Honda CRF250R Instruktionsbok [pt]

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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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Suspension Linkage Lubrication

Disassemble, clean, inspect and lubricate all suspension linkage pivot bearings with grease after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear.

Swingarm Pivot Lubrication

Clean, inspect and lubricate swingarm and suspension linkage pivots with grease. Be sure all of the dust seals are in good condition.

Swingarm

Do not attempt to weld or otherwise repair a damaged swingarm. Welding will weaken the swingarm.

Footpegs

Worn footpeg teeth can be repaired by filing the grooves between the teeth with a triangular-shaped file. Be aware that filing them too sharp will reduce boot sole lifespan. Sharpen only the points of the teeth. Filing the grooves deeper will weaken the footpegs. Be sure the pegs are free to pivot freely and that the pivot pin retaining cotter pins are in good condition.

Brake Fluid Replacement

Refer to Brake Pad Wear in your Owner’s Manual, page 80. Brake Caliper Inspection: Be sure both the front and rear calipers are able to move freely on the caliper bracket pins. Check pad thickness periodically and replace the pads when minimum thickness is reached. If the brakes fade when they are hot, inspect the pads for glazing or damage, and replace if necessary. Brake Fluid Replacement: Replace the hydraulic fluid in the brake system every 2 years. Replace the fluid more frequently if you subject your brakes to severe use. Heavy braking heats the brake fluid and it may deteriorate sooner than expected. Any type of riding, that requires frequent use of the brakes, such as in tight woods, can shorten the service life of brake fluid.

Water Leakage Check Hole

After every race, check the leakage check hole, located just below the water pump cover on the right crankcase cover. Clean away any clogged dirt or sand, if necessary. Look for coolant or oil leakage. Leaking coolant indicates a worn or damaged water seal. Leaking oil indicates a bad transmission oil seal. If replacement is necessary, both seals should be replaced.

Handgrips

Always use Hand Grip Cement when replacing handgrips.

Throttle Grip

Align the index mark on the throttle grip with the edge of the throttle cable guide. Left handlebar grip: Align the “ ” mark on the left handlebar grip with the paint mark on the handlebar. Refer to the Shop Manual for installation instructions.

For added security, you may choose to bind the hand grips to the handlebar and throttle pipe with safety wires to prevent the possibility of them loosening. Position the twisted wire ends away from your palms and be sure to bend the wire ends well into the handgrip rubber so they will not snag your glove.

Throttle Control

Remove the throttle control every few rides, clean the inside of the throttle pipe and the handlebar thoroughly. Inspect the cable carefully for kinks or other damage that may restrict throttle control in any way. Move the handlebar from lock to lock to be sure there is no cable interference. Make certain the throttle operation is perfect after servicing and inspecting.

Servicing Your Honda 25

General Competition Maintenance

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26 Servicing Your Honda

Before & After Competition Maintenance

Between Motos & Practice Maintenance

After practice or between motos you have a chance to make additional checks and adjustments.

• Clean accumulated dirt from under the fenders and off the wheels, suspension components, handgrips, controls, and footpegs. A stiff, nylon parts cleaning brush works well.

• Check tyre air pressure.

•

Check spoke tension, and make sure the rim locks are secure.

• Check to make sure the sprocket bolts and nuts are secure.

• Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary.

Do not perform maintenance while the engine is running. Injury to your fingers or hands may result.

• After adjustment, check that the chain adjuster index marks (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear.

• Suspend the front wheel above the ground and use the pressure release screws (2) to release the built-up pressure (in excess of normal atmospheric pressure: 0 kPa (0 kgf/cm

, 0 psi)) in the fork tubes. This pressure is caused by normal fork action while riding. (If you are riding at altitude, remember that fork pressure of 0 at sea level will increase as elevation increases.)

(1) chain adjuster index marks

(2) pressure release screw

(1)

(2)

After Competition Maintenance

It is important to the long-term performance of your CRF to practice a consistent maintenance program. Right after the event is a good time to begin your next maintenance cycle.

After Race Lubrication Apply a light coating of rust-inhibiting oil to the drive sprocket and any steel portions of the chassis or engine where the paint has worn away. This will prevent rusting of the exposed metal. Apply rust-inhibiting oil more heavily if the event was particularly wet or muddy. Take care to avoid spraying any oil near the brake pads or brake disc.

Take care to prevent catching your fingers between the chain and sprocket.

Remove the drive chain, clean and lubricate it. Be sure the chain is wiped clean and is dry before lubricating it.

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Servicing Your Honda 27

Before & After Competition Maintenance

Routine Cleaning If your CRF is only slightly dirty, it is best to clean it by hand with the aid of a stiff bristled nylon brush and some clean rags.

Take care to prevent catching your fingers between the chain and sprocket.

A variety of reasonably priced cleaning brushes are available from variety, drug, food, and hardware stores. Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF. Avoid using stiff, abrasive brushes on the plastic or rubber parts.

If your CRF was exposed to sea air or salt water, rinse it off as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts.

If you decide to wash your CRF or use cleaners, refer to

Appearance Care (page 95).

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28 Servicing Your Honda

Maintenance Component Locations

front brake caliper

choke knob

crankcase breather tube

drive chain

transmission oil drain bolt

engine oil drain bolt

throttle stop screw (engine idle speed)

engine oil filter

engine oil filler cap/ dipstick

air cleaner

rear brake caliper

rear suspension rebound damping adjuster

transmission oil filler cap

transmission oil check bolt

rear brake pedal

front suspension rebound damping adjuster

rear suspension high speed damping adjuster rear suspension low speed damping adjuster

front suspension compression damping adjuster

spark plug

rear suspension spring pre-load adjuster

rear brake fluid reservoir

steering damper adjuster

clutch lever

hot start lever

front brake fluid reservoir

front brake lever

fuel fill cap

radiator cap

throttle grip

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Servicing Your Honda 29

Seat Removal

Refer to Safety Precautions on page 19.

Removal

1. Remove the seat mounting bolts (1).

2. Remove the seat (2) by sliding it backward.

(1) seat mounting bolts (2) seat

Installation

1. Install the seat while aligning the front prong (3) with the seat bracket (4) and rear prong (5) with the tab (6) of the subframe.

2. Install and tighten the seat mounting bolts to the specified torque:

26 N·m (2.7 kgf·m, 19 lbf·ft)

(3) front prong (4) seat bracket (5) rear prong (6) tab

(2)

(1)

(3)

(5)

(4)

(6)

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30 Servicing Your Honda

Fuel Tank Removal

Refer to Safety Precautions on page 19.

Removal

1. Turn the fuel valve (1) OFF.

5. Pull the breather tube (5) out of steering stem nut.

6. Unhook the fuel tank band (6).

7. Remove the fuel tank bolt/collar (7).

(5) breather tube (6) fuel tank band (7) fuel tank bolt/collar

8. Disconnect the fuel line (8) from the fuel valve. The fuel line leading to the carburetor must be disconnected, not the fuel line leading to the fuel tank.

9. Remove the fuel valve bolt (9) and fuel valve.

10.Remove the fuel tank.

(8) fuel line (9) fuel valve bolt

WARNING

Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel.

• Stop the engine and keep heat, sparks

and flame away.

• Handle fuel only outdoors.

• Wipe up spills immediately.

(3)

(4)

(2)

(5)

(7)

(6)

(8)

(9)

(2) shroud A bolts/collars (3) shroud B bolts (4) shroud

(1)

(1) fuel valve

2. Remove the seat (page 29).

3. Remove the shroud A bolts/collars (2).

4. Remove the shroud B bolts (3) and shrouds (4).

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Servicing Your Honda 31

Fuel Tank Removal

(3)

(1)

(2)

(6)

(4)

(5)

(7)

(8)

(10)

(9)

(11)

Installation

1. Install the fuel tank on the frame.

2. Install the fuel valve (1) and tighten the fuel valve bolt (2).

3. Connect the fuel line (3) to the fuel valve.

(1) fuel valve (3) fuel line (2) fuel valve bolt

4. Install the fuel tank bolt/collar (4).

5. Hook the fuel tank band (5).

6. Put the breather tube (6) in the steering stem nut.

7. Install the shroud tab (7) onto the subframe (8).

(7) shroud tab (8) subframe

Install the shrouds (9) and shroud B bolts (10).

9. Install and tighten the shroud A bolts/collars (11).

10.Tighten the shroud B bolts to the specified torque:

5 N·m (0.5 kgf·m, 3.7 lbf·ft)

(9) shroud (10) shroud B bolts (11) shroud A bolts/collars

(4) fuel tank bolt/collar (5) fuel tank band (6) breather tube

11. Install the seat (page 29).

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32 Servicing Your Honda

Subframe Removal

Refer to Safety Precautions on page 19.

Removal

1. Remove the seat (page 29).

2. Remove the muffler (page 87).

3. Remove the exhaust joint pipe (page 89).

4. Disconnect the crankcase breather tube (1).

5. Unhook the fuel tank band (2).

6. Loosen the screw (3) on the air cleaner connecting tube clamp (4).

(1) crankcase breather tube (2) fuel tank band (3) screw (4) air cleaner connecting tube clamp

(2)

(1)

7. Remove the subframe lower mounting bolts (5) and subframe upper mounting bolt (6). Then remove the subframe (7) by pulling it straight backward.

(5)

(6)

(5)

(7)

(5) subframe lower mounting bolts (6) subframe upper mounting bolt (7) subframe

(4)

(3)

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Servicing Your Honda 33

Subframe Removal

2. Tighten the screw (4) on the air cleaner connecting tube clamp (5).

3. Hook the fuel tank band (6).

4. Connect the crankcase breather tube (7).

(4) screw (5) air cleaner connecting tube clamp (6) fuel tank band (7) crankcase breather tube

(6)

(7)

Installation

1. Loosely attach the upper and lower ends of the subframe (1) to the mainframe while connecting the air cleaner connecting tube to the carburetor. Be careful not to bend the subframe. Install the subframe upper mounting bolt (2) and subframe lower mounting bolts (3). Tighten the upper mounting bolt and lower mounting bolts to each specified torque: upper bolt:

30 N·m (3.1 kgf·m, 22 lbf·ft)

lower bolt: 49 N·m (5.0 kgf·m, 36 lbf·ft)

(1) subframe (2) subframe upper mounting bolt (3) subframe lower mounting bolts

(3)

(2)

(3)

(1)

5. Install the exhaust joint pipe (page 89) and muffler (page 88).

6. Install the seat (page 29).

(5)

(4)

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34 Servicing Your Honda

Fuel System

Refer to Safety Precautions on page 19.

Fuel Recommendation

We recommend that you use unleaded fuel because it produces fewer engine deposits and extends the life of exhaust system components.

Your engine is designed to use any petrol that has a pump octane number (R + M)/2 of 91 or higher, or a research octane number of 95 or higher. Petrol pumps at service stations normally display the pump octane number. For information on the use of

Petrol Containing Alcohol, see page

148.

Use of lower octane petrol can cause persistent “pinging” or “spark knock” (a louder rapping noise) which, if severe, can lead to engine damage. (Light pinging experienced while operating under a heavy load, such as climbing a hill, is no cause for concern.)

If pinging or spark knock occurs at a steady engine speed under normal load, change brands of petrol. If pinging or spark knock persists, consult your Honda dealer.

Never use stale or contaminated petrol. Avoid getting dirt, dust or water in the fuel tank.

