Honda CRF1000, CRF1000A, CRF1000D Shop Manual
SHOP MANUAL
CRF1000/A/D
CRF1000/A/D
G
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HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
motorcycle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the motorcycle.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the motorcycle. Any error or oversight
while servicing a motorcycle can result in faulty operation, damage to the motorcycle, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service or repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the motorcycle up in the air. Any time you lift the motorcycle, either with a hoist
or a jack, make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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HOW TO USE THIS MANUAL
How To Use This Manual
This manual describes the service procedures for the CRF1000/A/D-G.
Sections 1,2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may
be required to perform service described in the following sections.
Section 4 through 24 describe parts of the motorcycle, grouped according to location.
Follow the Maintenance Schedule recommendations to ensure that the motorcycle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: September, 2015
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HOW TO USE THIS MANUAL
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NOGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
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CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
CYLINDER HEAD/VALVE/CAMSHAFT
ALTERNATOR/STARTER CLUTCH
CLUTCH/GEARSHIFT LINKAGE (CRF1000/A)
ENGINE/ELECTRICAL
DUAL CLUTCH TRANSMISSION (DCT) (CRF1000D)
1
2
3
4
5
6
7
8
9
10
11
12
13
CRANKCASE/TRANSMISSION/BALANCER
CRANKSHAFT/PISTON/CYLINDER
ENGINE REMOVAL/INSTALLATION
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSION
HYDRAULIC BRAKE
CHASSIS
ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D)
BATTERY/CHARGING SYSTEM
FRAME
LIGHTS/METERS/SWITCHES
ELECTRICAL
IMMOBILIZER SYSTEM (HISS)
WIRING DIAGRAM
INDEX
14
15
16
17
18
19
20
21
22
23
24
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MEMO
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1. GENERAL INFORMATION
1
SERVICE RULES··································· 1-2
MODEL IDENTIFICATION ······················· 1-3
SPECIFICATIONS·································· 1-5
TORQUE VALUES ······························· 1-12
LUBRICATION & SEAL POINTS ············ 1-22
SPECIAL TOOL LIST ··························· 1-24
CABLE & HARNESS ROUTING ············· 1-26
EMISSION CONTROL SYSTEMS ··········· 1-47
TECHNICAL FEATURES ······················ 1-50
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GENERAL INFORMATION
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as show in the Cable and Harness Routing (page 1-26).
9. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
ABS Anti-lock Brake System
CKP sensor Crankshaft Position sensor
DCT Dual Clutch Transmission
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECT sensor Engine Coolant Temperature sensor
EEPROM Electrically Erasable Programmable Read Only Memory
EOP sensor Engine Oil Pressure sensor
EOT sensor Engine Oil Temperature sensor
EVAP Evaporative Emission
HSTC Honda Selectable Torque Control
IACV Idle Air Control Valve
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MCS Motorcycle Communication System
MIL Malfunction Indicator Lamp
PAIR Pulse Secondary Air Injection
PCM Powertrain Control Module
PGM-FI Programmed Fuel Injection
SCS Service Check Signal
TP sensor Throttle Position sensor
TR sensor Transmission Range Sensor
VS sensor Vehicle Speed sensor
DESTINATION CODE
Throughout this manual, the following codes are used to identify individual models for each region.
DESTINATION CODE REGION
ED, IIED, IIIED European direct sales
RU, IIRU, IIIRU Russia
U, IIU, IIIU Australia, New Zealand
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CRF1000/A:
CRF1000D:
[1]
[1]
[1]
[1]
[1]
[1]
MODEL IDENTIFICATION
SERIAL NUMBERS/LABELS
GENERAL INFORMATION
The motorcycle Identification Number (V.I.N) [1] is stamped
on the right side of the steering head.
The throttle body identification number [1] is stamped on the
upper front left side of the throttle body as shown.
The engine serial number [1] is stamped on the lower back
side of the crankcase.
The color label [1] is attached on the up side of the ETC tray.
When ordering color-coded parts, always specify the
designated color code.
The registered number plate (ED, RU models) [1] is attached
on the right side of the rear frame.
The compliance label (U model only) [1] is attached on the
front side of the down tube.
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GENERAL INFORMATION
TYPES
TYPE
CODE
CRF1000 ED, IIED, IIIED – – –
CRF1000A ED, IIED, IIIED –
CRF1000D ED, IIED, IIIED –
DESTINATION
CODE
U–––
RU, IIRU, IIIRU –
U, IIU, IIIU –
RU, IIRU, IIIRU –
U, IIU, IIIU –
Manual
Transmission
Dual Clutch
Transmission
Anti-lock
Brake System
HSTC
1-4
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GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,335 mm (91.9 in)
Overall width CRF1000 875 mm (34.4 in)
CRF1000A/D 930 mm (36.6 in)
Overall height 1,475 mm (58.1 in)
Wheelbase 1,575 mm (62.0 in)
Seat height 870 mm (34.3 in)
Footpeg height 351 mm (13.8 in)
Ground clearance 250 mm (9.8 in)
Curb weight CRF1000 228 kg (503 lbs)
CRF1000A 232 kg (511 lbs)
CRF1000D 242 kg (534 lbs)
Maximum weight capacity 195 kg (430 lbs)
FRAME Frame type Semi double cradle
Front suspension Telescopic fork
Front axle travel 204 mm (8.0 in)
Rear suspension Swingarm
Rear axle travel 220 mm (8.7 in)
Front tire size 90/90-21M/C 54H
Rear tire size 150/70R18M/C 70H
Front tire brand D610F (DUNLOP)
Rear tire brand D610 (DUNLOP)
Front brake Hydraulic double disc
Rear brake Hydraulic single disc
Caster angle 27° 30’
Trail length 113 mm (4.4 in)
Fuel tank capacity 18.8 liters (4.97 US gal, 4.14 Imp gal)
ENGINE Cylinder arrangement 2 cylinders in-line, slant angle 22.5°
FUEL DELIVERY
SYSTEM
DRIVE TRAIN
(CRF1000/A)
Bore and stroke 92.0 x 75.1 mm (3.62 x 2.96 in)
Displacement 998 cm
Compression ratio 10.0 : 1
Valve train Chain driven, OHC with valve lifter and rocker arm
Intake
valve
Exhaust
valve
Lubrication system Forced pressure and dry sump
Oil pump type Trochoid
