place the shim correctly and reinstall the camshaft holders VALVE CLEARANCES IN 0 005 0 001 in 0 12 0 03 mm EX 0 011 0 001 in 0 28 0 03 mm 13 feeler gauge 7 Remove the stopper tool 14 from the cam chain tensioner lifter 14 stopper tool 8 Install a new sealing washer 15 and cam chain tensioner lifter cover bolt 16 15 sealing washer 16 camchain tensioner lifter caver...

Page 79: ... packing 3 into the groove of the cylinder head cover 4 3 cylinder head cover packing 4 cylinder head cover 3 Install the cylinder head cover 5 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 cylinder head cover 6 cylinder head cover bolts 4 Connect the spark plug cap 7 and breather tube 8 7 spark plug cap 8 breather tube 5 Install the fuel tank and ...

Page 80: ... Remove the exhaust pipe joint nuts 1 exhaust pipe 2 and exhaust pipe gasket 3 1 exhaust pipe joint nuts 2 exhaust pipe 3 exhaust pipe gasket 8 Disconnect the spark plug cap 4 9 Remove any dirt around the spark plug base 4 spark plug cap 10 Remove the cylinder head cover page 66 11 Remove the spark plug 5 5 spark plug 12 Position the piston to top dead center on the compression stroke page 66 Remo...

Page 81: ...washers 12 and cylinder head 13 Loosen the nuts in a criss cross pattern in 2 or 3 steps Do not let the nuts washers valve lifters shims and cam chain fall into the crankcase NOTICE 12 cylinder head nuts washers 13 cylinder head 18 Remove the dowel pins 14 cylinder head gasket 15 and cam chain guide 16 Do not let the dowel pins and cam chain fall into the crankcase NOTICE 14 dowel pins 16 cam chai...

Page 82: ...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 Do not damage the piston Always support the piston when pressing out the pin Do not let the clips fall into the crankcase Under racing conditions the piston and rings should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hour...

Page 83: ...n with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower side rail NOTICE top ring oil ring top ring mark side rail oil ring side rail spacer Servicing Your Honda 77 Cam Shaft Holders Cylind...

Page 84: ...new pin clips Never reuse old clips Do not let the clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out NOTICE 1 piston 4 piston pin 2 IN mark 5 piston pin clip 3 large valve recesses 6 cut out Cylinder Installation 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the crankcase Be care...

Page 85: ...r walls NOTICE 3 cam chain 5 piston rings 4 cylinder 6 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 new cylinder head gasket 2 Do not let the dowel pins fall into the crankca...

Page 86: ...criss cross pattern in 2 or 3 steps NOTICE NOTICE 4 Install the cylinder bolt 5 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 nuts washers 5 cylinder bolt 6 cylinder head bolts 7 engine hanger plate 8 engine hanger nuts of the frame side 9 engine hanger nut of the engine side 4 3 6 5 7 8 9 80 Servicing Your Honda 5 Inst...

Page 87: ...am shaft page 71 8 Install the spark plug page 61 9 Install the cylinder head cover page 73 Connect the spark plug cap 12 12 spark plug cap 10 Install the exhaust pipe page 64 11 Install the carburetor 12 Install the subframe and muffler page 40 13 Install the fuel tank and the seat page 38 14 Fill the cooling system with the recommended radiator coolant page 48 10 11 Servicing Your Honda 81 12 ...

Page 88: ...ion 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 information page 104 for make all rebound and compression damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Te...

Page 89: ...es 119 and 120 Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning all the compression and rebound adjusters according to the procedures described in page 119 After adjusting the adjusters simultaneously suspension may be fine tuned by turning one of the comp...

Page 90: ...seal and guide bushing when the fork damper is removed To avoid damage hold both the outer tube and slider when removing the fork damper NOTICE 5 dust seal 7 slider 6 guide bushing 8 outer tube 3 Pour the fork oil from the outer tube 1 Pour the fork oil from the oil hole 9 of the fork damper 1 outer tube 9 oil hole 4 Drain the fork oil by turning the outer tube 1 upside down About 12 cc of fork oi...

