Honda CRF250R Instruktionsbok [pt]

CRF250R

OWNER’S MANUAL & COMPETITION HANDBOOK

MANUEL DU CONDUCTEUR ET DE COMPETITION

FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG

INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK

MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES

MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE

CRF250R_COVER 16/6/08, 20:401

HONDA O/M CRF250R(Eu) 3RKRN620 00X3R-KRN-6200

IMPORTANT NOTICES

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold.

All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

THIS 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.

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Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK

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Introduction

Congratulations on choosing your Honda CRF motocross motorcycle.

When you own a Honda, you’re part of a worldwide family of satisfied customers-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, of course. But it’s just as important to observe the break-in guidelines, and perform all the pre-ride and other periodic checks detailed in this manual.

You should also read the owner’s manual before you ride. It’s full of facts, instructions, safety information, and helpful tips. To make it easy to use, the manual contains a table of contents, a detailed list of topics at the beginning of each section, and an index at the back of the book.

As you read this manual, you will find information that is preceded by a symbol. This information is intended to help you avoid damage to your Honda, other property, or the environment.

Unless you are mechanically qualified and have the proper tools, you should see your Honda dealer for the service and adjustment procedures discussed in this manual.

If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction.

Happy riding!

• The following codes in this manual indicate each country.

NOTICE

Introduction

IIED

IIU

European direct sales

European direct sales (Type II)

Australia, New Zealand

Australia, New Zealand (Type II)

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A Few Words About Safety

Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility.

To help you make informed decisions about safety, this manual contains a section devoted to

Motorcycle Safety, as well as a number of Safety Messages

throughout the manual.

Safety Messages are preceded by a safety alert symbol and one of three signal words:

DANGER, WARNING, or CAUTION.

These signal words mean:

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.

