HONDA CRF250R 2018 OWNER’S MANUAL

IMPORTANT NOTICES

FOR COMPETITION USE ONLY

This Motorcycle is designed, manufactured and sold for closed-course competition use only. It does not confor m to Federal Motor Vehicle Safety Standards or U.S. EPA Noise and Emission Standards. Operation on public streets, roads, highways or for off-road recreation is illegal.

State and federal laws prohibit operation of this vehicle except in an organized racing or competitive event on a closed course, or by permit issued by the local governmental jurisdiction. This vehicle is sold “as is” with no warranties.

FOR EXPERIENCED RIDERS, NO PASSENGERS

This motorcycle is designed as an operator-only vehicle and for use by experienced riders only. The load limit and seating configuration do not safely permit the carrying of a passenger.

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

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

No part of this publication may be reproduced without written permission. This vehicle pictured in this owner’s manual may not match your actual vehicle. © Honda Motor Co., Ltd., 2017

2018 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK

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.

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 166). 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 Honda 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.

ABBREVIATION

Throughout this manual, the following abbreviations are used to identify the respective parts or system.

Abbrev. term Full term

CKP sensor Crankshaft Position sensor

DLC Data Link Connector

DTC Diagnostic Trouble Code

ECM Engine Control Module

ECT sensor Engine Coolant Temperature

sensor

IAT sensor Intake Air Temperature sensor

MAP sensor Manifold Absolute Pressure sensor

MIL Malfunction Indicator Lamp

PGM-FI Programmed Fuel Injection

TDC Top Dead Center

TP sensor Throttle Position sensor

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.

Introduction

Happy riding!

A Few Words About Safety

DANGER

WARNING

CAUTION

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 judgment.

Safety Messages

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

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

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

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

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

INSTRUMENTS & CONTROLS.................. 5

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

MIL (Malfunction Indicator Lamp) ................. 7

MIL Blink Pattern ......................................... 7

Current DTC/Freeze DTC............................. 7

Circuit Inspection.......................................... 8

DTC Index................................................. ....9

Mode Indicator ...............................................10

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 .................2 6

Before & After Competition Maintenance .....3 0

Between Motos & Practice Maintenance.....30

After Competition Maintenance ..................31

Service Preparations

Maintenance Component Locations ...............32

Seat .................................................................. 33

Fuel Tank ........................................................34

Subframe ......................................................... 37

Service Procedures

Fluids & Filters

Fuel System .....................................................41

Engine Oil .......................................................51

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 ........................79

Chassis

Suspension ...................................................... 88

Brakes ........................................................... 105

Wheels .......................................................... 109

Tires & Tubes .......... .....................................110

Drive Chain .................................................. 112

Exhaust Pipe/Muffler ....................................115

Additional Maintenance Procedures ............. 119

Electrical

Battery .......................................................... 121

Appearance Care .......................................... 123

Contents

ADJUSTMENTS FOR COMPETITION.. 125

Engine Mode Select Button .......................... 126

Current Mode ............................................ 126

Mode Selection.......................................... 126

Front Suspension Adjustments ..................... 127

Front Suspension Air Pressure.................. 127

Front Suspension Damping....................... 128

Fork Springs.............................................. 128

Fork Oil Adjustment.................................. 129

Rear Suspension Adjustments ...................... 130

Rear Suspension Spring Pre-Load............. 130

Rear Suspension Damping........................ 131

Rear Suspension Race Sag........................132

Suspension Adjustments for Track

Conditions .................................................. 134

Suspension Adjustment Guidelines .............. 135

Tuning Tips .................................................. 138

Spark Plug Reading................................... 138

Chassis Adjustments ..................................... 139

Rear End.................................................... 139

Fork Height/Angle..................................... 139

Wheelbase ................................................. 139

Gearing ......................................................... 140

Tire Selection for Track Conditions ............. 141

Personal Fit Adjustments .............................. 142

Control Positioning ................................... 142

Handlebar Position, Width & Shape......... 142

TIPS...............................................................143

Transporting Your Motorcycle .....................144

Storing Your Honda ......................................145

Preparation for Storage.................. ............145

Removal from Storage..... ..........................145

You & the Environment ................................146

Troubleshooting ............................................147

TAKING CARE OF THE UNEXPECTED..149

If a Fuse Blows .............................................150

If Your Battery Is Low (or Dead) .................151

TECHNICAL INFORMATION.................153

Vehicle Identification ....................................154

Serial Numbers ..........................................154

Specifications ................................................155

Torque Specifications ...................................156

Nuts, Bolts, Fasteners................................156

Oxygenated Fuels ..........................................159

Competition Logbook ...................................160

Optional Parts List ........................................162

Spare Parts & Equipment ..............................163

Spare Parts ................................................. 163

General Tools.............................................163

Honda Special Tools..................................163

Chemical Products.....................................163

Other Products ...........................................163

Wiring Diagram ............................................164

INDEX.......................................................... 170

QUICK REFERENCE

CONSUMER INFORMATION .................165

Authorized Manuals ......................................166

Contacting Honda .........................................167

Your Honda Dealer .......................................168

The Honda Rider’s Club (USA only) ...........169

Contents

Motorcycle Safety

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

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

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

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

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

Motorcycle Safety 1

Important Safety Information

Important Safety Precautions

Your CRF can provide many years of pleasure, if you take responsibility for your own safety and understand the challenges you can meet in competitive racing.

As an experienced rider, you know there is much you can do to protect yourself when you ride. The following are a few precautions we consider to be most important.

Never Carry a Passenger.

Your CRF is designed for one operator only. Carrying a passenger can cause 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.

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.

Lithium-Ion (Li-Ion) Battery.

If you smell an unusual odor coming from the lithium-ion (li-ion) battery, park your CRF in a safe place outside and away from flammable objects, then stop the engine. Have your CRF inspected by your dealer immediately.

Learn and Respect Your Limits.

Never ride beyond your personal abilities or faster than conditions warrant. Remember that alcohol, drugs, illness and fatigue can reduce your ability to perform well and ride safely.

2 Motorcycle Safety

Accessories & Modifications

WARNING

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.

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.

Accessories & Modifications

Motorcycle Safety 3

(For Canada)

Safety Labels

Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your dealer for replacement.

4 Motorcycle Safety

Instruments & Controls

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

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

MIL (Malfunction Indicator Lamp)...................7

MIL Blink Pattern..........................................7

Current DTC/Freeze DTC .............................7

Circuit Inspection...........................................8

DTC Index .....................................................9

Mode Indicator.................................................10

Instruments & Controls 5

Operation Component Locations

clutch lever

engine stop button

front brake lever

throttle grip

MIL/mode indicator

engine mode select button

start button

fast idle knob (engine idle speed)

shift lever

rear brake pedal

Operation Component Locations

6 Instruments & Controls

MIL (Malfunction Indicator Lamp)

(1)

MIL (Malfunction Indicator Lamp)

The MIL (1) 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) MIL (amber)

When starting the engine, the MIL (amber) will stays on for 2 seconds and then go off. This is normal.

The MIL blinks when there is any abnormality in the PGM-FI system. 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 168).

MIL Blink Pattern Current DTC/Freeze DTC

The MIL will blink the appropriate DTC number if the ECM detects an active problem while the engine is running at less than 4,000 rpm. The MIL will stay on when engine speed is over 4,000 rpm.

The MIL has two types of blinks: a long blink and short blink. The long blinking lasts for 1.2 seco nds, 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.

The DTC is indicated in two ways according to the failure status.

– When the engine starts, the MIL stays on for 2

seconds, then goes off. If the ECM detects a DTC, the MIL starts blinking (indicating the DTC number by the number of blinks in amber). Even when the MIL is blinking, you can change the engine modes. However, you cannot change the engine modes when the indicator is blinking DTC 1, 2 or 8. After an engine mode is selected, the MIL restarts blinking the current DTC number.

– 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.

If the MIL does not come on when the engine is started, have your dealer check it for problems.

Instruments & Controls 7

MIL (Malfunction Indicator Lamp)

(4)

(5)

(7)

(2)

(6)

(1)

(3)

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) CKP sensor connector (7) ECM connector

Remember, circuit inspection is not a “cure-all” for other problems in your engine’s PGM-FI system.

8 Instruments & Controls

DTC Index

Refer to MIL Blink Pattern on page 7.

MIL (Malfunction Indicator Lamp)

MIL blinks

1 MAP sensor circuit malfunction Poor performance (drivability)

2 MAP sensor performance problem Poor performance (drivability)

7 ECT sensor circuit malfunction Hard start at a low temperature

8 TP sensor circuit malfunction Poor engine acceleration

9 IAT sensor circuit malfunction Engine operates normally

12 Injector circuit malfunction

Should be serviced by your dealer, unless the owner has proper tools and is technically qualified. The series of 12 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 166) for troubleshooting of the PGM-FI symptom.

Function Failure Symptom/Fail-safe function

• Engine does not start

• Injector, fuel pump and ignition shut down

Instruments & Controls 9

Mode Indicator

(2)

(1)

Mode Indicator

The mode indicator (blue) (1) is located under the engine mode select button (2). The mode indicator indicates the currently selected mode by blinking the mode number once when the engine is started.

(1) mode indicator (blue) (2) engine mode select button

The mode indicator indicates a selected mode when you operate the engine mode select button (page 126).

If the mode indicator stays on or does not come on when it should, have your dealer check it for problems.

10 Instruments & Controls

Before Riding

Before each ride, you need to make sure you and your CRF 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 and other adjustments, see page 125.

Are You Ready to Ride?..................................12

Is Your Motorcycle Ready to Ride? ................13

Pre-ride Inspection.......................................13

Before Riding 11

Are You Ready to Ride?

WARNING

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 and other adjustments, see page 125.

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

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.

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

12 Before Riding

Is Your Motorcycle Ready to Ride?

WARNING

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):

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.

Pre-ride Inspection

Check the following before each ride:

• Engine oil level............................ .... ..... ...... 52

• Fuel line for condition ................................ 41

• 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 freeplay................................... 62

• Breather drain for cleaning ......................... 58

• Steering head bearing and related parts for

condition ................................................... 119

• Throttle operation ....................................... 59

• Tires for damage or improper inflation

pressure..................................................... 110

• Spokes for looseness................................. 109

• Rim locks for looseness............................109

• Front and rear suspension for proper

operation ............................................. 88, 104

• Front and rear brakes, check operation..... 105

• Drive chain for correct slack and adequate

lubrication.................. ....................... 112, 113

• Drive chain sliders and drive chain rollers

for damage or wear...........................112, 113

• Exhaust pipe/Muffler for looseness.......... 115

• Every possible part for looseness (such as cylinder head bolts, engine mounting bolts/ nuts, axle nuts, handlebar holder bolts/nuts, fork bridge pinch bolts, drive chain adjuster lock nuts, drive chain roller bolt/nut, wire

harness connectors)............................156-158

• MIL operation............ ................................... 7

Before Riding 13

14 Before Riding

Basic Operating Instructions

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

Safe Riding Precautions...............................1 6

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 15

Basic Operating Instructions

WARNING

Basic Operating Instructions

Safe Riding Precautions

Before riding your CRF for the first time, please review the Important Safety Precautions 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.

Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build-up of toxic carbon monoxide gas.

Breathing this colorless, odorless gas can quickly cause unconsciousness and lead to death.

