% k? HONDA C RF250R OWNER’S MANUAL & COMPETITION HANDBOOK © Honda Motor Co., Ltd. 2013 l a: lg? 4% 0 > i IMPORTANT NOTICES THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR COMPETITION USE ONLY AND IS SOLD “AS IS” WITH NO WARRANTY. IT DOES NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARDS AND OPERATION ON PUBLIC STREETS, ROADS, OR HIGHWAYS IS ILLEGAL. STATE LAWS PROHIBIT OPERATION OF THIS MOTORCYCLE EXCEPT IN AN ORGANIZED RACING OR COMPETITIVE EVENT UPON A CLOSED COURSE WHICH IS CONDUCTED UNDER THE AUSPICES OF A RECOGNIZED SANCTIONING BODY OR BY PERMIT ISSUED BY THE LOCAL GOVERNMENTAL AUTHORITY HAVING JURISDICTION. FIRST DETERMINE THAT OPERATION IS LEGAL. OPERATOR ONLY, NO PASSENGERS. This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and seating configuration do not safely permit the carrying of a passenger. READ THIS MANUAL CAREFULLY. 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. resen/es the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. © Honda Motor Co., Ltd., 2013 JP \' l r \ \/ JP \' l r \ \/ Honda CRF250R OWNER‘S MANUAL & COMPETITION HANDBOOK m \/ *fl \0 *W i as r \ \Tf Introduction Congratulations on choosing your Honda CRF motocross motorcycle. When you own a Honda, you’re part ofa worldwide family of satisfied customers 7 people who appreciate Honda’s reputation for building quality into every product. Your CRF is a high performance racing motorcycle that utilizes the latest motocross technology and is intended for competition use in sanctioned, closed-course events by experienced riders only. Be aware that motocross is a physically demanding sport that requires more than just a fine motorcycle. To do well, you must be in excellent physical condition and be a skillful rider. For the best results, work diligently on your physical conditioning and practice frequently. 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, ofcourse. But it’sjust 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 offacts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a table ofcontents, a detailed list oftopics at the beginning of each section, and an index at the back ofthe book. Introduction As you read this manual, you will find information that is preceded by a NOTICE 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. lfyou have any questions, or ifyou ever need a special service or repairs, remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction. Happy riding! - This vehicle pictured in this owner’s manual may not match your actual vehicle. ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or system. Abbrev. term Fuil term CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor HPSD Honda Progressive Steering Damper IAT sensor Intake Air Temperature sensor MAP sensor Manilold Absolute Pressure sensor MIL Malfunction Indicator Lamp PGM-FI Programmed Fuel Injection TDC Top Dead Centre TP sensor Throttle Position sensor is? A Few Words About Safety Your safety, and the safety ofothers, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Matarzycle Safety, as well as a number of Safety Messages throughout the manual. Safety Messages are preceded by a safety alert symbol A and one ofthree signal words: DANGER, WARNlNG, 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. A CAUTION You CAN be HURT if you don't follow instructions. of course, it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle. You must use your own good judgement. Safety Messages J. I as JP \1/ JP \1/ Contents MOTORCYCLE SAFETY Important Safety Information Important Safety Precautions Accessories & Modifications Accessories & Modifications . Safety Labels ......................... INSTRUMENTS & CONTROLS Operation Component Locations Indicator ............... MIL Blink Pattern Current DTC/Freeze Circuit Inspection DTC Index BEFORE RIDING Are You Ready to Ride Is Your Motorcycle Ready to Rid . Pre—ride Inspection .............. BASIC OPERATING INSTRUCTIONS 15 Basic Operating Instructions Safe Riding Precautions Starting & Stopping the Engine Fast Idle Knob . Preparation Starting Procedure How to Stop the Engine Break-in Guidelines ........................ .. 19 SERVICING YOUR HONDA ...... 21 Before You ServiCe Your Honda The Importance ofMaintenance . 22 Maintenance Safety ....... Important Safety Precautions Maintenance Schedule 24 General Competition Maintenance . 26 Before & After Competition Maintenance 30 Between Heats & Practice Maintenance After Competition Maintenance ..... Contents ServiCe Preparation: Maintenance Component Locations Seat Fuel Tank Subframe . ServiCe Procedures Fluids & Filte s Fuel System . Fuel Refueling Procedure. Fuel Line Inspection Fuel Pressure Relieving Fuel Line Replacement Fuel Pump Filter Replacemen Fuel Pressure Increasing Engine Oil Oil Recommendation Checking & Adding Oi Changing Engine Oil & Filter Transmission Oil Oil Recommendation Checking & Adding Oi Replacing Transmi ion Coolant ........... Coolant Recommendation Checking & Adding Coolant Cooling System Inspection Coolant Replacement ...... Air Cleaner Cleaning Crankcase Breather Draining ...................... Engine Throttle ..... Throttle Freeplay Throttle Inspection. Engine Idle Speed .. Idle Speed Adjustmen Clutch System . Clutch Lever Adj ustment. Clutch Lever Freeplay .. Other Inspections & Lubri Clutch Operation ........... Clutch Disc/Plate Remova Clutch Disc/Plate Inspection Clutch Disc/Plate Installation. Spark Plug Spark Plug Recommendation . Spark Plug Inspection & Replacement Valve Clearance .. Cylinder Head Cover Remova Positioning At TDC On The Compre. Stroke ..... Valve Clearance Inspection. Camshaft Removal Shim Selection.... Camshaft Installation. Crankshaft I-Iole Cap In. llation Cylinder Head Cover Installation Piston/Piston Rings/Piston Pin Cylinder Head Removal .. Cylinder Removal Piston Removal... Piston Ring Removal. . Piston/Piston Pin/Piston Ring Inspection .80 Piston Ring Installation . Piston Installation ...... Cylinder Installation ..... Cylinder Head Installation / \ \‘T/ 1 aa JP \1/ JP \1/ 0 l 41 Chassis Suspension Front Suspension Inspection Rear Suspension Inspection . Recommended Fork Oil Fork Oil C ange Brakes Front Brake Lever Adjustment Rear Brake Pedal Height Fluid Level Inspection... Brake Pad Wear Other Inspection Wheels Wheel Rims & Spokes Axles & Wheel Bearings Tyres & Tubes Air Pressure Inspection .. Tube Replacement Tyre Replacement Drive Chain Inspection Drive Chain Slider Drive Chain Rolle Adjustment Lubrication Removal, Cleaning & Replacement More About Drive Chain Exhaust Pipe/Muffler Exhaust Pipe/Muffler Inspection. Muffler Removal. Muffler Installation . Exhaust Pipe Removal .. Exhaust Pipe Installation Steering Damper ......... Steering Damper Operation Inspection Removal . Inspection Installation. Additional Maintena e Procedu Steering Head Bearing Inspectio .107 .107 Handlebar Inspection Control Cables ...... Nuts, Bolts, Fastener Appearance Care General Recommen ations Washing Your Motorcycle with a Mild Detergent ..... Condensation Control . After Cleaning Lubrication Aluminum Frame Maintenance Exhaust Pipe and Muffler Maintenance .1 10 Clean the Seat ............ .110 109 ADJUSTMENTS FOR COMPETIT10N....111 Front Suspension Adjustments . Front Suspension Air Pressure . Front Suspension Damping... Fork Springs... Front Suspension Disassembly. Damper Oil Change . Fork Assembly Rear Suspension Adju merits Rear Suspension Spring Pre—Load Rear Suspension Damping. Rear Suspension Race Sag. Suspension Adjustments for Track Conditions Suspension Adjustment Guidelines Tuning Tips Spark Plug Readin Steering Damper Adjustment Steering Damper Damping Steering Damper Adjustment Guidelines . Chassis Adjustments Rear End... Fork Height/Angle Wheelbase Gearing Tyre Selection for Track Conditions Personal Fit Adjustments Control Positioning. Handlebar Position, Width & Shape .131 .141 Contents TIPS Transporting Your Motorcycle Storing Your Honda Preparation for Storage. Removal from Storage You & the Environment Troubleshooting ........ TECHNICAL INFORMATION Vehicle Identification Serial Numbers Specifications .. Torque Specifications Nuts, Bolts, Fasteners Petrol Containing Alcohol Competition Logbook Optional Parts List . Spare Parts & Equipment . Spare Parts General Tools Honda Special Tools Chemical Product Other Products .... Wiring Diagram ............................................ 160 IN DEX ............ 162 Conlenls L l o / \ \‘T/ éL \ Hi / r \ r x 7’ 40 \H/ Qfi \H/ fie ‘7 Motorcycle Safety This section presents some ofthe 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. Important Safety Information Important Safety Precaution Accessories & Modifications Safety Labels Motorcycle Safely l “l 46%; e 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. As an experienced rider, you know there is much you can do to protect yourself when you ride. The following are a few precautions we consider to be most important. Never Carry a Passenger. Your CRF is designed for one operator only. Carrying a passenger can cause an accident in which you and others can be hurt. Wear Prlltective Gear. Whether you’re practicing to improve your skills, or riding in competition, always wear an approved helmet, eye protection, and proper protective gear. Take Time to Get to Knuw Your CRF. Because every motorcycle is unique, take time to become thoroughly familiar with how this one operates and responds to your commands before placing your machine, and yourself, in competition. Learn and Respect Your Limits. Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, illness and fatigue can reduce your ability to perform well and ride safely. 2 Motorcycle Safety Don ’t Drink and Ride. Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either. Keep yuur Honda in Safe Cllnllitian. Maintaining your CRF properly is critical to your safety. A loose bolt, for example, can cause a breakdown in which you can be seriously injured. Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation. could seriously impair your CRF’s handling, stability‘ and braking, making it unsafe to ride. A WARNING Improper accessories or modificalions can cause a crash in which you can be seriously hurt or killed. Follow all instruclions in lhis owner‘s manual regarding modifications and accessories. Mmorcyclc Safely 3 l are JP \1/ JP \1/ 0 i 4‘ Safety Labels This page shows the locations of safety labels on your CRF. These 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 a label comes off or becomes hard to read, contact your dealer for replacement. 4 Matnrcycle Safety iauaflhfim . . . .. .z mmuwfinummtmuu «magnum winnnuuuwinauvi’t fiumflafimulimfi‘uflsfiu fiatamfimmamaxuqmmw in infil‘imthuudé'ufignaannuumwin Iflumsnfiqiu'lufimutmuflmvhw mmnuunuuuummmmsm uaalwnnmndtflutiuma flw'fildufillanuvm’m maimmummgnminu . 1 naummmn'u miuifiufi€mu tum.mamawuawmm mimnuumfgfiiihmmviuiu 108 DANGER finamu yum minim is? Instruments & Controls Read this section carefully before you ride. lt Operation Component Locations presents the location ofthe basic controls on your Indicator CRF. MIL Blink Pattern Current DTC/Freeze DTC Circuit Inspection. DTC Index cxuuua lnslrumcnts & Controls 5 J. JP \1/ JP \1/ Operation Component Locations clutch lever engine stop button fast idle knob 6 Instruments & Controls (engine idle speed) lront brake lever * l l as l_ JP \1/ JP \1/ Indicator The MIL (l) on your CRF keeps you informed, alerts you to possible problems, and makes your riding safer and more enjoyable. Refer to the MIL frequently. (1) MIL The MIL flashes when there is any abnormality in the PGM-FI system. It should also light for a few seconds and then go off when the engine is started. Ifthe MIL comes on at any other time, reduce speed and refer to an official Honda Shop Manual available for purchase from your dealer. Ifthe MIL does not come on when it should, have your dealer check it for problems. MIL Blink Pattern The MIL will blink the appropriate DTC number if the ECM detects an active problem while the engine is running at less than 5,500 min" (rpm). The MIL will stay on when engine speed is over 5,500 min’| (rpm). The MIL has two types ofblinks: a long blink and short blink. The long blinking lasts for 1.2 seconds, the short blinking lasts for 0.4 seconds. One long blink is the equivalent often short blinks. For example, when one long blink is followed by two short blinks, the MIL is 12 (one long blink : 10 blinks, plus two short blinks). When the ECM stores more than one DTC, the MIL will indicate them by blinking in the order from the lowest number to highest number. Current DTC/Freeze DTC The DTC is indicated in two ways according to the failure status. 7 In the case that the ECM detects an active problem, the MIL will come on and will start to blink the DTC when the engine is started. 7 In the case that the ECM does not detect an active problem but has recorded a previous problem in its memory, the MIL will not come on. If it is necessary to retrieve any past problems stored in the memory, refer to an official Honda Shop Manual. Instruments 8; Controls 7 l %I% rip \1/ rip \1/ l i. /\ \/ Indicator Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-Fl system is often related to poorly connected or corroded connections. Check the following connections. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector (5) Injector connector (6) No.1/No.2 CKP sensor connector (7) ECM connector Remember, circuit inspection is nota“cure-all” for other problems in your engine’s PGM-Fl system. 8 Instruments & Controls DTC Index Refer to MIL Blink Pattern on page 7. MIL blinks Function Failure Symptom/FaiI-safe function 1 MAP sensor circuit malfunction Poor performance (driveability) 2 MAP sensor performance problem Poor performance (driveability) 7 ECT sensor circuit malfunction Hard start at a low temperature 8 TP sensor circuit malfunction Poor engine acceleration 9 IAT sensor circuit malfunction Engine operates normally . . . . -Engine does not start 12 Injector circuit malfunction -| . . . . njector, fuel pump and Ignition shut down 19 No.1 CKP sensor circuit malfunction 'EF‘Q'“ does not start . . . - Injector, fuel pump and ignition shut down 69 No.2 CKP sensor circuit malfunction ' 55‘9”“? does not start . . . - Injector, fuel pump and ignition shut down Should be serviced by your dealer, unless the owner has proper tools and is technically qualified. The MIL blinks of the 12, 19, and 69 times can not be checked because the engine can not start at the situation. Ifthe engine does not start, check all connector connections and/or refer to an official Honda Shop Manual for troubleshooting of the PGM—FI symptom. Indicator Instruments & Controls 9 \ %% / \ \1/ / \ \1/ ll] Instruments & Controls / \ \‘T/ 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, steering damper, and other adjustments, see page 1 ll. Are You Ready to Ride‘ Is Your Motorcycle Ready to Ride. Pre—ride Inspection ...... Before Riding 11 / % Are You Ready to Ride? Before riding your CRF for the first time. we strongly 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, steering damper, and other adjustments, see page 1 ll. Whether you’re preparing for competition or for practice, always make sure you are: - In good physical and mental condition - Free of alcohol and drugs - Wearing an approved helmet, eye protection, and other appropriate riding gear Although complete protection is not possible, wearing the proper gear can reduce the chance or severity ofinjury when you ride. 12 Before Riding 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. l 6P; 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. Pre—ride Inspection Check the following before each ride Cooling system and hoses for cond on ..... 54 Spark plug for proper heat range. carbon fouling and spark plug wire terminal for looseness ........................ 66 Air cleaner for condition and contamination. Clutch lever ad stment and treeplay Breather drain for cleaning ..... Steering head bearing and related pa for condition... Steering damper operation Throttle operation ...... Tyres for damage or improper inflation pressure Spokes for loosenes Rim locks for loosene Front and rear suspension for proper operation .. .............. , Front and rear brak check operation ....... 90 Drive chain for correct slack and adequate lubrication 97, 98 Drive chain s i ers an for damage or wear - Engine oil leve ..49 - Transmission or 52 - Fuel line for condition 39 - Coolant for proper level 53 .86 87 m >< 5‘ s = 5 *2. '5 Q a D a, _. a _, a G :3 a: Every possible part for looseness (, ch cylinder head bolts. engine mounting bolts/ nuts, axle nuts, handlebar holder bolts/ nuts, fork bridge pinch bolts, drive chain adjuster lock nuts, drive chain roller bolt/ nut, wire harne\ connectors, kickstarter arm bolt)... .1527154 Indicator ..... 7 Before Riding l3 éL \ .47 / r \ Before Riding 14 kg lg? This section gives basic information on how to start and stop your engine as well as break—in guidelines. Safe Riding Precautions..... Starting & Stopping the Engine Fast Idle Knob .................... Preparation Starting Procedure How to Stop the Engin Break-in Guidelines Basic Operating Instructions Basic Operating Instructions 15 it? «on Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time. please review the Important Safety Precautions beginning on page 2 and the previous section, titled Before Riding. For your safety. avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death. 16 Basic Operating instructions l are ‘+’ ‘+’ Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be kickstarted with the transmission in gear by pulling in the clutch lever before operating the kickstarter. Fast Idle Knob The fast idle knob has two functions: - When pulled out, the fast idle knob assists in first-time start-up for cold weather starting. - When pushed in, it acts like an idle adjustment screw. Refer to Idle Speed Adjustment on page 60. Preparation Make sure that the transmission is in neutral. Starting Procedure Always follow the proper starting procedure described as follows. Check the engine oil, transmission oil and coolant levels before starting the engine (pages 49, 52, 53). Cold Engine Starting 1. Shift the transmission into neutral. 2. lfthe temperature is 35°C (95°F) or below, pull the fast idle knob (1) fully out. (1) last Idle knob 3. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. 4. About a minute after the engine starts, push the fast idle knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. Warm Engine Starting 1. Shift the transmission into neutral. 2. Kick-start the engine. (Do not open the throttle.) lfDifficult to Start After Stalling l. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times to discharge excessive fuel from the engine. 3. Kick-start the engine. (Do not open the throttle.) Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe and muffler discolourations. Basic Operating Instructions 17 \ %% ‘+’ ‘+’ Starting & Stopping the Engine How to Stop the Engine Normal Engine Stop 1. Shift the transmission into neutral. 2. Lightly open the throttle (1) two or three times, and then close it. 3. Push and hold the engine stop button (2) until the engine stops completely. (1) - (1) throttle (2) engine stop button Emergency Engine Stop To stop the engine in an emergency, push and hold the engine stop button. 18 Basic Operating Instructions Jae? 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 25 km (15 miles). During this period. avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: - piston is replaced - piston rings are replaced - cylinder is replaced - crankshaft or crank bearings are replaced Basic Operating Instructions 19 J. \ %% / \ \1/ / \ \1/ 20 Basic Operating lnslruclions / \ \‘T/ l as l /i,\ \1/ /i,\ \1/ 0 l 4‘ i. /\ \/ 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 ECM system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. Ifyou want to check the ignition timing, refer to an official Honda Shop Manual. An optional tool kit may be available. Check with your dealer’s parts department. Before You Service Your [10min The Importance of Maintenance Maintenance Safety ..... Important Safety Precaution Maintenance Schedule General Competition Maintenance . Before & After Competition Maintenance Between Heats & Practice Maintenance After Competition Maintenance ......... Serviee Preparation: Maintenance Component Locations Seat Fuel Tank Subframe . Serviee Procedures Fluids & Filte Fuel System . Engine Oil Transmission Oil Coolant . Air Cleaner Crankcase Breat er Engine Throttle ........... Engine Idle Speed . Clutch System Spark Plug Valve Clearance Piston/Piston Rings/P on Pin Chassis Suspension . Front Suspension Inspection .86 Rear Suspension Inspection. 87 Recommended Fork Oil Fork Oil Change . Brakes Wheels Tyres & Tube. Drive Chain .. Exhaust Pipe/Muffler Steering Damper Additional Maintenance Procedure Appearance Care ........................................... 109 Servicing Your Honda 21 / \ \‘T/ The Importance of Maintenance Keeping your CRF well-maintained is absolutely essential to your safety. It’s also a good way to get maximum performance during each heat. Careful pre-ride inspections and good maintenance are especially important because your CRF is designed to be ridden in off-road competition. Remember, proper maintenance is your responsibility. Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section. A WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. 22 Servicing Your Hands J. / e Maintenance Safety This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions t‘ollow. 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 oft‘bet‘ore 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. - Read the instructions before you begin. and make sure you have the tools and skills required. To help prevent the motorcycle from falling over, park it on a firm, level surface, using an optional workstand or a maintenance stand to provide support. To reduce the possibility ot‘a fire or explosion, be careful when working around petrol. Use only a non—flammable (high flash point) solvent such as kerosene inot petroli to clean parts. Keep cigarette , parks, and flames away from all fuel—related parts. Servicing Your Honda 23 J. nil \ ea r \ \Tf J i. /\ \/ Maintenance Schedule To maintain the safety and reliability ofyour CRF, regular inspection and service is required as shown in the Maintenance Schedule that follows. The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual. The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in this schedule are provided in an official Honda Shop Manual available for purchase. Service intervals in the maintenance schedule are expressed in terms of races and riding hours. To avoid overlooking required service, we urge you to develop a convenient way to record the number of races and/or hours you ride. lfyou do not feel capable ofperforming 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. 24 Servicing Your Honda Perform the pre-ride inspection (page 13) at each scheduled maintenance period. Summary anaimenance Schedule Notes and Procedures: Notes: 1. Clean after every heat for dusty riding conditions. 2. Replace every 2 years. Replacement requires mechanical skill. 3. Replace after the first break-in ride. 4. Inspect after the first break-in ride. 5 Replace the transmission oil, ifthe clutch discs and plates are replaced. 