2012
Honda CRF250R
OWNER’S MANUAL & COMPETITION HANDBOOK
Introduction
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 CRF, other property, or the
environment.
Unless you are mechanically qualified and have
the proper tools, you should see your dealer for
the service and adjustment procedures discussed
in this manual.
An official Honda Service Manual for your CRF
is available (page 160). It is the same manual
your dealer uses. If you plan to do any service
on your CRF beyond the standard maintenance
procedures in this manual, you will find an
official Honda Service Manual a valuable
reference.
If you have any questions, or if you ever need a
special service or repairs, remember that your
dealer knows your CRF best and is dedicated to
your complete satisfaction.
Please report any change of address or ownership
to your dealer so we will be able to contact you
concerning important product information.
You may also want to visit our website at
USA: www.powersports.honda.com.
Canada: www.honda.ca.
Happy riding!
California Proposition 65
Warning
WARNING: This product contains or emits
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
NOTICE
ABBREVIATION
Throughout this manual, the following
abbreviations are used to identify the respective
parts or system.
Abbrev. term
CKP sensor
DTC
ECM
ECT sensor
HPSD
IAT sensor
MAP sensor
MIL
PGM-FI
TDC
TP sensor
Crankshaft Position sensor
Diagnostic Trouble Code
Engine Control Module
Engine Coolant Temperature sensor
Honda Progressive Steering Damper
Intake Air Temperature sensor
Manifold Absolute Pressure sensor
Malfunction Indicator Lamp
Programmed Fuel Injection
Top Dead Center
Throttle Position sensor
Full term
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
Contents
Contents
MOTORCYCLE SAFETY...............................1
Important Safety Information..............................2
Important Safety Precautions..........................2
Accessories & Modifications..............................3
Safety Labels.......................................................4
INSTRUMENTS & CONTROLS....................5
Operation Component Locations ........................6
Indicator ..............................................................7
MIL Blink Pattern...........................................7
Current DTC/Freeze DTC ..............................7
Circuit Inspection............................................8
DTC Index ......................................................9
BEFORE RIDING...........................................11
Are You Ready to Ride? ...................................12
Is Your Motorcycle Ready to Ride?..................13
Pre-ride Inspection........................................13
BASIC OPERATING INSTRUCTIONS ......15
Safe Riding Precautions................................16
Starting & Stopping the Engine........................17
Fast Idle Knob ..............................................17
Preparation....................................................17
Starting Procedure ........................................17
How to Stop the Engine................................18
Break-in Guidelines ..........................................19
SERVICING YOUR HONDA........................21
Before You Service Your Honda
The Importance of Maintenance .......................22
Maintenance Safety...........................................23
Important Safety Precautions........................23
Maintenance Schedule ......................................24
General Competition Maintenance ...................26
Before & After Competition Maintenance........30
Between Motos & Practice Maintenance .....30
After Competition Maintenance ...................30
Service Preparations
Maintenance Component Locations..................32
Seat....................................................................33
Fuel Tank...........................................................34
Subframe ...........................................................36
Service Procedures
Fluids & Filters
Fuel System.......................................................40
Engine Oil .........................................................49
Transmission Oil ...............................................52
Coolant ..............................................................54
Air Cleaner........................................................56
Crankcase Breather ...........................................58
Engine
Throttle..............................................................59
Engine Idle Speed .............................................61
Clutch System ...................................................62
Spark Plug .........................................................67
Valve Clearance.................................................68
Piston/Piston Rings/Piston Pin..........................76
Chassis
Suspension.........................................................85
Brakes................................................................90
Wheels...............................................................94
Tires & Tubes....................................................95
Drive Chain .......................................................97
Exhaust Pipe/Muffler ......................................100
Steering Damper..............................................103
Additional Maintenance Procedures ...............105
Appearance Care .............................................107
Contents
Contents
ADJUSTMENTS FOR COMPETITION ...109
Front Suspension Adjustments........................110
Front Suspension Air Pressure....................110
Front Suspension Damping.........................110
Fork springs.................................................111
Front Suspension Disassembly ...................112
Damper Oil Change ....................................115
Fork Assembly ............................................118
Rear Suspension Adjustments.........................125
Rear Suspension Spring Pre-Load..............125
Rear Suspension Damping..........................126
Rear Suspension Race Sag .........................127
Suspension Adjustments for Track
Conditions .......................................................129
Suspension Adjustment Guidelines.................130
Tuning Tips .....................................................133
Spark Plug Reading ....................................133
Steering Damper Adjustment..........................134
Steering Damper Damping .........................134
Steering Damper Adjustment Guidelines........135
Chassis Adjustments........................................136
Rear End .....................................................136
Fork Height/Angle......................................136
Wheelbase...................................................136
Gearing............................................................137
Tire Selection for Track Conditions................138
Personal Fit Adjustments ................................139
Control Positioning.....................................139
Handlebar Position, Width & Shape...........139
TIPS................................................................141
Transporting Your Motorcycle........................142
Storing Your Honda.........................................143
Preparation for Storage...............................143
Removal from Storage................................143
You & the Environment ..................................144
Troubleshooting...............................................145
TECHNICAL INFORMATION ..................147
Vehicle Identification ......................................148
Serial Numbers ...........................................148
Specifications ..................................................149
Torque Specifications......................................150
Nuts, Bolts, Fasteners .................................150
Oxygenated Fuels............................................153
Competition Logbook .....................................154
Optional Parts List ..........................................156
Spare Parts & Equipment................................157
Spare Parts ..................................................157
General Tools ..............................................157
Honda Special Tools ...................................157
Chemical Products......................................157
Other Products ............................................157
Wiring Diagram...............................................158
CONSUMER INFORMATION...................159
Authorized Manuals........................................160
Contacting Honda............................................161
Your Dealer .....................................................162
The Honda Rider’s Club (USA only) .............163
INDEX............................................................164
QUICK REFERENCE
Motorcycle Safety
Motorcycle Safety 1
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
Important Safety Information
2 Motorcycle Safety
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 a crash 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.
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.
4 Motorcycle Safety
Safety Labels
Read these labels carefully and don’t remove them.
If the label comes off or becomes hard to read, contact your dealer for replacement.
(For Canada)
Instruments & Controls 5
Instruments & Controls
Read this section carefully before you ride. It
presents the location of the basic controls on your
CRF.
Operation Component Locations .........................6
Indicator ...............................................................7
MIL Blink Pattern............................................7
Current DTC/Freeze DTC ...............................7
Circuit Inspection.............................................8
DTC Index .......................................................9
6 Instruments & Controls
Operation Component Locations
clutch lever
MIL
front brake lever
engine stop button
throttle grip
fast idle knob
(engine idle speed)
shift lever
kickstarter
rear brake pedal
Instruments & Controls 7
Indicator
The MIL on your CRF keeps you informed,
alerts you to possible problems, and makes your
riding safer and more enjoyable. Refer to the
MIL frequently.
(1)
(1) MIL
The MIL flashes when there is any abnormality
in the PGM-FI system. It should also light for a
few seconds and then go off when the engine is
started.
If the MIL comes on at any other time, reduce
speed and refer to an official Honda Service
Manual available for purchase from your dealer
(page 160).
If the MIL does not come on when it should,
have your dealer check it for problems.
MIL Blink Pattern
The MIL will blink the appropriate DTC number
if the ECM detects an active problem while the
engine is running at less than 5,500 rpm.
The MIL will stay ON when the engine speed is
over 5,500 rpm.
The MIL has two types of blinks: a long blink
and short blink. The long blinking lasts for 1.2
seconds, the short blinking lasts for 0.4 seconds.
One long blink is the equivalent of ten short
blinks. For example, when one long blink is
followed by two short blinks, the MIL is 12 (one
long blink = 10 blinks, plus two short blinks).
When the ECM stores more than one DTC, the
MIL will indicate them by blinking in the order
from the lowest number to highest number.
Current DTC/Freeze DTC
The DTC is indicated in two ways according to
the failure status.
– In the case that the ECM detects an active
problem, the MIL will come on and will start to
blink the DTC when the engine is started.
– In the case that the ECM does not detect an
active problem but has recorded a previous
problem in its memory, the MIL will not come
on. If it is necessary to retrieve any past
problems stored in the memory, refer to an
official Honda Service Manual.
8 Instruments & Controls
Indicator
Circuit Inspection
Always clean around the ECM and keep debris
away from the connectors before disconnecting
them.
A faulty PGM-FI system is often related to
poorly connected or corroded connections. Check
the following connections.
(1) MAP sensor connector
(2) ECT sensor connector
(3) TP sensor connector
(4) IAT sensor connector
(5) Injector connector
(6) No.1/No.2 CKP sensor connector
(7) ECM connector
Remember, circuit inspection is not a “cure-all”
for other problems in your engine’s PGM-FI
system.
(1)(2)
(5)
(7)
(6) (3) (4)
Instruments & Controls 9
Indicator
DTC Index
MIL blinks
1
2
7
8
9
MAP sensor circuit malfunction
MAP sensor performance problem
ECT sensor circuit malfunction
TP sensor circuit malfunction
IAT sensor circuit malfunction
12 Injector circuit malfunction
19 No.1 CKP sensor circuit malfunction
69 No.2 CKP sensor circuit malfunction
Engine operates normally
Engine operates normally
Hard start at a low temperature
Poor engine acceleration
Engine operates normally
• Engine does not start
• Injector, fuel pump and ignition shut down
• Engine does not start
• Injector, fuel pump and ignition shut down
• Engine does not start
• Injector, fuel pump and ignition shut down
Function Failure Symptom/Fail-safe Function
Should be serviced by your dealer, unless the owner has proper tools and is technically qualified.
The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started.
If the engine does not start, check all connector connections and/or refer to an official Honda Service
Manual (page 160) for troubleshooting of the PGM-FI symptom.
Refer to MIL Blink Pattern on page 7.
10 Instruments & Controls
Before Riding 11
Before each ride, you need to make sure you and
your Honda are both ready to ride. To help get
you prepared, this section discusses how to
evaluate your riding readiness, and what items
you should check on your CRF.