Type Unleaded

Research Octane Number

95 (or higher)

Refueling Procedure

Fuel Tank Capacity: 7.3R(1.9 US gal,

1.61 Imp gal)

(1) fuel fill cap (3) steering stem nut (2) breather tube

1. To open the fuel fill cap (1), pull the breather tube (2) out of the steering stem nut (3). Turn the fuel fill cap counterclockwise and remove it.

2. Add fuel until the level reaches the bottom of the filler neck. Avoid overfilling the tank. There should be no fuel in the filler neck.

3. Close the fuel fill cap and insert the breather tube in the steering stem nut.

WARNING

Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel.

• Stop the engine and keep heat, sparks

and flame away.

• Handle fuel only outdoors.

• Wipe up spills immediately.

Fuel Line

(1) fuel line

1. Check for leaks.

2. Check the fuel line (1) for cracks, deterioration, damage or leakage. Replace the fuel line, if necessary.

3. Check for interference between the frame and

fuel tank and adjust if necessary.

(3)

(2)

(1)

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Servicing Your Honda 35

Fuel System

(3) fuel filter (4) O-ring

(4)

(3)

(1)

(2)

Fuel Filter

The fuel filter is mounted on the bottom left side of the fuel tank. Dirt accumulated in the filter will restrict the flow of the fuel to the carburetor. Therefore, the fuel filter should be serviced frequently.

To service the fuel filter:

1. Drain the fuel from the fuel tank into an approved petrol container.

2. Remove the fuel tank (page 30).

3. Remove the fuel joint (1) from the fuel tank by removing the bolts (2).

4. Wash the fuel filter (3) in high flash-point cleaning solvent.

5. Reassemble the fuel filter in the reverse order of removal. Make sure the O-ring (4) is in good condition and install it onto the fuel joint.

6. Install the fuel joint in the fuel tank by tightening the bolts to the specified torque:

10 N·m (1.0 kgf·m, 7 lbf·ft)

7. Install the fuel tank (page 31) and refill the fuel. Turn the fuel valve to ON; check for fuel leaks.

(1) fuel joint (2) bolts

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36 Servicing Your Honda

Engine Oil

Refer to Safety Precautions on page 19.

Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the engine. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine.

Oil Recommendation

API classification

SG or higher except oils labeled as energy conserving on the circular API service label

suggested oil

Honda “4-STROKE MOTORCYCLE OIL” or equivalent

viscosity (weight)

SAE 10W-30

JASO T 903 MA

•Your CRF does not need oil additives. Use the recommended oil.

• Do not use API SH or higher 4-stroke engine oils displaying a circular API “energy conserving” service label on the container. They may affect lubrication.

Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range.

NOT RECOMMENDED OK

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Servicing Your Honda 37

Engine Oil

JASO T 903 standard The JASO T 903 standard is an index for engine oils for 4-stroke motorcycle engines. There are two classes: MA and MB. Oil conforming to the standard is labeled on the oil container. For example, the following label shows the MA classification.

(1) code number of the sales company of the oil (2) oil classification

Checking & Adding Oil

(1) engine oil filler cap/dipstick (3) lower level mark (2) upper level mark

1. Run the engine at idle for 3 minutes, then shut it off.

2. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the engine.

3. Support the CRF in an upright position on a level surface.

4. Remove the engine oil filler cap/dipstick (1), wipe it clean, and insert the engine oil filler cap/dipstick without screwing it in. Remove the engine oil filler cap/dipstick.

5. Check that the oil level is between the upper (2) and lower (3) level marks on the engine oil filler cap/dipstick.

• If the oil is at or near the upper level mark, you do not have to add oil.

• Before race or if the oil level is below or near the lower level mark, add the recommended oil until the upper level mark is reached. (Do not overfill.) Reinstall the engine oil filler cap/dipstick. Repeat steps 1 – 5.

6. Reinsert the engine oil filler cap/dipstick.

7. Check for oil leaks.

Changing Engine Oil & Filter

1. Run the engine at idle for 3 minutes, then shut it off.

2. Support the CRF in an upright position on a level surface.

3. Remove the engine oil filler cap/dipstick (1) from the left crankcase cover.

4. Place an oil drain pan under the engine to catch the oil. Then remove the engine oil drain bolt (2) and sealing washer (3).

5. With the engine stop button pushed, repeat kickstarter operation approximately 5 times to drain the engine oil completely.

6. After the oil has drained, apply fresh engine oil to the engine oil drain bolt threads.

7. Install and tighten the engine oil drain bolt with a new sealing washer to the specified torque:

16 N·m (1.6 kgf·m, 12 lbf·ft)

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 142).

Improperly disposal of drained fluids is harmful to the environment.

NOTICE

(1) engine oil filler cap/dipstick (2) engine oil drain bolt (3) sealing washer

(cont’d)

(2)

(1)

(2)

(1)

(2)

(3)

(1)

(2)

(3)

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38 Servicing Your Honda

Engine Oil

(6) oil filter cover bolts (10) spring (7) oil filter cover (11) rubber seal (8) oil filter (12) “OUT-SIDE” mark (9) oil filter cover O-ring

Using the wrong oil filter may result in leaks or engine damage.

13.Apply grease to the filter side of the spring end, then install the spring (10) into a new oil filter.

14.Position the spring against the engine crankcase and install a new oil filter with the rubber seal (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the rubber seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model.

If the oil filter is not installed properly, it will cause serious engine damage.

NOTICE

15.Apply engine oil to a new O-ring and install it to the oil filter cover.

16.Install the oil filter cover being careful not to damage the O-ring, then tighten the oil filter cover bolts to the specified torque:

12 N·m (1.2 kgf·m, 9 lbf·ft)

17.Install the left engine guard and bolt, then tighten it.

18.Fill the crankcase with the recommended oil. Capacity:

0.69R(0.73 US qt, 0.61 Imp qt)

after draining and oil filter change

0.66R(0.70 US qt, 0.58 Imp qt)

after draining

19.Install the engine oil filler cap/dipstick.

20.Check the engine oil level by following the steps in

Checking & Adding Oil (page 37).

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 142).

Improper disposal of drained fluids is harmful to the environment.

NOTICE

(5)

(4)

(10)

(12)

(9)

(8)

(11)

(7)

(6)

12. Check that the oil filter cover O-ring (9) is in good condition.

8. It is recommended to replace the oil and filter every 6 races or about every 15.0 hours. However, if you replace only the oil before the recommended interval, see page 21.

9. Remove the left engine guard bolt (4) and left engine guard (5).

(4) left engine guard bolt (5) left engine guard

10. Remove the oil filter cover bolts (6) and oil

filter cover (7).

11. Remove the oil filter (8) from the oil filter cover.

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Refer to Safety Precautions on page 19.

Using the proper oil, and regularly checking, adding, and changing oil will help extend the service life of the transmission and clutch. Even the best oil wears out. Changing oil helps get rid of dirt and deposits. Operating the engine with old or dirty oil can damage your engine. Running the engine with insufficient oil can cause serious damage to the engine and transmission.

Oil Recommendation

•Your CRF does not need oil additives. Use the recommended oil.

• Do not use oils with graphite or molybdenum additives. They may adversely affect clutch operation.

• Do not use API SH or higher 4-stroke engine oils displaying a circular API “energy conserving” service label on the container. They may affect lubrication and clutch performance.

Servicing Your Honda 39

Transmission Oil

Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range.

(1) code number of the sales company of the oil (2) oil classification

NOT RECOMMENDED OK

API classification (4-stroke engine oil only)

Viscosity (weight)

JASO T903 standard

others

suggested oil

SG or higher except oils labeled as energy conserving on the circular API service label

SAE 10W-30

without friction modifiers as molybdenum additives

Honda “4-STROKE MOTORCYCLE OIL” or equivalent

(2)

(1)

(2)

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40 Servicing Your Honda

Checking & Adding Oil

(1) transmission oil filler cap (3) sealing washer (2) oil check bolt

1. Run the engine at idle for 3 minutes, then shut it off.

2. Wait 3 minutes after shutting off the engine to allow the oil to properly distribute itself in the clutch and transmission.

3. Support the CRF in an upright position on a level surface.

4. Remove the transmission oil filler cap (1), oil check bolt (2) and sealing washer (3) from the right crankcase cover. A small amount of oil should flow out of the oil check bolt hole. Allow any excess oil to flow out of the oil check bolt hole. If no oil flows out of the oil check bolt hole, add oil slowly through the transmission oil filler hole until oil starts to flow out of the oil check bolt hole. Install the oil check bolt with a new sealing washer and transmission oil filler cap. Repeat step 1 – 4.

5. After inspecting the oil level or adding oil, tighten the oil check bolt to the specified torque: Oil Check Bolt:

12 N·m (1.2 kgf·m, 9 lbf·ft)

6. Install the transmission oil filler cap securely.

Replacing Transmission Oil

1. Run the engine at idle for 3 minutes, then shut it off.

2. Support the CRF in an upright position on a level surface.

3. Remove the transmission oil filler cap (1) from the right crankcase cover.

4. Place an oil drain pan under the engine to catch the oil. Then remove the transmission oil drain bolt (2) and sealing washer (3).

5. After the oil has drained, apply fresh engine oil to the transmission oil drain bolt threads.

6. Install and tighten the transmission oil drain bolt with a new sealing washer to the specified torque:

16 N·m (1.6 kgf·m, 12 lbf·ft)

Transmission Oil

(1)

(3)

(2)

(1)

(2)

(3)

(1) transmission oil filler cap (2) transmission oil drain bolt (3) sealing washer

7. Fill the crankcase with recommended oil. Capacity:

0.60R(0.63 US qt, 0.53 Imp qt)

after draining

8. Check the transmission oil level by following

the steps in

Checking & Adding Oil (this

page).

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 142).

Improper disposal of drained fluids is harmful to the environment.

NOTICE

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Servicing Your Honda 41

Your CRF’s liquid cooling system dissipates engine heat through the coolant jacket that surrounds the cylinder and cylinder head.

Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion.

Coolant Recommendation

Use high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. Check the antifreeze container label.

Use only distilled water as a part of the coolant solution. Water that is high in mineral content or salt may be harmful to the aluminum engine.

Using coolant with silicate inhibitors may cause premature wear of water seals or blockage of radiator passages. Using tap water may cause engine damage.

The factory provides a 50/50 solution of antifreeze and water in this motorcycle. This coolant solution is recommended for most operating temperatures and provides good corrosion protection.

Decreasing the concentration of antifreeze to less than 40% will not provide proper corrosion protection.

Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance. Higher concentrations of antifreeze (up to 60%) should only be used to provide additional protection against freezing. Check the cooling system frequently during freezing weather.

Checking & Adding Coolant

Refer to Safety Precautions on page 19.

1. With the engine cold, remove the radiator cap (1) and check coolant level. The coolant level is correct when it is at the bottom of the radiator filler neck (2).

(1) radiator cap (2) radiator filler neck

2. Add coolant up to the filler neck if the level is low.

Inspect the coolant level before each outing.

A coolant loss of 20 – 60 cm

(0.7 – 2.0 US oz, 0.7 – 2.1 Imp oz) through the overflow tube is normal. If coolant loss is more than this, inspect the cooling system. Capacity:

1.00R(1.06 US qt, 0.88 Imp qt) after disassembly

0.93R(0.98 US qt, 0.82 Imp qt) after draining

3. Install the radiator cap securely.

If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in overheating and engine damage.

NOTICE

Coolant

(2)

(1)

WARNING

Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you.

Always let the engine and radiator cool down before removing the radiator cap.