6. Replace every year. Maintenance Procedures: 1 : inspect and clean, adjust, lubricate, or replace, if necessary : clean : adjust : lubricate : replace WF>O (x 45% Maintenance Schedule Perform the Pre- ‘idf.’ Inspection (page 13) at each scheduled maintenance period. 1: Inspect and Clean. Adjust, Lubricate or Replace ifnecessary. C: Clean. A: Adjust. L: Lubricate. R: Replace. FREOUENCV Each race or Every 3 races or Every 5 races or Every 9 races or Every 12 races NOTE aoouI aoouI aoouI mom or about ReI. Page ITEMS 2 5 hours 7 5 hours 15,0 hours 225 hours 30,0 hours FUEL LINE (NOTE 5) I R 39, 40 FUEL PUMP FILTER (NOTE 5) R 43 THROTTLE OPERATION I 59 AIR FILTER (NOTE I) c 55 CRANKCASE DREATHER I 57 SPARK PLUG I as VALVE CLEARANCE (NOTE 4) I 67 — 75 ENGINE OIL (NOTE 3) I R 49 ENGINE OIL FILTER (NOTE 3) R 50 ENGINE IDLE SPEED I so PISTON AND PISTON RINGS R 75 PISTON PIN R 79 TRANSMISSION OIL (NOTE 5) I R 52 RADIATOR COOLANT (NOTE 2) I 53 COOLING SVSTEM I 54 DRIVE CHAIN LL R 97—99 DRIVE CHAIN SLIDER I 97 DRIVE CHAIN ROLLER I 95 _ DRIVE SPROCKET I 99 :/ DRIVEN SPROCKET I 99 DRAKE FLUID (NOTE 2) I 9I BRAKE PADS WEAR I 93 DRAKE SVSTEM I 90 CLUTCH SVSTEM (NOTE 5) I SI, 52 CONTROL CABLES LL I07 EXHAUST PIPE/MUFFLER I I00 SUSPENSION I as, 37 SWINGARM/SHOCK LINKAGE L 29, a7 FORK OIL EXCEPT DAMPER (NOTE 3) R 55 FORK OIL DAMPER R II7 NUTS, BOLTS. FASTENERS I 108.152 -154 WHEELSrTVRES I 94 — 96 STEERING HEAD BEARINGS I I07 ‘WE RECOMMEND THESE ITEMS BE SEFMCED BV REFERRING TO THE HONDA SHOP MANUAL. Tms maInIenahce Schedule Is based upon average home condmon Macmne sumecreo |o severe use requIre more (requehI servrcmg. NOTE: I CIean aher every neaI (ordust ndmg cohomon. 2 RepIace every 2 years. RepIacemehI requIves mechamcal sI l (14): (13) (ii) {roboks (14) grooves as 44 Servicing Your Honda if Ollie 9. Remove the fuel pump unit holder assembly (15) from the fuel pump base (16) and remove the O-ring (17). Wipe the spilled out fuel immediately. (17)/I . (15) fuel pump unit holder assembly (16) fuel pump base (17) O-ring 10. Remove the fuel pump stopper (18) and damper rubber (19). (18) fuel pump stopper (19) damper rubber 1 1. Remove the fuel pump assembly (20) with fuel pump filter (21), O-ring (22) from the fuel pump unit holder (23). W?) (23) (20) (22) (20) fuel pump assembly (21) fuel pump filter (22) O-ring (23) fuel pump unit holder 12. Check the fuel pump filter (21) for clog, damage or deterioration and replace it if necessary. 13. Remove the fuel pump filter from the fuel pump assembly (20). /<21> (20) fuel pump assembly (21) fuel pump filter 49.1 err 4197110 %H% 14% 414% Installation 1. Install a new fuel pump filter ( 1) onto the fuel pump assembly (2) aligning its hook (3) with the joint boss (4) completely. Be careful not to damage the hook. <1 ) / (1) fuel pump filter (new) (3) hook (2) fuel pump assembly (4) joint boss UMP 2. Apply small amount of engine oil to a new O-ring (5). Install a new O-ring to the fuel pump assembly (6). 3. Install the fuel pump assembly with fuel pump filter into the fuel pump unit holder (7) while routing the fuel pump red (8) and black (9) wires through the holder grooves (10) as shown. a) (6) (7) (9) (5) (5) O-ring (new) (6) fuel pump assembly (7) fuel pump unit holder (8) red wire (9) black wire (10) grooves 4. Install a new damper rubber (1 l) to the fuel pump filter as shown. Install the fuel pump stopper ([2). (11) damper rubber (new) (12) fuel pump stopper $ Fuel System 5. Apply small amount of engine oil to a new O-ring (13). Install a new O-ring to the fuel pump base (14). 6. Install the fuel pump unit holder assembly (15) into the fuel pump base while aligning its books (16) with the grooves (17) in the fuel pump base tabs (18). If the gap between the hooks and tabs is more than 1.0 mm (0.04 in), replace the fuel pump unit. Be sure that the hooks are completely seated. (15) (15) (17>(1e>\ v (13)/ 1.1 (13) O-ring (new) (14) fuel pump base (15) fuel pump unit holder assembly (16) hooks (17) grooves (16) tabs (cont’d) Servicing Your Hand: 45 491 err 4%. %ll1% 1 ea ‘i’ ‘i’ Fuel System 7. Connect the fuel pump red (19) and black (20) 9. Install a new O-ring (24) into the fuel tank 12. Install the conical spring washers (29), collars wire terminals to the fuel pump base terminals groove. (30), washers (31), stopper cable (32), stopper (21). Push the wire terminals until they stop as 10. Install the fuel pump unit (25) into the fuel tank cable guide (33) and fuel pump mounting bolts shown. (26). (34). Be careful not to damage the wires. Be careful not to damage the wires. 13' Install the fuel tank. Make sure that the convex surfaces of the conical 8. Apply 0.5 g (0.02 oz) maximum of engine oil (26) in . (25) spring washers are upside. to a new O-ring (22). Install a new O-ring onto the fuel pump unit (23). (29) (SO) (34) (23) (24) O-ring (new) (26) fuel tank ‘ , (25) fuel pump unit (:3; gglrllgcrzl Sprmg washers 11. Install the fuel pump plate (27) with its 8;; magical... (x identification mark (28) facing toward the (33) stopper cable guide / front side and facing up. (34) (“9' Pump MOUHNHQ b0“5 14. Tighten the fuel pump mounting bolts (34) to the specified torque in the specified sequence as shown: 11 N-m (1.1 kgf-m, 8 |bf~fl) (21) (19) red wire terminal (20) black wire terminal (21) fuel pump base terminals (22) O-ring (new) (23) fuel pump unit (27) (27) fuel pump plate (26) identification mark 15. Connect the fuel line (page 41). 16. Increase the fuel pressure (page 47). 46 Servicing Your Honda r), \ '/ l are ‘+’ ‘+’ Fuel System Fuel Pressure Increasing Make sure the fuel remains enough (1.0 E (0.3 US gal, 0.2 lmp gal) minimum) in the fuel tank and add fuel if necessary before increasing fuel pressure. 1. Connect the fuel pump connector (1 ). (1) luel pump connector 2. Disconnect the DLC/fuel pump sub harness connector (2). (2) DLC/fuel pump sub harness connector 3. Before connecting the battery harness cables to a 12V battery (3), make sure that the battery harness selector switches (4) are OFF. 4. Connect the battery harness positive (+) cable (5) first, then connect the battery harness negative (7) cable (6) to the terminals ofa 12 V battery. 5. Connect the battery harness adaptor (7) between the battery harness (8) and the DLC/ fuel pump sub harness connectors (2) as shown. - Battery harness 070MZ-MEN0100 - Battery harness adapter 070MZ-KRNO1OO (2) DLC/luel pump sub harness connectors (3) 12 V battery (4) battery harness selector switches (5) battery harness positive (+) cable (6) battery harness negative (7) cable (7) battery harness adaptor (8) battery harness Position the fuel tank on the main frame. Turn the “PUMP” selector switch (9) ON. The selector switches can be used to change power delivery as follows: 7 “ECM” selector switch ON: Power to ECM only. 7 “PUMP” selector switch ON: Power to fuel pump only. 7 Both selector switches ON: Power to ECM and fuel pump. Run the fuel pump for about 3 7 5 seconds, and fuel pressure will rise. Turn the “PUMP” selector switch OFF. Check that there is no leakage in the fuel line. “PUMP" selector switch . Make sure that the battery harness selector switches are OFF. . Disconnect the battery harness negative (7) cable from the battery first, then disconnect the battery harness positive (+) cable. . Remove the battery harness and battery harness adapter. . Connect the DLC/fuel pump sub harness connector. . Install the fuel tank (page 35). Servicing Your Honda 47 l are l_ as a Engine Oil /i,\ \1/ Refer to Important Safety Precautions on page 23. 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 ofdirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine. Oil Recommendation API 86 or higher except oils classification labeled as energy consen/ing or resource consen/ing on the circular API service label viscosity SAE 10W-30 (weight) C JASO T 903 standard MA Honda “Al-STROKE MOTORCYCLE OIL“ or equivalent suggested oil Servicing Your Honda 4 4s \ - Your CRF does not need oil additives. Use the recommended oil. - Do not use APl SH or higher 4—stroke engine oils displaying a circular APl “energy conserving” or “resource conserving” service label on the container. They may affect lubrication. ‘ 1/ NOT RECOMMENDED OK Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. .W-30 1 up 10 20 30 40 50C -30 -20 -1D 0 -20 O 20 4O 60 80 100 120T JASO T 903 standard The .lASO 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 classilication 14f 411% Engine Oil Checking & Adding on 1. Run the engine at idle for 3 minutes, then shut it off. 2. Wait 3 minutes afler shutting off the engine to allow the oil to properly distribute itself in the engine. 3. Support the CRF in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (1), wipe it clean, and insert it without screwing it in. Remove the oil fill cap/dipstick. 5. 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 it reaches the upper level mark. (Do not overfill.) Reinstall the engine oil fill cap/dipstick. Repeat steps 1 7 5. (1) engine oil fIII cap/dipstick (2) upper level mark (3) lower level mark 6. Check that the O-ring (4) is in good condition and replace it if necessary. 7. Reinstall the engine oil fill cap/dipstick ( 1). . 9 (1) engine oil fill cap/dipstick (4) O-ring 8. Check for oil leaks. Changing Engine Oil & Filter 1. Run the engine at idle for 3 minutes, then shut it ofE 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. With the engine stop button pushed, repeat kickstarter operation approximately five times to drain the engine oil completely. 6. After the oil has drained, apply engine oil to the drain bolt threads and seating surface, then tighten it with a new sealing washer to the specified torque: 16 N-m (1.6 kgf-m,12|bf‘ft) Pour the drained oil into a suitable container and dispose of it in an approved manner (page 146). NOTICE Improperly disposal of drained fluids is hurmfixl to the envirnnment. (1) engine oil fill cap/dipstick (2) engine oil drain bolt (3) sealing washer (new) (cont’d) Servicing Your Hand: 49 49.1 $1 4197110 %1W 1 % rip \1/ rip \1/ 0 1 41 l i. /\ \/ Engine Oil 7. 50 It is recommended to replace the oil and filter every 6 races or about every 15.0 hours. However, ifyou replace only the oil before the recommended interval, see page 25. Servicing Your Honda 8. Remove the oil filter cover bolts (4) and oil filter cover (5). 9. Remove the oil filter (6) and O-ring (7) from the oil filter cover. (4) oil lilter cover bolts (5) oil lilter cover (6) oil lilter (new) (7) O-ring (new) (8) spring (9) rubber seal (10) “OUT-SIDE“ mark NOTICE Uxing the wrong (Ii/filter may result in lea/m or engine damage. 10. Apply grease to the filter side ofthe spring end, then install the spring (8) into a new oil filter. 11. Position the spring against the engine crankcase and install a new oil filter with the rubber seal (9) facing out, away from the engine. You should see the “OUT-SIDE” mark (10) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. NOTICE Ifthe oilfilter is not installedproperly, it will cause Serious engine damage. 12. Apply engine oil to the 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: 12 N-m (112 kgflm, 9 |bf~ft) 14. Fill the crankcase with the recommended oil. Capacity: 0.69 2 (0.73 US qt, 0161 Imp qt) after draining and filter change 0.67 1?. (0.71 US qt, 0159 Imp qt) after draining 15. Install the engine oil fill cap/dipstick. 16. Check the engine oil level by following the steps in Checking & Adding 01'] (page 49). Pour the drained oil into a suitable container and dispose of it in an approved manner (page 146). NOTICE Improper disposal qfdrainedfluid: is harmful to the environment. i as i_ as p r \ \Tf Transmission Oil Refer to Impartant Safety Precautiam on page 23. Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the clutch and transmission. Oil Recommendation API classilication 86 or higher except oiis (Ii—stroke engine oii labeied as energy only) consen/ing or resource consen/ing on the circular API service labei viscosity SAE 10W-30 (weight) JASO T903 MA standard others without lriction modifiers as molybdenum additives Honda “4-STROKE MOTORCYCLE OIL“ or equivalent suggested oii - 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. Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range. -w—so I» 10 20 30 40 50C 730 720 .10 0 720 0 20 40 60 80 100 120? JASO T 903 standard The .lASO 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 classilication Servicing Your Honda 51 411% 14% Transmission Oil Checking & Adding Oil 1. Run the engine at idle for 3 minutes, then shut it off. 2. Wait 3 minutes afler 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 ofthe 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 starts to flow out of the oil check bolt hole. Install the oil check bolt with the sealing washer and transmission oil fill cap. Repeat steps 1 7 4. (1) transmission oil fill cap (2) oil check bolt (3) sealing washer (new) 5. Afler inspecting the oil level or adding oil, tighten the oil check bolt with a new sealing washer to the specified torque: 12 Nm (1.2 kgf-m, 9 Ibf‘ft) 52 Servicing Your Honda 6. Check that the O-ring (4) is in good condition and replace it if necessary. Reinstall the transmission oil fill cap (1). Check for oil leaks. P".\l (1) transmission oil till cap (4) O-ring 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 seating surface, then tighten it with a new sealing washer to the specified torque: 16 N-m (1.6 kgf-m,12|bf‘ft) (1) transmission 0" till cap (2) transmission oil drain bolt (3) sealing washer (new) 6. Fill the crankcase with recommended oil. Capacity: 0.68 2 (0.72 US qt, 0.60 Imp qt) after draining. 7. Install the transmission oil fill cap. 8. Check the transmission oil level by following the steps in Checking & Adding 01‘] (this page). Pour the drained oil into a suitable container and dispose of it in an approved manner (page 146). NOTICE Improper disposal of drained fluids is harmful to the envirnnment. 49.1 mitt 4197110 %1W l % rip \1/ rip \1/ i t. /\ \/ 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 only genuine HONDA PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines when adding or replacing the coolant. Genuine HONDA PRE-MIX COOLANT is excellent at preventing corrosion and overheating. The effects last for up to 2 years. The coolant should be inspected and replaced properly by following the maintenance schedule (page 25). Use any genuine HONDA PRE-MIX COOLANT without diluting with water. NOTICE Do not use non-ethylene glycol Coolant, tap water, nor mineral water when adding or replacing the coolant. Use o/‘improper coolant may Cause damage, such as corrosions in the engine, blockage of the cooling passage or radiator and premature wear oft/1e waterpump seal. Checking & Adding Coolant Refer to Important Safety Precautions on page 23. l. (1 Position your CRF on an optional workstand or equivalent support so that it is securely held in place in an upright position. With the engine cold, remove the radiator cap (1) and check coolant level. The coolant level is correct when it is at the bottom of the radiator filler neck (2). 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. ) radiator cap (2) radiator llller neck (3) air bleed bolt and O-rlng 3. lfthe coolant level is low, remove the air bleed bolt and O-ring (3) on the left radiator upper tank, and then add the coolant up to the filler neck. Inspect the coolant level before each outing. A coolant loss of20 7 60 cm3 (0.7 7 2.0 US oz, 0.7 r 2.1 lmp oz) through the overflow hose is normal. lfcoolant loss is more than this, inspect the cooling system. Capacity: 1.02 P. (1.08 US qt, 0.90 Imp qt) after disassembly 0.95 P. (1.00 US qt, 0.84 Imp qt) after draining 4. Tighten the air bleed bolt to with a new O-ring the specified torque: 1.6 Nvm (0.2 kgf~m,1.2|bf4ft) 5. Install the radiator cap securely. NOTICE If the radiator cap is not installed properly, it will Cause excessive coolant loss and may result in overheating and engine damage. Servicing Your Honda 53 l ere ‘+’ ‘+’ Coolant 1. (1) radiator hoses (2) overflow hose 54 Cooling System Inspection Check the cooling system for leaks (see an official Honda Shop Manual for troubleshooting of leaks). Check the radiator hoses (1) for cracks, deterioration, and radiator hose clamps for looseness. Check the radiator mount for looseness. Make sure the overflow hose (2) is connected and not clogged. Check the radiator fins (3) for clogging. Check the air bleed bolt (4) for looseness. (3) radiator tins (4) air bleed bolt Servicing Your Honda 7. Check the bleed hole (5) below the water pump cover (6) for leakage. Clean away any clogged dirt or sand, ifnecessary. Check the bleed hole of the water pump for signs of seal leakage. If water leaks through the bleed hole, replace the mechanical seal. lf oil leaks through the bleed hole, replace the oil seal. Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine. A small amount of coolant weeping from the bleed hole is normal. See an official Honda Shop Manual or consult your dealer for replacing the mechanical seal or oil seal. Both seals should be replaced at the same time. (5) bleed hole (6) water pump cover Coolant Replacement Refer to Important Safety Precautions on page 23. Coolant should be replaced by your dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to an official Honda Shop Manual. 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 on page 146. NOTICE Improper disposal of drained fluids is harmful to the environment. l are rip \1/ Air Cleaner Refer to Important Safety Precautions on page 23. 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, wom- 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. NOTICE Using the wrong air Cleaner may result in premature engine wear. Proper air cleaner maintenance can prevent premature engine wear or damage, expensive repairs, low engine power, poor gas mileage, and spark plug fouling. NOTICE Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear. Cleaning 1. Remove the seat (page 33). Unhook the air cleaner lid spring (1), and then remove the air cleaner lid (2) from the air cleaner case (3). (1) air cleaner lid spring (2) air cleaner lid (3) air cleaner case 3. Remove the air cleaner retaining bolt (4) and air cleaner assembly (5). (4) air cleaner retaining bolt (5) air cleaner assembly / \ \‘T/ ‘+’ (cont’d) Servicing Your Hand: 55 1 are JP \1/ JP \1/ Air Cleaner 4. Remove the air cleaner element (6) from the air cleaner holder (7) by releasing the holder tabs (8) from the holes (9) of the air cleaner element. (7) (6) air cleaner element (7) air cleaner holder (a) holder tabs (9) holes 5. Wash the air cleaner in clean non-flammable cleaning solvent. Then wash in hot, soapy water, rinse well, and allow to dry thoroughly. The air cleaner 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 to dry thoroughly. After drying, apply 50 cm1 (1.7 US oz, 1.81mp oz) of clean Honda Foam Air Filter Oil or an equivalent air cleaner oil from the inside of the element. Place the element into a plastic bag (10) and spread the oil evenly by hand. 56 Servicing Your Honda (1 0) plastic bag 8. Assemble the air cleaner element and holder. Install the holder tabs (8) in the holes (9) ofthe air cleaner element. 9. Apply 1.5 7 5.5 g (0.1 7 0.2 oz) ofl-Ionda White Lithium Grease or equivalent to the air cleaner housing contact area ofthe air cleaner element. 10. Install the air cleaner assembly (5) into the air cleaner housing by aligning its tabs (11) with the stay (12) of the air cleaner housing. 11. Carefully position the sealing flange of the element to prevent dirt intrusion. (11) (5) air cleaner assembly (11) air cleaner assembly tabs (12) air cleaner housing stay 12. Install and tighten the air cleaner retaining bolt (4) securely. (4) air cleaner retaining bolt NOTICE Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and Cylinder. 13. Install the air cleaner lid (2) to the air cleaner case (3), and then hook the air cleaner lid spring (1 ). (1) air cleaner lid spring (2) air cleaner lid (3) air cleaner case 14. Install the seat (page 33). l as JP \1/ ‘+’ Crankcase Breather Refer to Important Safety Precautions on page 23. Service more frequently if your CR1: is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the crankcase breather tubes. If the drain tube overflows, the air filter may become contaminated with engine oil causing poor engine performance. Draining 1. Remove the crankcase breather tube plugs (1) from the crankcase breather tubes (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plugs. C‘! (1) crankcase breather tube plugs (2) crankcase breather tubes Servicing Your Hand: 57 / \ \‘T/ 1 are ‘+’ ‘+’ Throttle Refer to Important Safety Precautions on page 23. Throttle Freeplay Inspection Check freeplay (1). Freeplay: 2 — 6 mm (0.08 — 0.24 in) If necessary, adjust to the specified range. (1) 44* (1) treeplay 58 Servicing Your Honda Upper Adjustment Minor adjustments are generally made with the upper adjuster. 1. Pull the dust cover (1) back. 2. Loosen the lock nut (2). 3. Turn the adjuster (3). Turning the adjuster in direction (7) will decrease freeplay and turning it in direction (+) will increase freeplay. (1) (1) dust cover (2) lock nut (3) adjuster (+) increase treeplay (—) decrease freeplay 4. Tighten the lock nut to the specified torque: 4.0 N-m (0.4 kgf-m, 3.0 Ibf-ft) Return the dust cover to its normal position. 5. 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: 4.0 N-m (0.4 kgf-m, 3.0 Ibf-ft) Install 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 throttle body. It is also used if you cannot get the proper adjustment with the upper adjuster. 1. Loosen the lock nut (1 ). 2. Turn the adjuster (2) in direction (7) to decrease freeplay, and in direction (+) to increase freeplay. (1) look nut (+) increase treeplay (2) adjuster (—) decrease treeplay 3. Tighten the lock nut to the specified torque: 4.0 N-m (0.4 kgf~m, 3.0 Ibf-ft) 4. Operate the throttle grip to ensure that it functions smoothly and returns completely. If you can’t get the freeplay within the specified range, contact your dealer. t at ‘+’ ‘+’ Throttle . 3. Inspect the condition of the throttle cables Throttle InSPCCthll from the throttle grip down to the throttle body. _ _ _ If the cable is kinked or chafed, have it 1. Check that the throttle assembly 15 positioned replaced. properly (1he 911d 0f the throttle housing (1) is 4. Check the cables for tension or stress in all aligned with the paint mark (2) on the steering positions. handlebar) and the securing bolts are “ght- 5. Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion. l (1) throttle housing (2) paint mark / \ \ 2. Check for smooth rotation of the throttle (3) / from fully open to fully closed in all steering positions. If there is a problem, see your dealer. (3) (3) throttle Servicing Your Honda 59 (re / j are ‘+’ ‘+’ Engine Idle Speed Refer to Important Safety Precautions on page 23. Remember, idle speed adjustment is not a “cure- all” for other problems in your engine’s PGM-Fl system. Adjusting the idle speed will not compensate for a fault elsewhere. The engine must be at normal operating temperature for accurate idle speed adjustment. When pushed in, the fast idle knob acts as the idle adjustment screw. Turning it counterclockwise results in a faster/ higher idle speed. Turning it clockwise results in a slower/lower idle speed. Idle Speed Adjustment 1. If the engine is cold, start it and warm it up 3 minutes. Then shut it off. 2. Connect a tachometer to the engine. (D 3. Shift the transmission into neutral. Start the engine. 