IMPORTANT NOTICES FOR RECREATIONAL OFF-ROAD 0R COMPETITION USE ONLY This motorcycle is designed and manufactured for recreational off-road use or competition only and is covered by noise control warranty. It does not conform to federal motor vehicle safety standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal.The vehicle is equipped with a USDA qualified spark arrester. If you need to cross a paved or public road, get off and walk your motorcycle across. Do not modify any emission-related items except for competition use. Any emission-related modifications should be restored to standard factory specifications before resuming recreational off- road use. No PASSENGERS This motorcycle is designed and constructed as an operator-only model.The motorcycle load limit and seating configuration do not safety permit the carrying of a passenger. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This vehicle pictured in this owner's manual may not match your actual vehicle. © Honda Motor Co., Ltd., 2016 _‘ l7ERHSUXJIIVIEYHOmdli l gong/mam ”MAJ, J O 2017 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It conforms to US EPA Noise Emission regulations, but does not conform to Federal MotorVehicle Safety Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal.The vehicle is equipped with a USDA qualified spark arrester. Obey local laws and regulations. It conforms to US EPA, California, and Environment Canada emission regulations for off-road motorcycles. :’\ _‘ l7[Kl-ASLIXgHMkY7I0mdh 2 \.. ZOIG/UG/UX nus 3i, Introduction Congratulations on choosing your Honda CRF off-road motorcycle. When you own a Honda, you‘re part of a worldwide family of s‘ sfred customersrpeople who appreciate Honda's reputation for building quality into every product. Your Honda was designed as a recreational motorcycle for off-road use by one rider only. Before riding, take time to get acquainted with your CRF and how it works. To protect your investment, we urge you to take responsibility for keeping your CRF well maintained. Scheduled service is a must, of course. But it's just as important to observe the break—in guidelines, and perform all the pre—ride and other periodic checks detailed in this manual. You should also read the owner’s manual before you ride. It's full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a table of contents, a detailed list of topics at the beginning of each section, and an index at the back of the book. As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment. Unless you are mechanically qualified and have the proper tools, you should see your dealer for the service and adjustment procedures discussed in this manual. Introduction _‘ l7L‘Rl-ASLIXJIMLYHOmdlv 3 The official Honda Service Manual for your CRF is available (page 174). It is the same manual your dealer uses. If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual, you will find the Service Manual a valuable reference. Read the Warranties Booklet (page 175) thoroughly so you understand the coverages that protect your new Honda and are aware of your rights and responsibilities. This motorcycle has no cooling fan. For this reason, engine overheating and coolant loss will occur if the engine is kept idling too long when hot. Additionally, when riding in mud or sand. or any condition that causes high engine load at low vehicle speed, the time it takes for the engine to overheat will be shortened, especially when the ambient temperature is hig . Continuing to operate the unit in these conditions will result in engine damage. Whenever you ride, tread lightly. By staying on established trails and riding only in approved areas, you help protect the environment and keep off—road riding areas open for the future. If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction. Please report any change of address or ownership to your dealer so we will be able to contact you concerning important product information. You may also want to visit our website at USA: www.powersports.honda.com. Canada: www.honda.ca. Happy riding! California Proposition 65 Warning WARNING: This product contains or emits chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. gong/mama ”453217 /\ u L A Few Words About Safety Your safety, and the safety of others. is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety. we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential haLards that could hurt you or others. Of course. it is not practical or possible to warn you about all haLards associated with operating or maintaining a motorcycle. You must use your own good judgment. You will find important safety information in a variety of forms, including: - Safety Labels 7 on the motorcycle. - Safety Messages 7 preceded by a safety alert symbol A and one of three signal words: DANGER, WARNING, or CAUTION. These signal words mean: A DANGER You WILL be KILLED or SERIOUSLY HURT if you don‘t follow instructions. A WARNING You CAN be KILLED or SERIOUSLY HURT if you don‘t follow instructions. \ J A AUTION You CAN be HURT if you don‘t follow instructions. - Safety Headings i such as Important Safety Reminders or Important Safety Precautions. - Safety Section 7 such as Motorcycle Safety. - Instructions 7 how to use this motorcycle correctly and safety. This entire book is filled with important safety informationi please read it carefully. Inlroduction l . / \ I7cmsuxgiMmimmiii a \./ guns/mama III, Contents MOTORCYCLE SAFETY . Important Safety Information Important Safety Precaution Loading Accessories Mo 1 icauo Safety Labels ................... OPERATING CONTROLS Operation Component Location BEFORE RIDING. Are You Ready to Ride Is Your Motorcycle Ready to Ride‘7 Pre—ride Inspection .............. BASIC OPERATING INSTRUCTIONS Safe Riding Precautions .. Starting & Stopping the Engine Preparatio Fuel Valve Starting Proc Flooded Engine. How to Stop the Engine Shifting Gears .......... Braking Parking Post-ride Inspection. Break-in Guideline SERVICING YOUR HONDA ........................ 23 Befnm You Sarvice Your Honda The Importance of Maintenance Maintenance Safety ..... Important Safety Precaution Maintenance Schedule General Competition M intenance Before & After Competition Main c Between Motos & Practice Maintenance After Competition Maintenance ....... Servim Preparatiom Maintenance Component Locations 35 Subframe Upright Position Contents _‘ l7ERl-ASLIXJIMEYHOmdb 5 Sari/icy Pmcvduras Fluids & Filte Fuel System.. Engine Oil Transmission Oil. Coolant.. Air Cleaner Crankcase Breather Engine Throttle ..... Clutch Syste Hot Start Lever .60 Spark Plug.... .61 Exhaust Pipe/Muffler. Spark Arrester. Valve Clearance Piston/Piston Rin Chas s Suspension ........................................................ 84 Brakes .88 .92 .93 Side Stand .95 Drive Chai Steering Damper ......................... Additional Maintenance Procedure. Electric' 1 Battery Headlight & Ta‘ Appearance Care. ADJUSTMENTS FOR COMPETITION...111 Front Suspension Adjustments Rear Suspension Adjustments. Suspension Adjustments for Tr Conditions Suspension Adjustment Guidelines Carburetor Adjustment & Tuning Tip. Steering Damper Adjustment ...... Steering Damper Adjustment Guideline Chassis Adj ‘ Gearing ..... Tire Selection for Track Condition Personal Fit Adjustments ........... TIPS ..... Transporting Your Motorcycle Storing Your Honda .. You & the Environmen Troubleshooting ........ TAKING CARE OF THE UNEXPECTED 153 If a Fuse Blows .. If Your Battery Is Low (or Dead TECHNICAL INFORMATION Vehicle Identification Specifications. Torque Specifi tions Emission Control System Oxygenated Fuel Competition Log Optional Parts List Spare Parts & Equipment. Wiring Diagram ........ CONSUMER INFORMATIO Authorized Manual Warranty Coverage Warranty Service Contacting Honda. Your Honda Dealer The Honda Rider’s Club (USA only) INDEX. QUICK REFERENCE gong/mama ”453217 /\ This section presents some of the most important information and recommendations to help you ride your CRF safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your CRF. _‘ t7cmsuxgnMmumm l Important Safety Information Important Safety Precaution Loading .. Acoessori Safety Labels... 'UiwaN /\ \ / l Motorcycle Safety Motorcycle Safely 1 20lt§/t)6/t)8 “45:11, Important Safety Information Important Safety Precautions Your CRF can provide many years of pleasure. if you take responsibility for your own safety and understand the challenges you can meet in competitive racing. There is much that you can do to protect yourself when you ride. You‘ll find many helpful recommendations throughout this manual. The following are a few that we consider to be most important. Always Wear a Helmet. It’s a proven fact: helmets significantly reduce the number and severity of head injuries. So always wear an approved motorcycle helmet. We also recommended that you wear eye protection. sturdy boots, gloves, and other protective gear. Never Carry a Passenger. Your CRF is designed for one person only. There are no handholds, footrests, or seat for a second personrso never carry a passenger. A passenger could interfere with your ability to move around to maintain your balance and control of the motorcycle. Ride Ofi-raad Only. Your CRF is designed and manufactured for off-road use only. The tires are not made for pavement, and the CRF does not have turn signals and other features required for use on public roads. If you need to cross a paved or public road, get off and walk your CRF across. Always Wear Protective Gear. We recommend that you wear sturdy boots, gloves, and other protective gear. The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. 2 Motorcycle Safety _‘ t7L‘Rl-ASLIXJIMkYHOmdh 2 Do not wear loose clothing which could catch on the control levers, kickstarter, footpegs, drive chain, or wheels. Take Time to Learn and Practice. Developing off—road riding skills is a gradual, step-by-step process. Start by practicing at low speeds in a safe area and slowly build your skills. Personal instruction from an experienced rider can also be valuable. If you need assistance, ask your dealer about riding groups in your area. Also be sure to read the Tim & Practice Guide for the Off-Highway Motorcyclist booklet that came with your CRF (USA only). Be Alert for Off-road Hazardr. The terrain can present a variety of challenges when you ride off-road. Continually “read" the terrain for unexpected turns, drop-offs, rocks, ruts, and other hazards. Always keep your speed low enough to allow time to see and react to hazards. Ride within Your Limitr. Pushing limits is another major cause of motorcycle crashes. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, fatigue, and inattention can significantly reduce your ability to make good judgments and ride safely. Don’t Drink and Ride. Alcohol and riding don't mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don't drink and ride, and don’t let your friends drink and ride either. Keep Your Honda in Safe Condition. It‘s important to keep your CRF properly maintained and in safe riding condition. Having a breakdown can be difficult, especially if you are stranded off—road far from your base. To help avoid problems, inspect your CRF before every ride and perform all recommended maintenance. ZOIG/UG/UX In, /\ Your CRF was designed as a rider-only motorcycle. It was not designed to carry a passenger or cargo. A passenger or cargo could interfere with your ability to move around to maintain your balance and control of the CRF. In addition. exceeding the weight limits or carrying an unbalanced load can seriously affect your CRF's handling. braking. and . ability. Adding accessories or making modifications that change this CRF's design and performance can also make it unsafe. Also, the weight of any accessories will reduce the maximum load the motorcycle can carry. More specific information on load limits, accessories, and modifications follows. Loading How much weight you put on your CRF. and how you load it. are important to your safety. If you decide to carry cargo, you should be aware of the following information. A WARNING Overloading or carrying a passenger can cause a crash and you can be seriously hurt or killed. Follow all loading guidelines in this manual. _‘ l7cmsuxguMrwmlmuy :a Loading Guidelines As discussed on this page, 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 does not interfere with your ability to shift position to maintain balance and stability. Place weight as close to the center of the motorcycle as possible. Do not attach large or heavy items (such as a sleeping bag or tent) to the handlebar, fork. or front fender. - Check that both tires are inflated properly. rs \ / l Loading Motorcycle Safely 3 gong/mama ”451117 Accessories & Modifications Accessories & Modifications Modifying your CRF or using non—Honda accessories can make your CRF unsafe. Before you consider making any modifications or adding an accessory, be sure to read the following information. A WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurl or killed. Follow all instructions in this owner’s manual regarding modifications and accessories. 4 Motorcycle Safety _‘ l7cmsuxgnMmlmmih a Accessories We strongly recommend that you use only Honda Genuine Accessories that have been specifically designed or approved and tested for your CRF. Because Honda cannot test all other accessories, you must be personally responsible for proper selection, installation, and use of non-Honda accessories. Check with your dealer for assistance and always follow this guideline: - Make sure the accessory does not reduce ground clearance and lean angle. limit suspension travel or steering travel, alter your riding position, or interfere with operating any controls. /\ \/ l Modifications We strongly advise you not to remove any original equipment or modify your CRF in any way that would change its design or operation. Such changes could seriously impair your CRF‘s handling. stability, and braking, making it unsafe to ride. We also advise you not to make any modifications or remove any equipment (such as the USDA qualified spark arrester or emission control system components) that would make the motorcycle illegal in your area. gong/omit HAS u U: Safety Labels This page shows the locations of safety labels on your CRF. Some labels warn you of potential hazards that could cause serious injury. Others 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 dealer for replacement. lMPORTANT mmmmuu Ms vehicle is destgned m: manumfimed (m at! me we only It dun: nut cunmvm to u s new motor vemcte samy stanuavas and opevanon on public stveetsnoadsm Nghways l5 mew Fm yum pmtnmmnjlwiys wnzvynm hclmflwmln (For Canada) mm Opemmv only No passenger: l l ”‘5 VEWE ‘5 A “ESTR‘CTED'USE :iide‘CSdZWSZIZQEFS:Ziiitlieyea nya DANGER em mewsw Mm“ ‘ A fine Motorcycle Safety 5 _‘ t7cmsuxgumnnouuh 5 gong/mama In, 6 Motorcycle Satay _‘ A7CRFASUXJIMkWIOmdh a ZOIG/DG/UX nus, Operating Controls Read this section carefully before you ride. It presents the location of the basic controls on your CRF. /\ _‘ t7cmsuxgnMummmm 7 Operation Component Locations. /\ \ / t Operating Controls 7 Bong/DBMS lldfiillli y U: Operation Component Locations tripmeter hot start lever clutch lever tront brake lever engine stop button throttle 9ND choke knob kickstarter fuel valve shift lever rear brake pedal 8 Operating Controls :’\ _‘ l7cmsuxgnmmmunu x \,. zone/cams ”may /\ Before Riding Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your CRF. For information about suspension, carburetor, and other adjustments see page 111. _‘ t7cmsuxgnMmmunuy a Are You Ready to Ride‘] Is Your Motorcycle Ready to Rid Pre-ride Inspection ....... rs \ / l Before Riding 9 gong/omit “45 :s /\ Are You Ready to Ride? Before riding your CRF for the fir time, we recommend that you read this owner‘s manual, make sure you understand the safety messages, and know how to operate the controls. Before each ride, it's also important to make sure you and your CRF are both ready to ride. For information about suspension, carburetor. and other adjustments. see page 111. Whether you‘re preparing for competition or for practice, always make sure you are: 0 In good physical and mental condition 0 Free of alcohol and drugs 0 Wearing an approved helmet, eye protection. and other appropriate riding gear Although complete protection is not possible, wearing the proper gear can reduce the chance or severity of injury when you ride. 10 Before Riding _‘ t7cmsuxgnMus/mun“, in A WARNING Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you always wear a helmet, eye protection and other protective apparel when you ride. 4._,7 /\ \ / EON/(Ilium “45 :s /\ Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the right): A WARNING Improperly maintaining this motorcycle or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed. Always perform a pre—ride inspection before every ride and correct any problems. _‘ i7cmsuxgiiMimoimih ll Pre-ride Inspection Check the following before each ride: 0 Engine oil level ...... 0 Transmission oil level 0 Coolant for proper level Cooling system and hoses for condition ...... 49 Spark plug for proper heat range. carbon fouling and spark plug wire terminal for looseness...... Air cleaner for condition and contamination .. Clutch operation and freeplay l-lot start lever freeplay. Breather drain for cleanin Steering head bearings and related par . for condition .......... Carburetor throttle oper oi Engine idle speed for stable and proper rpm ..... ....... 140 Tires for damage or mproper inflation pressure Spokes or oosenes Rim locks for loosene Front and rear suspension for proper operation Front and rear kes, check op Drive chain for correct slack and adequate lubrication ..... Drive chain slidei and drive c ain rollers for damage or wear ...... 98 Exhaust pipe/Muffler inspec on.. 62 Steering damper operation inspection. 99 Every possible part for looseness (such as cylinder head nuts, engine mounting bolts/ nuts. axle nuts, handlebar holder bolts, fork bridge pinch bolts, drive chain adjuster, drive chain guide. wire harness connectors, kickstarter mounting bolt, etc.) 160 , 163 . . . .... . . . . . . . . . . . . /\ \ / l Before Riding 11 BOIG/tlfi/UK iii, 12 Before Riding _‘ nemsuxgumwmmdh 12 gowns/us; nus \J Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions start and stop your engine as well as break-in Side Stand. guidelines. Tripmeter .. Starting & Stopping the Engine Preparation Fuel Valve. Starting Procedure. Flooded Engine... How to Stop the Engine Shifting Gears Braking. Parking. Post—ride Inspection . Break-in Guidelines. /'\ /\ x,/ \/ Basic Operaling Instructions 13 ~ . / \ t7CKHSUX}!Mk‘x’TIOmdh u \./ guns/mama n4, /\ Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precautiom beginning on page Z and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF's exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death. A 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 unconsciousness and lead to death. Only run your vehicle‘s engine when it is located in a well ventilated area outdoors. 14 Basic Operating Instructions _‘ l7ERHSUXJle‘flIOmdb M Side Stand The side stand (1) is used to support your CRF while parked (page 19). To operate, use your foot to lower the side stand until it is fully extended. Before riding, raise the side stand. (1) slde stand /\ \ / l Tripmeter The tripmeter (1) is used to record the distance traveled (USA: miles. Canada: kilometers) per trip or section of route. To operate, pull the tripmeter reset knob (2) out (OFF) and turn it until the meter shows all zeros (0), then push the knob in (ON). (1) tripmeter (2) tripmeter reset knob guns/mama Ha, Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button. Preparation Make sure that the transmission is in neutral. Fuel Valve (1) fuel valve The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. ON—Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF—Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor. RES—Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. _‘ l7CRFASUXJIMLYchndb lS Starting Procedure Always follow the proper starting procedure described as follow. (2) choke knob (1) fuel valve Check the engine oil, transmission oil and coolant levels before starting the engine (pages 44, 47, 48). To restart a warm engine, follow the procedure for “High Air Temperature.” Normal Air Temperature 10°C — 35°C 50°F — 95°F 1. Turn the fuel valve (1) ON. 2. Pull the choke knob (2) fully ON, if the engine is cold. 3. Keep the throttle fully closed. 4. Pull the clutch lever all the way in, and depress the start button. Or operate the kickstaner to start the engine. Starting from the top of the stroke, kick through to the bottom with a rapid, continuous motion. Do not operate the throttle. Allowmg the kit/(starter to snap backfreely against the pedal stop can damage the engine ease. 5. Warm up the engine; don't operate the throttle. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. lf idling is unstable, open the throttle slightly. Extende use of the choke may impair piston and cylinder wall lubrication and damage the engine. High Air Temperature 35°C 95°F) or above 1. Turn the fuel valve ON. 2. Do not use the choke. 3. Keep the throttle fully closed. 4. Start the engine following step 4 under “Normal Air Temperature.” Low Air Temperature 10°C 50°F or below 1. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 2. Follow steps 1 — 4 under “Normal Air Temperature." 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. Basic Operating Instructions 15 ZOIG/OG/Oél ll 45 3:{ Starting & Stopping the Engine Hot Engine Starting 1. Pull the hot s rt lever (3) all the way in and start the engine following step 4 under “Normal Air Temperature." 2. As soon as the engine starts, release the hot start lever. /:’) (3) hot start lever Snapping the throttle or fast idling for more than 5 minutes may cause exhaust pipe discoloration. 16 Basic Operating Instructions _‘ t7emsuxgumnnomdh 16 Flooded Engine Starting the engine after a stall during riding or after a fall: 1. Shift the transmission into neutral. 2. Pull the hot start lever all the way in and start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting a flooded engine: (Using the start button) 1. Do not use the choke. 2. Shift the transmission into neutral with the throttle fully opened. 3. Pull the clutch and hot start levers all the way in and depress the start button for 5 seconds. If the engine starts, quickly close the throttle. then open it slightly if idling is unstable. If the engine does not start, wait 10 seconds. and then follow the regular starting procedure. 4. As soon as the engine starts, release the hot start lever. (Using the kickstarter) . Do not use the choke. 2. Shift the transmission into neutral with the throttle fully opened. repeat kickstarter operation approximately ten times very slowly to discharge excessive fuel from the engine. Close the throttle. 3. Pull the hot start lever all the way in and start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. How to Stop the Engine (1) (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) two or three times. and then close it. 4. Push the engine stop button (2) until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow. result in hard starting. Emergency Engine Stop To stop the engine in an emergency, push the engine stop button. zone/ems I l 4, Your CRF has five forward gears in a one-down, four-up shift pattern. To start riding, after the engine has been warmed and the side stand raised. 1. Close the throttle and pull the brake lever in. 2. Pull the clutch lever all the way in. 3 Depress the shift lever from neutral down to first gear. 4. Release the brake lever. Gradually open the throttle while you slowly release the clutch lever. If the engine rpm (speed) is too low when you release the clutch lever, the engine will stall. If the engine rpm (speed) is too high or you release the clutch lever too quickly, your CRF may lurch forward. 5. When you attain a moderate speed, close the throttle, pull the el ch lever in, and raise the shift lever. After shifting, release the clutch lever and apply the throttle. 6. To continue shifting up to each higher gear, repeat step 5. 7. To shift down to a lower gear, close the throttle, pull the clutch lever in, and depress the shift lever. After shifting, release the clutch lever and apply the throttle. _‘ t7cmsuxgmvirwmmuh l7 Remember to close the throttle and pull the clutch lever in completely before shifting. Improper s ifting may damage the engine, transmisrion, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high. Downshift to a lower gear before you feel the engine laboring (lugging) at low rpm. ' 'ng can help SiOW your motorcycle, expecialiy on downhilix. However, downshifting when engine rpm is too high can cause engine damage. To prevent transmission damage, do not toast or tow the motorcycle for long distantex with the engine ojj‘. Shifting Gears Basic Operating Instructions 17 gong/mama In, Braking To slow or stop, apply the front brake lever and rear brake pedal smoothly, while downshifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop. For support, put your left foot down first, then your right foot when you are through using the rear brake pedal. For maximum braking, close the throttle and firmly apply the front brake lever and rear brake pedal controls. Applying the brakes too hard may cause the wheels to lock and slide, reducing control of your CRF. If this happens, release the brake controls, steer straight ahead until you regain control, then reapply the brakes more gently. Generally, reduce your speed or complete braking before beginning a turn. Avoid braking or closing the throttle quickly while turning. Either action may cause one or both wheels to slip. Any wheel slip will reduce your control of your CRF. When riding in wet or raining conditions, or on loose surfaces, the ability to maneuver and stop will be reduced. All of your actions should be smooth under these conditions. Rapid acceleration, braking, or turning may cause loss of control. For your safety, exercise extreme caution when braking, accelerating, or turning. When descending a long, steep grade, use engine compression braking by downshifting, with intermittent use of both brakes. When you brake to a stop, pull the clutch lever in before stopping completely to prevent stalling the engine. For support, put your left foot on the ground first, then your right foot when you have finished braking. 18 Basic Operating Instructions _‘ t7cmsuxgumnnomah is ZOIG/UG/UX In, Parking Lower the side stand to support your CRF. If you're through riding for the day, turn the fuel valve OFF. Always choose a level surface to park. /\ _‘ l7cmsuxgnMummmm m /\ \ / l Basic Operaling Instructions 19 Bong/DBMS lldSIlJi /\ Post-ride Inspection When you return home after riding. thoroughly clean your CRF and remove any dirt, mud. brush. rock: or other objects you may have picked up along the way. After cleaning, carefully inspect your CRF for leaks or damage. Be sure to lubricate the drive chain (page 98) to prevent rusting. 