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42 Servicing Your Honda

Cooling System Inspection

1. Check the cooling system for leaks (see the Honda Shop Manual for troubleshooting of leaks).

2. Check the water hoses (1) for cracks, deterioration, and hose clamp for looseness.

3. Check the radiator mount for looseness.

4. Make sure the overflow tube (2) is connected and not clogged.

5. Check the radiator fins for clogging.

6. Check the water leakage check hole (3) below the water pump cover (4) for leakage. Make sure the hole remains open. If water leaks through the check hole, the water seal is damaged. If oil leaks through the check hole, the oil seal is damaged. See the Honda Shop Manual or consult your Honda dealer for replacing the water seal or the oil seal. Both seals should be replaced at the same time.

Coolant Replacement

Refer to Safety Precautions on page 19.

Coolant should be replaced by your Honda dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the Honda Shop Manual.

To properly dispose of drained coolant, refer to

You & the Environment, page 142.

Improper disposal of drained fluids is harmful to the environment.

NOTICE

Coolant

WARNING

(2)

(1)

(3)

(4)

(1) water hoses (2) overflow tube (3) water leakage check hole (4) water pump cover

Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you.

Always let the engine and radiator cool down before removing the radiator cap.

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Servicing Your Honda 43

Air Cleaner

Refer to Safety Precautions on page 19.

The air cleaner uses polyurethane inner and outer pieces which can’t be separated. A dirty air cleaner will reduce engine power.

Proper air cleaner maintenance is very important for off-road vehicles. A dirty, water-soaked, worn-out, or defective air cleaner will allow dirt, dust, mud, and other impurities to pass into the engine.

Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.

Your CRF’s air cleaner has very specific performance requirements. Use a new Honda Genuine air cleaner specified for your model or an air cleaner of equal quality.

Using the wrong air cleaner may result in premature engine wear.

Proper air cleaner maintenance can prevent premature engine wear or damage, expensive repairs, low engine power, poor gas mileage, and spark plug fouling.

Improper or lack of proper air cleaner maintenance can cause poor performance and premature engine wear.

NOTICE

Cleaning

1. Remove the seat (page 29).

2. Remove the air cleaner retaining bolt (1).

3. Align the two access top tabs (2) of the air cleaner assembly (3) and “ ” mark (4) of the air cleaner housing by rotating the air cleaner assembly counterclockwise.

5. Remove the air cleaner element (5) from the air cleaner holder (6).

(1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “ ” mark

4. Remove the air cleaner keeping the two access top tabs up.

(5) air cleaner element (8) hole (6) air cleaner holder (9) air cleaner tab (7) holder tab

6. Wash the air cleaner element in clean nonflammable cleaning solvent. Then wash in hot, soapy water, rinse well, and allow to dry thoroughly. The air cleaner element is made in two pieces: inner and outer, which cannot be separated.

7. Clean the inside of the air cleaner housing.

8. Allow the air cleaner element to dry thoroughly. After drying, soak the air cleaner element in clean Honda Foam Air Filter Oil or an equivalent air cleaner oil. Apply air cleaner oil to the entire surface, inner and outer, and rub it with both hands to saturate the air cleaner element with oil. Squeeze out excess oil.

9. Apply a thin coat of Honda White Lithium Grease or equivalent to the sealing surface between the air cleaner element and air cleaner element holder.

10.Assemble the air cleaner element and holder. Install the holder tab (7) of the holder in the hole (8) of the air cleaner tab (9).

(cont’d)

(4)

(1)

(2)

(3)

(8) (7)

(5)

(9)

(6)

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44 Servicing Your Honda

Air Cleaner

Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder.

14.Reinstall the seat (page 29), making sure it is securely attached.

NOTICE

(1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “ ” mark (10) groove

(2)

(4)

(10)

(1)

(3)

11.Install the air cleaner assembly (3) into the air cleaner housing keeping the two access top tabs (2) up.

12.Carefully position the sealing flange of the element to prevent dirt intrusion.

13.Align the groove (10) of the air cleaner assembly with the “ ” mark (4) of the air cleaner housing by rotating the air cleaner assembly clockwise. Install and tighten the air cleaner retaining bolt (1) securely.

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Servicing Your Honda 45

Crankcase Breather

Refer to Safety Precautions on page 19.

Service more frequently if your CRF is ridden in the rain or often at full throttle. Service the breather if you can see deposits in the transparent section of the drain tube.

Draining

1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container.

2. Reinstall the crankcase breather tube plug.

(1) crankcase breather tube plug (2) crankcase breather tube

(1)

(2)

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46 Servicing Your Honda

Throttle

Refer to Safety Precautions on page 19.

Throttle Freeplay

(1) freeplay

Inspection Check freeplay (1). Freeplay:

3 – 5 mm (0.1 – 0.2 in)

If necessary, adjust to the specified range.

Upper Adjustment Minor adjustments are generally made with the upper adjuster.

Lower Adjustment The lower adjuster is used for major freeplay adjustment, such as after replacing the throttle cables or removing the carburetor. It is also used if you can not get the proper adjustment with the upper adjuster.

(1)

(2)

(4)

(3)

(+)

(–)

(5) lock nut (+) increase (6) lower adjuster (–) decrease

1. Remove the fuel tank (page 30).

2. Loosen the lock nut (5).

3. Turn the lower adjuster (6) in direction (–) to decrease freeplay, and in direction (+) to increase freeplay.

4. Tighten the lock nut to the specified torque:

4 N·m (0.4 kgf·m, 3.0 lbf·ft)

5. Operate the throttle grip to ensure that it functions smoothly and returns completely.

6. Install the fuel tank (page 31).

If you can’t get the freeplay within the specified range, contact your Honda dealer.

1. Pull the dust cover (2) back.

2. Loosen the lock nut (3).

3. Turn the upper adjuster (4). Turning the adjuster in direction (–) will decrease freeplay and turning it in direction (+) will increase freeplay.

4. Tighten the lock nut to the specified torque:

4 N·m (0.4 kgf·m, 3.0 lbf·ft)

Return the dust cover to its normal position.

5. After adjustment, check for smooth rotation of the throttle grip from fully closed to fully open in all steering positions.

If the adjuster is threaded out near its limit or the correct freeplay cannot be reached, turn the adjuster all the way in and back out one turn. Tighten the lock nut, install the dust cover and make the adjustment with the lower adjuster.

(2) dust cover (+) increase (3) lock nut (–) decrease (4) upper adjuster

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(5)

(+)

(–)

(6)

Servicing Your Honda 47

Throttle

Throttle Inspection

(1) throttle

1. Check that the throttle assembly is positioned properly and the securing bolts are tight.

2. Check for smooth rotation of the throttle (1) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer.

3. Inspect the condition of the throttle cables from the throttle grip down to the carburetor. If the cable is kinked or chafed, have it replaced.

4. Check the cables for tension or stress in all steering positions.

5. Lubricate the cables with a commerciallyavailable cable lubricant to prevent premature rust and corrosion.

(1)

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48 Servicing Your Honda

Engine Idle Speed

Refer to Safety Precautions on page 19.

The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled servicing, including carburetor adjustment.

Remember, idle speed adjustment is not a “cure-all” for other problems in your engine’s fuel-delivery system. Adjusting the idle will not compensate for a fault elsewhere.

The engine must be at normal operating temperature for accurate idle speed adjustment.

Idle Speed Adjustment

1. If the engine is cold, start it and warm it up 3 minutes and then shut it off.

2. Connect a tachometer to the engine.

3. Shift into neutral and start the engine.

4. Keep the motorcycle in an upright position.

5. Adjust idle speed with the throttle stop screw (1). Idle speed:

1,700 ± 100 min-1(rpm)

(1)

(1) throttle stop screw

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Servicing Your Honda 49

Clutch System

Refer to Safety Precautions on page 19.

Clutch Lever Adjustment

The distance between the tip of the clutch lever and grip may be adjusted.

Make sure to adjust the clutch lever freeplay after the clutch lever position adjustment or clutch cable disconnected.

(1) lock nut (2) adjuster

1. Loosen the lock nut (1).

2. To position the clutch lever farther away from the handgrip, turn the adjuster (2) counterclockwise. To position the brake lever closer to the handgrip, turn the adjuster clockwise.

3. Tighten the lock nut.

(3) cable end adjuster (+) increase freeplay (–) decrease freeplay

5. Loosen the lock nut (4) and turn the integral cable adjuster (5) to adjust the clutch lever freeplay 10 – 20 mm (0.4 – 0.8 in) at the tip of lever. Tighten the lock nut.

(1)

(2)

(3)

(+)

(–)

4. Turn the cable end adjuster (3) in direction (+) until it seats lightly and then turn it out 5 turns.

(4)

(+)

(–)

(5)

(4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay

6. Adjust the cable end adjuster for minor adjustement.

Clutch Lever Freeplay

(1) clutch lever

Inspection Check freeplay. Freeplay:

10 – 20 mm (0.4 – 0.8 in)

If necessary, adjust to the specified range. Improper freeplay adjustment can cause premature clutch wear.

(1)

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Other Inspections & Lubrication

• Check that the clutch lever assembly is positioned properly (the end of the holder (1) aligned with the paint mark (2) on the handlebar) and the securing bolts are tight.

Clutch System

50 Servicing Your Honda

Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit — or the correct freeplay cannot be obtained.

(3) lock nut (+) increase (4) integral cable adjuster (–) decrease

1. Turn the cable end adjuster in direction (+) until it seats lightly and then turn it out 5 turns.

2. Loosen the lock nut (3).

3. Turn the integral cable adjuster (4) to obtain the specified freeplay.

4. Tighten the lock nut. Check the adjustment.

5. Start the engine, pull the clutch lever in, and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. Your CRF should move smoothly and accelerate gradually.

If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the Honda Shop Manual.

(3)

(+)

(–)

(4)

Cable End Adjustment Minor adjustments are generally made with the clutch cable end adjuster.

(2)

(+)

(–)

(2) cable end adjuster (+) increase freeplay (–) decrease freeplay

Turning the cable end adjuster (2) in direction (+) will increase freeplay and turning it in direction (–) will decrease freeplay.

If the adjuster is threaded out near its limit or the correct freeplay cannot be reached, turn the adjuster all the way in direction (+) and back out one turn in direction (–) and make the adjustment with the integral cable adjuster.

(1) holder (2) paint mark

• Check the clutch cable for kinks or signs of wear. If necessary, have it replaced.

• Lubricate the clutch cable with a commercially-available cable lubricant to prevent premature wear and corrosion.

Clutch Operation

1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or clutch cable.

2. Check the clutch cable for deterioration, kinks, or damage.

(2)

(1)

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Servicing Your Honda 51

Clutch System

Clutch Cover/Disc/Plate Removal

1. Drain the transmission oil (page 40).

2. Remove the rear brake pedal (1) by removing its pivot bolt (2), washer (3) and dust seals (4).

(1) rear brake pedal (3) washer (2) pivot bolt (4) dust seals

3. Remove the five clutch cover bolts (5) and clutch cover (6).

(5) clutch cover bolts (6) clutch cover

4. Remove the five clutch spring bolts and clutch springs (7).

Loosen the bolts in a crisscross pattern in two or three progressive steps.

5. Remove the clutch pressure plate (8).

(7) clutch spring bolts/clutch springs (8) clutch pressure plate

6. Remove the clutch lifter (9) and clutch lifter rod (10).

7. Remove the eight clutch discs, seven clutch plates, judder spring and spring seat (11). Turn the lifter bearing plate of the clutch lifter bearing with your finger. The bearing plate should turn smoothly and quietly. Discard the clutch lifter if the bearing plate does not turn smoothly.