4. Keep the motorcycle in an upright position. 5. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 1 100 min" (rpm) “ (1) (1) last idle knob (1») increase (—) decrease 60 Servicing Your Honda r), \ '/ J t as JP \1/ JP \1/ 0 i 4‘ i. /\ \/ Clutch System Refer to Impartant Safety Precautiam on page 23. Clutch Lever Adjustment The distance between the tip of the clutch lever and the grip may be adjusted. Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected. 1. Loosen the lock nut (l). 2. To position the clutch lever farther away from the handgrip, turn the adjuster (2) counterclockwise. To position the clutch lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (1) lock nut (2) adjuster 4. Turn the cable end adjuster (3) in direction (+) until it seats lightly and then turn it out five turns. (3) cable end adjuster (1») increase freeplay (—) decrease freeplay 5. Loosen the lock nut (4) and turn the integral cable adjuster (5) to adjust the clutch lever freeplay at the tip oflever. Freeplay: 10 — 20 mm (0.4 — 08 in) Tighten the lock nut. (4) lock nut (5) integral cable adjuster (1») increase freeplay (—) decrease freeplay 6. Adjust the cable end adjuster for minor adjustment (page 62). zi‘p 4‘5 / Clutch Lever Freeplay Inspection Check freeplay (1). Freeplay: 10 — 20 mm (0.4 — 0.8 in) lfnecessary, adjust to the specified range. (1) lreeplay Improper freeplay adjustment can cause premature clutch wear. Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected. Servicing Your Hand: (,1 l are ‘+’ ‘+’ Clutch System Cable End Ad'ustment Minor adjustments are generally made with the clutch cable end adjuster. Turning the cable end adjuster ( 1) in direction (+) will increase freeplay and turning it in direction (,) will decrease freeplay. (1) cable end adjuster (1») increase freeplay (—) decrease freeplay lfthe 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. 62 Servicing Your Honda lntegral Cable Ad'ustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit 7 or the correct freeplay cannot be obtained. 1. Turn the cable end adjuster in direction (+) until it seats lightly and then turn it out five turns. 2. Loosen the lock nut (l ). 3. Turn the integral cable adjuster (2) to obtain the specified freeplay. 4. Tighten the lock nut. Check the freeplay. (1) look nut (+) increase lreeplay (2) integral cable adjuster (—) decrease lreeplay 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 64). Other Inspections & Lubrication - 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. (1) holder (2) paint mark - Check the clutch cable for kinks or signs of wear. If necessary, have it replaced. - 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 bolt sliding surface with grease and/or clutch cable with commercially available cable lubricant. 2. Check the clutch cable for deterioration, kinks, or damage. fie 4911* 011% Clutch Disc/Plate Removal 1. Drain the transmission oil (page 52). 2. Remove the clutch cover bolt A (1), clutch cover bolts B (2), and clutch cover (3). ham (1) clutch cover bolt A (3) clutch cover (2) clutch cover bolts B 3. Remove the five clutch spring bolts and springs (4). Loosen the bolts in a crisscross pattern in two or three progressive steps. 4. Remove the clutch pressure plate (5). (4) clutch spring bolts and springs (5) clutch pressure plate 5. Remove the clutch lifter assembly (6) first, then remove the clutch lifier rod (7). VII; Clutch System 6. Disassemble the clutch lifier (8), needle bearing (9) and washer (10) by removing the clip (11). 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. (11)—>© (1mg. (a) clutch lifter (10) washer (9) needle bearing (11) clip 7. Remove the eight clutch discs, seven clutch plates, judder spring and spring seat (12). (12) clutch discs, clutch plates, judder spring and spring seat Servicing Your Honda 63 r1110 *1W lie 44»H% 0MP W Clutch System Clutch DisdPlate Inspection - Replace the clutch discs (1) ifthey show signs of scoring or discoloration. Measure the thickness of each clutch disc. Service Limit: 235 mm (0112 in) Replace the clutch discs and clutch plates as a set. (1) (1) clutch disc - Check the clutch plates (2) for excessive war-page or discoloration. Check the plate warpage on a surface plate using a feeler gauge. Service Limit: 010 mm (0004 in) Replace the clutch discs and plates as a set. (2) clutch plate 64 Servicing Your Honda - If you feel the clutch slippage when replacing the clutch discs and plates, replace the clutch springs. Clutch Disc/Plate Installation 1. Install the spring seat (1) and judder spring (2) onto the clutch centre as shown. Coat the clutch discs (3) and clutch plates (4) with engine oil. 2. Install the clutch disc A (larger l.D. disc) (5) onto the clutch outer. Stack the seven clutch plates and seven clutch discs alternately. (1) spring seat (2) judder spring (3) clutch discs (4) clutch plates (5) clutch disc A 3. Apply engine oil to the needle bearing (6) and washer (7) and install them onto the clutch lifter (8). Then, install a new clip (9) by fitting it into the groove in the clutch lifter. © (9) /. <7) / (e) / (8) (6) needle bearing (7) washer (B) clutch lifler (9) clip (new) at rii ; i %Hi% 4111* 4. Apply grease to the clutch lifier rod (10) and insert it into the mainshaft. 5. Install the clutch lifier assembly (11) onto the rod. (10) clutch lifler rod (11) clutch Iifler assembly Install the clutch pressure plate (12). Install the five clutch springs and bolts (13). Tighten the bolts in a crisscross pattern in two or three steps to the specified torque: 12 Nm (1.2 kgf-m, 9 lbf‘ft) P°>'.°‘ (12) clutch pressure plate (13) clutch springs and bolts 9. Apply oil to a new O—ring (14) and install it in the groove of the clutch cover (15). 10. Install the cover by tightening the cover bolts A and B in a crisscross pattern in two or three steps to the specified torque: 10 N-m (1.0 kgf-m, 7 lbfrft) : . 4 w (14) O-ring (new) (15) clutch cover 4% Clutch System 11. Fill the crankcase with transmission oil (page 52). Servicing Your Honda 65 s11 ; 1* %H'1F 1 as ‘1“ Spark Plug Refer to Important Safety Precautions on page 23. Spark Plug Recommendation The recommended standard spark plug is satisfactory for most racing conditions. mum-(New Use only the recommended type of spark plugs in the recommended heat range. NOTICE Using a spar/(plug with an improperheat range or incorrect reach can cause engine damage. Using a nan-resistor spark plug may cause ignition problems. This motorcycle uses a spark plug that has an iridium tip in the centre 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 centre electrode and platinum tip of the side electrode, never use a “leaf-type feeler gauge.” Do not adjust the spark plug gap. lfthe gap is out of specification, replace the spark plug with a new one. . Remove the spark plug (2). (1) spark plug cap Spark Plug Inspection & Replacement . Remove the seat and hang the fuel tank to the left ofthe frame (pages 33, 34). . Disconnect the spark plug cap (1). . Clean any dirt from around the spark plug base. (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. . Check the spark plug gap (4), using a wire-type feeler gauge. lfthe gap is out of specifications, replace the plug with a new one. The recommended spark plug gap is: 0.6 — 0.7 mm (0024 — 0.028 in) 3mm / 111 mm mm tumult)“ Hum“ 7. To obtain accurate spark plug readings, accelerate up to speed on a straightaway. Press and hold the engine stop button and disengage the clutch by pulling the lever in. Coast to a stop, then remove and inspect the spark plug. The porcelain insulator around the centre electrode should appear tan or medium gray. lfyou’re using a new plug, ride for at least 10 minutes before taking a plug reading; a brand-new plug will not colour initially. 1f 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 (page 135). Check the PGM-Fl 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. - lfthe 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: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again: 1/8 turn after it seats. NOTICE An improperly tightened spark plug can damage the engine. Ifa plug is too loose, apistnn may be damaged. If a plug is too tight, the threads may be damaged. 10. Connect the spark plug cap. Take care to avoid ‘+’ (3) sealing gasket (4) spark plug gap pinching any cables or wires. 11. Install the fuel tank and seat (pages 33, 35). 66 Servicing Your Honda 44»H% 0MP Valve Clearance Refer to Important Safety Precautions on page 23. 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 valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule (page 25). 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. Cylinder Head Cover Removal Before inspection, clean the engine thoroughly to keep dirt from entering the engine. 1. Remove the seat and hang the fuel tank to the left of the frame (pages 33, 34). 2. Disconnect the breather tube (1) and spark plug cap (2) (1) breather tube (2) spark plug cap 3. Remove the cylinder head cover bolts, rubber seals (3) and cylinder head cover (4). (3) cylinder head cover bolts and rubber seals (4) cylinder head cover $ Positioning At TDC On The Compression Stroke 1. Remove the crankshafi hole cap (1). (1) crankshaft hole cap 2. Remove the spark plug (page 66). 3. Remove the cylinder head cover (this page). (cont’d) 67 Servicing Your Honda 494 viii Jill. %H'io he 44»H% g C bk Valve Clearance 4. 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 at TDC. 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, 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 (4) index mark (3) punch mark 68 Servicing Your Honda (5) exhaust rocker arm (1) feeler gauge (2) valve lifters (3) intake cam lobes Valve Clearance: IN: 0.12 x 003 mm (0005 :t 0.001 in) 4% 4%. Valve Clearance Inspection Set the piston at TDC on the compression stroke (page 67). Measure the intake valve clearance by inserting a feeler gauge (1) between the valve lifters (2) and intake cam lobes (3). %H'ir #ng 44»H% 0MP Valve Clearance 3. Measure the exhaust valve clearance by inserting a feeler gauge (1) between the exhaust rocker arm (4) and shims (5). (1) feeler gauge (4) exhaust rocker arm (5) exhaust valve shims Valve Clearance: EX:O.28 : 003 mm (0.011 1 0.001 in) If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (this page) and select the correct shim for each valve. Camshaft Removal 1. Record the intake valve and exhaust valve clearances (page 68). Make sure the piston is at TDC on the compression stroke (page 67). . Remove the condenser stay mounting bolts (1). (1) condenser stay mounting bolts 3. Remove the cam chain tensioner lifter cover bolt (2) and sealing washer (3). (2) cam chain tensioner lifter cover bolt (3) sealing washer 4. Insert the tensioner stopper (4) into the cam chain tensioner lifter (5). Turn the tensioner stopper clockwise and lock the cam chain tensioner lifter by pushing the handle (6) to the cam chain tensioner lifler. - Tensioner stopper 070MG-0010100 (4) tensioner stopper (5) cam chain tensioner lifter (6) handle (cont’d) Servicing Your Hand: 69 4st rtl 4%. %H1?F 44»H% i O Eh Valve Clearance 5. Make sure the piston is at TDC on the compression stroke (page 67). Loosen the camshaft holder bolts A (7), B (8) in a crisscross pattern in two or three steps. Remove the camshaft holder bolts, set rings and camshafl holders (9). As you remove the camshafl holder, set rings may be sticking in the camshaft holders. (7) camshaft holder bolts A (a) camshaft holder bolts B (9) set rings and camshaft holder NOTICE Do not let the set ringsfal] into the crankcase. If the set rings are remained on the camshaft holder, remove the set rings carefully. 70 Servicing Your Honda 6. Slide the left camshaft bearing (10) and remove the camshaft (l l) by removing the cam chain (12). Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase. NOTICE Do not let the cam chainfall into the crankcase. (1 0) left camshaft bearing (1 1) camshaft (12) cam chain 7. Remove the intake valve lifters (13). Keep the intake valve lifters and shims separate so you can easily identify the originally installed location such as intake or exhaust, right or left. (13) intake valve lifters $ 8. Remove the valve shims (14). (14) valve shims at eff 4%. %H'te fie 4M% Valve Clearance Shim Selection 1. Clean the valve shim contact area in the valve lifter (1) with compressed air. (1) (1 ) valve lifter 01W 2. Measure the shim thickness with a micrometer and record it. Sixty-nine different shims (2) are available in 0.025 mm thickness intervals, from 1.200 mm (the thinnest) to 2.900 mm (the thickest). (2) (2) shim 3. Calculate the new shim thickness using the equation below. A:(Bic)+D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness - Make sure of the correct shim thickness by measuring the shim with a micrometer. - Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2.900 mm. NOTICE Do not lap the intake valves. They are titanium and have a thin oxide coating. Lapping will damage this coating. If a calculated dimension is out of specifications, have your motorcycle inspected by your dealer. 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Hand: 71 49.1 riff 4%. %1W he 4M% 0MP it Valve Clearance Camshaft Installation 1. Install the newly selected shims (1) on the valve spring retainers (2). NOTICE Do not let the shimsfal] into the crankcase. (1) shims (2) valve spring retainers 2. Apply molybdenum disulfide oil (a mixture of [/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the following pans. 7 camshaft cam lobes 7 each valve lifler outer surface 72 Servicing Your Honda 3. Install the valve lifters (3) in their original locations into the cylinder head (4). (3) valve lifters (4) cylinder head 4. Make sure the piston is at TDC (page 67). 5. Place the camshaft (5) with the intake cam lobes (6) facing up and align the timing marks (7) on the cam sprocket (8) with the surface of the cylinder head (9). Install the cam chain (10) over the sprocket without rotating the camshaft. (10) earn chain (5) camshaft (6) intake carn lobes by (7) timing marks (a) cam sprocket (9) surface of the cylinder head viii %ii'i% Jéii% 011.1% Valve Clearance 6. Make sure that the dowel pins (1 l) are installed into the camshaft holders (12). 7. Install the set rings (13) on the camshafl bearing grooves ( 14). NOTICE Do not let the set ringsfal] into the crankcase. (11) dowel pins (12) camshaft holders (13) set rings (14) camshaft bearing grooves Each camshaft holder has an identification mark (15). (15) identification marks 8. Install the camshaft holders (12) in their proper position by aligning the camshaft holder groove with the set ring (13). 9. Apply oil to the camshaft holder bolt threads and seating surface. Tighten the camshaft holder bolts A (16) and B (17) to the specified torque: 16 N-m (1.6 kgf-m,12|bf‘ft) Tighten the camshaft holder bolts in a crisscross pattern in two or three steps. (12) camshaft holders (16) camshaft holder bolts A (17) camshaft holder bolts B $ 10. Remove the tensioner stopper (18) from the cam chain tensioner lifter. (1B) tensioner stopper 11. Install a new sealing washer (l9) and tighten the cam chain tensioner lifter cover bolt (20). (19) sealing washer (new) (20) cam chain tensioner litter cover bolt (cont’d) Servicing Your Hand: 73 491 rii 4197110 %ii'iF 11% Valve Clearance 4111* 12. Install the condenser stay (21) and tighten the 14. Measure the intake valve and exhaust valve _ condenser stay mounting bolt (22). clearances by inserting a feeler gauge (23). Crankshaft H019 Cap IllStallfithll . Valve Clearance: IN: 0.12 1: 0.03 mm (0.005 1: 0.001 in) 1- Install the spark plug (page 70). EX: 0.23 x 0.03 mm (0.011 1 0.001 in) 2- Coat anew O-n'ng (1) with engine oil and . install it onto the crankshaf‘t hole cap (2). Apply grease to the crankshaft hole cap threads. Install and tighten the crankshaft hole cap to the specified torque: 15 N-m (1.5 kgf-m, 11 Ibf‘ft) (21) condenser stay (22) condenser stay mounting bolts 13. Rotate the camshaft by rotating the crankshaf‘t (23) feeler gauge clockwise several times and make sure that the piston is at TDC on the compression stroke (page 71). (1) O-ring (new) (2) crankshaft hole cap 74 Servicing Your Honda 4197110 %111F 44»H% 0MP la Valve Clearance Cylinder Head Cover Installation 1. Check that the spark plug hole packing (1) is in good condition and replace it if necessary. Apply engine oil to the spark plug hole packing and install it to the cylinder head cover (2). 2. Check that the cylinder head cover packing (3) is in good condition and replace it if necessary. Install the cylinder head cover packing into the cylinder head cover groove. . :1 .\ (a) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing 3. Check that the rubber seals (4) are in good condition, replace them if necessary. Install the rubber seals onto the cylinder head cover with the “UP” marks (5) facing up. (4) (4) rubber seal (5) “U P" marks 4. Install the cylinder head cover (2) and tighten the cylinder head cover bolts (6) to the specified torque: 10 N-m (1.0 kgf-m, 7 |bf~ft) (2) cylinder head cover (6) cylinder head cover bolts 5. Connect the spark plug cap (7) and breather tube (8). (7) spark plug cap (a) breather lube 6. Install the fuel tank and seat (pages 33, 35). Servicing Your Hand: 75 at riff ; 4% %Hio 14f 411% Piston/Piston Rings/Piston Pin Cylinder Head Removal 1. Clean the area above the engine before disassembly to prevent dirt falling into the engine. 2. Drain the radiator coolant after cooling the motorcycle (page 145). 3. Remove the seat and hang the fuel tank (pages 33, 34). 4. Remove the left and right mufflers (page 100) and subframe (page 37). Remove the exhaust pipe (page 103). Remove the spark plug (page 66). Remove the cylinder head cover (page 67). Set the piston at TDC on the compression stroke (page 67). Remove the camshaft holders, camshaft, valve lifters and shims (page 69). 37°89?" :9 76 Servicing Your Honda 10. Disconnect the ECT sensor connector (1 l). (1) ECT sensor connector 11. Loosen the radiator hose clamp screw (2) and disconnect the radiator hose (3). (2) radiator hose clamp screw (3) radiator hose 12. Disconnect the crankcase breather tube A (4) from the air cleaner connecting tube. 13. Disconnect the IAT sensor connector (5). 14. Release the crankcase breather tube B (6) from the clip (7). (4) crankcase breather tube A (5) IAT sensor connector (6) crankcase breather tube B (7) clip 15. Loosen the screw (8) on the air cleaner connecting tube clamp (9). O (a) screw (9) air cleaner connecting tube clamp #91 #ng 4W. %1W we Piston/Piston Rings/Piston Pin 16. Remove the air cleaner case (10) along with the air cleaner connecting tube. (10) air cleaner case 17. Remove the rear shock absorber upper nut and bolt (1 1). v (11) rear shock absorber upper nut and bolt 18. Loosen the insulator band screw (12) and pull the throttle body (13) out from the insulator (14). Do not hang the throttle body and support it with a suitable strap. (12) insulator band screw (13) throttle body (14) insulator 19. Remove the cylinder head hanger bolts (15). Remove the cylinder head hanger plate bolts (16), left cylinder head hanger plate (17) and right cylinder head hanger plate (18). Left side: l i Right sifi: (16) (15) cylinder head hanger bolts (16) cylinder head hanger plate bolts (17) left cylinder head hanger plate (18) right cylinder head hanger plate (cont’d) Servicing Your Hand: 77 49.1 #11 Jill. %ll1% gall% Ollie Piston/Piston Rings/Piston Pin 20. Remove the cylinder head A bolts (19). 21. Loosen the cylinder bolt (20). (19) cylinder head A bolts (20) cylinder bolt 22. Remove the cylinder head B bolts, washers (21) and the cylinder head (22). Loosen the bolts in a crisscross pattern in two or three steps. NOTICE Do not let the washers and cam chainfal] intn the crankcase. Y . (21) cylinder head B bolts and washers (22) cylinder head 78 Servicing Your Honda 23. Remove the dowel pins (23) and cylinder head gasket (24). NOTICE Do not let the dowelpins and cam chainfall into the crankcase. (23) dowel pins (24) cylinder head gasket 24. Remove the cam chain guide (25) from the cylinder (26). (25) cam chain guide (26) cylinder Cylinder Removal 1. Remove the cylinder bolt (1) and cylinder (2). NOTICE Do not let the cam chain fall into the crankcase. Do not pry on or strike the cylinder. eel gill %ll'ie Jéii% 0MP Piston/Piston Rings/Piston Pin 2. Remove the dowel pins (3) and cylinder gasket (4)- NOTICE Do not let the dowel pins full intn the crankcase. (3) dowel pins (4) cylinder gasket Piston Removal 1. Place clean shop towels in the crankcase to keep the piston pin clips, or other parts, from falling into the crankcase. 2. Remove the piston pin clips (1) using a pair of needle-nose pliers. 3. Press the piston pin (2) out of the piston (3), and remove the piston. Under racing conditions, the piston and rings should be replaced every 6 races or about every 15.0 hours of running. Replace the piston pin every 6 races or about every 15.0 hours of running. (3) piston (1) piston pin clips (2) piston pin Piston Ring Removal Spread each piston ring (1) and remove by lifting it up at a point just opposite the gap. NOTICE Do not damage the pistnn ring by spreading the ends too far. (1) piston ring Servicing Your Honda 79 49.1 rii‘i ; i %iii% l a% 49 \1/ 49 \1/ 0 l 4‘ l t. /\ \/ Piston/Piston Rings/Piston Pin Piston/Piston Pin/Piston Ring Inspection We recommend you consult an official Honda Shop Manual or your dealer for correct Service Limit measurements. 80 Servicing Your Honda Piston Ring Installation 1. Remove the carbon deposits from the piston head and piston ring grooves. NOTICE Do not damage the piston when removing the carbon deposit. 2. Apply engine oil to each piston ring whole surface. 3. Install the spacer (1) first, then install the side rails (2) to the piston (3). 4. Install the top ring (4) to the piston with “RNM” mark (5) side facing up. NOTICE Do not damage the piston ring by spreading the ends too far. Do not damage the piston during piston ring installation. 5. After installing the piston rings they should rotate freely, without sticking. Space the ring end gaps 180 degrees apart between top ring and upper side rail. Space the ring end gaps 90 degrees apart between upper side rail, spacer and lower side rail. ’ +(2) % ...... 77—(1 V\(2) / \ x / (1) spacer (4) top ring (2) side rails (5) “RNM” mark (3) piston GR 444% 0MP lie Piston/Piston Rings/Piston Pin Piston Installation 1. Place clean shop towels (1) over the crankcase opening to keep the piston pin clips from falling into the crankcase. 2. Apply molybdenum disulfide oil (a mixture of [/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the connecting rod small end (2) inner surface. (1) shop towels (2) connecting rod small and 3. Install the piston (3) with the “0” mark (4) and/or the large valve recesses (5) facing the intake side of the engine. 4. Apply molybdenum disulfide oil (a mixture of [/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the piston pin (6) outer surface. Apply engine oil to the piston outer surface and piston pin hole inner surface. Install the piston pin and new piston pin clips (7)- NOTICE Use new pin clips. Never reuse old clips. Do not let the clipsfall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). (6) piston pin (7) piston pin clip (6) piston cut-out (3) piston (4) “0" mark (5) large valve recess Servicing Your Hand: 81 4i ail 4%. %H%F fie 44»H% Piston/Piston Rings/Piston Pin 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. 