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

DANGER

WARNING

CAUTION

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Contents

MOTORCYCLE SAFETY...............................1

Important Safety Information..............................2

Important Safety Precautions..........................2

Accessories & Modifications ..............................3

Safety Labels.......................................................4

OPERATING CONTROLS .............................5

Operation Component Locations ........................6

BEFORE RIDING ............................................7

Are You Ready to Ride? .....................................8

Is Your Motorcycle Ready to Ride?....................9

Pre-ride Inspection..........................................9

BASIC OPERATING INSTRUCTIONS ......11

Safe Riding Precautions................................12

Starting & Stopping the Engine ........................13

Preparation ....................................................13

Starting Procedure.........................................13

Flooded Engine .............................................13

How to Stop the Engine................................14

Break-in Guidelines ..........................................15

SERVICING YOUR HONDA........................17

Before You Service Your Honda

The Importance of Maintenance .......................18

Maintenance Safety...........................................19

Important Safety Precautions........................19

Maintenance Schedule ......................................20

General Competition Maintenance ...................22

Before & After Competition Maintenance........26

Between Motos & Practice Maintenance .....26

After Competition Maintenance ...................26

Service Preparations

Maintenance Component Locations..................28

Seat Removal ....................................................29

Fuel Tank Removal ...........................................30

Subframe Removal............................................32

Service Procedures

Fluids & Filters

Fuel System.......................................................34

Engine Oil .........................................................36

Transmission Oil ...............................................39

Coolant ..............................................................41

Air Cleaner ........................................................43

Crankcase Breather ...........................................45

Engine

Throttle ..............................................................46

Engine Idle Speed .............................................48

Clutch System ...................................................49

Hot Start Lever..................................................54

Spark Plug .........................................................55

Valve Clearance.................................................56

Piston/Piston Rings/Piston Pin..........................64

Chassis

Suspension.........................................................72

Brakes................................................................77

Wheels...............................................................81

Tyres & Tubes ...................................................82

Drive Chain .......................................................84

Exhaust Pipe/Muffler ........................................87

Steering Damper................................................91

Additional Maintenance Procedures .................93

Appearance Care ...............................................95

ADJUSTMENTS FOR COMPETITION .....97

Front Suspension Adjustments..........................98

Rear Suspension Adjustments .........................111

Suspension Adjustments for Track

Conditions .......................................................115

Suspension Adjustment Guidelines .................116

Carburetor Adjustments & Tuning Tips ..........119

Steering Damper Adjustment..........................132

Steering Damper Adjustment Guidelines........133

Chassis Adjustments........................................134

Gearing ............................................................135

Tyre Selection for Track Conditions...............136

Personal Fit Adjustments ................................137

TIPS ................................................................139

Transporting Your Motorcycle ........................140

Storing Your Honda.........................................141

You & the Environment ..................................142

Troubleshooting...............................................143

TECHNICAL INFORMATION ..................145

Vehicle Identification ......................................146

Specifications ..................................................147

Torque Specifications ......................................148

Petrol Containing Alcohol...............................151

Competition Logbook .....................................152

Optional Parts List ..........................................154

Spare Parts & Equipment................................155

Wiring Diagram...............................................156

TABLE OF CONTENTS ..............................158

INDEX ............................................................159

Manufacturer and Authorised

Representative for EU Market.....................162

Contents

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Motorcycle Safety

This section presents some of the most important information and recommendations to help you ride your CRF safely. Please take a few moments to read these pages. This section also includes information about the location of safety labels on your CRF.

Important Safety Information...............................2

Important Safety Precautions ..........................2

Accessories & Modifications ...............................3

Safety Labels........................................................4

Motorcycle Safety 1

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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 Protective 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 Know 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 abilites or faster than conditions warrant. Remember that alcohol, drugs, illness and fatigue can reduce your ability to perform well and ride safely.

Don’t Drink and Ride.

Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing conditions, and your reaction time gets worse with every additional drink. So don’t drink and ride, and don’t let your friends drink and ride either.

Keep your Honda in Safe Condition.

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.

2 Motorcycle Safety

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Accessories & Modifications

Motorcycle Safety 3

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.

WARNING

Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed.

Follow all instructions in this owner’s manual regarding modifications and accessories.

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4 Motorcycle Safety

Safety Labels

Read this label carefully and don’t remove it.

If the label comes off or becomes hard to read, contact your Honda dealer for replacement.

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Operating Controls 5

Operating Controls

Read this section carefully before you ride. It presents the location of the basic controls on your CRF.

Operation Component Locations .........................6

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6 Operating Controls

Operation Component Locations

clutch lever

hot start lever

front brake lever

engine stop button

throttle grip

choke knob

fuel valve

shift lever

kickstarter

rear brake pedal

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Before Riding 7

Before each ride, you need to make sure you and your Honda are both ready to ride. To help get you prepared, this section discusses how to evaluate your riding readiness, and what items you should check on your CRF.

For information about suspension, carburetor, and other adjustment for competition, see page 97.

Before Riding

Are You Ready to Ride?.......................................8

Is Your Motorcycle Ready to Ride?.....................9

Pre-ride Inspection...........................................9

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8 Before Riding

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, carburetor, and other adjustments, see page 97.

Whether you’re preparing for competition or for practice, always make sure you are.

• In good physical and mental condition

• Free of alcohol and drugs

•Wearing an approved helmet, eye protection, and other appropriate riding gear

Although complete protection is not possible, wearing the proper gear can reduce the chance or severity of injury when you ride.

WARNING

Not wearing a 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.

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Before Riding 9

Is Your Motorcycle Ready to Ride?

Competitive riding can be tough on a motorcycle, so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the right):

Pre-ride Inspection

Check the following before each ride:

• Engine oil level .............................................37

•Transmission oil level...................................40

• Coolant for proper level................................41

• Cooling system and hoses for condition.......42

• Spark plug for proper heat range, carbon fouling and high tension cord terminal for

looseness .......................................................55

• Air cleaner for condition and

contamination................................................43

• Clutch lever adjustment and freeplay ...........49

• Hot start lever freeplay .................................54

• Breather drain for cleaning ...........................45

• Steering head bearing and related parts

for condition..................................................91

• Carburetor throttle operation ........................47

•Tyres for damage or improper inflation

pressure ........................................................82

• Spokes for looseness.....................................81

• Rim locks for looseness ................................81

• Front and rear suspension for proper

operation .................................................72, 73

• Front and rear brakes, check operation ........77

• Drive chain for correct slack and adequate

lubrication .....................................................84

• Drive chain guide, sliders and drive chain

rollers for damage or wear......................84, 85

• Exhaust pipe/Muffler inspection...................87

• Steering damper operation inspection ..........91

• Every possible part for looseness (such as cylinder head nuts, engine mounting bolts/nuts, axle nuts, handlebar holder bolts, fork bridge pinch bolts, drive chain adjuster, drive chain guide, wire harness connectors,

kickstarter mounting bolt) ................148 – 150

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.