Only run your vehicle's engine when it is located in a well ventilated area outdoors.

16 Basic Operating Instructions

Starting & Stopping the Engine

(1)

(2)

Starting & Stopping the Engine

Always follow the proper starting procedure described below.

Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the start button.

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 like 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 and coolant levels before starting the engine (pages 52, 54).

Cold Engine Starting

1. Shift the transmission into neutral.

2. If the temperature is 50°F (10°C) or below, pull the fast idle knob (1) fully out.

3. With the throttle closed. Pull the clutch lever all the way in, and depress the start button (2).

(2) start button

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) fast idle knob

(cont’d)

Basic Operating Instructions 17

Starting & Stopping the Engine

(1)

Warm Engine Starting

1. Shift the transmission into neutral.

2. Pull the clutch lever all the way in, and depress the start button. (Do not open the throttle.)

Starting the engine excessively charged with fuel by throttle blipping or other reasons

1. Shift the transmission into neutral.

2. With the throttle fully opened, pull the clutch lever all the way in, and depress the start button for 5 seconds to discharge excessive fuel from the engine.

3. Pull the clutch lever all the way in, and depress the start button. (Do not open the throttle.)

Snapping the throttle or fast idling for more than about 5 minutes may cause exhaust pipe and muffler discolorations.

When starting the engine, the MIL (amber) will stay on for 2 seconds, then go off. And then the mode indicator (blue) indicates the current engine mode for 0.8 seconds, then goes off. If the MIL/ mode indicator (1) does not come on or go off when it should, have your dealer check it for problems.

(1) MIL (amber) / mode indicator (blue)

How to Stop the Engine

Normal Engine Stop

1. Shift the transmission into neutral.

2. Push and hold the engine stop button (1) until the engine stops completely.

(1) engine stop button

Emergency Engine Stop To stop the engine in an emergency, push and hold the engine stop button.

18 Basic Operating Instructions

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

Break-in Guidelines

Basic Operating Instructions 19

20 Basic Operating Instructions

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 CRF 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 an official Honda Service Manual (page 166).

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 ..................31

Service Preparations

Maintenance Component Locations ................32

Seat...................................................................33

Fuel Tank.........................................................34

Subframe..........................................................37

Service Procedures

Fluids & Filters

Fuel System......................................................41

Engine Oil........................................................51

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.........................79

Chassis

Suspension.......................................................88

Brakes............................................................ 105

Wheels...........................................................109

Tires & Tubes................................................110

Drive Chain ................................................... 112

Exhaust Pipe/Muffler.....................................115

Additional Maintenance Procedures.............. 119

Electrical

Battery ...........................................................121

Appearance Care ........................................... 123

Servicing Your Honda 21

The Importance of Maintenance

WARNING

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.

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.

22 Servicing Your Honda

Maintenance Safety

WARNING

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.

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.

Important Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards:

• 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.

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.

Servicing Your Honda 23

Maintenance Schedule

Notes:

Maintenance Schedule

To maintain the safety and reliability of your CRF, regular inspection and service is required as shown in the Maintenance Schedule that follows.

The Maintenance Schedule lists items that can be performed with basic mechanical skills and hand tools. Procedures for these items are provided in this manual.

The Maintenance Schedule also includes items that involve more extensive procedures and may require special training, tools, and equipment. Therefore, we recommend that you have your 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 166).

Service intervals in the maintenance schedule are expressed in terms of races and riding hours. To avoid overlooking required service, we ur ge you to develop a convenient way to record the number of races and/or hours you ride.

Perform the pre-ride inspection (page 13) at each scheduled maintenance period.

Summary of Maintenance Schedule Notes and Procedures:

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 engine 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 R: replace A: adjust L: lubricate

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.

24 Servicing Your Honda

Perform the Pre-ride Inspection (page 13) at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

Maintenance Schedule

FREQUENCY

ITEMS

FUEL LINE (NOTE 6) I R41 FUEL PUMP FILTER (NOTE 6) R 45 – 49 THROTTLE OPERATION I 60 AIR FILTER (NOTE 1) C 56 CRANKCASE BREATHER I 58 SPARK PLUG I 67 VALVE CLEARANCE/DECOMPRESSOR SYSTEM (NOTE 4) I 68 – 78

ENGINE OIL

ENGINE OIL FILTER (NOTE 3) R 52 ENGINE IDLE SPEED I 61 PISTON AND PISTON RINGS R79 PISTON PIN R82 RADIATOR COOLANT (NOTE 2) I 54 COOLING SYSTEM I 55 DRIVE CHAIN I, L R 112 DRIVE CHAIN SLIDER I 112 DRIVE CHAIN ROLLER I 113 DRIVE SPROCKET I 114 DRIVEN SPROCKET I 114 BRAKE FLUID (NOTE 2) I 106 BRAKE PADS WEAR I 108 BRAKE SYSTEM I 105 CLUTCH SYSTEM (NOTE 5) I 62 CONTROL CABLES I, L 119 EXHAUST PIPE/MUFFLER I 115 SUSPENSION I 88, 104 SWINGARM/SHOCK LINKAGE L

L EXCEP

FORK OI FORK OIL DAMPER R 98 – 101 NUTS, BOLTS, FASTENERS I 120, 156 – 158 WHEELS/TIRES I 109 – 111 STEERING HEAD BEARINGS I 119

WE RECOMMEND 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.

T DAMPER (NOTE 3) R 91, 92, 129

NOTE

(NOTE 3) (NOTE 5)

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

Ref. Page

29, 104

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 engine oil, if the clutch discs and plates are replaced.

6.Replace every year.

Servicing Your Honda 25

General Competition Maintenance

Perform maintenance on firm, level ground using an 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 equivalents when servicing your CRF.

Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling. Lubricate any sliding surfaces, 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 on page 13.

26 Servicing Your Honda

General Competition Maintenance

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).

Spark Plug Cap

Install a small plastic wire band around the spark plug cap to reduce any possibility of it loosening or of water penetration.

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. 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 o ff idle and in low rpm performance. Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda Foam Air Filter Sealer, or an equivalent, is handy for this because any dirt that penetrates this sealing area will show up clearly (page 56). Use the 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.

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.

(cont’d)

Servicing Your Honda 27

General Competition Maintenance

Fuel Line

Refer to Fuel Line Inspection on page 41. Check the fuel line for deterioration, damage, or leakage. Replace the fuel line every year.

Engine Mounting Bolts and Nuts

Make sure the engine mounting bolts and nuts are tightened to the proper torque specification.

Electrical Connectors

Clean electrical connectors and wrap them with electrical tape to reduce the possibility of unwanted disconnections, water shorts or corrosion.

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 pe riod, 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 109).

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.

Fork Oil/Performance

Disassemble, clean and inspect the fork and replace the 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 an official Honda Service Manual (page 166). Use only Pro Honda HP Fork Oil, SS-19 or an equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

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).

Battery

The start button uses current from the battery. Limited operation also allows the battery to discharge. If you do not ride frequently, we recommend that you charge the battery frequently (see Battery Charging on page 122). If you do not expect to ride your CRF for at least 2 weeks, we recommend you remove the battery – or at least disconnect the battery cables (negative cable first).

Gaskets

Always use new gaskets when reassembling components.

Cylinder head/Cylinder

Put a little grease on the dowel pins of the cylinder head and cylinder to prevent corrosion from dissimilar metals. The tolerances are quite tight, so it’s important to keep these dowels absolutely clean (pages 79, 81).

28 Servicing Your Honda

General Competition Maintenance

Brake Fluid Replacement

Refer to Brake Pad Wear on page 108. Brake Caliper Inspection: Be sure both the front and rear calipers are able to move freely on the caliper pin and 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 an official Honda Service Manual (page 166) for brake fluid replacement instructions. Replace the brake 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.

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 the bleed hole of the water pump for signs of seal leakage. If water leaks through the bleed hole, replace the mechanical seal. If oil leaks through the bleed hole, replace the oil seal. Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine. A small amount of coolant weeping from the bleed hole is normal. 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 molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive Moly Paste 77) after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear.

Swingarm

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

Swingarm Pivot Lubrication

Clean, inspect and lubricate the swingarm and suspension linkage pivots with molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive Moly Paste 77) after each 7.5 hours of running time in order to maintain proper suspension performance and minimize component wear. Be sure all of the dust seals are in good condition.

Handgrips

Always use Pro Honda Handgrip Cement or an equivalent when replacing handgrips. Refer to an official Honda Service Manual (page 166) for installation instructions.

Throttle Grip/Handlebar Grip

Right throttle grip: Align the index mark on the throttle grip with the index mark of the throttle pipe. Left handlebar grip: Align the index mark on the left handlebar grip with the paint mark on the handlebar.

For added security, you may choose to bind the handgrips 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 handlebar thoroughly. Inspect the cable carefully for kinks or other damage that may restrict throttle control in anyway. 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.

Fuse

Check the fuse before looking elsewhere for the cause of an electrical problem.

Engine Oil and Filter

Drain and replace engine oil often to ensure the greatest service life of the piston, cylinder, crankshaft, transmission and clutch. Also replace engine oil filter often to ensure the greatest service life. Frequent changes will also assure consistent performance of power, response, both shifting and clutch action (page 52).

Servicing Your Honda 29

Before & After Competition Maintenance

(1)

(2)

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.

• 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) chain adjuster index marks

• Suspend the front wheel above the ground and use the air pressure release screws (2) to release the built-up pressure in the forks. This pressure is caused by normal fork action while riding.

(2) air pressure release screw

• 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 engine is running. Injury to your fingers or hands may result.

30 Servicing Your Honda

Before & After Competition Maintenance

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.

Race Lubrication

After 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 the brake discs.

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

Remove the drive chain, clean and lubricate it (pages 113, 114). Be sure the chain is wiped clean and is dry before lubricating the chain.

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 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 123).

Servicing Your Honda 31

Maintenance Component Locations

clutch lever

front brake fluid reservoir

front brake lever

throttle grip

radiator cap

fuel fill cap

spark plug

fast idle knob (engine idle speed)

air cleaner

crankcase breather tube

drive chain

front brake caliper

front suspension compression damping adjuster (both left and right)

rear suspension rebound damping adjuster

• rear suspension high speed compression damping adjuster

• rear suspension low speed compression damping adjuster

engine oil fill cap

front suspension rebound damping adjuster (both left and right)

engine oil filter

rear brake pedal

rear brake fluid reservoir

battery

engine oil drain bolt

rear suspension spring pre-load adjuster

oil level inspection window

Maintenance Component Locations

32 Servicing Your Honda

Seat

(2)

(1)

(3)

(2)

(4) (5)

(5)

Seat

Refer to Important 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 slot (2) of the fuel tank and seat center prongs (3) with the seat support base slots (4).

2. Install and tighten the seat mounting bolts (5) to the specified torque:

19 lbf·ft (26 N·m, 2.7 kgf·m)

(1) seat front prong (4) seat support base slots (2) slot (5) seat mounting bolts (3) seat center prongs

Servicing Your Honda 33

Fuel Tank

NOTICE

(4)

(3)

(2)

(1)

(5)

(6)

(7)

(9)

(8)

(10)

(13)

(11)

(12)

WARNING

(14)

(15)

(16)

Fuel Tank

Refer to Important Safety Precautions on page 23. Removal

1. Remove the seat (page 33).

2. Remove the shroud A bolt (1), shroud B bolt (2) and shroud C bolt (3).

3. Slide the shroud (4) toward the up to separate from the air cleaner housing cover (5), and then remove the shroud.

The right and left shrouds can be removed in the same manner.