Page 91: ...on Slightly stiffer as it nears full compression Minimum oil capacity 10 4 US oz 308 cm3 2 scribe mark aftermarket parts No mark factory products 3 scribe mark Optional Stiffer 0 44 kgf mm Fork Spring Standard oil capacity 11 8 US oz 348 cm3 Maximum oil capacity 13 6 US oz 402 cm3 Slightly stiffer as it nears full compression Slightly stiffer as it nears full compression Minimum oil capacity 10 3 ...

Page 92: ...ston 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 Tighten the lock nut 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on t...

Page 93: ... the brake system and it must be bled Refer to the Honda Service Manual or see your Honda motorcycle dealer for brake bleeding Rear Brake Fluid Level Check 2 LOWER level mark With the motorcycle in an upright position check the fluid level It should be above the LOWER level mark 2 If the level is at or below the LOWER level mark check the brake pads for wear page 89 Worn brake pads should be repla...

Page 94: ... lbf ft 1 5 N m 0 15 kgf m Adding Rear Brake Fluid The recommended brake fluid is Honda DOT 4 brake fluid or an equivalent When adding brake fluid be sure the reservoir is horizontal before the cap is removed or brake fluid may spill out 4 bolts 6 diaphragm 5 reservoir cap 7 upper level mark 1 Remove the bolts 4 reservoir cap 5 and diaphragm Check the diaphragm 6 installation as shown 2 Fill the r...

Page 95: ...e disc 2 front brake caliper Rear Brake Pads Inspect the brake pads 4 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced 4 brake pads 6 brake disc 5 rear brake caliper Other Inspections Check that the front lever and rear pedal assemblies are positioned properly and the securing bolts are tight Make s...

Page 96: ...cessary to remove the wheels to perform the recommended service in the Maintenance Schedule pages 27 and 28 However information for wheel removal is provided for emergency situations Wheel Rims Spokes 1 rim lock 1 Inspect the wheel rims and spokes for damage 2 Tighten any loose spokes and rim locks 1 to the specified torque Spoke 2 7 lbf ft 3 68 N m 0 38 kgf m Rim Lock 9 4 lbf ft 13 N m 1 3 kgf m ...

Page 97: ...stall a new cap Always check air pressure when your tires are cold If you check air pressure when your tires are warm even if your motorcycle has only been ridden for a few miles the readings will be higher If you let air out of warm tires to match the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particu...

Page 98: ...oper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual Front 80 100 21 51M Rear 100 100 18 59M Type bias ply tube type Use a replacement tire equivalent to the original Replace the tube any time you replace a tire The old tube will probably be stretc...

Page 99: ...s on page 2 1 Check the side stand spring 1 for damage and loss of tension 2 Check the side stand assembly for freedom of movement 1 side stand spring If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean engine oil 1 ...

Page 100: ...t the transmission into neutral 2 Measure the drive chain plate 1 If the drive chain plate is worn anywhere to a thickness of 0 53 in 13 4 mm the drive chain must be replaced 1 drive chain plate inner If the chain is found to be slack in one segment of its length and taut in another this indicates that some of the links are either worn kinked or binding Kinking and binding can frequently be elimin...

Page 101: ...ngs Brushing will damage them Use of a solvent may also damage the O rings 2 Replace the drive chain if it has damaged rollers loose fitting links damaged O rings or other wise appears unserviceable Replacement Chain DID520MXV 3 Inspect the sprocket teeth for possible wear or damage Replace them if necessary Never install a new drive chain on badly worn sprockets or use new sprockets with a badly ...

Page 102: ...nt condition We recommend installing a new master link retaining clip when the drive chain is reassembled You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets 1 chain slider 2 Check the chain guide slider 2 for wear Replace the chian guide slider if it is worn to the bottom of the wea...

Page 103: ...t in the steering head the fork bushings may be worn Refer to the Honda Service Manual for replacement or adjustment procedures or see your Honda dealer Handlebar Inspection 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its proper position by inspecting the punch mark 3 Check the torque of the upper holder 2 bolts 16 lbf ft 22 N m 2 2 kgf m Tighten the f...

