Honda CRF450R 2006 Owner's Manual
  1. Manuals
  2. Brands
  3. Honda Manuals
  4. Motorcycle
  5. CRF450R 2006
  6. Owner's manual

Honda CRF450R 2006 Owner's Manual

Hide thumbs Also See for CRF450R 2006:
Table of Contents

Advertisement

Quick Links

See also: Service Manual
2006
Honda CRF450R
OWNER'S MANUAL & COMPETITION HANDBOOK

Advertisement

Table of Contents
loading

Related Manuals for Honda CRF450R 2006

Summary of Contents for Honda CRF450R 2006

  • Page 1 2006 Honda CRF450R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take responsibility for to your Honda dealer so we will be able to keeping your CRF well maintained. Scheduled contact you concerning important production service is a must, of course.
  • Page 3 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.
  • Page 4 Contacting Honda..........157 Before You Service Your Honda Brakes..............79 Your Honda Dealer..........158 The Importance of Maintenance .......18 Wheels...............83 The Honda Rider’s Club (USA only) .....159 Maintenance Safety...........19 Tires & Tubes ............84 Important Safety Precautions......19 Drive Chain ............86 TABLE OF CONTENTS ......160 Maintenance Schedule ........20...

  • Page 5: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Information.......2 information and recommendations to help you Important Safety Precautions......2 ride your CRF safely. Please take a few Accessories & Modifications .......3 moments to read these pages. This section also Safety Labels ............4 includes information about the location of the safety labels on your CRF.

  • Page 6: Important Safety Information

    Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.

  • Page 7: Accessories & Modifications

    Accessories & Modifications 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.

  • Page 8: Safety Labels

    Safety Labels Read this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety...

  • Page 9: Operating Controls

    Operating Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 10: Operation Component Locations

    Operation Component Locations hot start lever front brake lever clutch lever engine stop button throttle grip choke knob kickstarter fuel valve shift lever rear brake pedal Operating Controls...

  • Page 11: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........8 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?.....9 you prepared, this section discusses how to Pre-ride Inspection ..........9...

  • Page 12: Are You Ready To Ride

    Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls. chance of serious injury or death in a crash.

  • Page 13: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection 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 Check the following before each ride: right): •...
  • Page 14 Before Riding...

  • Page 15: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions ........12 start and stop your engine as well as break-in Starting & Stopping the Engine ......13 guidelines. Preparation ............13 Starting Procedure ........13 Flooded Engine ..........13 How to Stop the Engine........14 Break-in Guidelines ...........15 Basic Operating Instructions Basic Operating Instructions...

  • Page 16: Safe Riding Precautions

    Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage. Your CRF’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

  • Page 17: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting described below. levels before starting the engine (pages 37,40,41). 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3.
  • Page 18 Starting & Stopping the Engine How to Stop the Engine (1) throttle grip (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) 2 – 3 times, and then close it.

  • Page 19: Break-In Guidelines

    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: •...
  • Page 20 Basic Operating Instructions...

  • Page 21: Table Of Contents

    You’ll also find Drive Chain ............86 important safety precautions, information on oils, Service Preparations Exhaust Pipe/Muffler .........89 and tips for keeping your Honda looking good. Maintenance Component Locations....28 Additional Maintenance Procedures ....92 Seat Removal .............29 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...

  • Page 22: The Importance Of Maintenance

    Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 23: Maintenance Safety

    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...

  • Page 24: Maintenance Schedule

    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 genuine...
  • Page 25 This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every moto for dusty riding condition. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. Servicing Your Honda...

  • Page 26: General Competition Maintenance

    Use genuine Honda parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 27 Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Honda White Lithium...
  • Page 28 For added peace of mind, carburetor is screwed on tight. Make certain the throttle remove the nuts, clean the threads, and apply Honda Thread operation is perfect after servicing and inspecting. Lock or an equivalent prior to torquing the nuts.
  • Page 29 If replacement is necessary, both seals offers added assurance and security. Remove the nuts, clean should be replaced. the threads of both the nuts and bolts, apply Honda Thread Lock or an equivalent and tighten to the specified torque. Servicing Your Honda...

  • Page 30: Before & After Competition Maintenance

    (1) are in the same position on (2) pressure release screws 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. Servicing Your Honda...
  • Page 31 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 94). Servicing Your Honda...

  • Page 32: Maintenance Component Locations

    Servicing Your Honda...

  • Page 33: Seat Removal

    2. Remove the seat (2) by sliding it backward. 2. Install and tighten the seat bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat bolts (2) seat (3) seat front prong (4) seat bracket (5) seat rear prong (6) frame Servicing Your Honda...

  • Page 34: Fuel Tank Removal

    (4) breather tube (5) fuel tank band (6) air cleaner case cover (7) fuel tank bolt (10) (1) shroud A bolts/collars (2) shroud B bolts (3) shrouds (8) fuel line (10) fuel valve bolt (9) fuel valve Servicing Your Honda...
  • Page 35 5. Hook the air cleaner case cover (5). 6. Install and hook the fuel tank band (6). (10) (8) shroud (10) subframe (9) tab (4) fuel tank bolt (5) air cleaner case cover (6) fuel tank band Servicing Your Honda...