20 Basic Operating Instructions _‘ t7cmsuxgnMmmnnm zn /\ \ / l BOIG/tm/ntt HA, /\ Break-in Guidelines Help assure your CRF‘S future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full—throttle starts and rapid acceleration. This same procedure should be followed each time when: piston is replaced 1, ton rings are replaced ‘ylinder is replaced crankshaft or crank bearings are replaced _‘ t7cmsuxgnMmmnnm 2| /\ \ / l Basic Operaling Instructions 21 gotta/amt; HA, 22 Basic Operating Instructions _‘ nemsuxgumwmmdh 22 zone/06m nus Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It's also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step—by-step instructions for specific maintenance tasks. You'll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 174). For information about the exhaust emission and noise emission requirements of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Canada (EC), see page 164. USA only Maintenance, replacement or repair of the emission control devices and systems may he performed by any motorcycle repair establishment or individual using parts that are “certified” to EPA standards. An optional tool kit may be available. Check with your dealer’s pans department. _‘ t7ERl-ASLIXJIMLWlOmdlr 2:; Before You Service Your Honda The Importance of Maintenanc Maintenance Safety ..... Important Safety Precautions Maintenance Schedule General Competition Maintenance. Before & After Competition Maintenance Between Motos & Practice Maintenance After Competition Maintenance... Service Preparatiam Maintenance Component Locations Subframe Upright Po tion Service Pratedm‘ex Fluids & Filter Fuel System. Engine Oil ...... Transmission Oil Coolant.... Air Cleaner.. Crankcase Breathe Engine Throttle.... Clutch System Hot Start Leve Spark Plug... Exhaust Pipe/Muffle Spark Arrester Valve Clearance Piston/Piston Rings/ Chassis Suspension Front Suspe n Inspec on Rear Suspension Inspection Recommended Fork Oil Fork Oil Change ..... Brakes Side Stand Drive Chai Steering Damper Additional Maintenance Procedures Electrical Battery... Headlight & Taillight ...... Appearance Care... Servicing Your Honda 23 anus/mama In, /\ The Importance of Maintenance A well-maintained motorcycle is essential for sale. economical, and trouble—free ding. It will A WARNING also help reduce air pollution. Careful pre—ride Improperly maintaining this motorcycle inspections and good maintenance are especially or failing to correct a problem before you important because your CRF is designed to be ride can cause a crash in which you can ridden over rough off-road terrain. be seriously hurt or killed. T0 hell? You properly care for Your CRF, 1h“ Always follow the inspection and section of the manual provides a Maintenance maintenance recommendations and Schedule. The service intervals in this schedule schedules in this owner’s manual. are based on average riding conditions. More frequent service is needed if you subject your CRF to severe use or ride in unusually wet or dusty areas. Frequent servicing of the air cleaner is especially important to help you avoid a possible costly engine repair. If your CRF overturns or is involved in a crash, be sure your dealer inspects all major parts, even if you are able to make some repairs. Remember, proper maintenance is your responsibility. Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section. 24 Servicing Your Honda l rs l7 CKHSUXJHVIH’TIOuidh 24 \ ./ gong/manna llASilji This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However. we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner‘s manual. Important Safety Precautions - Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts Do not run the engine unless instructed to do so. _‘ l7cmsuxgnMus/mural, 25 - 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 an optional workstand to provide support. To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene inot gasolinei to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts. /\ \/ l Maintenance Safety Servicing Your Honda 25 gong/mama nAsaJi Maintenance Schedule To maintain the safety and reliability of your CRF, regular inspection and service is required as shown in the Maintenance Schedules , Regular OFF ROAD Use (non-competition) and Competition Use , that follow. The Maintenance Schedule list items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in these schedules are provided in a service manual available for purchase from your dealer (page 174). Because your CRF does not have an odometer. service intervals in the maintenance schedules are expressed in terms of riding days as well as miles. To avoid overlooking required service, we urge you to develop a convenient way to record the number of days and/or distance traveled (USA: miles, Canada: kilometers) you ride. If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability. 26 Servicing Your Honda _‘ i7L‘Rl-ASLIXJIMPYHOmdb 25 Perform the pre—ride inspection (page 11) at each scheduled maintenance period. Each item on the maintenance schedule requires some mechanical knowledge. Certain items (particularly those marked *and**) may require more technical information and tools. Consult your dealer. * Should be serviced by your dealer, unless the owner has the proper tools and service data and are mechanically qualified. Refer to the official l-londa Service Manual (page 174). ** In the interest of safety, we recommend these items be serviced only by your dealer. Maintenance Procedures: 1: inspect and clean, adjust, lubricate, or replace. if necessary : clean . adjust : lubricate : replace wr>o gong/mama ”45317 Maintenance Schedule MAINTENANCE SCHEDULE — REGULAR OFF-ROAD USE (NON-COMPETITION) Summary anairItenance Schedule Notes and Procedures; FREQUENCV gm“? 'Mm'a‘ Regular MaInlenance InlerVal r:nnes Irsl aInI Hem NOTES: ”'65 ‘09 50° 120° ”3‘70 21400 1° 1. Service more frequently when ridden in wet km 150 I000 2,000 1000 4,000 Page: or dusty Conditions. ITEMS NOTE Monlh 1 5 12 18 2A 2- USA and Canada ‘ype only. "‘ FUEL ”NE ' ' “ 3. Replace every 2 years. Replacement requires * :1 FUEL STRAINER SCREEN c C 42 mechanical Skill. >1: THROTTLE OPERATlON I | 55 AIR CLEANER (NOTE 1) C c c C 51 ORANKOASE BREATHER | I I I 53 SPARK PLUG I I I I 61 at VALVE CLEARANCE I I I I I as ENGINE OIL R R R R H 43 ENGINE OIL FILTER R H R R H 44 * DECOMFHESSOH SVSTEM I I I I I - )k 41 ENGINE IDLE SPEED I I I I I 1A0 RADIATOR COOLANT (NOTE 3) I H 42 1r COOLING SVSTEM I I I I 49 >1: SEGONDARV AIR SUPPLV SVSTEM (NOTE 2) I I _ "'\ TRANSMISSION OIL R H R R H 46 r \ ‘ DRIVE CHAIN (NOTE 1) I, L I, L. eVery 300 rnIIes (500 km) ora rnonlns 95 - 98 \ I DRIVE CHAIN SLIDER I I I I 92 BRAKE FLUID (NOTE 3) I I I I as BRAKE PADS WEAR I I I I 91 BRAKE SVSTEM I I I I I EB * HEADLIGHT AIM I I 107 OLLITOH SVSTEM I I I I 56 SIDE STAND I I 95 1r SUSPENSION I I 34‘ as >1: SPARK ARRESTER c: every 1,000 mlles (new km) or 65 every 100 operanng hours >1: NUTS( BOLTS FASTENERS I I I 103 lBfl— l63 a; * WHEELS/TIRES I I I I 92‘ 93 >11 * STEERING HEAD BEARINGS I I I 102 ’ SnouIn be SSNlCed by your dealen unless Ine owner nae Ine proper mole and serVIee data and Is meenanleaw quaIIIIea Reler Io Ine ollIcIaI Honda SerVIee Manual (page I74). " In Ine InIeresI ol salely we recommend Inese IIems be Sen/Iced only by your dealer, Servicing Your Honda 27 _‘ ITcklasuxgumwmmun 27 anus/mam Ins, Maintenance Schedule MAINTENANCE SCHEDULE — COMPETITION USE All items should be checked before each competition event. See your dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda. Perform the Pre-ride Inspection (page 11) at each scheduled maintenance period. 1: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. A: Adjust. L: Lubricate. R: Replace. FREOUENCV About About About About About NOTE 2.5 hours 7.5 hauls 15 0 hauls 22,5 hauls 30 0 hauls He" Page ITEMS THROTTLE OPERATION | 55 HOT STARTER I so AIR FILTER (NOTE 1) C 51 CRANKCASE BREATHER I 5:1 SPARK PLUG I 61 RADIATOR COOLANT (NOTE 2) I 45 VALVE CLEARANCE/ DECOMPRESSOR SVSTEM (NOTE A) I as ENGINE OIL (NOTE :1) I R 4:1 ENGINE OIL FILTER (NOTE :1) R 4A ENGINE IDLE SPEED I 140 PISTON AND PISTON RINGS R 79 PISTON PIN R 79 TRANSMISSION OIL (NOTE 5) I R 45 r \ COOLING SVSTEM I 49 \ I DRIVE CHAIN I, L R 95 DRIVE CHAIN SLIDER I ' 9a DRIVE CHAIN ROLLER I 95 DRIVE SPROCKET I 97 DRIVEN SPROCKET I 97 BRAKE FLUID (NOTE 2) I 59 BRAKE PADS WEAR I 91 BRAKE SYSTEM I ca CLUTCH SVSTEM (NOTE 5) I 55 CONTROL CABLES I, L ' 102 EXHAUST PIPE/MUFFLER I 62 SUSPENSION I 54‘ 55 SWINGARM/SHOCK LINKAGE L 32 FORK OIL FORK TUBE/SLIDER (NOTE :1) R 55 DAMPER R 117 NUTS BOLTS FASTENERS I 103, 160 — 163 WHEELS/TIRES I 92‘ 9a STEERING HEAD BEARINGS I 102 * We recommended these Items he seryrced by reternng to tne Honda seryrce manual The malntenance scneduIe rs based upon average ndrng candruen. Macnrne sumected to Severe use requIve more Ireduent seNICIng. NOTE: 1. CIean aIter every moto1or dusty ndmg CondItIonS 2. RepIaCe every 2 years. RepIaCement requrres mecnanrcaI SkIII. Cl. RepIaCe finer the Ilrsl break-In nde. A. Inspect aItertne lIrSt break-In nde. 5. RepIace tne Iransmtssten 911. II tne clutch dIScS and pIaIes are replaced. 28 Servicing Your Honda ‘I I7CKl-ASUXJIMkYHOuIdII 21; zomrnmx 1145, /\ General Competition Maintenance Perform maintenance on firm, level ground using the side stand, a workstand, or equivalent support. When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattem. Use l-londa Genuine Parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Lubricate any sliding surface, 0— 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-ride Inspection Item Refer to Pre-ridr’ Inspection page 11. _‘ t7cmsuxgmvirwImuuty 29 rs \ / t Servicing Your Honda 29 gong/mama ”MAJ, _‘ l7CRFASUXg‘lthY7Illuldb 30 General Competition Maintenance Spark Plug Some nonrresislor plugs may cause ignition problems. Refer Io Ihe recommendnrions elsewhere in this manual for specific lypes so you will be sure [0 use the proper reach and heal range, Replace periodically as specified in rhe Maintenance Schedule (pages 27. 28). Air Cleaner Clean and oil your air cleaner regularly because the volume of air able ro pass through it has a great effect on performance. Both engine periormance and long term durabiliry may be affected by an air cleaner rhar has dereriorared and allows dirt to pass. lnspecr rhe air cleaner closely each tlme lr’s serviced for evidence of small [ears or seam separation, Keep a spare arr cleaner oiled and ready to lnstall, sealed in a plastic bag. Riding in dusry conduions may require servicing the air cleaner or replacing it wirh a presserviced air cleaner belween moms. Be careful not to over or] the arr cleaner, While ii is imponanl IO ml the arr cleaner thoroughly over oiling will cause an overall rich running condillonc probably more noriceable off idle and in low rpm performance. Follow lhe servicing insrrucrions in the Mainrenance secrion, Use Pro Honda Foam Filter Ol] or an equivalenl. Be sure ro grease [he air cleaner flange where l[ Conracts [he air cleaner housing. Pro Honda White Lithium Greases or an equivalent. is handy for this because any dirt that penerrales rhis sealing area will show up clearly (page 51). Use the Honda Genuine air cleaner or an equivalenr air Spark Plug Cap lnsrall a small plasric tierwrap around the spark plug cap ro reduce any possrbiluy or it loosening or of waler penetranon. it 3 cleaner specified for your model. 3 Using rhe wrong l-londa air cleaner or a nonrHonda air / \ Engine Oil and m" l cleaner which is nor of equivalenl quality may cause \ / Dram and replace engine oil oflen ro ensure the greatesr mm” “3'“ W“ 0‘ Pe‘fo‘mm P‘Oblems' service life oflhe piston, cyllnder and crankshaft. Also replace engine oil filler oflen [0 ensure the greatesl service life. Frequenl changes Wlll also assure consrsrenr performance of power and response (page 44). 'h-ansmission Oil Air Cleaner Housing Sealing Drain and replm lmnsmission oil oflsn l0 ensure “I6 Remove and reseal lhe air cleaner connecung boor where ii grealen service life of me lmnsmmiou and clutch. Frequent connecrs ro rhe air cleaner housing wirh Pro Honda l-landgrip changes will also assure consistenl performance of bath Cemenr or equivalenr if rhere is any doubr ro lts sealing shlfimg and clutch mien (page 47). rnregriry. Inspecl [he air cleaner and air intake rracr regularly for signs of delerioranon or dirt penetration. 30 Servicing Your Honda ZOIG/OG/Oél I l as: Handgrips Always use Pro Honda Handgrip Cement or equivalent when replacing handgrrps. Throttle Grip Align the index mark on the throttle grip with the edge ofthe throttle cable guide Lef[ handlebar grip. Allgn the “a" mark on the lef[ handlebar grip with the paint mark on the handlebar. Refer to the Honda Service Manual (page 174) for installation instructions. For added security, you may choose to bind the handgrips to the handlebar and throttle pipe wrth safety wire to prevent the possibility of them loosening. Position the twisted wrre ends away from your palms and be sure to bend the wire ends well into the handgrips rttbber so they will not snag your glove. Throttle Control Remove the throttle control every few rides, clean the lnSlde of the throttle pipe and handlebar thoroughly. Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way. Move the handlebar from lock [0 lock to be sure [here is no cable interference, Make cenain the throttle operation is perfect after servicing and inspecting. _‘ l7cmsuxglthwunndb 3| General Competition Maintenance Fuel Filter Periodically drain the fuel from the fuel tank, remove and clean the fuel valve/filter. Replace the fuel valve Orring lf there are any signs ofdamage or deterioration (page 42). Gaskets Always use new gaskets when reassembllng components, Cylinder Put a little grease on the cylinder mounting dowels to prevenl corrosion from dissimilar melals. The [olerances are quite [ighL so it’s important to keep these dowels absolutely clean (page 78). Fuel Contamination Refer to Fuel Syxlt‘m in your Owner's Manual (page 41). Check [he fuel llnes for deterloration. damage, or leakage. Replace the fuel lines, if necessary. Periodically dram the fuel from the fuel [ank, remove and clean the fuel valve/filter. Replace [he fuel valve Orring lf there are any signs ofdamage or deterioration (page 42). Loosen [he carburetor drain screw and examlne [he fuel that flows ottt ofthe floal bowl, If you notice anything in the fuel. such as water or dirt, remove the float bowl and inspect ilS contents (page 137). For maximum efficiency, drain and replace fuel [ha[ has remained in your fuel [ank for more than a monlh, Fuse Check the fuse before looking elsewhere for the cause of an electrical problem. Battery Electrical accessories use current from the battery , even when the engine is off. 3 Limited operation also allows the battery to discharge. If you have elec[rlcal ac ories on your CRF r or do not rlde frequently, we recommend that you charge the battery freqttently (see Bunny Charging, page 105). If you do not expect to ride your CRF for at least 2 weeks. we recommend you remove the battery , or at least disconnect the battery cables (negative cable first). Electrical Connectors Clean elec[rlcal conneclors and wrap [hem wi[h electrical tape to reduce the possibility of unwanted disconnecttons. water shorts or corrosion. Additional corrosion protection is offered by using Pro Honda Dlelectric Grease on all electrical connections. Engine Mounting Bolts and Nuts Make sure the engine mounting bolts and nuts are tightened to the proper torqtte specification, For added peace of mind. remove the nuts, clean the threads and apply Pro Honda Hondalock or an equivalent prior to torqurng the nuts. Servicing Your Honda 31 ZOIG/OG/Oél ll 4 General Competition Maintenance Suspension Linkage Lubrication Disassemble, clean, inspect and lubricate all suspension linkage pivot bean'ngs with grease after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear. Brake Fluid Replacement Refer to Swim Fat! VVt'tlr in your Owner's Manual (page 91), Brake Caliper Inspectlon: Be sure both the front and rear calipers are able to move freely on the caliper pins and caliper bracket pins. Check pad thickne periodically and replace the pads when minlmum thlckness ls reached. If the brakes fade when they are hot. inspect the pads for glaztng or damage. and replace if necessary. Brake Fluld Replacement: Refer to the Honda Service Manual (Page 174) for brake fluid replacement lnstructions. Replace the hydraulic fluid in the brake system every 2 years, Replace the fluid more frequently ifyou subject your brakes to severe use, Heavy braking heats the brake fluid and it may deteriorate sooner than expected. Any type of riding, that requires frequent use ofthe brakes. such as in tight woods, can shorten the service life of brake fluid. Swingarni Pivot Lubrication Clean, inspect and lubricate the swingarm and suspension linkage pivots with grease. Be sure all of the dust seals are in good condition. Swingarni Do not attempt to weld or otherwise repair a damaged swingarm. Welding will weaken the swingarm. Footpegs Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular shaped file, Be aware that filing them too sharp will reduce boot sole lifespan, Sharpen only the points of the teeth, Filing the grooves deeper will weaken the footpegs. Be sure the footpegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition. Bleed Hole After every race, check the bleed hole, located just below the water pump cover on the right crankcase cover. Clean away any clogged dirt or sand, if necessary. Check for signs of seal leakage. A small amount of “weeplng” from the bleed hole is normal. 32 Servicing Your Honda _‘ l7CRFASUXg‘lleYHlluldll 32 ~ Steering Head Bearings Periodically clean, inspect and regrease the steering head bean'ngs 7 especially if wet, muddy or extremely dusty courses are encountered often. Use urea based multipurpose grease designed for high temperature, high pressure performance (example: EXCELITE EPZ manufactured by KYODO YUSHI, Japan or Shell Stamina EPZ or equivalent) Fork Oil/Performance Disassemble, clean and inspect the front fork and replace oil regularly. Contamination due to the tiny metal particles produced from the normal actlon of the fork, as well as normal oil breakdown. will deterlorate the performance of the suspension, Refer to the Honda Service Manual (page 174). Use only Pro Honda HP Fork Oil 5w or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension. Franie Because your CRF is a highrperformance machine. the frame should not be overlooked as pan of your overall competition maintenance program, Periodically inspect the frame closely for possible cracking or other damage. It makes good racing sense. Spokes Check spoke tension frequently between the first few rides. As the spokes. spoke nuts and rim contact points seatrln, the spokes may need to be retightened. Once past this initial seatingrin period, the spokes should hold their tension, Still, be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis (page 92). Nuts, Bolts, Etc. Application of a thread locking agent to essential fasteners offers added assurance and security, Remove the nuts, clean the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent and tighten to the specified torque. zolri/ari/al-l ll 4 U: Before & After Competition Maintenance Between Motos & Practice Maintenance After practice or between motos you have a chance to make additional checks and adjustments. O Clean accumulated dirt from under the fenders and off the wheels, suspension components, handgrips, controls, and footpegs. A stiff, nylon parts cleaning brush works well. O Check tire air pressure. O Check spoke tension and rim lock security. O Check to make sure the sprocket bolts and nuts are secure. O Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. O After adjustment, check that the chain adjuster index marks (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. _‘ l7CRFASLlXJlMEWlumdb 3:; (1) chain adjuster index marks O Suspend the front wheel above the ground and use the fork air pressure release screws (2) to release the built—up pressure (in excess of normal atmospheric pressure: 0 psi (0 kPa, 0 kgf/cm1)) 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.) (2) fork air pressure release screw After Competition Maintenance It is important to the long term performance of your CRF to practice a consistent maintenance program. Right after the event is a good time to begin your next maintenance cycle. After Race Lubrication Apply a light coating of rust-inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away. This will prevent rusting of the exposed metal. Apply rust-inhibiting oil more heavily if the event was particularly wet or muddy. Take care to avoid spraying any oil near the brake pads or the brake disc. Clean and lubricate the drive chain (page 98). Be sure the chain is wiped clean and is dry before lubricating the chain. /\ Take care to prevent catching your fingers between the chain and sprocket. Servicing Your Honda 33 zone/ems n 45317 /\ Before & After Competition Maintenance Routine Cleaning If your CRF is only slightly dirty, it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags. Take care to prevent catching your fingers between the chain and sprocket. A variety of reasonably priced cleaning brushes are available from variety, drug, food, and hardware stores. Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF. Avoid using stiff, abrasive brushes on the plastic or rubber parts. If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Apprarancr’ Care (page 108). 34 Servicing Your Honda _‘ t7cmsuxgumrwmmah 34 /\ \ / l gong/0mm Ha, Maintenance Component Locations steering damper adjuster hot start lever iront brake fluid reservoir tront brake lever olutoh lever throttle grip ‘ ? radiator cap fuel till cap ‘ ‘ ‘ ' ‘ a rear suspension high speed rear suspension ron suspension . K \ , l compression damping adjuster rebound damping cornpression damping \ / spark plug a" c eaner rear suspension low speed adjuster adjuster throttle stop screw ,i battery compression damping adjuster ,4 , (engine idlespeed) /w \ l front brake caliper 6%. i engine oil filter coolant reserve tank coolant reserve tank cap rear suspension spring pre-load adjuster \Lr ‘ \‘r transmission {A //y ' oil check bolt Rx x \ transmission oil iill cap rear brake pedal drive chain rear brake iront suspension rebound callper rear brake fluid dampmg adiuster reservoir engine oil drain bolt engine oil till cap/dipstick _‘ l7CRFASUXJleYHUmdli 35 Servicing Your Honda 35 ammo/ax ll 45 317 Seat Refer to Safary Prvmutions on page 25. Removal 1. Remove the seat mounting bolts (1). 2. Remove the seat (2) by sliding it backward. (1) seat mounting bolts (2) seat 36 Servicing Your Honda _‘ i7cxiasuxgumiwmmdh 3r: Installation 1. Install the seat (I) while aligning the seat front prong (2) with the seat bracket (3) and seat rear prongs (4) with the tabs (5) of the frame. 2. Install and tighten the seat mounting bolts (6) to the specified torque. 19 lbf-ft (26 N~m, 2.7 kgf~m) (1 ) seat (2) seat front prong (3) seat bracket (4) seat rear prongs (5) tabs (6) seat mounting bolts ZOIG/UG/UX nasal, J Refer to Safety Precautionr on page 25. Removal 1. Turn the fuel valve OFF. 2. Remove the seat (page 36). 3. Remove the shroud A bolts/collars (l). 4. Remove the shroud B bolts (2) and shrouds (3). r" ‘ \_\7 (1) shroud A bolts/collars (2) shroud B bolts (3) shroud _‘ l7CRFASLIXJIMkWIOmdli 37 5. Pull the breather tube (4) out of steering stem nut. Unhook and remove the fuel tank band (5). Unhook the air cleaner cover rubber (6). Remove the fuel tank bolt (7). 9°89 (4 (5 (6 (7 breather tube fuel tank band air cleaner cover rubber fuel tank bolt U: Fuel Tank 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. 10. Remove the fuel valve bolt (10) and fuel valve. 11. Remove the fuel tank. A WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuelt - Stop the engine and keep heat, sparks and flame away. - Handle fuel only outdoors. - Wipe up spills immediately. (8) fuel line (9) fuel valve (10) fuel valve bolt Servicing Your Honda 37 ZOIG/OG/Gél I l 45 xii Fuel Tank Installation 1. Install the fuel tank on the frame. 2. Install the fuel valve (1) and tighten the fuel valve bolt (2). 3. Connect the fuel line (3) to the fuel valve. Clamp the fuel line clamp (4) as shown. 1 a (1) fuel valve (3) fuel line (2) fuel valve bolt (4) fuel line clamp 4. Install and tighten the fuel tank bolt (5). 5. Hook the air cleaner cover rubber (6). 6. Install and hook the fuel tank band (7). 7. Put the breather tube (8) in the steering stem nut. (7) (5) fuel tank bolt (7) fuel tank band (6) air cleaner cover rubber (6) breather tube 38 Servicing Your Honda _‘ momsuxgnmrwmmdb as 8. Install the shrouds (9) by aligning its tab (10) with subframe (l 1). (9) shroud (10) tab (11) sublrame 9. Install the shroud B bolts (12) and shroud A bolts/collars (13). 10. Tighten the shroud B bolts to the specified torque: 3.7 Ibf-ft (5 N-m, 0.5 kgf-m) (12) shroud B bolts (13) shroud A bolts/collars 11. Install the seat (page 36). ZOlG/OG/Oél n 45 317 U: Subframe Upright Position Refer to Safety Precautiom on page 25. The subframe may be adjusted to an upright position to permit servicing of the rear suspension and carburetor. Upright Position 1. Remove the seat (page 36). 2. Remove the right side cover bolt (1) and right side cover (2). (1) right side cover bolt (2) right side cover 3. Open the air cleaner housing cover (3) by turning the quick fastener (4) counterclockwise and remove the left side cover bolt (5) and left side cover (6). (3) (4) (3) air cleaner housing cover (4) quick fastener (5) lelt side cover bolt (6) lelt side cover _‘ t7CRFASLlXJlMEWIOmdb as 4. Remove the muffler (page 62). 5. Loosen the screw (7) on the air cleaner connecting boot clamp (8). (7) screw (8) air cleaner connecting boot clamp 6. Loosen the subframe upper mounting bolts (9) and remove the subframe lower mounting bolts (10). A (9) sublrame per mounting bolts (10) sublrame lower mounting bolts 7. Lift the subframe (11) as shown. Tighten the subframe upper mounting bolts to the specified torque: 36 Ibf-ft (49 N-m, 5.0 kgf-m) (11) subframe Servicing Your Honda 39 zone/ems n 45 xii Subframe Upright Position Installation 1. Loosen the subframe upper mounting bolts (1)- 2. Loosely attach the lower ends of the subframe (2) to the mainframe while connecting the air cleaner connecting boot to the carburetor. Be careful not to bend the subframe. Install the subframe lower mounting bolts (3). Tighten the subframe upper mounting bolts first, then tighten the subframe lower mounting bolts to the specified torque: 36 lbf-ft (49 N~m, 5.0 kgf~m) J , ( (1) subtrame upper mounting bolts (2) subtrame (3) subtrame lower mounting bolts 40 Servicing Your Honda _‘ l7cmsuxgumrwromdb 40 3. Make sure the carburetor lug (4) aligns with the air cleaner connecting tube slot (5). 4. Tighten the screw (6) on the air cleaner connecting boot clamp (7). (4) carburetor lug (5) air cleaner connecting tube slot (6) screw (7) air cleaner connecting boot clamp 5. Install the muffler (page 63). 