Page 104: ...sion oil check bolt Clutch cover Cylinder bolt Oil filter cover Cylinder head bolts Drive sprocket Torque lbf ft N m kgf m 7 15 7 11 7 7 7 9 7 23 10 21 10 15 10 10 10 12 10 31 1 0 2 1 1 0 1 5 1 0 1 0 1 0 1 2 1 0 3 2 1 cylinder head cover 2 exhaust pipe joint nuts 3 water pump cover 4 crankshaft hole cap 5 transmission oil check bolt 6 clutch cover 1 2 3 5 4 6 9 8 7 10 RIGHT SIDE LEFT SIDE 7 cylind...

Page 105: ... remove the battery we recommend disconnecting the battery cables negative cable first NOTICE You will get the best storage results from removing the battery and slow trickle charging it every 30 days see Battery Charging Before you remove the battery be sure to read all the information that follows as well as the information on the battery label WARNING The battery gives off explosive hydrogen ga...

Page 106: ...sed or lowered Turn the adjusting screw 1 clockwise to move the headlight up or turn the adjusting screw counterclockwise to move the headlight down to proper adjustment Taillight The taillight uses LED illumination If the taillight does not function properly see your Honda dealer for service This model is equipped with an electric starter and battery for easy engine starting There is a possibilit...

Page 107: ...dust seals steering head bearings suspension pivot points 1 steering head bearings 2 suspension pivot points High pressure water or air can damage certain parts of your motorcycle You may 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 Hond...

Page 108: ...is manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust mud and road salt To remove stains use Scotch Brite Hand Pad 7447 maroon or an equivalent Wet the pad and polish the surface using strokes parallel to the length of the frame Clean the frame using a wet sponge and a m...

Page 109: ...to determine if your combined rider and sprung machine weight rider fully dressed for competition and machine coolant oil and fuel levels ready for competition requires an optional firmer or softer rear spring The need for either optional rear spring may need to be balanced by installing the optional fork springs of a similar rate Front Suspension Adjustments 104 Rear Suspension Adjustments 118 Su...

Page 110: ...legs by using the pressure release screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place a workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the pre...

Page 111: ...rings in CRF s are about right for riders weighing between 150 and 160 lbs less riding gear So if you re a heavier rider you have to go up on the oil level or get a stiffer spring Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension If the fork is too hard on big bumps turn the damping adjuster counterclockwise 1 turn...

Page 112: ...ap NOTICE 8 disc cover 9 bolts 8 Remove the tripmeter cable 10 and front axle nut 11 and loosen the axle pinch bolts 12 on both fork legs 6 upper pinch bolts 7 fork damper 7 Remove the disc cover 8 by removing the two bolts 9 8 9 3 Disconnect the head light connector 3 9 Pull the front axle shaft 13 out of the wheel hub and remove the front wheel 10 trip meter cable 12 axle pinch bolts 11 front ax...

Page 113: ...and turn the adjuster counterclockwise until it stops 14 Measure the length 25 between the axle holder and outer tube and record it before disassembling the fork 23 outer tube 25 lock nut wrench 24 fork damper 26 slider lower end 16 Pour the fork oil from the outer tube 23 Pour the fork oil from the oil hole 27 of the fork damper 23 outer tube 27 oil hole 25 length 21 22 24 23 25 25 23 26 23 24 23...

Page 114: ...ile applying pressure to the fork cap Be careful not to damage the lock nut and fork center bolt hole NOTICE 28 axle holder 32 push rod 31 lock nut 26 Remove the fork damper assembly 33 from the fork assembly 34 Remove the fork from the vise Remove the fork spring 35 from the fork 33 fork damper assembly 35 spring 34 fork assembly 28 30 31 29 28 32 31 33 35 34 17 Temporarily install the fork dampe...