For information about suspension, steering
damper, and other adjustments, see page 109.
Before Riding
Are You Ready to Ride?.....................................12
Is Your Motorcycle Ready to Ride?...................13
Pre-ride Inspection........................................13
12 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, steering
damper, and other adjustments, see page 109.
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.
Before Riding 13
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.............................................50
• Transmission oil level...................................53
• Fuel line for condition ..................................40
• Coolant for proper level............................... 54
• Cooling system and hoses for condition.......55
• Spark plug for proper heat range, carbon
fouling and spark plug wire terminal for
looseness .......................................................67
• Air cleaner for condition and
contamination................................................56
• Clutch lever adjustment and freeplay...........62
• Breather drain for cleaning...........................58
• Steering head bearing and related parts
for condition................................................105
• Steering damper operation..........................103
• Throttle operation .........................................59
• Tires for damage or improper inflation
pressure ........................................................95
• Spokes for looseness.....................................94
• Rim locks for looseness................................94
• Front and rear suspension for proper
operation .................................................85, 86
• Front and rear brakes, check operation ........90
• Drive chain for correct slack and adequate
lubrication................................................97-98
• Drive chain sliders and drive chain rollers
for damage or wear.................................97, 98
• Exhaust pipe/Muffler for looseness............100
• 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) ...................150-152
• Indicator..........................................................7
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.
14 Before Riding
This section gives basic information on how to
start and stop your engine as well as break-in
guidelines.
Safe Riding Precautions................................16
Starting & Stopping the Engine .........................17
Fast Idle Knob ..............................................17
Preparation....................................................17
Starting Procedure ........................................17
How to Stop the Engine................................18
Break-in Guidelines ...........................................19
Basic Operating Instructions 15Basic Operating Instructions 15
Basic Operating Instructions
16 Basic Operating Instructions16 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.
Basic Operating Instructions 17Basic Operating Instructions 17
Starting & Stopping the Engine
Always follow the proper starting procedure
described below.
Your CRF can be kickstarted with the
transmission in gear by pulling in the clutch lever
before operating the kickstarter.
Fast Idle Knob
The fast idle knob has two functions:
• When pulled out, the fast idle knob assists in
first-time start-up for cold weather starting.
• When pushed in, it acts as an idle adjustment
screw. Refer to
Idle Speed Adjustment on
page 61.
Preparation
Make sure that the transmission is in neutral.
Starting Procedure
Always follow the proper starting procedure
described as follows.
Check the engine oil, transmission oil and coolant
levels before starting the engine (pages 50, 53, 54).
Cold Engine Starting
1. Shift the transmission into neutral.
2. If the temperature is 95°F (35°C) or below,
pull the fast idle knob (1) fully out.
(1) fast idle knob
3. With the throttle closed, operate the
kickstarter starting from the top of the
kickstarter stroke, and kick through to the
bottom with a rapid, continuous motion.
4. About a minute after the engine starts, push
the fast idle knob back all the way to fully
OFF.
If idling is unstable, open the throttle slightly.
(1)
Warm Engine Starting
1. Shift the transmission into neutral.
2. Kick-start the engine (Do not open the
throttle).
If Dif
ficult to Start After Stalling
1. Shift the transmission into neutral.
2. With the throttle fully opened, repeat
kickstarter operation approximately 10 times
to discharge excessive fuel from the engine.
3. Kick-start the engine. (Do not open the
throttle.)
Snapping the throttle or fast idling for more than
5 minutes may cause exhaust pipe discoloration.
18 Basic Operating Instructions
Starting & Stopping the Engine
18 Basic Operating Instructions
How to Stop the Engine
(1)
(2)
(1) throttle (2) engine stop button
Normal Engine Stop
1. Shift the transmission into neutral.
2. Lightly open the throttle (1) two or three
times, and then close it.
3. Push and hold the engine stop button (2) until
the engine stops completely.
Emer
gency Engine Stop
To stop the engine in an emergency, push and
hold the engine stop button.
Basic Operating Instructions 19
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 15
miles (25 km).
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
20 Basic Operating Instructions
Servicing Your Honda 21
Servicing Your Honda
Keeping your CRF well maintained is absolutely
essential to your safety. It’s also a good way to
protect your investment, get maximum
performance, avoid breakdowns, and have more
fun.
To help keep your CRF in good shape, this
section includes a Maintenance Schedule for
required servicing and step-by-step instructions
for specific maintenance tasks. You’ll also find
important safety precautions, information on oils,
and tips for keeping your Honda looking good.
An ECM system is used on this motorcycle;
consequently, routine ignition timing adjustment
is unnecessary. If you want to check the ignition
timing, refer to the Honda Service Manual (page
160).
An optional tool kit may be available. Check
with your dealer’s parts department.
Before You Service Your Honda
The Importance of Maintenance ........................22
Maintenance Safety............................................23
Important Safety Precautions........................23
Maintenance Schedule .......................................24
General Competition Maintenance ....................26
Before & After Competition Maintenance.........30
Between Motos & Practice Maintenance .....30
After Competition Maintenance ...................30
Service Preparations
Maintenance Component Locations...................32
Seat ....................................................................33
Fuel Tank ...........................................................34
Subframe ...........................................................36
Service Procedures
Fluids & Filters
Fuel System........................................................40
Engine Oil ..........................................................49
Transmission Oil ................................................52
Coolant ...............................................................54
Air Cleaner.........................................................56
Crankcase Breather ............................................58
Engine
Throttle...............................................................59
Engine Idle Speed ..............................................61
Clutch System ....................................................62
Spark Plug ..........................................................67
Valve Clearance..................................................68
Piston/Piston Rings/Piston Pin...........................76
Chassis
Suspension..........................................................85
Front Suspension Inspection ...........................85
Rear Suspension Inspection ............................86
Recommended Fork Oil..................................87
Fork Oil Change..............................................87
Brakes.................................................................90
Wheels................................................................94
Tires & Tubes.....................................................95
Drive Chain ........................................................97
Exhaust Pipe/Muffler .......................................100
Steering Damper...............................................103
Additional Maintenance Procedures ................105
Appearance Care ..............................................107
22 Servicing Your Honda
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.
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.
Servicing Your Honda 23
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
gasoline. Use only a non-flammable (high
flash point) solvent such as kerosene — not
gasoline — 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.
24 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 list items that can be
performed with basic mechanical skills and hand
tools. Procedures for these items are provided in
this manual.
The Maintenance Schedule also includes items
that involve more extensive procedures and may
require special training, tools, and equipment.
Therefore, we recommend that you have your
dealer perform these tasks unless you have
advanced mechanical skills and the required
tools. Procedures for items in this schedule are
provided in an official Honda Service Manual
available for purchase from your dealer (page
160).
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 13) at each
scheduled maintenance period.
Summary of Maintenance Schedule Notes and
Procedures:
Notes:
1. Clean after every moto for dusty riding
condition.
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.
6. Replace every year.
Maintenance Procedures:
I: inspect and clean, adjust, lubricate or replace
if necessary
C: clean
A: adjust
L: lubricate
R: replace
Servicing Your Honda 25
Maintenance Schedule
ITEMS
FUEL LINE
FUEL PUMP FILTER
THROTTLE OPERATION
AIR FILTER
CRANKCASE BREATHER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
ENGINE OIL FILTER
ENGINE IDLE SPEED
PISTON AND PISTON RINGS
PISTON PIN
TRANSMISSION OIL
RADIATOR COOLANT
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 EXCEPT DAMPER
FORK OIL DAMPER
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARINGS
(NOTE 6)
(NOTE 6)
(NOTE 1)
(NOTE 4)
(NOTE 3)
(NOTE 3)
(NOTE 5)
(NOTE 2)
(NOTE 2)
(NOTE 5)
(NOTE 3)
I
I
C
I
I
I
I
I
I
I
I, L
I
I
I
I
I
I
I
I
I, L
I
I
I
I
40
44
60
56
58
67
68-75
49
50
61
79
80
52
54
54
97-99
97
98
99
99
91
93
90
62
105
100
85, 86
86
87
115
106, 150-152
94-96
105
R
L
R
I
R
R
R
R
R
R
R
R
I
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
WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL.
This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing.
NOTE: 1.Clean after every moto for dusty riding condition.
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.
6.Replace every year.
Perform the Pre-ride Inspection (page 13) at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. A: Adjust. L: Lubricate. R: Replace.
26 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 13.
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 25).
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 50).
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-rpm performance. Follow the servicing instructions in
the Maintenance section. Use Pro Honda Foam Filter Oil or
an equivalent. Be sure to grease the air cleaner flange where
it contacts the air cleaner housing. Pro Honda White
Lithium Grease, or an equivalent, is handy for this because
any dirt that penetrates this sealing area will show up clearly
(page 56).
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 53).
Air cleaner Housing Sealing
Remove and reseal the air cleaner housing boot where it
connects to the air cleaner housing with Pro Honda Handgrip
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.
Spark Plug Cap
Install a small plastic tie-wrap around the spark plug cap to
reduce any possibility of it loosening or of water
penetration.
Servicing Your Honda 27
General Competition Maintenance
28 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 (pages 76, 79).
Engine Mounting Bolts and Nuts
Make sure the engine mounting bolts and nuts are tightened
to the proper torque specification. For added peace of mind,
remove the nuts, clean the threads, and apply Pro Honda
Hondalock 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 Pro Honda Dielectric Grease to allthe
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 Service Manual. Use
only HP Fork Oil, SS-19 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 94).
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 Pro Honda
Hondalock or an equivalent and tighten to the specified
torque.
Fuel Line
Refer to Fuel System on page 40.
Check the fuel line for deterioration, damage, or leakage.
Replace the fuel line every year.
Bleed Hole
After every race, check the bleed hole below the water pump
cover for leakage. Clean away any clogged dirt or sand, if
necessary. Check for signs of seal leakage. A small amount
of “coolant weeping” from the bleed hole is normal. If water
leaks through the bleed hole, the mechanical seal is
damaged. If oil leaks through the bleed hole, the oil seal is
damaged. See an official Honda Service Manual or consult
your dealer for replacing the mechanical seal or oil seal.