(1) shroud A bolt (4) shroud (2) shroud B bolt (5) air cleaner housing cover (3) shroud C bolt

4. Disconnect the overflow hose (6) from the clamp (7).

5. Install a hose clamp (8) to the breather tube (9) and set the hose clamp securely.

6. Pull the breather tube (9) out of steering stem nut (10).

(8) hose clamp (10) steering stem nut (9) breather tube

7. Remove the fuel tank A bolt (11), B bolts (12) and washers (13).

Do not support the fuel tank by the fuel feed hose (16).

The fuel tank is made of titanium material. Since the fuel tank has not been painted, it might be discolored with mud and dust. To remove mud or dust, use a sponge or soft cloth and a stainless steel kitchen detergent, then rinse well clean water. After washing, rinse with plenty of water and dry with a clean cloth.

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.

(6) overflow hose (7) clamp

34 Servicing Your Honda

(11) fuel tank A bolt (13) washers (12) fuel tank B bolts

8. Lift the fuel tank (14) out of the frame and hang it to the left of the frame. Check the fuel tank stopper cable (15) for deterioration, kinks or other damage.

(14) fuel tank (15) fuel tank stopper cable (16) fuel feed hose

Fuel Tank

NOTICE

3.35 ± 0.10 in (85.0 ± 2.5 mm)

1.10 ± 0.10 in (28.0 ± 2.5 mm)

(17)

(4)

(2)

(1)

(3)

(5)

(7)

(6)

(8)

(9)

9. Check for interference between the frame and tank, and adjust the cushion rubbers (17) on the both sides of the frame if necessary.

(17) cushion rubbers

Do not ride your CRF in state which the cushion rubbers have been removed. It may cause the fuel tank cracking.

Installation

1. Install the fuel tank (1) on the frame.

2. Install the washers (2), fuel tank A bolt (3) and B bolts (4), and then tighten the fuel tank A bolt and B bolts to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

(1) fuel tank (3) fuel tank A bolt (2) washers (4) fuel tank B bolts

3. Put the breather tube (5) in the steering stem nut (6).

4. Remove the hose clamp (7) from the breather tube.

5. Connect the overflow hose (8) to the clamp (9).

(8) overflow hose (9) clamp

(5) breather tube (7) hose clamp (6) steering stem nut

(cont’d)

Servicing Your Honda 35

Fuel Tank

(10)

(14)

(15)

(16)

(13)

(11) (12)

6. Slide the shroud (10) toward the down so that the shroud tab (11) and the slot (12) on the air cleaner housing cover (13) is aligned.

7. Install the shroud C bolt (14), B bolt (15) and shroud A bolt (16). Tighten the shroud A and B bolts to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

Tighten the shroud C bolt to the specified torque:

3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)

The right and left shrouds can be installed in the same manner.

(10) shroud (14) shroud C bolt (11) shroud tab (15) shroud B bolt (12) slot (16) shroud A bolt (13) air cleaner housing cover

8. Install the seat (page 33).

36 Servicing Your Honda

Subframe

(4)

(3)

(2)

(1)

(5)

(7)

(6)

(7)

(9)

(8)

(10)

(9)

(11)

(12)

(13)

(14)

(15)

Subframe

Refer to Important Safety Precautions on page 23. Removal

1. Remove the seat (page 33).

2. Remove the shroud A bolt (1), shroud B bolt (2) and shroud C bolt (3).

3. Slide the shroud (4) toward the up to separate from the air cleaner housing cover (5), and then remove the shroud.

The right and left shrouds can be removed in the same manner.

(1) shroud A bolt (2) shroud B bolt (3) shroud C bolt (4) shroud (5) air cleaner housing cover

4. Remove the right and left mufflers (page 115).

5. Remove the seat support base mounting bolts (6), and collars (7).

6. Disconnect the starter/ignition relay connector (8) and remove the seat support base (9).

(6) seat support base mounting bolts (7) collars (8) starter/ignition relay connector (9) seat support base

7. Lift the seat support base (9) and hang it to the left of the subframe (10).

8. Disconnect the breather tube (11) and IAT sensor connector (12).

9. Loosen the air cleaner connecting tube clamp screw (13).

(11) breather tube (12) IAT sensor connector (13) air cleaner connecting tube clamp screw

10. Disconnect the negative (–) terminal (14) from the battery (15).

(14) negative (–) terminal (15) battery

(9) seat support base (10) subframe

(cont’d)

Servicing Your Honda 37

Subframe

(16)

(17)

(20)

(18)

(19)(21)(22)

(10)

(23)

(24)

(25)

(24)

(23)

Left side: Right side:

(1)

(2) (2)

(1)

11. Remove the starter relay switch stay bolt (16) and plastic wire band (17). Pull out the starter relay switch (18). Remove the starter relay switch cover (19) and then disconnect the starter relay switch connector (20). Remove the starter motor terminal bolt (21) and disconnect the starter motor terminal (22) from the starter relay switch.

(16) starter relay switch stay bolt (17) plastic wire band (18) starter relay switch (19) starter relay switch cover (20) starter relay switch connector (21) starter motor terminal bolt (22) starter motor terminal

12. Remove the subframe lower bolts (23) and upper bolts (24). Remove the subframe (10) while disconnecting the air cleaner box (25).

(10) subframe (23) subframe lower bolts (24) subframe upper bolts (25) air cleaner box

Installation

1. Loosely attach the upper and lower ends of the subframe to the main frame and loosely install all subframe bolts.

2. Tighten the subframe upper bolts (1) first and then tighten the lower bolts (2) to the specified torque: subframe upper bolts:

24 lbf·ft (32 N·m, 3.3 kgf·m)

subframe lower bolts:

36 lbf·ft (49 N·m, 5.0 kgf·m)

(1) subframe upper bolts (2) subframe lower bolts

38 Servicing Your Honda

Subframe

(8)

(9)

(6)

(4)

(7)(5)(3)

(10)

(11)

(12)

(14) (17)

(15)

(16)

(15)

0.30 ± 0.06 in (7.5 ± 1.5 mm)

(13)

3. Connect the starter motor terminal (3) to the starter relay switch (4). Install and tighten the starter motor terminal bolt (5) to the specified torque:

5.2 lbf·ft (7 N·m, 0.7 kgf·m)

Connect the starter relay switch connector (6) and then install the starter relay switch cover (7). Install the starter relay switch. Install and tighten the starter relay switch stay bolt (8) to the specified torque:

9 lbf·ft (12 N·m, 1.2 kgf·m)

Install the plastic wire band (9).

4. Connect the negative (–) terminal (10) to the battery (11). Tighten the negative (–) terminal bolt (12) to the specified torque:

1.5 lbf·ft (2.0 N·m, 0.2 kgf·m)

(10) negative (–) terminal (11) battery (12) negative (–) terminal bolt

5. Connect the air cleaner box (13) to the air cleaner connecting tube (14) and tighten the air cleaner connecting tube clamp screw (15) so the distance between the clamp ends is 0.30 ±

0.06 in (7.5 ± 1.5 mm).

6. Connect the breather tube (16) and IAT sensor connector (17).

(3) starter motor terminal (4) starter relay switch (5) starter motor terminal bolt (6) starter relay switch connector (7) starter relay switch cover (8) starter relay switch stay bolt (9) plastic wire band

(13) air cleaner box (14) air cleaner connecting tube (15) air cleaner connecting tube clamp screw (16) breather tube (17) IAT sensor connector

(cont’d)

Servicing Your Honda 39

Subframe

(19)

(21)

(20)

(18)

(20)

(22)

(26)

(27)

(28)

(25)

(24)

(23)

7. Connect the starter/ignition relay connector (18) and install the seat support base (19).

8. Install and tighten the collars (20), and seat support base mounting bolts (21) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

(18) starter/ignition relay connector (19) seat support base (20) collars (21) seat support base mounting bolts

9. Install the left and right mufflers (page 116).

10. Slide the shroud (22) toward the down so that the shroud tab (23) and the slot (24) on the air cleaner housing cover (25) is aligned.

11. Install the shroud C bolt (26), B bolt (27) and shroud A bolt (28). Tighten the shroud A and B bolts to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

Tighten the shroud C bolt to the specified torque:

3.8 lbf·ft (5.2 N·m, 0.5 kgf·m)

The right and left shrouds can be installed in the same manner.

40 Servicing Your Honda

(22) shroud (26) shroud C bolt (23) shroud tab (27) shroud B bolt (24) slot (28) shroud A bolt (25) air cleaner housing cover

12. Install the seat (page 33).

Fuel System

(3)

(4)

(2)

(1)

WARNING

(2)

(1)

Fuel System

Refer to Important Safety Precautions on page 23.

Fuel

Type Unleaded

Pump Octane Number 91 (or higher)

Use only unleaded fuel in your CRF. If you ride your CRF 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 159.

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.

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 (4) filler neck bottom

2. Add fuel until the level reaches the bottom of the filler neck (4). Fuel Tank Capacity: 1.66 US gal (6.3 ℓ)

• 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.

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.

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

Fuel Line Inspection

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.

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

(1) fuel quick connect fitting cover (2) fuel line

4. Install the fuel quick connect fitting cover.

5. Install the fuel tank (page 35).

Servicing Your Honda 41

Fuel System

(1)

(3)

Fuel pump side:Injector side:

(2) (3)

(4)

(5)

(6)

Injector side:

Fuel pump side:

(7)

Fuel Pressure Relieving

1. Hang the fuel tank to the left side of the frame (page 34).

2. Disconnect the fuel pump connector (1).

(1) fuel pump connector

3. Reposition the fuel tank and start the engine and let it idle until the engine stalls.

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 quick connect fitting cover (2) fuel pump (3) fuel quick connect fitting

5. Remove the bolt (4), clamp (5) and setting rubber (6).

(4) bolt (6) setting rubber (5) clamp

6. Place a shop towels (7) over the each fuel quick connect fitting.

42 Servicing Your Honda

(7) shop towels

Fuel System

WARNING

Injector side: Fuel pump side:

(8)

(10)

(9)

(8)

(9)

(10)

(11)

(13)

(12)

(9)

(1)

(2)

(3)

7. Unlock the slide retainer (8) of the quick connect fitting by completely pulling it up. Release the fuel quick connect fitting from the fuel joint (9) while holding the connector housing (10).

• 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.

• Dirt intruding into the connector housing

may cause slide retainer sticking.

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. Remove the rubber cover (11) from the fuel joint of the fuel pump.

(11) rubber cover

9. To prevent damage and keep foreign matter out, cover the disconnected connector (12) and fuel joint (9) with plastic bags (13).

Connection

1. Install the rubber cover (1) onto the fuel joint (2) of the fuel pump as shown.

(1) rubber cover (2) fuel joint

2. Be sure that the slide retainer (3) is completely pulled up before connecting the quick connect fitting.

• Do not bend or twist the fuel feed hose.

• Do not reuse the kinked or damaged fuel

hose.

• Do not use gloves or a shop towel while

installing the quick connect fitting.