(9) clutch lifter (10) clutch lifter rod (11) clutch discs, clutch plates, judder spring and spring

seat

(1)

(2)

(3)

(4)

(6)

(5)

(8)

(7)

(9)

(11)

(10)

Clutch Disc/Plate Inspection

Replace the clutch discs (1) if they show signs of scoring or discolouration. Measure the thickness of each clutch disc. Service Limit:

2.85 mm (0.112 in)

Replace the clutch discs and clutch plates as an assembly.

(1)

(1) clutch disc

Check the clutch plate (2) for excessive warpage or discolouration. Check the plate warpage on a surface plate using a feeler gauge. Measure the thickness of the clutch plates. Service Limit:

0.10 mm (0.004 in)

Replace the clutch discs and plates as a set.

(2)

(2) clutch plate

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52 Servicing Your Honda

Clutch System

Clutch Spring Inspection

(1) clutch spring

Measure the free length of each spring. Service Limit:

37.7 mm (1.48 in)

If one or more springs are beyond the service limit, replace the springs as a set.

Replace the clutch discs, clutch plates and clutch springs as a set if the clutch plates have been burnt/heat discolour.

Clutch Disc/Plate Installation

1. Install the spring seat (1) and judder spring (2) onto the clutch center as shown. Coat the clutch discs (3) and plates (4) with clean engine oil.

2 Install the clutch disc A (larger I.D. disc) (5)

onto the clutch outer. Stack the seven clutch plates and seven clutch discs alternately.

(1) spring seat (4) clutch plates (2) judder spring (5) clutch disc A (3) clutch discs

3. Apply grease to the clutch lifter rod (6) ends.

4. Insert the clutch lifter rod into the mainshaft.

5. Apply engine oil to the needle bearing of the clutch lifter.

6. Install the clutch lifter (7) onto the clutch lifter rod.

(6) clutch lifter rod (7) clutch lifter

7. Install the clutch pressure plate (8).

8. Install the five clutch springs and clutch spring bolts (9).

9. Tighten the bolts in a crisscross pattern in two or three steps, to the specified torque:

12 N·m (1.2 kgf·m, 9 lbf·ft)

(8) clutch pressure plate (9) clutch spring bolts/clutch springs

10.Apply oil to a new O-ring (10) and install in the groove of the clutch cover (11).

11. Install the cover by tightening the five cover bolts to the specified torque:

10 N·m (1.0 kgf·m, 7 lbf·ft)

(10) O-ring (11) clutch cover

(1)

(4)

(3)

(1)

(2)

(5)

(7)

(6)

(8)

(9)

(11)

(10)

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Servicing Your Honda 53

Clutch System

(12) dust seals (15) washer (13) rear brake pedal (16) brake pedal return spring (14) brake pedal pivot bolt

16.Fill the crankcase with transmission oil (page 40).

(13)

(16)

(14)

(15)

(12)

12.Lubricate the dust seals (12), rear brake pedal (13) pivot and rear brake pedal pivot bolt (14) with Honda Lithium Grease or equivalent.

13.Apply locking agent to the brake pedal pivot bolt threads.

14.Install the dust seals into the rear brake pedal.

15.Install the pivot bolt with the washer (15) and tighten the pivot bolt to the specified torque:

36 N·m (3.7 kgf·m, 27 lbf·ft)

Connect the brake pedal return spring (16) if it was removed.

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54 Servicing Your Honda

Hot Start Lever

Refer to Safety Precautions on page 19.

Hot Start Lever Freeplay

(1) hot start lever (2) hot start lever freeplay

Inspection Check freeplay:

2 – 3 mm (0.08 – 0.12 in)

If necessary, adjust to the specified range.

Adjustment Adjustments can be made with the cable adjuster.

Loosen the lock nut (3) and turn the adjuster (4). Turning the adjuster clockwise (+) will increase freeplay and turning it counterclockwise (–) will decrease freeplay. After adjustment, tighten the lock nut.

(3) lock nut (+) increase (4) adjuster (–) decrease

(2)

(1)

(3)

(+)

(–)

(4)

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Servicing Your Honda 55

Refer to Safety Precautions on page 19.

Spark Plug Recommendation

The recommended standard spark plug is satisfactory for most racing conditions.

Use only the recommended type of spark plugs in the recommended heat range.

Using a spark plug with an improper heat range or incorrect reach can cause engine damage. Using a non-resistor spark plug may cause ignition problems.

This motorcycle uses a spark plug that has an iridium tip in the centre electrode and a platinum tip in the side the electrode. Be sure to observe the following when servicing the spark plug.

• Do not clean the spark plug. If an electrode is

contaminated with accumulated objects or dirt, replace the spark plug with a new one.

•To check the spark plug gap, use only a “wire-

type feeler gauge.” To prevent damaging the iridium tip of the centre electrode and platinum tip of the side electrode, never use a “leaf-type feeler gauge.”

• Do not adjust the spark plug gap. If the gap is

out of specification, replace the spark plug with a new one.

NOTICE

Spark Plug

Spark Plug Inspection & Replacement

1. Remove the seat and fuel tank (pages 29, 30).

2. Disconnect the direct ignition coil (1).

3. Clean any dirt from around the spark plug bases.

4. Remove the spark plug (2).

7. To obtain accurate spark plug readings, accelerate up to speed on a straightaway. Push the engine stop button and disengage the clutch by pulling the lever in. Coast to a stop, then remove and inspect the spark plug. The porcelain insulator around the centre electrode should appear tan or medium gray.

If you're using a new plug, ride for at least 10 minutes before taking a plug reading; a brand-new plug will not appers colour initially.

If the electrodes appear burnt, or the insulator is white or light gray (lean) or the electrodes and insulator are black or fouled (rich), there is a problem elsewhere (page 131). Check the carburetor, fuel system and ignition timing.

8. With the sealing gasket attached. Thread the spark plug in by hand to prevent crossthreading.

9. Tighten the spark plug:

• If the old plug is good: 1/8 turn after it seats.

• If installing a new plug, tighten it twice to prevent loosening: a) First, tighten the plug:

NGK: 1/2 turn after it seats. b) Then loosen the plug. c) Next, tighten the plug again:

1/8 turn after it seats.

An improperly tightened spark plug can damage the engine. If a plug is too loose, a piston may be damaged. If a plug is too tight, the threads may be damaged.

NOTICE

(1) direct ignition coil (2) spark plug

5. Check the electrode for wear or deposits, the sealing gasket (3) for damage, and the insulator for cracks. Replace if you detect them.

6. Check the spark plug gap (4), using a wire-type feeler gauge. If the gap is out of specifications, replace the plug with a new one. The recommended spark plug gap is:

0.6 – 0.7 mm (0.024 – 0.028 in)

(3) sealing gasket (4) spark plug gap

(1)

(2)

(3)

(4)

Standard

Optional

R0409B-8 (NGK)

R0409B-9 (NGK)

10.Connect the direct ignition coil. Take care to avoid pinching any cables or wires.

11. Install the fuel tank and seat (pages 29, 31).

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56 Servicing Your Honda

Valve Clearance

Cylinder Head Cover Removal

Before inspection, clean the engine thoroughly to keep dirt from entering the engine.

1. Remove the seat and fuel tank (pages 29, 30).

2. Disconnect the breather tube (1) and direct ignition coil (2).

Positioning At Top Dead Centre On The

Compression Stroke

1. Remove the crankshaft hole cap (1).

(1) breather tube (2) direct ignition coil

3. Remove the cylinder head cover bolts/rubber seals (3) and cylinder head cover (4).

(3) cylinder head cover bolts/rubber seals (4) cylinder head cover

4. Remove the spark plug hole packing.

(1) crankshaft hole cap

2. Remove the spark plug (page 55).

(2)

(1)

(3)

(4)

(1)

Refer to Safety Precautions on page 19.

Excessive valve clearance will cause noise and eventual engine damage. Little or no clearance will prevent the valve from closing and cause valve damage and power loss. Check the valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule (page 21).

The checking or adjusting of the clearance should be performed while the engine is cold. The valve clearance will change as engine temperature rises.

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Servicing Your Honda 57

Valve Clearance

Valve Clearance Inspection

1. Measure the intake valve clearance by inserting a feeler gauge (1) between the valve lifters (2) and intake cams (3).

2. Measure the exhaust valve clearance by inserting a feeler gauge (1) between the exhaust rocker arm (4) and exhaust valve shims (5).

(1) feeler gauge (4) exhaust rocker arm (5) exhaust valve shims

Valve Clearances:

IN: 0.12 ± 0.03 mm (0.005 ± 0.001 in) EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)

If intake valve clearance and exhaust valve clearance need adjustment, see

Camshaft

Removal

(page 58) and select the correct shim for

each valve.

(5)

(3)

(2)

(1)

(4)

(5)

(1) feeler gauge (2) valve lifters (3) intake cams

3. Rotate the crankshaft by turning the primary drive gear bolt (2) (crankshaft) clockwise until aligning the punch mark (3) on the primary drive gear with the “ ” mark (4) on the right crankcase cover. In this position, the piston may either be on the compression or exhaust stroke. If the crankshaft passed the punch mark, rotate the primary drive gear bolt clockwise again and align the punch mark with the “ ” mark. The inspection must be made when the piston is at the top of the compression stroke when both the intake and exhaust valves are closed. This condition can be determined by moving the exhaust rocker arm (5). If it is free, it is an indication that the valves are closed and that the piston is on the compression stroke. If it is tight and the valves are open, rotate the primary drive gear bolt 360° and realign the punch mark to the “ ” mark.

(2)

(3)

(4)

(2) primary drive gear bolt (4) “ ” mark (3) punch mark

(5) exhaust rocker arm

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58 Servicing Your Honda

Valve Clearance

Camshaft Removal

1. Record the intake valve clearance and exhaust valve clearance (page 57).

(1) cam chain tensioner lifter cover bolt (2) sealing washer

Use the tensioner stopper tool.

• Tensioner stopper 070MG-0010100

3. Turn the tensioner shaft clockwise with the tensioner stopper (3) until it stops, in order to retract the tensioner fully. Then insert the tensioner stopper fully to hold the stopper in the fully retracted position.

(3) tensioner stopper

(2)

(1)

(3)

2. Remove the cam chain tensioner lifter cover bolt (1) and sealing washer (2).

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Servicing Your Honda 59

Valve Clearance

7. Remove the shims (8).

(8) shims

(8)

4. Remove the camshaft holder bolts (4) and camshaft holders (5). Loosen the camshaft holder bolts in a crisscross pattern in two or three steps.

5. Remove the camshaft (6), and then attach a piece of wire to the cam chain to prevent it from falling into the crankcase.

Be careful to not let the set rings of the camshaft holders fall into the crankcase.

(4) camshaft holder bolts (6) camshaft (5) camshaft holders

6. Remove the valve lifters (7).

Position the removed intake valve lifters and shims to indicate their location such as intake or exhaust, right or left.

Do not let the valve lifters or shims fall into the crankcase.

NOTICE

(7) valve lifters

(4)

(5)

(6)

(4)

(7)

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60 Servicing Your Honda

Valve Clearance

Shim Selection

1. Clean the valve shim contact area in the valve lifter (1) with compressed air.

(1) valve lifter

2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm.

3. Calculate the new shim thickness using the equation below.

A= (B – C) + D

A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness

• Make sure of the correct shim thickness by

measuring the shim with a micrometer.

• Reface the intake valve seat if carbon deposits

result in a calculated dimension of over

2.450 mm. Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over

2.900 mm.