2. Remove the shop towels. Do not let any gasket debris fall into the crankcase. 3. Install a new cylinder gasket (1) and dowel pins (2). NOTICE Do not let the dowelpimfa/l into the crankcase. (1) cylinder gasket (2) dowel pins 82 Servicing Your Honda W 0MP 4. Clean any gasket material off cylinder (3). 5. Apply engine oil to the cylinder wall, piston outer surface and piston rings (4). Route the cam chain (5) through the cylinder. Install the cylinder over the piston rings by hand while compressing the piston rings. NOTICE Do not damage the piston rings and cylinder walls. (3) cyllnder (5) cam chain (4) piston rings at riff 4W0 %\W he 44»H% Piston/Piston Rings/Piston Pin Cylinder Head Installation 1. Clean any gasket material off cylinder head. 2. Install the cam chain guide (I) and fit the cam chain guide tabs (2) in the cylinder cut-outs (3). Push the guide until it bottoms in the crankcase guide groove. (1) cam chain guide (2) cam chain guide tabs 0MP 3. Install the dowel pins (4) and a new cylinder head gasket (5). NOTICE Do not let the dowel pins fall inta the crankcase. (4) dowel pins (5) cylinder head gasket 4. Route the cam chain through the cylinder head and install the cylinder head (6). NOTICE Do not damage mating surfaces when installing the cylinder head. 5. Apply engine oil to all cylinder head B bolt threads and seating surface. Install the washers and cylinder head B bolts (7). Install the cylinder bolt (8) and cylinder head A bolts (9). 6. Tighten the washers and cylinder head B bolts to the specified torque in a crisscross pattern in two or three steps: 45 N-m (4.6 kgf-m, 33 |th) NOTICE Do not let the washer: fall into the crankcase. " . WW (6) cylinder head (7) washers and cylinder head B bolts 7. Tighten the cylinder bolt and cylinder head A bolts to the specified torque: 10 N-m (1.0 kgf-m, 7 Ibfrf‘t) (a) cylinder bolt (9) cylinder head A bolts (cont’d) 83 Servicing Your Honda at nil 4%. %\W 14f 4141* Ollie Piston/Piston Rings/Piston Pin 8. Install the left cylinder head hanger plate (10) and right cylinder head hanger plate (1 I), then loosely install the cylinder head hanger plate bolts (12) and cylinder head hanger bolts (13). Tighten the cylinder head hanger bolts and cylinder head hanger plate bolts to the specified torque: cylinder head hanger bolts: 54 N-m (5.5 kgf‘m, 40 lbfrf‘t) cylinder head hanger plate bolts: 32 N-m (3.3 kgf‘m, 24 lbfrf‘t) Left side: (13>; - (10) left cylinder head hanger plate (11) right cylinder head hanger plate (12) cylinder head hanger plate bolts (13) cylinder head hanger bolts 34 Servicing Your Honda 9. Install the throttle body (14) to the insulator (15) by aligning the tab of the throttle body with the groove of the insulator and tighten the insulator band screw (16) so the distance between the band ends is 11.0 i: 1.0 mm (0.43 i 0.04 in). 11.0 2: 1.0 mm (0.43 x 0.04 in) (14) throttle body (15) insulator (16) insulator band screw 10. Set the rear shock absorber (l7) and install the rear shock absorber upper bolt (18) and nut (19) as shown. Tighten the rear shock absorber upper nut to the specified torque: 44 N-m (4.5 kgf-m, 32 Ibf‘ft) (17) rear shock absorber (18) rear shock absorber upper bolt (19) nut 11. Install the air cleaner connecting tube (20) along with the air cleaner case to the throttle body. Tighten the air cleaner connecting tube band screw (21) so the distance between the band ends is 6 7 9 mm (0.2 7 0.4 in). \4\ 6 — 9 mm (0.2 — 0.4 in) (20) air cleaner connecting tube (21) air cleaner connecting tube band screw 49.1 #11 4197110 %H'1F 411% 01147 Piston/Piston Rings/Piston Pin 12. Connect the breather tube A (22). Connect the IAT sensor connector (23). 13. Secure the breather tube B (24) with the clip (25). (22) breather tube A (23) IAT sensor connector (24) breather tube B (25) clip 14. Connect the radiator hose (26) to the water hose joint (27) of the cylinder head. It (26) radiator hose (27) water hose joint 15. Tighten the radiator hose clamp screw (28) as illustrated below. i 071.0mm V (070.04in) A i (2B) radiator hose clamp screw 16. Connect the ECT sensor connector (29). (29) ECT sensor connector . Install the shims, valve lifters, camshaft and camshaft holder (page 72). . Install the crankshaft hole cap (page 74). . Install the cylinder head cover (page 75). . Install the spark plug (page 66). . Install the exhaust pipe (page 103). . Install the subframe (page 37) and left and right mufflers (page 101). . Install the fuel tank and seat (pages 33, 35). . Fill and bleed the cooling system (page 145). Check for the following: 7 compression leaks 7 abnormal engine noise 7 secondary air leaks 7 exhaust gas leaks 7 coolant leaks 7 oil leaks 85 Servicing Your Honda 7471 off ; 4r %H% l are ‘1“ Suspension Refer to Important Safety Precautions on page 23. 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 19). After break-in, test run your CRF with the front suspension at the standard setting before attempting any adjustments. - Refer to Suspension Adjustment Guidelines (page 132). 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 ofthe travel is still too stiff/soft. This is an important step that will help you solve suspension problems. . Make sure that the fork protectors (l) and dust seals (2) are clean and not packed with mud and dirt. . Check for signs of oil leakage. Damaged or 1.5 mm (0.06 in) (3) wear rings (4) outer tube ‘1“ For optimum fork performance, we recommend that you disassemble and clean the fork after riding your CRF for 3 hours. See page 118 for fork disassembly. Replace the fork oil every 3 races or 7.5 hours of running. See page 92 for oil capacity adjustment after changing the fork oil. Replace the damper oil every 9 races or 22.5 hours of running. See page 121 for damper oil replacement. Use only Cushion Oil 881‘) or Ultra CO special-1V. The fork oil 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. 3- 111599“ the wear rings (3) for wear 0" damage. Check the dust seals for dust, dirt, and foreign Replace the W93! ring if“ is 1-5 mm (0-05 in) materials. Check the oil for any contamination. or flash With the outer tube (4)- Remove “‘9 fork leg when replacing the wear ring. Install the wear ring with its end gap (5) facing rearward. leaking fork seals should be replaced before your CRF is ridden. (3) wear rings (5) end gaps 4. Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times. (1) lork protectors (2) dust seals 86 Servicing Your Honda 1 era 1_ JP \1/ JP \1/ 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 rear suspension’s spring pre-load and damping adjustments (compression and rebound) should be adjusted for the rider’s weight and track conditions (pages 129, 134). 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 CR1: is new, break it in for approximately 1 hour with the standard suspension settings before attempting to adjust the rear suspension. Refer [0 Suspension Adjustment Guidelines (page 134) for making all rebound and compression damping adjustments in one click or 1/ 12 turn increments. (Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment.) Test ride after each adjustment. If the rear suspension is too stiff/soft, adjust it by turning all the compression and rebound adjusters according to the procedures described in page 128. 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. 1. Bounce the rear of the motorcycle up and down and check for smooth suspension action. 2. Remove the right and left mufflers (page 100), subframe (page 37) and air cleaner case along with the air cleaner connecting tube (page 77). 3. Check for a broken or collapsed spring. 4. Check the rear shock absorber (1) for a bent rod or oil leaks. (1) rear 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 Hand: 87 / \ \‘T/ he 411% Suspension Recommended Fork Oil Cushion Oil $819 or Ultra CO special-IV suggested oil Fork Oil Change Refer to F rant Suspension Disassemhly on page 1 14 for front suspension removal. 1. Clean the fork assembly, especially the sliding surface of the slider and dust seal. 2. Hold the outer tube (1), then remove the fork damper (2) from the outer tube using a lock nut wrench (3). Gently slide the outer tube down onto the lower end of the slider (4). - Lock nut wrench 07WMA-KZ30100 <2) .. (1)\ ‘\ (4) (1) outer tube (2) fork damper (3) look nut wrench (4) slider 88 Servicing Your Honda NOTICE The outer tube (1) can drop on the slider (4) and damage thefork dust Seal (5). To avoid damage, hold both the outer tube andslider when removing the fork damper. (5) (1) (1) outer tube (4) slider (5) fork dust seal 3. Drain the fork oil from the outer tube (1). Drain the fork oil from the oil holes (6) of the fork damper. (1) outer tube (6) oil holes 4. Drain the fork oil by turning the outer tube (1) upside down. (About 13.7 cm} (0.46 US oz, 0.48 Imp oz) offork 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 146). NOTICE Improper disposal of drained oil is harmful to the environment. Amount of lork oil left in the fork (within damper and spring) unit: oma mlnule 5 10 20 35 55 85 145 w; 30/86 16.5 14.1 12.7 11.8 11 10.1 8.6 20/68 17.4 15 13.7 12.6 11.5 10.5 9.1 10/50 18.9 16.5 14.8 13.7 12.5 11.4 9.8 0/32 20 18.4 15.9 14.5 13.7 13 11.7 mm”) 30 25 0'C/32'F 10'C/50'F Amounlollork or) m me 120 My tso (mlnutes) o 20 4a 60 Invenedume 491 mill ; 1* %H'i% i are I_ as T7 r \ \Tf Suspension 5. Pour the recommended fork oil (page 88) into the outer tube. (1) outer tube Fork Oil Capacity Standard 4.59 N/mm (26.21 Ibl/in) Fork Spring (lactory products) or /T\gf\ 777— 2 scribe marks \Cy/ / Standard oil 357 cm3 capacity 12.1 US 02,) 12.6 Imp 02 Maximum 384 cm3 Siightly stiller as oil capacity 13.0 US 02,) it nears luii 13.5 Imp oz compression. Minimum oil 300 cm3 Siightly solter as capacity 10.1 US 02,) it nears luii 10.6 Imp oz compression. Optional Solter4.40 N/mm (25.12 Ibl/in) Fork Spring ’ M7 No mark Standard oil 354 cm3 capacity 12.0 US oz, ) 12.5 Imp 02 Maximum 381 cm3 Slightly stiller as oil capacity 12.9 US 02,) it nears luil 13.4 Imp oz compression. Minimum oil 298 cm3 Slightly solter as capacity 10.1 US 02,) it nears luil 10.5 Imp oz compression. Optional Stiller 4.80 N/mm (27.41 Ibl/in) Fork Spring 3 scribe marks Standard oil 350 cm3 capacity 11.8 US 02,) 12.3 Imp 02 Maximum 377 cm3 Slightly stiller as oil capacity 12.8 US 02,) it nears luil 13.3 Imp oz compression. Minimum oil 294 cm3 Slightly solter as capacity 9.9 US 02, ) it nears luil 10.3 Imp oz compression. Be sure the oil capacity is the same in both fork legs. 6. Check that the O—ring (7) on the fork damper (2) 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 120), tighten the fork damper to the specified torque using a lock nut wrench: Actual: 34 N-m (3.5 kgfm, 25 Ibfvfl) Torque wrench scale reading: 31 N-m (32 kgflm, 23 Ibfvfl), using a 50 cm (20 in) long deflecting beam type torque wrench. When using the lock nut wrench, use a 50 cm (20 in) long deflecting beam type torque wrench with a lock nut 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. (7) (1) outer tube (2) lork damper (7) O-ring Servicing Your Honda 89 44»H% g C it Brakes Refer to Important Safety Precautions on page 23. Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop. Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and the brake pads for wear. If the braking response of the front brake lever or rear pedal feels unusual, check the brake pads. If the brake pads are not worn beyond the recommended limit (page 93), there is probably air in the brake system. Refer to an official Honda Shop Manual or see your dealer to have the air bled from the system. 90 Servicing Your Honda Front Brake Lever Adjustment 1. Loosen the lock nut (1). 2. To position the front brake lever farther away from the handgrip, turn the adjuster (2) clockwise. To position the front brake lever closer to the handgrip, turn the adjuster counterclockwise. 3. While holding the adjuster, tighten the lock nut to the specified torque: 5.9 N-m (0.6 kgf‘m, 4.4 Ibf-ft) 4. Apply silicone grease to the contacting areas of the adjuster. (2) O " 7 Iéj‘ (1) (1) lock nut Q (2) adjuster Rear Brake Pedal Height The rear brake pedal height should be approximately level with the right footpeg. l. Loosen the lock nut (l) and turn the push rod (2) in direction (+) to raise the rear brake pedal (3) or in direction (7) to lower it. 2. Tighten the adjuster lock nut to the specified torque at the desired pedal height. 5.9 N‘m (0.6 kgf~m, 4.4 Ibf-ft) (1) look nut (2) push rod (3) rear brake pedal (+) raise the pedal height (—) lower the pedal height at ch 4%. %\W 44»H% 0MP Me 494 Brakes Fluid Level Inspection Front Brake Fluid Level Check (1) LWR mark With the motorcycle in an upright position, check the fluid level. It should be above the LWR mark (1). If the level is at or below the LWR mark, check the brake pads for wear (page 93). Wom brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. If the pulling distance for the front brake lever feels excessive, there is probably air in the brake system and it must be bled. Refer to an official Honda Shop Manual or see your dealer for brake bleeding. Honda recommends using DOT4 brake fluid from a sealed container, or an equivalent. Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Rear Brake Fluid Level Check (1) LOWER mark With the motorcycle in an upright position, check the fluid level. It should be above the LOWER mark (1). If the level is at or below the LOWER mark, check the brake pads for wear (page 93). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. If the travel for the rear brake pedal feels excessive, there is probably air in the brake system and it must be bled. Refer to an official Honda Shop Manual or see your dealer for brake bleeding. Honda recommends using DOT4 brake fluid from a sealed container, or an equivalent. Other Checks: Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Servicing Your Hand: 91 rGH 4%. %\W 411% Brakes #91 Adding Front Brake Fluid NOTICE Spilled brake fluid will severely damage painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make Sure the reservoir is horizontal first. - Always use fresh 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 DOT4 brake fluid or an equivalent. 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 overfill. 3. Install the diaphragm and reservoir cap. 4. Tighten the front brake reservoir cap screws to the specified torque: 1.0 N-m (0.1 kgf‘m, 0.7 Ibf-f‘t) (1 ) lront brake reservoir cap screws (2) reservoir cap (3) diaphragm (4) upper level mark 92 Servicing Your Honda Adding Rear Brake Fluid NOTICE Spilled brake fluid will severely damage painted surfaces. It is also harmful to some rubber parts. Be carefill whenever you remove the reservoir cap; make Sure the reservoir is horizontalfirst. - 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 DOT4 brake fluid or an equivalent. 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. (1) rear brake reservoir cap bolts (2) reservoircap (3) set plate (4) diaphragm (5) upper level mark Install the diaphragm, set plate and reservoir cap. Tighten the rear brake reservoir cap bolts to the specified torque: 1.0 N‘rn (0.1 kgf~m, 0.7 Ibf-ft) r11 ; 1* %H'ir \ air /i,\ \1/ /i,\ \1/ l i. /\ \/ Brakes Brake Pad Wear Brake pad wear depends on the severity of usage and track conditions. (Generally, the pads will wear faster with wet and diny track conditions.) Inspect the brake pads at each regular maintenance interval (page 25). Front Brake Pads Inspect the brake pads (I) through the front wheel to determine the brake pad wear. If either brake pad is worn anywhere to a thickness of] mm (0.04 in), both brake pads must be replaced. minimum thickness indicator 1.0 mm (0.04 in) (1). w replace (1) 1.0 mm (0.04 in): k wear indicator grooves (1) brake pads (2) iront brake caliper (3) brake disc Rear Brake Pads Inspect the brake pads (I) from the rear side ofthe caliper to determine the brake pad wear. If either brake pad is worn anywhere to a thickness of I mm (0.04 in), both brake pads must be replaced. minimum thickness indicator 1 ,0 mm (0.04 in) an replace (1) brake pads (2) rear brake caliper (3) brake disc Other Inspections Check that the front brake lever and rear brake pedal assemblies are positioned properly (page 90) 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 Hand: 93 J i are JP \1/ JP \1/ 0 i 4‘ i. /\ \/ Wheels Refer to Important Safety Precautions on page 23. Keeping the wheels true (round) and maintaining correct spoke tension are critical to safe motorcycle operation. During the first few rides, spokes will loosen more rapidly due to the initial seating ofthe 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 tyre slippage. 94 Servicing Your Honda Wheel Rims & Spokes 1. Inspect the wheel rims ( 1) and spokes (2) for damage. 2. Tighten, any loose spokes and rim locks (3) to the specified torque: Spokes: 3.7 N~m (0.4 kgf-m, 2.7 Ibf-fl) Rim Locks: 12 N-m (1.2 kgf-m, 9 lbf-f‘t) 3. Check wheel rim runout. lfrunout is noticeable, see an official Honda Shop Manual for inspection instructions. (1) wheel rim (2) spokes (3) rim lock Axles & Wheel Bearings See an official Honda Shop Manual for inspection information: 1. Check the axle shaft for runout. 2. Check the condition ofthe wheel bearings. Tyres & Tubes Refer to Impartant Safety Premmz'ans on page 23. To safely operate your CRF, the tyres must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated. A WARNING Using tyres 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 tyre inflation and maintenance. The following pages give detailed information on how and when to check your air pressure, how to inspect your tyres for wear and damage, and our recommendations on tyre repair and replacement. Air Pressure Properly inflated tyres provide the best combination ofhandling, tread life, and riding comfort. Generally, underinflated tyres wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Underinflated tyres can also cause wheel damage on hard terrain. Overinflated tyres 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. Always check air pressure when your tyres are “cold.” If you check air pressure when your tyres are “warm" 7 even ifyour CRF has only been ridden for a few miles 7 the readings will be higher. lfyou let air out ofwarm tyres to match the recommended cold pressures, the tyres will be underinflated. The correct “cold” tyre pressures are: Front 100 kPa (1.0 kgf/cmz, 15 psi) Rear 100 kPa (1.0 kgf/cmz, 15 psi) lfyou decide to adjust tyre pressures for a particular riding condition, make changes a little at a time. Inspection Take time to inspect your tyres and wheels before you ride. - Inspect carefully for bumps or bulges in the side of the tyre or the tread. Replace any tyre that has a bump or bulge. Look closely for cuts, slits, or cracks in the tyres. Replace a tyre ifyou can see fabric or cord. Check for rocks or other objects embedded in the tyre or tread. Remove any objects. Check the position ofboth valve stems. A tilted valve stem indicates the tube is slipping inside the tyre or the tyre is slipping on the rim. Tube Replacement lfa 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 95 J 6P; % Tyres & Tubes Tyre Replacement The tyres 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. Installing improper tyres 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 tyres recommended in this owner’s manual. 50/100-21 51 M Front DUNLOP ‘ MX51FA 100/90-19 57M Rear DUNLOP i MX51 Type bias-ply, tube - Use a replacement tyre equivalent to the original. - Replace the tube any time you replace a tyre. The old tube will probably be stretched and. if installed in a new tyre. could fail. 96 Servicing Your Hands l are /l,\ \1/ /l,\ \1/ 0 l 4‘ l t. /\ \/ Drive Chain Refer to Important Safety Precautions on page 23. 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. When the motorcycle is ridden on unusually dusty or muddy tracks, more frequent maintenance will be necessary. Before servicing your drive chain, turn the engine OFF and check that your transmission is in neutral. Inspection 1. Turn the engine off, raise the rear wheel offthe 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 sprocket (2) and driven sprocket (3). Drive chain slack should allow the following vertical movement by hand: 25—35 mm (1‘0—1.4 in) (1) drive chain slack (2) drive sprocket (3) driven sprocket 3. Check drive chain slack at several points along the chain. The slack should remain constant. If it isn’t, some links may be kinked and binding. Lubricating the chain will often eliminate binding and kinking. NOTICE Excerrive chain Slack may allow the drive chain to damage the engine cares. 4. Inspect the drive chain for: - damaged rollers - loose pins - dry or rusted links - kinked or binding links - excessive wear Replace the drive chain (page 99) if it has damaged rollers, loose pins, or kinks that cannot be free. Lubricate the drive chain (page 98) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack ifneeded (page 98). Drive Chain Sliders 1. Check the chain slider (l) for wear. Replace it if below the service limit. SERVICE LIMIT: upper side: 5 mm (0.2 in) lower side: 25 mm (0.10 in) / \ \ / (1) chain slider 2. Check the chain guide slider (Z) for wear. Replace the guide slider ifit is worn to the bottom of the wear limit (3). (2) chain guide slider (3) wear limit servicing Your Hand: 97 (re / Jéll% Drive Chain Drive Chain Rollers Check the upper drive chain roller (1) and lower drive chain roller (2) for wear or damage. Measure the diameter of the drive chain rollers and replace them if below the service limit. Service Limit: Upper roller: 33 mm (1.3 in) Lower roller: 35 mm (1.4 in) Replace the roller if necessary as follows. Install the upper drive chain roller (Green) with the “a” mark (3) facing toward the bracket and lower drive chain roller (Black) with the large concave facing outside. Install the drive chain roller bolt and nut. (1) upper drive chain roller (Green) (2) lower drive chain roller (Black) (a) 11—." mark Clean the threads of the drive chain roller bolt and apply locking agent to the threads. Tighten the drive chain roller bolt and nut to the specified torque: 12 Nm (1.2 kgf~m, 9 Ibf-ft) 9s Servicing Your Honda Adjustment 1. Loosen the rear axle nut (1). 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 (1) rear axle nut (4) index marks (2) chain adjuster lock nuts (5) axle plates (3) adjusting bolts (6) relerence marks 3. Tighten the rear axle nut to the specified torque: 128 N~m (13.1 kgf~m, 94 lbf-f‘t) 4. Recheck chain slack and adjust as necessary. 5. Turn the adjusting bolt counterclockwise until it touches the axle plates lightly. Then tighten the chain adjuster lock nuts to the specified torque while holding the adjusting bolts with a wrench. 27 N-m (2.8 kgf-m, 20 Ibf‘ft) Lubrication Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil. Drive chain lubricant is recommended. If not available, use SAE 80 or 90 gear oil. Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers. 491 nil Jill. %lli% l ea l_ JP \1/ JP \1/ Drive Chain Removal, Cleaning & Replacement For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing. 1. Remove the master link retaining clip ( 1) with pliers. Do not bend or twist the clip. 2. Remove the master link (2). Remove the drive chain. 