Both seals should be replaced at the same time.
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 93.
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: Refer to the Honda Service
Manual (page 160) for brake fluid replacement instructions.
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.
Handgrips
Always use Pro Honda Handgrip 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 Service 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 29
General Competition Maintenance
30 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 tire 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.
(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.
(2) pressure release screw
(1) chain adjuster index marks
• 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 psi (0 kPa, 0 kgf/cm
2
))
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.)
Servicing Your Honda 31
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 107).
32 Servicing Your Honda
Maintenance Component Locations
front brake caliper
crankcase breather tube
drive chain
transmission oil
drain bolt
engine oil drain bolt
fast idle knob
(engine idle speed)
engine oil filter
engine oil fill cap/
dipstick
air cleaner
rear brake
caliper
rear suspension
rebound damping adjuster
transmission
oil fill cap
transmission
oil check bolt
rear brake pedal
front suspension rebound
damping adjuster
rear suspension high speed
compression damping adjuster
rear suspension low speed
compression damping adjuster
front suspension compression
damping adjuster
spark plug
steering damper
adjuster
rear suspension
spring pre-load
adjuster
rear brake fluid
reservoir
clutch lever
front brake fluid reservoir
front brake lever
fuel fill cap
radiator cap
throttle grip
Servicing Your Honda 33
Seat
Refer to Safety Precautions on page 23.
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 seat front
prong (1) with the seat bracket (2) and seat
rear prong (3) with the ECM bracket (4).
2. Install and tighten the seat mounting bolts to
the specified torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
(1) seat front prong
(2) seat bracket
(3) seat rear prong
(4) ECM bracket
(2)
(1)
(2)
(1)
(3)
(4)
34 Servicing Your Honda
Fuel Tank
Refer to Safety Precautions on page 23.
Removal
1. Remove the seat (page 33).
2. Remove the shroud A bolts and collars (1).
3. Remove the shroud B bolts (2) and shrouds (3).
7. Remove the fuel tank bolt and collar (7).
WARNING
Gasoline 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.
(8) fuel feed hose (11) fuel tank stopper cable
(10) fuel tank
10. Check for interference between the frame and
tank and adjust the cushion rubbers (12) if
necessary.
(1) shroud A bolts and collars (3) shrouds
(2) shroud B bolts
4. Install a hose clamp (4) to the breather tube
(5) and shut the hose clamp securely
(4) hose clamp (5) breather tube
5. Pull the breather tube (5) out of steering stem
nut.
6. Unhook the fuel tank band (6).
(5) breather tube
(6) fuel tank band
(7) fuel tank bolt and collar
8. Unhook the fuel feed hose (8) from the clamp
(9).
(12)
2.4 in (60 mm)
(12) cushion rubbers
(8) fuel feed hose (9) clamp
9. Pull the fuel tank (10) out of the frame and
hang it to the left of the frame.
Check the fuel tank stopper cable (11) for
deterioration, kinks or other damage.
Do not support the fuel tank by the fuel feed
hose (8).
(3)
(2)
(1)
(5)
(4)
(5)
(7)
(6)
(8)
(9)
(8)
(11)
(10)
Servicing Your Honda 35
Fuel Tank
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Installation
1. Install the fuel feed hose (1) to the clamp (2)
if it is removed.
(1) fuel feed hose (2) clamp
2. Install the fuel tank (3) on the frame.
3. Install the collar and fuel tank bolt (4).
4. Hook the fuel tank band (5).
5. Put the breather tube (6) in the steering stem
nut (7).
6. Remove the hose clamp (8) from the breather
tube.
(6) breather tube (8) hose clamp
(7) steering stem nut
7. Install the shrouds (9) by aligning shroud tabs
(10) with the air cleaner housing cover tabs
(11).
(3) fuel tank (5) fuel tank band
(4) collar and fuel tank bolt
(9)
(12)
(13)
(10)
(11)
(9) shrouds
(10) shroud tabs
(11) air cleaner housing cover tabs
(12) shroud B bolts
(13) collars and shroud A bolts
8. Install the shroud B bolts (12), collars and
shroud A bolts (13).
Tighten the shroud B bolts to the specified
torque:
3.7 lbf·ft (5 N·m, 0.5 kgf·m)
9. Install the seat (page 33).
36 Servicing Your Honda
Subframe
Refer to Safety Precautions on page 23.
Removal
1. Remove the side covers (1) by removing the
seat mounting bolts (2) and bolts (3).
2. Remove the seat (4).
(1) side covers (3) bolts
(2) seat mounting bolts (4) seat
3. Loosen the muffler clamp bolt (5).
(3)
(4)
(2)
(1)
(5) muffler clamp bolt
(5)
(15)
(16)
4. Remove the muffler mounting A bolt (6),
muffler mounting B bolt (7), washer A (8),
washer B (9) and muffler (10).
(6) muffler mounting A bolt (9) washer B
(7) muffler mounting B bolt (10) muffler
(8) washer A
5. Disconnect the IAT sensor connector (11).
6. Remove the ECM mounting rubber (12) from
the ECM bracket (13).
Unhook the fuel tank band (14).
(12) ECM mounting rubber
(13) ECM bracket
(14) fuel tank band
7. Loosen the screw (15) on the air cleaner
connecting tube clamp (16).
(15) screw
(16) air cleaner connecting tube clamp
(6)
(7)
(8)
(9)
(10)
(12)
(14)
(13)
(11) IAT sensor connector
(11)
Servicing Your Honda 37
Subframe
8. Remove the right subframe lower bolt (17)
and left subframe lower bolt (18).
Remove the subframe upper bolts (19).
(17) right subframe lower bolt
(18) left subframe lower bolt
(19) subframe upper bolts
9. Slightly pull the subframe (20) backward and
disconnect the crankcase breather tube (21)
from the air cleaner connecting tube.
Remove the subframe.
Be careful not to damage the ECM and wires.
(20) subframe
(21) crankcase breather tube
Right side:
(19) (19)
(17)
(18)
Left side:
(21)
(20)
(1)
(1) crankcase breather tube
2. Position the ECM (2) in the bracket (3).
3. Align the shroud tabs (4) with the air cleaner
housing cover tabs (5).
4. Loosely attach the upper and lower end of the
subframe to the main frame while connecting
the air cleaner connecting tube (6) to the
throttle body (7).
5. Loosely install all subframe bolts.
Installation
1. Connect the crankcase breather tube (1).
(2) ECM (5) air cleaner housing cover tabs
(3) bracket (6) air cleaner connecting tube
(4) shroud tabs (7) throttle body
(2)
(3)
(7)
(6)
(5)
(4)
6. Align the subframe with the rear wheel and
tighten the subframe upper bolts (8), left
subframe lower bolt (9) and right subframe
lower bolt (10) to the specified torque:
subframe upper bolts:
24 lbf·ft (33 N·m, 3.4 kgf·m)
left subframe lower bolt:
24 lbf·ft (33 N·m, 3.4 kgf·m)
right subframe lower bolt:
36 lbf·ft (49 N·m, 5.0 kgf·m)
(8) subframe upper bolts
(9) left subframe lower bolt
(10) right subframe lower bolt
Right side:
(8)
(10)
(9)
Left side:
(8)
(cont’d)
38 Servicing Your Honda
Subframe
7. Make sure the air cleaner connecting tube tab
(11) aligns with the air cleaner connecting
tube clamp hole (12).
(11) air cleaner connecting tube tab
(12) air cleaner connecting tube clamp hole
8. Tighten the screw (13) on the air cleaner
connecting tube clamp to the specified torque:
0.5 lbf·ft (0.7 N·m, 0.1 kgf·m)
Check the distance between the band ends is
0.18 ± 0.06 in (4.5 ± 1.5 mm).
(12)
(11)
9. Hook the fuel tank band (14).
Install the ECM mounting rubber (15) to the
ECM bracket (16).
(14) fuel tank band
(15) ECM mounting rubber
(16) ECM bracket
(15)
(14)
(16)
(18) muffler clamp (20) exhaust pipe
(19) gasket (new)
13. Install the muffler (21).
14. Install the muffler clamp (18) by aligning the
tab (22) of the muffler clamp with the cutout
(23) of the muffler.
(18)
(19)
(20)
(13) screw
(13)
0.18 ± 0.06 in
(4.5 ± 1.5 mm)
(17) IAT sensor connector
(17)
(18) muffler clamp (22) tab
(21) muffler (23) cutout
(23)
(21)
(22)
(18)
11. Remove the old gasket from exhaust pipe.
12. Install the muffler clamp (18) and a new
gasket (19) to the exhaust pipe (20).
10. Connect the IAT sensor connector (17).
Servicing Your Honda 39
Subframe
15. Install the washer A (24), washer B (25),
muffler mounting B bolt (26) and muffler
mounting A bolt (27).
(24) washer A
(25) washer B
(26) muffler mounting B bolt
(27) muffler mounting A bolt
16. Tighten the muffler clamp bolt (28) to the
specified torque:
15 lbf·ft (21 N·m, 2.1 kgf·m)
(27)
(26)
(24)
(28)
17. Tighten the muffler mounting B bolt (26) and
muffler mounting A bolt (27) to the specified
torque:
19 lbf·ft (26 N·m, 2.7 kgf·m)
18. Install the seat (29).
19. Install the side covers (30), seat mounting
bolts (31) and bolts (32). Then tighten the seat
mounting bolts and side cover bolts to the
specified torque:
seat mounting bolts:
19 lbf·ft (26 N·m, 2.7 kgf·m)
side cover bolts:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(26) muffler mounting B bolt
(27) muffler mounting A bolt
(29) seat
(30) side covers
(31) seat mounting bolts
(32) bolts
(31)
(30)
(32)
(27)
(29)
(26)
(28) muffler clamp bolt
(28)
Refer to Safety Precautions on page 23.