6. Install the left side cover (8) and left side cover bolt (9). Close the air cleaner housing cover (10) and turn the quick fastener (11) clockwise. (11) (10) air cleaner housing cover (11) quick fastener /\ (8) lelt side cover (9) lelt side cover bolt 7. Install the right side cover (12) and right side cover bolt (13). (12) right side cover (13) right side cover bolt 8. Install the seat (page 36). zone/ems n 45 xii Refer to Safety Precautionr on page 25. Fuel Recommendation Type Unleaded Pump Octane Number 91 (or higher) Use only unleaded fuel in your Honda. If you ride your Honda in a country where leaded fuel might be available, take precautions to use only unleaded fuel. Your engine is designed to use any unleaded gasoline that has a pump octane number of 91 or higher. Gasoline pumps at service stations normally display the pump octane number. For information on the use of oxygenated fuels, see page 166. Use of lower octane gasoline can cause persistent “pinging" or “spark knock" (a louder rapping noise) which, if severe, can lead to engine damage. (Light pinging experienced while operating under a heavy load, such as climbing a hill, is no cause for concern.) If pinging or spark knock occurs at a steady engine speed under normal load, change brands of gasoline. lf pinging or spark knock persi consult your dealer. Never use stale or contaminated gasoline. Avoid getting dirt, dust, or water in the fuel tank. _‘ t7CRFASUXJleWIthndh 4| Refueling Procedure Fuel Tank Capacity: 1.90 US gal (7.2 P.) (1) fuel (ill cap (2) breathertube (3) steering stern nut 1. To open the fuel fill cap (I), pull the breather tube (2) out of the steering stem nut (3). Turn the fuel fill cap counterclockwise and remove it. 2. Add fuel until the level reaches the bottom of the filler neck. Avoid overfilling the tank. There should be no fuel in the filler neck. 3. Close the fuel fill cap by turning the cap clockwise and insert the breather tube in the steering stem nut. A WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. - Stop the engine and keep heat, sparks and flame away. - Handle fuel only outdoors. - Wipe up spills immediately. Fuel System Fuel Line (1) fuel line 1. Check for leaks. 2. Check the fuel line (1) for cracks, deterioration, damage, or leakage. Replace the fuel line, if necessary. 3. Check for interference between the frame and tank and adjust if necessary. Servicing Your Honda 41 zolfi/oG/ox I l 4, , U: Fuel System Fuel Filter The fuel filter is mounted on the bottom left side of the fuel tank. Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor. Therefore. the fuel filter should be serviced frequently. To service the fuel filter: 1. Remove the fuel tank (page 37). 2. Drain the fuel from the fuel tank into an approved gasoline container. Disconnect the fuel valve and fuel lines (1). 3. Remove the fueljoint (2) from the fuel tank by removing the bolts (3). (1) fuel valve and fuel lines (2) fuel joint (3) bolts 42 Servicing Your Honda _‘ l7CRFASUXJleYHOmdh 42 4. Wash the fuel filter (4) in high flash—point cleaning solvent. 5. Check that the O-ring (5) is in good condition. 6. Install the fuel joint in the fuel tank by tightening the bolts to the specified torque: 7 lbf-ft (10 N~m, 1.0 kgf-rn) Attach the fuel valve and fuel lines. 7. Install the fuel tank (page 38). Refill the fuel tank and turn the fuel valve to ON or RES; check for fuel leaks. (4) fuel filter (5) O-ring zolfi/ofi/ox I l 45317 /\ Refer to Safety Precautiom on page 25. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the engine. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine. _‘ l7cmsuxguMnnolmm 4:: Oil Recommendation API SG or higher except oils labeled classlllcatlon as energy conservtng or resource conserving on the circular API service label viscosity SAE 1ow-ao (weight) JASO T 903 MA standard Pro Honda GN4 4-stroke Oll (USA 8. Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil‘ suggested oll' >14 Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label. /\ \ / l Engine Oil - Your CRF does not need oil additives. Use the recommended oil. - Do not use API SH or higher 4—stroke engine oils displaying a circular API “energy conserving" or “resource conserving" service label on the container. They may affect lubrication. EC \ch NOT RECOMMENDED 6K - Oil is a major factor affecting the performance and service life of the engine. Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. .* 10 20 30 40 50C 730 720 710 0 720 0 20 4O 60 80 100120‘F Servicing Your Honda 43 EttllsrnlS/UK ”4511f Engine Oil JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification. (1) oil code (2) oil classification 44 Servicing Your Honda _‘ nonrasuxgmrwmmdb M 4% Checking & Adding Oil (1) engine oil lill cap/dipstick (2) upper level mark (3) lower level mark 1. 2. Run the engine at idle for 3 minutes, then shut it off. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine. Support the CRF in an upright position on a level surface. Remove the engine oil fill cap/dipstick (1), wipe it clean, and insert the engine oil fill cap/dipstick without screwing it in. Remove the engine oil fill cap/dipstick. Check that the oil level is between the upper (2) and lower (3) level marks on the engine oil fill 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, add the recommended oil until the upper level mark. (Do not overfill) Reinstall the engine oil fill cap/dipstick. Repeat steps 1 — 5. Install the engine oil fill cap/dipstick securely. Check for oil leaks. % Changing Engine Oil & Filter 1. Run the engine at idle for 3 minutes, then shut it off. 2. Support the CRF in an upright position on a level surface. 3. Remove the engine oil fill cap/dipstick (1) from the left crankcase cover. 4. Place an oil drain pan under the engine to catch the oil. Then remove the engine oil drain bolt (2) and sealing washer (3). 5. After the oil has drained, apply engine oil to the drain bolt threads and tighten it with a new sealing washer to the specified torque: 12 Ibf-ft (16 N-m, 1.6 kgf~m) Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). Improper disposal ofdminedfluidr is harmful to the environment. (1) engine oil lill cap/dipstick (2) engine oil drain bolt (3) sealing washer ZUlG/OG/Oél n as 3y 6. It is recommended to replace the oil and filter every 15.0 hours. However, if you replace only the oil before the recommended interval. see pages 27, 28. 7. Remove the left engine guard bolt (4) and left engine guard (5). (4) left engine guard bolt (5) left engine guard _‘ l7CRI-ASLIXJIthlOuidli 45 8. Remove the oil filter cover bolts (6), oil filter cover (7) and O-ring (8). 9. Remove the oil filter (9) and spring (10) from the filter cover. 10. Apply grease to the filter side of the spring end. then install the spring into a new oil filter. (6) oil lllier cover bolts (7) oil lllier cover (8) oil lllier cover O-ring (9) oil lllier (10) spring (11) rubber seal (12) “OUT-SIDE" mark Using the wrong oilfilter may result in leaks or engine damage. 11. Position the spring against the engine crankcase and install a new oil filter with the rubber seal (11) facing out, away from the engine. You should see the “OUT—SIDE" mark (12) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. Engine Oil Ifthe oilfilter is not installed properly, it will cause serious engine damage. 12. Apply engine oil to a new O-ring and install it to the oil filter cover. 13. Install the oil filter cover being careful not to damage the O-ring, then tighten the oil filter cover bolts to the specified torque: 7 Ibf-fl (10 N-rn, 110 kgf-m) 14. Install the left engine guard and tighten the left engine guard bolt. 15. Fill the crankcase with the recommended oil. Capacity: 0.74 US qt (0.70 1’.) after draining and filter change 0.71 US qt (0.67 B) after draining 16. Install the engine oil fill cap/dipstick. 17. Check the engine oil level by following the steps in Checking & Adding 0i] (page 44). Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). Improper disposal ofdrainedfluids is harmful to the environment. Servicing Your Honda 45 eons/mama IIASMF U: /\ Transmission Oil Refer to Safety Precautionr on page 25. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil c' use serious damage to the engine and transi on. 46 Servicing Your Honda _‘ t7cmsuxguMnnotmiv an Oil Recommendation API classification 86 or higher except oris (4-stroke engine labeled as energy conserving orl only) or resource conserving on the circuiarAPI service label Viscosity (weight) SAE 10W—30 JASO T 903 MA standard others without lrictlon modilrers such as molybdenum addrtlves Pro Honda GN4 4—stroke oil (USA & Canada), or Honda 4-stroke ori, or an equivalent motorcycle oil‘ suggested ori' * Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label. - Your CRF does not need oil additives. Use the recommended oil. - Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation. - Do not use API SH or higher 4—stroke engine oils displaying a circular API “energy conserving" or “resource conserving" service label on the container. They may affect lubrication and clutch performance. rs \ / l - Oil is a major factor affecting the performance and service life of the transmission and clutch. Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. up -30 -20 -10 0 10 20 30 40 50C III- 720 O 20 40 60 80 100 120? JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example. the following label shows the MA classification. (1) oil code (2) oil classification gotta/norms lldSMF U: Transmission Oil Checking & Adding Oil (1) transmission oil iill cap (3) sealing washer (2) oil check bolt 1. Run the engine at idle for 3 minutes, then shut it off. 2. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission. 3. Support the CRF in an upright position on a level surface. 4. Remove the transmission oil fill cap (1), oil check bolt (2) and sealing washer (3) from the right crankcase cover. A small amount of oil should flow out of the oil check bolt hole. Allow any excess oil to flow out of the oil check bolt hole. If no oil flows out of the oil check bolt hole, add oil slowly through the transmission oil fill hole until oil stan to flow out of the oil check bolt hole. Install the oil check bolt with a new sealing washer and transmission oil fill cap. Repeat step 1 — 4. 5. After checking the oil level or adding oil, install the oil check bolt with a new sealing washer. Tighten the oil check bolt to the specified torque: 7 Ibf-ft (1O N-m, 1.0 kgf-m) 6. Install the transmission oil fill cap securely. _‘ l7CRl-‘45EIXJIMEY7IOm-lb 47 Replacing Transmission Oil 1. Run the engine at idle for 3 minutes, then shut it off. 2. Support the CRF in an upright position on a level surface. 3. Remove the transmission oil fill cap (I) from the right crankcase cover. 4. Place an oil drain pan under the engine to catch the oil. Then remove the transmission oil drain bolt (2) and sealing washer (3). 5. After the oil has drained, apply engine oil to the drain bolt threads and tighten it with a new sealing washer to the specified torque: 12 Ibf-ft (16 N~m,1.6 kgf~m) (1) transmission oil fill cap (2) transmission oil drain bolt (3) sealing washer 6. Fill the crankcase with recommended oil. Capacity: 069 US qt (0.65 2) after draining. 7. Check the transmission oil level by following the steps in Checking & Adding Oil (this page). Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). Improper dirpnral (If drainedfluidx is harmful to the environment. Servicing Your Honda 47 2016/06/08 lldellf Coolant Your CRF's liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head. Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion. Coolant Recommendation Use Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Check the antifreeze container label. Use only distilled water as a part of the coolant solution. Water that is high in mineral content or salt may be harmful to the aluminum engine. Using coolant with silicate inhibitors may cause premature wear of water seals or blockage of radiator passages. Using tap water may muse engine damage. The factory provides a 50/50 solution of antifreeze and water in this motorcycle. This coolant solution is recommended for most operating temperatures and provides good corrosion protection. Decreasing the concentration of antifreeze to less than 40% will not provide proper corrosion protection. 48 Servicing Your Honda _‘ ncxrasuxgnmrwmmub as 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 during freezing weather. Checking 8; Adding Coolant Refer to Safety Precautions on page 25. 1. With the engine at normal operating temperature, check the coolant level in the reserve tank. It should be between the UPPER (l) and LOWER (2) level marks. If the reserve tank (3) is empty, or if coolant loss is excessive, check for leaks and see your dealer for repair. (1) UPPER level mark (3) reserve tank (2) LOWER level mark 2. Remove the reserve tank cap (4). Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. (4) reserve tank cap W 3. Add coolant to the reserve tank as require to bring the coolant level to the UPPER level mark. \ 1 Install the reserve tank cap. Cooling System Inspection 1. Check the cooling system for leaks (see the Honda Service Manual for troubleshooting of leaks). 2. Check the water hoses (1) for cracks, deterioration, and radiator hose clamp for looseness. 3. Check the radiator mount for looseness. 4. Make sure the siphon hose (2) is connected and not clogged. Check the radiator fins for clogging. Check the bleed hole (3) below the water pump cover (4) for leakage. Check for signs of seal leakage. A small amount of “weeping’ from the bleed hole is normal. See the Honda Service Manual or consult your dealer for replacing the water seal or the oil seal. Both seals should be replaced at the same time. 9F" _‘ l7emsuxgnmiwmmuu 49 (1) water hoses (2) siphon hose (3) bleed hole (4) water pump cover U: Coolant Coolant Replacement Refer to Safety Preeautionr on page 25. Coolant should be replaced by your dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the Honda Service Manual (page 174). A WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. To properly dispose of drained coolant, refer to You & the Environment, page 151. /\ Improper dirposal of drained fluidr [r harmful to the environment. Servicing Your Honda 49 ammo/ax n as 417 J Coolant . . 3. Remove the reserve tank cap (3) and fill the 4. Bleed air from the system as follows: Cooling SyStem Bleed A“ reserve tank to the UPPER level line (4). - Shift the transm sion into neutral. Start the ‘ engine and let it idle Z , 3 minutes. 1- Remove the radiator CHP (1)- - Snap the throttle three , four times to bleed 2. Fill the system with the recommended coolant through the filler opening up to filler neck (2). Use a fresh recommended coolant mixture (page 48). Capacity: 128 US ql (1.21 P.) (1) radiator cap (2) filler neck 50 Servicing Your Honda _‘ t7cunsuxgumnnomdh so (3) reserve tank cap (4) UPPER level line air from the system. - Stop the engine and, if necessary, add coolant up to the proper level. Reinstall the radiator cap. - Check the level of coolant in the reserve tank and fill to the UPPER level if it is low. If the radiator cap is not inrtalledpmperly, it will mare excessive coolant Iosr and may rem/I in overheating and engine damage. 5. Install the reserve tank cap. zone/0mg nus 4:17 Air Cleaner Refer to Safety Precautionr on page 25. The air cleaner uses polyurethane inner and outer pieces which can’t be separated. A dirty air cleaner will reduce engine power. Proper air cleaner maintenance is very important for off-road vehicles. A dirty, water-soaked, worn—out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine. Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your dealer can help you determine the correct service interval for your riding conditions. Your CRF's air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality. Using the wmng 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. Impmper or lack Ufpraper air cleaner maintenance can cause poor performance and premature engine wear _‘ l7CRl-‘ASUXJlMEYHUmdb SI 1. Cleaning Open the air cleaner housing cover (1) by turning the quick fastener (2) counterclockwise. (1) air cleaner housing cover (2) quick lastener 2. 3. Remove the air cleaner element retaining bolt (3). Remove the air cleaner element assembly (4) while turning it as shown. (3) air cleaner element retaining bolt (4) air cleaner element assembly 4. Remove the air cleaner element (5) from the air cleaner holder (6). (9) (5) air cleaner element (6) air cleaner holder (7) tab (8) hole (9) air cleaner element tab 5. Wash the air cleaner element in clean non- flammable cleaning solvent. Then wash in hot, soapy water, rinse well, and allow to dry thoroughly. The air cleaner element is made in two pieces: inner and outer, which cannot be separated. 6. Clean the inside of the air cleaner housing. 7. Allow the air cleaner element to dry thoroughly. After drying, soak the air cleaner element in clean Pro Honda Foam Filter Oil or an equivalent air cleaner oil. Apply air cleaner oil to the entire surface of the air cleaner element and rub it with both hands to saturate the air cleaner element with oil. Squeeze out excess oil. (cont'd) Servicing Your Honda 51 zone/ems n 45417 J Air Cleaner 8. Assemble the air cleaner element and holder. Install the tab (7) of the holder in the hole (8) of the air cleaner element tab (9). 9. Apply 0.05 — 0.19 oz (1.5 — 5.5 g) of Pro Honda White Lithium Grease or equivalent to the air cleaner housing contact area of the air cleaner element. 10. Install the air cleaner element assembly into the air cleaner housing. 11. Carefully position the sealing flange of the element to prevent dirt intrusion. Align the access tab (10) of the air cleaner element holder with the “A” mark (I 1) of the air cleaner housing by rotating the air cleaner element assembly counterclockwise. Install and tighten the air cleaner element retaining bolt (3) securely. (10) (3) air cleaner element retaining bolt (10) access tab (11) “A" mark 52 Servicing Your Honda _‘ i7CRl-‘45EIXJIMEY7IOm-Jb 52 Improper Installation of the air cleaner element assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 12. Close the air cleaner housing cover (I) and turn the quick fastener (2) clockwise. / /(1) M ‘ (1) air cleaner housing cover (2) quick lastener Refer to Safary Precautions on page 25. Service more frequently if your CRF is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube. Draining 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 _‘ l7CRFASUXJIMLYHUmdb 5:; é Crankcase Breather Servicing Your Honda 53 ZOIG/OG/Oél ll 4, U: J Throttle Refer to Safary Precautions on page 25. Throttle Freeplay (1 ) freeplay Inspection Check freeplay (1). Freeplay: 1/8 — 3/16 in (3 — 5 mm) If necessary, adjust to the specified range. Upper Ad'ustment Minor adjustments are generally made with the upper adjuster. (2) dust cover (3) upper lock nut (4) upper adjuster (+) increase (—) decrease 54 Servicing Your Honda ‘j l7CRFASUXJIMLYHUmle 54 P’F’?‘ Pull the dust cover (2) back. Loosen the upper lock nut (3). Turn the upper adjuster (4). Turning the adjuster in direction (—) will decrease freeplay and turning it in direction (+) will increase freeplay. Tighten the lock nut to the specified torque: 3l0 Ibf-ft (4 N-m, Ol4 kgf-rn) Return the dust cover to its normal position. After adjustment, check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions. If the adjuster is threaded out near its limit or the correct freeplay cannot be reached, turn the adjuster all the way in and back out one turn. Tighten the lock nut to the specified torque: 3l0 Ibf-ft (4 N-m, Ol4 kgf-rn) Return the dust cover and make the adjustment with the lower adjuster. Lower Ad'ustment The lower adjuster is used for major freeplay adjustment, such as after replacing the throttle cables or removing the carburetor. It is also used if you can not get the proper adjustment with the upper adjuster. (5) lower lock nut (6) lower adjuster (+) increase (—) decrease 1. Remove the seat and fuel tank (pages 36, 37). 2. Loosen the lower lock nut (5). 3. Turn the lower adjuster (6) in direction (—) to decrease freeplay, and in direction (+) to increase freeplay. 4. Tighten the lock nut to the specified torque: 3l0 Ibf-f‘t (4 N~m, 0l4 kgf-m) Operate the throttle grip to ensure that it functions smoothly and returns completely. 5. Install the fuel tank and seat (pages 36, 38). If you can’t get the freeplay within the specified range, see your dealer. zone/ems n as if Throttle Inspection (1) (1) throttle 1. Check that the throttle assembly is positioned properly and the securing bolts are tight. 2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions. If there is a problem, see your 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. _‘ l7CRl-‘ASUXJIMLYHOmdb 55 Throttle Servicing Your Honda 55 zone/ems ll 4, U: Clutch System Refer to Safety Precautiom on page 25. Clutch Lever Freeplay (1) clutch lever Inspection Check freeplay. Freeplay: 3/8 — 13/16 in (10 — 20 mm) If necessary, adjust to the specified range. Improper freeplay adjustment can cause premature clutch wear. Make sure to adjust the clutch lever (l) freeplay after the clutch cable is disconnected. 56 Servicing Your Honda _‘ i7curasuxgumwmmdh 55 Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster. (1) (1) cable end adjuster (+) increase freeplay (—) decrease lreeplay Turning the cable end adjuster (l) in direction (+) will increase freeplay and turning it in direction (7) will decrease freeplay. If the adjuster is threaded out near its limit or the correct freeplay cannot be reached, turn the adjuster all the way in and back out one turn and make the adjustment with the integral cable adjuster. Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained. (1) (1) lock nut (2) integral cable adjuster (1») increase (—) decrease 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 (Z) to obtain /\ the specified freeplay. 4. Tighten the lock nut. Check the freeplay. 5. Start the engine, pull the clutch lever in, and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. Your CRF should move smoothly and accelerate gradually. If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 58). gong/mama Has 417 Other Inspections & Lubrication O Check that the clutch lever assembly is positioned properly (the end of the holder (1) is aligned with the paint mark (2) on the handlebar) and the securing bolts are tight. A (1) holder (2) paint mark O Check the clutch cable for kinks or signs of wear. If necessary, have it replaced. O Lubricate the clutch cable with a commercially-available cable lubricant to prevent premature wear and corrosion. Clutch Operation 1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or clutch cable. 2. Check the clutch cable for deterioration, kinks, or damage. _‘ ncxrasuxgumrwmmub 57 Clutch Cover/Disc/Plate Removal 1. Drain the transmission oil (page 47). 2. Remove the rear brake pedal (1) by removing the pin (2), pivot bolt (3), washer (4) and dust seals (5). / (3) (5) (1) rear brake pedal (4) washer (2) pin (5) dust seals (3) pivot bolt Clutch System 3. Remove the six clutch cover bolts (6) and clutch cover (7). (6) clutch cover bolts (7) clutch cover 4. Remove the six clutch spring bolts and clutch springs (8). Loosen the clutch spring bolts in a crisscross pattern in two or three progressive steps. / \ 5. Remove the clutch pressure plate (9). "u (8) clutch spring bolts/clutch springs (9) clutch pressure plate (cont’d) Servicing Your Honda 57 ZOlG/OG/Oél n 45417 J Clutch System 4% 6. Remove the washer (10), needle bearing (1 l), clutch lifter (12) and clutch lifter rod (13). 7. Remove the eight clutch discs and seven clutch plates (14). Assemble the clutch lifter, needle bearing and washer. Turn the needle bearing with your finger. The needle bearing should turn smoothly and quietly. Replace the needle bearing and washer if the needle bearing does not turn smoothly. (10) washer (11) needle bearing (12) clutch Iifler (13) clutch Iifler rod (14) clutch discs/clutch plates 58 Servicing Your Honda _‘ momsuxgnmrwmmub s: Clutch Disc/Plate Inspection Replace the clutch discs (I) if they show signs of scoring or discoloration. Measure the thickness of each clutch disc. Service Limit: 0.112 in (2.85 mm) Replace the clutch discs and clutch plates as a set. (1) (1) clutch disc Check the clutch plates (2) for excessive warpage or discoloration. Check the plate warpage on a surface plate using a feeler gauge. Service Limit: 0.006 in (0.15 mm) Replace the clutch discs and clutch plates as a set. A (2) clutch plate Clutch Spring Inspection (WEN) (1) clutch spring Measure the free length of each spring. Service Limit: 1.72 in (43.7 mm) Replace the clutch springs as a set if any one of them is below the service limit or if the clutch plates have been bumflheat discolored. ZUlG/OG/Oél n 4,5417 U: Clutch System Clutch Disc/Plate Installation 1. Coat the clutch disc A (1), B (2) and plates (3) with engine oil. 2. Starting and ending with the two clutch disc A, alternately install the six clutch disc B and seven clutch plates. A , 417 (1) clutch dISC A ‘~ (2) clutch disc B (3) clutch plates 3. Apply grease to the clutch lifter rod (4). 4. Insert the clutch lifter rod into the mainshaft. 5. Apply engine oil to the needle bearing (5) and washer (6) and install them to the clutch lifter (7). 6. Install the clutch lifter onto the rod. ._, fl/dN (6) washer (7) clutch lilter (4) clutch lilter rod (5) needle bearing _‘ l7CRl-‘ASUXJIMEWmmdb 59 7. Install the clutch pressure plate (8). 8. Install the six clutch springs and bolts (9). 9. Tighten the bolts in a crisscross pattern in two or three steps, to the specified torque: 9 Ibf-ft (12 N-m, 1.2 kgf-m) (8) clutch pressure plate (9) clutch spring bolts/springs 10. Apply oil to a new O—ring (10) and install it in the groove of the clutch cover (1 l). 11. Install the clutch cover by tightening the six clutch cover bolts in a crisscross pattern in two or three steps to the specified torque: 7 Ibf-ft (10 N~m, 1.0 kgf-m) (10) O-ring (11) clutch cover 12. Lubricate the dust seals (12), rear brake pedal (13) pivot and pivot bolt (14) with Pro Honda White Lithium Grease or equivalent. 13. Install the dust seals into the rear brake pedal. 14. Install the pivot bolt with the washer (15) and tighten the pivot bolt to the specified torque: 27 Ibf-ft (36 N-m, 3.7 kgf-m) Connect the brake pedal return spring (16) if it is removed. 15. Insert the pin (17). (12) (15) (12) dust seals (13) rear brake pedal (14) pivot bolt (15) washer (16) brake pedal return spring (17) pin 16. Fill the crankcase with transmission oil (page 47). Servicing Your Honda 59 zone/ems “454i, J /\ Hot Start Lever Refer to Safary Prvmmians on page 25. Hot Start Lever Freeplay (1) hot start lever (2) treeplay lnsg ‘tion Check freeplay (Z). Freepluy: 1/16 — 1/8 in (2 — 3 mm) If necessary, adjust to the specified range. 60 Servicing Ymu' Honda _‘ t7cmsuxgmvm7mmutt (an Ad‘ustment Adjustments can be made with the cable end adj u ster. Loosen the lock nut (l) and turn the adjuster (2). Turning the adjuster clockwise (+) will increase freeplay and turning it counterclockwise (,) will decrease freeplay. After adjustment, tighten the look nut. (1) lock nut (+) increase (2) adjuster (—) decrease /\ \ ./ gong/mama HASMF U: Spark Plug Refer to Safety Precautions on page 25. Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions. Standard |FR8H11 (NGK) or VK24PRZ11 (DENSO) Optional |FR9H11 (NGK) or VK27PRZ11 (DENSO) Use only the recommended type of spark plugs in the recommended heat range. Using a spark plug with an improper neat range or incorrect reach can cause engine damage. /"\ Using a non-resistor spark plug may cause ignition problems. This motorcycle uses a spark plug that has an iridium tip in the center electrode and a platinum tip in the side electrode. Be sure to observe the following when servicing the spark plug. . Do not clean the spark plug. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one. . To check the spark plug gap, use only a “wire- type feeler gauge." To prevent damaging the iridium tip of the center electrode and platinum tip of the side electrode, never use a “leaf—type feeler gauge.” Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. . _‘ l7CRl-‘ASUXJIMEWmmdb 5| Spark Plug Inspection & Replacement Remove the seat and fuel tank (pages 36, 37). Disconnect the spark plug cap ( 1). Clean any dirt from around the spark plug base. Remove the spark plug (2). :’>P’!":" (1) spark plug cap (2) spark plug 5. Check the electrodes for wear or deposits, the sealing gasket (3) for damage, and the insulator for cracks. Replace if you detect them. 6. Check the spark plug gap (4), using a wire—type feeler gauge. If the gap is out of specifications, replace the plug with a new one. The recommended spark plug gap is: 0.039 — 0.043 in (1.0 — 1.1 mm) (4) (3) (3) sealing gasket (4) spark plug gap 7. To obtain accurate spark plug readings, accelerate up to speed on a straightaway. Push the engine stop button and disengage the clutch by pulling the lever in. Coast to a stop, then remove and inspect the spark plug. The porcelain insulator around the center electrode should appear tan or medium gray. If you’re using a new plug, ride for at least 10 minutes before taking a plug reading; a brand- new plug will not color initially. If the electrodes appear burnt, or the insulator is white or light gray (lean) or the electrodes and insulator are black or fouled (rich), there is a problem elsewhere. Check the carburetor, fuel system and ignition timing. 8. With the sealing gasket attached, thread /\ the spark plug in by hand to prevent cross— \ / threading. 9. Tighten the spark plug: . If the old plug is good: 1/8 turn after it seats. . lf installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug: NGK: 3/4 turn after it seats. DENSO: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. CE An improperly tightened spark plug can damage the engine. Ifa plug is (no loose, apiston may be damaged. [fa plug is too tiglzt, the threads may be damaged. 10. Connect the spark plug cap. Take care to avoid pinching any cables or wires. 11. Install the fuel tank and seat (pages 36, 38). Servicing Your Honda 61 zone/ems “454i, Exhaust Pipe/Muffler Exhaust Pipe/Muffler Inspection Check the mounting bolts and exhaust pipe joint nuts for tightness. Check the exhaust pipe and muffler for cracks or deformation. A damaged exhaust pipe and muffler may reduce engine performance. 62 Servicing Your Honda _‘ l7ERl-ASLIXJleYHOmdb 52 Muffler Removal 1. Remove the seat mounting bolt (1). side cover bolt (2) and right side cover (3). (1) seat mounting bolt (2) side cover boil (3) right side cover 2. Loosen the muffler clamp bolt (4). 3. Remove the rear muffler mounting bolt/ washer (5), front muffler mounting bolt (6) and muffler (7). (4) muiiler clamp bolt (5) rear muffler mounting bolt/washer (6) iron! muiiler mounting bolt (7) muiiler anus/mama Has a? U: Exhaust Pipe/Muffler . 5. Install the front muffler mounting bolt (7), 7. Install the right side cover (10) and side cover Muffler mwnat‘wn rear muffler mounting bolUwasher (8) and bolt (11). 1. Remove the gasket (1). 2. Install the muffler clamp (Z) and a new gasket onto the exhaust pipe (3). (1) gasket (2) mufller clamp (3) exhaust pipe 3. Install the muffler (4). 4. Install the muffler clamp (2) by aligning the tab (5) of the muffler clamp with the cut-out (6) of the muffler. / (s) bAQ/fi\\ (5) (2) mufller clamp (4) mufller (5) tab (6) cut-out _‘ l7CRFASLlXJIMhWItImdb 5:; loosely tighten them. Tighten the front muffler mounting bolt and rear muffler mounting bolt to the specified torque: 19 |bf-ft(26 N-m, 2.7 kgf-m) 6. Tighten the muffler clamp bolt (9) to the specified torque: 15 Ibf-ft (21 N-m, 2.1 kgf-m) (7) front mufller mounting bolt (8) rear muffler mounting boll/washer (9) mufller clamp bolt 8. Install the seat mounting bolt (12) and tighten it to the specified torque: 19 lbf-ft (26 N-m, 2.7 kgf-m) (10) right side cover (11) side cover bolt (12) seat mounting bolt Servicing Your Honda 63 ZOIG/Ofi/Oél u may A 4% U: Exhaust Pipe/Muffler Exhaust Pipe Removal Exhaust Pipe Installation 1. Remove the muffler (page 62). 1. Install a new exhaust pipe gasket ( 1) as Remove the exhaust pipe joint nuts (1), shown. exhaust pipe (2) and old exhaust pipe gasket 2. Install the exhaust pipe (2) and exhaust pipe (3). joint nuts (3). (1) exhaust pipe joint nuts (1) new exhaust pipe gasket (2) exhaust pipe (2) exhaust pipe (3) old exhaust pipe gasket (3) exhaust pipe joint nuts 3. Install the muffler (page 63) 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 muffler clamp bolt, front muffler mounting bolt and rear muffler mounting bolt (page 63). 6. Installation can be done in the reverse order of removal. 64 Servicing Your Honda _‘ HCRFASEIXJIMEWIDm-ib m $ ZOlG/OG/OS “555i, Spark Arrester Inspection The spark arrester must be serviced every 1,000 miles (1,600 km) of running or 100 operating hours to maintain its efficiency. Regular servicing prevents carbon buildup (which can diminish engine performance) and also complies with USDA regulations for regular maintenance to assure proper function. The spark arrester prevents random sparks from the combustion process in your engine from reaching the environment. 1. Allow the engine and muffler to cool. 2. Remove the bolts (1), spark arrester (2), and gasket (3) from the muffler. (2) (1) bolts (3) gasket (2) spark arrester _‘ neurasoxjmrwmmdb 55 4% 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 breaks and holes. Replace, if necessary. 4. Apply a seizure inhibitor (Three Bond 1901 or equivalent) to the bolts threads. 5. Install a new gasket and the spark arrester in the muffler and tighten the bolts (1) to the specified torque: 4.4 |bf>ft (6 Nrrn, 0.6 kgfrm) " (1) bolts U: Spark Arrester Servicing Your Honda 65 zone/ems n as of Valve Clearance Refer to Safety Precautionr on page 25. Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve from closing and cause valve damage and power loss. Check the valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule (pages 27, 28). The checking or adjusting of the valve clearance should be performed while the engine is cold. The valve clearance will change as engine temperature rises. 66 Servicing Your Honda _‘ nonrasuxgimrmumdb as 4% Cylinder Head Cover Removal Before inspection, clean the engine thoroughly to keep dirt from entering the engine. 1. Remove the seat and fuel tank (pages 36, 37). 2. Disconnect the breather tube (1) and spark plug cap (2). (1) breathErtube (2) spark plug cap 3. Remove the spark plug (page 61). 4. Remove the cylinder head cover A bolt/ rubber seal (3), cylinder head cover B bolts/ rubber seals (4) and cylinder head cover (5). (3) cylinder head cover A boll/rubber seal (4) cylinder head cover B bolts/rubber seals (5) cylinder head cover % 5. Remove the plug hole packing and cylinder head cover packing. Positioning At Top Dead Center On The Compression Stroke 1. Remove the crankshaft hole cap (1). (1) crankshaft hole cap zone/cams n as ”if J Valve Clearance Z. Rotate the crankshaft by turning the primary drive gear bolt (2) clockwise until the punch mark (3) on the primary drive gear aligns with the index mark (4) on the right crankcase cover. In this position, the piston may either be on the compression or exhaust stroke. If the crankshaft passed the punch mark, rotate the primary drive gear bolt clockwise again and align the punch mark with the index mark. The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed. This condition can be determined by moving the exhaust rocker arm (5). If it is free, it is an indication that the valves are closed and that the piston is on the compression stroke. If it is tight and the valves are open, rotate the primary drive gear bolt 360° and realign the punch mark with the index mark. (2) primary drive gear bolt (3) punch mark (4) index mark _‘ t7cxmsuxgumtwmmdb 57 ,. n (5) exhaust rocker arm Valve Clearance Inspection 1. Measure the intake valve clearance by inserting a feeler gauge ( 1) between the valve lifters (2) and intake cam lobes (3). (1) feeler gauge (2) valve lilters (3) intake cam lobes Valve Clearance: IN: 0006 1 0.001 in (0.16 1 0.03 mm) 2. Measure the exhaust valve clearance by inserting a feeler gauge ( 1) between the exhaust rocker arm (4) and shims (5). , -, \v (1) leeler gauge (4) exhaust rocker arm (5) exhaust valve shims Valve Clearance: EX: 0.011 1 0001 in (0.28 1 003 mm) If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Holder Assembly Removal (page 68) and select the correct shim for each valve. Servicing Your Honda 67 ZOIG/Ofi/Oél H ”Al, U: Valve Clearance Camshaft Holder Assembly Removal 1. Record the intake valve and exhaust valve clearances. Make sure the piston is at TDC (Top Dead Center) on the compression stroke (page 66). 2. Remove the cam chain tensioner lifter cover bolt (1) and sealing washer (2). fl (1) cam chain tensioner litter cover bolt (2) sealing washer 68 Servicing Your Honda _‘ ncxrasuxgnmrwmmdb as Use the tensioner stopper tool. . Tensioner stopper 07AMG-001A100 3. Turn the tensioner shaft clockwise with the tensioner stopper (3) until it stops, in order to retract the tensioner fully. Then insert the tensioner stopper fully to hold the stopper in the fully retracted position. (3) i (3) tensioner stopper 4. Loosen the cam sprocket bolt (4). Rotate the primary drive gear bolt (crankshaft) clockwise one tum and remove the other sprocket bolt. Rotate the primary drive gear bolt (crankshaft) clockwise one turn again and remove the remaining sprocket bolt. 5. Remove the cam sprocket (5) and then attach a piece of wire to the cam chain (6) to prevent it from falling into the crankcase. Do not let the bolts, .rpraeke! and mm chainfull into the crankcase. (4) cam sprocket bolts (5) cam sprocket (6) cam chain ZOlG/OG/Oél n 45 Stif J 6. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. Loosen the camshaft holder assembly bolts (7) in a crisscross pattern in two or three steps. Remove the camshaft holder assembly bolts, camshaft holder assembly (8), intake valve lifters and shims. . As you remove the camshaft holder assembly, the intake valve lifters and intake valve shims may be sticking in the camshaft holder assembly. Keep the intake valve lifters and the shims separate so you can easily identify the originally installed location such as intake or exhaust, right or left. . (7) camshaft holder assembly bolts (3) camshaft holder assembly Do not let the valve lifters, Shimr, decompresmr shaft and plungerfall into the crankcase. _‘ l7CRl-‘45EIXJIMEY7I0m-lb 59 4% 7. Remove the intake valve lifters (9), decompressor shaft (10) and plunger (11). (9) intake valve lifters (10) decompressor shaft (11) plunger 8 Valve Clearance . Remove the valve shims (12). 12) valve shims Servicing Your Honda 69 ZUlG/OG/Oél “555i, M: J Valve Clearance 4% Shim Selection 1. Clean the shim contact area in the valve lifter (1) with compressed air. (1) (1) valve lifter 70 Servicing Your Honda _‘ l7CRl-‘450leMEY7IDm-ib 70 2. Measure the shim thickness with a micrometer and record it. Seventy-three different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (3.000 mm thickness) in intervals of 0.025 mm. (2) (2) shim 3. Calculate the new shim thickness using the equation below. A=(B—C)+D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness - Make sure of the correct shim thickness by measuring the shim with a micrometer. - Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2.450 mm. Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 mm. 1.80 mm 1.825 mm 1.85 mm 1.875 mm zone/ems “555i, 4% U: Valve Clearance Camshaft Holder Assembly Installation 1. Install the newly selected shims (1) on the valve spring retainers (2). Do not let the Shimrfall into the crankcase. (1) shims (2) valve spring retainers 2. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the following parts. — camshaft cam lobes — each valve lifter outer surface — plunger whole surface — decompressor shaft sliding area _‘ nourasuxgnmrwmmub 7| 3. Install the plunger (3) into the camshaft (4) with its rounded surface facing up and groove (5) side toward the decompressor shaft (6). Install the decompressor shaft while aligning its tab (7) with the groove of the plunger shown. Check the operation of the plunger by turning the decompressor shaft with your finger, then pushing down and pull up the plunger smoothly. (3) plunger (6) decompressor shaft (4) oamshall (7) lab (5) groove 4. Install the each valve lifter (8) in their original location into the camshaft holder assembly (9). (6) Valve lifters (9) oamshall holder assembly % 5. Install the camshaft holder assembly (9) onto the cylinder head with the intake cam lobes (10) facing up as illustrated below. Apply engine oil to the camshaft holder assembly bolt threads and seating surface. Tighten the camshaft holder assembly bolts (1 l) to the specified torque: 10 lbf-ft (14 N-m, 1‘4 kgf-m) Do not let the deeamprerrar shaft and plunger fall into the crankcase. Tighten the camshaft holder assembly bolts in a crisscross pattern in two or three steps. (9) camshaft holder assembly (10) intake cam lobes (11) camshaft holder assembly bolts (cont’d) Servicing Your Honda 71 ZUlG/OG/Oél “455i, J Valve Clearance 6. While holding the cam chain, rotate the primary drive gear bolt (12) (crankshaft) clockwise and align the punch mark (13) with the index mark (14). Make sure the piston is at TDC (Top Dead Center) on the compression stroke. (12) primary drive gear bolt (13) punch mark (14) index mark 7. Install the cam chain (15) over the sprocket without rotating the sprocket. Place the cam sprocket (16) and align the timing mark (17) on the cam sprocket with the “A" mark (18) on the camshaft holder assembly. When installing the cam sprocket, position the decompressor weight pin (19) toward the front side. 72 Servicing Your Honda _‘ l7CRl-‘ASUXJIMEWmmdb 72 8. Set the decompressor weight (20) by aligning its hole (21) with out side weight pin (22) as shown. (15) earn chain (16) earn sprocket (17) timing mark (16) “A" mark (19) decompressor weight pin (20) decompressor weight (21) hole (22) outside weight pin 9. Clean and apply a locking agent to the cam sprocket bolt (25) threads (coating width as shown). (23) 0.26 t 0.04 in (24) 0.04 — 0.08 in (6.5 t 1.0 mm) (1.0 — 2.0 mm) (25) (23) coating width (24) no coating width (25) cam sprocket bolt 10. Temporarily install the cam sprocket bolt (25) by aligning the bolt holes of the cam sprocket and camshaft. Rotate the primary drive gear bolt (crankshaft) clockwise one turn and tighten the sprocket bolt to the specified torque: 15 |bf~ft (20 N~m, 2.0 kgf-m) Rotate the primary drive gear bolt (crankshaft) clockwise one turn again and tighten the other sprocket bolt to the specified torque (see above). Do not let the bolts fall into the crankcase. (25) cam sprocket bolts ZOIG/OG/Oél n “ELF J Valve Clearance 11. Check the operation of the plunger (3) by pushing the decompressor weight (20) with your finger and then pushing the plunger down. Release the decompressor weight and pull up the plunger. (20) decompressor weight 12. Remove the tensioner stopper (26) from the cam chain tensioner lifter. (26) tensioner stopper _‘ l7CRl-‘45EIXJIMEY7IOui-lb 73 13. Rotate the primary drive gear bolt (crankshaft) clockwise two turns and align the punch mark (13) with the index mark (14). Make sure that the timing mark (17) on the sprocket align with the “A” mark (18) on the camshaft holder assembly. If the timing mark doesn’t align with the “A” mark, remove the cam sprocket. Then realign the valve timing. \ s \131 \C/(>‘\( (13) punch mark (14) index mark (17) timing mark (18) “A" mark [4. Measure the intake valve and exhaust valve clearances by inserting a feeler gauge (27). Valve Clearance: IN: 0.006 1 01001 in (0116 :l: 0103 mm) EX:0.011 : 0.001 in (0.28 x 0.03 mm) (27) feeler gauge 15. Install a new sealing washer (28) and tighten the cam chain tensioner lifter cover bolt (29). \ / (28) sealing washer (29) earn chain tensioner Iiiter cover bolt Servicing Your Honda 73 ZOlG/OG/Oél n 455,{ Valve Clearance 4% Crankshaft Hole Cap Installation Coat a new O-ring (1) with engine oil and install it onto the crankshaft hole cap (2). Apply grease to the crankshaft hole cap threads. Install and tighten the crankshaft hole cap to the specified torque: 11 lbf-ft (15 N~m, 1‘5 kgf-m) (1) O-ring (2) crankshaft hole cap 74 Servicing Your Honda _‘ ncxrasuxgumrwmmdb 74 Cylinder Head Cover Installation 1. Check the spark plug hole packing (1) is in good condition, replace it if necessary. Apply engine oil to the spark plug hole packing and install it to the spark plug hole (2). (1) spark plug hole packing (2) spark plug hole 2. Inspect the cylinder head cover packing (3) for damage or deterioration, replace it if necessary. Install the cylinder head cover packing into the groove of the cylinder head cover (4). (3) cylinder head cover packing (4) cylinder head cover % 3. Check the rubber seals (5) are in good condition, replace them if necessary. Install the rubber seals onto the cylinder head cover with the “UP” marks (6) facing up. / (6) Q (5) (6) (5) rubber seal (6) “UP" marks 4. Install the cylinder head cover (4). 5. Tighten the cylinder head cover A bolVrubber seal (7) and cylinder head cover B bolts/ rubber seals (8) to the specified torque: 7 lbf-ft (10 N-m, 1.0 kgf-m) (4) cylinder head cover (7) cylinder head cover A bolt/rubber seal (6) cylinder head cover B bolts/rubber seals ZUlG/OG/Oél n 45517 J U: Valve Clearance 6. Install the spark plug (page 61) 7. Connect the spark plug cap (9) and breather tube (10). (1o A (9) spark plug cap (10) breather tube 8. Install the fuel tank and seat (pages 36, 38). _‘ HCRFASUXJIMEWlOmdb 75 Servicing Your Honda 75 ZUlG/OG/Oél nos if Piston/Piston Rings/Piston Pin 4% Cylinder Head Removal 1. Clean the area above the engine before disassembly to prevent dirt falling into the engine. Drain the engine oil (page 44). Drain the radiator coolant after cooling the motorcycle (page 149). Remove the seat and fuel tank (pages 36, 37). Remove the muffler (page 62). Lift the subframe to the upright position (page 39). Remove the carburetor (page 136). Remove the exhaust pipe (page 64). Remove the spark plug (page 61). 57W"? 5”!" 957°.“ 76 Servicing Your Honda _‘ l7CRl-‘450leMEY7le-ib 75 10. Remove the bolt A (1), bolt B (2) and O-ring (3)- 11. Disconnect the air suction hose (4) and vacuum hose (5). Remove the PAIR control valve (6). (1) bolt (4) air suction hose (2) bolt B (5) vacuum hose (3) O—ring (6) PAIR control valve 12. Remove the cylinder head cover (page 66). 13. Position the piston at top dead center on the compression stroke (page 66). 14. Remove the camshaft holder assembly, lifters and shims (page 68). 15. Remove the left radiator grill (7) and left radiator mounting bolts/washers (8). (7) left radiator grill (3) left radiator mounting bolts/washers % 16. Disconnect the primary wire connector (9). Remove the bolt (10) and ignition coil (1 1). (9) primary wire connector (10) bolt (11) ignition coil 17. Loosen the radiator hose clamp (12) and disconnect the radiator hose (13). (12) radiator hose clamp (13) radiator hose zone/acme n as 517 4% U: Piston/Piston Rings/Piston Pin 18. Remove the engine hanger nut (14), engine hanger bolt (15) and fuel hose guide (16). Remove the engine hanger plate bolts (17), clutch cable stay (18), left engine hanger plate (19) and right engine hanger plate (20). (14) engine hanger nut (15) engine hanger bolt (16) fuel hose guide (17) engine hanger plate bolts (16) clutch cable stay (19) left engine hanger plate (20) right engine hanger plate _‘ momsuxjimuwmmdb 77 19. Remove the cylinder head bolts (21). 20. Loosen the cylinder bolt (22). '.-. . , (21) cylinder head bolts (22) cylinder bolt 21. Remove the cylinder head nuts/washers (23) and cylinder head (24). Loosen the nuts in a criss-cross pattern in two or three steps. Do not let the nuts. washers and Cam chain fall into the Crunkmxe. A (23) cylinder head nuts/washers (24) cylinder head % 22. Remove the dowel pins (25), cylinder head gasket (26) and cam chain guide (27). Do not let the dowel pins and Cam L‘hainfall into the Eran/(mm. (25) dowel pins (26) cylinder head gasket (27) cam chain guide Servicing Your Honda 77 ZOlG/OG/US n as 5i, A 4% U: Piston/Piston Rings/Piston Pin Cylinder Removal Piston Removal Piston Ring Removal 1. Disconnect the breather hose (1) from the 1. Place clean shop towels in the crankcase to Spread each piston ring (1) and remove by lifting cylinder. keep the piston pin clips, or other parts, from it up at a point just opposite the gap. 2. Remove the cylinder bolt (2) and cylinder (3). falling into the crankcase. - 2. Remove the piston pin clips (1) using a pair of needle-nose pliers. D d h . . b d' h 3. Press the piston pin (2) out of the piston (3), 0 not amage I 8 ”ma" rmg y Sprm mg I 8 ends trmfar. and remove the piston. Do not let the mm Chain fall into the crankcase. Do not pry on or strike the Cylinder Under racing conditions, the piston and rings should be replaced after 15.0 hours of running. Replace the piston pin after 30.0 hours of running. (1) breather hose (2) cylinder bolt (1) piston ring 3. Remove the dowel pins (4) and cylinder gasket (5). (1) piston pin clips Do not let the dowel pinrfull into the crankcase. (2) piston pin (3) piston ., A \ (4) dowel pins (5) cylinder gasket 78 Servicing Your Honda ‘i l7CRF45EIleMEY7le-lb 75 $ zone/acme “555i: U: Piston/Piston Rings/Piston Pin Piston/Piston Pin/Piston Ring Inspection We recommend you consult the Service Manual or your dealer for correct Service Limit measurements. _‘ ncxrasuxgumrwmmub 79 Piston Ring Installation 1. Remove the carbon deposits from the piston head and piston ring grooves with the removed ring (1). (1) removed ring 2. Apply engine oil to each piston ring whole surface and install them to the piston. Do not damage the piston ring by .rpreading the ends tonfax Do not damage the piston during pixmn ring installation. . To install the oil ring, install the spacer first, then install the side rails. . Install the top ring on the piston with the marking side facing up. 3. After installing the rings they should rotate freely, without sticking. Space the ring end gaps 180 degrees apart between top ring and upper side rail. Space the ring end gaps 90 degrees apart between upper side rail, spacer and lower side rail. W top ring / gt] 4— fie" ring oil ring Servicing Your Honda 79 ZOlG/OG/Oél n 45 5‘17 Piston/Piston Rings/Piston Pin Piston Installation 1. Place clean shop towels over the crankcase opening to keep the piston pin clips from falling into the crankcase. 2. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulftde additive) to the connecting rod small end inner surface. 3. Install the piston (1) with the “IN” mark (2) and/or the large valve recesses (3) facing the intake side of the engine. 4. Apply engine oil to the piston pin (4) outer surface. 5. Apply engine oil to the piston outer surface and piston pin hole inner surface. Install the piston pin and new piston pin clips (5). Use new piston pin clips. Never reuse (11d piston pin clips. Do not In! the piston pin cliprfall into the crankcase. Do not align the piston pin clip and gap with the piston cut-(mt (6). 80 Servicing Your Honda _‘ t7CKl-‘ASEIXJIMEY7IOindb Eu (4) piston pin (5) piston pin clips (6) piston cut-out (1) piston (2) “IN" mark (3) large vaive recesses 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 careful not to remove any metal from the gasket surface. 2. Remove the shop towel. Do not let any gasket debris fall into the crankcase. 3. Install the dowel pins (1) and new cylinder gasket (2). Do not let the dowel pinsfall into the crankcase. a (1) dowel pins (2) cylinder gasket 4. Clean any gasket material off the cylinder. ZOlG/OG/Oél n 45 5‘17 J 5. Apply engine oil to the cylinder wall, piston outer surface and piston rings. Route the cam chain (3) through the cylinder (4). Install the cylinder over the piston rings by hand while compressing the piston rings (5). Do not damage the piston ring; and Cylinder wall. (3) cam chain (4) cylinder (5) piston rings _‘ HORFASEIXJIMEWIDm-ib El 4% 6. Temporarily install the cylinder bolt (6) and connect the breather tube (7) to the cylinder. (6) cylinder bolt (7) breather tube 7. Install the cam chain guide (8) and fit the cam chain guide tabs (9) in the cylinder cut— outs (10). Push the cam chain guide until it bottoms in the crankcase guide hole. l,‘ (B) cam chain guide (9) cam chain guide tabs (10) cylinder cut-outs Piston/Piston Rings/Piston Pin Cylinder Head Installation 1. Install the dowel pins (1) and new cylinder head gasket (2). Do not let the dowel pins fall into the crankcase. (1) dowel pins (2) cylinder head gasket (cont’d) Servicing Your Honda 81 zone/acme n as 5i, Piston/Piston Rings/Piston Pin 4% 2. Route the cam chain through the cylinder head (3). Install the cylinder head. Do not damage mating surface; when installing the cylinder head. 3. Apply engine oil to all cylinder head nut threads and seating surface. Install the cylinder head nuts/washers (4) and tighten them to the specified torque: 49 lbf‘ft (66 N-m, 67 kgf-m) Do not let the washers and rmtrfall into the crankcase. Tighten the cylinder head nuts in a criss—cross pattern in two or three steps. (3) cylinder head (4) cylinder head nuts/washers 82 Servicing Your Honda _‘ l7CRl-‘45EIXJIMEY7IDm-1b 52 4. Install and tighten the cylinder bolt (5) and cylinder head bolts (6) to the specified torque: 7 mm (10 N-m, 1.0 kgf‘m) (5) cylinder bolt (6) cylinder head bolts 5. Install the left engine hanger plate (7), right engine hanger plate (8), clutch cable stay (9) and engine hanger plate bolts (10) and tighten the engine hanger plate bolts until the engine hanger plates lightly contact the frame. 6. Install the engine hanger bolt (11), fuel hose guide (12) and engine hanger nut (13) and tighten the engine hanger nut until it lightly contacts the engine hanger plates. 7. Tighten the engine hanger plate bolts to the specified torque: 19 lbf‘ft (26 N-m, 2.7 kgf-m) Tighten the engine hanger nut to the specified torque: 4o Ibf-ft (54 N-m, 5.5 kgf-m) (7) left engine hanger plate (a) right engine hanger plate (9) clutch cable stay (10) engine hanger plate bolts (11) engine hanger bolt (12) fuel hose guide (13) engine hanger nut 2016/06/03 H as oi, 8. Connect the radiator hose (14) to the cylinder head. (14) radiator hose 9. Tighten the radiator hose clamp screw (15) as illustrated below. 0— 0.04 in (D- 1.0 mm) (15) radiator hose clamp screw _‘ l7CRl-‘450leMEY7IDm-ib a: 4% 10. Install the ignition coil (16), ground wire (17) and bolt (18), then tighten the bolt. Connect the primary wire connector (19). Clamp the siphon hose (20) to the clamp (21). (17) (16) ignition coil (17) ground wire (16) bolt (19) primary wire connector (20) siphon hose (21) clamp 11. Install and tighten the left radiator mounting bolts/washers (22). Install the left radiator grill (23). (22) left radiator mounting bolts/washers (23) left radiator grill [2. Install the camshaft holder assembly (page 71). 13. Install the crankshaft hole cap (page 74). 14. Install the cylinder head cover (page 74). 15. Install the spark plug and plug cap (page 61). 4% U: Piston/Piston Rings/Piston Pin 16. Connect the vacuum hose (24) and air suction hose (25). 17. Install the PAIR control valve (26), new 0- ring (27) and tighten the boltA (28), bolt B (29). (24) vacuum hose (27) O-ring (25) air suction hose (2B) bolt A (26) PAIR control valve (29) bolt B 18. Install the exhaust pipe (page 64). 19. Install the carburetor (page 139). 20. Install the subframe and muffler (pages 40, 63). 21. Install the fuel tank and seat (pages 36, 38). 22. Fill and bleed the cooling system (page 50). 