(1)

(2)

(2) shim

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Servicing Your Honda 61

Valve Clearance

4. Apply molybdenum oil solution to the camshaft journals and cam lobes. Place the camshaft (7) with the intake cam lobes (8) facing up and align the timing marks (9) on the cam sprocket (10) with the surface of the cylinder head (11). Install the cam chain (12) over the sprocket without rotating the camshaft.

(4) primary drive gear bolt (5) punch mark (6) “ ” mark

(7) camshaft (8) intake cam lobes (9) timing marks (10) cam sprocket (11) surface of the cylinder head (12) cam chain

(4)

(5)

(6)

(7)

(11)

(9)

(8)

(10)

(12)

Camshaft Installation

1. Install the newly selected shims (1) on the valve retainers (2).

Do not let the shims fall into the crankcase.

NOTICE

(1) shims (2) valve retainers

2. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the outer surface of the each the valve lifters (3). Install the valve lifters to the proper position.

(3) valve lifters

3. Rotate the primary drive gear bolt (4) (crankshaft) clockwise and align the punch mark (5) with the “ ” mark (6).

(1)

(2)

(3)

(cont’d)

5. Apply grease to the set rings (13) and install it onto the camshaft holders (14).

(14)

(13)

(13) set ring (14) camshaft holder

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62 Servicing Your Honda

Valve Clearance

(13) set ring (14) camshaft holders (16) camshaft bearing groove (17) camshaft holder bolts

10.Rotate the camshaft by rotating the crankshaft clockwise several times.

11. Insert the feeler gauge (21) between the intake valve lifter and cam lobe. If the feeler gauge cannot be inserted, the shim is caught between the valve lifter and the valve retainer. Remove the camshaft holders, place the shim correctly, and reinstall the camshaft holders. Valve Clearances:

IN: 0.12 ± 0.03 mm (0.005 ± 0.001 in) EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)

(21) feeler gauge

(17)

(14)

(13)

(16)

(21)

8. Remove the tensioner stopper (18) from the cam chain tensioner lifter.

(18)

(18) tensioner stopper

9. Install a new sealing washer (19) and tighten the cam chain tensioner lifter cover bolt (20).

(19) sealing washer (20) cam chain tensioner lifter cover bolt

(19)

(20)

(15) identification marks

6. Install the camshaft holders (14) in their proper position by aligning the camshaft bearing groove (16) with the set ring (13).

7. Apply oil to the camshaft holder bolt threads and seating surface. Tighten the camshaft holder bolts (17) to the specified torque:

16 N·m (1.6 kgf·m, 12 lbf·ft)

Tighten the camshaft holder bolts in a criss-cross pattern in two or three steps.

Each camshaft holder has an identification mark (15).

(15)

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Servicing Your Honda 63

Valve Clearance

12.Install the spark plug (page 55).

13.Coat a new O-ring (22) with oil and install it onto the crankshaft hole cap (23). Apply grease to the crankshaft hole cap threads. Install and tighten the crankshaft hole cap to the specified torque:

15 N·m (1.5 kgf·m, 11 lbf·ft)

(22) O-ring (23) crankshaft hole cap

Cylinder Head Cover Installation

1. Check the spark plug hole packing (1) is in good condition, replace it if necessary. Install the spark plug hole packing to the spark plug hole (2).

2. Inspect the cylinder head cover packing (3) for damage or deterioration, replace it if necessary. Install the cylinder head cover packing into the groove of the cylinder head cover (4).

(1) spark plug hole packing (2) spark plug hole

(3) cylinder head cover packing (4) cylinder head cover

3. Check the rubber seals (5) are in good condition, replace them if necessary. Install the rubber seals onto the cylinder head cover with the “UP” marks (6) facing up.

(5) rubber seal (6) “UP” marks

4. Install the cylinder head cover (4) and tighten the cylinder head cover bolts (7) to the specified torque:

10 N·m (1.0 kgf·m, 7 lbf·ft)

(4) cylinder head cover (7) cylinder head cover bolts

5. Connect the direct ignition coil (8) and breather tube (9).

(8) direct ignition coil (9) breather tube

6. Install the fuel tank and the seat (pages 29, 31).

(22)

(23)

(1)

(2)

(5)

(6)

(4)

(3)

(7)

(4)

(8)

(9)

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64 Servicing Your Honda

11. Remove the engine hanger nuts/bolts (3) and engine hanger plates (4).

(3) engine hanger nuts/bolts (4) engine hanger plates

(4)

(3)

Piston/Piston Rings/Piston Pin

Cylinder Head Removal

1. Clean the area above the engine before disassembly to prevent dirt falling into the engine.

2. Drain the radiator coolant after cooling the motorcycle (page 42).

3. Remove the seat and fuel tank (pages 29, 30).

4. Remove the subframe (page 32).

5. Remove the carburetor (page 122).

6. Remove the exhaust pipe (page 90).

7. Remove the spark plug (page 55).

8. Remove the cylinder head cover (page 56).

9. Position the piston at top dead centre on the compression stroke (page 56). Remove the camshaft (page 58).

10.Loosen the water hose clamp (1) and disconnect the water hose (2).

(1) water hose clamp (2) water hose

(2)

(1)

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Servicing Your Honda 65

Piston/Piston Rings/Piston Pin

12.Remove the cylinder head bolts (5).

13.Loosen the cylinder bolt (6).

(5) cylinder head bolts (6) cylinder bolt

(7) cylinder head nuts/washers (8) cylinder head

15.Remove the dowel pins (9), cylinder head gasket (10) and cam chain guide (11).

Do not let the dowel pins and cam chain fall into the crankcase.

NOTICE

(9) dowel pins (11) cam chain guide (10) cylinder head gasket

(6)

(5)

(8)

(7)

(10)

(9)

(11)

14.Remove the cylinder head nuts/washers (7) and cylinder head (8). Loosen the nuts in a crisscross pattern in two or three steps.

Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase.

NOTICE

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66 Servicing Your Honda

Piston/Piston Rings/Piston Pin

Cylinder Removal

1. Remove the cylinder bolt (1) and cylinder (2).

Do not let the cam chain fall into the crankcase. Do not pry on or strike the cylinder.

NOTICE

(1) cylinder bolt (2) cylinder

2. Remove the dowel pins (3) and cylinder gasket (4).

Do not let the dowel pins fall into the crankcase.

NOTICE

(3) dowel pins (4) cylinder gasket

Piston Removal

1. Place clean shop towels in the crankcase to keep the piston pin clips or other parts from falling into the crankcase.

2. Remove the piston pin clips (1) using a pair of needle-nose pliers.

3. Press the piston pin (2) out of the piston (3), and remove the piston.

Under racing conditions, the piston and rings should be replaced after 15.0 hours of running. Replace the piston pin after 15.0 hours of running.

Piston Ring Removal

Spread each piston ring (1) and remove by lifting it up at a point just opposite the gap.

Do not damage the piston ring by spreading the ends too far.

NOTICE

(1)

(2)

(3)

(4)

(3)

(2)

(1)

(1) piston pin clip (3) piston (2) piston pin

(1)

(1) piston ring

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Servicing Your Honda 67

Piston/Piston Rings/Piston Pin

Piston Ring Installation

1. Clean the piston ring thoroughly.

2. Apply engine oil to the piston rings and install them.

Do not damage the piston ring by spreading the ends too far. Do not damage the piston during piston ring installation.

• To install the oil ring, install the spacer first,

then install the side rails.

• Install the top ring on the piston with the

marking side facing up.

3. After installing the rings they should rotate freely, without sticking. Space the ring end gaps 180 degrees apart between the top ring and the upper side rail. Space the ring end gaps 90 degrees apart between the upper side rail, spacer, and the lower side rail.

NOTICE

mark

top ring

oil ring

side rail

spacer

top ring

oil ring

Piston/Piston Pin/Piston Ring

Inspection

We recommend you consult the Shop Manual or your Honda dealer for correct Service Limit measurements.

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68 Servicing Your Honda

Piston/Piston Rings/Piston Pin

Piston Installation

1. Place clean shop towels over the crankcase opening to keep the piston pin clips from falling into the crankcase.

2. Apply molybdenum disulfide grease (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive) to the inner surface of the connecting rod small end.

3. Install the piston (1) with the “O” mark (2) and/or the large valve recess (3) facing the intake side of the engine.

4. Apply engine oil to the piston pin (4) and inner surface of the piston pin hole. Install the piston pin and new piston pin clips (5).

Use new piston pin clips. Never reuse old piston pin clips. Do not let the piston pin clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cut-out (6).

NOTICE

(1) piston (4) piston pin (2) “O” mark (5) piston pin clip (3) large valve recess (6) piston cut-out

Cylinder Installation

1. Place clean shop towels over the crankcase opening to prevent dust or dirt from entering the engine.

2. Clean off any gasket material from the gasket surface of the crankcase.

3. Remove the shop towel. Do not let any gasket debris fall into the crankcase.

4. Install the dowel pins (1) and a new cylinder gasket (2).

Do not let the dowel pins fall into the crankcase.

NOTICE

(1) dowel pins (2) cylinder gasket

5. Clean any gasket material off the cylinder.

(1)

(2)

(3)

(1)

(4)

(5)

(2)

(6)

(5)

(1)

(2)

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Servicing Your Honda 69

Piston/Piston Rings/Piston Pin

6. Apply clean engine oil to the cylinder wall, piston outer surface and piston rings. Route the cam chain (3) through the cylinder (4). Install the cylinder over the piston rings by hand while compressing the piston rings (5).

Do not damage the piston rings and cylinder walls.

NOTICE

(3) cam chain (5) piston rings (4) cylinder

7. Install the cam chain guide (6) and fit the cam chain guide tabs (7) in the cylinder cut-outs (8). Push the guide until it bottoms in the crankcase guide hole.

(6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs

Cylinder Head Installation

1. Install the dowel pins (1) and a new cylinder head gasket (2).

Do not let the dowel pins fall into the crankcase.

NOTICE

(1) dowel pins (2) cylinder head gasket

(3)

(4)

(5)

(6)

(8)

(7)

(2)

(1)

(cont’d)

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70 Servicing Your Honda

Piston/Piston Rings/Piston Pin

2. Route the cam chain through the cylinder head (3). Install the cylinder head.

Do not damage mating surfaces when installing the cylinder head.

3. Apply engine oil to the cylinder head nut threads. Install the washers and cylinder head nuts (4). Tighten the cylinder head nuts in a crisscross pattern in two or three steps to the specified torque:

39 N·m (4.0 kgf·m, 29 lbf·ft)

Do not let the washers and nuts fall into the crankcase.

NOTICE

4. Install the cylinder bolt (5) and cylinder head bolts (6) and tighten them to the specified torque:

10 N·m (1.0 kgf·m, 7 lbf·ft)

5. Install the engine hanger plates (7), engine hanger nuts/bolts of the frame side (8) and engine hanger nut/bolt of the engine side (9). Tighten the engine hanger nut to the specified torque: frame side:

34 N·m (3.5 kgf·m, 25 lbf·ft)

engine side: 54 N·m (5.5 kgf·m, 40 lbf·ft)

(3) cylinder head (4) cylinder head nuts/washers

(5) cylinder bolt (6) cylinder head bolts

(7) engine hanger plates (8) engine hanger nuts/bolts of the frame side (9) engine hanger nut/bolt of the engine side

(3)

(4)

(5)

(6)

(7)

(9)

(8)

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Servicing Your Honda 71

Piston/Piston Rings/Piston Pin

6. Connect the radiator hose (10) to the cylinder head and tighten the radiator hose clamp (11) securely.

(10) radiator hose (11) radiator hose clamp

7. Install the shims, valve lifters and camshaft (page 61).

8. Install the spark plug (page 55).

9. Install the crankshaft hole cap (page 63).

10.Install the cylinder head cover (page 63).