(8) slide retainer (9) fuel joint (10) connector housing

(9) fuel joint (12) disconnected connector (13) plastic bags

(3) slide retainer

(cont’d)

Servicing Your Honda 43

Fuel System

Injector side:

Fuel pump side:

(3)

(4)

(2)

(4)

(3)

(2)

(6)

(5)

(2)

(7)

(8)

(10)

(9)

(11)

(1)

3. Connect the quick connect fitting to the fuel joint (2) until you hear the “click” while holding the connector housing (4). Lock the slide retainer (3) by pushing it until you hear the “click”.

If it is hard to connect, put a small amount of engine oil on the pipe end of the fuel joint.

(2) fuel joint (3) slide retainer (4) connector housing

4. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing.

5. Install the setting rubber (5) toward the recess (6) of the setting rubber to the fuel joint (2).

6. Install the clamp (7) and bolt (8) by aligning the clamp tab (9) with the groove (10) of the stay. Tighten the bolt securely.

(7) clamp (9) clamp tab (8) bolt (10) groove

7. Install the fuel quick connect fitting cover (11). Be sure the rubber cover (1) is properly installed

between the fuel quick connect fitting cover and fuel pump.

(1) rubber cover (11) fuel quick connect fitting cover

8. Increase the fuel pressure (page 50).

9. Install the fuel tank (page 35).

(2) fuel joint (6) recess (5) setting rubber

44 Servicing Your Honda

Fuel System

WARNING

(2)

(3)

(1)

(4)

(6)

(5)

(2)

(7)

(8)

(9)

(10)

(11)

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.

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 42).

2. Disconnect the fuel line from the fuel pump (page 42).

3. Remove the fuel tank (1) by releasing the stopper cable (2) from the frame hook (3) of the frame.

4. Pull the harness band clip (4) while pressing both side of the anchor and disconnect it.

5. Remove the fuel pump mounting nuts (5), fu el pump mounting cap nut (6), stopper cable guide (7), stopper cable (2), washer (8), collars (9), conical spring washers (10) and fuel pump plate (11) while holding the fuel tank.

(1) fuel tank (3) frame hook (2) stopper cable (4) harness band clip

(2) stopper cable (5) fuel pump mounting nuts (6) fuel pump mounting cap nut (7) stopper cable guide (8) washer (9) collars (10) conical spring washers (11) fuel pump plate

(cont’d)

Servicing Your Honda 45

Fuel System

(13)

(12)

(14)

(16)

(15)

(18)

(19)

(18)

(17)

(17) (19)

(20)

(21)

(16)

(22)

(23)

6. Remove the fuel pump unit (12), dust seal (13) and O-ring (14).

Be careful not to damage the fuel pump unit.

(12) fuel pump unit (14) O-ring (13) dust seal

7. Disconnect the fuel pump wire terminals (15) from the fuel pump base (16).

Be careful not to damage the wires when disconnecting the fuel pump wire terminals.

8. Check the hooks (17) of the fuel pump unit holder and tabs (18) 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.

9. Release the hooks of the fuel pump unit holder from the grooves (19) in 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.

10. Remove the fuel pump unit holder assembly (20) from the fuel pump base (16) and remove the O-ring (21).

Wipe the spilled out fuel immediately.

(16) fuel pump base (20) fuel pump unit holder assembly (21) O-ring

11. Remove the fuel pump stopper (22) and damper rubber (23).

(15) fuel pump wire terminals (16) fuel pump base

46 Servicing Your Honda

(17) hooks (19) grooves (18) tabs

(22) fuel pump stopper (23) damper rubber

Fuel System

(26)

(24)(25)

(24)

(27)

(2)

(3)

(4)

(1)

(9)

(8)(6)

(7) (5)

(9)

(7)

(8)

(2)

(11)

(10)

12. Remove the fuel pump assembly (24) from the fuel pump unit holder (25).

13. Remove the O-ring (26) from the fuel pump assembly (24).

(24) fuel pump assembly (25) fuel pump unit holder (26) O-ring

14. Remove the fuel pump filter (27) from the fuel pump assembly (24).

15. Check the fuel pump filter for clog, damage or deterioration and replace it if necessary.

Installation

1. Install the 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) fuel pump filter (3) hook (2) fuel pump assembly (4) joint boss

2. Apply small amount of engine oil to a new O-ring (5). Install the 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 yellow (7) and green (8) wires through the holder grooves (9) as shown.

(2) fuel pump assembly (7) yellow wire (5) O-ring (new) (8) green wire (6) fuel pump unit holder (9) grooves

4. Install a new damper rubber (10) to the fuel pump filter as shown. Install fuel pump stopper (11).

(24) fuel pump assembly (27) fuel pump filter

(10) damper rubber (new) (11) fuel pump stopper

(cont’d)

Servicing Your Honda 47

Fuel System

(13)

(16) (17)

(12)

(17)(16)

(14)

(15)

(18)

(19)

(20)

(18)

(20)

(19)

(13)

(21)

(24)

(25)

(24)

(23)(22)

(28)

(29)

(26)

(27)

(29)

(30)

(31)

5. Apply small amount of engine oil to a new O-ring (12). Install the 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.

(18) yellow wire terminal (19) green wire terminal (20) fuel pump base terminals

8. Install a new dust seal (21) by aligning its tabs (22) with the fuel pump unit grooves (23).

Check the dust seal lug (24) which is located the index mark (25) of the fuel pump base (13).

9. Apply small amount of engine oil to a new O-ring (26). Install the new O-ring into the between the collar A (27) and collar B (28) of the fuel pump unit (29).

(26) O-ring (new) (28) collar B (27) collar A (29) fuel pump unit

10. Install the fuel pump unit (29) into the fuel tank (30) with its hose joint (31) facing forward.

Be careful not to damage the fuel pump unit.

(12) O-ring (new) (13) fuel pump base (14) fuel pump unit holder assembly (15) hooks (16) grooves (17) tabs

7. Connect the fuel pump yellow (18) and green (19) wire terminals to the fuel pump base terminals (20). Push the wire terminals until they stop as shown.

Be careful not to damage the wires.

48 Servicing Your Honda

(13) fuel pump base (23) grooves (21) dust seal (new) (24) dust seal lug (22) tabs (25) index mark

(29) fuel pump unit (30) fuel tank (31) hose joint

Fuel System

(24) (33)

(34)

(32)

(36)

(37)

(35)

(40)

(32)(42)

(35)

Upside

(39)

(38)

(41)

(40)

(41)

(44)

(30)

(39)

(38)

(43)

11. Install the fuel pump plate (32) by aligning with its groove (33) with fuel pump unit lug (34).

Check the dust seal lug (24) is in position as shown.

(24) dust seal lug (32) fuel pump plate (33) groove (34) fuel pump unit lug

12. Install the conical spring washers (35), collars (36), washer (37), stopper cable (38), stopper cable guide (39), fuel pump mounting nuts (40) and fuel pump mounting cap nut (41).

Make sure that the convex surfaces of the conical spring washers are upside. Make sure that the cap nut is in position of the identification mark (42) on the fuel pump plate (32).

13. Tighten the fuel pump mounting nuts (40) and cap nut (41) to the specified torque in the specified sequence as shown:

8 lbf·ft (11 N·m, 1.1 kgf·m)

(40) fuel pump mounting nuts (41) fuel pump mounting cap nut

14. Install the harness band clip (43) to the stopper cable guide (39).

15. Install the stopper cable (38) to the frame hook (44) of the frame while holding the fuel tank (30).

(32) fuel pump plate (35) conical spring washers (36) collars (37) washer (38) stopper cable (39) stopper cable guide (40) fuel pump mounting nuts (41) fuel pump mounting cap nut (42) identification mark

(30) fuel tank (43) harness band clip (38) stopper cable (44) frame hook (39) stopper cable guide

16. Connect the fuel line (page 43).

17. Increase the fuel pressure (page 50).

18. Install the fuel tank (page 35).

Servicing Your Honda 49

Fuel System

Fuel Pressure Increasing

Make sure the fuel remains enough (0.3 US gal (1.0 ℓ) minimum) in the fuel tank and add fuel if necessary before increasing fuel pressure.

With the throttle closed. Pull the clutch lever all the way in, and depress the start button.

The engine will start up by increasing the fuel pressure.

If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 166) for troubleshooting of the PGM-FI symptom.

50 Servicing Your Honda

Engine Oil

NOT RECOMMENDED RECOMMENDED

(1)

(2)

Engine Oil

Refer to Important 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

Viscosity (weight)

JASO T 903 standard MA

Suggested oil* Pro Honda GN4 4-stroke

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

SAE 10W-30

Oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil

• 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” or “resource 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.

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

* Suggested 4-stroke engine oils are equal performance

to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.

Servicing Your Honda 51

Engine Oil

(1)

(2)

(3)

(4)

(4)(5)

(1)

(2)

(3)

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. Check that the oil level is between the upper (1) and lower (2) level marks in the oil level inspection window (3).

• 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, remove the oil fill cap (4) and add the recommended oil until it reaches the upper level mark. (Do not overfill.)

5. Check that the O-ring (5) is in good condition and replace it if necessary.

6. Reinstall the engine oil fill cap (4).

(4) engine oil fill cap (5) O-ring

7. Check for oil leaks.

Changing Engine Oil & Filter

1. Remove the engine guard A bolts/washers (1), B bolt/washer (2) and engine guard (3).

(1) upper level mark (2) lower level mark (3) inspection window (4) engine oil fill cap

52 Servicing Your Honda

(1) engine guard A bolts/washers (2) engine guard B bolt/washer (3) engine guard

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

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

Engine Oil

NOTICE

(4)

(6)

(5)

(11)

(8)

(7)

(12)

(9)

(13) (10)

4. Remove the engine oil fill cap (4) from the right crankcase cover.

5. Place an oil drain pan under the engine to catch the oil. Then remove the engine oil drain bolt (5) and sealing washer (6).

Note that more engine oil may splatter than the 2017 year model CRF250R.

6. With the engine stop button pushed, pull the clutch lever all the way in, and depress the start button to drain the engine oil completely.

7. After the oil has drained, apply engine oil to the drain bolt threads, seating surface and a new sealing washer, then tighten the drain bolt with the sealing washer installed 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 146).

Improper disposal of drained fluids is harmful to the environment.

8. It is recommended to replace the oil and filter every 6 races or about every 15.0 hours. However, if you replace only the oil before the recommended interval, see page 25.

9. Remove the oil filter cover bolts (7) and oil filter cover (8).

10. Remove the oil filter (9) and O-ring (10) from the oil filter cover.

11. Remove the spring (11).

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

12. Apply grease to the filter side of the spring end, then install the spring into a new oil filter.

13. Position the spring against the engine crankcase and install a new oil filter with the rubber seal (12) facing out, away from the engine. You should see the “OUT-SIDE” mark (13) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model.

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

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

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

7 lbf·ft (10 N·m, 1.0 kgf·m)

16. Install the engine guard, then tighten the engine guard A bolts/washers and B bolt/ washer to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

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

1.18 US qt (1.12 ℓ) after draining and filter change

1.14 US qt (1.08 ℓ) after draining

18. Install the engine oil fill cap.

19. Check the engine oil level by following the steps in Checking & Adding Oil (page 52).

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 146).

(4) engine oil fill cap (5) engine oil drain bolt (6) sealing washer (new)

Improper disposal of drained fluids is harmful to the environment.