23. Add engine oil (page 44). Check for the following: — compression leaks — abnormal engine noise — secondary air leaks — coolant leaks Servicing Your Honda 83 zone/acme u may Suspension Refer to Safety Precautionr on page 25. Loose, worn, or damaged suspension components may adversely affect the handling and stability of your CRF. If any suspension components appear worn or damaged, see your dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts or repairs are needed. Front Suspension Inspection . When your CRF is new, break it in for approximately 1 hour to ensure that the suspension has worked in (page 21). After break-in, test run your CRF with the front suspension at the standard setting before attempting any adjustments. For optimum fork performance, we recommend that you disassemble and clean the fork after riding your CRF for 3 hours. See page 113 for fork disassembly. Replace the fork oil every 7.5 hours of running. See page 87 for oil capacity adjustment after changing the fork oil. Replace the damper oil every 22.5 hours of running. See page 117 for damper fork oil replacement. Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension. Periodically check and clean all front suspension parts to assure top performance. Check the dust seals for dust, dirt, and foreign materials. Check the oil for any contamination. . . . . . . 84 Servicing Your Honda ‘j t7CRFASLlXJlMLWIOmdb 2m ' Refer to Surpenrian Adjurtmen! Guidelines (page 131). Make all rebound and compression damping adjustments in one- click increments. (Adjusting two or more clicks at a time may cause you to pass over the best adjustment.) Test ride after each adjustment. - If you become confused about adjustment settings, return to the standard position and start over. - If the fork is still too stiff/soft after adjusting compression damping, determine which portion of the travel is still too stiff/soft. This is an important step that will help you solve suspension problems. 1. Make sure that the fork protectors (1) and dust seals (2) are clean and not packed with mud and dirt. 2. Check for signs of oil leakage. Damaged or leaking fork seals should be replaced before your CRF is ridden. (1) fork protector (2) dust seal 3. Inspect the wear rings (3) for wear or damage. Replace the wear ring if it is 0.08 in (2.0 mm) or flat with the outer tube (4). When replacing the wear ring, remove the fork leg (page 113). Install the wear ring with its end gap (5) facing rearward. 0.08 in (2.0 mm) (4) outer tube (3) (3) wear ring (3) wear rings (5) and gap 4. Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times. ammo/ax n moi, Suspension Rear Suspension Inspection The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure. The gas pressure in the reservoir is contained within a rubber bladder. The shock absorber’s spring pre-load and damping adjustments (compression and rebound) should be adjusted for the rider's weight and track conditions (pages 130 r 133). Do not attempt to disassemble, service, or dispose of the damper; see your dealer. The instructions found in this owner‘s manual are limited to adjustments of the shock assembly only. ~ When your CRF is new, break it in for approximately 1 hour with the standard suspension settings before attempting to adjust the rear suspension. Refer to Suspension Adjurlmem Guidelines (page 133). Make all rebound and compression damping adjustments in one click or 1/12 turn increments. (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 127. After adjusting the adjusters simultaneously, suspension may be fine-tuned by turning one of the compression and rebound damping adjusters in one click or in 1/12 turn increments. If you have a problem finding an acceptable adjustment, return to the standard position and begin again. _‘ l7CRFASUXJleYHOmdb as 1. Bounce the rear of the motorcycle up and down and check for smooth suspension action. 2. Lift the subframe to the upright position (page 39). 3. Check for a broken or collapsed spring. 4. Check the shock absorber (1) for a bent rod or oil leaks. (1) shock absorber 5. Push the rear wheel sideways to check for worn or loose swingarm bearings. There should be no movement. If there is, have the bearings replaced by your dealer. Servicing Your Honda 85 zolfi/ufi/ua um of Suspension Recommended Fork Oil viscosity (weight) 5 W Pro Honda HP Fork Oil or equivalent suggested oil Fork Oil Change Refer to Front Suspension Dirassembly on page 1 1 3 . 1. Clean the fork assembly, especially the sliding surface of the slider and dust seal. 2. Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops. 3. Hold the outer tube (1), then remove the fork 492 damper (2) from the outer tube using the lock “ nut wrench (3). Gently slide the outer tube down onto the lower end of the slider (4). l v We) (1)\“ ‘ (3) (1) outer tube (3) look nut wrench (2) iork damper (4) slider, lower end 86 Servicing Your Honda _‘ l7emsuxgnmrwmmdtr as The outer tube (1) can drop on the Slider (5) and damage the fork durl seal ( 6 ) and guide bur/ling (7) when the fork damper it removed. To avoid damage hold both the outer tube and .riider when removing the fork damper NO GOOD any (5) NO GOOD (6) fork dust seal (7) guide bushing (1) outer tube (5) slider 4. Drain the fork oil from the outer tube (1). Drain the fork oil from the oil holes (8) of the fork damper. (1) (1) outer tube (8) oil holes 5. Drain the fork oil by turning the outer tube (1) upside down. (About 0.4 US oz (12 cm3) of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20 °C/68°F.) (1) (1) outer tube Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). Improper rsposai of drained oil is harmful to the environment. Amount 01 fork oil left in the iork (within damper and spring) unit: omi 5 10 20 35 55 85 145 ~ch 30/86 27 15.3 10.6 9.4 6.3 7.9 7.9 20/66 29.4 16.5 11.8 10.6 9.4 6.2 6.2 10/50 26.2 21.2 16.5 15.3 12.9 11.6 11.6 0/32 30.6 22.4 16.8 16.5 16.5 15.3 14.1 35 Dee/32°F '5 an ( f 25 ‘- o 10°C/50“F 20“C/68°F 30°C/86° F l) 10 AD so 80 100 120 140 150 Inverted time (minutes) ZOIG/OG/Oél n moi, /\ Suspension 6. Pour the recommended fork oil (page 86) into the outer tube. Fork Oil Capacity: Standard 26.32 Ibl/in (4.61 N/mm) Fork Spring No mark (laclory products) or 1 scribe mark (aftermarket parts) Standard oil 11.0 US oz capacity (324 cm3) Maximum oil 13.6 US oz Slightly stilter as capacity (402 cm3) It nears full compression. Minimum oil 10.3 US oz Slightly solter as capacity (306 cm3) It nears full compression. _‘ t7cmsuxgnMmiotmih :47 Optional Softer 25.18 lbflln (4.41 N/mm) Fork Spring @\- 2 scnbe marks Standard oil 11.2 US oz capacity (330 cm3) Maximum oil 13.8 US oz Slightly stifler as capacity (407 cm3) it nears lull compression. Minimum oil 10.5 US oz Slightly soiter as capacity (311 cm3) it nears lull compression. Optional Stifler 27.47 lbl/In (4.81 Nlmm) Fork Spring Q \3 scribe marks Standard oil 11.1 US oz capacity (327 cm3) Maximum oil 13.7 US oz Slightly stiller as capacity (405 cm3) it nears full compression. Minimum oil 10.5 US oz Slightly solter as capacity (309 cm3) it nears full compression. Be sure the oil capacity is the same in both fork legs. rs \ / l 7. Check that the O-ring (9) on the fork damper (Z) is in good condition. Apply the recommended fork oil to the O-ring. Temporarily install the fork damper to the outer tube (1). After installing the fork leg (page 123), tighten the fork damper to the specified torque: Actual: 25 lbf~ft (34 Nm 3.5 kgfvm) Torque wrench e reading: 23 lbf~ft (31 Nm, 3.2 kgfvm), using a 20 in (50 cm) long torque wrench. When using the lock nut wrench, use a 20 in (50 cm) long deflecting beam type torque wrench. The lock nut wrench increases the torque wrench‘s leverage. so the torque wrench reading will be less than the torque actually applied to the fork damper. (9) (1) outer tube (2) lork damper (9) O-ring Servicing Your Honda 87 gong/noun “Milli, Brakes Refer to Safety Precautiom on page 25. Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and brake pads for wear. If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding, check the brake pads. If they are not worn beyond the recommended limit (page 91), there is probably air in the brake system. Refer to the Honda Service Manual or see your dealer to have the air bled from the system. 88 Servicing Your Honda _‘ i7emsuxgumnnomuty as Front Brake Lever Adjustment 3/8—13/16 in (10—20 mm) (1) look nut (2) adjuster (3) piston l. Loosen the lock nut (1). 2. To position the brake lever farther away from the handgrip, turn the adjuster (2) clockwise. To position the brake lever closer to the handgrip, turn the adjuster counterclockwise. 3. While holding the adjuster. tighten the lock nut to the specified torque: 4i4 |bf~ft (5.9 N-m, 0.6 kgf~m) 4. Apply the brake. release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times. 5. Check freeplay by pulling in slowly on the brake lever until the brake starts to engage. Freeplay: 3/8 — 13/16 in (10 — 20 mm) 6. Apply silicone grease to the contacting faces of the adjuster and piston (3). Rear Brake Pedal Height The brake pedal height should be approximately level with the right footpeg. l. Loosen the lock nut (1) and turn the adjusting bolt (2) in direction (+) to raise the brake pedal (3) or in direction (,) to lower it. 2. Tighten the lock nut to the specified torque at the desired pedal height. 44 Ibf-f‘t (5.9 N~m, 0.6 kgf-m) 3 l t s, (+) raise the pedal height (—) lower the pedal height (1) look nut ‘ (2) adjusting bolt (3) brake pedal ZOIG/OG/Gél ll may Brakes Fluid Level Inspection Rear Brake Fluid Level Check Front Brake Fluid Level Check (1) LOWER mark With the motorcycle in an upright position, check (1) LWR mark the fluid level. It should be above the LOWER mark (1). If the With the motorcycle in an upright position, check level is at or below the LOWER mark, check the the fluid level. brake pads for wear (page 91). It should be above the LWR mark (1). If the level Worn brake pads should be replaced. If the pads is at or below the LWR mark, check the brake are not worn, have your brake system inspected pads for wear (page 91). for leaks. Worn brake pads should be replaced. If the pads If the brake pedal freeplay exceeds 13/16 in (20 are not worn, have your brake system inspected mm), there is probably air in the brake system for leaks. and it must be bled. Refer to the Honda Service If the brake lever freeplay exceeds 13/ 16 in (20 Manual or see your dealer for brake bleeding. mm), there is probably air in the brake system and it must be bled. Refer to the Honda Service Manual or see your dealer for brake bleeding. Servicing Your Honda 89 _‘ l7CRl-‘ASUXJIMLYchndb as ZOIG/Ofi/Ox n deaf Brakes Adding Front Brake Fluid Spilled brakefluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be Careful whenever you remove the reservoir cap: make sure the reservoir is horizontalfirsl. . Always use fresh DOT4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they may not be compatible. . The recommended brake fluid is Pro Honda DOT4 brake fluid or an equivalent. (1) (1 (2 (3 (4 lront brake reservoir cap screws reservoir cap diaphragm upper level mark 1. Remove the front brake reservoir cap screws (1), reservoir cap (2) and diaphragm (3). 2. Fill the reservoir with DOT4 brake fluid to the upper level mark (4). Do not overflll. Install the diaphragm and reservoir cap. 4. Tighten the front brake reservoir cap screws to the specified torque: 0.7 |bf~ft (1 N-m, 0.1 kgf~m) L» 90 Servicing Your Honda _‘ l7cxmsuxgumwmmutr ac Adding Rear Brake Fluid Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be Careful whenever you remove the reservoir tap: make sure the reservoir is horizontal first. - Always use fresh DOT4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they may not be compatible. - The recommended brake fluid is Pro Honda DOT4 brake fluid or an equivalent. (1) rear brake reservoir cap bolts (2) reservoir cap (3) set plate (4) diaphragm (5) upper level mark 1. Remove the rear brake reservoir cap bolts (1). reservoir cap (2), set plate (3) and diaphragm (4). 2. Fill the reservoir with DOT4 brake fluid to the upper level mark (5). Do not overflll. 3. Install the diaphragm, set plate and reservoir cap. Do not bend to the diaphragm during installation. 4. Install and tighten the rear brake reservoir cap bolts to the specified torque: 0i7 |bf~ft (1 N~m, 0.1 kgf~m) Other Inspection - Make sure there are no fluid leaks. - Check for deterioration or cracks in the hoses and fittings. zone/0mm; n Mali Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions. (Generally, the pads will wear faster on wet and dirty tracks) Inspect the pads at each regular maintenance interval (pages 27 and 28). Front Brake Pads Inspect the brake pads (1) through the front wheel to determine the pad wear. If either pad is worn anywhere to a thickness of 0.04 in (1 mm), both pads must be replaced. mllumllm lhickncss mil mm ' L 0.04 m H mm) wear indicator grooves (1) brake pads (2) front brake caliper (3) brake disc _‘ l7ERl-ASLIXJIMkYHOmdli an Rear Brake Pads Inspect the brake pads (1) from the rear side of the caliper to determine the pad wear. If either pad is wom anywhere to a thickness of 0.04 in (1 mm), both pads must be replaced. minimum thickness indicator 0.04 in (1 mm) replace (1) brake pads (2) rear brake caliper (3) brake disc Other Inspections Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight. Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Servicing Your Honda 91 gong/0mm nu , /\ Wheels Refer to Safety Precautions on page 25. Keeping the wheels true (round) and maintaining correct spoke tension is critical to safe motorcycle operation. During the first few rides, spokes will loosen more rapidly due to the initial seating of the parts. Excessively loose spokes may result in instability at high speeds and the possible loss of control. It’s also important that the rim locks are secure to prevent tire slippage. It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule (pages 27 and 28). However, information for wheel removal is provided for emergency situations. Wheel Rims & Spokes K \ \(2) (5% \ C\ 175) \ (1) wheel rim (2) spoke (3) rim lock 1. Inspect the wheel rims (l) and spokes (2) for damage. 92 Servicing Your Honda _‘ t7cmsuxgmvirwimuuh 92 2. Tighten, any loose spokes and rim locks (3) to the specified torque: Spokes : (front) 2.7 Ibfvft (3.68 Nlm, 0.4 kgf-m) (rear) 2.7 Ibfvft (3.7 N~m, 0.4 kgfvm) Rim Locks : 9 Ibfvft (12 Nm, 1.2 kgfvm) 3. Check wheel rim runout. If runout is noticeable, see the Honda Service Manual for inspection instructions. Axles & Wheel Bearings See the Honda Service Manual for inspection information: 1. Check the axle shaft for runout. 2. Check the condition of the wheel bearings. /\ \ / l gong/0mm ll M , /\ Tires & Tubes Refer to Safrry Prrmmians on page 25. To safely operate your CRF. the tires must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. A WARNING Using tires that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding tire inflation and maintenance. The following pages give detailed information on how and when to check your air pressure, how to inspect your tires for wear and damage, and our recommendations on tire replacement. Air Pressure Properly inflated tires provide the best combination of handling. tread life, and riding comfort. Generally. underinflated tires wear unevenly, adversely affect handling. and are more likely to fail from being overheated. Underinllated tires can also cause wheel damage on hard terrain. Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. Make sure the valve stem caps are secure. If necessary, install new caps. _‘ t7cmsuxgmvuwIotmm as Always check air pressure when your tires are “cold." If you check air pressure when your tires are “waim" i even if your CRF has only been ridden for a few miles 7 the readings will be higher. If you let air out of warm tires to match the recommended cold pressures. the tires will be underintlated. The correct “cold" tire pressures are: Front 15 psi (100 kPa, 1.0 kgt/cmz) Rear 15 psi (100 kPa, 1.0 kgt/cmz) If you decide to adjust tire pressures for a particular riding condition, make changes a little at a time. Inspection Take time to inspect your tires and wheels before you ride. - Inspect carefully for bumps or bulges in the side of the tire or the tread. Replace any tire that has a bump or bulge. Look closely for cuts, slits, or cracks in the tires. Replace a tire if you can see fabric or cord. Check for rocks or other objects embedded in the tire or tre Remove any objects. Check the position of both valve stems. A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim. /\ \ / l 'Dube Replacement If a tube is punctured or damaged, you should replace it as soon as possible. A repaired tube may not have the same reliability as a new one, and it may fail while you are riding. Use a replacement tube equivalent to the original. Servicing Your Honda 93 EON/Imam nasal, Tires & Tubes Tire Replacement The tires that came on your CRF were designed to provide a good combination of handling, braking. durability, and comfort across a broad range of riding conditions. A WARNING Installing improper tires on your motorcycle can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed. Always use the size and type of tires recommended in this owner’s manual. 80/100-21 51M /' \ Front H DUNLOP ‘ D742FA 110/100-13 64M Rear ‘ D756 DUNLOP Type bias-ply, tube type 0 When replacing. use the original equipment tires or equivalent tires of the same size, construction. speed rating. and load range as the originals. 0 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. 94 Servicing Your Honda _‘ l7CKHSUXJIMleTIOmdli 5J4 /\ \ / i Bong/DBMS “45017 n u: Side Stand Refer to Safary Prvmuzians on page 25. 1. Check the side stand spring (1) for damage and loss of tension. 2. Check the side stand assembly for freedom of movement. (1) side stand spring /\ If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with grease. Servicing Your Honda 95 gong/mama ”deaf _‘ l7ERHSUXJlMEYHOmdb as Drive Chain Refer to Safety Preeaatiom on page 25. An endless (riveted master link) chain connects the drive and driven sprockets. The O-ring chain uses rubber between the side plates of the pin and roller links to seal in the manufacturer-installed lubricating grease and keep out moisture and dirt. The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets. Under severe usage, or when the motorcycle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary. Before servicing your drive chain, turn the engine OFF, raise the rear wheel off the ground by placing an optional workstand or equivalent support under the engine and check that your transmission is in neutral. It is not necessary to remove or replace the drive chain to perform the recommended service in the Regular off—road Use Maintenance Schedule (page 27). 96 Servicing Your Honda _‘ l7cumuxgumrwmmdb as Inspection 1. Stop the engine and raise the rear wheel off the ground by placing an optional workstand or equivalent support under the engine and shift the transmission into neutral. 2. Check the drive chain slack (1) in the upper drive chain run midway between the drive (2) and driven sprockets (3). Drive chain slack should allow the following vertical movement by hand: 1—1 3/8 in (25 —35 mm) Excel l ive chain slack may allow the drive chain to damage the engine cares. (1) drive chain slack (2) drive sprocket (3) driven sprocket If the chain is found to be slack in one segment of its length and taut in another, this indicates that some of the links are either wom, kinked or binding. Kinking and binding can frequently be eliminated by thorough cleaning and lubrication. If the drive chain requires adjustment, procedure is as follows: (1) rear axle nut (2) chain adjuster lock nut (3) adjusting bolt Adjustment . Loosen the rear axle nut (l). 2. Loosen the chain adjuster lock nuts (2) and turn the adjusting bolts (3) counterclockwise to decrease slack or clockwise to increase slack. Align the index marks (4) of the axle plates (5) with the same reference marks (6) on both sides of the swingarm. (4) index mark (5) axle plate (6) relerence marks 3. Tighten the rear axle nut to the specified torque: 94 Ibf-ft (128 N-m, 13.1 kgf-m) . Recheck chain slack and adjust if necessary. . Turn the adjusting bolts counterclockwise until they touch the axle plates lightly. Then tighten the chain adjuster lock nuts to the specified torque while holding the adjusting bolts with a wrench. 2o Ibf-ft (27 N-m, 2.8 kgf-m) zone/ems “deaf /\ Drive Chain Removal, Cleaning & Replacement For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing. Your CRF has an endless (riveted master link) type chain. It should only be removed or replaced by your dealer. The O—rings can be damaged by steam cleaning, high pressure washers. and certain solvents. 1. Clean the side surfaces of the chain with a dry cloth. Use a high flash point solvent such as kerosene , not gasoline. Do not brush the rubber O-rings. Brushing will damage them. Use of a solvent may also damage the O-ring Replace the drive chain if it has damaged rollers, loose fitting links, damaged O-rings, or otherwise appears unserviceable. Measure the drive chain plate (1). If the drive c ain plate is worn anywhere to a thickness of 0.53 in (13.4 mm), the drive chain must be replaced. Replacement chain: Size/link: DID520MXV/114 0.53 in (13.4 mm) (1) drive chain plate (inner) _‘ t7cmsuxgnMmlotmm 5:7 4. Inspect the sprocket teeth for p or damage Replace them if nec Never install a new drive chain on badly worn sprockets, or use new sprockets with a badly worn drive chain. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket(s) will wear rapidly. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any sprocket, which is damaged or exce ively worn. Damaged Sprocket/T\ /T\Worn SPFOCKE‘ Normal Sprocket Teeth GOOD REPLACE REPLACE Uxe ofa new Chain wit/1 warn sprockets will muse rapid chain wean rs \ ./ 1 5. Lubricate the drive chain. 6. Recheck chain slack and adjust if necessary. Servicing Your Honda 97 gong/mama ll 46 (NF J Drive Chain Drive Chain Sliders 1. Check the chain slider (1) for wear. If the wear is 0.2 in (5 mm) or more, replace it. (1) chain slider ,~\ 2. Check the chain guide slider (2) for wear. Replace the chain guide slider if it is worn to the bottom of the wear limit (3). (2) chain guide slider (3) wear iimit 98 Servicing Your Honda _‘ i7ckusuxgumivnouuti as Drive Chain Rollers 1. Measure the diameter of the upper (1) and lower drive chain rollers (2). Replace them if below the service limit. Service Limit: UPPER ROLLER: 1.5 in (39 mm) LOWER ROLLER: 1.4 in (35 mm) 2. Replace the roller if necessary as follows: Install the upper drive chain roller (Green) with the “_." mark (3) facing toward the frame and lower drive chain roller (Black) with the “_." mark (3) side facing out. Tighten the drive chain roller bolt and nut to the specified torque: Upper roller bolt: 9 Ibfvf‘t (12 Nm, 1.2 kgf-m) Lower roller nut: 9 Ibfvft (12 Nm, 1.2 kgf-m) (1) upper drive chain roller (Green) (2) lower drive chain roller (Black) (3) “4p“ mark Lubrication Lubricate the drive chain with Pro Honda HP Chain Lube or an equivalent chain lubricant designed specifically for use on O-ring chains. Wipe off the excess chain lubricant. Commercial chain lubricants not designed for motorcycle drive chains may contain solvents which could damage the O-rings. ZOIG/UG/UX n “ML Refer to Safary Pramun‘on on page 25. Loose, worn or damaged steering damper components may adversely affect the handling and stability of your CRF. If any steering damper components appear worn or damaged, see your dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts are needed. Do not attempt to disassemble the steering damper; see your dealer. The instructions found in this owner’s manual are limited to adjustment and service of the steering damper assembly only. Steering Damper Operation Inspection - When your CRF is new, break it in for approximately 1 hour to ensure that the steering damper has worked in (page 21). After break-in, test run your CRF with the steering damper at the standard setting before making any adjustments. Check the spherical bearings and dust seal for dust, dirt, and foreign materials. Make all damping adjustments in one-click increments. (Adjusting two or more clicks at a time may cause you to pass over the best adjustment.) Test ride after each adjustment. If you have a problem finding an acceptable adjustment, return to the standard position and begin again. _‘ l7CRFASUXJIMEWIttmdb as 1. Remove the front visor bolts (1) and pull out the front visor (2). (1) front visor bolts (2) front visor 2. Disconnect the headlight connector (3). (3) headlight connector U: Steering Damper 3. Check the steering damper (4) for deformation or oil leaks. Check the damper rod (5) for bending or damage. Replace the damper case or damper rod if there is any abnormality. Refer to Honda Service Manual or see your dealer for steering damper disassembly. Check the torque of the steering damper mounting bolts (6): 15 |bf~ft (20 N~m, 2.0 kgt-m) ‘ ‘ r \ (4) steering damper \ 1 (5) damper rod (6) steering damper mounting bolts 4. With your CRF on a box or an optional workstand (front wheel elevated), check that the steering moves smoothly from side-to- side. (cont'd) Servicing Your Honda 99 zone/ems “460i, J Steering Damper 5. Connect the headlight connector (3). Install the front visor (Z) by aligning its grommets (7) with the tabs (8) on the steering stem. Install and tighten the front visor bolts (1). (2) lront visor (7) grommets (3) headlight connector (8) tabs (1) lront visor bolts 100 Servicing Your Honda _‘ l7CRl-‘ASUXJlMleHUmle mu Removal 1. Remove the front visor (page 99). 2. Remove the steering damper mounting bolts (1), collarA (2), collar B (3) and steering damper (4). (2) (4) (1) steering damper mounting bolts (2) collar A (3) collar B (4) steering damper Inspection 1. Check the damper rod (1) operation. The damper rod is fully extended and compressed by hand. Release the damper rod, then check that it extends to its maximum length. If the damper rod does not extend to its maximum length, disassemble and inspection for steering damper. Refer to the Honda Service Manual or see your dealer. (1) damper rod zone/ems u may J U: Steering Damper 2. Check the condition of the spherical bearings (2). Move the spherical bearing with your finger. The spherical bearing should move smoothly and quietly. Replace the spherical bearing if it does not move smoothly and quietly. Refer to the Honda Service Manual or see your dealer. (2) (2) spherical bearings _‘ l7cmsuxgumrmomdb ml Installation 1. Clean and apply a locking agent to the steering damper mounting bolt threads. 2. Install the steering damper (1) with its “UP" mark (2) facing up and forward. Turn the damper rod and its stopper ring (3) facing toward the front side. 3. Install the collar A (4), collar B (5) and steering damper mounting bolts (6). Be sure to install the collarA and collar B with its wide flange side facing toward the steering head pipe side. 4. Tighten the steering damper mounting bolts to the specified torque: 15 lbf-ft (20 N~m, 2.0 kgf~m) (1) steering damper (2) “UP" mark (3) stopper ring (4) collarA (5) collar B (6) steering damper mounting bolts 6. With your CRF on a box or an optional workstand (front wheel elevated), check that the steering moves smoothly from side-to- side. Install the front visor (page 100). Servicing Your Honda 101 zone/ems “may J Additional Maintenance Procedures Refer to Safety Precautionr on page 25. Steering Head Bearing Inspection 1. With your CRF on a box or optional workstand (front wheel elevated), turn the handlebar to the right and left to check for roughness in the steering head bearings. 