11. Install the exhaust pipe (page 90).

12.Install the carburetor (page 126).

13.Install the subframe (page 33).

14.Install the fuel tank and the seat (pages 29, 31).

(10)

(11)

15.Pour a fresh recommended coolant mixture (page 41).

Check for the following: – compression leaks – abnormal engine noise – secondary air leaks – coolant leaks

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72 Servicing Your Honda

Suspension

Refer to Safety Precautions on page 19.

Loose, worn, or damaged suspension components may adversely affect the handling and stability of your CRF. If any suspension components appear worn or damaged, see your Honda dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts or repairs are needed.

Front Suspension Inspection

• When your CRF is new, break it in for approximately 1 hour to ensure that the suspension has worked in (page 15).

• After break-in, test run your CRF with the front suspension at the standard setting before attempting any adjustments.

• For optimum fork performance, we recommend that you disassemble and clean the fork after riding your CRF for 3 hours. See page 99 for fork disassembly.

• Replace the fork oil every 3 races or 7.5 hours of running. See page 74 for oil capacity adjustment after changing the fork oil.

• Replace the damper fork oil every 9 races or

22.5 hours of running. See page 102 for damper fork oil level adjustment after changing the fork oil.

• Use Honda ULTRA CUSHION OIL SPECIAL 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension.

• Periodically check and clean all front suspension parts to assure top performance. Check the dust seals for dust, dirt, and foreign materials. Check the oil for any contamination.

• Refer to

Suspension Adjustment Guidelines

(page 116). Make all rebound and compression damping adjustments in one-click increments. (Adjusting two or more clicks at a time may cause you to pass over the best adjustment.) Test ride after each adjustment.

• If you become confused about adjustment settings, return to the standard position and start over.

• If the fork is still too stiff/soft after adjusting compression damping, determine which portion of the travel is still too stiff/soft. This is an important step that will help you solve suspension problems.

1. Make sure that the fork protectors (1) and dust seals (2) are clean and not packed with mud and dirt.

2. Check for signs of oil leakage. Damaged or leaking fork seals should be replaced before your CRF is ridden.

(1) fork protector (2) dust seal

3. Inspect the wear rings (3) for wear or damage. Replace the wear ring if it is 1.5 mm (0.06 in) or flat with the outer tube (4). When replacing the wear ring, remove the fork leg (page 99). Install the wear ring with its end gap facing rearward.

(3) wear ring (4) outer tube

(3) wear rings

4. Make a quick check of fork operation by locking the front brake and pushing down on the handlebar several times.

(1)

(2)

(3)

(4)

(3)

1.5 mm (0.06 in)

(3)

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Servicing Your Honda 73

Suspension

Rear Suspension Inspection

The swingarm is controlled by one hydraulic shock absorber with an aluminum reservoir for oil and nitrogen gas pressure. The gas pressure in the reservoir is contained within a rubber bladder.

The shock absorber’s spring pre-load and damping adjustments (compression and rebound) should be adjusted for the rider’s weight and track conditions (page 115).

Do not attempt to disassemble, service, or dis

pose of the damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustments of the shock assembly only.

• When your CRF is new, break it in for approximately one hour with the standard suspension settings before attempting to adjust the rear suspension.

• Make all compression and rebound damping adjustments in the specified increment or turns described in page 112. (Adjusting two or more increments or turns at a time may cause you to pass over the best adjustment.) Test ride after each adjustment.

• If the rear suspension is too stiff/soft, adjust it by turning all the compression and rebound adjusters according to the procedures described in page 112. After adjusting the adjusters simultaneously, suspension may be fine-tuned by turning one of the compression and rebound damping adjusters in one click or in 1/12 turn increments.

• If you have a problem finding an acceptable adjustment, return to the standard position and begin again.

1. Bounce the rear of the motorcycle up and down and check for smooth suspension action.

2. Remove the subframe (page 32).

3. Check for a broken or collapsed spring.

4. Check the rear shock absorber (1) for a bent shaft or oil leaks.

(1) rear shock absorber

5. Push the rear wheel sideways to check for worn or loose swingarm bearings. There should be no movement. If there is, have the bearings replaced by your Honda dealer.

(1)

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Suspension

74 Servicing Your Honda

Recommended Fork Oil

Fork Oil Change

Refer to Front Suspension Disassembly on page 99.

1. Record the rebound damping adjuster position and turn the adjuster counterclockwise until it stops.

2. Hold the outer tube (1), then remove the fork damper (2) from the outer tube using a lock nut wrench (3). Gently slide the outer tube down onto the axle holder (4).

viscosity (weight) 5 W

suggested oil

Honda ULTRA CUSHION OIL SPECIAL

(1) outer tube (3) lock nut wrench (2) fork damper (4) axle holder

The outer tube (1) can drop on the slider and damage the fork dust seal (5) and guide bushing (6) when the fork damper is removed. To avoid damage, hold both the outer tube and slider (7) when removing the fork damper.

NOTICE

(1) outer tube (6) guide bushing (5) fork dust seal (7) slider

3. Drain the fork oil from the outer tube (1). Drain the fork oil from the oil hole (9) of the fork damper.

(1) outer tube (9) oil hole

4. Drain the fork oil by turning the outer tube (1) upside down. (About 12 cm

(0.4 US oz) of fork oil will be left in the outer tube when it is left inverted for about 20 minutes at 20°C/68°F.)

(1) outer tube

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 142).

Improper disposal of drained oil is harmful to the environment

NOTICE

Amount of fork oil left in the fork (within damper and spring) unit: cm

minute

°C/°F

30/86

20/68

10/50

0/32

29.4

28.2

30.6

15.3

16.5

21.2

22.4

10.6

11.8

16.5

18.8

9.4

10.6

15.3

16.5

8.3

9.4

12.9

16.5

7.9

8.2

11.8

15.3

145

7.9

8.2

11.8

14.1

(4)

(3)

(1)

(2)

(5)

(6)

(7) (1)

(1)

(9)

(1)

(cm3)

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Servicing Your Honda 75

Suspension

5. Pour the recommended fork oil into the outer tube (1).

Fork Oil Capacity

Standard 4.510 N/mm (25.75 lbf/in) Fork Spring

Standard oil capacity

368 cm

12.4 US oz,

13.0 Imp oz

Maximum oil capacity

414 cm3

14.0 US oz,

14.6 Imp oz

Slightly stiffer as it nears full compression.

Slightly softer as it nears full compression.

Minimum oil capacity

318 cm

10.8 US oz,

11.2 Imp oz

Optional Softer 4.310 N/mm (24.61 lbf/in) Fork Spring

(

Standard oil capacity

373 cm

12.6 US oz,

13.2 Imp oz

Maximum oil capacity

419 cm3

14.2 US oz,

14.7 Imp oz

Slightly stiffer as it nears full compression.

Slightly softer as it nears full compression.

Minimum oil capacity

323 cm

10.9 US oz,

11.4 Imp oz

(

5 scribe marks (aftermarket parts)

No mark (factory products)

4 scribe marks

Optional Stiffer 4.710 N/mm (26.89 lbf/in) Fork Spring

Standard oil capacity

362 cm

12.2 US oz,

12.7 Imp oz

Maximum oil capacity

409 cm3

13.8 US oz,

14.4 Imp oz

Slightly stiffer as it nears full compression.

Slightly softer as it nears full compression.

Minimum oil capacity

313 cm

10.6 US oz,

11.0 Imp oz

(

3 scribe marks

(1)

Be sure the oil capacity is the same in both fork legs.

(1) outer tube

(cont’d)

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Suspension

76 Servicing Your Honda

6. Check that the O-ring (10) on the fork damper (2) is in good condition. Apply the recommended fork oil to the O-ring.

(2) fork damper (10) O-ring

7. Temporarily install the fork damper to the outer tube. After installing the fork leg (page 109) tighten the fork damper to the specified torque: Actual:

34 N·m (3.5 kgf·m, 25 lbf·ft)

Torque wrench scale reading: 31 N·m (3.2 kgf·m, 23 lbf·ft) using a 500 mm (20 in) long torque wrench.

When using the lock nut wrench, use a 500 mm (20 in) long deflecting beam type torque wrench. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the fork damper.

(2)

(10)

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Servicing Your Honda 77

Brakes

Refer to Safety Precautions on page 19.

Both the front and rear brakes are the hydraulic disc type. As the brake pads wear, the brake fluid level will drop. A leak in the system will also cause the level to drop.

Frequently inspect the system to ensure there are no fluid leaks. Periodically inspect the brake fluid level and the brake pads for wear.

If the front brake lever or rear brake pedal freeplay does not feel within the normal range while riding, check the brake pads. If they are not worn beyond the recommended limit (page 80), there is probably air in the brake system. Refer to the Honda Shop Manual or see your Honda dealer to have the air bled from the system.

(1) lock nut (2) adjuster

1. Loosen the lock nut (1).

2. To position the brake lever farther away from the handgrip, turn the adjuster (2) clockwise. To position the brake lever closer to the handgrip, turn the adjuster counterclockwise.

3. While holding the adjuster, tighten the lock nut to the specified torque:

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

4. Apply the brake, release it, then spin the wheel and check that it rotates freely. Repeat this procedure several times.

5. Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage. Freeplay:

10 – 20 mm (0.4 – 0.8 in)

6. Apply silicone grease to the contacting faces of the adjuster.

Rear Brake Pedal Height

The brake pedal height should be approximately level with the right footpeg.

1. Loosen the lock nut (1) and turn the adjusting bolt (2) in direction (+) to raise the rear brake pedal (3) or in direction (–) to lower it.

2. Tighten the lock nut to the specified torque at the desired pedal height.

5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

(1) lock nut (+) raise the pedal height (2) adjusting bolt (–) lower the pedal height (3) rear brake pedal

(1)

(2)

10 – 20 mm (0.4 – 0.8 in)

(+)

(–)

(3)

(1)

(2)

Front Brake Lever Adjustment

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78 Servicing Your Honda

Brakes

Fluid Level Inspection

Front Brake Fluid Level Check

(1) LWR mark

With the motorcycle in an upright position, check the fluid level. It should be above the LWR mark (1). If the level is at or below the LWR mark, check the brake pads for wear (page 80). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. If the brake lever freeplay exceeds 20 mm (0.8 in), there is probably air in the brake system and it must be bled. Refer to the Honda Shop Manual or see your Honda dealer for brake bleeding.

Rear Brake Fluid Level Check

(2) LOWER level mark

With the motorcycle in an upright position, check the fluid level. It should be above the LOWER level mark (2). If the level is at or below the LOWER level mark, check the brake pads for wear (page 80). Worn brake pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. If the brake pedal freeplay exceeds 20 mm (0.8 in), there is probably air in the brake system and it must be bled. Refer to the Honda Shop Manual or see your Honda dealer for brake bleeding.

(1)

(2)

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Servicing Your Honda 79

Brakes

Adding Front Brake Fluid

Spilled brake fluid will severely damage the painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first.

• Always use fresh DOT4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible.

• The recommended brake fluid is DOT4 brake fluid or an equivalent.