Page 115: ... fork damper 6 Pump the fork damper piston rod 6 slowly several times to bleed the air from the fork damper 2 2 fork damper 6 piston rod 2 3 1 4 2 5 2 2 2 6 5 Extend the fork damper piston rod to maximum Pour the recommended fork oil into the fork damper Recommended Oil Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount 6 6 US oz 195 cc 6 9 Imp oz 2 Remove the fork cap assembly 4 from the ...

Page 116: ... 2 in an upright position and pump the fork piston rod 6 to 3 9 in 100 mm slowly several times 2 3 1 9 Tighten the fork cap 1 while holding the cut out of the fork damper 2 using the lock nut wrench 3 to the specified torque 22 Ibf ft 30 N m 3 1 kgf m 2 fork damper 8 Apply fork oil to the bushing and new O ring on the fork cap 1 assembly Extend the fork damper piston rod to maximum holding it inst...

Page 117: ...chamber through the oil hole and cause 178 cm3 of fork fluid to be left in the chamber 12 Blow the extra oil off to the fork damper 2 spring chamber 8 by pumping the fork damper piston rod to full stroke 14 Blow out the oil from the fork damper spring chamber using compressed air to the oil hole Wipe the oil completely off the fork damper 15 If you can not use compressed air remove the pressure re...

Page 118: ...h A as shown Standard 0 43 0 51 in 11 13 mm Wipe the oil completely off the fork damper 2 lock nut A thread length 3 Wipe the oil completely off the fork spring 3 Install the fork spring Install the fork damper 4 to the outer tube slider 1 1 outer tube slider 4 fork damper assembly 3 spring 1 Amount of fork oil left in the fork without damper and spring unit cc minute C F 30 86 20 68 10 50 0 32 5 ...

Page 119: ...n the center bolt fully by hand NOTICE 2 lock nut 7 O ring 5 stopper tool 8 center bolt 6 push rod 9 adjusting rod 8 Measure the length of the lock nut 2 and center bolt 8 clearance Standard 0 06 0 08 in 1 5 2 0 mm If the clearance is out of specification check the lock nut and center bolt installation 2 lock nut 8 center bolt 9 Tighten the lock nut 2 to the center bolt 8 closely by hand Tighten t...

Page 120: ... kgf mm Fork Spring Standard oil capacity 11 8 US oz 350 cm3 Maximum oil capacity 13 6 US oz 404 cm3 Slightly stiffer as it nears full compression Slightly softer as it nears full compression Minimum oil capacity 10 4 US oz 308 cm3 No mark factory products 3 scribe mark 2 scribe mark aftermarket parts or Optional Stiffer 0 44 kgf mm Fork Spring Standard oil capacity 11 8 US oz 348 cm3 Maximum oil ...

Page 121: ...d then tighten the fork damper 4 to the specified torque using a special tool 25 Ibf ft 34 N m 3 5 kgf m For ease of releasing air pressure after the forks are installed Ioosen the lower pinch bolts and position the outer tubes so that the pressure release screws are in front of the rebound damping adjusters 17 Tighten the fork lower pinch bolts 13 to the specified torque 14 Ibf ft 20 N m 2 0 kgf ...

Page 122: ...t fork leg clamp inner surface Tighten the front axle nut 19 to the specified torque 65 Ibf ft 88 N m 9 0 kgf m 19 front axle nut 21 Align the brake caliper 20 and hose with the left fork leg making sure that the brake hose is not twisted 22 Clean the threads of the caliper mounting bolts 21 and brake caliper thoroughly Apply locking agent to the bolt threads Install the brake caliper on the slide...

Page 123: ...he fork up and down several times to seat the axle and check front brake operation 27 Tighten the left axle pinch bolts 29 alternately first While keeping the forks parallel alternately tighten the right axle pinch bolts to the specified torque 14 Ibf ft 20 N m 2 0 kgf m 29 axle pinch bolts 30 tripmeter cable 29 Clean the threads of the disk cover bolts and axle holder thoroughly Install the disc ...