(7) oil filter cover bolts (8) oil filter cover (9) oil filter (new) (10) O-ring (new) (11) spring (12) rubber seal (13) “OUT-SIDE” mark

Servicing Your Honda 53

Coolant

NOTICE

WARNING

(2)

(1)

(3)

Coolant

Refer to Important Safety Precautions on page 23. 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 the mechanical seal or blockage of the radiator passages. Using tap water may cause engine damage.

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 Important Safety Precautions on page 23.

1. Position your CRF on an optional workstand or equivalent support so that it is securely held in place in an upright position.

2. 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).

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.

(1) radiator cap (3) overflow hose (2) radiator filler neck

3. If the coolant level is low, add the coolant up to the filler neck. Inspect the coolant level before each outing. A coolant loss of 0.7 – 2.0 US oz (20 – 60 cm

through the overflow hose (3) is normal. If coolant loss is more than this, inspect the cooling system. Capacity:

1.14 US qt (1.08 ℓ) after disassembly

0.99 US qt (0.94 ℓ) after draining

4. Install the radiator cap securely.

)

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.

54 Servicing Your Honda

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

Coolant

NOTICE

(2)

(3)

(1)

(4)

(5)

WARNING

(6)

Cooling System Inspection

1. Check the cooling system for leaks (see an official Honda Service Manual for troubleshooting of leaks).

2. Check the radiator hoses (1) for cracks, deterioration, and radiator hose clamps for looseness.

3. Check the radiator mount for looseness.

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

5. Check the radiator fins (3) for clogging.

(1) radiator hoses (3) radiator fins (2) overflow hose

6. Check the bleed hole (4) below the water pump cover (5) for leakage. Clean away any clogged dirt or sand, if necessary. Check the bleed hole of the water pump for signs of seal leakage. If water leaks through the bleed hole, replace the mechanical seal. If oil leaks through the bleed hole, replace the oil seal. Make sure that there is no continuous coolant leakage from the bleed hole while operating the engine. A small amount of coolant weeping from the bleed hole is normal. 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.

(4) bleed hole (5) water pump cover

7. Check the radiator air passages for clogging or damage. Straighten bent fins (6), and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

(6) fins

Radiator should be replaced by your dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to an official Honda Service Manual (page 166).

Coolant Replacement

Refer to Important 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 an official Honda Service Manual (page 166).

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.

To properly dispose of drained coolant, refer to

You & the Environment on page 146.

Improper disposal of drained fluids is harmful to the environment.

Servicing Your Honda 55

Air Cleaner

NOTICE

(1)

(2)

(5)

(4)

(6)

(3)

Air Cleaner

Refer to Important 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, wornout, 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.

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.

Cleaning

1. Remove the seat (page 33).

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

(1) air cleaner retaining bolt (2) air cleaner assembly

3. Remove the air cleaner element (3) from the air cleaner holder (4) by releasing the hole (5) of the air cleaner element from the holder tab (6).

56 Servicing Your Honda

(3) air cleaner element (5) hole (4) air cleaner holder (6) holder tab

Air Cleaner

NOTICE

(7)

(8)

(9)

(2)

(1)

4. Wash the air cleaner in clean non-flammable cleaning solvent such as Pro Honda Foam Air Filter Cleaner. 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 1.4 US oz (40 cm

) of clean Pro Honda Foam Air 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.

(7) plastic bag

7. Assemble the air cleaner element and holder. Install the holder tab in the hole of the air cleaner element.

8. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda Foam Air Filter Sealer or equivalent to the air cleaner element contact area of the air cleaner housing.

9. Install the air cleaner assembly (2) into the air cleaner housing stay (8) with the “UP” mark tab (9) facing up.

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

(2) air cleaner assembly (8) air cleaner housing stay (9) “UP” mark tab

11. Install and tighten the air cleaner retaining bolt (1) to the specified torque:

1.8 lbf·ft (2.4 N·m, 0.2 kgf·m)

(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).

Servicing Your Honda 57

Crankcase Breather

(1)

(2)

Crankcase Breather

Refer to Important 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 crankcase breather tubes. If the drain tube overflows, the air filter may become contaminated with engine oil causing poor engine performance.

Draining

1. Remove the crankcase breather tube plug (1) from the crankcase breather 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

58 Servicing Your Honda

Throttle

(1)

(–)

(+)

(2)

(–)

(+)

(2)

(1)

Throttle

Refer to Important Safety Precautions on page 23.

Throttle Freeplay

Inspection Check freeplay (1). Freeplay: 1/16 – 1/4 in (2 – 6 mm) If necessary, adjust to the specified range.

(1) freeplay

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

1. Loosen the lock nut (1).

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

(1) lock nut (+) increase freeplay (2) adjuster (–) decrease freeplay

3. Tighten the lock nut securely.

4. 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 securely. Make the adjustment with the lower 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. Loosen the lock nut (1).

2. Turn the adjuster (2) in direction (–) to decrease freeplay, and in direction (+) to increase freeplay.

(1) lock nut (+) increase freeplay (2) adjuster (–) decrease freeplay

3. Tighten the lock nut to the specified torque:

3.0 lbf·ft (4.0 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.

Servicing Your Honda 59

Throttle

NOTICE

(2)

(1)

(3)

(4)

(1) (3)

(7)(8)

(4)

(5)

(8)

(2)(6)

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 housing bolts (3) are tight.

(1) throttle housing (3) housing bolts (2) paint mark

2. Check for smooth rotation of the throttle (4) from fully open to fully closed in all steering positions. If there is a problem, see your dealer.

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.

Throttle Cable Lubrication

Check for smooth rotation of the throttle. If necessary, apply multi-purpose grease to sliding surface of the throttle cable ends.

1. Slide the dust cover (1).

2. Remove the throttle housing bolts (2).

3. Remove the throttle housing (3) from the throttle pipe (4).

4. Thoroughly lubricate the throttle cable ends (5) with multi-purpose grease.

5. Install the throttle housing to the throttle pipe. Check that the throttle assembly is positioned properly (the end of the throttle housing is aligned with the paint mark (6) on the handlebar) and tighten the throttle housing bolts to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

Align the lugs (7) of the wire guide with the grooves (8) of the throttle housing.

(1) dust cover (5) throttle cable ends (2) housing bolts (6) paint mark (3) throttle housing (7) lugs (4) throttle pipe (8) grooves

(4) throttle

60 Servicing Your Honda

6. Install the dust cover reverse order.

If the throttle operation is not smooth, replace the throttle cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions.

Engine Idle Speed

(–)

(+)

(1)

Refer to Important Safety Precautions on page 23.

Engine Idle Speed

Remember, idle speed adjustment is not a “cure

all” for other problems in your engine’s PGM-FI system. Adjusting the idle speed 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 adjustment 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. Adjust idle speed with the fast idle knob (1). Idle speed: 2,000 ± 100 rpm

(1) fast idle knob (+) increase (–) decrease

Servicing Your Honda 61

Clutch System

(1)

(–)

(+)

(1)

(–)

(+)

(2)

Clutch System

Refer to Important Safety Precautions on page 23.

Clutch Lever Freeplay

Inspection Check freeplay (1). Freeplay: 3/8 – 13/16 in (10 – 20 mm) If necessary, adjust to the specified range.

(1) freeplay

Improper freeplay adjustment can cause premature clutch wear.

Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected.

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

Turning the clutch cable end adjuster (1) in direction (+) will increase freeplay and turning it in direction (–) will decrease freeplay.

(1) clutch cable end adjuster (+) increase freeplay (–) 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 and back out five turns and make the adjustment with the integral cable adjuster.

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.

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

2. Loosen the lock nut (1).

3. Turn the integral cable adjuster (2) to obtain the specified freeplay.

4. Tighten the lock nut. Check the freeplay.

(1) lock nut (+) increase freeplay (2) integral cable adjuster (–) decrease freeplay

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.

62 Servicing Your Honda

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).

Clutch System

(1)(2)

(3)

(1) (2)

(3) (4) (5)

(6)

Other Inspections

• Check that the clutch lever assembly is positioned properly (the end of the holder (1) is aligned with the paint mark (2) on the handlebar) and the securing bolts (3) are tight.

(1) holder (3) bolts (2) paint mark

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

Clutch Cable Lubrication

Check for smooth clutch lever operation. If necessary, apply multi-purpose grease to sliding surface of the clutch cable ends.

1. Release the dust cover (1).

2. Turn the adjuster (2) and remove the clutch cable (3).

3. Disconnect the clutch cable end (4) from the clutch lever (5).

4. Thoroughly lubricate the clutch cable end (4) with multi-purpose grease.

7. Remove the clutch cable end adjuster (6).

8. Apply multi-purpose grease to the clutch cable end adjuster inside surface.

(6) clutch cable end adjuster

9. Recheck clutch lever freeplay and adjust as necessary (page 62).

If the clutch lever operation is not smooth, replace the clutch cable.

Clutch Operation

1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot bolt sliding surface with grease and/or clutch cable with commercially available cable lubricant.

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

(1) dust cover (4) clutch cable end (2) adjuster (5) clutch lever (3) clutch cable

5. Connect the clutch cable end to the lever.

6. Install the clutch cable and turn the adjuster.

Servicing Your Honda 63

Clutch System

(2)

(3)(4)

(1)

(6)

(5)

(7)

(9)

(8)

(10)

Clutch Disc/Plate Removal

1. Drain the engine oil (page 52).

2. Remove the clutch cover A bolts (1), washer (2) clutch cover B bolts (3) and clutch cover (4).

(1) clutch cover A bolts (3) clutch cover B bolts (2) washer (4) clutch cover

4. Remove the clutch pressure plate (6).

(5) clutch spring bolts and springs (6) clutch pressure plate

5. Check the operation of the bearing (7) with your finger. The bearing should turn smoothly and quietly.

6. Remove the clutch lifter (8) first, then remove the clutch lifter rod (9).

(8) clutch lifter (9) clutch lifter rod

7. Remove the eight clutch discs, seven clutch plates, judder spring and spring seat (10).

3. Remove the five clutch spring bolts and springs (5).

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

64 Servicing Your Honda

(10) clutch discs, clutch plates, judder spring and spring

seat

(7) bearing

If the operation is not smooth, refer to an official Honda Service Manual (page 166) for bearing disassembly or see your dealer.

Clutch System

(1)

(2)

(3)

(6)

paint: black

paint: none

disc A

(3) (2) (1)

(5)

(4)

disc Bdisc C

paint: green

(6) (5) (3)

Clutch Disc/Plate/Spring 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 a set.

(1) clutch disc

• Check the clutch plates (2) for excessive

warpage or discoloration. Check the plate warpage on a surface plate using a feeler gauge. Service Limit: 0.004 in (0.10 mm) Replace the clutch discs and plates as a set.

• Check the clutch springs (3) for wear or damage. Measure the free length of each clutch spring. Service Limit: 1.967 in (49.96 mm) Replace the clutch springs as a set.

(3) clutch spring

• If you feel the clutch slippage when replacing the clutch discs and plates, replace the clutch springs.

Clutch Disc/Plate Installation

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

2. Install the clutch disc A (larger I.D. disc and green painted to the clutch disc lug surface) (3) onto the clutch outer. Stack the seven clutch plates (4), six clutch discs B (5) alternately as shown. Install the clutch disc C (6) (black painted to the clutch disc lug surface).