Fuel
Type Unleaded
Pump Octane Number 91 (or higher)
40 Servicing Your Honda
Fuel System
Refueling Procedure
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.
(1) fuel fill cap (3) steering stem nut
(2) breather tube
2. Add fuel until the level reaches the bottom of
the filler neck.
Fuel Tank Capacity:
1.5 US gal (5.7R)
Be careful not to damage the fuel pump while
filling the fuel tank.
Avoid overfilling the tank. There should be no
fuel in the filler neck.
WARNING
Gasoline 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.
(1) fuel quick connect fitting cover
(2) fuel line
(3)
(2)
(1)
(1)
(2)
3. Close the fuel fill cap and insert the breather
tube in the steering stem nut.
Fuel Line
1. Hang the fuel tank to the left side of the frame
(page 34).
2. Remove the fuel quick connect fitting cover
(1).
3. Check the fuel line (2) for cracks,
deterioration, damage or leakage. Replace the
fuel line, if necessary.
4. Install the fuel quick connect fitting cover.
5. Install the fuel tank (page 35).
Use only unleaded fuel in your Honda. If you
ride your Honda in a country where leaded fuel
might be available, take precautions to use only
unleaded fuel.
Your engine is designed to use any unleaded
gasoline that has a pump octane number of 91 or
higher. Gasoline pumps at service stations
normally display the pump octane number. For
information on the use of oxygenated fuels, see
page 153.
Use of lower octane gasoline 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 gasoline. If pinging or spark knock persists,
consult your dealer.
Never use stale or contaminated gasoline. Avoid
getting dirt, dust or water in the fuel tank.
Dirty fuel will clog the fuel pump filter and can
damage the fuel pump. Commercially available
fuel straining devices may reduce the occurrence
of dirty fuel.
Servicing Your Honda 41
Fuel System
Fuel Pressure Relieving
1. Disconnect the fuel pump sub-harness
connector (1).
(1) fuel quick connect fitting cover
(2) fuel pump
(3) fuel quick connect fitting
5. Remove the bolt (4), clamp and setting rubber
(5).
(2)
(1)
Injector side: Fuel Pump side:
(3)
(1)
Fuel Line Replacement
Disconnection
1. Relieve the fuel pressure (this page).
2. Hang the fuel tank to the left side of the frame
(page 34).
3. Remove the fuel quick connect fitting cover
(1) from the fuel pump (2).
4. Check the fuel quick connect fitting (3) for
dirt, and clean if necessary.
(1) fuel pump sub-harness connector
2. Start the engine and let it idle until the engine
stalls.
(5)
(4)
6. Pull and release the joint rubber (6) of the
injector side from the retainer (7).
(6) joint rubber (injector side only)
(7) retainer
7. Place a shop towel (8) over the fuel quick
connect fitting.
(6)
(7)
(8) shop towel
Injector side: Fuel Pump side:
(8)
(cont’d)
(4) bolt (5) clamp and setting rubber
42 Servicing Your Honda
Fuel System
8. Hold the connector with one hand and squeeze
the retainer tabs (9) with the other hand to
remove them from the locking pawls (10).
Pull the connector off, then remove the retainer.
• Use a shop towel to absorb the remaining
fuel in the fuel feed hose.
• Be careful not to damage the hose or other
parts.
• Do not use tools.
• If the connector does not move, keep the
retainer tabs pressed down, and alternately
pull and push the connector until it comes
off easily.
(9) retainer tabs
(10) locking pawls
WARNING
Gasoline 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.
Injector side: Fuel Pump side:
(9)
(9)
(10)
(10)
9. To prevent damage and keep foreign matter
out, cover the disconnected connectors (11)
and fuel joints (12) with plastic bags (13).
(11) disconnected connector
(12) fuel joint
(13) plastic bags
(13)
(12)
(11)
Connection
1. Insert a new retainer (1) into the connector (2)
by aligning its locking pawls (3) with the
connector grooves (4).
• Always replace the retainer of the quick
connect fitting when the fuel feed hose is
disconnected.
• If the joint rubber is damaged or cut, replace
it with a new one.
• Do not bend or twist the fuel feed hose.
• If any retainer needs replacing, use the same
manufacture’s retainer as the ones being
removed (The various manufacture’s feature
different retainer specification).
(1) retainer (new) (3) locking pawls
(2) connector (4) connector grooves
(2)
(4)
Align
(1)
(3)
Servicing Your Honda 43
Fuel System
2. Install the joint rubber (5) and seat it onto the
fuel joint as shown. Align the fuel quick
connect fitting with the fuel joint. Then press
the quick fitting onto the pipe of the fuel joint
until both retainer pawls lock with a “click”.
If it is hard to connect, put a small amount of
engine oil on the pipe end.
(5) joint rubber (injector side only)
(5)
3. Make sure the connection is secure and that
the pawls are firmly locked into place; check
visually and by pulling the connector.
4. Make sure the joint rubber (5) is in place
between the flange (6) and retainer tab (7).
(5) joint rubber (injector side only)
(6) flange
(7) retainer tab
5. Install the rubber (8), clamp (9) and bolt (10)
by aligning the clamp tab (11) with the groove
(12) of the stay.
(5)
(7)
(6)
6. Install the fuel quick connect fitting cover
(13) and set the rubber cover tab (14) to the
hole (15) of the fuel quick connect fitting
cover.
Be sure the rubber cover (16) is properly
installed between the fuel quick connect fitting
cover and fuel pump.
(13) fuel quick connect fitting cover
(14) rubber cover tab
(15) fuel quick connect fitting cover hole
(16) rubber cover
7. Install the fuel tank (page 35).
8. Increase the fuel pressure (page 48).
(13)
(15)
(14)
(16)
(8) rubber (11) clamp tab
(9) clamp (12) groove
(10) bolt
(10)
(11)
(12)
(9)
(8)
44 Servicing Your Honda
Fuel System
Fuel Pump Filter Replacement
Empty the fuel tank into an approved gasoline
container using a commercially available hand
siphon or an equivalent method.
Be careful not to damage the fuel pump while
draining the fuel in the fuel tank.
WARNING
Gasoline 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.
Removal
1. Relieve the fuel pressure (page 41).
2. Disconnect the fuel line (page 41).
3. Remove the fuel pump mounting bolts (1),
stopper cable guide (2), stopper cable (3),
washers (4), collars (5), conical spring
washers (6) and fuel pump plate (7) while
holding the fuel tank.
4. Remove the fuel tank.
Be careful not to drop the fuel tank when
removing the stopper cable.
(1) fuel pump mounting bolts
(2) stopper cable guide
(3) stopper cable
(4) washers
(5) collars
(6) conical spring washers
(7) fuel pump plate
5. Remove the fuel pump unit (8) and O-rings
(9).
Be careful not to damage the fuel pump unit.
(8) fuel pump unit (9) O-rings
6. Disconnect the fuel pump wire terminals (10)
from the fuel pump base (11).
Be careful not to damage the wires when
disconnecting the fuel pump wire terminals.
(10) fuel pump wire terminals
(11) fuel pump base
(7)
(6)
(5)
(4)
(1)
(3)
(2)
(8)
(9)
(11)
(10)
Servicing Your Honda 45
Fuel System
7. Check the hooks (12) of the fuel pump unit
holder and tabs (13) on the fuel pump base for
damage or discoloration.
If the hooks and tabs are damaged or
discolored, replace the fuel pump unit as an
assembly.
8. Release the hooks of the fuel pump unit
holder from the grooves (14) on the fuel pump
base tabs while pushing the holder against the
base and slightly spreading the base tabs.
Be careful not to damage the hooks and tabs.
9. Remove the fuel pump unit holder assembly
(15) from the fuel pump base (11) and remove
the O-ring (16).
Wipe the spilled out fuel immediately.
(11) fuel pump base
(15) fuel pump unit holder assembly
(16) O-ring
10. Remove the fuel pump stopper (17) and
damper rubber (18).
(12) hooks (14) grooves
(13) tabs
(17) fuel pump stopper
(18) damper rubber
11. Remove the fuel pump assembly (19) with
fuel pump filter (20), O-ring (21) from the
fuel pump unit holder (22).
(19) fuel pump assembly
(20) fuel pump filter
(21) O-ring
(22) fuel pump unit holder
12. Check the fuel pump filter (20) for clog,
damage or deterioration and replace if
necessary.
13. Remove the fuel pump filter from the fuel
pump assembly (20).
(19) fuel pump assembly (20) fuel pump filter
(12)
(13)
(14)
(13)(12) (14)
(15)
(16)
(11)
(17)
(18)
(22)
(21)
(19) (20)
(19)
(20)
46 Servicing Your Honda
Fuel System
Installation
1. Install a new fuel pump filter (1) onto the fuel
pump assembly (2) aligning its hook (3) with
the joint boss (4) completely.
Be careful not to damage the hook.
(1) new fuel pump filter (3) hook
(2) fuel pump assembly (4) joint boss
2. Apply a small amount of silicone grease to a
new O-ring (5).
Install a new O-ring to the fuel pump
assembly (2).
3. Install the fuel pump assembly with fuel pump
filter into the fuel pump unit holder (6) while
routing the fuel pump red (7) and black (8)
wires through the holder grooves (9) as
shown.
(2) fuel pump assembly (7) red wire
(5) O-ring (new) (8) black wire
(6) fuel pump unit holder (9) grooves
4. Install a new damper rubber (10) to the fuel
pump filter as shown.
Install the fuel pump stopper (11).
(10) new damper rubber (11) fuel pump stopper
5. Apply a small amount of silicone grease to a
new O-ring (12).
Install a new O-ring to the fuel pump base
(13).
6. Install the fuel pump unit holder assembly
(14) into the fuel pump base while aligning its
hooks (15) with the grooves (16) in the fuel
pump base tabs (17).
If the gap between the hooks and tabs is more
than 0.04 in (1.0 mm), replace the fuel pump
unit.
Be sure that the hooks are completely seated.