NOTICE

(1) screws (2) reservoir cap (3) diaphragm (4) upper level mark

1. Remove the screws (1), reservoir cap (2) and diaphragm (3).

2. Fill the reservoir with DOT4 brake fluid to the upper level mark (4). Do not overfill.

3. Reinstall the diaphragm and reservoir cap.

4. Tighten the screws to the specified torque:

1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

Adding Rear Brake Fluid

Spilled brake fluid will severely damage the painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first.

• Always use fresh DOT4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible.

• The recommended brake fluid is DOT4 brake fluid or an equivalent.

NOTICE

(5) bolts (8) diaphragm (6) reservoir cap (9) upper level mark (7) set plate

1. Remove the bolts (5) reservoir cap (6), set plate (7) and diaphragm (8).

2. Fill the reservoir with DOT4 brake fluid to the upper level mark (9). Do not overfill.

3. Set the diaphragm as shown.

4. Reinstall the set plate and reservoir cap.

5. Tighten the bolts to the specified torque:

1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

(3)

(2)

(1)

(4)

(5)

(6)

(8)

(7)

(9)

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80 Servicing Your Honda

Brakes

Brake Pad Wear

Brake pad wear depends on the severity of usage and track conditions. (Generally, the pads will wear faster on wet and dirty tracks) Inspect the pads at each regular maintenance interval (page 21).

Front Brake Pads Inspect the brake pads (2) through the front wheel to determine the pad wear. If either pad is worn anywhere to a thickness of 1 mm (0.04 in), both pads must be replaced.

(1) front brake caliper (3) brake disc (2) brake pads

Rear Brake Pads Inspect the brake pads (5) from the rear side of the caliper to determine the pad wear. If either pad is worn anywhere to a thickness of 1 mm (0.04 in), both pads must be replaced.

(4) rear brake caliper (6) brake disc (5) brake pads

Other Inspections

Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight.

Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings.

(3)

(1)

wear indicator grooves

replace

1 mm

(0.04 in)

(2)

minimum thickness indicator

replace

1 mm

(0.04 in)

(2)

replace

1 mm

(0.04 in)

minimum thickness indicator

(4)

(5)

(6)

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Servicing Your Honda 81

Wheels

Refer to Safety Precautions on page 19.

Keeping the wheels true (round) and maintaining correct spoke tension is critical to safe motorcycle operation. During the first few rides, spokes will loosen more rapidly due to the initial seating of the parts. Excessively loose spokes may result in instability at high speeds and the possible loss of control. It’s also important that the rim locks are secure to prevent tyre slippage.

It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule (page 21). However, information for wheel removal is provided for emergency situations.

Wheel Rims & Spokes

(1) wheel rim (3) rim lock (2) spoke

1. Inspect the wheel rims (1) and spokes (2) for damage.

2. Tighten, any loose spokes and rim locks (3) to the specified torque: Front Spoke

3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) Rear Spoke :

3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

Rim Lock : 12 N·m (1.2 kgf·m, 9 lbf·ft)

3. Check wheel rim runout. If runout is

noticeable, see the Honda Shop Manual for inspection instructions.

Axles & Wheel Bearings

See the Honda Shop Manual for inspection information:

1. Check the axle shaft for runout.

2. Check the condition of the wheel bearings.

(1)

(3)

(2)

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82 Servicing Your Honda

Tyres & Tubes

WARNING

Using tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed.

Follow all instructions in this owner’s manual regarding tyre inflation and maintenance.

Front 100 kPa (1.0 kgf/cm2, 15 psi)

Rear 100 kPa (1.0 kgf/cm2, 15 psi)

Refer to Safety Precautions on page 19.

To safely operate your CRF the tyres must be the proper type (off-road) and size, in good condition with adequate tread, and correctly inflated.

The following pages give detailed information on how and when to check your air pressure, how to inspect your tyres for wear and damage, and our recommendations on tyre repair and replacement.

Air Pressure

Properly inflated tyres provide the best combination of handling, tread life, and riding comfort. Generally, underinflated tyres wear unevenly, adversely affect handling, and are more likely to fail from being overheated. Underinflated tyres can also cause wheel damage on hard terrain. Overinflated tyres make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly.

Make sure the valve stem caps are secure. If necessary, install new caps.

Always check air pressure when your tyres are “cold.” If you check air pressure when your tyres are “warm” — even if your CRF has only been ridden for a few kilometers — the readings will be higher. If you let air out of warm tyres to match the recommended cold pressures, the tyres will be underinflated. The correct “cold” tyre pressures are:

If you decide to adjust tyre pressures for a particular riding condition, make changes a little at a time.

Inspection

Take time to inspect your tyres and wheels before you ride.

• Inspect carefully for bumps or bulges in the side of the tyre or the tread. Replace any tyre that has a bump or bulge.

• Look closely for cuts, slits, or cracks in the tyres. Replace a tyre if you can see fabric or cord.

• Check for rocks or other objects embedded in the tyre or tread. Remove any objects.

• Check the position of both valve stems. A tilted valve stem indicates the tube is slipping inside the tyre or the tyre is slipping on the rim.

Tube Replacement

If a tube is punctured or damaged, you should replace it as soon as possible. A repaired tube may not have the same reliability as a new one, and it may fail while you are riding.

Use a replacement tube equivalent to the original.

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Servicing Your Honda 83

Tyres & Tubes

Tyre Replacement

The tyres that came on your CRF were designed to provide a good combination of handling, braking, durability, and comfort across a broad range of riding conditions.

U, IIU type:

• When replacing, use the original equipment

tyre of the same size, construction, speed rating, and load range as the originals.

• Replace the tube any time you replace a tyre.

The old tube will probably be stretched and, if installed in a new tyre, could fail.

Front

Rear

Type

80/100-21 51M

DUNLOP

100/90-19 57M

DUNLOP

D742FA

D756

bias-ply, tube

Front

Rear

Type

80/100-21 M/C 51M MST

PIRELLI

100/90-19 57M NHS

PIRELLI

SCORPION MX MIDSOFT 32

bias-ply, tube

WARNING

Installing improper tyres on your motorcycle can affect handling and stability. This can cause a crash in which you can be seriously hurt or killed.

Always use the size and type of tyres recommended in this owner’s manual.

ED, IIED type:

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84 Servicing Your Honda

Drive Chain

Refer to Safety Precautions on page 19.

The service life of the chain depends on proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain or sprockets.

When the motorcycle is ridden on unusually dusty or muddy tracks, more frequent maintenance will be necessary.

Before servicing your drive chain, turn the engine OFF, raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and check that your transmission is in neutral.

It is not necessary to remove or replace the drive chain to perform the recommended service in the Maintenance Schedule.

Drive Chain Inspection

1. Turn the engine off, raise the rear wheel off the ground by placing the optional workstand or equivalent support under the engine and shift the transmission into neutral.

2. Check slack (1) in the upper drive chain run midway between the sprockets (2)(3). Drive chain slack should allow the following vertical movement by hand:

25 – 35 mm (1.0 – 1.4 in)

(1) drive chain slack (3) driven sprocket (2) drive sprocket

3. Check drive chain slack at several points along the chain. The slack should remain constant. If it isn’t, some links may be kinked and binding. Lubricating the chain will often eliminate binding and kinking.

Excessive chain slack may allow the drive chain to damage the engine cases.

4. Inspect the drive chain for:

• damaged rollers

• loose pins

• dry or rusted links

•kinked or binding links

• excessive wear

Replace the drive chain (page 86) if it has damaged rollers, loose pins, or kinks that cannot be free. Lubricate the drive chain (page 85) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed.

NOTICE

(1) chain slider

2. Check the chain guide slider (2) for wear. Replace the chain guide slider if it is worn to the bottom of the wear limit (3).

(2) chain guide slider (3) wear limit

(2)

(3)

(1)

(2)

(3)

Drive Chain Sliders

1. Check the chain slider (1) for wear. If the wear is 5 mm (0.2 in) or more, replace it.

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Servicing Your Honda 85

Drive Chain

(1) upper drive chain roller (3) “//” mark (2) lower drive chain roller

(1) rear axle nut (4) index mark (2) lock nut (5) axle plate (3) adjusting bolt (6) reference mark

3. Tighten the rear axle nut to the specified torque:

128 N·m (13.1 kgf·m, 94 lbf·ft)

4. Recheck chain slack and adjust as necessary.

5. Loosen the adjusting bolt counterclockwise lightly until it touches the axle plate. Then, while holding the adjusting bolt with a wrench, tighten the lock nut to the specified torque:

27 N·m (2.8 kgf·m, 20 lbf·ft)

(1)

(3)

(2)

(6)

(4)

(1)

(2)

(5)

(3)

Lubrication

Commercially prepared drive chain lubricants may be purchased at most motorcycle shops and should be used in preference to motor oil. Chain Lube or an equivalent, or SAE 80 or 90 gear oil is recommended.

Saturate each chain joint so that the lubricant penetrates the space between adjacent surfaces of the link plates and rollers.

Adjustment

1. Loosen the rear axle nut (1).

2. Loosen both lock nuts (2) and turn the adjusting bolts (3) counterclockwise to decrease slack or clockwise to increase slack. Align the index marks (4) of the axle plates (5) with the same reference marks (6) on both sides of the swingarm.

Drive Chain Rollers

1. Check the upper drive chain roller (1) and lower drive chain roller (2) for wear or damage.

2. Measure the diameter of the drive chain

rollers and replace them if below the service

limit. Service Limit: Upper roller:

39 mm (1.5 in)

Lower roller: 31 mm (1.2 in)

Replace the roller if necessary as follows. Install the upper drive chain roller (Green) with the “

/” mark (3) facing toward the frame and lower drive chain rollar (Black) as shown. Tighten the drive chain roller bolt and nut to the specified torque: Upper roller bolt:

12 N·m (1.2 kgf·m, 9 lbf·ft)

Lower roller nut: 12 N·m (1.2 kgf·m, 9 lbf·ft)

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86 Servicing Your Honda

Drive Chain

4. Inspect the sprocket teeth for wear or damage. We recommend replacing the sprocket whenever a new chain is installed. Both chain and sprockets must be in good condition, or the new replacement chain or sprocket(s) will wear rapidly. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any sprocket which is damaged or excessively worn.

Use of a new chain with worn sprockets will cause rapid chain wear.

5. Measure a section of the drive chain to determine whether the chain is worn beyond its service limit. Put the transmission in gear, and then turn the rear wheel forward until the lower section of the chain is pulled taut. With the chain held taut and any kinked joints straightened, measure the distance between a span of 17 pins, from pin centre to pin centre. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service.

NOTICE

MEASURE A SPAN OF 17 PINS (16 PITCHES)

6. Lubricate the drive chain.

7. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation.

8. Recheck chain slack and adjust as necessary.

More About Drive Chain

• The master link is the most critical element of drive chain security. Master links are reusable, as long as they remain in excellent condition. We recommend installing a new master link retaining clip when the drive chain is reassembled.

•You may find it easier to install a new chain by connecting it to the old chain with a master link and pulling the old chain to position the new chain on the sprockets.

Removal, Cleaning & Replacement

For maximum service life, the drive chain should be cleaned, lubricated, and adjusted before each outing.

1. Remove the master link retaining clip (1) with pliers. Do not bend or twist the clip. Remove the master link (2). Remove the drive chain.