Cooling system Liquid cooled
Air filtration Viscous paper element
Engine dry weight CRF1000/A 68.2 kg (150.4 lbs)
Firing order 1 - 2
Type PGM-FI
Throttle bore 44 mm (1.73 in)
Clutch system Multi-plate, wet
Clutch operation system Cable operating
Transmission Constant mesh, 6-speeds
Primary reduction 1.733 (78/45)
Final reduction 2.625 (42/16)
Gear ratio 1st 2.866 (43/15)
Gearshift pattern Left foot operated return system,
opens at 1 mm (0.04 in) lift 5° BTDC
closes at 1 mm (0.04 in) lift 40° ABDC
opens at 1 mm (0.04 in) lift 40° BBDC
closes at 1 mm (0.04 in) lift 5° ATDC
CRF1000D 76.4 kg (168.4 lbs)
2nd 1.888 (34/18)
3rd 1.480 (37/25)
4th 1.230 (32/26)
5th 1.100 (33/30)
6th 0.968 (31/32)
3
(60.9 cu-in)
1 - N - 2 - 3 - 4 - 5 - 6
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GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN
(CRF1000D)
ELECTRICAL Ignition system Full transistorized ignition
Clutch system 2 Multi-plate wet clutches
Clutch operation system Automatic
Transmission Constant mesh, 6-speeds
Primary reduction 1.883 (81/43)
Final reduction 2.625 (42/16)
Gear ratio 1st 2.562 (41/16)
2nd 1.761 (37/21)
3rd 1.375 (33/24)
4th 1.133 (34/30)
5th 0.972 (36/37)
6th 0.882 (30/34)
Gearshift pattern Automatic and electric shift (left hand operated)
return system,
N - 1 - 2 - 3 - 4 - 5 - 6
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier FET shorted/triple phase full wave rectification
Lighting system Battery
PGM-FI SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
IAT sensor resistance (at 40°C/104°F) 1.0 – 1.3 k
Fuel injector resistance (at 20°C/68°F) 11 – 13
2 sensor heater resistance (at 20°C/68°F) 6.7 – 10.5
O
IACV resistance (at 25°C/77°F) 99 – 121
IGNITION SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug SILMAR8A9S (NGK)
Spark plug gap 0.8 – 0.9 mm (0.03 – 0.04 in)
Ignition coil primary peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
Ignition timing ("F"mark) 10° BTDC at idle
FUEL SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number GQA5A
Engine idle speed 1,200 ± 100 min-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.08 – 0.24 in)
Fuel pressure at idle 324 – 367 kPa (3.3 – 3.7 kgf/cm
Fuel pump flow (at 12 V) 319 cm3 (4.2 US oz, 4.4 Imp oz) minimum/10 seconds
PAIR control solenoid valve resistance (at 20°C/68°F) 24 – 28
2
, 47 – 53 psi)
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GENERAL INFORMATION
COOLING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and
engine
Reserve tank 0.33 liter (0.35 US qt, 0.29 Imp qt)
Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm
Thermostat Begin to open 80 – 84°C (176 – 183°F)
Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Recommended antifreeze High quality ethylene glycol antifreeze containing
Standard coolant concentration 1:1 mixture with distilled water
CRF1000/A 1.63 liters (1.72 US qt, 1.43 Imp qt)
CRF1000D 1.65 liters (1.74 US qt, 1.45 Imp qt)
2
, 16 – 20 psi)
silicate-free corrosion inhibitors
LUBRICATION SYSTEM SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Engine oil
capacity
Recommended engine oil Honda "4-stroke motorcycle oil" or an
Oil pressure (at oil filter cartridge) 499 – 637 kPa (5.1 – 6.5 kgf/cm
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
CRF1000/A After draining 3.9 liter (4.1 US qt, 3.4 Imp qt) –
After draining/engine oil
filter change
After disassembly 4.9 liter (5.2 US qt, 4.3 Imp qt) –
CRF1000D After draining 4.0 liter (4.2 US qt, 3.5 Imp qt) –
After draining/engine oil
filter/clutch oil filter
change
After disassembly 5.2 liter (5.5 US qt, 4.6 Imp qt) –
4.1 liter (4.3 US qt, 3.6 Imp qt) –
4.2 liter (4.4 US qt, 3.7 Imp qt) –
equivalent motor oil.
API classification: SG or higher
JASO T903 standard: MA
Viscosity: SAE 10W-30
72 – 92 psi) at 5,000 min
(80°C/176°F)
-1
(rpm)/
2
,
Unit: mm (in)
–
–
CYLINDER HEAD/VALVE/CAMSHAFT SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 500 rpm 1,245 kPa (12.7 kgf/cm
Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) –
EX
Valve, valve guide Valve stem O.D. IN 5.475 – 5.490 (0.2352 – 0.2358) 5.465 (0.215)
EX 5.465 – 5.480 (0.2152 – 0.2157) 5.465 (0.214)
Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.542 (0.219)
Valve guide projection
above cylinder head
Valve seat width IN 1.1 – 1.3 (0.04 – 0.05) 1.5 (0.06)
Valve spring Free length 43.20 (1.701) 42.2 (1.97)
Valve lifter Valve lifter O.D. IN 28.978 – 28.993 (1.1409 – 1.1415) 28.97 (1.141)
Valve lifter bore I.D. IN 29.010 – 29.026 (1.1421 – 1.1428) 29.04 (1.143)
Rocker arm Arm I.D. EX 12.000 – 12.018 (0.4724 – 0.4731) 12.05 (0.474)
Shaft O.D. EX 11.977 – 11.990 (0.4715 – 0.4720) –
Camshaft Cam lobe height IN 41.240 – 41.480 (1.6236 – 1.6331) 41.21 (1.622)
Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Cylinder head warpage – 0.10 (0.004)
IN 17.7 – 18.0 (0.70 – 0.71) –
EX 17.8 – 18.1 (0.70 – 0.71) –
EX 1.3 – 1.5 (0.05 – 0.06) 1.9 (0.07)
EX 41.531 – 41.771 (1.6351 – 1.6445) 41.50 (1.634)
0.23 ± 0.02 (0.009 ± 0.001)
(between roller and cam lobe)
3
, 181 psi) –
Unit: mm (in)
–
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GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 57.749 – 57.768 (2.2736 – 2.2743) –
I.D. 44.000 – 44.016 (1.7323 – 1.7329) –
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (CRF1000/A)
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 – 20 (0.4 – 0.8) –
Clutch Spring free length 52.48 (2.066) 51.48 (2.02)
Disc thickness 3.22 – 3.38 (0.127 – 0.133) 3.0 (0.12)
Plate warpage – 0.20 (0.008)
Primary driven gear I.D. 41.958 – 41.983 (1.6519 – 1.6529) –
Clutch outer guide O.D. 34.975 – 34.991 (1.3770 – 1.3776) –
I.D. 28.000 – 28.021 (1.1024 – 1.1032) –
Mainshaft O.D. at clutch outer guide 27.967 – 27.980 (1.1011 – 1.1016) –
DUAL CLUTCH TRANSMISSION SPECIFICATIONS (CRF1000D)
Unit: mm (in)
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Shift clutch Clutch clearance 0.9 – 1.1 (0.035 – 0.043) –
Disc thickness 1.88 – 2.00 (0.074 – 0.079) worn out lining
Plate thickness 1.95 – 2.05 (0.077 – 0.081) discoloration
EOT sensor resistance (20°C/68°F) 2.5 – 2.8 k –
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (CRF1000/A)
ITEM STANDARD SERVICE LIMIT
Transmission Gear I.D. M5, M6 31.000 – 31.025 (1.2205 – 1.2215) –
C1 25.000 – 25.021 (1.3780 – 1.3789) –
C2, C3, C4 33.000 – 33.025 (1.2992 – 1.3002) –
Shift fork,
fork shaft
Gear bushing
O.D.