(12) O-ring (new)
(13) fuel pump base
(14) fuel pump unit holder assembly
(15) hooks
(16) grooves
(17) tabs
(2)
(3)
(4)
(1)
(9)
(9)
(6)
(8)
(8)
(7)
(7)
(9)
(9)
(5)
(2)
(10)
(11)
(12)
(13)
(14)
(15)
(16) (17)
Servicing Your Honda 47
7. Connect the fuel pump red (18) and black (19)
wire terminals to the fuel pump base terminals
(20).
Push the wire terminals until they stops as
shown.
Be careful not to damage the wires.
8. Apply 0.5 g maximum of engine oil to a new
O-ring (21).
Install a new O-ring onto the fuel pump unit
(22).
(18) red wire terminal
(19) black wire terminal
(20) fuel pump base terminals
(21) O-ring (new)
(22) fuel pump unit
9. Install a new O-ring (23) into the fuel tank
groove.
10. Install the fuel pump unit (24) into the fuel
tank (25).
Be careful not to damage the wires.
(23) O-ring (new) (25) fuel tank
(24) fuel pump unit
11. Install the fuel pump plate (26) with its
identification mark (27) facing toward the
front side and facing up.
(26) fuel pump plate (27) identification mark
12. Install the conical spring washers (28), collars
(29), washers (30), stopper cable (31), stopper
cable guide (32) and fuel pump mounting
bolts (33).
13. Install the fuel tank.
Make sure that the convex surface of the conical
spring washers are upside.
(28) conical spring washers
(29) collars
(30) washers
(31) stopper cable
(32) stopper cable guide
(33) fuel pump mounting bolts
14. Tighten the fuel pump mounting bolts to the
specified torque in the specified sequence as
shown.
8 lbf·ft (11 N·m, 1.1 kgf·m)
15. Connect the fuel line (page 42).
16. Increase the fuel pressure (page 48).
(21)
(18)
(18)
(19)
(19)
(22)
(20)
(24)
(23)(25)
(26)
(27)
(33)(29)(28)
(32)
(31)
(30) (33)(29)(28)
Fuel System
48 Servicing Your Honda
Fuel System
Fuel Pressure Increasing
Make sure the fuel remains enough (0.3 US gal
(1.0
r) minimum) in the fuel tank and add fuel if
necessary before increasing fuel pressure.
1. Connect the fuel pump sub-harness connector
(1).
(1) fuel pump sub-harness connector
2. Before connecting the battery harness cables
to a 12V battery, make sure that the battery
harness selector switches are OFF.
3. Connect the battery harness (2) and battery
harness adapter (3) between the main and
sub-harness as shown.
Connect the battery harness positive (+) cable
first, then connect the battery harness negative
(–) cable to a 12V battery terminals.
• Battery harness
070MZ-MEN0100
• Battery harness adapter 070MZ-KRN0100
(1)
(2) battery harness
(3) battery harness adapter
4. Position the fuel tank on the main frame.
5. Turn the “PUMP” selector switch (4) ON.
The selector switches can be used to change
power delivery as follows:
–“ECM” selector switch ON:
Power to ECM only.
–“PUMP” selector switch ON:
Power to fuel pump only.
– Both selector switches ON:
Power to ECM and fuel pump.
(2)
(3)
6. Run the fuel pump for about 3 – 5 seconds,
and fuel pressure will rise.
7. Turn the “PUMP” selector switch OFF.
Check that there is no leakage in the fuel line.
(4) “PUMP” selector switch
8. Remove the battery harness.
(4)
Servicing Your Honda 49
* Suggested 4-stroke engine oils are equal
performance to SJ oils that are not labeled as
energy conserving on the circular API service
label.
Engine Oil
Refer to Safety Precautions on page 23.
Using the proper oil, and regularly checking,
adding, and changing oil will help extend the
service life of the engine. Even the best oil wears
out. Changing oil helps get rid 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*
Pro Honda GN4 4-stroke oil
(USA & Canada), or Honda
4-stroke oil (Canada only), or
an equivalent motorcycle oil*
viscosity
(weight)
SAE 10W–30
JASO T 903 standard 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
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) oil code
(2) oil classification
(2)
(1)
(2)
50 Servicing Your Honda
Engine Oil
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinsert the engine oil fill cap/dipstick (1).
(1) engine oil fill cap/dipstick
(2) engine oil drain bolt
(3) sealing washer (new)
(1)
(3)
(2)
(1)
(1)
(3)
(2)
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 fill cap/dipstick (1)
from the left crankcase cover.
4. Place an oil drain pan under the engine to
catch the oil. Then remove the engine oil
drain bolt (2) and sealing washer (3).
5. With the engine stop button pushed, repeat
kickstarter operation approximately five times
to drain the engine oil completely.
6. After the oil has drained, apply engine oil to
the drain bolt threads and tighten it with a
new sealing washer to the specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 144).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
Checking & Adding Oil
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 fill cap/dipstick (1),
wipe it clean, and insert the engine oil fill
cap/dipstick without screwing it in. Remove
the oil fill cap/dipstick.
5. Check that the oil level is between the upper
(2) and lower (3) level marks on the engine oil
fill cap/dipstick.
• If the oil is at or near the upper level mark,
you do not have to add oil.
• If the oil is below or near the lower level
mark, add the recommended oil until it
reaches the upper level mark. (Do not
overfill)
Reinstall the engine oil fill cap/dipstick.
Repeat steps 1–5.
(1) engine oil fill cap/dipstick
(2) upper level mark
(3) lower level mark
(1)
(4)
(1) engine oil fill cap/dipstick
(4) O-ring
8. Check for oil leaks.
Servicing Your Honda 51
Engine Oil
If the oil filter is not installed properly, it will
cause serious engine damage.
13. Apply engine oil to a new O-ring and install it
to the oil filter cover.
14. Install the oil filter cover being careful not to
damage the O-ring, then tighten the oil filter
cover bolts to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
15. Fill the crankcase with the recommended oil.
Capacity:
0.73 US qt (0.69R)
after draining and oil filter change
0.70 US qt (0.67R)
after draining
16. Install the engine oil fill cap/dipstick.
17. Check the engine oil level by following the
steps in
Checking & Adding Oil (page 50).
Pour the drained oil into a suitable container and
dispose of it in an approved manner (page 144).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
NOTICE
(6)
(7)
(5)
(4)
(10)
(9)
(8)
8. Remove the oil filter cover bolts (4) and oil
filter cover (5).
9. Remove the oil filter (6) from the oil filter cover.
10. Check that the oil filter cover O-ring (7) is in
good condition.
(4) oil filter cover bolts
(5) oil filter cover
(6) oil filter
(7) oil filter cover O-ring
(8) spring
(9) rubber seal
(10) “OUT-SIDE” mark
Using the wrong oil filter may result in leaks or
engine damage.
NOTICE
7. 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 25.
11. Apply grease to the filter side of the spring
end, then install the spring (8) into a new oil
filter.
12. Position the spring against the engine
crankcase and install a new oil filter with the
rubber seal (9) facing out, away from the
engine. You should see the “OUT-SIDE” mark
(10) on the filter body, near the rubber seal.
Use a new Honda Genuine oil filter or a filter
of equal quality specified for your model.
52 Servicing Your Honda
* Suggested 4-stroke engine oils are equal
performance to SJ oils that are not labeled as
energy conserving on the circular API service
label.
• 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.
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.
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
MA
without friction modifiers as
molybdenum additives
Pro Honda GN4 4-stroke oil
(USA & Canada), or Honda
4-stroke oil (Canada only), or
an equivalent motorcycle 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.
Refer to
Safety Precautions on page 23.
Using the proper oil, and regularly checking,
adding, and changing oil will help extend the
service life of the transmission and clutch. Even
the best oil wears out. Changing oil helps get rid
of dirt and deposits. Operating the engine with
old or dirty oil can damage your engine.
Running the engine with insufficient oil can
cause serious damage to the engine and
transmission.
Oil Recommendation
(2)
(1)
(2)
(1) oil code
(2) oil classification
Servicing Your Honda 53
Transmission Oil
(1)
(2)
(3)
(1)
(2)
(3)
(1) transmission oil fill cap
(2) transmission oil drain bolt
(3) sealing washer
7. Fill the crankcase with recommended oil.
Capacity:
0.72 US qt (0.68R) after draining
8. Install the transmission oil fill cap.
9. 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 144).
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
Checking & Adding Oil
(1) transmission oil fill 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 fill 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 fill 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:
9 lbf·ft (12 N·m, 1.2 kgf·m).
6. Check that the O-ring (4) is in good condition
and replace it if necessary.
7. Reinstall the transmission oil fill cap (1).
8. Check for oil leaks.
(4)
(1)
(1) transmission oil fill cap
(4) O-ring
Replacing Transmission Oil
1. Run the engine at idle for 3 minutes, then shut
it off.
2. Support the CRF in an upright position on a
level surface.
3. Remove the transmission oil fill cap (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:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Coolant
54 Servicing Your Honda
(1)
(2)
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.
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 Pro Honda HP coolant or an equivalent 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.
NOTICE
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 23.
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 0.7 – 2.0 US oz (20 – 60
cm
3
) through the overflow tube is normal. If
coolant loss is more than this, inspect the
cooling system.
Capacity:
1.16 US qt (1.10R) after disassembly
1.09 US qt (1.03R) 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
Servicing Your Honda 55
WARNING
(2)
(1)
(4)
(3)
(3) bleed 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.
Cooling System Inspection
1. Check the cooling system for leaks (see the
Honda Service 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 bleed hole (3) below the water
pump cover (4) for leakage. Clean away any
clogged dirt or sand, if necessary. Check for
signs of seal leakage. A small amount of
“coolant weeping” from the bleed hole is
normal. If water leaks through the bleed hole,
the mechanical seal is damaged. If oil leaks
through the bleed hole, the oil seal is
damaged. See an official Honda Service
Manual or consult your dealer for replacing
the mechanical seal or oil seal.
Both seals should be replaced at the same
time.