2. Stand in front of your CRF, grab the fork (at the axle), look at the steering head, and push the fork in and out (toward the engine) to check for play in the steering head bearings. 102 Servicing Your Honda _‘ l7CRFASLlXJleYchndh 102 If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to the Honda Service Manual for replacement or adjustment procedures, or see your dealer. Handlebar Inspection 1. Remove the handlebar pad. 2. Check the handlebar (1) for bends or cracks. 3. Check that the handlebar has not moved from its proper position (by inspecting the paint mark (2)). 4. Check the torque of the handlebar upper holder bolts (3): 16 Ibf-ft (22 N-rn, 2.2 kgf-rn) Tighten the front bolts first. (1) handlebar (2) painl mark (3) handlebar upper holder bolls Control Cables Periodically, disconnect the throttle, clutch and hot start cables at their upper ends. Thoroughly lubricate the cable pivot points with a commercially available cable lubricant. If the clutch lever, hot start lever and throttle operation is not smooth, replace the cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions. zolfi/oG/ox n "mi, Additional Maintenance Procedures Nuts, Bolts, Fasteners Check and tighten nuts. bolts, and fasteners before every outing. Torque "em lbl-tt N-m kgl-m ENGINE 1 Cylinder head cover bolts 7 10 1.0 2 Clutch cover bolts 7 10 1.0 a Water pump cover bolts 7 10 1.0 4 Transmission oil check bolt 7 10 1.0 5 Crankshaft hole cap 11 15 1.5 6 Oil filler Cover bolts 7 10 1.0 7 Cylinder bolt 7 10 1.0 8 Cylinder head bolts 7 10 1.0 9 Exhaust pipe jairrt nuts 15 21 2.1 10 Drive sprocket bolt 23 31 3.2 /' \ 11 Engine oil drain bolt 12 16 1.6 x./ 12 Transmission oil drain bolt 12 16 1.6 13 Coolant drain bolt 7 10 1.0 _‘ 17cmsuxgnMewmrmui 103 RIGHT SIDE (1) cylinder head cover bolts (2) clutch cover bolts (3) water pump cover bolts (4) transmission Oll check bolt (5) crankshaft hole cap (9) exhaust pipe joint nuts 13) coolant drain bolt t /\ \/ i LEFT SIDE (6) oil filter cover bolts (7) cylinder bolt (8) cylinder head bolts 10) drive sprocket bolt 11) engine oil drain bolt 12) transmission oil drain bolt t t t Servicing Your Honda BOItS/tltS/UK HANDY Battery Refer to Safety Preeautiom on page 25. Your CRF has a maintenance-free type battery. You do not have to check the battery electrolyte level or add distilled water as you would with a conventional-type battery. Your battery is a maintenanee-free type and can be permanently damaged if the tap .rtrip is removed. Electrical accessories use current from the battery, even when the engine is stopping. Limited operation also allows the battery to discharge. If you have electrical accessories on your CRF or do not ride frequently, we recommended that you charge the battery frequently (see Battery Charging on page 105). If you do not expect to ride your CRF for at least 2 weeks, we recommended you remove the battery, or at least disconnect the battery cables (negative cable first). If you plan to store your CRF, see Battery Storage (this page). If your battery seems weak and/or is leaking electrolyte (cause slow starting or other electrical problems), see your dealer. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Battery Storage If you plan to store your CRF, we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life. If you do not remove the battery, we recommend disconnecting the battery cables (negative cable first). 104 Servicing Your Honda ‘i l7ERl-ASLIXJIMkYHOmdli ma You will get the best storage results from removing the battery and slow charging it every 30 days (see Battery Charging on page 105). Before you remove the battery, be sure to read all the information that follows, as well as the information on the battery label. A WARNING The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance. The battery is located under the seat. Removal 1. Remove the seat (page 36). 2. Remove the battery band (1). 3. Remove the positive terminal cover (2). 4 Disconnect the negative (,) terminal (3) first, then the positive (+) terminal (4) and remove the battery (5). (1) battery band (4) positive (+) terminal (2) positive terminal cover (5) baflery (3) negative (—) terminal 5. Unless you have been riding regularly, charge the battery (see page 105). 6. Store your battery in an easy—to-reach location off the floor, in an area protected from freezing temperatures and direct sunlight. 7. Clean the battery box after removing the battery for storage. Dry the battery box. 8. Slow charge the battery (see page 105) once every 30 days. Installation 1. Reinstall the battery in the reverse order of removal. Be sure to connect the positive (+) terminal first, then the negative (7) terminal. 2. Check all the bolts and other fasteners are secure. 3. Install the battery band (1) as shown. (1) battery band eons/mama n “any Battery Battery Charging Be sure to read the information that came with your battery charger and follow the instructions on the battery. Improper charging may damage the battery. We recommended using a charger (1) designed specifically for your Honda, which can be purchased from your dealer. These units can be left connected for long periods without risking damage to the battery. However, do not intentionally leave the charger connected longer than the time period recommended in the charger‘s instructions. Avoid using an automotive-type battery charger. An automotive charger can overheat a motorcycle battery and cause permanent damage. (1 ) charger Servicing Your Honda 105 /\ J7 l7cmsuxgummmum ms \./ guns/mama new l J Headlight & Taillight 4% Refer to Safety Precaution on page 25. Headlight Bulb 1. Remove the front visor bolts (1) and pull out the front visor (2). (1) lront visor bolts (2) lront visor 2. Disconnect the headlight connector (3). Remove the dust cover (4). (3) headlight connector (4) dust cover 106 Servicing Your Honda _‘ ncxrasuxgmrmumdb we 3. To pull the headlight bulb out, push and turn the headlight bulb socket (5) counterclockwise. (5) headlight bulb socket 4. Install a new headlight bulb (6) into the headlight unit while aligning the tab (7) with the groove (8) of the headlight unit. If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent early bulb failure. (6) headlight bulb (7) tab (a) groove 5. To install the headlight bulb socket (5), push and turn it clockwise. 6. Install the dust cover (4) tightly against the headlight unit with its “TOP” mark (9) facing (4) dust cover (5) headlight bulb Socket (9) “TOP" mark 7. Connect the headlight connector (3). Install the front visor by aligning its grommets (10) with the tabs (1 l) on the steering stem. Install and tighten the front visor bolts. (3) headlight connector (10) grommets (11) tabs ZOlG/OG/OS n as mi, Headlight Aim The headlight aim can be raised or lowered. Turn the adjusting screw (1) clockwise to move the headlight up or turn the adjusting screw counterclockwise to move the headlight down to proper adjustment. 1 (1) adjusting screw Taillight The taillight uses LED illumination. If the taillight does not function properly, see your dealer for service. ‘j l7CRl-‘45EIXJlMEY7l0m-lb m7 This model is equipped with an electric starter and battery for easy engine starting. There is a possibility of damage to the lighting system if the battery is carelessly removed. Never kick-start the engine without the battery connected. If it becomes necessary to kick-start the engine with the battery removed, remove the relays to the battery to prevent damage to the lighting. U: Headlight & Taillight Servicing Your Honda 107 ZOlG/OG/Oél l l “0‘17 Appearance Care Refer to Safety Precautiom on page 25. Frequent cleaning and polishing will keep your Honda looking newer longer. Frequent cleaning also identifies you as an owner who values his motorcycle. A clean CRF is also easier to inspect and service. While you’re cleaning, be sure to look for damage, wear, and gasoline or oil leaks. General Recommendations 0 To clean your CRF you may use: 7 water , a mild, neutral detergent and water , a mild spray and wipe cleaner/polisher , a mild spray and rinse cleaner/degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your CRF or discolor the seat and decals. If your CRF i still warm from recent operation, give the engine and exhaust system time to cool off. We recommend the use of a low pressure garden hose to wash your CRF. High pressure washers (like those at coin-operated car washes) can damage certain parts of your CRF. The force of water under extreme pressure can penetrate the dust seals of the suspension pivot points and steering head bearings-driving dirt inside and needed lubrication out. \ / . . . 108 Servicing Your Honda _‘ t7CRHSUXJIMEYHOmdh ma If you use a high pressure washer, avoid spraying the following areas: wheel hubs muffler outlet area under seat engine stop button brake master cylinders under fuel tank drive chain carburetor steering head bearings suspension pivot points (1) steering head bearings (2) suspension pivot points ngh prerrure water (or air) can damage certain parts ofyour CRF. You may use Pro Honda Hondabrite, a multi- surface cleaner/degreaser, to remove both dirt and petroleum-based grime from paint, alloy, plastic, and rubber surfaces. Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge. Washing Your Motorcycle with a Mild Detergent 1. Rinse your CRF thoroughly with cool water to remove loose dirt. 2. Fill a bucket with cool water. Mix in a mild. neutral detergent, such as dish washing liquid or a product made especially for washing motorcycles or automobiles. 3. Wash your CRF with a sponge or a soft towel. As you wash, check for heavy grime. If necessary, use a mild cleaner/degreaser to remove the grime. Do not use Steel wool to Clean the frame ar 1'! could damage or dircalor the frame surface. Muffler Stain remover (Scotch Brim Hand Pad #7447-mar00n) isfor removing stair” (m the non- /\ coated aluminum frame only. 4. After washing, rinse your CRF thoroughly with plenty of clean water to remove any residue. Detergent residue can corrode alloy parts. 5. Dry your CRF with a chamois or a soft towel. Leaving water on the surface to air dry can cause dulling and water spots. As you dry, inspect for chips and scratches. 6. Lubricate the drive chain to prevent rusting. 7. Start the engine and let it idle for several minutes. The engine heat will help dry moist areas. 8. As a precaution, ride at a slow speed and apply the brakes several times. This will help dry the brakes and restore normal braking performance. If the inside of the headlight lens appears clouded immediately after washing, it should clear after a few minutes of riding. eons/mama n “ml, Appearance Care Condensation Control Some condensation can form within the transmission cavity as well. This is natural and just one more reason you should change the engine and transmission oil often. _‘ t7ERl-ASLIXJIMkYHOmdh n19 After Cleaning Lubrication There are some things you should do just after washing your CRF to help prevent rust and corrosion. Once your CRF is clean and dry, you should protect any bare steel from rusting by applying a light coating of a rust-inhibitor. Lubricate the drive chain and drive sprocket after removing and thoroughly cleaning in solvent. Be sure the chain is wiped clean and is dry before applying the chain lube. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust, mud and road salt. To remove stains, use Scotch-Brite Hand Pad #7447 (maroon) or an equivalent. Wet the pad and polish the surface using strokes parallel to the length of the frame. Clean the frame using a wet sponge and a mild detergent, then rinse well with clean water. Dry the frame with a soft clean cloth, using strokes parallel to the length of the frame. Do not are steel wool to clean the frame ax it could damage or discolor the frame .mrface. Mufi‘ler stain remover (Scorch-Brim Hand Pad #7447-maroon) ixfor removing .rtains on the non- L‘oated aluminum frame only. Exhaust Pipe And Muffler Maintenance The exhaust pipe and muffler are stainless steel but may become stained by mud or dust. To remove mud or dust, use a wet sponge and a liquid kitchen abrasive, then rinse well with clean water. Dry with chamois or a soft towel. If nec sary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. When the exhaust pipe and muffler are painted. do not use a commercially available abrasive kitchen cleaning compound. Use a neutral detergent to clean the painted surface on the exhaust pipe and muffler. If you are not sure if your exhaust pipe and muffler are painted, contact your dealer. /\ Servicing Your Honda 109 gong/mama It 460117 1 10 Servicing Your Honda _‘ A7CRFASUXJIMkWIOmdh no ZOIG/DG/UX um ml, This section tells you how to fine tune your CRF for maximum competition performance. Initial suspension adjustments should be performed after a minimum of 2 hours of easy break-in time. Optional front and rear suspension springs are available in both stiffer and softer than standard rates. in order to tailor your CRF specifically for your weight, riding style and course conditions. Follow the instructions given in the rear suspension sag setting section of Rear Surpmrian Adjmtmenrr to determine if your combined rider and sprung machine weight (rider fully dressed for competition and machine coolant, oil and fuel levels ready for competition) requires an optional stiffer or softer rear spring. The need for either optional rear spring may need to be balan ed by installing the optional fork springs of a similar rate. _‘ l7ERl-ASLIXJleYHOmdh m Front Suspension Adjustments Front Suspension Air Pressure Front Suspension Damping Fork Springs Front Suspension D Damper Oil Change Fork Assembly.... Rear Suspension Adjustmenti Rear Suspension Spring Pre—Load Rear Suspension Dampin Rear Suspension Race Sa Suspension Adju ments for Track Conditions Suspension . Carburetor Adjustments & Tuning Tip Carburetor Components... Carburetor Removal ..... Carburetor Disassembly Carburetor Assembly ldle Speed Adjustment . Steering Damper Adjustment Steering Damper Adjustment Steering Damper Adjustment Guidelines Chassis Adjustments Rear End...... Fork Height/Angle. Wheelb se. Gearing... Tire Selection for Track Conditions Personal Fit Adjustments Control Positioning Handlebar Position, Width & Shape Adjustments for Competition Adjustments for Competition 11 1 BOIG/tlo/UX It 460117 H: Front Suspension Adjustments The front suspension can be adjusted for the rider's weight and riding conditions by using one or more of the following methods: O Oil volume 7 The effects of higher or lower fork oil capacity are only felt during the final 3.9 in (100 mm) of fork travel. O Compression damping 7 Turning the compression damping adjuster adjusts how quickly the fork compresses. O Rebound damping 7 Turning the rebound damping adjuster adjusts how quickly the fork extends. O Fork Springs 7 Optional springs are available in softer and stiffer types than the standard rate. (page 169) The inverted fork on your CRF features sealed damper cartridges with dual (separate air and oil) chambers to prevent aeration. The design also 4% isolates the oil in each fork tube/slider, which ‘ may contain air bubbles and/or metal particles, from the sealed cartridge to provide more consistent damping. (1) compression damping adjuster (2) rebound damping adjuster 112 Adjustments for Competition _‘ i7emsuxgnmnnomuir in: Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it worked (such as in a fork). Air pressure acts as a progressive spring and affects the entire range of fork travel. This means the fork action on your CRF will get stiffer during a race. For this reason, release built-up air pressure in the fork legs between motos. Be sure the fork is fully extended with the front tire off the ground when you release the pressure. The standard air pressure is 0 psi (0 kPa, 0 kgf/ cmZ). You may relieve accumulated air pressure in the fork legs by using the fork air 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 an optional 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 fork air pressure release screw (1). Check that the O-ring (2) is in good condition. 4. Install and tighten the fork air pressure release screw to the specified torque: 019 |bf~ft (1.2 N-m, 011 kgf-m) ca (1) fork air pressure release screw (2) O—ring Front Suspension Damping Rebound Damping Ad'ustment The fork rebound damping adjuster (1) has 16 positions or more. Turning the adjuster screw one full turn clockwise advances the adjuster four positions. To adjust the rebound damping to the standard setting, proceed as follows: Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard position. The adjuster is set in the standard position when the adjuster is turned counterclockwise 6 clicks. Make sure that both fork legs are adjusted to the same position. . ment affects how quickly the fork compresses. The fork compression damping adjuster (2) has 16 positions or more. Turning the adjuster screw one full turn changes the /\ adjuster four positions. To adjust the compression damping adjuster to the standard position, proceed as follows: Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard position. The adjuster is set in the standard position when the adjuster is turned counterclockwise 11 clicks. Make sure that both fork legs are adjusted to the same position. ZOIG/OG/Oél I l 45 HF Both compression and rebound damping can be increased by turning the adjuster clockwise. Alwaj rtart with fall hard when adjusting damping. Do not turn the adjurter .rcrew more than the given positions or the adjuster may be damaged. Be rare that the rebound and camprexsion adjusters arefirmly Ioealed in a detent, and not between pmitiam. (1) rebound damping adjuster (2) compression damping adjuster _‘ t7CRl-ASLIXJleYHOuidll H3 Fork Springs The fork springs in CRF‘s are about right for riders weighing between 1501b (68 kg) and 160 lb (73 kg) (less riding gear). So if you're a heavier rider, you have to go up on the oil capacity or get a stiffer spring. Do not use less oil than the minimum specified for each spring or there will be a loss of rebound damping control near full extension. If the fork is too hard on big bumps, turn the damping adjuster counterclockwise 1-turn and lower the oil capacity in increments of 0.2 oz (5 cm7‘) in both fork legs until the desired performance is obtained. Do not, however, lower the oil capacity below the minimum oil capacity. Minimum oil level: Standard spring: Softer spring: Stiffer spring: 103 US 02 (306 ems) 10.5 US 02 (311 cm3) 10.5 US 02 (309 ems) When adjusting oil capacity, bear in mind that the air in the fork will increase in pressure while riding; therefore, the higher the oil capacity, the higher the eventual pressure of any air in the fork. lam 16m Oll level l3.5 us 02 (402 cm1) A (MAX) / z woo I mm on level l lo us 02 (32A ma) ‘/ 9 Wu (STANDARD) ' o / U- 300 sou 400 zoo 0 oil level to 3 us oz (306 cm!) (MIN) l 41 u so so an 120 lso no zlo 24a 270 300 Stroke (mm) Front Suspension Adjustments Front Suspension Disassembly - If your CRF is brand-new, put enough part— throttle break-in time (about 1 hour) on it to ensure that the suspension has worked in. For optimum performance, and extended fork life, the fork should be completely dis ssembled and cleaned after the first 3 hours of riding. See the Service Manual or your dealer for this service. When disassembling the fork, turn the rebound (l) and compression (2) damping adjusters counterclockwise to the softest position to prevent damaging the adjustment needle (be sure to record the number of turns from the starting position). (2) (1) rebound damping adjuster (2) compression damping adjuster Adjustments for Competition 113 zoltsllmlnx nus HF Front Suspension Adjustments 1. Place your CRF on an optional workstand or equivalent support with the front wheel off the ground. 2. Remove the steering damper (page 100) and handlebar pad. Remove the handlebar lower holder nuts, washers, mounting rubbers (3) and handlebar (4). Keep the master cylinder upright to prevent air from entering system. (3) handlebar lower holder nuts/washers/mounting rubbers (4) handlebar 114 Adjustments for Competition _‘ l7cmsuxgumrmouub m 3. Loosen the fork bridge upper pinch bolts (5). 4. Loosen the fork damper (6) using a lock nut wrench (7), but do not remove it yet. Do not use an adjurrabla wrench r0 looren the fork damper: i! may damage them. (5) tork bridge upper pinch bolts (6) tork damper (7) look nut wrench 5. Remove the disc cover (8) by removing the disc cover bolts (9). (8) disc cover (9) disc cover bolts 6. Remove the tripmeter cable (10) and front axle nut (11) and loosen the axle pinch bolts (12) on both fork legs. 7. Pull the front axle shaft (13) out of the wheel hub and remove the front wheel. 1%: ??‘ 20% . (10) tripmeter cable (11) front axle nut (12) axle pinch bolts (13) front axle shaft 8. Remove the fork protector bolts (14), tripmeter cable clamp screws (15), brake hose clamp bolts (16) and fork protectors (17). Remove the brake caliper mounting bolts (18) and brake caliper (19). The fork protector bolts and caliper mounting bolts have a locking agent applied. zone/ems nae ‘J7 4% H: Front Suspension Adjustments 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. (14) (14) (19) (14) iork protector bolts (15 tripmeter cable clamp screws 16 brake hose clamp bolts (17) iork protectors (18) brake caliper mounting bolts (19) brake caliper 9. Loosen the fork bridge lower pinch bolts (20), then pull the fork legs down and out. (20) fork bridge lower pinch bolts _‘ l7CRl-‘45EIXJIMEY7IUm-ib HS 10. Clean the fork assembly, especially the sliding surface (21) of the slider and fork dust seal (22). ll. Measure the length (23) between the axle holder and outer tube and record it before disassembling the fork. (22) \ i” (23) C0? (21) sliding surface (22) fork dust seal (23) length 12. Hold the outer tube (24), then remove the fork damper (6) from the outer tube using a lock nut wrench (7). Gently slide the outer tube down onto the lower end (axle holder) (25). (6) fork damper (7) lock nut wrench (24) outer tube (25) axle holder The outer tube (24) can drop on the slider (26) and damage thefark durt seal (22) and guide bushing (27) when thefnrk damper is removed. To avoid damage hold both the outer tube and slider when removing the fork dampen NO GOOD X (22) (27) X L¢' l lll 'l\ (26) 5"” NO GOOD (24) (22) fork dust seal (26) slider (24) outer tube (27) guide bushing [3. Drain the fork oil from the outer tube/slider (28). Drain the fork oil from the oil holes (29) of the fork damper. (2B) outer tube/slider (29) oil holes (cont’d) Adjustments for Competition 115 zone/acme n as ‘J7 Front Suspension Adjustments 4% 14. Temporarily install the fork damper to the outer tube. 15. Place the lower end (axle holder) (25) of the slider in a vise with a piece of wood or soft jaws to avoid damage. Over-tightening the vise can damage the axle holder 16. Loosen the fork center bolt (30). ~ 5 (25) (25) axle holder (30) fork center bolt 116 Adjustments for Competition _‘ momsoxjimmomdb no 17. Make the mechanic‘s stopper tool out of a thin piece of steel (0.08 in (2.0 mm) thick) as shown if you do not have the special tool. 2.2 in (55 mm) 1.0 in (25 mm) H030 in 7 _ —(7.?. mm) 18. Push out the fork center bolt (30) from the axle holder (25) of the slider by pushing the fork damper. While the fork center bolt is pushed out, install the piston base (31) or a mechanic’s stopper tool between the axle holder and fork center bolt lock nut (32). 19. Hold the fork center bolt lock nut and remove the fork center bolt from the fork damper. 1.5m (39 mm) 0.6 m 5 mm) Do not remove the lack nut from the fork damper plrtari rad. Ifthe lack hat 1'; removed the piston rod will fall in the fork damper and you cannot reassemble the fork damper 2,, [.. (31) piston base (32) fork center bolt lock nut (25) axle holder (30) fork center bolt % 20. Remove the push rod (33) from the fork damper. 21. Remove the piston base (31) or mechanic's stopper tool between the axle holder (25) and fork center bolt lock nut (32) while pushing the fork damper. Be Careful not to damage the lack nut andfork L‘enter bolt hole. \\ . (25) axle holder (31) piston base (32) fork center bolt lock nut (33) push rod 22. Remove the fork damper assembly (34) from the fork assembly (35). Remove the fork from the vise. Remove the fork spring (36) from the fork assembly. (35) (34) fork damper assembly (35) fork assembly (36) fork spring zone/acme n as 117 4% U: Front Suspension Adjustments Damper Oil Change 1. Place the fork damper (1) in a vise with a piece of wood or softjaws to avoid damage. 2. Loosen the fork cap assembly (2) while holding the fork damper using a lock nut wrench (3). (1) fork damper (2) fork cap assembly (3) look nut wrench _‘ l7CRl-‘45EIXJIMEY7I0m-lb m 3. Remove the fork cap assembly (2) from the fork damper (1). Be careful not to damage the fork cap bushing. Do not disassemble the fork cap assembly. Replace the fork cap as an assembly if it is damaged. (2) (1)—» (1) fork damper (2) fork cap assembly 4. Empty the fork oil from the oil holes (4) of the fork damper spring chamber (5) by pumping the damper rod several times. (4) oil holes (5) fork damper spring chamber 5. Clean the fork cap and fork damper threads. 4% 6. Extend the fork damper piston rod to maximum. Pour the recommended fork oil into the fork damper (1). Recommended Oil: Pro Honda HP Fork Oil 5 W or equivalent Recommended Amount: 65 US 02 (192 oma, 6.8 Imp oz) (1) fork damper 7. Pump the fork damper piston rod (6) slowly several times to bleed the air from the fork damper (l). (1) fork damper (6) fork damper piston rod (cont’d) 117 ZUlG/OG/Oél n as 1J7 Adjustments for Competition J Front Suspension Adjustments 8. Extend the fork damper piston rod to maximum. Adjust the oil level of the fork damper (1) as shown. Oil Level: 1.7 — 1.9 in (42 — 47 mm) (1) 1.7— 1.9 in (42—47 mm) (1) fork damper 9. Apply fork oil to the bushing (7) and new O—rings (8) on the fork cap assembly (2). Extend the fork damper piston rod to 47’“ maximum, holding it, install the fork cap \‘ assembly to the fork damper (1). Be careful not to damage the fork cap bushing. If it is difficult to install the fork cap assembly, the fork damper oil level might be higher than standard oil level. Inspect the fork damper oil level again. (1) fork damper (2) fork cap assembly (7) bushing (8) O—rings 118 Adjustments for Competition _‘ l7emsuxgumnnomdtr iu-i 10. Place the fork damper (1) in a vise with a piece of wood or soft jaws to avoid damage. 11. Tighten the fork cap assembly (2) while holding the cut out of the fork damper using a lock nut wrench (3) to the specified torque: 22 |bf~ft (30 N-m, 311 kgf-m) (3) (1) fork damper (2) fork cap assembly (3) look nut wrench 12. Hold the fork damper (1) in an upright position and pump the fork damper piston rod (6) to 3.9 in (100 mm) slowly several times. (1)\J (6) 3.9 in (100 mm) (1) fork damper (6) fork damper piston rod 13. Screw in the fork center bolt lock nut (9) to the fork damper piston rod (6) fully. (6) (9) (6) fork damper piston rod (9) fork center bolt look nut Turn the rebound adjuster and compression adjuster counterclockwise to the softest position. Check the fork damper piston rod sliding surface for damage. Apply fork oil to the fork damper piston rod sliding surface. /\ Cover the fork damper piston rod end with soft jaws (10) to prevent fork damage. Be careful not to bend or damage the fork damper piston md when the piston rod is .rtmked. ZOIG/OG/OS I l 45 I:{ 14. Blow the extra oil off to the fork damper spring chamber (5) by pumping the fork damper piston rod to full stroke. 