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10 Before Riding

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Basic Operating Instructions 11Basic Operating Instructions 11

Basic Operating Instructions

This section gives basic information on how to start and stop your engine as well as break-in guidelines.

Safe Riding Precautions.................................12

Starting & Stopping the Engine .........................13

Preparation .....................................................13

Starting Procedure..........................................13

Flooded Engine ..............................................13

How to Stop the Engine.................................14

Break-in Guidelines ...........................................15

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12 Basic Operating Instructions12 Basic Operating Instructions

Basic Operating Instructions

Safe Riding Precautions

Before riding your CRF for the first time, please review the

Important Safety Precaution

beginning on page 2 and the previous section, titled

Before Riding.

For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

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(1)

(2)

Basic Operating Instructions 13Basic Operating Instructions 13

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.

Preparation

Make sure that the transmission is in neutral. Turn the fuel valve ON.

Starting Procedure

Always follow the proper starting procedure described as follow.

Check the engine oil, transmission oil and coolant levels before starting the engine (pages 37, 40, 41).

Cold Engine Starting

1. Turn the fuel valve (1) ON.

2. Shift the transmission into neutral.

3. If the temperature is 35°C (95°F) or below, pull the choke knob (2) fully out.

4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.)

5. 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. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kickstarting difficult.)

6. About a minute after the engine starts, push the choke knob all the way to fully OFF. If idling is unstable, open the throttle slightly.

Warm Engine Starting

1. Turn the fuel valve ON.

2. Shift the transmission into neutral.

3. Pull the hot start lever (3) and kick-start the engine. (Do not open the throttle.)

4. As soon as the engine starts, release the hot start lever.

(1) fuel valve (2) choke knob

(3)

(3) hot start lever

Starting the engine after a stall during riding or after a fall

1. Shift the transmission into neutral.

2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.)

3. As soon as the engine starts, release the hot start lever.

Flooded Engine

If the engine fails to start after repeated attempts, it may be flooded with excess fuel. To clear a flooded engine:

1. Shift the transmission into neutral.

2. With the throttle fully opened, repeat kickstarter operation approximately ten times very slowly to discharge excessive fuel from the engine.

3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.)

4. As soon as the engine starts, release the hot start lever.

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14 Basic Operating Instructions

Starting & Stopping the Engine

14 Basic Operating Instructions

How to Stop the Engine

(2)

(1)

(1) throttle grip (2) engine stop button

Normal Engine Stop

1. Shift the transmission into neutral.

2. Turn the fuel valve OFF.

3. Lightly open the throttle grip (1) two or three times, and then close it.

4. Depress and hold the engine stop button (2) until the engine stops completely.

Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting.

Emergency Engine Stop To stop the engine in an emergency, depress the engine stop button.

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Basic Operating Instructions 15

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

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16 Basic Operating Instructions

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Servicing Your Honda 17

Servicing Your Honda

Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun.

To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good.

An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Shop Manual.

An optional tool kit may be available. Check with your Honda dealer’s parts department.

Before You Service Your Honda

The Importance of Maintenance ........................18

Maintenance Safety............................................19

Important Safety Precautions.........................19

Maintenance Schedule .......................................20

General Competition Maintenance ....................22

Before & After Competition Maintenance.........26

Between Motos & Practice Maintenance ......26

After Competition Maintenance ....................26

Service Preparations

Maintenance Component Locations...................28

Seat Removal .....................................................29

Fuel Tank Removal ............................................30

Subframe Removal.............................................32

Service Procedures

Fluids & Filters

Fuel System........................................................34

Engine Oil ..........................................................36

Transmission Oil ................................................39

Coolant ...............................................................41

Air Cleaner .........................................................43

Crankcase Breather ............................................45

Engine

Throttle ...............................................................46

Engine Idle Speed ..............................................48

Clutch System ....................................................49

Hot Start Lever...................................................54

Spark Plug ..........................................................55

Valve Clearance..................................................56

Piston/Piston Rings/Piston Pin...........................64

Chassis

Suspension..........................................................72

Front Suspension Inspection..........................72

Rear Suspension Inspection...........................73

Recommended Fork Oil.................................74

Fork Oil Change ............................................74

Brakes.................................................................77

Wheels................................................................81

Tyres & Tubes ....................................................82

Drive Chain ........................................................84

Exhaust Pipe/Muffler .........................................87

Steering Damper.................................................91

Additional Maintenance Procedures ..................93

Appearance Care ................................................95

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18 Servicing Your Honda

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.