(2) clutch plate

(1) spring seat (4) clutch plates (2) judder spring (5) clutch discs B (3) clutch disc A (6) clutch disc C

(cont’d)

Servicing Your Honda 65

Clutch System

(7)

(8)

(9)

(10)

(11)

(12)

(14)

(13)

(15)

3. Insert the clutch lifter rod (7) into the mainshaft.

4. Apply engine oil to the clutch lifter (8), install the clutch lifter onto the clutch lifter rod.

(7) clutch lifter rod (8) clutch lifter

5. Install the clutch pressure plate (9).

6. Install the five clutch springs and bolts (10).

7. 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)

8. Apply engine oil to a new O-ring (11) and install it in the groove of the clutch cover (12).

(11) O-ring (new) (12) clutch cover

9. Install the cover by tightening a new washer (13), four clutch cover A bolts (14) and two clutch cover B bolts (15) in a crisscross pattern in two or three steps to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

(9) clutch pressure plate (10) clutch springs and bolts

66 Servicing Your Honda

(13) washer (new) (14) clutch cover A bolts (15) clutch cover B bolts

10. Fill the crankcase with the recommended engine oil. (page 52).

Spark Plug

NOTICE

(1)

(2)

(4)

(3)

Spark Plug

Refer to Important Safety Precautions on page 23.

Spark Plug Recommendation

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

Standard R0451B-8 (NGK)

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 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 “wiretype 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.

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).

(1) spark plug cap (2) spark plug

5. Check the electrodes 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 (0.60 – 0.70 mm)

(3) sealing gasket (4) spark plug gap

7. To obtain accurate spark plug readings, accelerate up to speed on a straightaway. Press and hold 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 insulato r 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 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 138). 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:

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, the piston may be damaged. If a plug is too tight, the threads may be damaged.

10. Connect the spark plug cap. Take care to avoid pinching any cables or wires.

11. Install the fuel tank and seat (pages 33, 35).

Servicing Your Honda 67

Valve Clearance

(2)

(1)

(3)

(6)

(4)

(5)

(9)

(7)

(8)

Valve Clearance

Refer to Important 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 valve clearance when the engine is cold at the intervals specified in the Maintenance Schedule (page 25).

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

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).

(1) breather tube (2) spark plug cap

3. Disconnect the ignition coil A connector (3) and B connector (4). Remove the ignition coil (5) by removing the ignition coil bolts (6).

(3) ignition coil A connector (5) ignition coil (4) ignition coil B connector (6) ignition coil bolts

4. Remove the cylinder head cover socket bolts, rubber seals (7), cylinder head cover packing (8) and cylinder head cover (9).

68 Servicing Your Honda

(7) cylinder head cover socket bolts, rubber seals (8) cylinder head cover packing (9) cylinder head cover

Valve Clearance

NOTICE

(2)

(1)

(5)

(4)

(3)

(7)(7)

(8)

Align

(8)

Align Align

(6)

(1)

(2)

(3)

(1)

(2)

Positioning At TDC On The Compression Stroke

1. Remove the timing hole cap (1) and crankshaft hole cap (2).

(1) timing hole cap (2) crankshaft hole cap

2. Remove the spark plug (page 67).

3. Remove the cylinder head cover (page 68).

4. Rotate the crankshaft by turning the flywheel (3) counterclockwise until the matching mark (4) on the flywheel aligns with the index mark (5) on the left crankcase cover. In this position, the piston may either be on the compression or exhaust stroke at TDC. If the crankshaft passed the matching mark, rotate the flywheel counterclockwise again and align the matching mark with the index mark.

Valve Clearance Inspection

1. Set the piston at TDC on the compression stroke (this page).

2. Measure the valve clearances of each intake valve by inserting a feeler gauge (1) between the intake rocker arms (2) slipper surface and camshaft cam lobes (3).

Be careful not to damage the intake rocker arms.

(3) flywheel (5) index mark (4) matching mark

5. Make sure that the decompressor weight (6) is in the lower position. Check the timing marks (7) on each cam sprocket are aligned with the cylinder head mating surface (8).

(6) decompressor weight (7) timing marks (8) cylinder head mating surface

(1) feeler gauge (3) camshaft cam lobes (2) intake rocker arms

Valve Clearance:

IN: 0.004 ± 0.001 in (0.11 ± 0.03 mm)

(cont’d)

Servicing Your Honda 69

Valve Clearance

NOTICE

(1)

(4)

(3)

(1)(4)

(1)

(2)

(4)

(3)

(5)

(6)

(7)

3. Measure the valve clearances of each exhaust valve by inserting a feeler gauge (1) between the exhaust rocker arms (4) slipper surface and camshaft cam lobes (3).

Be careful not to damage the exhaust rocker arms.

Camshaft Removal

1. Remove the cam chain guide bolts (1) and cam chain guide (2).

Do not let the cam chain guide bolts fall into the crankcase.

(1) cam chain guide bolts (2) cam chain guide

2. Rotate the crankshaft by turning the flywheel (3) counterclockwise until the decompressor weight (4) faces up as illustrated below.

3. Remove the cam sprocket bolt (5) of the intake camshaft.

Do not let the cam sprocket bolt fall into the crankcase.

(5) cam sprocket bolt

4. Rotate the camshaft by turning the flywheel and make sure the piston is at TDC on the compression stroke (page 69).

5. Remove the cam chain tensioner lifter cover bolt (6) and sealing washer (7).

(1) feeler gauge (4) exhaust rocker arms (3) camshaft cam lobes

Valve Clearance:

EX: 0.007 ± 0.001 in (0.19 ± 0.03 mm)

If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (this page) and select the correct shim for each valve.

70 Servicing Your Honda

(3) flywheel (4) decompressor weight

(6) cam chain tensioner lifter cover bolt (7) sealing washer

Valve Clearance

NOTICE

(10)

(9)

(8)

(15)

(14)

(11) (13)

(12)

(5)

(18)

(16)

(19)

(17)

6. Insert the tensioner stopper (8) into the cam chain tensioner lifter (9). Turn the tensioner stopper clockwise and lock the cam chain tensioner lifter by pushing the handle (10) to the cam chain tensioner lifter.

• Tensioner stopper 07AMG-001A100

(8) tensioner stopper (9) cam chain tensioner lifter (10) handle

7. Loosen the camshaft holder A bolts (11) and B bolts (12) in a crisscross pattern in two or three steps. Remove the camshaft holder A bolts, B bolts, washers (13), rocker arm shaft stopper bolt (14) and camshaft holder (15).

Do not let the camshaft holder bolts washer and rocker arm shaft stopper bolt fall into the crankcase.

(11) camshaft holder A bolts (12) camshaft holder B bolts (13) washers (14) rocker arm shaft stopper bolt (15) camshaft holder

(5) cam sprocket bolt

9. Remove the intake camshaft (16) from the intake cam sprocket (17). Remove the intake cam sprocket and exhaust camshaft (18) by removing the cam chain (19).

Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase.

Do not let the cam chain and intake cam sprocket fall into the crankcase.

8. Remove the cam sprocket bolt (5) of the intake camshaft.

Do not let the cam sprocket bolt fall into the crankcase.

(16) intake camshaft (17) intake cam sprocket (18) exhaust camshaft (19) cam chain

(cont’d)

Servicing Your Honda 71

Valve Clearance

NOTICE

(20)

(21)

(20)

(21)

(1)

1.80 mm 1.825 mm 1.85 mm

1.875 mm

10. Lift the rocker arms (20) up and remove the shims (21). Record the original position of each shim.

(20) rocker arms (21) shims

Be careful not to damage the rocker arms. Do not clean the rocker arms using a commercially available compound cleaner.

Shim Selection

1. Measure the shim thickness with a micrometer and record it. Seventy-three different shims (1) are available in 0.025 mm thickness intervals, from 1.200 mm (the thinnest) to 3.000 mm (the thickest).

(1) shim

2. 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 exhaust valve seat if carbon deposits

result in a calculated dimension of over 3.000 mm.

Do not lap the valves. They are titanium and have a thin oxide coating. Lapping will damage this coating.

If required shim size is outside the available range, have your motorcycle inspected by your dealer.

72 Servicing Your Honda

Valve Clearance

NOTICE

(1)

(2)

(3) (1)

(3)

(2)

(1)

(3)

(5)

(6)

(4)

(5)

(7)

(8)

(7)

(4)

(10)

(9)

(11)

(13)

(12)

Camshaft Installation

1. Lift the rocker arms (1) up and install the newly selected valve shims (2) on the valve spring retainers (3).

Do not let the valve shims fall into the crankcase.

(1) rocker arms (3) valve spring retainers (2) valve shims

2. Check the operation of the plunger (4) by moving the decompressor weight (5) of the exhaust camshaft (6) with your finger. The plunger should be retracted and protruded smoothly.

If the operation is not smooth, refer to an official Honda Service Manual (page 166) for decompressor disassembly or see your dealer.

3. Make sure the piston is at TDC on the compression stroke (page 69).

4. Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive Moly Paste 77) to the following parts. – camshaft cam lobes (7) – journal surfaces (8) – decompressor weight (5) –plunger (4)

(4) plunger (5) decompressor weight (7) camshaft cam lobes (8) journal surfaces

5. Remove the sealing bolt (9) and sealing washer (10).

(9) sealing bolt (10) sealing washer

6. Insert the rocker arm shaft stopper bolt (11) aligning the cut-out of the rocker arm shaft (12) with the rocker arm shaft stopper bolt by rotating a suitable 4 mm bolt (13).

Do not let the rocker arm shaft stopper bolt fall into the crankcase.

(4) plunger (6) exhaust camshaft (5) decompressor weight

(11) rocker arm shaft stopper bolt (12) rocker arm shaft (13) 4 mm bolt

(cont’d)

Servicing Your Honda 73

Valve Clearance

NOTICE

(14)

(9)

0.18 ± 0.03 in (4.5 ± 1.0 mm)

0.03 - 0.12 in (1.0 - 3.0 mm)

locking agent

(5)

(18)

(6)

(16)

(20)

(17)

(15)

(19)

(21)

(22)

Align

(22)

Align Align

(21)(7)

(17)

(23) (11)

7. Clean the threads of the sealing bolt (9). Apply locking agent to the bolt threads. Install a new sealing washer (14) and tighten sealing bolt to the specified torque:

13 lbf·ft (18 N·m, 1.8 kgf·m)

(9) sealing bolt (14) sealing washer (new)

8. Install the exhaust camshaft (6) onto the cylinder head (15) with the decompressor weight (5) facing down as illustrated below .

9. Install the cam chain (16) to the intake (17) and exhaust (18) cam sprockets while the “O” mark (19) of the intake cam sprocket is facing outside as shown.

(5) decompressor weight (17) intake cam sprocket (6) exhaust camshaft (18) exhaust cam sprocket (15) cylinder head (19) “O” mark (16) cam chain (20) intake camshaft

11. Make sure that the timing marks (21) on the cam sprockets align with the cylinder head mating surface (22). Make sure that the intake camshaft cam lobe (7) is in position as shown.

12. Clean the threads of the cam sprocket bolt (23) and intake cam sprocket (17) thoroughly. Install and temporarily tighten the cam sprocket bolt.

13. Remove the rocker arm shaft stopper bolt (11).

Do not let the cam sprocket bolt and rocker arm shaft stopper bolt fall into the crankcase.