4%,, (1) master link retaining clip (2) master link 3. Clean the drive chain in high flash-point solvent and allow it to dry. 4. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable. Chain: Size/link: D.|.D 520DMA4/116RB RK520TXZ/1 16RJ 5. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket(s) will wear rapidly. Excessively wom sprocket teeth have a hooked, worn appearance. Replace any sprocket which is damaged or excessively worn. Damaged Sprocket Worn Sprocket Teeth Teeth REPLACE ‘ ‘ REPLACE Normal Sprocket Teeth GOOD NOTICE Use of a new chain with worn sprockets will cause rapid chain wear. 6. Install the chain. 7. Measure a section of the drive chain to determine whether the chain is worn beyond its service limit. Put the transmission in gear, and then turn the rear wheel forward until the lower section of the chain is pulled taut. With the chain held taut and any kinked joints straightened, measure the distance between a span of 17 pins, from pin centre to pin centre. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. .0?" Service limit: 2590 mm (10.20 in) MEASURE A SPAN OF 17 PINS (16 PITCHES) Lubricate the drive chain (page 98). Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent driven sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. 10. Recheck chain slack and adjust as necessary. More About Drive Chain - The master link is the most critical element of drive chain security. Master links are reusable, as long as they remain in excellent condition. We recommend installing a new master link retaining clip when the drive chain is reassembled. You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets. Servicing Your Hand: 99 / \ \‘T/ léfi Jéll% 0MP W Exhaust Pipe/Muffler Exhaust Pipe/Muffler Inspection Check the mounting bolts and exhaust pipe joint nuts for tightness. Check the exhaust pipe and mufflers for cracks or defamation. A damaged exhaust pipe and mufflers may reduce engine performance. 100 Servicing Your Honda Muffler Removal 1. Remove the seat (page 33). 2. Remove the side covers (1) and air cleaner housing covers (2) by removing the bolts (3). (1) side covers (2) air cleaner housing covers (3) bolts 3. Loosen the left muffler clamp bolt (4). \ 4. Remove the left muffler mounting bolt (5), washer (6) and left muffler (7). (5) left muffler mounting bolt (6) washer (7) left muffler eel rgll %ll% 14A 414% Exhaust Pipe/Muffler 5. Loosen the right muffler clamp bolt (8). (a) right mufller clamp bolt 6. Remove the right muffler mounting A bolt (9), washer A (10), right muffler mounting B bolt (11), washer B (12) and right muffler (13). (11) (10) / (13) \ (9) right mufller mounting A bolt (10) washer A (11) right muffler mounting B bolt (12) washer B (13) right muffler Ollie Muffler Installation 1. 2. (1) (2) 3. 4. Remove the gasket (1). Install the right muffler clamp (2) and a new gasket onto the exhaust pipe (3). gasket (new) (3) exhaust pipe right muffler clamp Install the right muffler (4). Install the right muffler clamp (2) by aligning the tab (5) of the right muffler clamp with the cut-out (6) of the right muffler. Install the washer B (7), right muffler mounting B bolt (8), washer A (9), and right muffler mounting A bolt (10). (2) right muffler clamp (4) right muffler (5) tab (6) cut-out (7) washer B (a) right muffler mounting B bolt (9) washer A (10) right muffler mounting A bolt 6. Tighten the right muffler clamp bolt (1 l) to the specified torque: 20 N-m (2.0 kgf-m, 15 |th) (11) right muffler clamp bolt (cont’d) 101 Servicing Your Honda 491 rill Jill. %ll1h 11% 4111* g C 11% Exhaust Pipe/Muffler 7. Tighten the right muffler mounting B bolt (8) and right muffler mounting A bolt (10) to the specified torque: 26 N~m (217 kgf-m, 19 lbf-ft) (a) right mufller mounting B bolt (10) right muffler mounting A bolt 8. Remove the gasket (12). 9. Install a new gasket onto the right muffler (4). 102 Servicing Your Honda (4) right muffler (12) gasket (new) 10. Install the left muffler (13). 11. Install the left muffler mounting bolt (14) and washer (15). Tighten the left muffler mounting bolt (14) to the specified torque: 26 Nm (2.7 kgf~m, 191131-11) (13) left mufller (14) left mufller mounting bolt (15) washer 12. Tighten the left muffler clamp bolt (16) to the specified torque: 20 Nm (2.0 kgf~m, 15 lbf-f‘t) ~\. (16) left muffler clamp bolt 13. Install the air cleaner housing covers (17) and side covers (18), and then tighten the bolts (19) to the specified torque. 10 Nm (1.0 kgf~m, 7 lbf-ft) (17) air cleaner housing covers (16) side covers (19) bolts 14. Install the seat (page 33). 41.17 r11 %ll'1b fie 4M% 011.1% 491 4197110 Exhaust Pipe/Muffler Exhaust Pipe Removal 1. Remove the left and right mufflers (page 104). 2. Remove the exhaust pipe joint nuts (I), exhaust pipe (2) and gasket (3). (1) exhaust pipe joint nuts (2) exhaust pipe (3) gasket Exhaust Pipe Installation 1. Install a new exhaust pipe gasket ( 1) as shown. 2. Install the exhaust pipe (2) and exhaust pipe joint nuts (3) but do not tighten the nuts yet. (1) . ' ; (1) exhaust pipe gasket (new) (2) exhaust pipe (3) exhaust pipe joint nuts 3. Install the right muffler (page 101) but do not tighten the bolts yet. 4. Tighten the exhaust pipe joint nuts to the specified torque: 21 N-m (2.1 kgf-m, 15 Ibf‘ft) 5. Tighten the right muffler clamp bolt, right muffler mounting A bolt and B bolt (page 102) 6. Install the left muffler (page 102). Servicing Your Honda 103 %1W $1 Me i O lib Steering Damper Refer to Important Safety Precautions on page 23. 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. 104 Servicing Your Honda 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 19). 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. 1. Unlock the number plate tab (1) from the handlebar pad. Remove the bolts (2) and number plate (3). (1) number plate tab (2) bolts (3) number plate 2. 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 an official Honda Shop Manual or see your dealer for steering damper disassembly. Check the torque of the steering damper mounting bolts (6): 20 N-m (2.0 kgf-m, 15 Ibf‘ft) (4) steering damper (5) damper rod (6) steering damper mounting bolts at rill Jill. %llir 14% 44% Ollie Steering Damper 3. With your CRF on a box or an optional workstand (front wheel elevated), check that the steering moves smoothly from side-to—side. )1 ‘x 4. Install the number plate (3) by aligning its holes (7) with the tabs (8) on the steering stem. Install and tighten the bolts (2). Route the number plate tab (1) around the handlebar pad (9) as shown. (1) number plate tab (2) bolts (3) number plate (7) holes (3) tabs (9) handlebar pad Removal 1. Remove the number plate (page 104). 2. Remove the steering damper mounting bolts (1), collar (2), connector stay (3) and steering damper (4). (1) steering damper mounting bolts (2) collar (3) connector stay (4) steering damper Inspection 1. Check the damper rod (1) operation. Compress the fully extended damper rod 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, refer to an official Honda Shop Manual for disassembly and inspection instructions or see your dealer. (1) damper rod (cont’d) 105 Servicing Your Honda 491 nil Jill. %ll% 44»H% 0MP he lib 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 hearing if it does not move smoothly and quietly. Refer to an official Honda Shop Manual or see your dealer. (2) (2) spherical bearings 106 Servicing Your Hond- 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 connector stay (4), collar (5) and steering damper mounting bolts (6). - Be sure to install the collar with its wide flange side facing toward the steering head pipe side. - Align the connector stay tab (7) with the steering head pipe lug (8). 4. Tighten the steering damper mounting bolts to the specified torque: 20 N-m (2.0 kgf-m, 15 Ibf‘ft) (1) steering damper (2) “UP" mark (3) stopper ring (4) connector stay (5) collar (6) steering damper mounting bolts (7) connector stay tab (a) steering head pipe lug 5. With your CRF on a box or an optional workstand (front wheel elevated), check that the steering moves smoothly from side to side. 6. Install the number plate (page 105). 4% nil Jill. %Hi% la 4M% Additional Maintenance Procedures Refer to Important Safety Precautions on page 23. 1. 0MP Steering Head Bearing Inspection With your CRF on a box or optional workstand (front wheel elevated), tum the handlebar to the right and left to check for roughness in the steering head bearings. Stand in front of your CRF, grab the fork (at the axle), look at the steering head, and push the fork in and out (toward the engine) to check for play in the steering head bearings. If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to an official Honda Shop Manual for replacement or adjustment procedures, or see your dealer. Handlebar Inspection 1. Check the handlebar (l) for bends or cracks. 2. Check that the handlebar has not moved from its original position where the end of the right handlebar holders (2) is aligned with the paint mark (3). 3. Check the torque of the handlebar upper holder bolts (4): 22 N-m (2.2 kgf-m, 16 Mail) Tighten the front bolts first. (1) handlebar (2) right handlebar holders (3) paint mark (4) handlebar upper holder bolts $ Control Cables Periodically, disconnect the throttle and clutch cables at their upper ends. Thoroughly lubricate the cable pivot points with a commercially available cable lubricant. If the clutch 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. 107 Servicing Your Honda at ail ; is %lli% t. i %% i? Additional Maintenance Procedures JP \1/ RIGHT SIDE LEFI' SIDE Nuts, Bolts, Fasteners Check and tighten nuts, bolts, and fasteners before every outing. Torque Item N-m kgl-m lhlvft 1 Cylinder head cover bolts 10 1.0 7 2 Exhaust pipe joint nuts 21 2.1 is 3 Water pump cover bolts 10 1.0 7 4 Crankshaft hole cap 15 1.5 it 5 Transmission oil check bolt 12 1.2 9 6 Clutch cover bolts 10 1.0 7 7 Coolant drain bolt 10 1.0 7 8 Engine oil drain bolt 16 1.6 12 9 Cylinder bolt 10 1'0 7 (1) cylinder head cover bolts (9) cylinder bolt / \ 10 Oil filter cover bolts 12 1.2 9 (2) exhaust pipe joint nuts (10) oil filter cover bolts / \ \ / . (3) water pump cover bolts (11) cylinder head A bolts \ / 11 Cylinder head A bolts 10 1'0 7 (4) crankshalt hole cap (12) drive sprocket bolt 12 Drive sprocket bolt 31 3.2 23 (5) transmission oil check bolt (13) transmission oil drain bolt . . (6) clutch cover bolts (14) cylinder head B bolts 13 Transmission oil drain (7) coolant drain bolt bolt 16 1.6 i2 , . . (8) engine oil drain bolt 14 Cylinder head B bolts 45 4.6 33 108 Servicing Your Honda \ r), 1 \ '/ l as: /l,\ \1/ /l,\ \1/ 0 l 4‘ l i. /\ \/ Appearance Care Refer to Impartant Safety Precautiam on page 23. 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 petrol or oil leaks. General Recommendations - 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 discolour the seat and decals. lfyour CRF is still warm from recent operation, give the engine and exhaust system time to cool off. We recommend the use of a garden hose to wash your 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 din inside and needed lubrication out. If you use a high pressure washer, avoid spraying the following areas: brake master cylinders drive chain electrical circuit muffler outlet steering head bearings suspension pivot points throttle body under fuel tank under seat (1) steering head bearings (2) suspension pivot points NOTICE High pressure water (or air) can damage certain part: nfynur CRF. You may use 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 multi—surface cleaner/degreaser and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge. zi‘p 4‘5 / Washing Your Motorcycle with a Mild Detergent Allow the engine, muffler, brakes, and other high— temperature parts to cool before washing. 1. Rinse your CRF thoroughly using a garden hose 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. NOTICE Do not use Steel wool to clean theframe as it could damage or dixealaur the frame Surface. Mufller Stain remover (Seateh Brite Hand Pad #7447-mar00n) isfnr remavz'ng stains on the rum- eaated 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. Stan 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. 109 Servicing Your Honda f l o / \ \‘T/ \ ea /l,\ \1/ /l,\ \1/ 0 l 4‘ l i. /\ \/ Appearance Care Condensation Control Some condensation can form within the transmission cavity as well. This is natural andjust one more reason you should change the engine and transmission oil often. After Cleaning Lubrication There are some things you should dojust 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 ofa 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 ofthis manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. 110 Servicing Your Honda Aluminum Frame Maintenance Aluminum corrodes when it comes in contact with dust, mud and road salt. To remove stains, use Scotch Brite l-land 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. NOTICE Do not use Steel wool to clean theframe as it could damage ar disealaur thefiame Surface. Mufller Stain remover (Scatch Brite [land Pad #7447-marnzm) isfar remaving stain: on the rum- caated aluminum frame only. Exhaust Pipe and Muffler Maintenance The exhaust pipe and muffler are stainless steel but may became 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. lfnecessary, remove heat stains by using a commercially available fine texture compound. Then rinse by the same manner as removing mud or dust. Clean the Seat Due to the top coat design, the seat surface tends to catch and trap dirt or dust in its texture. Using plenty of water, clean the seat with a sponge and mild detergent. After washing, dry with a soft, clean cloth. ‘Qp‘i f l o / \ \‘T/ l as l_ (1.x /1,\ \1/ /1,\ \1/ g o l 41 do T Adjustments for Competition This section tells you how to fine tune your CRF for maximum competition performance. Initial suspension adjustments should be performed after a minimum of2 hours of easy break-in time. Optional front and rear suspension springs are available 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 ofRear Suspension Adjustment: to determine if your combined rider and sprung machine weight (rider fully dressed for competition and machine filled coolant, oil and fuel levels ready for competition) requires an optional stiffer or softer rear spring. The need for either optional rear spring may need to be balanced by installing the optional fork springs ofa similar rate. .112 .112 .112 .113 .114 .117 Front Suspension Adjustment Front Suspension Air Pre ure . Front Suspension Damping Fork Springs Front Suspension isassem y. Damper Oil Change . Fork Assembly Rear Suspension Adjustments .. Rear Suspension Spring Pre—Load Rear Suspension Damping.... Rear Suspension Race Sag.... Suspension Adjustments for Track Conditions Suspension Adjustment Guidelines Tuning Tips Spark Plug Reading Steering Damper Adjustment Steering Damper Damping Steering Damper Adjustment Guidelines . Chassis Adjustments Rear End... Fork Height/Angle Wheelbase Gearing Tyre Selection for Track Conditions Personal Fit Adjustments Control Positioning. Handlebar Position, Width & Shape 131 .141 Adjustments tor Competitinn lll / \ \‘T/ 4M% 011% lib 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: - Oil volume 7 The effects of higher or lower fork oil capacity are only felt during the final [00 mm (3.9 in) of fork travel. - Compression damping 7 Turning the compression damping adjuster (1) adjusts how quickly the fork compresses. - Rebound damping 7 Turning the rebound damping adjuster (2) adjusts how quickly the fork extends. - Fork springs 7 Optional springs are available in softer and stiffer types than the standard rate. (page 156) The inverted fork on your CRF features sealed damper cartridges with dual (separate air and oil) chambers to prevent aeration. The design also isolates the oil in each fork/damper, 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 Front Suspension Air Pressure Air is an unstable gas which builds up pressure as it is worked (such as in a fork). Air pressure acts as a progressive spring and affects the entire range of ork travel. T is 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 heats. Be sure the fork is fully extended with the front tyre off the ground when you release the pressure. The standard air pressure is 0 kPa (0 kgf/cm{ 0 psi). You may re ieve accumulated air pressure in the fork legs by using the pressure release screws. The front wheel should be off the ground before you release the pressure. The air pressure should be adjusted according to the altitude and outside temperature. 1. Place a workstand under the engine, so that the front wheel is off the ground. Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings. 2. Remove the pressure release screw (1). 3. Check that the O-rings (2) are in good condition. 4. Install and tighten the pressure release screw to the specified torque: 1.3 N-m (0.1 kgf‘m,1.0lbf-ft) , (1) s‘ (2) O-rings (1) pressure release screw $ Front Suspension Damping Compression Damping Adjustment This adjustment affects how quickly the fork compresses. The fork compression damping adjuster has 16 positions or more. Turning the compression damping adjuster screw (1) one full turn changes the adjuster4 positions. To adjust the adjuster to the standard position, proceed as follows: Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard position. The adjuster is set in the standard position when the adjuster is turned counterclockwise 6 clicks. Make sure that both fork legs are adjusted to the same position. Rebound Damping Ad'ustment The fork rebound damping adjuster has 16 positions or more. Turning the rebound damping adjuster screw (2) one full turn clockwise advances the adjuster 4 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 [1 clicks. Make sure that both fork legs are adjusted to the same position. 491 #11 419110 %1W 440% 0MP Both compression and rebound damping can be increased by turning the adjuster clockwise. NOTICE Always start with full hard when adjusting damping. Do not turn the adjuster screw more than the given positinns or the adjuster may be damaged. Be sure that the compressinn and rebound adjusters are firmly located in a detent, and not between positions. (1) compression damping adjuster screw (2) rebound damping adjuster screw Fork Springs The fork springs in CRF ’s are about right for riders weighing between 77 and 91 kg (170 and 200 lb) (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 stiff on big bumps, turn the damping adjuster counterclockwise 1-click and lower the oil capacity in increments of 5 cm1 (0.2 US oz, 0.2 lmp oz) in both fork legs until the desired performance is obtained. Do not, however, lower the oil capacity below the minimum oil capacity. Minimum oil capacity: Standard spring: 300 cm3 (10.1 US OZ, 10.6 Imp oz) Softer spring: 298 cm3 (10.1 US 02, 10.5 Imp oz) Stiffer spring: 294 cm3 (9.9 US OZ, 10.3 Imp 02) 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. 160!) on capacity 304 cm (13.0 us oz. 13.5 Imp oz) (MAX) _/ on capacity 357 cm 5/ (12.1 us oz, 12.5 Imp oz) (STANDARD) / mm 1200 on ca acity 300 cm (10.1 s oz. 10.6 Imp oz) (MIN) . Force (N) o «a so 90 120 150 no 210 240 270 see Stroke (mm) $ at Front Suspension Adjustments 113 Adjustments for Competition at 4%. %II'%F 4M% 011% Front Suspension Adjustments 1% 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 disassembled and cleaned afier the first 3 hours of riding. See an official Honda Shop Manual or your dealer for this service. When disassembling the fork, turn the compression ( 1) and rebound (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). (1) compression damping adjuster (2) rebound damping adjuster 114 Adjustments for Competition 1. Remove the number plate (page 104). 2. Place your CRF on an optional workstand or equivalent support with the front wheel off the ground. 3. Remove the handlebar lower holder nuts, washers, mounting rubbers (3) and handlebar (4)- NOTICE Keep the master cylinder upright to prevent air from entering system. 'i‘ MIIII'VUU' 7' ' 5”! ~ " (3) handlebar lower holder nuts, washers and mounting rubbers (4) handlebar 4. Loosen the fork bridge upper pinch bolts (5). 5. Loosen the fork damper (6) using a lock nut wrench (7), but do not remove them yet. ' Lock nut wrench 07WMA—KZ30100 NOTICE Do not use an adjustable wrench ta laosen the fork damper: it may damage them. (5) fork bridge upper pinch bolts (6) fork damper (7) look nut wrench 6. Remove the disc cover (8) by removing disc cover socket bolts (9). (a) disc cover (9) disc cover socket bolts #91 d1 4%. %1W la 4M% 0MP Front Suspension Adjustments 7. Remove the front axle nut (10) and loosen the axle pinch bolts (1 l) on both forks. Pull the front axle shaft (12) out of the wheel hub and remove the front wheel with collars. . _ . a, (10) front axle nut (11) axle pinch bolts 8. Remove the brake hose clamp bolts (13), stay A (14) and stay B (15). 9. Remove the front brake caliper mounting bolts (16) and brake caliper (l7). - 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. (13) brake hose clamp bolts (14) stay A (15) stay B (16) front brake caliper mounting bolts (17) brake caliper 10. Remove the fork protector socket bolts (18) and fork protectors (19). (19)\. (19) (13) (1 B) (18) fork protector socket bolts (19) fork protectors 1 l. Loosen the fork bridge lower pinch bolts (20), then pull the fork legs down and out. (20) fork bridge lower pinch bolts 12. Clean the fork assembly, especially the sliding surface (21) of the slider and fork dust seal (22). 13. Measure the length (23) between the axle holder and outer tube and record it before disassembling the fork. (22) (21) l a o (23) (21) sliding surface (22) fork dust seal (23) length (cont’d) 115 Adjustments for Competition 49.1 Jill. %lltF riff 1e we Ulla lib Front Suspension Adjustments 14. Hold the outer tube, 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) (24). (6) fork damper (24) axle holder (7) lock nut wrench NOTICE The outer tube (25) can drop on the slider (26) and damage the fork dust seal (22). T 0 avoid damage, hold both the outer tube and slider when removing the fork damper. (22) (26) (22) fork dust seal (25) outer tube (26) slider 116 Adjustments ror Competition 15. Drain the fork oil from the outer tube/slider (27) and oil holes (28) of the fork damper. (27) (27) outer tube/slider (28) oil holes 16. Place the lower end (axle holder) (24) of the slider in a vise with a piece of wood or soft jaws to avoid damage. NOTICE Over-tightening the vise can damage the axle holder. 17. Remove the fork center bolt (29). (29) Iork center bolt (24) axle holder $ 18. Push the fork center bolt (29) out from the axle holder (24) of the slider by pushing the fork damper. While the fork center bolt is pushed out, install the piston base (30) or a mechanic’s stopper tool between the axle holder and fork center bolt lock nut (31). - Piston base 07958-250000] Make the mechanic’s stopper tool out of a thin piece of steel (2.0 mm (0.08 in) thick) as shown if you do not have a special tool. 55 mm (2.2 in) 19. 25 mm(l.0 m) R7.5 mm W36 in) ' 7 20. Hold the fork center bolt lock nut and remove the fork center bolt from the fork damper. 39 mm (1.5 m) 15 mm 10.5 m) NOTICE Do not remove the lock nut from the fork damper piston rod. Ifthe lock nut is removed, the piston rod willfall in thefork damper andynu may not reassemble the fork damper. 