Gear bushing I.D. M5 27.985 – 28.006 (1.1018 – 1.1026) –
Mainshaft O.D. at M5 27.967 – 27.980 (1.1011 – 1.1016) –
Countershaft
O.D.
Fork I.D. 12.000 – 12.018 (0.4724 – 0.4731) –
Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.83 (0.230)
Shift fork shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) –
M5 30.955 – 30.980 (1.2187 – 1.2197) –
M6 30.950 – 30.975 (1.2185 – 1.2195) –
C1 24.959 – 24.980 (0.9826 – 0.9835) –
C2 32.955 – 32.980 (1.2974 – 1.2984) –
C3, C4 32.950 – 32.975 (1.2972 – 1.2682) –
C1 21.985 – 22.006 (0.8655 – 0.8664) –
C2 29.985 – 30.006 (1.1805 – 1.1813) –
at C1 21.987 – 22.000 (0.8656 – 0.8661) –
at C2 29.967 – 29.980 (1.1798 – 1.1803) –
Unit: mm (in)
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GENERAL INFORMATION
CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS (CRF1000D)
ITEM STANDARD SERVICE LIMIT
Transmission Gear I.D. M5 35.000 – 35.025 (1.3780 – 1.3789) –
M6 43.000 – 43.025 (1.6929 – 1.6939) –
C1 35.000 – 35.025 (1.3780 – 1.3789) –
C2 25.000 – 25.021 (0.9843 – 0.9851) –
C3, C4 33.000 – 33.025 (1.2992 – 1.3002) –
Gear bushing O.D. M5 34.950 – 34.975 (1.3760 – 1.3770) –
M6 42.950 – 42.975 (1.6909 – 1.6919) –
C1 34.950 – 34.975 (1.3760 – 1.3770) –
C2 24.959 – 24.980 (0.9826 – 0.9835) –
C3, C4 32.950 – 32.975 (1.2972 – 1.2982) –
Gear bushing I.D. M5 32.000 – 32.025 (1.2598 – 1.2608) –
M6 40.007 – 40.028 (1.5751 – 1.5759) –
C1 30.000 – 30.021 (1.1811 – 1.2067) –
C2 21.985 – 22.006 (0.8655 – 0.8664) –
Inner mainshaft O.D. M5 31.957 – 31.970 (1.2581 – 1.2587) –
Outer mainshaft O.D. M6 39.975 – 39.991 (1.5738 – 1.5744) –
Countershaft O.D. C1 29.967 – 29.980 (1.1798 – 1.1803) –
C2 21.987 – 22.000 (0.8656 – 0.8661) –
Shift fork I.D. 12.000 – 12.018 (0.4724– 0.4731) –
Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.83 (0.230)
Shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) –
Unit: mm (in)
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.20 (0.004 – 0.008) 0.35 (0.014)
Runout – 0.05 (0.002)
Main journal bearing oil clearance 0.019 – 0.038 (0.0007 – 0.0015) 0.05 (0.002)
Crankpin bearing oil clearance 0.027 – 0.045 (0.0011 – 0.0018) 0.065 (0.0026)
Cylinder I.D. 92.000 – 92.015 (3.6220 – 3.6226) 92.10 (3.626)
Piston,
pis-ton pin,
piston ring
Connecting rod small end I.D. 22.030 – 22.044 (0.8673 – 0.8679) 22.054 (0.8683)
Piston O.D. at 12 mm (0.5 in) from
bottom
Piston pin hole I.D. 22.002 – 22.008 (0.8662 – 0.8665) 22.02 (0.867)
Piston pin O.D. 21.994 – 22.000 (0.8659 – 0.8661) 21.98 (0.865)
Piston ring end gap Top 0.15 – 0.30 (0.006 – 0.012) 0.40 (0.016)
Second 0.45 – 0.60 (0.018 – 0.024) 0.70 (0.028)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.90 (0.035)
Piston ring-to-ring
groove clearance
Top 0.030 – 0.060 (0.0012 – 0.0024) –
Second 0.030 – 0.060 (0.0012 – 0.0024) –
91.981 – 91.996 (3.6213 – 3.6218) 91.89 (3.618)
1-9
dummyheaddummyhead
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire
pressure
Axle runout – 0.2 (0.01)
Wheel rim
runout
Wheel hub-to-rim distance 28.5 – 30.5 (1.12 – 1.20) –
Wheel balance weight – 60 g (2.1 oz) max.
Fork Spring free length 433.7 (17.07) 425.0 (16.73)
Steering head bearing pre-load 9.8 – 14.7 N (1.0 – 1.5 kgf, 2.2 – 3.3 lbf) –
Driver only 200 kPa (2.00 kgf/cm
Driver and passenger 200 kPa (2.00 kgf/cm2, 29 psi) –
Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Recommended fork fluid Honda Ultra Cushion Oil 10W (SS-47) –
Fluid level 95.0 (3.74) –
Fluid capacity 721 ± 2.5 cm
25.4 ± 0.1 Imp oz)
Pre-load adjuster
standard position
Rebound adjuster standard position 2 1/4 turns from maximum position –
Compression adjuster standard position 8 clicks from maximum position –
CRF1000/A 5 turns from the full soft position –
CRF1000D 8.5 turns from the full soft position –
3
(24.4 ± 0.1 US oz,
2
, 29 psi) –
–
REAR WHEEL/SUSPENSION SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cold tire pressure Driver only 250 kPa (2.50 kgf/cm2, 36 psi) –
Driver and passenger 280 kPa (2.80 kgf/cm2, 41 psi) –
Axle runout – 0.2 (0.01)
Wheel rim runout Radial – 1.0 (0.04)
Axial – 1.0 (0.04)
Wheel hub-to-rim distance 5.2 – 7.2 (0.205 – 0.283) –
Wheel balance weight – 60 g (2.1 oz) max.
Drive chain Slack 35 – 45 (1.4 – 1.8) –
Size/link DID525HV3-124LE –
Shock absorber Pre-load adjuster standard
position
Rebound adjuster standard
setting
Compression adjuster
standard position
7 clicks from maximum position
(first click is "0" position)
11 clicks from maximum position
14 clicks from maximum position –
–
–
HYDRAULIC BRAKE SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Front Specified brake fluid DOT 4 brake fluid –
Brake disc thickness 4.5 ± 0.1 (0.18 ± 0.004) 3.5 (0.14)
Brake disc warpage – 0.20 (0.008)
Master cylinder I.D. 14.000 – 14.043 (0.5512 – 0.5529) –
Master piston O.D. 13.957 – 13.984 (0.5495 – 0.5506) –
Caliper cylinder
I.D.