1- E ((10) (5) fork damper spring chamber (10) soit jaws _‘ WCRFASEIXJIMEYHDui-lb my 4% [5. Drain the extra oil from the oil holes (4) of the fork damper spring chamber (5). By doing this procedure, about 0.6 US oz (17 cm‘) of fork fluid will be drained from the damper spring chamber through the oil hole and cause 5.9 US oz (175 cm‘) of fork fluid to be left in the chamber. U: Front Suspension Adjustments 16. 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. 17. If you can not use compressed air, remove the fork air pressure release screw (11) on the fork cap (12). Hold the fork damper upside down for 10 minutes and drain the oil from the fork damper spring chamber. (4) oil holes (5) iork damper spring chamber (12) (11) fork air pressure release screw (12) iork cap Pour the drained oil into a suitable container and dispose of it in an approved manner (page 151). Improper dirpnml (If drained/[Midis is harmful to the environment. Adjustments for Competition 119 ZOlG/OG/OS n 56117 J Front Suspension Adjustments Fork Assembly 1. Drain the fork oil from the fork assembly (1) by placing it upside down. (About 0.2 US oz (7cm3) of fork oil will be left in the fork assembly when it is left inverted for about 20 minutes at 20°C (68°F).) (1) ,////,a:/ (1) fork assembly To properly dispose of drained fluids. refer to You & [/16 Environment (page 151). Improper disposal ofdrainedfluids is harmful to the environment. 120 Adjustments for Competition _‘ t7L‘Rl-ASLIXJleYHO"idly izo Amount of fork oil left in the fork (without damper and spring) mm. unit: cmi 5 1 0 20 35 55 65 1 45 w; 30/86 7.1 5.9 4.7 4.2 3.5 3.5 3.5 20/66 10.6 8.2 7.1 5.9 5.6 4.7 4.7 10/50 11.6 8.3 7.2 6.2 5.6 4.9 4.6 0/32 12.9 10.6 9.4 8.2 7.9 7.1 5.9 (Ema) 15 (PC/32°F 10”C/50°F 20“C/68°F SOT/86°F Amount of fork oil o 20 40 so so 100 120 140 150 Inverted tlme (mlnutes) 2. Tighten the fork center bolt lock nut (2) fully and measure the thread length (A) as shown. Standard: 0.4 — 0.5 in (11 — 13 mm) Wipe the oil completely off the fork damper. (2) (2) fork center boll lock nut (A) thread length 3. Blow out the oil completely off the fork spring (3) using the compressed air. Install the fork spring. Install the fork damper assembly (4) to the fork assembly (1). (4) (1) fork assembly (3) fork spring (4) fork damper assembly gong/11131113 11413117 J 4% U: Front Suspension Adjustments 4. Place the lower end (axle holder) of the slider in a vise with a piece of wood or soft jaws to avoid to damage. Over-ttghtening the vire can damage the axle holder. 5. Push out the fork damper piston rod from the axle holder of the slider by pushing the fork damper. Apply pressure to the fork damper and insert the piston base (5) or mechanic’s stopper tool between the axle holder and fork center bolt lock nut (2). Measure the thread length again. Standard: 0.4 — 0.5 in (11 — 13 mm) 6. Install the push rod (6) into the fork damper piston rod until it stops. Check the push rod installation by turning the push rod right and left. 7. Apply fork oil to a new O-ring (7) and install it to the fork center bolt (8). Install the fork center bolt to the fork damper piston rod aligning the adjusting rod (9) with the push rod. Tighten the fork center bolt fully by hand. (2) fork center bolt lock nut (5) piston base (6) push rod (7) O-ring (B) fork center bolt (9) adjusting rod _‘ HORFASEIXJIMEWIDm-ib 121 8. Measure the length of the fork center bolt lock nut (2) and fork center bolt (8) clearance. Standard: 0.06 — 0.08 in (1.5 — 2.0 mm) If the clearance is out of specification, check the fork center bolt lock nut and fork center bolt installation. (2) 0.06 — 0.08 in (1.5— 2.0 mm) - (a) (2) fork center bolt lock nut (B) fork center bolt 9. Tighten the fork center bolt lock nut (2) to the fork center bolt (8) closely by hand. Tighten the fork center bolt lock nut to the specified torque: 16 Ibf-ft (22 N-m, 2.2 kgf-m) (2) fork center bolt lock nut (B) fork center bolt 4% 10. Remove the piston base or mechanic’s stopper tool while pushing to the fork damper. Apply locking agent to the fork center bolt threads. Install the fork center bolt (8) to the axle holder and tighten it to the specified torque: 51 Ibf-ft (69 N-m, ZO kgf-m) (B) fork center bolt 11. Measure the length (10) between the axle holder and outer tube. Standard: 12.5 x 0.1 in (317 x 2 mm) 12. Compare the length at assembly and at disassembly. They should be the same length. If the length at assembly is longer than at disassembly, check the fork center bolt and lock nut installation. (10) length (cont’d) 121 zmc/ac/as n as Iii Adjustments for Competition Front Suspension Adjustments 13. Pour the recommended fork oil (11) into the fork assembly (1). Recommended Oil: Pro Honda HP Fork Oil 5 W or equivalent. (1) lork assembly (11) lork Oll 122 Adjustments for Competition _‘ 17(:msnxgnMmiotmm 122 Fork Oil Capacii : Standard 26.32 Ibl/in (4.61 Nlmm) Fork Spring K. No mark (laclory products) or 1 scribe mark @k/ (aftermarket parts) Standard oll 11.0 US oz capacity (324 cm3) Maximum oll 13.6 US oz Slightly stllier as capacity (402 cm3) it nears full compresslon. Mlnimum oil 10.3 US oz Slightly solter as capacity (306 cm3) it nears full compresslon. Optional Solter25.18 Ibl/in (4.41 Nlmm) Fork Spring W 2 scrlbe marks Standard oll 11.2 US oz capacity (330 cm3) Maximum oll 13.8 US oz Slightly stllier as capacity (407 cm3) it nears full compresslon. Mlnimum oil 10.5 US oz Slightly solter as capacity (311 cm3) it nears full compresslon. /\ \ ./ Optlonal Stiller 27.47 Ibi/in (4.81 N/mm) Fork Spring ©‘\3 scribe marks Standard oll 11.1 US 02 capacity (327 cm3) Maximum oll 13.7 US 02 Slightly stiller as capacity (405 cm3) it nears full compression. Minimum oil 10.5 US 02 Slightly softer as capacity (309 cm3) it nears full compression. Be sure the oil capacity is the same in both fork legs. 2016/05/08 H413 HF 14. Check that the O-ring (12) on the fork damper assembly (4) is in good condition. Apply the recommended fork oil to the O— ring. 15. Pull up the fork assembly (1) slowly and install the fork damper assembly into the outer tube. (1 2) (4) \ <1) i- (1) fork assembly (4) fork damper assembly (12) O-ring 16. Insert both fork legs into the fork clamps. Tighten the fork bridge lower pinch bolts (13) to the specified torque: 15 Ibf-ft (20 N-m, 2.0 kgf-m) (13) fork bridge lower pinch bolts _‘ momsuxgimrwmumb 123 4% 17. Tighten the fork damper (14) to the specified torque using a lock nut wrench (15). Actual: 25 Ibf-ft (34 N-m, 3.5 kgf~m) Torque wrench scale reading: 23 Ibf-fl (31 N-m, 3.2 kgf~m), using a 20 in (50 cm) long torque wrench. When using a lock nut wrench, use a 20 in (50 cm) long deflecting beam type torque wrench. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the fork damper. (15) (14) fork damper (15) lock nut wrench 18. For ease of releasing air pressure after the forks are installed, loosen the fork bridge lower pinch bolts and position the outer tubes so that the fork air pressure release screws (16) are in front of the compression damping adjusters (l7). Align (18) the top of the outer tube (19) with the top surface of the fork top bridge (20). 4% U: Front Suspension Adjustments (16) fork air pressure release screw (17) compression damping adjuster (18) align (19) outertube (20) fork top bridge 19. Tighten the fork bridge lower pinch bolts ( 13) to the specified torque: 15 Ibf-ft (20 N-m, 2.0 kgf~m) 20. Tighten the fork bridge upper pinch bolts (21) to the specified torque: 16 Ibf-ft (22 N-m, 2.2 kgf~m) Over-tightening the pinch bolts can deform the outer tuber. Deformed outer tuber must be replaced. (13) fork bridge lower pinch bolts (21) fork bridge upper pinch bolts (cont’d) 123 2016/06/08 n 461i, Adjustments for Competition J Front Suspension Adjustments 4% 21. Clean the threads of the fork protector bolts (22) and axle holder thoroughly. Apply locking agent to the fork protector bolt threads. Install the fork protectors (23), fork protector bolts, brake hose clamp bolts (24) and tripmeter cable clamp screws (25). Tighten the fork protector bolts to the specified torque: 5.2 Ibf-ft (7 N-m, 0.7 kgf-m) Tighten tripmeter cable clamp screws to the specified torque: 0.5 Ibf-ft (0.7 N-m, 0t1 kgf-m) 22. Align the brake caliper (26) and hose with the let 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. 23. Clean the threads of the brake caliper mounting bolts (27) and brake caliper thoroughly. Apply locking agent to the bolt threads. Install the brake caliper on the slider and tighten the caliper mounting bolts to the specified torque: 22 |bf~ft (30 Nm, 3.1 kgf‘m) (22) fork protector bolts (23) fork protectors (24) brake hose clamp bolts (25) tripmeter cable clamp screws (26) brake caliper (27) brake caliper mounting bolts 124 Adjustments for Competition _‘ WCRFASEIXJIMEWIDm-ib 124 24. Check the left side collar (28) and tripmeter gear box (29) for wear or damage. Apply grease to the dust seal lips. Install the left side collar to the left wheel hub. Install the tripmeter gear box while aligning its tabs (30) of the tripmeter gear box with the grooves (31) on the right wheel hub. (30) tabs (31 ) grooves (29) tripmeter gear box 25. Clean the clamping surface of the axle shaft and axle holders. Install the front wheel (32) between the fork legs while inserting the disc between the pads, and align (33) the tab of the tripmeter gear box as shown. Check that the tripmeter gear box O-ring (34) is in good condition, replace it if necessary. Apply a thin layer of grease to the front axle shaft (35) and insert the front axle shaft from the right side. (32) front wheel (34) O-ring (33) align (35) front axle shalt 26. Install and tighten the front axle nut (36) to the specified torque. 65 lb”! (88 N-m, 9t0 kgf-m) Tighten the left axle pinch bolts (37) to the specified torque. 15 lbf‘ft (20 Nam, 20 kgf-m) (36) front axle nut (37) left axle pinch bolts zone/cams r l as if J 27. Install the handlebar (38), mounting rubbers (39), washers and handlebar lower holder nuts (40) and tighten the handlebar lower holder nuts to the specified torque: 32 Ibf-ft (44 N-rn, 4.5 kgf-m) (38) handlebar (39) mounting rubbers (40) washers/handlebar lower holder nuts 28. With the front brake applied, pump the fork up and down several times to seat the axle and check front brake operation. _‘ t7CRFASLlXJlMLWIOmdb 125 29. While keeping the forks parallel, altemately tighten the right axle pinch bolts (41) to the specified torque: 15 Ibf-ft (20 N-rn, 2.0 kgf-m) To avoid damage when rarquing the axle pinch halts, be rare the axle ir saatadfirmly onto the rightfork leg clamp inner rarfaea. 30. Connect the tripmeter cable (42) and tighten the lock nut securely. (41) right axle pinch bolts (42) tripmeter cable U: Front Suspension Adjustments 31. Install the disc cover (43) and tighten the disc cover bolts (44) to the specified torque: 10 |bf~ft (13 N~m, 1.3 kgf-rn) (44) (43) disc cover (44) disc cover bolts 32. Turn the rebound damping (45) and compression damping (46) adjuster back to their original settings. (46) K \ (45) (45) rebound damping adjuster (46) compression damping adjuster 33. Install the steering damper (page 101) and handlebar pad. Adjustments for Competition 125 ZOIG/GG/Oél n as ”[7 Rear Suspension Adjustments The rear suspension can be adjusted for the rider's weight and riding conditions by changing the spring pre-load and the rebound and compression damping. The rear shock absorber assembly includes a damper unit that contains high pressure nitrogen gas. Do not attempt to di semble, service, or dispose of the damper; see your dealer. The instructions found in this owner's manual are limited to adjustments of the shock assembly only. Puncture or exposure to flame may also result in an explosion, causing serious injury. Service or disposal should only be done by your dealer or a qualified mechanic, equipped with the proper tools, safety equipment and the Honda Service Manual. If your CRF is new, put enough part-throttle break—in time (about 1 hour) on it to ensure that the suspension has worked in. Rear Suspension Spring Pre-Load Pre-load should be adjusted when the engine is cold because it is necessary to remove the muffler (page 62). Optional pin spanners are available for turning the lock nut and adjusting nut to adjust spring pre-load. 1. Place your CRF on an optional workstand or equivalent support with the rear wheel off the ground. 2. Lift the subframe to the upright position (page 39). 126 Adjustments for Competition _‘ l7CRHSUXJIMLYHOmdlv 126 3. Check that the spring pre—load is adjusted to the standard length. Adjust as necessary by loosening the shock spring lock nut (1) and turning the adjusting nut (2). Each complete turn of the adjusting nut changes the spring length by 0.06 in (1.5 mm). 4. After adjustment, hold the adjusting nut and tighten the shock spring lock nut to the specified torque: 32 |bf«ft (44 N«rn, 4.5 kgf-m) (1) shock spring lock nut (2) adjusting nut (3) pln spanners (4) spring length To increase spring pre—load: Loosen the shock spring lock nut with the optional pin spanners (3) and turn the adjusting nut to shorten the spring length (4). Do not shorten to less than: 980 in (249.0 mm) To decrease spring pre—load: Loosen the shock spring lock nut with the optional pin spanners (3) and turn the adjusting nut to increase the spring length (4). Do not increase to more than: 10.20 in (2590 mm) Each turn of the adjuster changes spring length and spring pre—load. One turn equals: spring length/spring pre-load: 0.06 in (1.5 mm)/18.18 Ibf (80.85 N) Pin spanners should be used for turning the shock spring lock nut and adjusting nut. See page 169 for optional pin spanners. Spring pre-load length (Standard spring) Standard: 10.16 in (2580 mm) Min.: 9.80 in (2490 mm) Spring pre-load length (Optional spring) Min. (Softer, 296.9 Ibf/in (52.0 N/mm)): 93 in (251 mm) Min. (StifTer, 319.21bf/in (55.9 N/mm)): 93 in (251 mm) ZOIG/UG/UX nus NJ, Rear Suspension Damping Compre n Damping Compression damping may be adjusted in two stages with separate adjusters. The high speed compression damping adjuster (1) is effective when compression damping adjustment is desired for high speed operation. The low speed compression damping adjuster (2) should be used when compression damping adjustment is desired at relatively low speeds. - Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise. - Adjust the high speed compression damping adjuster in 1/12 turn increments. - Be sure the low speed compression damping /"\ adjuster is firmly located in a detent, and not between positions. (1) high speed compression damping adjuster (2) low speed compression damping adjuster _‘ t7emsuxgumiwmmdh 127 High Speed Camprarsion Damping: The high speed compression damping can be adjusted by turning the hexagonal portion of the compression adjuster. The high speed compression damping adjuster has 3-1/2 turns or more. To adjust to the standard position: 1. Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard setting. 2. Turn the adjuster counterclockwise 7/12 , 1-1/12 turns and the punch marks are aligned. Law Spwd Compression Damping: The low speed compression damping can be adjusted by turning the center screw of the compression adjuster. The low speed compression damping adjuster has 13 positions or more. Turning the adjuster one full turn clockwise advances the adjuster 4 positions. To adjust to the standard position: 1. Turn the adjuster clockwise until it will no longer turn (lightly seat). This is the full hard setting. 2. Turn the adjuster counterclockwise 10 clicks and the punch marks are aligned. Rear Suspension Adjustments Rebound Damping The rebound damping adjuster (1) is located at the lower end of the shock absorber. It has 17 positions or more. Turning the adjuster one full turn advances the adjuster 4 positions. - Rebound damping can be increased by turning the adjuster clockwise. - Be sure that the rebound damping adjuster is firmly located in a detent, and not between positions. (1) rebound damping adjuster To adjust to the standard position: 1. Turn the adjuster clockwi. until it will no longer turn (lightly seat). This is the full hard position. 2. Turn the adjuster counterclockwise 10 , l3 clicks with the punch marks on the adjuster and the shock absorber aligned. Adjustments for Competition 127 ZOIG/UG/UX n 46sz Rear Suspension Adjustments Rear Suspension Race Sag Setting the proper race sag (ride height) is very important for competition use. Race sag refers to the amount of rear wheel travel used by your CRF at rest, ready to ride, with you on the seat. As a general rule of thumb, the race sag dimension should be about one-third of the maximum travel. On your CRF, ride height is changed by adjusting the rear suspension spring pre—load. Spring Pre—load & Race Sag Ad'ustment The following adjustment procedure establishes the correct starting point for any suspension tuning 7 the proper rear spring pre-load adjustment for your specific needs. Your CRF should be at normal racing weight. including fuel and transmission oil. You should be wearing all your normal protective apparel. You will need two helpers. To calculate the proper adjustment, it is necessary to measure between two fixed points 7 from the center of the rear fender mounting bolt to the center of the chain adjuster lock nut as illustrated here i for three different situations: unloaded: motorcycle on an optional workstand with rear suspension fully extended, no rider. loaded with rider: motorcycle on ground, with rider. loaded without rider: motorcycle on ground, without rider. 1. Support your CRF on an optional workstand or equivalent with the rear wheel off the ground. 2. Measure the unloaded dimension. 128 Adjustments for Competition _‘ l7cunsuxgumrwmmdh 123 REAR FENDER MOUNTING BOLT 3. Measure the loaded with rider dimension. Remove the workstand. With two helpers available, sit as far forward as possible on your CRF‘s seat, wearing your riding apparel. Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs. Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point. Ask the other helper to measure the loaded with rider dimension. REAR FENDER MOUNTING BOLT (with rider) EXAMPLE: 15.7 in (sun mm) Example: Unloaded - 23 6 in (600 mm) , Loaded in 500 mm Race Sag ‘9 in (100 mm) 4. Calculate the race mg dimension. To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Standard Race Sag: 3.9 in (100 mm) Adjust spring pre-load as necessary to obtain the desired handling results. Dec ing the race sag dimension (example: 3.5 in, 90 mm) improves turning ability for tight terrain at the cost of slightly reduced straight line stability. Increasing the race sag dimension (example: 4.3 in, 110 mm) may improve stability on faster terrain with less turns, but will reduce turning performance slightly and may upset the balance between the front and rear suspension, producing a harsher ride. This will happen if the adjustment shifts the effective wheel travel toward the more progressive end of its range. 5. Measure the loaded without rider dimension. Do this with your CRF set at the standard race sag. BIKE LOADED iwiihoul rider) EXAMPLE: 21.7 in [550 mm) Example: Unloaded = 23. in (600 mm) 7 Loaded 550 mm Sag 2.0 n (50 mm) (Without Rider) zone/(mix HAG 2-lmproperpllor screw leot screw adlustment' adjustment' CORRECT A. oneck carburetor _LOGGED - Contannnants lntne tuel jets and accelerator ——>- Not cleaned pump lor clogs lrequently enougn NOT CLOGGED (“‘37) 5. Try spark IeSI‘ WEAK OR »- Faulty, carbon or wet INTERMITTENT louled spark plug (PEI) I:I0°D SPARK SPARK - Faulty Ignltlon control module - Faulty exclter Coll‘ - Faulty tgnltlon coll~ - Broken or snoned spark plug wtre - Faulty tgnltlon pulse generator' - Loose or dlsconnecled Ignltlon system wtres - Faulty englne stop button 6, Ctleck the throttle INCORRECT - Faulty ttlrottle posttlon posttlon Sensov‘ Sensor" CORRECT 7, Test Cyllnder LOW - Rlng worn CompreSSIorI' - Cylrnder worn or damaged" CORRECT ' Plstcrl worn or damaged" - Head gasket not seallng - Value stuck open POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES l. Dlsconnect Iuel FLIEL FLOW - Lack ot tuel In tank RESTRICTED (Rm llne at carburetor and check Ior Clogged Iuel llne clogglng (R41) (RAH - Clogged Iuelllll EUELEEEE‘WTED cap breatner tupe (Rm - Clogged luelvalve (PAH - Clogged Iuellllter (PAH 2. Remove alr DIRTY ‘ N0! Cleaned cleaner (Psl) treguently enougn AIR CLEANER (”5" NOT DIFITV l 3. Check Cam“ retor lets tor cloggrng NOT CLOGGED CLOGGED - Contamlnants In the Iuel 4. Check valve INCORRECT - Cam sprocket not / \ tlmrng lnstalled properly CORRECT 5. Try spark teSI' GOOD SPARK WEAK CR » . Faulty, carbon or wet lNTERMI‘I‘rENT louled spark plug SPARK (Rel) . Faulty Igmtlon control module' . Faulty excrter Coll' Faulty Ignltlon Call' . Broken or snorted spark plug wlre . Faulty Ignltlon pulse generator‘ . Loose or dtsconnected Ignltlon system wnes . Faulty englne stop button 5. Test Cyllnder LOW CampreSSlon‘ - Rlng worn Cyllndev worn or damaged- ‘ Flsrorl worn or damaged- - Head gasket not seallng - Improper value llmlrlg‘ - Valve stuck open EON/DBMS Ilulsz J U: Taking Care of the Unexpected This section gives practical advice to help you solve problems. /\ _‘ l7cmsuxgnMummmm 15:; If a Fuse Blows. If Your Buttery Ii /\ \ / l 154 155 Taking Care of line Unexpected 153 Bong/DBMS H452? If a Fuse Blows All of the electrical circuits on your CRF have a fuse to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your CRF stops working, the first thing you should check for is a blown fuse. Check the fuse before looking elsewhere for another possible cause of the problem. Replace a blown fuse and check component operation. 0 The main fuse (and spare) are located on the starter motor magnetic switch behind the left side cover. Recommended Main Fuse: 15A 1. To prevent an accidental short circuit, stop the engine. 2. Open the air cleaner housing cover by turning /"\ the quick fastener (1) counterclockwise and remove the left side cover bolt (2), seat mounting bolt (3) and left side cover (4). (1 (2 (3 (4 quick fastener left side cover bolt seat mounting bolt left side cover 154 Taking Care of the Uncxpccwd _‘ t7cmsuxgumnnommt m 3. Remove the starter magnetic switch (5) with the rubber case. 4. Disconnect the wire connector (6) of the starter magnetic switch. 5. Pull out the main fuse (7). If it is blown (8), install the spare main fuse (9). (5) starter magnetic switch (6) wire connector (7) main fuse (8) blown fuse (9) spare main fuse 6. Reconnect the wire connector and install the starter magnetic switch. If you do not have a replacement fuse with the proper rating for the circuit, install one with a lower rating. Replarmg afure wit/1 one that har a higher rating greatly increarer the chance afdamage to the electrical .ryrmm. If you replace a blown fuse with a spare fuse that has a lower rating, replace the fuse with the correct rating as soon as you can. Also remember to replace the spare fuse that was installed. If the replacement fuse of the same rating burns out in a short time. there is probably a serious electrical problem on your CRF. Leave the blown fuse in that circuit and have your CRF checked by your dealer. 7. Install the left side cover and left side cover bolt. 8. Close the air cleaner housing cover. gong/mama ”462i, /\ Jump-starting is not recommended. especially if you use an automobile battery. The greater amperage of an automobile battery when the car engine is running can damage your CRF‘s electrical system. Bump starting is also not recommended. If you can‘t charge the battery or it appears unable to hold a charge, see your dealer. _‘ t7cmsuxgnMmumm 155 /\ \ / l If Your Battery Is Low (or Dead) Taking Care 01‘ I110 Unexpected 155 gong/(mm “A“? 156 Taking Care of the Unexpected _‘ A7CRFASUXJIMkWIOmdh 155 ZOIG/DG/UX um 247 This section contains dimensions. capacities, and other technical data. /\ _‘ t7cmsuxgnMmlmmm 157 Vehicle Identification Oxygenated Fuels. Competition Logbook. Optional Parts List Spare Parts & Equipmen Wiring Diagram .......... l Emission Control Systems /\ \ / Technical Information Technical Information 157 EDIE/(Ilium “Ami, Vehicle Identification Serial Numbers The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of the manual. The VIN (1) is stamped on the right side of the steering head. RIGHT SIDE (1) VIN 158 Technical Information _‘ WCRFASUXJIMEWIOmdb 158 The engine number (2) is stamped on the left crankcase. LEFT SIDE I (2) engine number ZOlG/OG/Oél Has 2!, Spec1ficatlons Item English Metric Item English Metric Ilem l English l Metric Dimension Engine Drive train Overall length 05.8 in 2,180 mm Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall Wldth 32.3 in 820 mm Cylinder arrangement Single 6 intcllnled trom Transmission 5-speed, constant mesh Overall height 50.2 in 1,275 mm ver lca Primary reduction 2.739 Wheelbase 50.5 in 1,485 mm Bore and stroke 3.78 x 2.44 ln 96%;?2-1 Gear ratio l 2.230 Seat height 37.9 In 963 mm Displacement 27.4 cu-ln 449 cm3 Gear ratio ll 1.625 Footpeg height 17.0 in 431 mm Compression ratio 120 :1 Gear ratio lll 1.235 Ground clearance 13.6 in 345 mm Intake: 0.006 1 0.001 in Gear ratio lV 1.000 Frame V | | Id (0.16 r 0.03 mm) Gear ratio V 0.826 T e Twm tube a V5 C Balance (80 ) Exhaust: 0'0“ 1 0'001 in Final reduction 3 923 W (0.28 1 0.03 mm) - F. suspension Telescopic lork, travel 11.0 in (279 mm) stroke 12.4 in (315 mm) Fl. suspension Pro-link, travel 12.3 in (313 mm) Engine ol| capacity Alter draining 0.71 US qt 0.67 E Alter draining and oil lilter change 0.74 US qt 0.70 K Tire size, front 80/100— 2151M Alter dlsassembly 0.92 US qt 0.87 K DUNLOP l D742FA Tire size, rear 110/100 — 18 64M DUNLOP ( D756 Transmission oil capacity Alter draining 0.69 US qt 0.65 E » Lelt foot-operated return Gear shift pattern system 1-N-2-3-4-5 Electrical Battery YTZ7$ 12V—6 Ah (10HR) Ignition ICM Starting system Electric, Kickstarter Spark plug : Standard NGK Tire type bias-ply, tube type Alter dlsassembly 0.79 US qt 0.75 K |FR8H11 Tire pressure, troht (cold) 15 psi (100 kPa, 1.0 kgt/cmzl Cooling system, NSR/Kgltpnzn Tire ressure, rear cold 15 100 kP 1.0 k t/ 2 CaPaCIly . p ( ) ps‘l a’ g cm ) Alter draming 1.28 us qt (1.21 2) Optional NGK F brake swept area Single disc brake |FR9H11 - i 518 in2 (3345 ma) Alter dlsassembly 1.53 US qt (1.45 z) N so Single disc brake Carburetor VK27PRZ11 Fl. brake, swept area 2 2 . 