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 moto. 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.

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Servicing Your Honda 19

Maintenance Safety

This section includes instructions on how to perform some important maintenance tasks. Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Important Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs.

This will help eliminate several potential

hazards:

Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation

whenever you operate the engine.

Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching.

Injury from moving parts. Do not run the engine unless instructed to do so.

• Read the instructions before you begin, and make sure you have the tools and skills required.

•To help prevent the motorcycle from falling over, park it on a firm, level surface, using an optional workstand or a maintenance stand to provide support.

•To reduce the possibility of a fire or explosion, be careful when working around petrol. Use only a non-flammable (high flash point) solvent such as kerosene — not petrol — to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

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.

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20 Servicing Your Honda

Maintenance Schedule

To maintain the safety and reliability of your 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 Honda dealer perform these tasks unless you have advanced mechanical skills and the required tools. Procedures for items in this schedule are provided in a 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.

If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only Honda Genuine Parts or their equivalents for repair or replacement to ensure the best quality and reliability.

Perform the pre-ride inspection (page 9) at each scheduled maintenance period.

Summary of Maintenance 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, if the clutch discs and plates are replaced.

Maintenance Procedures: I:inspect and clean, adjust, lubricate, or replace,

if necessary

C: clean L:lubricate R: replace

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Servicing Your Honda 21

Maintenance Schedule

ITEMS THROTTLE OPERATION HOT START SYSTEM AIR FILTER CRANKCASE BREATHER SPARK PLUG RADIATOR COOLANT VALVE CLEARANCE/DECOMPRESSOR SYSTEM ENGINE OIL ENGINE OIL FILTER ENGINE IDLE SPEED PISTON AND PISTON RINGS PISTON PIN TRANSMISSION OIL COOLING SYSTEM DRIVE CHAIN DRIVE CHAIN SLIDER DRIVE CHAIN ROLLER DRIVE SPROCKET DRIVEN SPROCKET BRAKE FLUID BRAKE PADS WEAR BRAKE SYSTEM CLUTCH SYSTEM CONTROL CABLES EXHAUST PIPE/MUFFLER SUSPENSION SWINGARM/SHOCK LINKAGE

FORK OIL

NUTS, BOLTS, FASTENERS WHEELS/TYRES STEERING HEAD BEARINGS

(NOTE 1)

(NOTE 2) (NOTE 4) (NOTE 3) (NOTE 3)

(NOTE 5)

(NOTE 2)

(NOTE 5)

(NOTE 3)

I I

I I I

I I

I, L

I I I I I I I I

I, L

I I

L R

I R R

R R R

46 54 43 45 55 41 57 36 37 48 66 66 39 41 84 84 85 86 86 78 80 77 49 93 87 72

25, 73

102

94, 148 – 150

81, 82

FORK TUBE/SLIDER DAMPER

FREQUENCY

NOTE Ref. Page

Each race

or about

2.5 hours

Every 3 races

or about

7.5 hours

Every 6 races

or about

15.0 hours

Every 9 races

or about

22.5 hours

Every 12 races

or about

30.0 hours

This maintenance schedule is based upon average riding condition. Machines subjected to severe use require more frequent servicing.

NOTE: 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, if the clutch discs and plates are replaced.

Perform the Pre-ride Inspection at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate. R: Replace.

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22 Servicing Your Honda

General Competition Maintenance

Perform maintenance on firm, level ground using the optional workstand, or equivalent support.

When tightening bolts, nuts or screws, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a crisscross pattern.

Use Honda Genuine Parts or their equivalent when servicing your CRF.

Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Lubricate any sliding surface, O-rings, and seals before reassembling. Grease parts by coating or filling where specified.

After any engine disassembly, always install new gaskets, O-rings, cotter pins, piston pin clips, snap rings, etc. when reassembling. After reassembly, check all parts for proper installation and operation.

All Pre-ride Inspection Items

Refer to Pre-ride Inspection page 9.

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Servicing Your Honda 23

Spark Plug

Some non-resistor plugs may cause ignition problems. Refer to the recommendations elsewhere in this manual for specific types so you will be sure to use the proper reach and heat range. Replace periodically as specified in the Maintenance Schedule (page 20).