Caliper piston
O.D.
Rear Specified brake fluid DOT 4 brake fluid –
Master cylinder push rod length 83.0 – 85.0 (3.28 – 3.35) –
Brake disc thickness 6.0 ± 0.2 (0.24 ± 0.008) 5.0 (0.20)
Brake disc warpage – 0.30 (0.012)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) –
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) –
Caliper cylinder I.D. 38.18 – 38.23 (1.503 – 1.505) –
Caliper piston O.D. 38.098 – 38.148 (1.4999 – 1.5019) –
Upper 30.230 – 30.280 (1.1902 – 1.1921) –
Lower 27.000 – 27.050 (1.0630 – 1.0650) –
Upper 30.148 – 30.198 (1.1869 – 1.1889) –
Lower 26.918 – 26.968 (1.0598 – 1.0617) –
1-10
dummyheaddummyhead
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Type YTZ14S
Capacity 12 V – 11.2 Ah (10 HR)/11.8 Ah (20 HR)
Current leakage 0.66 mA max.
Voltage
(20°C/68°F)
Charging current Normal 1.1 A/5 – 10 h
Alternator Capacity 0.49 kW/5,000 min
Charging coil resistance (20°C/68°F) 0.1 – 1.0
Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Quick 5.5 A/h
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight Hi LED
Lo LED
Brake/taillight LED
Position light LED
Front turn signal/position light (CRF1000) 12 V – 21/5 W x 2
Front turn signal light (CRF1000A/D) LED
Rear turn signal light CRF1000 12 V – 21 W x 2
CRF1000A/D LED
License light 12 V – 5 W
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
Low oil pressure indicator LED
Fuel reserve indicator LED
MIL LED
High coolant temperature indicator LED
HISS indicator LED
ABS indicator (CRF1000A/D) LED
Rear ABS indicator (CRF1000A/D) LED
Parking brake indicator (CRF1000D) LED
Torque control indicator (CRF1000A/D) LED
Torque control off indicator (CRF1000A/D) LED
Fuse Main fuse 30 A
FI fuse 15 A
ABS MAIN fuse (CRF1000A/D) 30 A
DCT M fuse (CRF1000D) 30 A
Sub fuse CRF1000 20 A x 1, 10 A x 1, 7.5 A x 5
CRF1000A 20 A x 1, 10 A x 1, 7.5 A x 6
CRF1000D 20 A x 1, 10 A x 1, 7.5 A x 7
ECT sensor resistance 40°C (104°F) 1.0 – 1.3 k
100°C (212°F) 0.14 – 0.18 k
Open air temperature sensor resistance 25°C (77°F) 4.9 – 5.1 k
Fuel level sensor resistance Full 6.4 – 10.4
Empty 204.8 – 210.8
GENERAL INFORMATION
-1
(rpm)
1-11
dummyheaddummyhead
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE
FASTENER TYPE
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm bolt (Include SH flange bolt)
and nut
8 mm bolt and nut 22 (2.2, 16)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
N·m (kgf·m,
lbf·ft)
10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
6 mm flange bolt (Include NSHF) and
nut
FASTENER TYPE
TORQUE
N·m (kgf·m,
lbf·ft)
12 (1.2, 9)
ENGINE & FRAME TORQUE VALUES
FRAME BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY
Windscreen mounting screw 4 5 0.42 (0.04, 0.3)
Skid plate mounting bolt 3 8 26 (2.7, 19)
Left rear cover mounting bolt 2 6 12 (1.2, 9)
Brake hose oil bolt (CRF1000A/D) 2 10 34 (3.5, 25)
Brake pipe joint nut (CRF1000A/D) 2 10 14 (1.4, 10) Apply brake fluid to the threads.
Exhaust pipe cover C pan screw 3 6 9.0 (0.9, 6.6)
Exhaust outer cover screw 1 6 9.0 (0.9, 6.6)
Exhaust pipe joint nut 4 8 20 (2.0, 15)
Exhaust pipe cover A pan screw 1 6 9.0 (0.9, 6.6)
Exhaust pipe cover B band screw 1 – 3.5 (0.4, 2.6)
Muffler band bolt 2 8 17 (1.7, 13)
Muffler cover pan screw 2 6 9.0 (0.9, 6.6)
Tail cap cover bolt 2 6 9.0 (0.9, 6.6)
Exhaust pipe stud bolt 4 8 – See page 2-18
Sidestand pivot bolt 1 10 10 (1.0, 7) See page 2-19
Sidestand pivot nut 1 10 29 (3.0, 21) See page 2-19
DIA. (mm)
N·m (kgf·m,
lbf·ft)
U-nut
REMARKS
1-12
dummyheaddummyhead
GENERAL INFORMATION
MAINTENANCE
THREAD TORQUE
ITEM Q'TY
Throttle cable adjuster lock nut
(throttle grip side)
Throttle cable A lock nut
(throttle body side)
Air cleaner element mounting screw 4 5 1.1 (0.1, 0.8) Tapping screw
Air cleaner cover screw 8 5 1.1 (0.1, 0.8) Tapping screw
Spark plug 4 10 22 (2.2, 16)
Valve adjusting screw lock nut 4 5 10 (1.0, 7) Apply engine oil to the threads and
Timing hole cap 1 14 6.0 (0.6, 4.4) Apply grease to the threads.
Crankshaft hole cap 1 30 8.0 (0.8, 5.9) Apply grease to the threads.
Engine oil drain bolt 2 12 30 (3.1, 22)
Oil filter boss (crankcase side) 1 20 – Apply locking agent to the threads.
Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.
Clutch oil filter cover bolt
(CRF1000D)
Rear axle nut 1 18 100 (10.2, 74) U-nut
Drive chain adjuster lock nut 2 8 27 (2.8, 20) UBS-nut
Drive sprocket bolt 1 10 54 (5.5, 40)
Driven sprocket nut 5 12 100 (10.2, 74) U-nut
Parking brake adjuster lock nut
(CRF1000D)
Front spoke 36 BC 3.5 3.7 (0.4, 2.7)
Rear spoke 32 BC 3.5 3.7 (0.4, 2.7)
1 7 3.8 (0.4, 2.8)
1 8 8.5 (0.9, 6.3)
2 6 12 (1.2, 9)
1 8 17.2 (1.8, 13)
DIA. (mm)
N·m (kgf·m,
lbf·ft)
seating surface.