(1) water hoses
(2) overflow tube
Coolant Replacement
Refer to Safety Precautions on page 23.
Coolant should be replaced by your dealer, unless
you have the proper tools and service data and
are mechanically qualified. Refer to the Honda
Service Manual (page 160).
To properly dispose of drained coolant, refer to
You & the Environment, page 144.
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
56 Servicing Your Honda
Air Cleaner
Refer to Safety Precautions on page 23.
The air cleaner uses polyurethane inner and outer
pieces which can’t be separated.
A dirty air cleaner will reduce engine power.
Proper air cleaner maintenance is very important
for off-road vehicles. A dirty, water-soaked,
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 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.
NOTICE
Cleaning
1. Remove the seat (page 33).
2. Remove the air cleaner retaining bolt (1) and
air cleaner assembly (2).
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
(1) air cleaner retaining bolt
(2) air cleaner assembly
(1)
(2)
Servicing Your Honda 57
Air Cleaner
(1) air cleaner retaining bolt
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.
12. Install the seat (page 33)
NOTICE
(2) air cleaner assembly
(8) air cleaner assembly tabs
(9) air cleaner housing stay
(9)
(8)
(2)
10. Carefully position the sealing flange of the
element to prevent dirt intrusion.
3. Remove the air cleaner element (3) from the air
cleaner holder (4) by releasing the holder tab
(5) from the hole (6) of the air cleaner element.
(3) air cleaner element (5) holder tab
(4) air cleaner holder (6) hole
4. Wash the air cleaner in clean non-flammable
cleaning solvent. Then wash in hot, soapy
water, rinse well, and allow to dry thoroughly.
The air cleaner element is made in two pieces:
inner and outer, which cannot be separated.
5. Clean the inside of the air cleaner housing.
6. Allow the air cleaner to dry thoroughly. After
drying, apply 1.7 oz (50 cm
3
) of clean Pro
Honda Foam Filter Oil or an equivalent air
cleaner oil from the inside of the element.
Place the element into a plastic bag (7) and
spread the oil evenly by hand.
(3)
(4)
(6)
(5)
11. Install and tighten the air cleaner retaining
bolt (1) securely.
(1)
(7) plastic bag
7. Assemble the air cleaner element and holder.
Install the holder tab (5) in the hole (6) of the
air cleaner element.
8. Apply 0.1 – 0.2 oz (3 – 5 g) of Pro Honda
White Lithium Grease or equivalent to the air
cleaner housing contact area of the air cleaner
element.
9. Install the air cleaner assembly (2) into the air
cleaner housing by aligning its tabs (8) with
the stay (9) of the air cleaner housing.
(7)
Crankcase Breather
58 Servicing Your Honda
Refer to Safety Precautions on page 23.
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)
Throttle
Servicing Your Honda 59
Refer to Safety Precautions on page 23.
Throttle Freeplay
(1) freeplay
Inspection
Check freeplay (1).
Freeplay:
1/8 – 3/16 in (3 – 5 mm)
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 throttle body. It is also
used if you cannot get the proper adjustment with
the upper adjuster.
(1)
(2)
(4)
(3)
(+)
(–)
(5) lock nut (+) increase
(6) lower adjuster (–) decrease
1. Loosen the lock nut (5).
2. Turn the lower adjuster (6) in direction (–) to
decrease freeplay, and in direction (+) to
increase freeplay.
3. Tighten the lock nut to the specified torque:
3.0 lbf·ft (4 N·m, 0.4 kgf·m)
4. Operate the throttle grip to ensure that it
functions smoothly and returns completely.
If you can’t get the freeplay within the specified
range, contact your dealer.
(5)
(6)
(+)
(–)
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:
3.0 lbf·ft (4 N·m, 0.4 kgf·m)
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
60 Servicing Your Honda
Throttle
Throttle Inspection
1. Check that the throttle assembly is positioned
properly (the end of the throttle housing (1) is
aligned with the paint mark (2) on the
handlebar) and the securing bolts are tight.
3. Inspect the condition of the throttle cables
from the throttle grip down to the throttle
body. 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 commercially
available cable lubricant to prevent premature
rust and corrosion.
(3)
(1) throttle housing (2) paint mark
2. Check for smooth rotation of the throttle (3)
from fully open to fully closed in all steering
positions. If there is a problem, see your
dealer.
(1)
(2)
(3) throttle
Servicing Your Honda 61
Engine Idle Speed
Refer to Safety Precautions on page 23.
Remember, idle speed adjustment is not a “cureall” for other problems in your engine’s PGM-FI
system. Adjusting the idle will not compensate
for a fault elsewhere.
The engine must be at normal operating
temperature for accurate idle speed adjustment.
When pushed in, the fast idle knob acts as the
idle adjust screw.
Turning it counterclockwise results in a
faster/higher idle speed.
Turning it clockwise results in a slower/lower
idle speed.
Idle Speed Adjustment
1. If the engine is cold, start it and warm it up 3
minutes. Then shut it off.
2. Connect a tachometer to the engine.
3. Shift the transmission into neutral. Start the
engine.
4. Keep the motorcycle in an upright position.
5. Adjust idle speed with the fast idle knob (1).
Idle speed:
2,000 ± 100 rpm
(1)
(+)
(–)
(1) fast idle knob
(+) increase
(–) decrease
Clutch System
62 Servicing Your Honda
Refer to Safety Precautions on page 23.
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 3/8 – 13/16 in (10 – 20 mm) 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) freeplay
Inspection
Check freeplay (1).
Freeplay:
3/8 – 13/16 in (10 – 20 mm)
If necessary, adjust to the specified range.
Improper freeplay adjustment can cause
premature clutch wear.
Make sure to adjust the clutch lever freeplay after
the clutch cable is disconnected.
(1)
Clutch System
Servicing Your Honda 63
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.
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.
Inspect the clutch discs and plates (page 65).
(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.
(1)(2)
64 Servicing Your Honda
Clutch System
Clutch Cover/Disc/Plate Removal
1. Drain the transmission oil (page 53).
2. Remove the clutch cover bolt A (1), clutch
cover bolts B (2), and clutch cover (3).
(1) clutch cover bolt A (3) clutch cover
(2) clutch cover bolts B
3. Remove the five clutch spring bolts and clutch
springs (4).
Loosen the bolts in a crisscross pattern in two or
three progressive steps.
4. Remove the clutch pressure plate (5).
(4) clutch spring bolts/clutch springs
(5) clutch pressure plate
5. Remove the clutch lifter (6) and clutch lifter
rod (7).
6. 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.
(3)
(1)
(2)
(5)
(4)
(7)
(6)
(6) clutch lifter
(7) clutch lifter rod
(8) clutch discs, clutch plates, judder spring and spring
seat
(8)
7. Remove the eight clutch discs, seven clutch
plates, judder spring and spring seat (8).
Servicing Your Honda 65
Clutch Disc/Plate Inspection
Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit:
0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as an
assembly.
(1)
(1) clutch disc
(2)
(2) clutch plate
If you feel the clutch slippage when replacing the
clutch discs and plates, replace the clutch springs.
Clutch System
Check the clutch plate (2) for excessive warpage
or discoloration. Check the plate warpage on a
surface plate using a feeler gauge.
Measure the thickness of the clutch plates.
Service Limit:
0.004 in (0.10 mm)
Replace the clutch discs and plates as a set.
66 Servicing Your Honda
Clutch System
Clutch Disc/Plate Installation
1. Install the spring seat (1) and judder spring (2)
onto the clutch center as shown.
2. Coat the clutch discs (3) and plates (4) with
engine oil.
3. Install the clutch disc A (larger I.D. disc) (5)
onto the clutch outer.
Stack the seven clutch plates and seven clutch
discs alternately.
4. Apply grease to the clutch lifter rod (6) ends.
5. Insert the clutch lifter rod into the mainshaft.
6. Apply engine oil to the needle bearing of the
clutch lifter.
7. Install the clutch lifter (7) onto the clutch
lifter rod.
(6) clutch lifter rod (7) clutch lifter
8. Install the clutch pressure plate (8).
9. Install the five clutch springs and clutch
spring bolts (9).
(8) clutch pressure plate
(9) clutch spring bolts/clutch springs
(10) O-ring (new) (11) clutch cover
(4)
(1)
(2)
(5)
(3)
(6)
(7)
(8)
(9)
(10)
(11)
11. Apply oil to a new O-ring (10) and install in
the groove of the clutch cover (11).
12. Install the cover by tightening the cover bolts
A, and B in a crisscross pattern in two or
three steps to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(1) spring seat (4) clutch plates
(2) judder spring (5) clutch disc A
(3) clutch discs
10. Tighten the bolts in a crisscross pattern in two
or three steps, to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
Servicing Your Honda 67
Refer to Safety Precautions on page 23.
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 center 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 center
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 hang the fuel tank to the
left of the frame (pages 33, 34).
2. Disconnect the spark plug cap (1).
3. Clean any dirt from around the spark plug base.
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 center
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 show color 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 133).
Check the PGM-FI 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) spark plug cap
(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:
0.024 – 0.028 in (0.6 – 0.7 mm)
(3) sealing gasket
(4) spark plug gap
(1)
(2)
(3)
(4)
Standard R0451B-8 (NGK)
10. Connect the direct ignition coil. Take care to
avoid pinching any cables or wires.
11. Install the fuel tank and seat (pages 33, 35).
Refer to Safety Precautions on page 23.
Excessive valve clearance will cause noise and
eventual engine damage. Little or no clearance
will prevent the valve from closing and cause
valve damage and power loss. Check the valve
clearance when the engine is cold at the intervals
specified in the Maintenance Schedule (page 25).
The checking or adjusting of the clearance should
be performed while the engine is cold.
The valve clearance will change as engine
temperature rises.
Valve Clearance
68 Servicing Your Honda
Cylinder Head Cover Removal
Before inspection, clean the engine thoroughly to
keep dirt from entering the engine.
1. Remove the seat and hang the fuel tank to the
left of the frame (pages 33,34).