60'6 I" (3911 cm ) Type P'S‘O" valve Spark plug gap 0.039 — 0.043 in unleaded gasoline, pump ldentiticatlon number FCR1GC (1.0 — 1.1 mm) Fuel recommendation octane number of 91 or . higher Mam Jet #145 Light Fuel capacity 1.90 us gal 72 l J: "elem NNEU Headllgh‘ l ‘2V'35 W Fuel reserve capacity 0.42 US gal 1.6 K low 16‘ #45 Fuse Pilot screw opening 1-1/8 turns out Main luse l 15 A caSter angle 27003, Fl t | | 0 31 B 0 Tral| length 4.53 in 115 mm oa eve ' m ' mm Fork Oil capacity (except tork damper per leg) 11.0 US oz 324 cm3 ld|e speed 1,700 r 100 rpm _‘ l1cxlssuxgnMmloimlli last /\ l \ / Technical Information 159 goltsintsrnll “A“? Torque Specifications Nuts, Bolts, Fasteners Check and tighten nuts, bolts. and fasteners before every outing. Engine 1 60 Technical Informalion _‘ i7cmsuxgnMmioimuy mo /\ \/ ENGINE Torque Item Remarks lbf-ft N-m kgl-m 1 Cylinder head cover bolls 7 10 1.0 2 Clulcn Cover bolls 7 10 1.0 a Waler pump cover bolls 7 10 1.0 4 Transmission oii check boll 7 10 1.0 5 Crankshaft noie cap 11 15 1.5 NOTE 2 S Oil liller Cover balls 7 10 1.0 7 Cylinder boll 7 10 1.0 5 Cylinder head bolts 7 10 1.0 9 Exhausl pipe Joint nuls 15 21 2.1 10 Drive sprockel ball 23 31 3.2 NOTE 1 11 Engine aildrain boll 12 16 1.6 NOTES 12 Transmission oii drain boll 12 16 1.6 NOTES 13 Coolam drain ball 7 10 1.0 NOTES: 1. was hair 2. Apply grease to the threads 3. Apply on to the threads and sealing surlace. EON/minis ”A“? Torque Specifications Frame _‘ l7ERHSLlXjHMkY7IOlndll lfil FRAME l Torque Fl k ‘em lel N-m kgl-rn 9”” S 1 Sleerlng slem nut 80 108 11.0 2 Fork bridge upper pinch bolls 16 22 2.2 3 Fork bridge lower pinch bolls 15 20 2.0 4 Handlebar upper holder bolts 16 22 2.2 5 Handlebar lower holder nuls 32 44 4.5 6 Fronl axle nul 65 68 9.0 7 Axle pinch bolls 15 20 2.0 8 Rear axle nul 94 128 13.1 NOTE 1 9 Chain ad)usler lack nuls 20 27 2.6 NOTE 2 10 Fronl engine hanger nul 40 54 5.5 11 Middle engine hanger nul 40 54 5.5 12 Engine hanger nut 40 54 5.5 13 Engine hanger plale bolls 19 26 2.7 14 Shock absorber (upper) 32 44 45 NOTE 1 (lower) 32 44 4.5 NOTE 1 15 Swingarm plvol nul 65 Ba 9.0 NOTE 1 16 Fork (lork damper) 25 34 3.5 (lork cap assembly) 22 30 3.1 17 Rear shack arm nuls (swingarm srde) 39 53 5.4 NOTE 1, 6 (shack link side) 39 53 5.4 NOTE 1, 6 18 Rear shack llnk nuls 39 53 5.4 NOTE 1, 6 19 Shock spring lack nul 32 44 4.5 20 Kickslarler arm boll 26 38 3.9 21 Shroud B bolls 3.7 5 0.5 NOTES: Urnul . UBS nut. . SH boll. . Alock boll replace witn a new one. . Apply molybdenum oil lo the threads and rlange surraee. . Apply a seizure inhibitor (Three Bond 1901 or equivalent) to the bolt threads 1. 2 s 4. Apply locklng agent to tne threads. 5 s 7 Technical Information 161 zollsrnlsrnx ll 46le Torque Specifications Frame 162 Technical Information _‘ 17Eki-ASLIXJIMLWIOmdli 152 FRAME Torque “em leI N-m kgt-in “em”: 22 Spark arres1er mouming boils 4.4 6 0.6 NOTE 7 23 Brake pedal adjusler lock nul 4.4 5.9 0.6 24 From brake maslei cyhnder hoider boils 7.3 9.9 1.0 25 Brake hose balls 25 34 3.5 26 From brake caliper mnunling bolts 22 30 3.1 NOTE 5 27 From brake disc nuts 12 16 1.6 NOTE 1 28 Rear brake disc nuts 12 16 1.6 NOTE 1 29 Brake pedal pivol ball 27 36 3.7 30 Spokes (iron!) 2.7 3.68 0.4 (rear) 2.7 3.7 0.4 31 Flim locks 9 12 1.2 32 Sublrame mounting (upper) 36 49 5.0 belts (lower) as 49 5.0 33 DHVe chain mller(upper) 9 12 1.2 NOTE 3 / \ (iower) 9 12 1.2 NOTE 1 \ 1 34 Fork cenlei ball 51 69 7.0 NOTE 4 35 Fork cenlei boll lock nul 16 22 2.2 36 Disc cover balls 10 13 1.3 37 Fork prolecmr boils 5.2 7 0.7 NOTE 5 38 Tripmeter cable clamp screws 0.5 0.7 0.1 39 From brake hose guide boils 3.8 5.2 0.5 40 Muffler mnunling boils (iron!) 19 26 2.7 (rear) 19 26 2.7 41 Muffler clamp b0“ 15 21 2.1 42 DHVen spiockel nuls 24 32 3.3 NOTE 1 43 Sean mounling boils 19 26 2.7 NOTES: UrnuL . UBS nut . SH boil. . Alock bolt: repiaee with a new one. . Appiy moiybdenum 011 to the threads and tiange sunace. . Appiy a seizure inhibitor tThree Bond 1901 or equivalent) to the boil threads. 1 . 2 a 4. Appiy iocking agent to the threads 5 e 7 ZOIG/UG/UX ”4(3th Frame _‘ l7cumsuxgilmkwmnidli lszi (44) (4e) (50) g / Torque Specifications . UBS nut. . SH boll . Alock boll: replace will. a new one. . Apply molybdenum oil lo the threads and flange suriace. . Apply a seizure inhibitor (Three Bond 1901 or equivalenn to the bolt threads. 1. 2 a 4. Apply locking agent to ine threads. 5 e 7 FRAME Torque R k "em lbf-ft N-m kgl-m em” 5 44 Fronl brake reservoir cap screws 0.7 1 0.1 45 Rear brake reservoir cap bolls 0.7 1 0.1 46 Fork air pressure release screw 0.9 1.2 0.1 47 RighI/lefl step biackel mounllng bolls (upper) 41 55 5.6 (lower) 22 30 3.1 48 Sleering damper mounllng bolls 15 20 2.0 NOTE 5 49 Fuel jomt mounling bolls 7 10 1.0 50 Throllle cable adjuster lack nuls 3.0 4 0.4 NOTES: Urnul. Technical Information 163 ZOIG/DG/DX HAG 2y Emission Control Systems Exhaust Emission Requirements The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Canada (EC) require that your CRF comply with applicable exhaust emissions standards during its useful life, when operated and maintained according to the instructions provided. The vehicle emission control information label (1) (Z) is attached on the left side frame. (1) vehicle emission control inlormation label (2) vehicle emission control inlormalion label (Canada only) Noise Emission Requirements The EPA also requires that motorcycles built after January 1,1983 comply with applicable noise emission standards for one year or 1,865 miles (3,000 km) after the time of sale to the ultimate purchaser, the time operated and maintained according to the instructions provided. (USA only) 164 Technical Information _‘ i7crrasuxgumrwmmdh rm Noise Emission Control System TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. federal law prohibits, or Canadian provincial laws may prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance. repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: - Removal of, or puncturing the muffler, baffles, header pipes, or any other component which conducts exhaust gases. Removal of, or puncturing of any part of the intake system. Lack of proper maintenance. Removing or disabling any emissions compliance component, or replacing any compliance component with a non-compliant component. Problems that May Affect Motorcycle Emissions If you are aware of any of the following symptoms, have the vehicle inspected and repaired by your dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring during acceleration. After—buming (backfiring). Poor performance (driveability) and poor fuel economy. .L":’>.‘*'.'":“ Federal regulations prohibit removing or disabling a device or element of design that may affect your engine‘s emission performance unless your CRF will be used exclusively in competition. If you modify your engine for use in sanctioned competition events, you must deface or destroy the emission control information label. gong/mama ”“st Emission Control Systems Source of Emission The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx), and hydrocarbons (HC). Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions. they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Exhaust Emission Control System The exhaust emission control system is composed of appropriate carburetor settings. No adjustments should be made except for an idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. Secondary Air Injection System The exhaust em' sion control system consists of a secondary air injection system. The secondary air injection system introduces filtered air into the exhaust gases in the exhaust port. The secondary air injection system helps improve emission control performance. No adjustments to this system should be made although periodic inspection of the components is recommended. Crankease Emission Control System The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion muffler through the air cleaner and the carburetor. _‘ i7cmsuxgumiwmmdh ms Fuel Permeation Emission Control System This vehicle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Environment Canada (EC). The fuel tank, fuel hoses, and fuel vapor charge hoses used on this vehicle incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations. Technical Information 165 gong/mama ”“st Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump. The following are the EPA-approved percentages of oxygenates: ETHANOL (ethyl or grain alcohol) up to 10% by Volume You may use gasoline containing up to 10% ethanol 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 methanol containing up to 15% methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system. If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline. 166 Technical Information _‘ t7ERl-ASLIXJIMkY7IOmdh 1m; Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty. Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling the fuel tank. Wipe up any spills immediately. Oxygenart’dfualr can damagv paint andplasric. gong/mama It 462117 Competition Logbook Any serious competition effort relies heavily on the knowledge gained and compiled from previous racing events. The best way to organize the many hits of information is to record them in a logbook. Your logbook can include such information as suspension adjustments, gearing, and tire selection. This detailed information, along with your comments, can prove valuable when you compete at the same track or on similar terrain. Your logbook can also tell you when maintenance was performed and when it will be necessary again. Your logbook also lets you record any repairs and lets you keep track of the running time on the engine and suspension components. If you choose to sell your CRF, the accurate maintenance records in your logbook might be the deciding deal-maker for a potential buyer. Consider using different color pens or pencils to record important information on specific subjects. For example, record results in black, suspension/ cha settings in blue, and gearing selections in green. Color codes will help you identify the information you want with a glance. _‘ t7CRl-ASLIXJleYHOmdh m7 Tuning & Adjustment Records Keep track of the settings and adjustments that worked best at a particular location. These items include: - basic track conditions, altitude, and temperature - suspe sion settings - cha. adjustments tested and selected - gearing - tire selection - air pressure Competition Records - your placings - thoughts to improve performance next time: both yours and your CRF's - strategy notes Maintenance Records - regular interval maintenance - repairs - running time on engine - running time on suspension components 'I‘imekeeping This Manual lists maintenance intervals for every-so-many hours of running. The most effective way to schedule maintenance is by the hours you have run your CRF. An official “guesstimate” is close enough for our timekeeping purposes. You may choose to record your time the same way aircraft operators do (but without the benefit of an electrical hourmeter). All running time is broken down into hours and tenths of an hour (each six minutes represents one tenth of an hour). Racing Records Information worth recording for this section of your logbook may include: - Your placing in each moto and overall finishing position. - Thoughts on what you could do to improve your performance next time. - Notes on any patterns noted in choice of starting gate positions or in riding portions of the course as the day progressed that may prove helpful in future events. - Any places on the course where you chose the wrong line and were passed too easily. - Notes on strategy used by your competition or by riders in another event that are worth remembering. Maintenance Records Regular maintenance items you'll want to record in your logbook should include: - Dates and results of cylinder, piston and ring \ / examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance Engine, transmission, and suspension oil changes Chain, sprockets, chain guide and slider replacements Coolant changes and related component replacements Spark plug, brake pads and control cable replacements In addition, you should record any irregularities noted in component wear so you’ll remember to keep a close eye on these areas in the future. Technical Information 167 gong/mama nus <17 /\ Competition Logbook Date Running Time Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Performed, etc.) (Make severai photocoples at this page for luture use) 168 Technical Information _‘ l7cmsnxguMmmmmm my. i /\ \ ./ sous/mama H4621 Optional Parts List _‘ 17cmsuxgnMerrimmur ins» /\ \/ l These parts and tools may be ordered from your TOOLS Remarks FRAME Remarks dealer. Pin spanner A To adjust spring pre-load. Shock spring 307.8 lbt/ln (53.9 N/mm) FRAME Remarks ‘7: (M0 Spanners renulred) 3‘3“an 47/ No mark Driven sprocket < >: Drive chain links Workstand For maintenance (factory products) Standard 51 Teeth, Aluminum. <114> A F h or Red . . Ir gauge or c ecking tire air pressure paint Optional 50 Teeth, Aluminum W (aftermarket parts] <114> , 52 T th AI ‘ <11: Y “mm“m Opstic'r‘ial 296.9 lbt/ln (52.0 N/mm) 0 er Drive chain W Blue size/link DID520MXV/120 g ‘ paint Handlebar . . lower holder Stiller 319.2 lbt/in(55.9Pli\ll1/l:nm) Standard 3 mm oflset palnt Optional no ofiset Fork spring 26.32 lbt/ln (4.61 N/mm) Standard No mark . ©/ (factory products) A x,/ or 7* 1 scribe mark q (aftermarket parts) Optional 25.18 lbt/ln (4.41 N/mm) Solter @% 2 scribe marks Stiller 27.47 lbt/ln (4.81 N/mm) Q 7,7,, 3 scribe marks The standard fork spring and shock spring mounted on the motorcycle when it leaves the factory are not marked. Before replacing the springs, be sure to mark them so they can be distinguished from other optional springs. Technical Information 169 gong/noun nus <17 Spare Parts & Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day of riding. In addition to the usual nuts and bolts, consider the following: Spare Parts spark plugs shims air cleaner (clean & oiled, sealed in a plastic bag) chain & masterlink/plate chain guide slider chain slider chain rollers inner tubes (front & rear) fenders footpegs front visor & side covers handlebar grips levers (brake, clutch & hot start) clutch lever handlebar mount clutch cable hot start cable throttle assembly throttle cable shift lever brake pedal spokes (front & rear, each side) sprockets (smaller than standard, for gearing changes & collision damage replacement) assorted nuts, bolts, washers, screws, cotter pins headlight bulbs battery fuses Ad itional Spares front brake assembly rear brake assembly wheels & tires (front & rear, mounted) clutch discs and plates engine & transmission oil 170 Technical Information _‘ l7ERl-ASLIXJleYHOmdh no seat ignition components radiator hoses radiator shrouds (L & R) brake hoses (front & rear) General Tools sockets (3/8 in drive) screwdrivers: blade & Phillips No. 1, 2, 3 wrench, large adjustable wrenches: open end & box wrenches: hex (Allen) wrench, spoke torque wrench (metric scale, click-stop style) pliers: standard, needle—nose, channel—lock set hammer, plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vemier caliper (metric) pressure/vacuum testing equipment (USA only) Honda Special Tools Any special tools for your CRF purchased from your dealer. - Lock Nut Wrench - Tensioner Stopper - Spoke Wrench - Piston Base ()7WMA-KZ30100 ()7AMG—(J01A 100 071 MA-MR60100 07958—250000] Chemical Products Pro Honda GN4 4-stroke Oil (Engine and Transmission Oil) SAE 80 or 90 gear oil Pro Honda HP Fork Oil 5W Pro Honda DOT4 Brake Fluid Pro Honda HP Chain Lube Pro Honda Foam Filter Oil Pro Honda Hondabrite Pro Honda Dielectric Grease Pro Honda Handgrip Cement Pro Honda Hondalock Molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive) Pro Honda White Lithium Grease Multi-purpose Grease Rust-inhibiting Oil Cable lubricant Pro Honda HP Coolant Urea based multi-purpose grease designed for high temperature, high pressure performance (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan or Shell Stamina EPZ or equivalent) Other Products pliers-safety wire safety wire mechanic’s wire duct tape plastic tie-wraps hose clamps drop light electrical tape Scotch-Brite Hand Pad #7447 (maroon) Teflon tape gong/0mm no , ering Diagram REGULATOR/RECT‘F‘ER STARTER MAGNEUC SWWCH STARTER Sw‘TCH ENG‘NE STOP BUTTON H15: HA .1: Er. 4 ,fi, mum swwcw r ‘r. 0 W K w E u ‘._‘ ,_. K' 1 zgzész ggtsn » ‘F a 5, ;a _ mmfiofi) ; a) 0 ;01m :Etng 9 3 mafia; $335 E?” m w 2 . Sg>o m 3; g z WIFE v—DQ—Gv -.-$ 1 3’ we —B\—D<1—B\ } HEADLIGHT masw <3; 2% 2 :g E; g’mm m 5'}; ”E SE :5 Eu : cm 9% 0 m a? > f ,- mgawoa a o a I = \GNWONCO‘L g” = waomg PosmoN sston SPARK MG \GNWDN msz sawmmn 7777 a: max 5' aRowN mwmmpmm srmmswm y vELLow 0 ORANGE r ‘5 v v Bu BLUE Lb LIGHYBLUE s GREEN Lg uewenem a RED p mm W WH‘TE G! GRAY avssvw chhnicallnformatinn 171 /'\ 4._.7 n cmsuxgnmm / IOmdh m \ ./ EDIE/UlS/DK H452, 172 Technical Information A7CRFASUXJIMkWIOmdh 172 ZOIG/DG/UX um 2, Consumer Information This section contains information about contacting Honda and how to get an official Honda service manual. /\ _‘ t7cmsuxgnMummmm 17:; Authorized Manuals Warranty Coverage Warranty Service Contacting Honda. Your Honda Deale The Honda Rider‘s Club (USA only) /\ \ / l Consumer Information 173 EDIE/(Ilium nu , /\ Authorized Manuals The Service Manual used by your authoriLed dealer is available from your Honda dealer or Helm. Inc (USA only, Canada: See your dealer to order authoriLed manuals.) Also available, but not necessary to service your model, is the Honda Common Service Manual, which explains basic service information for various systems on Honda motorcycles, scooters, and ATV. The Winter Sim-age Guide in conjunction with the 0wner'.r Manual and Sen/icy Manual can help you prepare your Honda motorcycle, scooter, ATV. and 5x5 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. Publication Item No. Description 61MEV10 2017 CRF450X Service Manual G1CSM00 Common Service Manual $9507 Winter Storage Guide 31MEV710 2017 CRF450X Owner‘s Manual Order On-Line: www.helminc.com Order Toll Free: 1-888-CYCLE93 (1-888-292-5393) (NOTE: For Credit Card Orders Only) Monday - Friday 8:00 AM - 6:00 PM EST 1 74 Consumer Information /\ l7 L‘kHsnxguMLWlomdti m \ ./ i BOIG/tltS/tlx ll 462117 Warranty Coverage - Emission Control System Warranty - Noise Control Warranty (USA only) Your new Honda is covered by certain warranties as described in the Honda Motorcycle Warranties Booklet that was provided to you by your Honda dealer. Please read this booklet and be aware of the responsibilities, restrictions, and exclusions which apply. Please also keep your Honda owner's card with your Warranties Booklet. Canada: Please refer to the Warranty Booklet posted on our website at www.honda.ca. It is important to realize that your warranty for your Honda applies to defects in material or factory workmanship. Your warranty coverage does not apply to normal wear or deterioration associated with using the motorcycle. Your warranty coverage will not be voided if you choose to perform your own maintenance. However, you should have the proper tools and service information and be mechanically qualified. Failures that occur due directly to improper maintenance or lack of maintenance are not covered. _‘ l7L‘RHSUXJIMPY7lOurdli 175 Consumer Information 175 Bttltwllfi/llx ll us <17 Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items. (such as brakes, tires, etc.) If you believe you have a problem with your Honda, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the motorcycle, you will be asked to authorize that inspection. Your dealer will give you the results of the inspection. If the problem is covered under warranty, your dealer will perform the warranty repairs for you. If you have questions about warranty coverage or the nature of the repair, it is best to talk to the Service Manager of your Honda dealer. Sometimes, in spite of the best intentions of all concerned, a misunderstanding may occur. If you aren't satisfied with your dealer’s handling of the situation, we suggest you discuss your problem with the appropriate member of the dealerships management team. If the problem has already been reviewed with the Service Manager, Parts Manager, Sales Manager, etc., contact the Owner of the dealership or his designated representative. 1 76 Consumer Information _‘ l7ERl-ASLIXJleYHOmdh ms gong/mama nus <17 Contacting Honda Your owner’s manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner’s manual can be answered by your Honda dealer. If he doesn’t have the answer right away, he will get it for you. If you have a difference of opinion with your dealer, please remember that each dealership is independently owned and operated. That‘s why it’s important to work to resolve any differences at the dealership level. If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following addre Motorcycle Division, American Honda Motor Co., Inc, PO. 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 L6G 0H9, telephone: (888) 946 , 6329, facsimile: (877) 939 , 0909. E—mail: hondaicr@ch.honda.com Please include the following information in your letter: 0 name, address, and telephone number 0 product model, year, and VIN 0 date of purchase 0 dealer name and address We will likely ask your Honda dealer to respond. or possibly acknowledge your comments directly. _‘ l7cmsuxgmvirwmmdh 177 Consumer Information 177 ammo/ox nu , Your Honda Dealer Once you purchase your new Honda. get familiar with the organization of your Honda dealer so you can utilize the full range of services available. The service department is there to perform regular maintenance and unexpected repairs. It has the latest available service information from Honda. The pans department offers Honda Genuine Parts. Pro Honda products, 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. 1 78 Consumer Information _‘ t7ERl-ASLIXJHvlkYHOmdh m Your Honda dealer can inform you about competition events in your area. You‘ll also find that your dealer is a source of information (USA only) about the Honda Rider’s Club of America. We're sure you’ll be as pleased with the service your Honda dealer continues to provide after the sale as you are with the quality and dependability of your Honda. BOIo/UG/UX It 462117 {3 \J The Honda Rider’s Club (USA only) The Honda Rider‘s Club ofAmericu (HRCA) sponsors local riding chapters a1 Authorized Honda Dealerships across the country. /' \ \,/ Consumer Information 179 /'\ l7 CKHSUXVZH Mlz‘x’7 l0 mdh I79 \ ./ Bong/DBMS nan , U: Index A C E accessories.. capacity, fuel ............. engine, adjustments, carburetor, flooded . carbureto adjustmen idle speed chassis assembly number. control freeplay circuit functio . oil . for competition components pinging. gearing .. disassembly starting . personal fit idle speed stop button steering dampe 141 removal stopping 16 suspension, front. 112 care, appearance. won't start . 152 suspension, rea suspension, trac con tttons tire selection... after competition maintenanc air cleaner... air pressure. front suspension ...................... tires ....... apparel, protective appearance care. authorized manuals ...................... B basic operation before riding... between motos & prac brakes, fluid level ..... lever, front adjustmen pad wear pedal heigh break—in guidelines e maintenance Ham—taco 1 80 Index _‘ t7cmsuxgmvnwImuuh no chain drive chassis adjustment or trac con ition choke knob cleaner, air cleaning, appearance care clutch system, adjustment competition logbook consumer information contacting l-londa.. controls, operating coolant ...... customer service cylinder system .. D damping adjustments. front rear dealer, your Honda diagram, wirin drive chain... environment, protecting F filter. air . fuel oil . flooded engine, starting .................................... 16 fork. front suspension adjustment ...................... 112 front suspension inspection oil recommendation front brake lever adjustment front suspension maintenance ........................... 84 fuel, filter ...... line oxygenate . 166 recommendation 41 gong/0mm nu , /\ Index G M R gap, spark plug .................................................. 61 maintenance, rear suspension maintenance ............................ 85 gasohol after competition.... Rider's Club Honda ..... gasoline before & after competitio riding, gearing. between motos & practice apparel. guidelines, component locations basic oper ' steering damper ..... 142 general competition before .. suspension adjustment. importance .......... important guidelines, suspension adjustment .................. 131 safety.. safety precautions schedule. 26, 27, 28 manual, serv e. 174 H modification 4 S handlebar inspection ....................................... 102 safety, Honda, 0 a few words about... contacting. 177 important information Rider’s Club 179 oil, important precaution service manual 174 engine. labels... your dealer .. 178 fork.. maintenance ti ' riding precautio I operating, schedule, maintenance. controls .. serial numbers....... identification, vehi e. 158 instructions service, idle speed, engine 140 operation component locations.... inspection, pre—ride . optional, parts list ............................... L sprockets ox enated fuels labels, safety.. .5 yg spark arrester logbook, compe ion. 167 P spark knock spark plug. _‘ t7cmsuxgmvirwmmuh m pads, brake .. parts, optional. personal fit adjustments pinging, engin plug, spark... pre-load, rear suspension pre-ride inspection protective apparel.. /\ \ / l maintenance specifications... spring pre-load, rear su. en on starting. engin troubleshooting steering damper, adjustment.. guidelines operation inspection (cont'd) Index 18 l gong/mama um . /\ Index steering head bearing inspection stopping engine. storage ........ subl‘rame ..... suspension, front.... rear.. suspension adjustment, for track conditions throttle, freeplay . inspectio air pressure .............................. flat... selection tools torque speei lLallOnb, carbureto engine.... frame ..... transmission or]. transporting tripmeter.. troubleshooting. tubes, replacing. tuning tips 161 7 163 ..46 148 .. 14 152 93 134 V valve clearance valve, fuel... 1 82 Index _‘ l7CRHSUXJIMhYHOmdli 132 W warranty, coverage. extended. washing your motorcycle weight limit. wheels wiring diag m /\ \ / 1 gong/mama um , The following is a brief, but important collection of information you need to know about your Honda. You'll also find space to record important notes. How To Avoid Costly Repairs The engine of your Honda can be the most expensive component to repair. Proper maintenance, especially the use of the recommended fluids and filters, prevents premature wear and damage. Frequent cau s of costly engine repairs a : - Transm on oil & engine oil 7 insufficient quantity, improper oil. - Air cleaner 7 dirty, leaking because of improper installation (poor seal). _‘ 17cmsuxgnMmioimiii I83 Quick Reference Record important information here: VIN Engine No. Owner‘s: Name Address City/State Phone Dealer‘s: Name Address City/State Phone Service Mgr. Maintenance The maintenance schedule (pages 27-28) lists service lrequencies for: about 2.5 hours, about 7.5 hours. about 15.0 hours, about 22.5 hours, and about every 30.0 hours. Pre-ride Inspection Check the items listed on the Pre—ride inspection checklist each time before you ride (page 11): Fuel/Capacity unleaded gasoline, pump octane number of 91 or higher tank: 1.90 US gal (22 Z), reserve: 0.42 US gal (1.6 2) Engine oil Pro Honda GN4 4-stroke oil (USA 8. Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. Transmission oil Pro Honda GN4 4-stroke oil (USA 8. Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. Tires Front 80/100-21 51M Rear 110/100-18 64M DUNLOP ‘ D742FA DUNLOP D756 Type bias-ply, tube type Tire Pressure Front: 15 psi (100 kPa, 1.0 kgflcmz) (cold) Rear: 15 psi (100 kPa, 1.0 kgl/cmz) Spark Plug standard: |FR8H11 (NGK) or VK24PRZ11 (DENSO) optional: |FR9H11 (NGK) or VK27PRZ11 (DENSO) Coolant ethylene glycol antifreeze (silicate—free) lor aluminum engines in 50/50 solution with Pro Honda HP Coolant or an equivalent distilled water Fuse main: 15 A Drive Chain DID 520MXV/114 Size/Link Quick Reference rs \ ./ gong/mama HAG l y u: Quick Reference These symbols are used in Operating Controls and Basic Operating Instructions sections: SYMBOL COMPONENT SEE PAGE N choke knob 8,15 6) START button 3,15 /\ Quick Reference | /\ ( n cmsuxgnMmmmm m \ ./ guns/mama HABM‘