See page 3-12
REMARKS
PGM-FI SYSTEM
THREAD TORQUE
ITEM Q'TY
ECT sensor 1 10 12 (1.2, 9)
IAT sensor mounting screw 2 5 1.1 (0.1, 0.8)
O
2 sensor 1 12 24.5 (2.5, 18)
PAIR reed valve cover bolt 2 6 12 (1.2, 9)
ELECTRIC STARTER
ITEM Q'TY
Starter motor setting bolt 2 5 4.9 (0.5, 3.6)
Starter cable terminal nut/washer 1 6 10 (1.0, 7)
Negative brush mounting screw/
washer
1 5 3.7 (0.4, 2.7)
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
N·m (kgf·m,
lbf·ft)
REMARKS
REMARKS
1-13
dummyheaddummyhead
GENERAL INFORMATION
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY
Fuel filler cap bolt 3 4 1.8 (0.2, 1.3)
Fuel pump/reserve sensor terminal
screw
Fuel pump mounting nut 5 6 12 (1.2, 9) See page 7-10
Fuel pump mounting cap nut 1 6 12 (1.2, 9) See page 7-10
Connecting hose band screw 2 4 1.5 (0.2, 1.1) See page 7-12
IACV holder screw 3 5 3.4 (0.3, 2.5)
Throttle cable A/B lock nut
(throttle body side)
Insulator band screw
(throttle body side)
IACV setting plate screw 2 4 2.1 (0.2, 1.5)
Fuel injector assembly mounting bolt 4 5 5.1 (0.5, 3.8)
PAIR reed valve cover bolt 2 6 12 (1.2, 9)
COOLING SYSTEM
ITEM Q'TY
Coolant drain bolt 1 6 13 (1.3, 10)
Thermostat cover bolt 2 6 12 (1.2, 9)
Fan motor shroud bolt 6 6 8.5 (0.9, 6.3)
Cooling fan mounting nut 2 3 1.0 (0.1, 0.7) Apply locking agent to the threads.
Fan motor mounting screw 6 4 2.7 (0.3, 2.0)
Water pump cover bolt 4 6 13 (1.3, 10) Apply locking agent to the threads.
2 4 1.0 (0.1, 0.7)
2 8 8.5 (0.9, 6.3)
2 – – See page 7-15
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
N·m (kgf·m,
lbf·ft)
(*1) See page 1-20
REMARKS
REMARKS
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY
Engine oil filter cartridge 1 20 26 (2.7, 19) Apply engine oil to the threads.
Sealing bolt (22 mm) 1 22 30 (3.1, 22) Apply locking agent to the threads.
Sealing bolt (24 mm) (CRF1000D) 1 24 30 (3.1, 22) Apply locking agent to the threads.
Oil pump flange bolt 6 6 12 (1.2, 9)
Oil pump mounting bolt 3 6 16 (1.6, 12)
CYLINDER HEAD/VALVE/CAMSHAFT
ITEM Q'TY
Cylinder head cover bolt 3 6 10 (1.0, 7)
Rocker arm shaft bolt 2 6 12 (1.2, 9) Apply engine oil to the threads and
Rocker arm shaft stopper bolt 1 14 18 (1.8, 13)
Camshaft holder bolt 6 6 12 (1.2, 9) Apply engine oil to the threads and
Cam sprocket bolt 2 7 20 (2.0, 15) Apply locking agent to the threads.
Cylinder head bolt 6 12 83 (8.5, 61) Apply molybdenum oil solution to
Insulator band screw (engine side) 2 – – See page 10-19
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
(*2) See page 1-21
(*2) See page 1-21
N·m (kgf·m,
lbf·ft)
seating surface.
seating surface.
(*2) See page 1-21
the threads and seating surface.
Apply engine oil solution to the
washer.
REMARKS
REMARKS
1-14
dummyheaddummyhead
GENERAL INFORMATION
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM Q'TY
Alternator cover bolt 12 6 12 (1.2, 9)
Stator mounting bolt 5 6 12 (1.2, 9) Apply locking agent to the threads.
CKP sensor mounting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
Flywheel mounting bolt 1 12 137 (14.0, 101) Apply engine oil to the threads and
Starter clutch torx bolt 6 8 29 (3.0, 21) Apply locking agent to the threads.
CLUTCH/GEARSHIFT LINKAGE (CRF1000/A)
ITEM Q'TY
Right crankcase cover bolt 15 6 12 (1.2, 9)
Engine right side rear cover bolt 2 6 10 (1.0, 7)
Clutch center nut 1 25 128 (13.1, 94) Apply engine oil to the threads and
Clutch set plate bolt 3 6 12 (1.2, 9)
Primary drive gear mounting bolt 1 10 103 (10.5, 76) Apply engine oil to the threads and
Cam chain tensioner pivot bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
Shift drum center bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
Gearshift spindle set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
Gearshift spindle cover bolt 2 6 12 (1.2, 9)
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
(*1) See page 1-20
(*1) See page 1-20
seating surface.
(*2) See page 1-21
N·m (kgf·m,
lbf·ft)
seating surface.
seating surface.
(*1) See page 1-20
(*1) See page 1-20
(*1) See page 1-21
(*1) See page 1-20
REMARKS
REMARKS
1-15
dummyheaddummyhead
GENERAL INFORMATION
DUAL CLUTCH TRANSMISSION (CRF1000D)
THREAD TORQUE
ITEM Q'TY
Feed pipe guide plate bolt 2 5 5 (0.5, 3.7)
Feed pipe cover bolt 3 6 12 (1.2, 9)
Right crankcase cover bolt 15 6 12 (1.2, 9)
Water pipe mounting bolt 2 6 12 (1.2, 9)
Clutch EOP sensor wire stay bolt 1 6 12 (1.2, 9)
Clutch EOP sensor cover socket bolt 2 6 10 (1.0, 7)
Shift spindle angle sensor mounting
bolt
Engine right side rear cover bolt 2 6 10 (1.0, 7)
Linear solenoid valve body cover
bolt
Linear solenoid valve stopper plate
bolt
Linear solenoid valve body mounting
bolt
Primary drive gear mounting nut
(left-hand thread)
Reduction gear cover torx bolt 3 6 14 (1.4, 10)
Shift control motor mounting torx bolt 3 6 14 (1.4, 10)
Shift control motor cover bolt 2 6 12 (1.2, 9)
Shift drum center bolt 1 8 31 (3.2, 23) Apply locking agent to the threads.
Drum shifter guide plate/drum shifter
assembly mounting bolt
TR sensor mounting bolt 1 6 12 (1.2, 9)
No.1/No.2 clutch EOP sensor 2 10 20 (2.0, 15)
Clutch line EOP sensor 1 10 20 (2.0, 15)
EOT sensor 1 10 15 (1.5, 11) Apply engine oil to the threads and
Neutral switch 1 10 12 (1.2, 9)
Neutral switch terminal nut 1 4 1.7 (0.2, 1.3)
1 6 12 (1.2, 9)
4 6 12 (1.2, 9)
1 6 12 (1.2, 9) Apply locking agent to the threads.
4 6 12 (1.2, 9)
1 22 118 (12.0, 87) Apply engine oil to the threads and
2 6 12 (1.2, 9) Apply locking agent to the threads.
DIA. (mm)
N·m (kgf·m,
lbf·ft)
(*1) See page 1-20
seating surface.
(*2) See page 1-21
(*1) See page 1-20
seating surface.