(11) rocker arm shaft stopper bolt (17) intake cam sprocket (23) cam sprocket bolt

Do not let the cam chain and intake cam sprocket fall into the crankcase.

10. Insert the intake camshaft (20) into the intake cam sprocket (17).

74 Servicing Your Honda

(7) camshaft cam lobe (21) timing marks (22) cylinder head mating surface

Valve Clearance

NOTICE

(24)

(26)

(25)

(11)

(27) (29)

(28)

(30)

(31)

(21)(21)

(22)

Align

(22)

Align Align

(33)

(32)

14. Make sure that the dowel pins (24) are installed into the camshaft holder (25). Coat a new O-ring (26) with engine oil and install it onto the camshaft holder.

(24) dowel pins (25) camshaft holder (26) O-ring (new)

15. Apply engine oil to the camshaft holder A bolts (27) and B bolts (28) threads and seating surfaces. Install the camshaft holder (25). Install a new washers (29), the camshaft holder A bolts and B bolts, and tighten the camshaft holder A bolts and B bolts to the specified torque:

10 lbf·ft (13 N·m, 1.3 kgf·m)

Install and tighten the rocker arm shaft stopper bolt (11) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

(11) rocker arm shaft stopper bolt (25) camshaft holder (27) camshaft holder A bolts (28) camshaft holder B bolts (29) washers (new)

16. Remove the tensioner stopper (30) from the cam chain tensioner lifter (31).

• Tensioner stopper 07AMG-001A100

17. Make sure that the piston is at TDC on the compression stroke (page 69). Check that the timing marks (21) on the cam sprockets aligns with the cylinder head mating surface (22).

(21) timing marks (22) cylinder head mating surface

18. Install a new sealing washer (32) and the cam chain tensioner lifter cover bolt (33) securely.

Do not let the camshaft holder A bolts, B bolts, washers and rocker arm shaft stopper bolt fall into the crankcase.

(30) tensioner stopper (31) cam chain tensioner lifter

(32) sealing washer (new) (33) cam chain tensioner lifter cover bolt

(cont’d)

Servicing Your Honda 75

Valve Clearance

NOTICE

(23)

0.14 ± 0.03 in (3.5 ± 1.0 mm)

0.02 - 0.06 in (0.5 - 1.5 mm)

locking agent

(17)

(5)(34)

(23)

0.14 ± 0.03 in (3.5 ± 1.0 mm)

0.02 - 0.06 in (0.5 - 1.5 mm)

(17)

locking agent

(35)

(36)

(37)

19. Remove the cam sprocket bolt (23). Apply locking agent to the bolt threads. Install the cam sprocket bolt to the intake cam sprocket (17), and tighten the cam sprocket bolt to the specified torque:

15 lbf·ft (20 N·m, 2.0 kgf·m)

Do not let the cam sprocket bolt fall into the crankcase.

(17) intake cam sprocket (23) cam sprocket bolt

21. Clean the threads of the cam sprocket bolt (23) and intake cam sprocket (17) thoroughly. Apply locking agent to the bolt threads. Install and tighten the cam sprocket bolt to the specified torque:

15 lbf·ft (20 N·m, 2.0 kgf·m)

Do not let the cam sprocket bolt fall into the crankcase.

22. Install the cam chain guide (35) with the “ ” mark (36) facing forward. Install and tighten the cam chain guide bolts (37) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

Do not let the cam chain guide bolts fall into the crankcase.

(35) cam chain guide (37) cam chain guide bolts (36) “ ” mark

20. Rotate the crankshaft by turning the flywheel (34) counterclockwise until the decompressor weight (5) faces up as illustrated below.

(5) decompressor weight (34) flywheel

76 Servicing Your Honda

23. Rotate the camshaft by rotating the flywheel counterclockwise several times.

24. Measure the intake and exhaust valve clearances (page 69).

(17) intake cam sprocket (23) cam sprocket bolt

Valve Clearance

(1)

(2)

(3)

(1)(1)

(3)

(2)

Crankshaft/Timing Hole Cap Installation

1. Coat a new O-rings (1) with engine oil and install them onto the crankshaft hole cap (2) and timing hole cap (3). Apply grease to the crankshaft hole cap and timing hole cap threads. Install and tighten the crankshaft hole cap to the specified torque:

11 lbf·ft (15 N·m, 1.5 kgf·m)

Install and tighten the timing hole cap to the specified torque:

4.4 lbf·ft (6.0 N·m, 0.6 kgf·m)

Cylinder Head Cover Installation

1. Apply liquid sealant (TB1207B or equivalent) to the cylinder head semi-circular cut-outs (1) as shown after cleaning these area.

(1) cylinder head semi-circular cut-outs

2. Apply liquid sealant (TB5211B or equivalent) to the cylinder head cover groove (2) as shown after degreasing the groove, and install the cylinder head cover packing (3) into it.

(1) O-rings (new) (3) timing hole cap (2) crankshaft hole cap

(2) cylinder head cover groove (3) cylinder head cover packing

(cont’d)

Servicing Your Honda 77

Valve Clearance

(4)

(5)

(4)

(6)

(7)

(10)

(9)

(12)

(8)(11)

(9) (13)

(14)

(15)

3. Check that 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 seals (5) “UP” marks

4. Install the cylinder head cover (6) and tighten the cylinder head cover socket bolts (7) with the rubber seals (4) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

5. Install the ignition coil (8) and tighten the ignition coil bolts (9) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

Connect the ignition coil A connector (10) to the blue terminal (11). Connect the ignition coil B connector (12) to the black terminal (13).

(8) ignition coil (9) ignition coil bolts (10) ignition coil A connector (11) blue terminal (12) ignition coil B connector (13) black terminal

6. Install the spark plug (page 67).

7. Connect the spark plug cap (14) and breather tube (15).

(14) spark plug cap (15) breather tube

8. Install the fuel tank and seat (page 33, 35).

(4) rubber seals (6) cylinder head cover (7) cylinder head cover socket bolts

78 Servicing Your Honda

Piston/Piston Rings/Piston Pin

(1)

(4)

(3)

(2)

(6)

(5)

(7)

(8)

(9)

Piston/Piston Rings/Piston Pin

Refer to Important Safety Precautions on page 23.

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 145).

3. Remove the seat and hang the fuel tank (pages 33, 34).

4. Remove the left and right mufflers (page 115).

5. Remove the left and right exhaust pipes (page 118).

6. Remove the subframe (page 37).

7. Remove the spark plug (page 67).

8. Remove the cylinder head cover (page 68).

9. Set the piston at TDC on the compression stroke (page 69).

10. Remove the cam chain guide, camshaft holder, intake cam sprocket, camshafts and shims (page 70).

11. Disconnect the ECT sensor connector (1).

12. Pull the harness band clip (2) while pressing both side of the anchor and disconnect it.

13. Loosen the left radiator hose clamp screw (3) and disconnect the left radiator hose (4).

(1) ECT sensor connector (2) harness band clip (3) left radiator hose clamp screw (4) left radiator hose

14. Loosen the right radiator hose clamp screw (5) and disconnect the right radiator hose (6).

15. Loosen the insulator band screw (7) and pull the throttle body (8) out from the insulator (9).

Do not hang the throttle body. Support it with a suitable strap.

(7) insulator band screw (8) throttle body (9) insulator

(5) right radiator hose clamp screw (6) right radiator hose

(cont’d)

Servicing Your Honda 79

Piston/Piston Rings/Piston Pin

NOTICE

Left side:

(11)

(12)(10)

Right side:

(11)

(10)

(13)

(14)

(15)

(16) (17)

(18)

(19)

(20)

16. Remove the cylinder head hanger bolts (10). Remove the cylinder head hanger plate bolts (11), left cylinder head hanger plate (12) and right cylinder head hanger plate (13).

17. Remove the cylinder head A bolts (14).

18. Loosen the cylinder bolt (15).

(14) cylinder head A bolts (15) cylinder bolt

19. Remove the cylinder head B bolts (16), washers (17) and the cylinder head (18).

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

20. Remove the dowel pins (19) and cylinder head gasket (20).

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

(19) dowel pins (20) cylinder head gasket

(10) cylinder head hanger bolts (11) cylinder head hanger plate bolts (12) left cylinder head hanger plate (13) right cylinder head hanger plate

80 Servicing Your Honda

Do not let the washers and cam chain fall into the crankcase.

(16) cylinder head B bolts (17) washers (18) cylinder head

Piston/Piston Rings/Piston Pin

NOTICE

(2)

(1)

(4)

(3)

(6)

(5)

Cylinder Removal

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

(1) cylinder bolt (2) sealing washer

2. Remove the cylinder (3) while holding the piston (4)

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

(3) cylinder (4) piston

3. Remove the dowel pins (5) and cylinder gasket (6).

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

(5) dowel pins (6) cylinder gasket

Servicing Your Honda 81

Piston/Piston Rings/Piston Pin

NOTICE

(3)

(1)

(4)

(2)

(1)

Piston Removal

1. Place a clean shop towel (1) in the crankcase to keep the piston pin clips, or other parts, from falling into the crankcase.

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

3. Press the piston pin (3) out of the piston (4), and remove the piston.

Under racing conditions, the piston, rings and piston pin should be replaced every 6 races or about every 15.0 hours of running.

Be careful not to damage or give a shock to the piston pin. Do not clean the piston pin using a commercially available compound cleaner.

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.

(1) piston ring

Piston/Piston Pin/Piston Ring Inspection

We recommend you consult an official Honda Service Manual or your dealer for correct Service Limit measurements.

(1) shop towel (3) piston pin (2) piston pin clips (4) piston

82 Servicing Your Honda

Piston/Piston Rings/Piston Pin

NOTICE

(4)

(2)

(1)

(2)

(5)

(4)

(2)

(1)

(2)

(3)

(1)

(2)

Piston Ring Installation

1. Remove the carbon deposits from the piston head and piston ring grooves.

Do not damage the piston when removing the carbon deposit.

2. Apply engine oil to each piston ring whole surface.

3. Install the spacer (1) first, then install the side rails (2) to the piston (3).

4. Install the top ring (4) to the piston with “T” mark (5) side facing up.

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

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

Piston Installation

1. Place a clean shop towel (1) 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 Moly Paste 77) to the connecting rod small end (2) inner surface.

(1) shop towel (2) connecting rod small end

(1) spacer (4) top ring (2) side rails (5) “T” mark (3) piston

(cont’d)

Servicing Your Honda 83

Piston/Piston Rings/Piston Pin

NOTICE

(4)

(5)(3)

(7)

(8)

(7)

(6)

(7)

(1)

(3)

(2)

3. Install the piston (3) with the “○” mark (4) and/ or the large valve recesses (5) facing the intake side of the engine.

(3) piston (5) large valve recesses (4) “ ” mark

Apply molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease containing more than 3% molybdenum disulfide additive Moly Paste 77) to the piston pin (6) outer surface. Apply engine oil to the piston pin hole inner surface. Install the piston pin and new piston pin clips (7).

Cylinder Installation

1. Clean the cylinder mating surfaces (1) of the crankcase, being careful not to let any material fall into the crankcase.

(6) piston pin (8) piston cutout (7) piston pin clips (new)

(1) crankcase mating surface

2. Remove the shop towels.

3. Install the dowel pins (2) and a new cylinder gasket (3).

Be careful not to damage or give a shock to the piston pin. Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8).

84 Servicing Your Honda

Do not let the dowel pins fall into the crankcase.