Page 124: ... Service Manual If your CRF is new put enough part throttle break in time about one hour on it to ensure that the suspension has worked in Rear Suspension Spring Pre Load An optional pin spanner is available for turning the lock nut and adjusting nut to adjust spring pre load 1 Place a workstand under the engine to raise the rear wheel off the ground 2 Loosen the connecting tube clamp screw and re...

Page 125: ...eed damping adjuster High Speed Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer turn lightly seats This is the full hard setting 2 Turn the adjuster counterclockwise 1 7 12 2 1 12 turns and the punch marks are aligned Low Speed Damping The low speed d...

Page 126: ...hes the correct starting point for any suspension tuning the proper rear spring pre load adjustment for your specific needs Your motorcycle should be at normal racing weight including fuel and transmission oil You should be wearing all your normal protective apparel You will need two helpers To calculate the proper adjustment it is necessary to measure between two fixed points from the top of the ...

Page 127: ...imension step 2 Free sag indicates the distance your rear suspension should sag from the weight of the sprung portion of your motorcycle With the spring pre load set to obtain the proper race sag the rear suspension should sag 10 to 25 mm 0 4 to 1 0 in If the rear of your motorcycle sags more than 25 mm 1 0 in from its own weight the spring is too stiff for your weight It is not compressed enough ...

Page 128: ...r aftermarket springs front and rear may help especially if you are heavier than the average rider Your motorcycle may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much 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 com...

Page 129: ...n large bumps especially downhill bumps Entire travel too soft 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 ...

Page 130: ...makes the suspension too stiff over the full range of travel test softer compression damping adjustments in one click increments until the desire compression damping for initial travel is obtained 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 sti...

Page 131: ...bumps Entire travel too stiff Entire travel too soft Rear end sways 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 ...

Page 132: ...er when cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder 1 choke knob 4 throttle valve 2 starter jet 5 orifice 3 air passage Hot Start Circuit A lean mixture must be...

Page 133: ...rcuit Fuel is metered by the slow jet 1 and mixed with air from the air passage 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 1 slow jet 4 pilot outlet 2 air passage 5 pilot screw 3 bypass Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters t...

Page 134: ...mediately 1 float bowl plug 3 Install the float bowl plug 1 128 Adjustments for Competition 4 Remove the fuel tank page 37 5 Remove the band 2 and rear suspension upper mounting nut 3 and pull out the rear suspension upper mounting bolt 4 2 band 3 upper mounting nut 4 upper mounting bolt 6 Lift the sub frame to the upright position page 39 7 Loosen the intake band screw 5 5 intake band screw 8 Dis...

Page 135: ... arm set screw 7 When installing the link arm set screw apply a locking agent to the link arm set screw threads 4 Remove the throttle valve 8 throttle valve roller 9 and floating valve 10 7 link arm set screw 9 throttle valve roller 8 throttle valve 10 floating valve 2 1 3 6 5 4 7 8 9 10 8 10 Remove the throttle drum cover bolt 8 and throttle drum cover 9 8 throttle drum cover bolt 9 throttle drum...

Page 136: ...e D ring into the accelerator pump cover 13 make sure the D ring s flat side faces down away from the float bowl 18 13 accelerator pump cover 16 spring 14 D ring 17 diaphragm 15 O ring 18 float bowl 7 Remove the holder screw 19 throttle stop screw holder 20 float bowl screws 21 tube guides 22 and float bowl 18 18 float bowl 19 holder screw 20 throttle stop screw holder 21 float bowl screws 22 tube...

Page 137: ... jet 26 27 28 18 29 Adjustments for Competition 131 1 throttle cables 2 hot start cable 3 throttle sensor connector 4 air vent hoses 5 overflow hose 2 1 3 4 5 4 5 4 Carburetor Assembly To assemble reverse the disassembly procedures To install the carburetor reverse the removal procedures After installing the carburetor adjust the throttle cable 1 free play and hot start cable 2 free play After ins...

Page 138: ...itions Engine response and appearance of the firing end of a spark plug are highly indicative of the engine condition 132 Adjustments for Competition Adjustment Procedure 1 Turn the pilot screw in until it is lightly seated and record the number of turns Turn the pilot screw 1 out the same number of turns 1 pilot screw 2 If the engine is cold start it and warm it up three minutes Then shut it off ...