REMARKS
CRANKCASE/TRANSMISSION/BALANCER
THREAD TORQUE
ITEM Q'TY
Front balancer right bearing set plate
bolt
Front balancer gear bolt 1 10 103 (10.5, 76) Apply engine oil to the threads and
Oil pump driven gear set plate bolt 1 6 12 (1.2, 9) Apply locking agent to the threads.
Rear balancer shaft holder bolt 3 8 29 (3.0, 21)
Mainshaft bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent to the threads.
Shift drum bearing setting bolt 2 6 12 (1.2, 9) Apply locking agent to the threads.
Main journal bolt 6 10 43 (4.4, 32) Apply molybdenum oil solution to
Crankcase 6 x 40 mm bolt 1 6 12 (1.2, 9) Blue paint
Crankcase 8 mm bolt 9 8 24 (2.4, 18)
Crankcase 10 mm bolt 1 10 39 (4.0, 29)
Cam chain tensioner bolt 1 8 23 (2.3, 17) Apply locking agent to the threads.
3 6 12 (1.2, 9) Apply locking agent to the threads.
DIA. (mm)
N·m (kgf·m,
lbf·ft)
(*1) See page 1-20
seating surface.
(*1) See page 1-20
(*1) See page 1-20
(*1) See page 1-20
the threads and seating surface.
(*1) See page 1-20
REMARKS
1-16
dummyheaddummyhead
GENERAL INFORMATION
CRANKSHAFT/PISTON/CYLINDER
THREAD TORQUE
ITEM Q'TY
Crankpin bearing cap bolt (new) 4 9 22 (2.2, 16) + 120° Apply engine oil to the threads and
Main journal bolt 6 10 43 (4.4, 32) Apply molybdenum oil solution to
Crankpin bearing cap bolt
(retightening)
ENGINE REMOVAL/INSTALLATION
ITEM Q'TY
Right lower frame bolt 4 10 44 (4.5, 32)
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
Rear lower nut (10 mm) 1 10 44 (4.5, 32)
Front lower nut (10 mm) 1 10 44 (4.5, 32)
Front middle nut (8 mm) 2 8 32 (3.3, 24)
Front middle nut (10 mm) 1 10 44 (4.5, 32)
Front upper bolt 3 8 32 (3.3, 24)
Rear upper bolt (8 x 25 mm) 2 8 32 (3.3, 24)
Rear upper nut (8 mm) 1 8 32 (3.3, 24)
Drive sprocket bolt 1 10 54 (5.5, 40)
EOT sensor (CRF1000D) 1 10 15 (1.5, 11)
Clutch EOP sensor wire stay bolt
(CRF1000D)
Clutch EOP sensor cover socket bolt
(CRF1000D)
4 9 22 (2.2, 16) + 90° Apply engine oil to the threads and
1 6 12 (1.2, 9)
2 6 10 (1.0, 7)
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
seating surface.
Replace with a new one.
the threads and seating surface.
seating surface.
N·m (kgf·m,
lbf·ft)
seating surface.
U-nut
REMARKS
REMARKS
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY
Handlebar weight bolt 2 18 55 (5.6, 41) ALOC bolt: replace with new ones.
Lower handlebar holder mounting
nut
Upper handlebar holder socket bolt 4 8 32 (3.3, 24)
Left handlebar switch housing
screw/washer
Right handlebar switch housing
screw/washer
Front brake master cylinder holder
bolt
Pulser ring bolt (CRF1000A/D) 3 5 7 (0.7, 5.2) ALOC bolt: replace with new ones.
Front brake disc bolt 12 6 20 (2.0, 15) ALOC bolt: replace with new ones.
Front axle holder pinch bolt 4 8 22 (2.2, 16)
Front axle nut 1 16 60 (6.1, 44)
Fork bolt 2 – 35 (3.6, 26)
Fork damper lock nut 2 10 20 (2.0, 15)
Fork socket bolt 2 – 34 (3.5, 25)
Fork bottom bridge pinch bolt 4 8 25 (2.5, 18)
Fork top bridge pinch bolt 4 8 22 (2.2, 16)
Front brake hose clamp mounting
bolt
Steering stem adjusting nut 1 26 15 (1.5, 11) See page 17-26
Steering stem nut 1 24 100 (10.2, 74) See page 17-26
2 10 39 (4.0, 29) U-nut
2 5 2.5 (0.3, 1.8)
2 5 2.5 (0.3, 1.8)
2 6 9.8 (1.0, 7.2)
1 6 10 (1.0, 7)
DIA. (mm)
N·m (kgf·m,
lbf·ft)
REMARKS
1-17
dummyheaddummyhead
GENERAL INFORMATION
REAR WHEEL/SUSPENSION
THREAD TORQUE
ITEM Q'TY
Rear brake disc bolt 6 8 42 (4.3, 31) ALOC bolt: replace with new ones.
Driven sprocket nut 5 12 100 (10.2, 74) Apply engine oil to the threads and
Pulser ring bolt (CRF1000A/D) 4 5 7 (0.7, 5.2) ALOC bolt: replace with new ones.
Rear axle nut 1 18 100 (10.2, 74) U-nut
Rear shock absorber upper
mounting nut
Rear shock absorber lower mounting
nut
Lower cushion arm nut 1 10 55 (5.6, 41) U-nut
Upper cushion arm nut 1 12 74 (7.5, 55) U-nut
Cushion connecting rod mounting
nut
Drive chain slider screw 3 5 4.2 (0.4, 3.1) ALOC screw: replace with new
Drive chain guard bolt 2 6 10 (1.0, 7) ALOC bolt: replace with new ones.
Swingarm pivot nut 1 16 80 (8.2, 59) Apply engine oil to the threads and
Parking cable guide bolt
(CRF1000D)
Rear brake hose clamp mounting
bolt
Rear brake hose guide mounting
screw
2 10 54 (5.5, 40) U-nut
2 10 44 (4.5, 32) U-nut
1 10 45 (4.6, 33) Apply engine oil to the threads and
1 6 10 (1.0, 7)
1 6 10 (1.0, 7)
3 5 1.2 (0.1, 0.9) ALOC screw: replace with new
DIA. (mm)
N·m (kgf·m,
lbf·ft)
seating surface.
U-nut
seating surface.
U-nut
ones.
seating surface.
U-nut
ones.