2. Disconnect the breather tube (1) and spark
plug cap (2).
Positioning At Top Dead Center On The
Compression Stroke
1. Remove the crankshaft hole cap (1).
(1) breather tube (2) spark plug cap
3. Remove the cylinder head cover bolts/rubber
seals (3) and cylinder head cover (4).
(3) cylinder head cover bolts/rubber seals
(4) cylinder head cover
4. Remove the spark plug hole packing.
(1) crankshaft hole cap
2. Remove the spark plug (page 67).
(2)
(1)
(4)
(3)
(1)
Valve Clearance
Servicing Your Honda 69
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:
0.005 ± 0.001 in (0.12 ± 0.03 mm)
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)
If intake valve clearance and exhaust valve
clearance need adjustment, see
Camshaft
Removal
(page 70) and select the correct shim for
each valve.
(5)
(1) (2)
(3)
(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)
(4)
(3)
(2) primary drive gear bolt (4) “∆” mark
(3) punch mark
(5) exhaust rocker arm
70 Servicing Your Honda
Valve Clearance
Camshaft Removal
1. Record the intake valve clearance and exhaust
valve clearance (page 69).
(1) cam chain tensioner lifter cover bolt
(2) sealing washer
Use the tensioner stopper tool.
• Tensioner stopper 070MG-0010100
07AMG-001A100
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).
Servicing Your Honda 71
Valve Clearance
7. Remove the shims (11).
(11) shims
(11)
(11)
(10) valve lifters
(6)
(6)
(5)
(4)
(10)
(4) camshaft holder bolts A
(5) camshaft holder bolts B
(6) camshaft holders
Do not let the set rings fall into the crankcase.
If the set rings are remained on the camshaft
holder, remove the set rings carefully.
NOTICE
(7) left camshaft bearing
(8) camshaft
(9) cam chain
6. Remove the valve lifters (10).
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
(9)
(8)
(7)
5. Slide the left camshaft bearing (7) and remove
the camshaft (8) and cam chain (9), then
attach a piece of wire to the cam chain to
prevent it from falling into the crankcase.
4. Make sure the piston is at TDC on the
compression stroke (page 68).
Remove the camshaft holder bolts A (4), B (5)
and camshaft holders (6).
Loosen the camshaft holder bolts in a
crisscross pattern in two or three steps.
Valve Clearance
72 Servicing Your Honda
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
Valve Clearance
Servicing Your Honda 73
(4) primary drive gear bolt (6) “∆” mark
(5) punch mark
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.
(7) cam shaft (12) cam chain
(8) intake cam lobes
(4)
(5)
(6)
(12)
(7)
(8)
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. Rotate the primary drive gear bolt (4)
(crankshaft) clockwise and align the punch
mark (5) with the “
∆” mark (6).
(1)
(1)
(2)
(2)
(3)
(13) set rings
(15) camshaft bearing grooves
(13)
(15)
(13)
(9) timing marks
(10) cam sprocket
(11) surface of the cylinder head
5. Apply grease to the set rings (13) and install it
onto the camshaft bearing grooves (15).
(10)
(11)
(9)
(3) valve lifters
(cont’d)
Valve Clearance
74 Servicing Your Honda
(14) camshaft holders
(17) camshaft holder bolts A
(18) camshaft holder bolts B
10. Rotate the camshaft by rotating the crankshaft
clockwise several times.
11. Insert the feeler gauge (22) between the intake
valve lifter and cam.
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: 0.005 ± 0.001 in (0.12 ± 0.03 mm)
EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm)
(22) feeler gauge
12. Install the spark plug (page 67).
13. Coat a new O-ring (23) with oil and install it
onto the crankshaft hole cap (24).
Apply grease to the crankshaft hole cap
threads.
Install and tighten the crankshaft hole cap to
the specified torque:
11 lbf·ft (15 N·m, 1.5 kgf·m)
(14)
(14)
(18)
(17)
(22)
8. Remove the tensioner stopper (19) from the
cam chain tensioner lifter.
(19)
(19) tensioner stopper
9. Install a new sealing washer (20) and tighten
the cam chain tensioner lifter cover bolt (21).
(20) sealing washer
(21) cam chain tensioner lifter cover bolt
(20)
(21)
(16) identification marks
6. Install the camshaft holders (14) in their
proper position by aligning the camshaft
bearing grooves (15) with the set rings (13).
7. Apply oil to the camshaft holder bolt threads
and seating surface.
Tighten the camshaft holder bolts A (17) and
B (18) to the specified torque:
12 lbf·ft (16 N·m, 1.6 kgf·m)
Tighten the camshaft holder bolts in a criss-cross
pattern in two or three steps.
(16)
(23) O-ring (new)
(24) crankshaft hole cap
(24)
(23)
Each camshaft holder has an identification mark
(16).
Valve Clearance
Servicing Your Honda 75
4. Install the cylinder head cover (2) and tighten
the cylinder head cover bolts (6) to the
specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(2) cylinder head cover
(6) cylinder head cover bolts
5. Connect the spark plug cap (7) and breather
tube (8).
(7) spark plug cap
(8) breather tube
6. Install the fuel tank and the seat (pages 33, 35).
(2)
(6)
(7)
(8)
3. Check the rubber seals (4) are in good
condition, replace them if necessary.
Install the rubber seals onto the cylinder head
cover with the “UP” marks (5) facing up.
(4) rubber seal
(5) “UP” marks
(4)
(5)
(5)
Cylinder Head Cover Installation
1. Check that the spark plug hole packing (1) is
in good condition and replace it if necessary.
Apply engine oil to the spark plug hole
packing and install it to the cylinder head
cover (2).
2. Check that the cylinder head cover packing
(3) is in good condition and replace it if
necessary.
Install the cylinder head cover packing into
the cylinder head cover groove.
(1) spark plug hole packing
(2) cylinder head cover
(3) cylinder head cover packing
(2)
(3)
(1)
76 Servicing Your Honda
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 143).
3. Remove the seat and hang the fuel tank (pages
33, 34).
4. Remove the muffler (page 100) and subframe
(page 36).
5. Remove the exhaust pipe (page 102).
6. Remove the spark plug (page 67).
7. Remove the cylinder head cover (page 68).
8. Set the piston at TDC on the compression
stroke (page 68).
9. Remove the camshaft holder, camshaft, valve
lifters and shims (page 70).
(1) ECT sensor connector
11. Loosen the radiator hose clamp screw (2) and
disconnect the radiator hose (3).
(2) radiator hose clamp screw
(3) radiator hose
(3)
(2)
10. Disconnect the ECT sensor connector (1).
(1)
(4) shock absorber upper nut
(5) bolt
13. Loosen the insulator band screw (6) and pull
the throttle body (7) out from the insulator
(8).
Do not hang the throttle body and support it with
a suitable strap.
(6) insulator band screw
(7) throttle body
(8) insulator
(7)
(6)
(8)
12. Remove the shock absorber upper nut (4) and
bolt (5).
(4)
(5)
Servicing Your Honda 77
Piston/Piston Rings/Piston Pin
14. Remove the cylinder head hanger bolts (9).
Remove the cylinder head hanger plate bolts
(10), left cylinder head hanger plate (11) and
right cylinder head hanger plate (12).
(9) cylinder head hanger bolts
(10) cylinder head hanger plate bolts
(11) left cylinder head hanger plate
(12) right cylinder head hanger plate
(9)
(12)
(10)
(9)
(11)
(10)
15. Remove the cylinder head bolts (13).
16. Loosen the cylinder bolt (14).
(13) cylinder head bolts
(14) cylinder bolt
(15) cylinder head stud bolts/washers
(16) cylinder head
(13)
(14)
(16)
(15)
17. Remove the cylinder head stud bolts/washers
(15) and cylinder head (16).
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
(cont’d)
78 Servicing Your Honda
Piston/Piston Rings/Piston Pin
18. Remove the dowel pins (17), cylinder head
gasket (18) and cam chain guide (19).
Do not let the dowel pins and cam chain fall into
the crankcase.
NOTICE
(17) dowel pins (19) cam chain guide
(18) cylinder head gasket
(19)
(18)
(17)
Piston/Piston Rings/Piston Pin
Servicing Your Honda 79
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 every 6 races or about every
15.0 hours of running. Replace the piston pin every
6 races or about every 15.0 hours of running.
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)
(4)
(3)
(3)
(2)
(1)
(1) piston pin clip (3) piston
(2) piston pin
(1)
(1) piston ring
Piston/Piston Rings/Piston Pin
80 Servicing Your Honda
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
top ring
oil ring
mark
top ring
oil
ring
side rail
side rail
spacer
Piston/Piston Pin/Piston Ring
Inspection
We recommend you consult the Service Manual
or your dealer for correct Service Limit
measurements.
Piston/Piston Rings/Piston Pin
Servicing Your Honda 81
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 oil (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)
(3)
(2)
(1)
(4)
(5)
(2)
(6)
(5)
(2)
(1)
(cont’d)
Piston/Piston Rings/Piston Pin
82 Servicing Your Honda
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
(5)
(4)
(3)
(7)
(6)
(8)
(2)
(1)
Piston/Piston Rings/Piston Pin
Servicing Your Honda 83
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 stud bolt
threads.
Install the washers and cylinder head stud
bolts (4).
Tighten the cylinder head stud bolts in a
crisscross pattern in two or three steps to the
specified torque:
33 lbf·ft (45 N·m, 4.6 kgf·m)
Do not let the washers and nuts fall into the
crankcase.
NOTICE
NOTICE
4. Install the cylinder bolt (5) and cylinder head
bolts (6) and tighten them to the specified
torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(3) cylinder head
(4) cylinder head stud bolts/washers
(5) cylinder bolt
(6) cylinder head bolts
(3)
(4)
(6)
(5)
(7) left cylinder head hanger plate
(8) right cylinder head hanger plate
(9) cylinder head hanger plate bolts
(10) cylinder head hanger bolts
(10)
(7)
(9)
5. Install the left cylinder head hanger plate (7)
and right cylinder head hanger plate (8), then
loosely install the cylinder head hanger plate
bolts (9) and cylinder head hanger bolts (10).