(2) dowel pins (3) cylinder gasket (new)

Piston/Piston Rings/Piston Pin

NOTICE

(6)

(5)

(4)

(7)

(8)

(1)

(2)

(5) (6)

(4)

(3)

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

Do not damage the piston rings and cylinder bore. Do not let the cam chain fall into the crankcase.

(4) cylinder bore (5) piston outer surface and piston rings (6) cam chain

5. Temporarily tighten the cylinder bolt (7) with a new sealing washer (8).

Cylinder Head Installation

1. Clean any gasket material off cylinder head.

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

Do not let the dowel pins fall into the crankcase.

(1) dowel pins (2) cylinder head gasket (new)

3. Route the cam chain (3) through the cylinder head and install the cylinder head (4).

4. Apply engine oil to all cylinder head B bolt threads and seating surface. Install the washers (5) and cylinder head B bolts (6) and tighten them to the specified torque in a crisscross pattern in two or three steps:

35 lbf·ft (48 N·m, 4.9 kgf·m)

Do not let the washers fall into the crankcase.

(3) cam chain (4) cylinder head (5) washers (6) cylinder head B bolts

(7) cylinder bolt (8) sealing washer (new)

Do not damage mating surfaces when installing the cylinder head. Do not let the cam chain fall into the crankcase.

(cont’d)

Servicing Your Honda 85

Piston/Piston Rings/Piston Pin

(7)

(8)

(11)

(9)(12)

Left side:

(11)

(12)

(10)

Right side:

(14)

(15)

(13)

Align

0.43 ± 0.04 in

(11.0 ± 1.0 mm)

5. Install the cylinder head A bolts (7) and tighten it to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

6. Tighten the cylinder bolt (8) to the specified torque:

7 lbf·ft (10 N·m, 1.0 kgf·m)

(7) cylinder head A bolts (8) cylinder bolt

7. Install the left cylinder head hanger plate (9) and right cylinder head hanger plate (10), then loosely install the cylinder head hanger plate bolts (11) and cylinder head hanger bolts (12). 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 (32 N·m, 3.3 kgf·m)

8. Install the throttle body (13) to the insulator (14) by aligning the tab of the throttle body with the groove of the insulator and tighten the insulator band screw (15) so the distance between the band ends is 0.43 ± 0.04 in (11.0 ±

1.0 mm).

(13) throttle body (15) insulator band screw (14) insulator

86 Servicing Your Honda

(9) left cylinder head hanger plate (10) right cylinder head hanger plate (11) cylinder head hanger plate bolts (12) cylinder head hanger bolts

Piston/Piston Rings/Piston Pin

(16)

(17)

(18)

0 – 0.02 in (0 – 0.5 mm)

(19)

(20) (21)

(22)

(18)

0 – 0.02 in (0 – 0.5 mm)

9. Connect the right radiator hose (16) to the right radiator hose joint (17) as shown.

(16) right radiator hose (17) right radiator hose joint

10. Tighten the radiator hose clamp screw (18) as illustrated below.

11. Connect the left radiator hose (19) to the left water hose joint (20) of the cylinder head as shown.

12. Connect the ECT sensor connector (21).

13. Install the harness band clip (22).

(19) left radiator hose (20) left water hose joint (21) ECT sensor connector (22) harness band clip

14. Tighten the radiator hose clamp screw (18) as illustrated below.

15. Install the valve shims, intake cam sprocket, camshafts, camshaft holder and cam chain guide (page 73).

16. Install the crankshaft hole cap and timing hole cap (page 77).

17. Install the cylinder head cover (page 77).

18. Install the spark plug (page 67).

19. Install the left and right exhaust pipes (page 118).

20. Install the subframe (page 38) and left and right mufflers (page 116).

21. Install the fuel tank and seat (pages 33, 35).

22. Fill and bleed the cooling system (page 145). Check for the following: – compression leaks – abnormal engine noise – secondary air leaks – exhaust gas leaks – coolant leaks – oil leaks

(18) radiator hose clamp screw

Servicing Your Honda 87

Suspension

(1)

(2)

0.06 in (1.5 mm)

(4)

(3)

(5)

(3)

Suspension

Refer to Important 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 with the standard setting to ensure that the suspension has broken-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 89 for front suspension removal.

• Replace the fork oil every 3 races or 7.5 hours of running. See page 92 for oil capacity adjustment after changing the fork oil.

• Replace the damper oil every 9 races or 22.5 hours of running. See page 98 for damper fork oil replacement.

• Use Pro Honda 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 135) 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.

3. Inspect the wear rings (3) for wear or damage. Replace the wear ring if it is 0.06 in (1.5 mm) or flush with the outer tube (4). Remove the fork leg when replacing the wear ring. Install the wear ring with its end gap (5) facing rearward.

(3) wear ring (4) outer tube

88 Servicing Your Honda

(3) wear rings (5) end gaps

(1) fork protector (2) dust seal

Suspension

NOTICE

(1)

(2)

(5)

(4)

(3)

(7)

(6)

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

Front Suspension Removal

• When disassembling the fork, turn the compression damping (1) and rebound damping (2) adjusters counterclockwise to the softest position to prevent damaging the adjustment needle (be sure to record the number of turns from the starting position).

(1) compression damping adjuster (2) rebound damping adjuster

1. Unlock the number plate tab (3) from the handlebar pad. Remove the number plate bolts (4) and number plate (5).

2. Place your CRF on an optional workstand or equivalent support with the front wheel off the ground.

3. Remove the handlebar lower holder nuts, washers, mounting rubbers (6) and handlebar (7).

Keep the master cylinder upright to prevent air from entering system.

(6) handlebar lower holder nuts, washers and mounting

rubbers

(7) handlebar

(3) number plate tab (5) number plate (4) number plate bolts

(cont’d)

Servicing Your Honda 89

Suspension

NOTICE

(10)

(8)

(11)

(9)

(12)

(13)

(15)

(16) (17)

(15)

(14)(17)

(21)

(22)

(18)

(19)

(20)

(24)

(23)

4. Loosen the fork bridge upper pinch bolts (8).

5. Loosen the fork bolt assembly (9), but do not remove it yet.

6. Loosen the fork damper assembly (10) using the lock nut wrench (11), but do not remove it yet.

• Lock nut wrench 07WMA-KZ30100

The procedure is the same for the both right and left fork legs.

Do not use an adjustable wrench to loosen the fork damper: it may damage the fork damper.

(12) disc cover (13) disc cover socket bolts

8. Remove the front axle nut (14) and loosen the axle pinch bolts (15) on both forks. Pull the front axle shaft (16) out of the wheel hub and remove the front wheel with collars (17).

• Do not operate the brake lever after the front wheel is removed. To do so will cause difficulty in fitting the brake disc between the brake pads.

(18) brake hose clamp bolts (19) stay A (20) stay B (21) front brake caliper mounting bolts (22) brake caliper

11. Remove the fork protector socket bolts (23) and fork protectors (24).

(8) fork bridge upper pinch bolts (9) fork bolt assembly (10) fork damper assembly (11) lock nut wrench

7. Remove the disc cover (12) by removing disc cover socket bolts (13).

90 Servicing Your Honda

(14) front axle nut (16) front axle shaft (15) axle pinch bolts (17) collars

9. Remove the brake hose clamp bolts (18), stay A (19) and stay B (20).

10. Remove the front brake caliper mounting bolts (21) and brake caliper (22).

• Do not support the brake caliper by the brake

hose.

(23) fork protector socket bolts (24) fork protectors

Suspension

NOTICE

(25)

(28)

(27)

(26)

(1)

(4)

(2)

(1)

(3)

(1)

(5)

(4)

(1)

(2)

(7)

(6)

12. Loosen the fork bridge lower pinch bolts (25), then pull the both fork legs down and out.

(25) fork bridge lower pinch bolts

13. Clean the fork assembly, especially the sliding surface (26) of the slider and fork dust seal (27).

14. Measure the length (28) between the axle holder and outer tube and record it before disassembling the fork.

Recommended Fork Oil

suggested oil Pro Honda HP Fork Oil, SS-19

Fork Outer Tube Disassembly

Refer to Front Suspension Removal on page 89.

1. Clean the fork assembly, especially the sliding surface of the slider and dust seal.

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

• Lock nut wrench 07WMA-KZ30100

The outer tube (1) can drop on the axle hold er (4) and damage the fork dust seal (5). To avoid damage, hold both the outer tube and slider when removing the fork damper.

(1) outer tube (5) fork dust seal (4) axle holder

3. Drain the fork oil from the outer tube (1) and oil holes (6) of the fork damper assembly (2). Remove the O-ring (7) from the fork damper assembly.

(26) sliding surface (28) length (27) fork dust seal

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

(1) outer tube (6) oil holes (2) fork damper assembly (7) O-ring

(cont’d)

Servicing Your Honda 91

Suspension

NOTICE

(1)

Inverted time

32°F/0°C

50°F/10°C

68°F/20°C

86°F/30°C

Amount of fork oil

(minutes)

(1)

(2)

(3)

(4)

(3)

(1)

4. Drain the fork oil by turning the outer tube (1)

upside down. (About 0.46 US oz (13.7 cm

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

(1) outer tube

Pour the drained oil into a suitable container and dispose of it in an approved manner (page 146).

Improper disposal of drained oil is harmful to the environment.

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

minute

°F/°C

86/30 16.5 14.1 12.7 11.8 11 10.1 8.6 68/20 17.4 15 13.7 12.6 11.5 10.5 9.1 50/10 18.9 16.5 14.8 13.7 12.5 11.4 9.8

32/0 20 18.4 15.9 14.5 13.7 13 11.7

5 1020355585145

Fork Oil Refilling

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

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

(1) outer tube

Recommended Oil:

Pro Honda HP Fork Oil, SS-19

Recommended Standard Amount:

12.0 US oz (356 cm

Fill the fork oil which is obtained by docking off the amount of the remaining oil in the fork from the recommended standard fork oil capacity.

Refer to Front Suspension Air Pressure on page 127.

)

2. Apply the recommended fork oil to a new O-ring (2). Install the O-ring on the fork damper assembly (3).

(2) O-ring (new) (3) fork damper assembly

3. Pull up the outer tube (1) slowly and temporarily tighten the fork damper assembly (3) using the lock nut wrench (4).

• Lock nut wrench 07WMA-KZ30100

92 Servicing Your Honda

(1) outer tube (4) lock nut wrench (3) fork damper assembly

HONDA CRF250R 2018 OWNER’S MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

A Few Words About Safety

Contents

Motorcycle Safety

Important Safety Information

Accessories & Modifications

Safety Labels

Instruments & Controls

Operation Component Locations

MIL (Malfunction Indicator Lamp)

Mode Indicator

Before Riding

Are You Ready to Ride?

Is Your Motorcycle Ready to Ride?

Basic Operating Instructions

Starting & Stopping the Engine

Break-in Guidelines

Servicing Your Honda

The Importance of Maintenance

Maintenance Safety

Maintenance Schedule

General Competition Maintenance

Before & After Competition Maintenance

Maintenance Component Locations

Seat

Fuel Tank

Subframe

Fuel System

Engine Oil

Coolant

Air Cleaner

Crankcase Breather

Throttle

Engine Idle Speed

Clutch System

Spark Plug

Valve Clearance

Piston/Piston Rings/Piston Pin

Suspension