Page 139: ... 120 in the 90 100 mm range Fork Height Angle Standard Position The position of the outer tubes in the clamps is not adjustable Align the top of the fork tube 1 with the top of the upper fork clamp 2 STANDARD POSITON Wheelbase Adjusting your motorcycle s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change the ...

Page 140: ...eally 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 speed Average conditions use the standard sprocket Hard but not slippery track condi...

Page 141: ...emember they will be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface 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 unus...

Page 142: ...depressed when sitting or standing comfortably on your motorcycle 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 forward either 3 mm using optional handlebar lower holders or 6 mm by...

Page 143: ...37 Here s helpful advice on how to transport and store your Honda as well as two troubleshooting flow charts Transporting Your Motorcycle 138 Storing Your Motorcycle 139 You the Environment 141 Troubleshooting 142 ...

Page 144: ...ailer rail Attach the lower ends of two straps to the tie down hooks on your vehicle Attach to 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 an...

Page 145: ...r thoroughly inspect your Honda and correct any problem before storing it That way needed repairs won t be forgotten and it will be easier to get your motorcycle running again To reduce or prevent deterioration that can occur during storage also follow the following procedures Preparation for Storage 1 Completely clean all parts of your CRF If your CRF has been exposed to sea air or salt water was...

Page 146: ...tlet 3 Fill the fuel tank with recommended fuel page 41 4 Charge the battery page 99 as required Install the battery 5 Pour a fresh recommended coolant mixture page 48 slowly into the radiator filler hole up to the filler neck Capacity 1 27 US qt 1 20R at disassembly 1 19 US qt 1 13R at draining Remove the radiator reserve tank cap and fill the reserve tank to the upper level line Bleed air from t...

Page 147: ...leaning 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 a...

Page 148: ...Faulty ignition control module Faulty alternator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition pulse generator Ring worn Cylinder worn or damaged Piston worn or damaged Head gasket not sealing POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Disconnect fuel line at carburetor and check for clogging P 41 UNRESTRICTED FUEL FLOW FUEL FLOW RESTRICTED DIRTY 2 Remove air c...

Page 149: ...Taking Care of the Unexpected Taking Care of the Unexpected 143 This section gives practical advice to help you problems If a Fuse Blows 144 If Your Battery is Low or Dead 145 ...

Page 150: ...ollars 4 right side cover 3 Disconnect the wire connector 5 of the starter magnetic switch 6 4 Pull main fuse 7 out If it is blown 8 install the spare main fuse 9 5 wire connector 6 starter magnetic switch 7 main fuse 8 blown fuse 9 spare main fuse 5 Reconnect the wire connector If you do not have a replacement fuse with the proper rating for the circuit install one with a lower rating Replacing a...

Page 151: ... battery The greater amperage of an automobile battery when the car engine is running can damage your motorcycle s electrical system Bump starting is also not recommended If you can t charge the battery or it appears unable to hold a charge contact your Honda dealer Taking Care of the Unexpected 145 ...

Page 152: ...146 Taking Care of Unexpected ...

Page 153: ...cities and other technical data Vehicle Identification 148 Specifications 149 Torque Specifications 151 High Altitude Carburetor Adjustment 154 Emission Control Systems 155 Oxygenated Fuels 156 Competition Logbook 157 Optional Parts List 159 Spare Parts Equipment 160 Wiring Diagram 161 ...

Page 154: ...rts You may record these numbers in the Quick Reference section at the rear of the manual The Vin vehicle identification number 1 appears on the Safety Certification Label attached to the left side of the frame LEFT SIDE 1 vin The frame number 2 is stamped on the right side of the steering head RIGHT SIDE 2 frame number The engine number 3 is stamped on the left crankcase LEFT SIDE 3 engine number...