Engine Oil and Filter Drain and replace the engine oil often to ensure the greatest service life of the piston, cylinder and crankshaft. Also replace the engine oil filter often to ensure the greatest service life. Frequent oil changes will also assure consistent engine power and response (page 37).

Air Cleaner

Clean and oil your air cleaner regularly because the volume of air able to pass through it has a great effect on performance. Both engine performance and long-term durability may be affected by an air cleaner that has deteriorated and allows dirt to pass through it. Inspect the air cleaner closely each time it’s serviced for evidence of small tears or seam separation. Keep a spare air cleaner oiled and ready to install, sealed in a plastic bag. Riding in dusty conditions may require servicing the air cleaner or replacing it with a pre-serviced air cleaner between motos. Be careful not to over oil the air cleaner. While it is important to oil the air cleaner thoroughly, over oiling will cause an overall rich running condition, probably more noticeable off idle and in low-min

-1

(rpm) performance. Follow the servicing instructions in the Maintenance section. Use Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium Grease, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 43). Use a Honda Genuine air cleaner or an equivalent air cleaner specified for your model. Using the wrong Honda air cleaner or a non-Honda air cleaner which is not of equivalent quality may cause premature engine wear or performance problems.

Transmission Oil

Drain and replace the transmission oil often to ensure the greatest service life of the transmission and clutch. Frequent changes will also assure consistent shifting and clutch performance (page 40).

Air cleaner Housing Sealing

Remove and reseal the air cleaner housing boot where it connects to the air cleaner housing with Hand Grip Cement or an equivalent if there is any doubt to its sealing integrity. Inspect the air cleaner and air intake tract regularly for signs of deterioration or dirt penetration.

General Competition Maintenance

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24 Servicing Your Honda

General Competition Maintenance

Gaskets

Always use new gaskets when reassembling components.

Cylinder Removal

Put a little grease on the cylinder mounting dowels to prevent corrosion from dissimilar metals. The tolerances are extremely tight, so it’s important to keep these dowels absolutely clean (page 66).

Fuel Filter

Periodically drain the fuel from the fuel tank, remove and clean the fuel valve and fuel filter. Replace the fuel valve Oring if there are any signs of damage or deterioration (page 35).

Fuel Contamination

Refer to Fuel System, page 34. Check the fuel lines for deterioration, damage, or leakage. Replace the fuel lines, if necessary. Periodically drain the fuel from the fuel tank, remove and clean the fuel valve and fuel filter. Replace the fuel valve Oring if there are any signs of damage or deterioration (page 35). Loosen the drain screw and examine the fuel that flows out of the float bowl. If you notice anything in the fuel, such as water or dirt, remove the float bowl and inspect its contents (page 124). For maximum efficiency, drain and replace fuel that has been in the fuel tank for more than a month.

Engine Mounting Bolts and Nuts

Make sure the engine mounting bolts and nuts are tightened to the proper torque specification (page 148). For added peace of mind, remove the nuts, clean the threads, and apply Honda Thread Lock or an equivalent before torquing the nuts.

Electrical Connectors

Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections, water shorts or corrosion. For additional corrosion protection, apply Honda Dielectric Grease to all the electrical connections.

Steering Head Bearings

Periodically clean, inspect and regrease the steering head bearings — especially if wet, muddy or extremely dusty courses are encountered often. Use urea based multi-purpose grease designed for high temperature, high pressure performance (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan or Shell Stamina EP2 or equivalent).

Fork Oil/Performance

Disassemble, clean and inspect the front fork and replace oil regularly. Contamination due to the tiny metal particles produced from the normal action of the fork, as well as normal oil breakdown, will deteriorate the performance of the suspension. Refer to the Honda Shop Manual. Use only Honda ULTRA CUSHION OIL SPECIAL 5W or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

Frame

Because your CRF is a high-performance machine, the frame should not be overlooked as part of your overall competition maintenance program. Periodically inspect the frame closely for possible cracking or other damage. It makes good racing sense.

Spokes

Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact points seat-in, the spokes may need to be retightened. Once past this initial seating-in period, the spokes should hold their tension. Still, be sure your race maintenance program includes checking spoke tension and overall wheel condition on a regular basis (page 81).

Nuts, Bolts, Etc

Application of a thread locking agent to essential fasteners offers added assurance and security. Remove the nuts, clean the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque.

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