Tighten the cylinder head hanger bolts and
cylinder head hanger plate bolts to the
specified torque:
cylinder head hanger bolts:
40 lbf·ft (54 N·m, 5.5 kgf·m)
cylinder head hanger plate bolts:
24 lbf·ft (33 N·m, 3.4 kgf·m)
(10)
(8)
(9)
(cont’d)
(11) throttle body (13) insulator band screw
(12) insulator
7. Set the rear shock absorber (14) and install the
rear shock absorber upper bolt (15) and nut
(16).
Tighten the rear shock absorber upper nut to
the specified torque:
32 lbf·ft (44 N·m, 4.5 kgf·m)
84 Servicing Your Honda
Piston/Piston Rings/Piston Pin
(17) radiator hose
(18) water hose joint
9. Tighten the radiator hose clamp screw (19) as
illustrated below.
(19) radiator hose clamp screw
(19)
0 – 0.04 in
(0 – 1.0 mm)
(16)
(15)
(14)
(14) rear shock absorber (16) nut
(15) rear shock absorber upper bolt
8. Connect the radiator hose (17) to the water
hose joint (18) of the cylinder head.
(17)
(18)
10. Connect the ECT sensor connector (20).
(20) ECT sensor connector
11. Install the shims, valve lifters, camshaft and
camshaft holder (page 73).
12. Install the crankshaft hole cap (page 74).
13. Install the cylinder head cover (page 75).
14. Install the spark plug (page 67).
15. Install the exhaust pipe (page 102).
16. Install the subframe (page 37) and muffler
(page 101).
17. Install the fuel tank and seat (pages 33, 35).
18. Fill and bleed the cooling system (page 143).
Check for the following:
– compression leaks
– abnormal engine noise
– secondary air leaks
– coolant leaks
– oil leaks
(20)
6. Install the throttle body (11) to the insulator
(12) by aligning the tab of the throttle body
with the groove of the insulator and tighten
the insulator band screw (13) so the distance
between the band ends is 0.43 ± 0.04 in (11.0 ±
1.0 mm).
(13)
(11)
(12)
0.43 ± 0.04 in
(11.0 ± 1.0 mm)
Align
Servicing Your Honda 85
Suspension
Refer to Safety Precautions on page 23.
Loose, worn, or damaged suspension components
may adversely affect the handling and stability of
your CRF. If any suspension components appear
worn or damaged, see your dealer for further
inspection. Your dealer is qualified to determine
whether or not replacement parts or repairs are
needed.
Front Suspension Inspection
• When your CRF is new, break it in for
approximately 1 hour to ensure that the
suspension has worked in (page 19).
• After break-in, test run your CRF with the
front suspension at the standard setting before
attempting any adjustments.
• For optimum fork performance, we
recommend that you disassemble and clean
the fork after riding your CRF for 3 hours.
See page 112 for fork disassembly.
• Replace the fork oil every 3 races or 7.5 hours
of running. See page 87 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 115 for
damper fork oil level adjustment after
changing the fork oil.
• Use HP Fork Oil, SS-19 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 130). 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 0.06 in (1.5 mm)
or flat with the outer tube (4).
When replacing the wear ring, remove the
fork leg (page 112).
Install the wear ring with its end gap (5)
facing rearward.
(3) wear ring (4) outer tube
(3) wear rings (5) end gaps
4. Make a quick check of fork operation by
locking the front brake and pushing down on
the handlebar several times.
(2)
(1)
(3)
(4)
(3)
(5)
(3)
Suspension
86 Servicing Your Honda
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 129).
Do not attempt to disassemble, service, or
dis
pose of the damper; see your dealer. The
instructions found in this owner’s manual are
limited to adjustments of the shock assembly only.
• When your 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 126. 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 126. 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.
(Adjusting two or more increments or turns at
a time may cause you to pass over the best
adjustment.)
• 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 36).
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 dealer.
(1)
Servicing Your Honda 87
Suspension
Recommended Fork Oil
Fork Oil Change
Refer to Front Suspension Disassembly on page
112.
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).
• Lock nut wrench 07WMA-KZ30100
suggested oil HP Fork Oil,
SS-19
(1) outer tube (3) lock nut wrench
(2) fork damper (4) axle holder
The outer tube (1) can drop on the slider (5) and
damage the fork dust seal (6). To avoid damage,
hold both the outer tube and slider when
removing the fork damper.
NOTICE
(1) outer tube (6) dust seal
(5) slider
3. Drain the fork oil from the outer tube (1).
Drain the fork oil from the oil hole (7) of the
fork damper.
(1) outer tube (7) oil hole
4. Drain the fork oil by turning the outer tube (1)
upside down. (About 0.4 US oz (12 cm3) 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 144).
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
3
minute
°C/°F
30/86
20/68
10/50
0/32
5
16.5
17.4
18.9
20
10
14.1
15
16.5
18.4
20
12.7
13.7
14.8
15.9
35
11.8
12.6
13.7
14.5
55
11
11.5
12.5
13.7
85
10.1
10.5
11.4
13
145
8.6
9.1
9.8
11.7
(1)
(2)
(3)
(1)
(4)
(6)
(5)
(1)
(1)
(7)
(1)
0°C/32°F
10°C/50°F
20°C/68°F
30°C/86°F
(cont’d)
88 Servicing Your Honda
Suspension
5. Pour the recommended fork oil into the outer
tube (1).
No mark
Fork Oil Capacity:
Standard 25.12 lbf/in (4.4 N/mm) Fork Spring
Standard oil
capacity
12.6 US oz
(372 cm
3
)
Maximum oil
capacity
12.9 US oz
(380 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.0 US oz
(296 cm
3
)
Optional Softer 23.98 lbf/in (4.2 N/mm) Fork Spring
Standard oil
capacity
12.8 US oz
(377 cm
3
)
Maximum oil
capacity
13.0 US oz
(385 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.2 US oz
(301 cm
3
)
1 scribe mark
Optional Stiffer 26.20 lbf/in (4.59 N/mm) Fork Spring
Standard oil
capacity
12.7 US oz
(375 cm
3
)
Maximum oil
capacity
12.9 US oz
(382 cm
3
)
Slightly stiffer as
it nears full
compression.
Slightly softer as
it nears full
compression.
Minimum oil
capacity
10.1 US oz
(299 cm
3
)
2 scribe marks
(1)
Be sure the oil capacity is the same in both fork
legs.
(1) outer tube
Servicing Your Honda 89
Suspension
6. Check that the O-ring (8) on the fork damper
(2) is in good condition. Apply the
recommended fork oil to the O-ring.
(1) outer tube (8) O-ring
(2) fork damper
7. Temporarily install the fork damper to the
outer tube (1).
After installing the fork leg (page 112) tighten
the fork damper to the specified torque:
Actual:
25 lbf·ft (34 N·m, 3.5 kgf·m)
Torque wrench scale reading:
23 lbf·ft (31 N·m, 3.2 kgf·m), using a 20 in
(500 mm) long torque wrench.
When using the lock nut wrench, use a 20 in
(500 mm) 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.
(8)
(1)
(2)
90 Servicing Your Honda
Brakes
Refer to Safety Precautions on page 23.
Both the front and rear brakes are the hydraulic
disc type. As the brake pads wear, the brake
fluid level will drop. A leak in the system will
also cause the level to drop.
Frequently inspect the system to ensure there are
no fluid leaks. Periodically inspect the brake
fluid level and the brake pads for wear.
If the braking response of the front brake
lever or rear pedal feels unusual, check the
brake pads. if the brake pads are not worn
beyond the recommended limit (page 93),
there is probably air in the brake system.
Refer to an official Honda Service Manual
or see your 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:
4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
4. 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.
4.4 lbf·ft (5.9 N·m, 0.6 kgf·m)
(1) lock nut (+) raise the pedal height
(2) adjusting bolt (–) lower the pedal height
(3) rear brake pedal
(1)
(2)
(3)
(1)
(2)
(+)
(–)
Front Brake Lever Adjustment
Servicing Your Honda 91
Brakes
Fluid Level Inspection
Front Brake Fluid Level Check
(1) LWR mark
With the motorcycle in an upright position, check
the fluid level.
It should be above the LWR mark (1). If the level
is at or below the LWR mark, check the brake
pads for wear (page 93).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the pulling distance for the front brake lever
feels excessive , there is probably air in the brake
system and it must be bled.
Refer to an official Honda Service Manual or see
your dealer for brake bleeding.
Honda recommends using Honda DOT 4
brake fluid from a scaled container, or an
equivalent.
Other Checks:
Make sure there are no fluid leaks.
Check for deterioration or cracks in the
hoses and fittings.
Rear Brake Fluid Level Check
(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 93).
Worn brake pads should be replaced. If the pads
are not worn, have your brake system inspected
for leaks.
If the travel for the rear brake pedal feels
excessive , there is probably air in the brake
system and it must be bled. Refer to an
official Honda Service Manual or see your dealer
for brake bleeding.
Honda recommends using Honda DOT 4
brake fluid from a scaled container, or an
equivalent.
Other Checks:
Make sure there are no fluid leaks.
Check for deterioration or cracks in the
hoses and fittings.
(1)
(2)
92 Servicing Your Honda
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 Pro Honda
DOT 4 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 DOT 4 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:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
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 Pro Honda
DOT 4 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 DOT 4 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:
0.7 lbf·ft (1.0 N·m, 0.1 kgf·m)
(3)
(2)
(4)
(1)
(5)
(6)
(8)
(7)
(9)
Servicing Your Honda 93
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 25).
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 0.04 in (1 mm),
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 0.04 in
(1 mm), 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.
minimum thickness
indicator
wear indicator
grooves
replace
replace
0.04 in
(1 mm)
0.04 in
(1 mm)
(1)
(3)
(2)
(2)
replace
0.04 in
(1 mm)
minimum thickness
indicator
(5)
(5)
(4)
(6)
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