Page 155: ...bly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR02A 130 NCVT Needle clip position standard Slow jet standard Pilot screw opening Float level Liquid cooled 4 stroke 3rd groove 40 2 1 4 turns out Type Metric 660 cm3 690 cm3 850 cm3 670 cm3 750 cm3 78 0 x 52 2 mm 8 0mm Engine Carburetor 12 9 1 Clutch type ...

Page 156: ...er disassembly After disassembly Transmission oil capacity After draining Type Identification number Main jet standard Jet needle standard Piston valve FCR02A 130 NCYV Needle clip position standard Slow jet standard Pilot screw opening Float level Liquid cooled 4 stroke 2rd groove 40 2 turns out Type Metric 660 cm3 690 cm3 850 cm3 670 cm3 750 cm3 78 0 x 52 2 mm 8 0mm Engine Carburetor 12 9 1 Clutc...

Page 157: ... 5 6 7 8 9 10 ENGINE Cylinder head cover Clutch cover Water pump cover Transmission oil check bolt Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolt Exhaust pipe joint nut Drive Sprocket Torque Remarks lbf ft N m kgf m 7 7 7 7 11 9 7 7 15 23 10 10 10 10 15 12 10 10 21 31 1 0 1 0 1 0 1 0 1 5 1 2 1 0 1 0 2 1 3 2 9 3 4 5 2 1 8 7 10 6 ...

Page 158: ...ivot nut Fork fork damper fork cap Rear shock arm nuts swingarm side shock link side Rear shock link nuts Shock spring lock nut Kickstarter arm bolt Torque Remarks lbf ft N m kgf m 80 16 14 16 33 65 14 94 20 47 40 47 40 25 33 33 65 25 22 39 39 39 33 28 108 22 20 22 44 88 20 127 27 64 54 64 54 34 44 44 88 34 29 53 53 53 44 38 11 0 2 2 2 0 2 2 4 5 9 0 2 0 13 0 2 8 6 5 5 5 6 5 5 5 3 5 4 5 4 5 9 0 3 5...

Page 159: ...eservoir cap screws Rear brake reservoir cap bolts Fork air pressure release screw Side stand mounting bolts upper lower Torque Remarks lbf ft N m kgf m 7 25 22 12 12 20 2 7 9 4 22 36 51 16 9 5 19 19 15 24 20 1 1 1 1 0 9 40 29 9 9 34 30 16 16 26 3 68 13 30 49 69 22 13 7 26 26 21 32 26 1 5 1 5 1 2 54 39 1 0 3 5 3 1 1 6 1 6 2 6 0 38 1 3 3 1 5 0 7 0 2 2 1 3 0 7 2 7 2 7 2 1 3 3 2 7 0 15 0 15 0 12 5 5 ...

Page 160: ...to compensate for this high altitude richness However the carburetor must be returned to standard factory specifications when lower altitude riding is desired See your Honda dealer for high altitude modification Sustained operation at altitudes below 5 000 feet 1 500 m with high altitude carburetor modifications may cause engine overheating and damage 154 Technical Information High Altitude Carbur...

Page 161: ...nt which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other those specified by the manufacturer Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms have the vehicle inspected and repaired by yo...

Page 162: ...ol 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 performa...

Page 163: ...on engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guestimate is close enough for our timekeeping purposes You may choose to record your time the same way aircra...

Page 164: ...nsumer Information Date Running Location Event Comments Suspension Settings Gearing Chassis Adjustments Maintenance Time Performed etc Make several photocopies of this page for future use Competition Logbook ...

Page 165: ...s 53 Teeth Aluminum 114 Optional 50 Teeth Aluminum 114 Optional no offset 52 Teeth Aluminum 114 Handlebar lower holder Standard 3 mm offset TOOLS Remarks For checking tire air pressure Pin spanner A Workstand To adjust spring preload two spanners required For maintenance Air gauge ENGINE Remarks Cooling system assembly Orange Red and Black 280 lbf in 5 00 kgf mm 291 2 lbf in 5 20 kgf mm Wite Blue ...

Page 166: ...nches hex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Honda Special Tools Any special tools for your motorcycle purchased from your Honda dealer Clutch...