4% ail Jill. %ll%a we Front Suspension Adjustments (24) axle holder (29) fork oenter bolt (30) piston base (31) fork center bolt look nut 21. Remove the push rod (32) from the fork damper. 22. Remove the piston base (30) or mechanic’s stopper tool between the axle holder (24) and fork center bolt lock nut (3 1) while pushing the fork damper. NOTICE Be careful rtnt tn damage the lock nut andfork center halt hole. \_ a // ‘ (31) fork center bolt look nut (32) push rod (24) axle holder (30) piston base 23. Remove the fork damper assembly (33) from the fork assembly (34). Remove the fork from the vise. Remove the fork spring (35), spring retainer (36) and collar/washer (37) from the fork assembly. Remove the O-ring (3 8). NOTICE Do not attempt to separate the fork assembly and drop the axle holder out from the outer tube, which can damage the guide bushings (39). To avoid damage, hnld both the outer tube and slider. NO GOOD (39) \k $ (39) guide bushings (37) (33) \\’ (36) (38) (33) fork damper assembly (36) spring retainer (34) fork assembly (37) collar/washer (35) fork spring (38) O—ring $ Damper Oil Change 1. Place the fork damper (1) in a vise with apiece of wood or soft jaws to avoid damage. NOTICE Over-tightening the vise can damage the fork damper. 2. Loosen the fork cap assembly (2) while holding the fork damper (1) using the lock nut wrench (3). - Lock nut wrench 07WMA-KZ30100 (3) (1) fork damper (2) fork cap assembly (3) look nut wrench (cont’d) Adjustments for Competition 117 at rill 4%. %ll'ita %ll% 0MP Front Suspension Adjustments 3. Remove the fork cap assembly (2) from the fork damper threads and then pop it out by pumping the fork damper piston rod (4) slowly. 4. Remove the fork cap assembly (2). Be careful not to damage the fork cap bushings. Do not disassemble the fork cap assembly. Replace the fork cap as an assembly if it is damaged. (2) < / / \(3> (3) (3) collar (6) washer (4) C-ring (7) spring retainer (5) fork damper assembly 4. Blow out the oil completely off the fork spring (8) using compressed air. Install the fork spring to the fork damper assembly (5). Install the fork damper assembly to the fork assembly (1). (5) (1) fork assembly (5) fork damper assembly (6) fork spring 5. Place the lower end (axle holder) of the slider in a vise with a piece of wood or softjaws to avoid to damage. NOTICE Over-tightening the vise can damage the axle holder. 6. 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 (9) or mechanic’s stopper tool between the axle holder and fork center bolt lock nut (2). Measure the thread length again. Standard: 11 — 13 mm (043 — 0.51 in) - Piston base 07958-2500001 7. Install the push rod (10) into the fork damper piston rod until it stops. 8. Apply fork oil to new O-ring (1 l) and install it to the fork center bolt (12). Install the fork center bolt to the fork damper piston rod. Tighten the fork center bolt fully by hand. (2) fork center bolt lock nut (9) piston base (10) push rod (11) O-ring (new) (12) fork center bolt (cont’d) 121 Adjustments for Competition 49$ mitt 4%. %H%F 440% 0MP Vb Front Suspension Adjustments 9. Measure the clearance between the fork center bolt lock nut (2) and fork center bolt (12). Standard: 1.5 — 2.0 mm (0.06 — 0.08 in) If the clearance is out of specification, check the fork center bolt lock nut and fork center bolt installation. <— (2) 1.5 — 2.0 mm (0.06 — 0.03 in) (12) (2) lork center bolt lock nut (12) lork center bolt 10. Tighten the fork center bolt lock nut (2) to the fork center bolt (12) closely by hand. Tighten the fork center bolt lock nut to the specified torque: 22 N~m(212 kgf-m, 1e Ibf-ft) (2)10rk center bolt lock nut (12) fork center bolt 122 Adjustments ror Competition 1 1. Remove the piston base or mechanic’s stopper tool while pushing the fork damper. Apply locking agent to the fork center bolt threads. Install the fork center bolt (12) to the axle holder and tighten it to the specified torque: 69 N-m (7.0 kgf-m, 51 |th) (12) fork center bolt 12. Measure the length between the axle holder and outer tube. Standard: 316.5 1 2 mm (12.5 1 0.1 in) 13. Compare the length (13) 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 fork center bolt lock nut installation. H\' 0r. 97,0 .4 (13) (13) length 491 rGF‘l 4%. %ll1% 14. Remove the fork damper from the fork. 15. Pour the recommended fork oil (14) into the fork assembly (1). Recommended Oil: Cushion Oil $819 or Ultra CO special-IV (1) Iork assembly (14) fork oil Fork Oil Capacity Standard 4.59 N/mm (26.21 lbI/in) Fork Spring 47 No mark (factory products) or (‘%;7 2 scribe marks Standard oil 357 cm3 capacity 12.1 US oz.) 12.6 Imp 02 Maximum 384 cm3 Slightly stiffer as oil capacity 13.0 US oz.) it nears full 13.5 Imp oz compression. Minimum oil 300 cm3 Slightly softer as capacity 10.1 US oz.) it nears full 10.6 Imp oz compression. Optional Solter4.40 N/mm (25.12 lbI/in) Fork Spring Standard oil 354 cm3 capacity 12.0 US oz.) 12.5 Imp 02 Maximum 381 cm3 Slightly stiffer as oil capacity 12.9 US oz.) it nears full 13.4 Imp oz compression. Minimum oil 298 cm3 Slightly softer as capacity 10.1 US oz.) it nears full 10.5 Imp oz compression. Front Suspension Adjustments Optional Stifler4.80 N/mm (27.41 lbI/in) Fork Spring 3 scribe marks Standard oil 350 cm5 capacity 11.8 US oz.) 12.3 Imp oz Maximum 377 cm5 Slightly stiffer as oil capacity 12.8 US oz.) it nears full 13.3 Imp oz compression. Minimum oil 294 cm3 Slightly softer as capacity 9.9 US 02, ) it nears full 10.3 Imp oz compression. Be sure the oil capacity is the same in both fork legs. (cont’d) 123 Adjustments for Compclitinn Ari he 4M% 01% 1% Front Suspension Adjustments 16. Install a new O-ring (15) on the fork damper assembly (5). Apply the recommended fork oil to the O-ring. 17. Pull up the fork assembly ( 1) slowly and install the fork damper assembly into the outer tube. (15) (5) (1) (1) fork assembly (5) fork damper assembly (15) O—ring (new) 18. Insert both fork legs into the fork clamps. Tighten the fork bridge lower pinch bolts (16) to the specified torque: 20 Nm (2.0 kgf-m, 15 Ibf-ft) (16) fork bridge lower pinch bolts 124 Adjustments for Competition 19. Tighten the fork damper (17) to the specified torque using the lock nut wrench (18): Actual: 34 N-m (3.5 kgf-m, 25 Ibf‘ft) Torque wrench scale reading: 31 N-m (3.2 kgf-rn, 23 Ibfrft), using a 500 mm (20 in) long deflecting beam type torque wrench. - Lock nut wrench O7WMA-KZ30100 When using the lock nut wrench, use a 500 mm (20 in) 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. (17) fork damper (1B) lock nut wrench 20. For ease of releasing air pressure after the forks are installed, loosen the fork bridge lower pinch bolts and position the outer tubes so that the fork air pressure release screws are in front of the compression damping adjusters. Align the top of the outer tube (19) with the top surface of the upper fork bridge (20). (19) outer tube (20) upper fork bridge 21. Tighten the fork bridge lower pinch bolts (16) to the specified torque: 20 N-m (2.0 kgf-m, 15 Ibf‘ft) 22. Tighten the fork bridge upper pinch bolts (21) to the specified torque: 22 N-m (2.2 kgf-m, 16 Ibf‘ft) NOTICE Over-tightening the pinch bolts can deform the outer tubes. Deformed outer tubes must be replaced. (16) fork bridge lower pinch bolts (21) fork bridge upper pinch bolts #91 $1 4197110 %ll'ib he we 0MP Front Suspension Adjustments 23. Clean the threads of the fork protector socket bolts (22) and axle holder thoroughly. Apply locking agent to the bolt threads. Install the fork protectors (23), fork protector socket bolts. Tighten the fork protector socket bolts to the specified torque: 7 N-m (0.7 kgf-m, 5.2 lbf-fl) (23) (23) (22) v, (22) (22) fork protector socket bolts (23) fork protectors 24. Align the brake caliper (24) and hose (25) with the left fork leg, making sure that the brake hose is not twisted. An improperly routed brake hose may rupture and cause a loss of braking efficiency. 25. Assemble the stay B (26), brake hose (25) and stay A (27). Install and tighten them to the left fork protector using the brake hose clamp bolts (28). 26. Clean the threads of the front brake caliper mounting bolts (29) and brake caliper thoroughly. Apply locking agent to the bolt threads. Install the brake caliper (24) on the slider and tighten the front brake caliper mounting bolts to the specified torque: 30 N-m (3.1 kgf-m, 22 lbf-ft) (27) (24) brake caliper (25) brake hose (26) stay B (27) stay A (28) brake hose clamp bolts (29) front brake caliper mounting bolts 27. Clean the surfaces where the axle and axle clamps contact each other. Apply grease to each dust seal lip of the front wheel. Install the left side collar (30) and right side collar (31) into the wheel hub. (30) left side collar 28. 29. (31) right side collar Install the front wheel between the fork legs while inserting the disc between the pads, being careful not to damage the pads. Insert the front axle shaft through the forks and wheel hub from the right side. Make sure that the front axle shaft is seated firmly onto the left fork leg clamp inner surface. Tighten the front axle nut (32) to the specified torque: 88 N-m (9.0 kgf-m, 65 lbf‘ft) Tighten the left axle pinch bolts (33) to the specified torque: 20 N-m (2.0 kgf-m, 15 lbf‘ft) (32) front axle nut (33) left axle pinch bolts (cont’d) 125 Adjustments for Competition 4% rtl 4%. %ll% he 44»H% g C Eh Front Suspension Adjustments 30. Install the handlebar (34), mounting rubbers, washers and handlebar lower holder nuts (35) and tighten the handlebar holder nuts to the specified torque: 44 N-m (4.5 kgf-m, 32 Ibf-ft) ‘ Wm, ' I’WU’ (34) handlebar (35) mounting rubbers, washers and handlebar lower holder nuts 31. Install the number plate (page 108). 126 Adjustments for Competition 32. With the front brake applied, pump the fork up and down several times to seat the axle and check front brake operation. While keeping the forks parallel, alternately tighten the right axle pinch bolts (36) to the specified torque: 20 N-m (2.0 kgf-m, 15 Ibf‘ft) 33. \ (36) right axle pinch bolts NOTICE To avoid damage when torquing the axle pinch bolts, be sure the axle is seatedfirmly onto the left fork leg clamp inner surface. $ 34. Install the disc cover (37) and tighten the disc cover socket bolts (38) to the specified torque: 13 N-m (1.3 kgf-m,10|bf-ft) I (37) disc cover (38) disc cover socket bolts 35. Turn the rebound damping (39) and compression damping (40) adjuster screws back to their original settings. (39) rebound damping adjuster (40) compression damping adjuster V eat 3H 4W0 %H% l as /i,\ \1/ /i,\ \1/ 0 l 41 1 i. /\ \/ 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 suspension assembly includes a damper unit that contains high pressure nitrogen gas. 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 ofthe 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 an official Honda Shop Manual. 1fyour 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. An optional pin spanner is available for turning the shock spring 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. Remove the subframe (page 37). 3. Remove the air cleaner case along with the air cleaner connecting tube (page 77). 4. 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 tum of the adjusting nut changes the spring length by 1.5 mm (0.06 in). 5. After adjustment, hold the adjusting nut and tighten the shock spring lock nut to the specified torque: 44 N-m (4.5 kgf«rn, 32 Ibfvft) / _ , ,. (1) shock spring lock nut (2) adjusting nut (3) pin spanners (4) spring length Refer to the following pages for the installation procedure of the removed parts: - air cleaner case and air cleaner connecting tube: page 84 (Cylinder Head Installation) - subframe: page 37 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: Standard (Medium) spring (52 N/mm (297 lbf/in)): 236 mm (9.3 in) Optional Soft spring (50 N/mm (286 lbf/in)): 238 mm (9.4 in) Optional Stiff spring (54 N/mm (308 lbf/in)): 240 mm (9.4 in) 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: 250 mm (9.8 in) Each turn of the adjusting nut changes spring length and spring pre-load. One turn equals: spring length/spring pre—load: Standard: 115 mm (0.06 in)/78 N (18 Ibf) Pin spanners should be used for turning the shock spring lock nut and adjusting nut. See page 158 for optional pin spanners. Spring pre—load length (Standard spring) Standard: 250 mm (9.8 in) Max. : 250 mm (9.8 in) Min. : 236 mm (9.3 in) 127 Adjustments tor Compelitinn 1 ea /i,\ \1/ /i,\ \1/ 0 l 41 Rear Suspension Adjustments Rear Suspension Damping Compression Damping Compression damping may be adjusted in two stages with separate adjusters. The high speed damping adjuster (l) is effective when damping adjustment is desired for high speed operation. The low speed damping adjuster (2) should be used when damping adjustment is desired at relatively low speeds. - Both the high and low speed compression damping can be increased by turning the appropriate adjuster clockwise. - Adjust the high speed compression adjuster in 1/12 tum increments. - Be sure the low speed compression adjuster is firmly located in a detent, and not between positions. (1) high speed damping adjuster (2) low speed damping adjuster 128 Adjustments for Competition High Speed Damping: The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. The high speed damping adjuster has 3 1/2 turn or more. To adjust to the standard position: 1. Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard setting. 2. Turn the adjuster counterclockwise 2 1/2 7 3 turns and the punch marks are aligned. Low Speed Damping: The low speed damping can be adjusted by turning the centre screw of the compression adjuster. The low speed compression adjuster has 13 positions or more. Turning the adjuster one full turn clockwise advances the adjuster 4 positions. To adjust to the standard position: 1. Turn the adjuster clockwise until it will no longer tum (lightly seat). This is the full hard setting. 2. Turn the adjuster counterclockwise 8 clicks and the punch marks are aligned. Rebound Damping The rebound damping adjuster (3) is located at the lower end of the rear shock absorber. It has 17 positions or more. Turning the adjuster one full turn advances the adjuster 6 positions. - Rebound damping can be increased by turning the adjuster clockwise. - Be sure that the rebound adjuster is firmly located in a detent, and not between positions. (3) rebound damping adjuster To adjust to the standard position: 1. Turn the adjuster clockwise until it will no longer turn (lightly seat). This is the full hard position. 2. Turn the adjuster counterclockwise 11 clicks with the punch marks on the adjuster and the rear shock absorber aligned. I %f% 1 /i,\ \1/ /i,\ \1/ 0 I 4I t. /\ \/ Rear uspension 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 ofthumb, 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 i the proper rear suspension spring preload adjustment for your specific needs. Your CRF should be at normal racing weight, including fuel, oil and coolant. You should be wearing all your normal protective apparel. You will need two helpers. To calculate the proper adjustment, it is necessary to measure between two fixed points i from the centre of the seat mounting bolt to the centre of the chain adjuster lock nut as illustrated here i for two different situations: unloaded: motorcycle on an optional workstand with rear suspension fully extended, no rider. loaded with rider: motorcycle on ground, with rider. 1. Support your CRF on an optional workstand with the rear wheel offthe ground. 2. Measure the unloaded dimension. SEAT MOUNTING BOLT (wlthout nder) EXAMPLE: 525 mm (24.5 in) CHAIN ADJUSTER LO K NUT 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. SEAT MOUNTING BOLT /. LOADED MEASUREMENT {with nder) EXAMPLE: 525 mm (20.7 in) ‘i <0) CHAIN ADJUSTER LOCK NUT Example: Unloaded = 625 mm (24.6 in) 7 Loaded = 525 mm (20.7 in) Race Sag = 100 mm (3.9 in) 4. Calculate the race sag dimension. To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Standard Race Sag: 105 mm (411 in) Adjust spring pre-load as necessary to obtain the desired handling results. Decreasing the race sag dimension (example: 95 mm, 3.7 in) improves turning ability for tight terrain at the cost of slightly reduced straight line stability. Increasing the race sag dimension (example: 115 mm, 4.5 in) 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. Adjustments tor Competition 129 / \ \‘T/ l as l /i,\ \1/ /i,\ \1/ 0 l 4‘ i. /\ \/ Rear Suspension Adjustments Spring Rates If you are lighter or heavier than the average rider and cannot set the proper ride height without altering the correct spring pre-load, consider an aftermarket rear shock spring. A spring that is too soft for your weight forces you to add excessive spring pre—load to get the right race sag and, as a result, the rear end ofthe motorcycle is raised. This can cause the rear wheel to unload too much in the air and top out as travel rebounds. The rear end may top out from light braking, or kick sideways over lips and square— edged terrain. It may even top-out when you dismount your CRF. Because ofthe great absorption quality ofthe shock bumper rubber, it may be difficult for you to notice when your CRF’s suspension is bottoming. Some riders may think the damping or perhaps the leverage ratio is too harsh. In reality, the problem is most likely insufficient spring pre-load or a spring that is too soft. Either situation prevents utilizing the full travel. Keep in mind that a properly adjusted suspension system may bottom slightly every few minutes at full speed. Adjusting the suspension to avoid this occasional bottoming may cost more in overall suspension performance than it is worth. 130 Adjustments for Competition A spring that is too stiff for your weight will not allow the rear tyre to hook up under acceleration and will pass more bumps on to you. / \ \‘T/ l 46%; Suspension Adjustments for Track Conditions Soft Surface 0n soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover. You may want a little bit stiffer front suspension for sand tracks to help keep the front end up and improve straight-line stability. In a muddy event, stiffer aftermarket springs front and rear may help, especially ifyou are heavier than the average rider. Your CRF may be under— sprung because of the added weight of the clinging mud. This additional weight may compress the suspension too much and affect traction. Hard Surface For a fast, hard track with no largejumps, you can probably run the same spring as normal, but run softer damping both ways-compression and rebound. lfyou run softer rebound damping, the wheel will follow the rough ground and small bumps much better, and you will hook up better. With a lot ofrebound damping, the wheel returns very slowly and doesn’t contact the ground quickly enough after each bump. The result is a loss of traction and slower lap times. Adjustments for Compclitinn 131 l a: leg? \ l "\ j Suspension Adjustment Guidelines i Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 1 12 7 130. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type ol Track Hard-surlaced track Begin with the standard setting. Il the suspension is too stilf/solt, adjust according to the chart below. Sand track Adjust to a stilfer position. Example: — Turn the compression damping adjuster to a stiller position. — Install the optional stIll spring. (Adjust compression damping to a softer position and rebound damping to a stiller position at this time.) Mud track Adjust to a stilfer position because mud build-up increases your CRF‘s weight. Example: — Turn the compression damping adjuster to a stiller setting. — Install the optional stilf spring. Adjustments for Too Soll/Stifl Damping Symptom Action Solt suspension Initial travel too soft: — Test stIller compression damping adjustments in one-click increments. - Steering is too quick. — Test stIller rebound damping in one-click increments. - Front end darts while cornering or riding in a straight line. {if Middle travel too solt: |l suspension isn‘t still in initial travel: :\ - Front end dives when cornering. — Test stiller compression damping adjustments in one-click increments. |l initial travel becomes stilf because of the above adjustment: — Reduce the rebound damping In one-click increments. — Test softer compression damping adjustments in one-click increments. N that doesn‘t solve the problem, install the optional still spring. Final travel too soft: |l initial and middle travel aren't still: - Bottoms on landings. — Test stiller compression damping adjustments in one-click increments. - Bottoms on large bumps, especially downhill bumps. |l initial and middle travel are stilf: — Install the optional stifl spring. |l initial travel is still after installing the optional stilf sprin ' — Test softer compression damping adjustments in one-click increments. |l initial travel is still solt alter installing the optional stifl spring: — Test stiller compression damping adjustments in one-click increments. |l linal travel is still solt after installing the optional stilf spring: — Increase the lork on capacity in increments ol 5 cmi‘ (0.2 US oz, 0.2 Imp oz). Entire travel too solt: — Install the optional stifl spring. - Front end shakes. — Test stiller compression damping adjustments in one-click increments. - Fork bottoms over any type ol terrain. — Increase rebound damping In one-click Increments. 132 Adjustments for Competition we l s: I? "\ 1 \ ll Suspension Adjustment Guidelines Sym ptom Action Stiff suspenslon Initial travel too stlff: - Still on small bumps while rlding at full throttle in a stralght line. - Still on small cornering bumps. - Front end wanders while ridlng at full throttle in a straight line. — Test softer compression damping adjustments in one-click increments. — Reduce the rebound damping adjustments in one-click increments. — Check for dlrt in the dust seals. Check the fork oil for any contaminatlon. If the front end dlves while cornering after the above adjustment: Reduce the rebound damping in one-click increments. If that doesn't solve the problem, install the optlonal stifl spring. If the stllf spring makes the suspension too still over the full range of travel: — Test softer compression damping adjustments in one-click increments until the desired compresslon damping for initial travel is obtained. Middle travel too still: - Still on bumps when cornerlng. - Front end wanders when cornering. - Still suspension on bumps, especially downhlll bumps. - Whlle braking, front end dives during lnitlal travel, then feels stlff. ll lnitlal travel lsn‘t stiff: — Test stifler compression damping adjustments in one-click increments. (Thls should produce smooth fork action from initial to mlddle travel.) If lnitlal and middle travel ls stifl: — Test softer compression damping adjustments in one-click increments. — Reduce the rebound damping in one-click increments. Final travel too stlff: - Doesn‘t bottom on landings, but feels stlff. - Still on large bumps, especlally downhill bumps. - Still on large bumps when cornerlng. ll lnitlal and middle travel aren't still: — Test stifler compression damping adjustments in one-click increments. (Thls should produce smooth fork action from initial to mlddle travel.) If linal travel is stlll stifl after the above adjustment, or If lnitlal and middle travel becomes stiff: — Install the optional soft sprlng. — Test softer compression damping adjustments in one-click increments. If the entire travel feels stllf after the above adjustment: — Test softer compression damping adjustments in one-click increments until the desired initial travel compresslon damping is obtained. — Lower the oil capacity by 5 cmi‘ (0.2 US oz, 0.2 Imp oz). Entire travel too stifl: - Still suspension on any type of terraln. — Test softer compression damping adjustments in one-click increments. — Reduce the rebound damping in one-click increments. — Lower the oil capacity by 5 cm“ (0.2 US oz, 0.2 Imp oz). Adjustments for Compelitinn l e: l \ ll "\ 1 (x il 46%; Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. ll the suspension is too stifl/solt, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: — Turn the compression damping adjuster and, especially, rebound damping adjuster to a stiffer setting. — Increase standard Race Sag (+5 to 10 mml0.2 to 0.4 In). Mud track Adjust to a stilfer position because mud build-up increases your CRF‘s weight. Example: — Adjust the compression and rebound damping adjusters to stifler settings. — Install an optional stifl spring. — Reduce standard Race Sag (—5 to —1 0 mm/—0.2 to —0.4 in). Symptoms and Adjustment - Always begin With the standard settings. - Turn the low speed compression and rebound adjusters in one-click increments, and the high speed compression adjuster in 1/12 turn Increments at a time. Adjusting two or more clicks or turns at a time may cause you to pass over the best adjustment. Test ride after each adjustment. - If, alter setting, the suspension feels unusual, lind the corresponding symptom in the table and test stifler or solter compression and/or rebound damping adjustments until the correct settings are obtained as described. Stifl suspension Symptom Action Suspension feels stilt on small bumps 1. Test softer low speed compression adjustment. 