REMARKS
1-18
dummyheaddummyhead
GENERAL INFORMATION
HYDRAULIC BRAKE
THREAD TORQUE
ITEM Q'TY
Brake caliper bleed valve 3 8 5.4 (0.6, 4.0)
Front brake master cylinder reservoir
cap screw
Rear brake master cylinder reservoir
cap screw
Rear brake master cylinder reserve
tank mounting bolt
Front brake caliper mounting bolt 4 10 45 (4.6, 33) ALOC bolt: replace with a new
Rear brake caliper mounting bolt 1 8 22 (2.2, 16) ALOC bolt: replace with a new
Rear brake pad pin 1 10 17 (1.7, 13)
Parking brake caliper mounting bolt
(CRF1000D)
Parking brake caliper cover socket
bolt (CRF1000D)
Parking brake pad pin (CRF1000D) 2 8 17.2 (1.8, 13) ALOC bolt: replace with a new
Front brake master cylinder holder
bolt
Brake hose oil bolt 5 10 34 (3.5, 25)
Front brake light switch mounting
screw
Front brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Front brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Step bracket mounting bolt 4 10 35 (3.6, 26)
Rear brake master cylinder
mounting bolt
Rear brake master cylinder hose
joint screw
Rear brake master cylinder push rod
lock nut
Parking brake lever pivot bolt
(CRF1000D)
Parking brake lever pivot nut
(CRF1000D)
Parking brake lock lever pivot bolt
(CRF1000D)
Parking brake stopper stay flange
bolt (CRF1000D)
Parking brake stopper stay HEX bolt
(CRF1000D)
Parking brake switch mounting
screw (CRF1000D)
Parking brake adjuster lock nut
(CRF1000D)
Parking brake caliper pin bolt
(CRF1000D)
2 4 1.5 (0.2, 1.1)
2 4 1.5 (0.2, 1.1)
1 6 10 (1.0, 7)
2 8 31 (3.2, 23) ALOC bolt: replace with a new
2 6 9 (0.9, 6.6)
2 6 9.8 (1.0, 7.2)
1 4 1.2 (0.1, 0.9)
2 6 14 (1.4, 10)
1 4 1.5 (0.2, 1.1) Apply locking agent to the threads.
1 8 17.2 (1.8, 13)
1 6 1.0 (0.1, 0.7)
1 6 5.9 (0.6, 4.4)
1 6 6.9 (0.7, 5.1)
1 6 11.9 (1.2, 9)
1 4 2.3 (0.2, 1.7)
1 4 1.2 (0.1, 0.9) Apply locking agent to the threads.
1 8 17.2 (1.8, 13)
1 8 22 (2.2, 16)
DIA. (mm)
N·m (kgf·m,
lbf·ft)
one.
one.
one.
one.
(*1) See page 1-20
REMARKS
1-19
dummyheaddummyhead
2.0 ± 1.0 mm
(0.08 ± 0.04 in)
Do not apply this area.
6.5 ± 1.0 mm
(0.26 ± 0.04 in)
Apply this area.
The bolt shown is typical.
GENERAL INFORMATION
ANTI-LOCK BRAKE SYSTEM (ABS) (CRF1000A/D)
THREAD TORQUE
ITEM Q'TY
Front brake hose clamp mounting
bolt
Rear brake hose clamp mounting
bolt
Rear brake hose guide mounting
screw
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake pipe joint nut 2 10 14 (1.4, 10) Apply brake fluid to the threads.
Front wheel speed sensor mounting
bolt
Rear wheel speed sensor mounting
bolt
LIGHTS/METERS/SWITCHES
ITEM Q'TY
Turn signal light mounting nut
(CRF1000)
License light cover screw 2 5 3.8 (0.4, 2.8)
Combination meter mounting screw/
washer
EOP switch (CRF1000/A) 1 PT 1/8 12 (1.2, 9) Apply sealant to the threads.
EOP switch terminal bolt/washer
(CRF1000/A)
EOP sensor (CRF1000D) 1 10 22 (2.2, 16)
Ignition switch mounting bolt 2 8 26 (2.7, 19) Replace with a new one.
Gear position switch mounting bolt
(CRF1000/A)
Sidestand switch mounting bolt 1 6 10 (1.0, 7) Replace with a new one.
1 6 10 (1.0, 7)
1 6 10 (1.0, 7)
3 5 1.2 (0.1, 0.9) ALOC screw: replace with new
1 6 10 (1.0, 7) ALOC bolt: replace with a new
1 6 10 (1.0, 7) ALOC bolt: replace with a new
4 6 8.8 (0.9, 6.5)
4 5 1.0 (0.1, 0.7) Tapping screw
1 4 2 (0.2, 1.5)
1 6 10 (1.0, 7)
DIA. (mm)
THREAD TORQUE
DIA. (mm)
N·m (kgf·m,
lbf·ft)
ones.
one.
one.
N·m (kgf·m,
lbf·ft)
See page 22-20
REMARKS
REMARKS
OTHERS
THREAD TORQUE
ITEM Q'TY
Clutch lever pivot bolt (CRF1000/A) 1 6 1.0 (0.1, 0.7)
Clutch lever pivot nut (CRF1000/A) 1 6 5.9 (0.6, 4.4) U-nut
Pillion step bracket mounting bolt 4 8 34 (3.5, 25)
Throttle cable A/B nut
(switch housing side)
*1: Apply locking agent to the threads as shown.
2 10 1.5 (0.2, 1.1)
DIA. (mm)
N·m (kgf·m,
lbf·ft)
REMARKS
1-20
dummyheaddummyhead
6.5 ± 1.0 mm
(0.26 ± 0.04 in)
The bolt shown is typical.
Apply this area.
*2: Apply locking agent to the threads as shown.