(1) retaining clip (2) master link

2. Clean the drive chain in high flash-point solvent and allow it to dry.

3. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has damaged rollers, loose fitting links, or otherwise appears unserviceable. Replacement chain: Size/link:

DID 520 DMA4-114RB RK 520 TXZ-114RJ

(2)

(1)

Service limit: 259.0 mm (10.20 in)

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Servicing Your Honda 87

Exhaust Pipe/Muffler

Exhaust Pipe/Muffler Inspection

Check the mounting bolts and joint nuts for tightness. Check the exhaust pipe, exhaust joint pipe and mufflers for cracks or deformation. A damaged exhaust pipe, exhaust joint pipe and mufflers may reduce engine performance.

Muffler Removal

1. Remove the seat mounting bolts (1), side cover bolts (2) and side covers (3).

(1) seat mounting bolt (3) side cover (2) side cover bolt

2. Loosen the muffler clamp bolts (4).

3. Remove the mufflers (5) by removing the muffler mounting bolts (6) and washers (7).

(4) muffler clamp bolt (5) muffler (6) muffler mounting bolt (7) washer

(1)

(3)

(2)

(5)

(6)

(7)

(4)

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88 Servicing Your Honda

Exhaust Pipe/Muffler

Muffler Installation

1. Remove the old gasket.

2. Install the muffler clamp (1) by aligning the tab (2) of the muffler clamp with the cut-out (3) of each muffler (4).

(1) muffler clamp (3) cut-out (2) tab (4) muffler

3. Install a new gaskets (5) to the exhaust joint pipe (6).

4. Install each muffler to the exhaust joint pipe.

(5) gasket (6) exhaust joint pipe

5. Install each muffler mounting bolt (7) and washer (8).

6. Tighten each muffler clamp bolt (9) to the specified torque:

21 N·m (2.1 kgf·m, 15 lbf·ft)

7. Tighten each muffler mounting bolt to the specified torque:

26 N·m (2.7 kgf·m, 19 lbf·ft)

(7) muffler mounting bolt (8) washer (9) muffler clamp bolt

(10) side cover (12) seat mounting bolt (11) side cover bolt

(4)

(3)

(1)

(2)

(5)

(6)

(7)

(8)

(9)

(11)

(10)

(12)

8. Install and tighten the side covers (10) and side cover bolts (11).

9. Install the seat mounting bolts (12) and tighten them to the specified torque:

26 N·m (2.7 kgf·m, 19 lbf·ft)

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Exhaust Pipe/Muffler

Servicing Your Honda 89

Exhaust Joint Pipe Removal

1. Remove the muffler (page 87).

2. Remove the mud guard (1) by removing the mud guard screws (2).

(1) mud guard (2) screws

3. Loosen the joint pipe clamp bolt (3).

4. Remove the exhaust joint pipe mounting bolt (4) and exhaust joint pipe (5).

(1)

(2)

(3)

(4)

(5)

(3) joint pipe clamp bolt (4) exhaust joint pipe mounting bolt (5) exhaust joint pipe

Exhaust Joint Pipe Installation

1. Remove the old gasket.

2. Install the joint pipe clamp (1) by aligning the tab (2) of the joint clamp with the cut-out (3) of the exhaust joint pipe (4).

(1) joint pipe clamp (3) cut-out (2) tab (4) exhaust joint pipe

3. Install a new gasket (5) to the exhaust pipe (6).

4. Install the exhaust joint pipe (4) to the exhaust pipe, and temporarily install the joint pipe clamp bolt and exhaust joint pipe mounting bolt.

(4)

(1)

(3)

(2)

(5)

(4)

(6)

(4) exhaust joint pipe (5) gasket (6) exhaust pipe

5. Install the exhaust joint pipe mounting bolt.

6. Install the muffler (page 88), but do not tighten the bolt yet.

7. Tighten the joint pipe clamp bolt to the specified torque:

21 N·m (2.1 kgf·m, 15 lbf·ft)

8. Tighten the exhaust joint pipe mounting bolt to the specified torque:

26 N·m (2.7 kgf·m, 19 lbf·ft)

9. Tighten the muffler clamp bolts and muffler mounting bolts (page 88).

10.Install the mud guard and tighten the mud guard screws to the specified torque:

1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)

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90 Servicing Your Honda90 Servicing Your Honda

Exhaust Pipe/Muffler

Exhaust Pipe Installation

1. Install a new exhaust pipe gasket (1) as shown.

2. Install the exhaust pipe (2) and exhaust pipe joint nuts (3)

(1) exhaust pipe gasket (new) (2) exhaust pipe (3) exhaust pipe joint nuts

3. Install the exhaust joint pipe (page 89) but do not tighten the bolt yet.

4. Install the muffler (page 88) but do not tighten the bolt yet.

5. Tighten the exhaust pipe joint nuts to the specified torque:

21 N·m (2.1 kgf·m, 15 lbf·ft)

6. Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt (page 89).

7. Tighten the muffler clamp bolts and muffler mounting bolts (page 88).

8. Installation can be done in the reverse order of removal.

Exhaust Pipe Removal

1. Remove the muffler (page 87).

2. Remove the exhaust joint pipe (page 89).

3. Remove the exhaust pipe joint nuts (1), exhaust pipe (2) and old gasket (3).

(1) exhaust pipe joint nuts (2) exhaust pipe (3) gasket (old)

(1)

(2)

(3)

(1)

(3)

(2)

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Steering Damper

Servicing Your Honda 91

Refer to Safety Precautions on page 19.

Loose, worn or damaged steering damper components may adversely affect the handling and stability of your CRF. If any steering damper components appear worn or damaged, see your Honda dealer for further inspection. Your dealer is qualified to determine whether or not replacement parts are needed. Do not attempt to disassemble the steering damper; see your Honda dealer. The instructions found in this owner’s manual are limited to adjustment and service of the steering damper assembly only.

Steering Damper Operation Inspection

• When your CRF is new, break it in for approximately 1 hour to ensure that the steering damper is broken (page 15).

• After break-in, test run your CRF with the steering damper at the standard setting before making any adjustments.

• Check the spherical bearings and dust seal for dust, dirt, and foreign materials.

• Make all damping adjustments in one-click increments. (Adjusting two or more clicks at a time may cause you to pass over the best adjustment.) Test ride after each adjustment.

• If you have a problem finding an acceptable adjustment, return to the standard position and begin again.

1. Unlock the number plate tab (1) from the handlebar pad. Remove the bolts (2) and number plate (3).

(1) number plate tab (3) number plate (2) bolts

2. Check the steering damper (4) for deformation or oil leaks. Check the damper rod (5) for bending or damage. Replace the damper case or damper rod if there is any abnormality. Refer to the Honda Shop Manual or see your Honda dealer for steering damper disassembly. Check the torque of the steering damper mounting bolts (6):

20 N·m (2.0 kgf·m, 15 lbf·ft)

(4) steering damper (5) damper rod (6) steering damper mounting bolts

3. Place your CRF on the workstand or equivalent support with the front wheel off the ground. Check that the steering moves smoothly from side-to-side.

4. Install the number plate (3) by aligning its holes (7) with the tabs (8) on the steering stem. Install and tighten the bolts (2) securely. Route the number plate tab (1) around the handlebar pad (9) as shown.

(1) number plate tab (7) holes (2) bolts (8) tabs (3) number plate (9) handlebar pad

(3)

(2)

(1)

(4)

(5)

(6)

(3)

(2)

(1)

(9)

(7)

(8)

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Steering Damper

92 Servicing Your Honda

Removal

1. Remove the number plate (page 91).

2. Remove the steering damper mounting bolts (1), collar (2) and steering damper (3).

(1) steering damper mounting bolts (2) collar (3) steering damper

Inspection

Check the damper rod (1) operation. The damper rod is fully extended and compressed by hand. Release the damper rod, then check that it extends to its maximum length.

If the damper rod does not extend its maximum length, disassemble and inspect for steering damper. Refer to the Honda Shop Manual or see your Honda dealer.

(1) damper rod

2. Check the condition of the spherical bearings (2). Move the spherical bearing with your finger. The spherical bearing should move smoothly and quietly.

Replace the spherical bearing if it does not move smoothly and quietly. Refer to the Honda Shop Manual or see your Honda dealer.

(2) spherical bearings

Installation

1. Clean and apply a locking agent to the steering damper mounting bolt threads.

2. Install the steering damper (2) with its “UP” mark (3) facing up and forward. Turn the damper rod and its stopper ring (4) facing toward the front side.

3. Install the collar (5) and steering damper mounting bolts (1). Be sure to install the collar with its wide flange side facing toward the steering head pipe side.

4. Tighten the steering damper mounting bolts to the specified torque:

20 N·m (2.0 kgf·m, 15 lbf·ft)

(1) steering damper mounting bolts (2) steering damper (3) “UP” mark (4) stopper ring (5) collar

5. Place your CRF on the workstand or equivalent support with the front wheel off the ground. Check that the steering moves smoothly from side-to-side.

6. Install the number plate (page 91).

(2)

(3)

(1)

(2)

(1)

(5)

(2)

(4)

(3)

(1)

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Servicing Your Honda 93Servicing Your Honda 93

Additional Maintenance Procedures

Refer to Safety Precautions on page 19.

Steering Head Bearings Inspection

1. With your CRF on a box or workstand (front wheel elevated), turn the handlebar to the right and left to check for roughness in the steering head bearings.

Handlebar Inspection

1. Remove the handlebar pad.

2. Check the handlebar (1) for bends or cracks.

3. Check that the handlebar has not moved from its proper position (by inspecting the paint mark (3)).

4. Check the torque of the upper holder (2) bolts:

22 N·m (2.2 kgf·m, 16 lbf·ft)

Tighten the front bolts first.

(1) handlebar (2) handlebar upper holders (3) paint mark

Control Cables

Periodically, disconnect the throttle, clutch and hot start cables at their upper ends. Thoroughly lubricate the cable pivot points with a commercially-available cable lubricant. If the clutch lever, hot start lever and throttle operation is not smooth, replace the cable. Be sure the throttle returns freely and automatically from fully open to fully closed in all steering positions.

(2)

(3)

(1)

2. Stand in front of your CRF, grab the fork (at the axle), look at the steering head, and push the fork in and out (toward the engine) to check for play in the steering head bearings.

If any roughness or play is felt, but you do not see any movement in the steering head, the fork bushings may be worn. Refer to the Honda Shop Manual for replacement or adjustment procedures, or see your Honda dealer.

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94 Servicing Your Honda94 Servicing Your Honda

Additional Maintenance Procedures

Nuts, Bolts, Fasteners

Check and tighten nuts, bolts, and fasteners before every outing.

Item

1 2 3 4

6 7 8 9

10 11

12 13

ENGINE

Cylinder head cover bolts Exhaust pipe joint nuts Water pump cover bolts Crankshaft hole cap

Tr ansmission oil check bolt

Clutch cover bolts Coolant drain bolt Engine oil drain bolt Cylinder bolt Oil filter cover bolts Cylinder head bolts

Drive sprocket bolt Tr ansmission oil drain bolt

Torque

N•m kgf•m

10 21 10 15

12 10

10 16 10 12 10

31 16

1.0

2.1

1.0

1.5

1.2

1.0

1.6

1.0

1.2

1.0

3.2

1.6

lbf•ft

9 7

7 9 7

23 12

(1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts (7) coolant drain bolt (8) engine oil drain bolt

(9) cylinder bolt (10) oil filter cover bolts (11) cylinder head bolts (12) drive sprocket bolt (13) transmission oil drain bolt

(1)

(2)

(3)

(7)

(5)

(4)

(8)

(6)

(12)

(13)

(10)

(9)

(11)

RIGHT SIDE

LEFT SIDE

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Honda CRF250R Instruktionsbok [pt]

Specifications and Main Features

Frequently Asked Questions

User Manual