2. ll It still feels stifl, lurther test softer low and high speed compression adjustments simultaneously. Suspension feels stilt on large bumps 1. Test softer high speed compression adjustment. 2. ll It still feels stifl, lurther test softer low and high speed compression adjustments simultaneously. Entire travel too stifl 1. Test softer high and low speed compression adjustments and rebound adjustment simultaneously. 2. ll it still feels stifl, replace the spring With a solter spring (optional) and begin with the standard settings to softer settings. Soft suspension Entire travel too soft . Test stiffer high and low speed compression adjustments simultaneously. . ll it still feels solt, replace the spring With a stifferspring (optional) and begin With the standard settings to stifler setting. Rear end sways . Test stiffer high and low speed compression adjustments and rebound adjustment to stilfer settings simultaneously. Suspension bottoms Suspension bottoms at landing after jumping . Test stiffer high speed compression adjustment. . ll it still bottoms, test stilfer high and low speed compression adjustments, and replace the spring With a stilfer spring (optional) If necessary. Suspension bottoms alter landing . Test stiffer low speed compression adjustment. . ll it still bottoms, test stilfer high and low speed compression adjustments, and replace the spring With a stilfer spring (optional) If necessary. Suspension bottoms alter end ol continuous bumps . Test softer rebound dumping adjustment. . ll It still bottoms, test stifler high and low speed compression adjustments and solter rebound damping adjustment, and replace the spring with a stifler spring (optional) Il necessary. 134 Adjustments for Competition 45% (x l a l rlp \1/ rl,\ \1/ 0 l gl t. /\ \/ Tuning Tips An optional PGM—Fl setting tool can change the ignition timing and amount ofthe fuel injection (page 159). Be sure to observe the PGM-Fl setting by checking the spark plug. Spark Plug Reading Refer to Spark Plug on page 66. The following procedure is recommended. You may not get an accurate reading ifyou simply turn offthe engine and pull the plug for inspection. Use a new spark plug. Inspect the plug before installing it. NOTICE Uring Spar/(plugs with an improper heat range or incorrect reach can cause engine damage. Ride for 10 7 15 minutes before taking a plug reading. A new plug will not colour immediately. Before removing the spark plug, clean the spark plug area thoroughly to prevent dirt from entering the cylinder. To obtain an accurate reading ofa new spark plug: 1. Accelerate at full throttle on a straight. 2. Depress and hold the engine stop button and pull the clutch lever in. 3. Coast to a stop. 4. Remove the spark plug. 5 Use a magnifying glass to inspect the spark plug. The porcelain insulator (1) around the centre electrode (2) should appear clean and colourless with a gray ring around the centre electrode where it exits the porcelain. Light gray or white colour streaks on the porcelain insulator and centre electrode indicate lean air-fuel mixture. Wet or black sooty streaks on the porcelain indicate rich air— fuel mixture. NOTICE An improperly tightened spar/(plug can damage the engine. [fa plug is too loose, apiston may be damaged. If a plug is too tight, the threads maybe damaged. (1) porcelain insulator (2) centre electrode S ark Plu Colourin Guidelines Condition Spark Plug Appearance Mlxture Normal Dark brown to light tan correct colour with dry electrode Overheatlng Light gray or white colour lean (Lean) Wet (Rlch) Wet or sooty rich Remember that in addition to improper air-fuel mixture: - A lean condition can be caused by air leaks in the inlet tract or exhaust system, the passage of too much air because ofthe use ofthe wrong air cleaner, or the use ofa less-restrictive aftermarket exhaust system. A rich condition can be caused by a plugged or dirty air cleaner, use of a more—restrictive aftermarket exhaust system, or excessive oil on the air cleaner. Excessive smoking will occur. 135 Adjustments for Compelitinn f l o / \ \‘T/ he 44»H% g C Eh Steering Damper Adjustment The steering damper can be adjusted for riding conditions by using following method: . Damping 7 Turning the steering damper adjuster adjusts how quickly the steering damper compresses or extends. 136 Adjustments tor Competition Steering Damper Damping The steering damper adjuster (1) has 13 positions or more. Turning the adjuster one full turn clockwise advances the adjuster six positions. To adjust the adjuster to the standard setting, proceed as follows: Turn the adjuster clockwise until it will no longer turn (lightly seats). This is the full hard position. The adjuster is set in the standard position when the adjuster is turned counterclockwise 9 7 12 clicks. Damping can be increased by turning the adjuster clockwise. NOTICE Always start with full hard when adjusting damping. Do not turn the adjuster more than the given positians or the adjuster may be damaged Be sure that the steering damper adjuster isfirmly located in a detent, and nut between pasitions. I . ' . \ (1) steering damper adjuster 49$ ail Jill. %Hia Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF. Symptoms and Adjustment - Always begin with the standard settings. - Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment. Symptom Action Steering Is wobbling on large bumps Adjust the steering damper adjuster to a stifler settjng. Steering Is wobbling on a sand track Adjust the steering damper adjuster to a stifler settjng. Steering Is heavy when cornering Adjust the steering damper adjuster to a softer settjng. Adjustments for Compclitinn 137 J. AH l as JP \1/ JP \1/ 0 l 41 l i. /\ \/ Chassis Adjustments The following suggestions may improve a specific concern. Subtle changes in overall handling may also be noted. Rear End If you have a problem with rear wheel traction, raise the rear end of your CRF by increasing the rear suspension spring pre-load. Instead ofrunning 105 mm (4.1 in) ofsag, you can run 95 mm (3.7 in) so the rear ofthe motorcycle will sit a little higher. This should produce more traction because ofthe change to the swingann and location ofyour CRF’s centre ofgravity. If you have a problem with the steering head shaking when you use the front brake hard or if your CRF wants to turn too quickly, lower the rear ofthe motorcycle by reducing the rear suspension spring pre—load. This will increase fork rake and trail and should improve stability in a straight line. The effective suspension travel will be transferred toward the firmer end of wheel travel. Keep the race sag adjustment (page 129) in the 95 7115 mm (3.7 7 4.5 in) range. 138 Adjustments for Competition Fork Height/Angle The position ofthe fork in the clamp is not adjustable. Align the top of the outer tube (not the top ofthe fork damper) with the upper fork of the top bridge. Standard Position The top ofthe outer tube (1 ) (not the top ofthe fork cap) is aligned with the top ofthe upper fork bridge (2). (1) top 01 outer tube (2) upper fork bridge Wheelbase Adjusting your CRF’s wheelbase can offer subtle changes in overall handling. You may adjust wheelbase by adding or removing links on the drive chain. lfyou change the wheelbase, be sure to recheck race sag and adjust, if necessary. In the past, a general rule was lengthen the wheelbase to add straight line stability, shorten the wheelbase to improve turning. However, we suggest you do not lengthen the wheelbase ofyour CRF unless you are racing on a track with more fast sections than normal. As a general recommendation, keep the wheelbase as short as possible. This positions the wheels closer together, improves turning response, increases weighting (traction) on the rear wheel, and lightens weighting on the front wheel. With your CRF, you will probably find that the standard setting or a shorter wheelbase will offer more overall benefits. l as /i,\ \1/ /i,\ \1/ l i. /\ \/ Gearing You can “adjust” the power delivery ofthe standard engine to suit track conditions by changing gearing. This allows you to utilize a different portion of the engine’s power range at a given throttle setting. New gearing may provide the change you are looking for without the need to consider further modifications. The ponion ofyour engine’s power range you use can be adjusted by changing the final drive ratio with different sized driven sprockets. Gearing changes allow you to more closely match the type of terrain and the available traction. Normally, a change of one tooth on the driven sprocket will be sufficient. There is a choice of both higher and lower final drive ratios with two optional driven sprockets. Like the optional springs, these sprockets are listed in the Optional Parts List section of this manual (page 158). Unless you have the required mechanical know- how, tools, and an official Honda Shop Manual, sprocket changing should be done by your dealer. Higher Gearing (less driven sprocket teeth) - increases top speed in each gear (provided the engine will pull the higher gearing) - reduces frequency of shifting (wider gear ratios) - reduces engine min" (rpm) at a given throttle setting or ground speed (which may allow better rear wheel traction on slippery or loose terrain) However: - the engine may not pull the higher gearing - the spacing between gears may be too wide - engine min" (rpm) may be too low Lower Gearing (more driven sprocket teeth) - decreases top speed in each gear - increases frequency of shifting (narrower gear ratios) - increases engine min" (rpm) at a given throttle setting or ground speed (which may provide more power-to—the-ground on good traction surfaces) However: - spacing between gears may be too narrow - engine min’| (rpm) may be too high Some tracks may be watered heavily prior to the first race, then lightly or not at all during the day. This results in a track surface that is slippery during the first few races, then changes from good to great and back to good and possibly ends the day with a slick rock—hard consistency. Ideally, your gearing should be adjusted to suit all these conditions. - Wet and slippery or sandy conditions: use a higher gear (less teeth) to keep engine min" (rpm) down, and avoid unwanted wheelspin. The engine may bog in certain corners so you’ll need to slip the clutch to compensate; downshifting may be too drastic a change in speed. Hard (but not slippery) track conditions: use lower gearing (more teeth) to keep the engine min’| (rpm) high where the engine produces the most power. This may require an extra upshift on certain sections or perhaps you can just rev it out a bit longer. For tight tracks, consider lower gearing to avoid having to slip the clutch frequently. Repeated fanning or pulling of the clutch lever in a turn to raise engine min" (rpm) may eventually damage the clutch system. fl‘p 4‘5 / Average conditions: use the standard sprocket. A gearing change may help for riding in sand, where you want to keep the front end light so it can float from the peak ofone sand whoop to the next. Generally, with higher gearing, it is easier to maintain that perfect attitude (maximum rear wheel traction and a light front end) because you remain in the powerband longer in each gear. The higher gearing allows you to steer more efficiently with throttle control and body English. If you are riding a track with sections where you choose to over-rev the engine temporarily rather than shifting up, higher gearing might help. Sometimes you have to sacrifice performance on one section of the track to gain a better overall time. Your goal is the fastest overall lap time, even ifthe cost is some sections where the gearing feels wrong. If you decide to try a gearing change, have someone check your times with a stopwatch (before and after the change) to get an accurate appraisal of the change. “Seat—of—the-pants” feelings can’t be trusted. Eliminating wheelspin with a gearing change can make you feel like you’re going slower when, in reality, you’ve decreased your time by increasing your speed with better traction. These gearing recommendations should be evaluated by considering your ability, your riding style, and the track. 139 Adjustments tor Competition / \ \‘T/ \ ae r \ \j’f J i. /\ \/ Tyre Selection for Track Conditions Choosing the correct tyre tread pattern and rubber compound can affect your placing in competition. The tyres on your CRF offer a “happy medium” for the variety of soil conditions the majority ofriders are likely to encounter. Experienced competitors often switch to tyres developed for specific terrain conditions. lfyou do switch, stay with the factory recommended sizes. Other tyres may affect handling or acceleration. Be aware that tyre sizes (width and aspect ratio) do vary from manufacturer to manufacturer or even among tyres made by the same manufacturer. Variations in tyres, especially the sidewall profile, can change the attitude of your CRF and its handling. Tyre variations that raise or lower the rear ofyour CRF have a more significant effect on handling than variations in front tyres which, generally, don’t vary as much. Often, you can see or feel the change in tyre size. Another way to check is to measure the rolling circumference of the old and new tyres. A higher profile tyre will have a larger rolling circumference. If you do switch to tyres designed for special terrain use, remember they will be less acceptable in other circumstances. For example, an aggressive mud tyre will give excellent grip on wet, loamy terrain, but less impressive grip on a hard surface. 140 Adjustments for Competition lfyou choose a tyre with a sticky compound for added traction, remember that it may transfer additional loads to the transmission because it grips so well, especially when riding in situations that normally place unusual demands on the transmission. Complete consumer information can be obtained from the various tyre manufacturer representatives and dealers. Some general recommendations for specific terrain follow: Hard, Slick Soil Use tyres with many relatively short knobs that are close together in order to obtain the largest possible contact patch on the surface. The rubber compound needs to be softer for hard ground in order to hook up, but not so soft that the knobs roll over easily and affect holding a straight line. These tyres tend to wear more quickly than standard tyres because ofthe combination of soft rubber and hard terrain. Muddy Soil Use a more open tread pattern to avoid clogging. For these conditions, the relatively long knobs will probably be made from a harder rubber compound to reduce any tendency to bend back under acceleration or wear quickly. Loose, Sandy Soil Use a tyre that is similar in construction to those needed for tacky soil and mud, but with a few more knobs. t as J /i,\ \1/ /i,\ \1/ 0 t 4‘ i. /\ \/ Personal Fit Adjustments The following suggestions may make your ride both more comfortable and more responsive to your control input. Control Positioning - Position the control levers so that you can use them comfortably when seated and standing. Adjust the mounting bolt torque ofthe clutch and front brake lever assemblies so that they can rotate on the handlebar in a fall. If an assembly does not rotate, it may bend or break a control lever. Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained. Tighten the top bolts first. (1) control lever mounting bolts As an alternative, consider wrapping the handlebar area under the control assemblies with Teflon tape. Then tighten the assemblies to their normal torque. Upon impact, the fully-tightened assemblies should rotate on the Teflon tape. Position the shift lever and rear brake pedal so they are close to your boot for rapid access, but not so close that either is depressed when sitting or standing comfortably on your CRF. Handlebar Position, Width & Shape - Position the handlebar so that both gripping the bar and operating the controls are comfortable while both seated and standing, while riding straight ahead and turning. Tighten the forward handlebar upper holder bolts first. The handlebar position may be moved rearward either 3 mm (0.1 in) (using optional handlebar lower holders) or 6 mm (0.2 in) (by rotating the standard holders 180 degrees). Refer to an official Honda Shop Manual for installation instructions. Be sure to check control cable and wiring harness routing after the adjustment. Handlebar width can be trimmed with a hacksaw to better suit your panicular shoulder width and riding preference. Think this through carefully and cut offj ust a small amount at a time from both sides equally. It is obviously much easier to make the handlebar narrower than it is to add material. Chamfer the edges to remove burrs and other irregularities or roughness after sawing the handlebar. An alternate handlebar shape, through varying rise or rearward sweep dimensions, will provide further adjustment to riding position and may better suit your particular body size or riding style. Each ofthe ergonomic dimensions of the machine were determined to suit the greatest possible number ofriders based on an average size rider. Adjustments for Competition 141 / \ \1/ / \ \1/ 142 Adjustments for Competition f \ o / \ \‘T/ Here’s helpful advice on how to transport and store your l-londa, as well as three troubleshooting flow charts. Transporting Your Motorcycle Storing Your Honda Preparation for Storag Removal from Storage You & the Environment Troubleshooting .......... \ a% J JP \1/ JP \1/ 0 l 4‘ i. /\ \/ Transporting Your Motorcycle lfyou use a truck or motorcycle trailer to transport your l-londa, we recommend that you follow these guidelines: - Use a loading ramp. - Relieve the fuel pressure (page 40) and drain the fuel from the fuel tank into an approved petrol container. - Secure the motorcycle in an upright position, using motorcycle tie-down straps. Avoid using rope, which can loosen and allow the motorcycle to fall over. 144 Tips To secure your CRF, brace the front wheel against the front ofthe truck bed or trailer rail. Attach the lower ends oftwo straps to the tie-down hooks on truck bed or trailer rail. Attach the upper ends ofthe straps to the handlebar (one on the right side, the other on the left), close to the fork. Check that the tie—down straps do not contact any control cables or electrical wiring. Tighten both straps until the front suspension is compressed about half-way. Too much pressure is unnecessary and could damage the fork seals. Use another tie-down strap to keep the rear ofthe motorcycle from moving. We recommend that you do not transport your CRF on its side. This can damage the motorcycle, and leaking petrol could be a hazard. 411% 011% Storing Your Honda lfyou won’t be riding for an extended period, such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be forgotten and it will be easier to get your CRF running again. To reduce or prevent deterioration that can occur during storage, also follow the following procedures. Preparation for Storage 1. Completely clean all pans ofyour CRF. Ifyour CRF has been exposed to sea air or salt water, wash it down with fresh water and wipe dry. Change the engine oil and filter (page 49). Change the transmission oil (page 52). Remove the radiator cap and coolant drain bolt and sealing washer (l) at the water pump cover (2) to drain coolant. After the coolant has been completely drained, reinstall the drain bolt with a new sealing washer and radiator cap. Tighten the drain bolt to the specified torque: 10 N~m (1.0 kgf-m, 7 Ibf‘ft) Pam.“ ,»\ u! ’t.’ (1) coolant drain bolt and sealing washer (new) (2) water pump cover 5. Lubricate the drive chain. 6. Relieve the fuel pressure (page 40) and drain the fuel from the fuel tank into an approved petrol container. 7. lnflate the tyres to their recommended pressures. 8. Place your CRF on an optional workstand or equivalent to raise both tyres off the ground. 9. Stuff a rag into the muffler outlet. Then tie a plastic bag over the end of the muffler to prevent moisture from entering. Store your CRF in an unheated area, free of dampness, away from sunlight, with a minimum of daily temperature variation. 11. Cover your CRF with a porous material. Avoid using plastic or similar non-breathing, coated materials that restrict air flow and allow heat and moisture to accumulate. 10. 1. Removal from Storage Uncover and clean your CRF. Change the engine and transmission oil if more than 4 months have passed since the start of storage. Uncover the end ofthe muffler and remove the rag from the muffler outlet. Fill the fuel tank with the recommended fuel (page 39) and increase the fuel pressure (page 47). Pour a fresh recommended coolant mixture slowly into the radiator fill hole up to the filler neck (page 53). Capacity: 1.02 P. (1.08 US qt, 0.90 Imp qt) after disassembly 0.95 P. (1.00 US qt, 0.84 Imp qt) after draining Lean your CRF slightly right and left several times to bleed trapped air in the cooling system. If the coolant level lowers, add coolant and repeat the above procedure. Install the radiator cap securely. Perform all maintenance checks (page 13). Tips 145 491 rtf 4197110 %\W l as rip \1/ rip \1/ l i. /\ \/ You & the Environment Owning and riding a motorcycle can be enjoyable, but you must do your part to protect nature. When you show respect for the land, wildlife, and other people, you also help preserve the sport ofoff—road riding. Following are tips on how you can be an environmentally responsible motorcycle owner. 0 Choose Sensible Cleaners. Use a biodegradable detergent when you wash your CRF. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Don’t throw cleaning solvents away; see the following guidelines for proper disposal. 0 Recycle Wastes. It’s illegal and thoughtless to put used engine oil in the trash, down a drain, or on the ground. Used oil, petrol, coolant, and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water, lakes, rivers, and oceans. Before changing your oil, make sure you have the proper containers. Put oil and other toxic wastes in separate sealed containers and take them to a recycling centre. Call your local of public works or environmental services to find a recycling centre in your area and get instructions on how to dispose of non recyclable wastes. 146 Tips NOTICE Improper disposal qfdrainedfluids is harmful to the environment. / \ \‘T/ / \ \1/ / \ \1/ Troubleshooting The items that are serviceable using this Manual are followed by the page number reference in parenthesis. The items that require use of an official Honda Shop Manual are followed by an asterisk (*). ENGINE DOES NOT START OR IS HARD TO START CHECK POSSIBLE CAUSES I. Check the spark INCORRECT Incorrect spark plug neat plug condttlon range (P 66) CORRECT - Incorrect spark plug gap - Dtrty atr cleaner element N g 2 g e i- i WEAK OR 4» FauIty spark plug (Peel NO SPARK - FouIed spark plug (P est - FauIty ECM’ - Broken or shorted spark plug wtre - FauIty allernalor‘ - Faulty Igmtlon oorl~ - Faulty engtne stop bullon‘ - Loose ordlsconnected Igmtlon system ereS - Faulty CKP sensor- - Faulty regulator/recllller‘ - Faulty condenser~ . CheckthePGM-FI INCORRECT Faulty PGM-FI system (P3) system (PJI GOOD SPARK u CORRECT 1 s . Check the IueI pump operatlon andlnspecttneIueI Ilow- CORRECT INCORRECT Faulty Iuel pump- - Clogged Iuel pump Irlter (Put 1 on . Check the IueI Injeclor operattng INCORRECT - Faulty PGM-FI system (P 9) - Faulty Iuel tnyeotor CORRECT Valve Clearance too small - Valve stuck open - Worn oyIlnder and plston VIrIg‘ - Damaged cyItnder head gasket - Improper valve (ImIng‘ - Selzed valve 5" o m oa' o 3!: g Ea a re: "‘5 %9 =52 CORRECT Start py IoIIowrng ENGINE e. Insulator Ieaklng normal stamng STARTS BUT - Improperrgnltton tlmtng procedure SOON STOPS (Faulty ECM or CKP sensort' - Fast IdIe knob stuck open or damaged - Fuel contamtnated ENGINE LACKS POWER CHECK I 2 u on m POSSIBLE CAUSES Brake draggtng - Worn or damaged wheel beanngs ' Bent axle shall - Dnve chaln too tIght INCORRECT Faulty valve core - Punctured tyre Check the wheel sptns smoothness Check the tyre pressure (P 95) Check the englne NO GOOD Cluton sllpprng speed changes . ImproperIy adtusted accordlngly when cIutcn Ieyer IreepIay the clutch Is (Rel engaged- - Worn qutcn dtscs/plates (P.64t IE . Warped clutch dISCs/ plates (Pest - Weak clutch Sprlngs‘ - Stlcklng clutch IIIter - Addlttye In transmlsslon on Check the engtne NO GOOD nlrty arr cleaner element speed Increase - Clogged muIIIer - Fast Idle knop stuck open GOOD or damaged - Restrlcted Iuel IIII cap breather tupe - Restrlcted Iuel IIow Check Ior englne Worn plston and Cyllrlder’ knocklng when accelerattng or runntngthe engtne at mgh speed Check the Ignttton INCORRECT Faulty ECM‘ tlmrng~ - Faulty CKF sensor- - Use 0! poorqualtty Iuel - ExCeSSIve Carbon bulld- up In combustlon Chamber - Igmtlon ttmlng too advanced (Faulty ECM)’ ' Lean IueI mixture - Valve clearance too small 7 Test cyltnder compresston' - Valve stuck open - Worn cyllnder and plston CORRECT “ma - Damaged cyltnder head gasket - Impropevvalvellmlng' - Faulty decompressor system‘ Check the PGM-FI INCORRECT - Faulty PGM-Fl system (Pet system (P.7t CORRECT m4 1 to Check the Iuel INCORRECT - FaultyIueI pump untt‘ pump operatlon - Clogged tuel pump Illter andtnspectthetuel (P.44t Ilow~ CORRECT 1 II).Check the spark INCORRECT - Incorrect spark plug plug condttlon - Incorrect spark plug gap (Peel - Dlny aIr cleaner element CORRECT r \ “Check the engtne INCORRECT - Engtne all level too hlgn \ / on level and - Engtne all level too low condttlon (PAS) CORRECT - Contamtnated engtne on 1 INCORRECT - Faulty oll pump‘ - Faulty pressure relIeI valve‘ - Clogged oll paSSage‘ - Clogged oll strarner screen‘ I2,Remoue the cyIIndernead cover Tips 147 / \ \1/ / \ \1/ Troubleshooting POOR PERFORMANCE AT LOW AND IDLE SPEED CHECK POSSIBLE CAUSES . Check the spark INCORRECT Incorrect spark plug neat plug Condltlon range as - Incorrect spark plug gap - Plug not Sen/Iced CORRECT lrequently enough 1: m . Check the Igmtlorl INCORRECT Faulty ECM‘ tImlng' - Faulty CKP sensor- CORRECT 1 u . CheCKthePGM-Fl INCORRECT Faulty PGM-FISyStem (Pa) systern IPJI CORRECT 1 A. Check the tueI Faulty tueI pump umr pump operatron - Clogged tueI pump trIter arrmnspecttheluel (PAAI lIow- CORRECT 1 or .Checkthernsulator INCORRECT -Loose Insulator lor leaks - Damaged msuIator CORRECT 1 m . Check the valve INCORRECT Faulty valve Clearance clearance IP.e7I - Faulty valve' - Faulty yalye Seat‘ CORRECT - Faulty camshalt~ 1 or . Try spark teSt‘ WEAK OR Faulty, carbon or wet INTERMITTENT louleo spark plug IReeI SPARK - Faulty ECM‘ - Faulty alternator‘ - Faulty Ignltlon oorI~ - Broken or shorted spark plug wrre - Faulty CKP sensor- - Loose ororsconnecteo Ignltlon system wrres - Faulty englne stop button‘ - Faulty vegulator/rectlller‘ - Faulty conuenser~ 148 Tips POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES 1 Check the Ignltlon INCORRECT Faulty ECM‘ trmrng~ - Faulty CKR sensor- CORRECT 2 Remove the aIr DIRTv Not Cleaned lrequently cleaner (P 55) enough AIR CLEANER NCT DIRTV V a Checkthe PCM—FI INCORRECT Faulty PGM-Fl system IPaI systern IPJI CORRECT 1 9 o m p INCORRECT Faulty luel purnp umt‘ pump operatron and - Clogged tueI pump tIIter Inspecltheluelllow‘ IRMI CORRECT Check the valve INCORRECT Carnsnatt not Installed tImlng properly (P 72) CORRECT Check the valve INCORRECT Faulty valve clearance clearance (13.67) - Faulty value~ - Faulty valve Seat‘ 1 or 1 m CORRECT - Faulty oamshalr 7 Check the valve WEAR Faulty ualye sprmgs~ Sprlngs‘ GOOD m A a g e i WEAK OR >. Faulty, Carbon or wet INTERMITTENT Iouled s ark Iu Ree GOOD SPARK SRARK - Faulty EpCM‘p at i - Faulty alternator - Faulty Ignttlorr colI‘ - Broken or shorted spark plug wtre - Faulty CKR sensor- ' Loose or dISCaNIeCted tgnltlon system wtres - Faulty englne stop button' - Faulty regulator/rectlller - Faulty condenser~ Remove the Faulty oamshalr Camshalt and Inspect the cam lobe helght‘ CORRECT no zl‘p 4‘5 / POOR HANDLING Steering is heavy - Steering stem adjusting nut too tight* - Damaged steering head bearings ' Faulty HPSD" Either wheel is wobbling - Excessive wheel bearing play - Bent rim - Improperly installed wheel hub - Excessively worn swingarm pivot bearings - Bent frame The motorcycle pulls to one side - Front and rear wheels not aligned - Bent fork - Bent swingarm - Bent axle shaft - Bent frame lg? This section contains dimensions, capacities, and other technical data. Vehicle Identification Serial Numbe Specifications Petrol Containing Alcohol Competition Logbook Optional Parts List ..... Spare Parts & Equipment Spare Parts . General Tools Honda Special Too , Chemical Products Other Product, Wiring Diagram Technical Information Technical Informalinn 149 44»H% i O W 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 pans. The VIN (vehicle identification number) (1) is stamped on the right side of the steering head. ‘wz’ r\//\/* \ \ $3 , (1) VIN 150 Technical Information The engine number (2) is stamped on the left crankcase. (2) engine number 4st riff %\W (x err Spec1ficat10ns llem Melric English Item Melric English Item 1 Metric 1 English Dimension Engine Drive train Overall length 2,181 mm 85.9 1n Type Liquid coo1ed. 4-slroke Clulch type Wei. mulli-plate iype Overall widlh 827 mm 32.6 1n Cyhnder arrangement Sing1e 5“eirr:cchar|:ed from Transmission 5-speed( constant mesh Overall herght 1.271 mm 50.01n V ‘ > Primary reduction 3.166 Wheelbase 1.489 mm 58.6 1n Bore and slroke 76 B X 53 ’3 rnm 3'02 X 212"" Gear ratio | 2.357 Seal heighl 951 mm 37.41n D'SP‘acem?“ > 249-4 “7“ 152‘ 0“" Gear ratio H 1.888 Foolpeg herght 418 mm 16.5 1n Compression ratio 15'5 : 1 Gear ratio I” 1.555 Ground clearance 322 mm 12.7 1n Intake 031020: 0'03 "‘1'“ Gear ratio IV 1.333 Valve clearance (co1d) ,( ' t 0'00 m - Frame Exhausl.0.28 1 0.03 mm Gear ratio V 1.136 Type Twin tube (0'0“ 3 0-001 ”0 Fina1 reduclron 3.769 » Engrne oiI capacily g 71 US t _ Te1escopic lork - q r . Lell loot operated relurn F. suspensron lravel 273 mm (10.7 in) After drarning 0'67 Z 0-59 Imp 111 Gear 5m“ pallern system 1-N-2-3»4-5 “me 3‘0 ml" (”'2'") After drarning and oil a 69 z 0.73 US qt Eleclrical R suspensron Pro-link > lr1ter change 0.61 Imp qt 1gnilron ECM lravel 313 mm (12.3 in) Arte d'sassemm 0 90 US t 30/100-21 51M ' ' V 0.55 a 0-75 m 8 ‘t Stanrng syslem Krckstarler From tyre . , . . ' p q Spark plug: DUNLOP MX51FA Transmissron all capacrty o 68 z 012 US qt‘ 5 d d NGK H0451B»8 Rear re 100/90-19 57M After drarning ‘ 0-60 "“9 at '3" 3' ‘y DUNLOP 1 MX51 After disassemmy o 75 z 0.79 us qt. Spark plug gap (01%341050'ggnm) / _ Tyre type bras-ply. lube 0'66 Imp at x 2 Tyre pressure lront (com) 100 kPa (1 0 kgl/cmx. 15 ps1 ) Throttle body Tyre pressure rear (cold) 100 kPa (1 0 kgl/cmx. 15 ps1) Elenlifwalcilon number GQZBA ‘ ( ) , . 2.000 1100 min rpm Sing1e disc brake e spee F- maker swept area 334.5 cm2 (51.8 in?) Cooling system Sing1e disc brake Coohng capacity 1 00 US t Fl.brake.s e ta ea . - q. w p r 391-1 cm? (60-5 ma) alter drarning 0'95 z 0-54 Imp qt un1eaded pelrol. research » F“e‘ octane number at 95 or hrgher 3“” d'sassemb‘y 1.02 r 3,383 iJrprSt 1.66 US gal. Fue1capacrly 6.3 E 1.391rnp gal Caster ang1e 27“23’ Trarl lenglh 118 mm 4.6 1n Fork oil capacity 12.1 US oz. (except lork damper) 357 cm: 12.6 Imp oz Fork oil capacity 8.2 US oz, (damper) 243 cm3 8.6 Imp oz Technical lnformatinn 151 i 4.5% €51.13 1 es 1_ do s JP \‘11/ Torque Specifications Nuts, Bolts, Fasteners ENGINE Torque Check and tighten nuts, bolts, and fasteners before every outing. "em Nam kgqqn IhMt Remarks RIGHT SIDE 1 Cy1inder head covey balls 10 1.0 7 2 Exhausl p1pe joinl nu1s 21 2.1 15 3 Wa1er pump cover bolts 10 1.0 7 4 Crankshafl hole cap 15 1.5 11 NOTE 1 5 Transmissmn oil check b0” 12 1.2 9 6 Cmtch covey balls 10 1.0 7 7 Coolanl drain boll 10 1.0 7 8 Engine oi1dvain Dan 16 1.6 12 NOTE 2 9 Cy‘inder b0“ 10 1.0 7 10 O11filter cover boHs 12 1.2 9 11 Cy1inder head A bons 10 1.0 7 12 Dnve sprocket be” 31 3.2 23 13 Transmissmn oi1dvain bolt 16 1.6 12 NOTE 2 O 14 Cy1inder head B bons 45 4.6 33 NOTE 2 0 NOTES: 1. Apply grease to Ihe 1hreads. 2. Apply engme oil Io1he Ihveads and sealing sur1ace. LEFT SIDE (1) 152 Technical lnfarmalian \ r), 1 \ '/ l 4% l_ do TF7 / ff r x '7’ fit Torque Specifications LEFT SIDE FRAME Torque Item N-m kgl-m tht Remarks 1 Sleering slem nul 108 11.0 80 2 Fork bridge upper pinch bolls 22 2.2 16 3 Fork bridge lower pinch bolls 20 2.0 15 4 Handlebar upper holder bolls 22 2.2 16 5 Handlebar lower holder nuls 44 4.5 32 6 Front axle nut 88 9.0 65 7 Axle pinch bolts 20 2.0 15 8 Rear axle nut 128 13.1 94 NOTE 1 9 Chain adjuster lock nuts 27 2.8 20 NOTE 2 10 Front engine hanger nuls 54 5.5 40 Front engine hanger plale nuls 26 2.7 19 11 Lower engine hanger nul 54 5.5 40 12 Cylinder head hanger C (14) (17) bolls 54 5.5 40 C / 13 Cylinder head hanger / plale bolls 32 3.3 24 RIGHT SIDE 14 Rear suspension (upper) 44 4.5 32 NOTE 1 (lower) 44 4.5 32 NOTE 1 15 Swingarm pivot nul 88 9.0 65 NOTE 1 16 Fork (fork cap assembly) 30 3.1 22 (fork damper) 34 3.5 25 17 Rear shock arm nuts (swingarm side: nul widlh 17 mm) 53 5.4 39 NOTE 1, 6 (shock link side: nul widlh 19 mm) 53 5.4 39 NOTE 1, 6 18 Rear shock link nul 53 5.4 39 NOTE 1, 6 19 Rear shock spring lock nut 44 4.5 32 20 Kickstarler arm bolt 38 3.9 28 NOTE 5 21 Fuel pump mounllng bolts 11 1.1 8 NOTES: 1. U-nut 2. UBS nul 5. Alock boll: replace with a new one. 6. Apply molybdenum oil lo lhe threads and llange surface. 'l'echnicnllnformalinn 153 (re / i %% 49 \1/ / \ \1/ 0 i 4‘ Torque Specifications LEFT SIDE RIGHT SIDE 154 Technical Informalion FRAME Torque Item N-m kgl-m tht Remarks 22 Front brake mastercylinder holder bolts 9.9 1.0 7.3 23 Brake nose oii boits 34 3.5 25 24 Front brake caliper mounting boits 30 3.1 22 NOTE 5 25 Front brake disc nuts 16 1.6 12 NOTE 1 26 Rear brake disc nuts 16 1.6 12 NOTE 1 27 Brake pedal pivot boit 36 3.7 27 NOTE 5 2B Spokes (front) 3.7 0.4 2.7 (rear) 3.7 0.4 2.7 29 Rim locks 12 1.2 9 30 Drive chain roiler (upper) 12 1.2 9 NOTE 4. 5 (lower) 12 1.2 9 NOTE 1 31 Sublrame boils (upper) 32 3.3 24 (Tower) 49 5.0 35 32 Fork Centre bolt 69 7.0 51 NOTE 3 33 Fork Centre bolt lock nut 22 2.2 16 34 Disc cover socket boits 13 1.3 1D 35 Fork protector socket boits 7.0 0.7 5.2 NOTE 5 as Len/right mumer clamp bolts 20 2.0 15 37 Driven sprocket nuts 32 3.3 24 NOTE 1 38 Seat mounting boits 26 2.7 19 39 Front brake resenloircap screws 1.0 0.1 0.7 40 Rear brake reservoir cap bolts 1.0 0.1 0.7 41 Fork air pressure release screw 1.3 0.1 1.0 42 FlignI/lefl muffler mounting B bolt (rear) 26 2.7 19 Riont mumer mounting A bot (lront) 26 2.7 19 4s Steering damper mounting bolts 20 2.0 15 NOTE 5 44 Throttle cabie adjuster lock nuts 4.0 0.4 3.0 45 Rear master cyhnder pusn rod iock nut 5.9 0.6 4.4 46 Shroud B boils lupber) 5.2 0.5 3.8 47 Left engine guard ooit/ Washer 10 1.0 7 48 Air bleed boit 1.6 0.2 1 2 49 Mud guard screws 1.5 0.2 50 Side cover boits 1D 1.0 NOTES: 1, Urnut 2, UBS nut 3,A | aiockin a enttotnethreads. 4,8EFbyoit g g 5, Aiock boil: replace with a new one. f i o / \ \‘T/ Petrol Containing Alcohol lfyou decide to use a petrol containing alcohol (gasohol), be sure it’s octane rating is at least as high as that recommended by Honda. Do not use petrol that contains more than 20% ethanol. - When certain types of petrol containing alcohol are used, problems such as hard starting, poor performance, etc. may occur. If you notice any undesirable operating symptoms while using a petrol that contains alcohol, or one that you think contains alcohol. try another station or switch to another brand of petrol. When a problem resulting from the use ofpetrol containing alcohol occurs, contact your dealer. Technical Information 155 l as r \ \Tf 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 bits of information is to record them in a logbook. Your logbook can include such information as suspension adjustments, steering damper adjustments, gearing, and tyre 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 ofthe 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 colour pens or pencils to record important information on specific subjects. For example, record results in black, steering damper setting in red, suspension/chass . settings in blue, and gearing selections in green. Colour codes will help you identify the information you want with a glance. 156 Technical lnformalion 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 - suspension settings - steering damper settings - chassis adjustments tested and selected - gearing - tyre 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 Timckceping This Manual lists maintenance intervals for every— so-many races or every-so-many hours of running. Because all races are not the same, the most effective way to schedule maintenance is by the hours you have run your CRF. An official “guesstimate” is close enough for our timekeeping purposes. You may choose to record your time 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 6 minutes represents one tenth of an hour). Racing Records Information worth recording for this section of your logbook may include: Your placing in each heat 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 ofcylinder, piston and ring / \ examinations Patterns for frequency of need for decarbonization with a particular oil When you last performed shock linkage and swingarm pivot bearing maintenance Engine, transmission, and suspension oil changes Chain, sprocket, chain roller and slider replacements Coolant changes and related component replacements Spark plug, brake pad and control cable replacements In addition, you should record any irregularities noted in component wear so you’ll remember to keep a close eye on these areas in the future. ‘ k? Competition Logbook Date Running Location/Event Comments (Suspension Settings, Steering Damper Settings, Gearing, Chassis Adjustments, Time Maintenance Performed, etc.) (Make several photocopies of We page for future use) Technical Information 157 % i as he Optional Parts List "\ i \ ii These parts and tools may be ordered from your . FRAME Remarks authorized dealer. Shock spring 52 N/mm (297 lbt/In) Standard No mark FRAME Remarks / Y/(tactory products) Driven sprocket < >: Drive chain links Standard :é?1T6te:3th, Aiuminum. or Lime green paint Optionai 48 Teeth, Aiuminum Waltermarket parts) 50 T th Ai ’ > . ee ’ uminum Optional 50 N/mm (286 lbt/In) Drive chain D.|.D 520 DMA4/120RB size/iink RK520TXZ/120RJ 30W 7.7. Yeuow pair" Handlebar @362] lower holder 3 mm (0.1 in) offset “ " Optionai no oflset Stiller 54 N/mm (308 lbt/In) M Brown paint TOOLS Remarks 4’ Pin spanner A To adiust spring preload. Fork Sprlng 4.59 N/mm (26.21 Ibffin) (two spanners required) _\ 7 Standard (V, Workstand v For maintenance No mark (factory products) Air gauge For checking tyre air pressure , 2 scribe marks Optional 4.40 N/mm (25.12 Ibffin) Softer No mark Stiller 4.80 N/mm (27.41 Ibffin) 158 Technical lnfarmalian / //"R\ 1,; gé‘ 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. (x @i, e, ri l as /i,\ \1/ /i,\ \1/ l i. /\ \/ Spare Parts & Equipment There are numerous spare parts you can take to an event to help ensure you get in a full day ofriding. In addition to the usual nuts and bolts, consider the following: Spare Parts spark plugs air cleaner (clean & oiled, sealed in a plastic bag) chain & masterlinks chain guide slider chain slider chain rollers inner tubes (front & rear) fenders footpegs fuel feed hose and retainers fuel pump filter number plate & side covers handlebar grips levers (brake & clutch) clutch lever handlebar mount clutch cable throttle assembly throttle cable shift lever brake pedal spokes (front & rear, each side) sprockets (larger & smaller than standard) assorted nuts, bolts, washers, screws, cotter pins Additional Spares fuel pump front brake master cylinder rear brake assembly wheels & tyres (front & rear, mounted) clutch discs and plates engine & transmission oil 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 tyre pressure gauge tyre irons tyre pump or air tank feeler gauge set Vernier caliper (metric) pressure/vacuum testing equipment Honda Special Tools Any special tools for your CRF purchased from your dealer. - Tensioner Stopper 070MG—0010100 Lock Nut Wrench 07WMA—K230100 Spoke Wrench 07JMA-MR60100 Spoke Wrench 070MA—KZ30100 07958—250000] 070MZ-MEN0100 070MZ-KRN0100 - Piston Base - Battery Harness - Battery Harness Adapter You can purchase the PGM-Fl setting tools [ l ], [2] and [3] from your CRF dealer. [1] Serial-USB unit assy 38880-N lC-770 [2] Data Setting Tool Application CD-ROM 38772-NX7—000 [3] Data Setting Tool Manual CD-ROM 38773-N lD-AOO Chemical Products Honda “4-STROKE MOTORCYCLE OIL” or equivalent (Engine and Transmission Oil) SAE 80 or 90 gear oil Cushion Oil 881') or Ultra CO special—IV DOT 4 Brake Fluid Drive chain lubricant. Honda Foam Air Filter Oil Honda Dielectric Grease Hand Grip Cement Honda Thread Lock Molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive) Honda White Lithium Grease Multi—Purpose Grease Rust—inhibiting Oil Cable Lubricant HONDA PRE-MIX COOLANT Urea based multi—purpose grease designed for high temperature, high pressure performance (example: EXCELITE EPZ manufactured by KYODO YUSHI, Japan or Shell Stamina EP2 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 159 Technical Information *ng Wiring Diagram ENGINE STOP SWITCH CONDENSER REGuLATOR/ FUEL PuMP MIL RECTIFIER ECM (x (x ; 7 g; 1 2 z z 3 EE “5 m ; 5% £595; “a $05 $50 ch Wm; WM; mm mm av 27 z? 3? SF BI m m cm 5qu I z : IGNITION agg>og coIL \— J-L ‘x’c ECTSENSDR msmson TPSENSDR MAPSENSOR a, SPARK nus INJECTOR FRAME '1 GfiouND NOICKPSENSOR NochPSENsoR ALTERNATOR ENGINE STOP SWITCH BI BLACK Br BROWN E It; v VELLOW 0 ORANGE PUSH 0—40 Bu BLUE Lb LIGHT BLUE FREE G GREEN Lg LIGHT GREEN COLOR Bl/W R/v R RED P PINK w WHITE Gr GRAV 160 Technical lnfarmalian / \ \1/ / \ \1/ Technical Information 161 f \ o / \ \‘T/ C E chassis. control freeplay for competition gearing... personal fit steering damper .. suspension, front. suspension, rear suspension, track conditions tyre selection, track condition after competition maintenance . air cleaner air pressure, front suspen ‘on tyre apparel, protective appearance care B basic operation before riding between heats & p brakes, fluid leve lever, front a justmen pad wear pedal heigh break-in guidelines .......................... 162 Index capacity, fuel care, appearance. chain drive.... chassis adjustments cleaner, air.... cleaning, appearance care clutch system, adjustment competition logbook . control coolant cylinder system ............... D damping adjustments fron rear steering damper. diagram, wiring drive chain.... engine, flooded .. idle speed. lacks powe number oil pinging starting .. stop button stopping does not start...... environment, protecting. F filter, air ....... fuel pump. oil flooded engine starting . fork, front suspension adjustment .. front suspension inspection oil recommendation front brake lever adjustment front suspension adjustments fuel fuel, line ..... line replacement. pump filter refueling system . tank capacity ............................................... 39 Index G M R gap, spark plug steering damper ...... suspension adjustmen maintenance, before & after competition between heats & practice component locations .. general competition. H handlebar inspection ........................ 107 O 1 oil, identification, vehicl :ggljne """"""""""""" idle knob, fast.... transmission id: spleed, engine ............................ operating instructions m “in 05 . . operation component locations .......................... 6 circuit inspection ........................ optional 131i: Sid? parts list ...................... 158 t t m ’ sprockets .................... 139 inspection, pre de instruments ............................................... P L pads, brake labels, safety .. logbook, competition parts, optiona personal fit adjustments petro petrol containing alcoho pinging, engine plug, spark pre—load, rear s pre—ride inspectio protective apparel rear suspension adjustments 127 riding, apparel ..... basic operation before important safety information. important safety precautions. S safety, a few words about. important information important precautions .. labels.. maintenance riding precaution schedule, maintenance seat ...... serial numbers Safety Messages 2 spare parts .. spark knock spark plug, maintenance .66 reading .. 135 specifications spring pre-load, rear suspension. starting, engine.... troubleshooting steering damper, adjustment guidelines. operation inspection steering stem inspection. stopping engine ....... storage. subframe . (cont’d) Index 163 Index suspension, front rea suspension adj tment. for track condition ' throttle, freeplay.. inspection . tools .. torque specificatio transporting. troubleshooting tubes, repl' in tuning tips tyres, air pr “ flat selection. re V valve clearance vehicle identification no. (VIN) W washing your motorcycle wheels wiring di gram 164 Index