Page 167: ...Technical Information 161 Wiring Diagram ...

Page 168: ...162 Technical Information ...

Page 169: ...Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual Authorized Manuals 164 Contacting Honda 165 Your Honda Dealer 166 The Honda Rider s Club USA only 167 ...

Page 170: ...to order authorized manuals Authorized Manuals Publication Item No Description Price Each 61KSC01 2005 CRF250X Service Manual 48 00 61CM002 Common Manual 48 00 31KSC610 2005 CRF250X Owner s Manual 16 00 Prices are subject to change without notice and without incurring obligation Prices are subject to change without notice and without incurring obligation Orders are mailed within 10 days Please all...

Page 171: ...es at the dealership level If you wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address USA only Motorcycle Division American Honda Motor Co Inc P O Box 2220 Torrance CA 90509 2220 mailstop 100 4W 5B telephone 310 532 9811 Canada Refer to the warrantly booklet that was supplied with your vehicle Please include the following infor...

Page 172: ...ondaline accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area You ll also find that your dealer is a source of information US...

Page 173: ...long as your Honda is aboard or in tow Vehicle transport to the nearest Honda dealer or service center if necessary An exclusive HRCA website complete with access to the official Honda Common Service Manual contests insider information and more Reimbursement up to 75 for Motorcycle Safety Foundation training Separate free training from the Speialty Vehicle Institute of America for ATV owners One f...

Page 174: ...ice Preparations Component Locations 35 Seat Removal 36 Fuel Tank Removal 37 Subframe Upright Position 39 Service Procedures Fluids Filters Fuel System 41 Engine Oil 43 Transmission Oil 46 Coolant 48 Air Cleaner 51 Crankcase Breather 53 Engine Throttle 54 Clutch System 56 Hot Start Lever 60 Spark Plug 61 Exhaust Pipe Muffler 62 Spark Arrester 65 Valve Clearance 66 Piston Piston Rings Piston Pin 74...

Page 175: ...titude Carburetor Adjustment 154 Emission Control Systems 155 Oxygenated Fuels 156 Competition Logbook 157 Optional Parts List 159 Spare Parts Equipment 160 Wiring Diagram 161 CONSUMER INFORMATION 163 Authorized Manuals 164 Contacting Honda 165 Your Honda Dealer 166 The Honda Rider s Club USA only 167 Table of Contents 169 ...

Page 176: ...stment 154 idle speed 132 care appearance 101 chain drive 94 chassis adjustment for track conditions 135 choke knob 15 cleaner air 51 cleaning appearance care 101 clutch system adjustment 56 consumer information 163 controls operating 7 component locations maintenance 35 operating controls 8 competition logbook 157 contacting Honda 165 controls operating 8 coolant 48 customer service 163 cylinder ...

Page 177: ...ts list 159 sprockets 159 oxygenated fuels 156 pads brake 89 parts optional 159 personal fit adjustments 136 pinging engine 41 plug spark 61 pre load rear suspension 118 pre ride inspection 11 protective apparel 2 rear suspension maintenance 83 Rider s Club Honda 167 riding apparel 2 basic operation 13 before 9 important safety information 2 safety precautions 2 safety a few words about Safety Mes...

Page 178: ...ransmission oil 46 tuning tips 126 throttle freeplay 54 inspection 55 tires air pressure 91 flat 91 selection 92 tools 160 torque specifications 151 153 transporting 138 troubleshooting 142 tubes replacing 91 valve fuel 15 vehicle identification 148 washing your motorcycle 101 weight limit 3 wheels 90 writing diagram 161 W V T ...

Page 179: ...Memo 173 ...

Page 180: ...a 1 0kgf cm2 standard IMR8C 9H NGK or VUH24D DENSO optional IMR9C 9H NGK or VUH27D DENSO D I D 520DMXV Maintenance Pre ride Inspection Fuel Capacity Engine oil Transmission oil Tires Tire Pressure cold Spark Plug Drive Chain Quick Reference Record important information here Frame No Engine No Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr The following is ...