GENERAL INFORMATION
1-21
dummyheaddummyhead
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARKS
Sealant
(TB1207B manufactured by
ThreeBond or an equivalent)
Sealant
(TB5211C manufactured by
ThreeBond, KE45T
manufactured by Shin-Etsu
Silicone or an equivalent)
Molybdenum oil solution
(a mixture of 1/2 engine oil
and 1/2 molybdenum
disulfide grease)
Engine oil Valve adjusting screw threads
Lithium based multi-purpose
grease NLGI #2 or equivalent
Locking agent Cam chain guide plate bolt threads Coating width;
UNIREX N3 manufactured by
ExxonMobil or equivalent
Crankcase mating surface See page 14-27
Alternator cover mating surface See page 11-6
CKP sensor wire grommet See page 11-7
Right crankcase cover mating surface CRF1000/A: See page 12-6
CRF1000D: See page 13-55
Linear solenoid valve wire grommet See page 13-61
Cylinder head cover packing See page 10-5
Rocker arm sliding area and thrust surface
Rocker arm shaft outer surface
Camshaft journals cam lobes, and thrust surface
Valve stem sliding area and stem end
Starter reduction gears shaft outer surfaces
Clutch outer guide entire surface (CRF1000/A)
Primary driven gear teeth and clutch outer sliding surface
(CRF1000/A)
Judder spring and judder spring seat entire surface
(CRF1000/A)
Primary drive gear sliding surface
Primary driven gear teeth, friction springs, and boss
sliding area (dual clutch assembly, CRF1000D)
Front balancer driven gear sliding area and thrust surface
Rear balancer driven gear, sub driven gear, friction
spring, and washer sliding surface
Rear balancer thrust spring sliding surface
Rear balancer driven gear sliding area and thrust surface
Oil pump driven gear shaft outer surface
Each transmission bushing inner/outer surface
Each transmission needle bearing inner/outer surface
Each transmission spline bushing outer surface
M3, M4, C5, C6 gear
(shift fork grooves and spline area)
Shift fork shaft outer surface
Main journal bearing sliding surface
Crankshaft thrust surface
Crankpin bearing sliding surface
Connecting rod small end inner surface
Piston pin outer surface
Oil strainer seal ring entire surface
Starter one-way clutch sliding surface
Clutch discs entire surface
Dual clutch assembly O-ring entire surface (CRF1000D)
Piston pin hole inner surface
Piston sliding surface
Piston ring groove
Piston ring entire surface
Each bearing rolling area and contact surface
Each gear teeth and rotating surface
Each O-ring entire surface
Other rotating area and sliding surface
Each oil seal lips
See page 1-20
Shift reduction gear teeth and journal (CRF1000D) 2 – 4 g (0.07 – 0.14 oz)
1-22
dummyheaddummyhead
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Urea based multi-purpose
extreme pressure grease
NLGI #2 (EXCELITE EP2
manufactured by KYODO
YUSHI CO., LTD. or
equivalent)
Lithium based multi-purpose
grease NLGI #2 or equivalent
Molybdenum disulfide grease
(containing more than 3%
molybdenum disulfide, NLGI
#2 or equivalent)
Cable lubricant Seat lock cable outer inside
Honda Bond A or an
equivalent
ThreeBond 1521 or an
equivalent
Silicone grease Front brake lever pivot bolts sliding surface 0.10 g (0.004 oz) minimum
DOT 4 brake fluid Brake master piston and cups
Fork fluid Fork cap O-ring
Dive chain lubricant designed
specifically for O-ring chains
or SAE #80-90 gear oil
Steering head bearing rolling contact surface 3 – 5 g (0.1 – 0.2 oz)
Steering head dust seal lips
Seat catch hook sliding area
Gearshift pedal pivot sliding area (grease groove)
(CRF1000/A)
Throttle cable end and throttle grip pipe flange groove
Wheel dust seal lips
Rear wheel hub O-ring (driven flange side)
Rear brake middle arm pivot sliding surface
Parking brake stopper stay teeth and lock lever pivot
sliding surface (CRF1000D)
Parking brake lever pivot sliding surface (CRF1000D)
Clutch lever pivot sliding area (CRF1000/A)
Sidestand collar outer surface
Sidestand pivot sliding surface
Swingarm pivot dust seal lips
Swingarm pivot needle bearings
Cushion arm dust seal lips
Cushion arm needle bearings
Cushion connecting rod needle bearings
Handlebar grip rubber inside
Swingarm cap mating surface
Rear brake pad retainer mating surface
Front brake lever-to-master piston contacting area 0.10 g (0.004 oz) minimum
Rear brake master cylinder push rod sliding surface 0.10 g (0.004 oz) minimum
Rear brake master cylinder push rod boot fitting area 0.10 g (0.004 oz) minimum
Rear brake pad pin stopper ring
Brake caliper dust seals
Rear brake caliper sleeve sliding surface 0.4 g (0.01 oz) minimum
Rear brake caliper pin bolt sliding surface 0.4 g (0.01 oz) minimum
Parking brake push rod rolling surface (CRF1000D) 0.4 g (0.01 oz) minimum
Parking brake piston sliding surface (CRF1000D) 0.4 g (0.01 oz) minimum
Parking brake shaft threads (CRF1000D) 0.4 g (0.01 oz) minimum
Parking brake shaft boot lips (CRF1000D) 0.4 g (0.01 oz) minimum
Parking brake pin bolt sliding surface (CRF1000D) 0.4 g (0.01 oz) minimum
Parking brake caliper bracket pin sliding surface
(CRF1000D)
Brake caliper piston
Brake caliper piston seals
Rear master cylinder reservoir hose joint O-ring
Fork dust seal and oil seal lips
Drive chain whole surface
0.4 g (0.01 oz) minimum
1-23
dummyheaddummyhead
GENERAL INFORMATION
SPECIAL TOOL LIST
TITLE TOOL No TOOL NAME
MAINTENANCE 07708-0030400 Valve adjusting wrench
07HAA-PJ70101 Oil filter wrench
07HMH-MR10103 Drive chain tool set
PGM-FI SYSTEM 070PZ-ZY30100 SCS connector
07ZAJ-RDJA110 Test probe
FRXM17 (Snap on) Sensor socket wrench
IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor
07ZAJ-RDJA110 Test probe
FUEL SYSTEM 07406-0040004 Fuel pressure gauge
070MJ-K260100 Pressure gauge attachment set
07ZAJ-S5A0130 Hose attachment, 6 mm/9 mm
07ZAJ-S7C0100 Hose attachment, 8 mm/9 mm
07ZAJ-S7C0200 Attachment joint, 8 mm/9 mm
07ZAJ-S5A0150 Attachment joint, 6 mm/9 mm
LUBRICATION SYSTEM 070MJ-0010101 Oil pressure gauge attachment
07HAA-PJ70101 Oil filter wrench
07506-3000001 Oil pressure gauge set
07406-0030000 Oil pressure gauge attachment
CYLINDER HEAD/VALVE/CAMSHAFT 070MG-0010100 Tensioner holder B
07757-0010000 Valve spring compressor
07742-0010100 Valve guide driver 5.5 mm
07743-0020000 Valve guide driver
07984-2000001 Valve guide reamer, 5.5 mm
07781-0010101 Cutter holder, 5.5 mm
07780-0010500 Seat cutter, 40 mm (45° IN)
07780-0010400 Seat cutter, 35 mm (45° EX)
07780-0013000 Flat cutter, 42 mm (32° IN/EX)
07780-0014700 Interior cutter, 34 mm (60° IN/EX)
ALTERNATOR/STARTER CLUTCH 07725-0040001 Flywheel holder
07733-0020001 Rotor puller
CLUTCH/GEARSHIFT LINKAGE
(CRF1000/A)
DUAL CLUTCH Transmission (DCT)
(CRF1000D)
07724-0050002 Clutch center holder P.D. 48 - 135
07916-9690000 Lock nut wrench 30 x 40 mm
07749-0010000 Driver
07746-0010100 Attachment, 32 x 35 mm
07746-0040400 Pilot, 17 mm
07QAD-P0A0100 Attachment, 42 mm
07746-0010300 Attachment, 42 x 47 mm
07746-0040800 Pilot, 35 mm
07724-0010100 Gear holder, 2.5
07ZAJ-RDJA110 Test probe
07HGJ-0020100 Peak voltage adaptor
07741-0010201 Remover weight
07JAC-PH80200 Bearing remover shaft
07JAC-PH80100 Adjustable bearing puller, 20 – 40 mm
07936-3710600 Bearing remover set, 20 mm
07936-3710100 Remover handle
07749-0010000 Driver
07746-0010400 Attachment, 52 x 55 mm
07746-0040900 Pilot, 40 mm
07746-0040500 Pilot, 20 mm
07LAE-PX40000 Clutch compressor set
07724-0010100 Gear holder, 2.5
1-24
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