CRF250R
HONDA O/M CRF250R(Eu) 3RKRN620 00X3R-KRN-6200
CRF250R
OWNER’S MANUAL & COMPETITION HANDBOOK
E
MANUEL DU CONDUCTEUR ET DE COMPETITION
F
FAHRER-HANDBUCH und WETTBEWERBSANLEITUNG
G
INSTRUCTIEBOEK JE & WEDSTRIJDHANDBOEK
D
MANUAL DEL PROPIETARIO Y GUÍA DE COMPETICIONES
S
MANUALE D’USO E DEGLI ASSETTI DA COMPETIZIONE
I
© Honda Motor Co., Ltd. 2008
CRF250R_COVER 16/6/08, 20:401
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.
© Honda Motor Co., Ltd., 2008
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
ED
IIED
U
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)
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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
74
102
94, 148 – 150
81, 82
93
R
I
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 O-
ring 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 O-
ring 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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