  • Page 36: Subframe Removal

    (14) by pulling it straight backward. (13) (14) (12) (3) muffler clamp bolt (4) muffler A bolt (12) subframe mounting A bolts (5) muffler B bolt/washers (13) subframe mounting B bolts (6) muffler (14) subframe Servicing Your Honda...
  • Page 37 7. Install the muffler clamp (9) and new gasket specified torque: (10) to the exhaust pipe. 15 lbf·ft (21 N·m, 2.1 kgf·m) (15) (16) (17) (10) (15) muffler B bolt/washers (9) muffler clamp (10) gasket (16) muffler A bolt (17) muffler clamp bolt Servicing Your Honda...

  • Page 38: Fuel System

    (2) fuel filter of gasoline. If pinging or spark knock persists, WARNING consult your Honda dealer. 1. Check the fuel valve (1) and fuel filter (2) for Gasoline is highly flammable and contamination.
  • Page 39 Install the fuel filter in the fuel tank. Refill the fuel tank. Attach the fuel valve and fuel line, and turn the fuel valve to ON; check for leaks. (1) fuel filter (3) O-ring (2) bolts Servicing Your Honda...

  • Page 40: Engine Oil

    (weight) the engine. JASO T 903 standard MA or MB NOT RECOMMENDED suggested oil* Pro Honda GN4, HP4 (without molybdenum additives), or HP4M (with Other viscosities shown in the following chart molybdenum additives) 4- may be used when the average temperature in stroke engine oil or an your riding area is within the indicated range.
  • Page 41 Repeat steps 1–4. every 6 races or about every 15.0 hours. 6. Reinsert the engine oil filler cap. However, if you replace only the oil before 7. Check for oil leaks. the recommended interval, see page 21. (cont’d) Servicing Your Honda...
  • Page 42 (11) facing out, away from the engine. You should see the ”OUT-SIDE” mark (12) on the filter body, near the seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 43: Transmission Oil

    Other viscosities shown in the following chart may be used when the average temperature in suggested oil* Pro Honda HP Trans oil, Pro Honda GN4 or HP4 your riding area is within the indicated range. (without molybdenum additives) 4-stroke engine...
  • Page 44 (1) transmission oil filler cap steps 1–4. (2) transmission oil drain bolt 5. After inspecting the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque:. 7 lbf·ft (10 N·m, 1.0 kgf·m) Servicing Your Honda...

  • Page 45: Coolant

    Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is low. Use Pro Honda HP Coolant or an equivalent high Refer to Safety Precautions on page 19. Inspect the coolant level before each outing.
  • Page 46 Refer to Safety Precautions on page 19. Honda Service Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2. Check the water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.

  • Page 47: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions. Your CRF’s air cleaner has very specific performance requirements.
  • Page 48 Air Cleaner 5. Remove the air cleaner (3) from the air 9. Apply a thin coat of Honda White Lithium NOTICE cleaner holder (5). Grease to the sealing surface. 10. Assemble the air cleaner and holder. Improper installation of the air cleaner assembly...

  • Page 49: Crankcase Breather

    Service the breather if you can see deposits in the transparent section of the drain tube. Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 50: Throttle

    5. Operate the throttle grip to ensure that it functions smoothly and returns completely. 6. Install the fuel tank (page 31). If you can’t get the freeplay within the specified range, contact your Honda dealer. (–) (2) dust cover (+)increase (3) lock nut (–)decrease...
  • Page 51 If the cable is kinked or chafed, have it replaced. 4. Check the cables for tension or stress in all steering positions. 5. Lubricate the cables with a commercially-available cable lubricant to prevent premature rust and corrosion. Servicing Your Honda...

  • Page 52: Engine Idle Speed

    3. Connect a tachometer to the engine. 4. Shift the transmission into neutral. Start the engine. 5. Keep the motorcycle in an upright position. 6. Adjust idle speed with the throttle stop screw (2). Idle speed: 1,700 ± 100 rpm Servicing Your Honda...

  • Page 53: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. (cont’d) Servicing Your Honda...
  • Page 54 If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the Honda Service Manual (page 156). Servicing Your Honda...
  • Page 55 4. Remove the six clutch spring bolts and springs (5). (7) washer (10) clutch lifter rod Loosen the bolts in a crisscross pattern in 2 or 3 (8) needle bearing (11) clutch discs and plates progressive steps. (9) clutch lifter (2) clutch plate Servicing Your Honda...
  • Page 56 (3) clutch lifter rod (5) washer (4) needle bearing (6) clutch lifter pivot and pivot bolt (13) with Honda Lithium Grease and tighten the pivot bolt to the Clutch Disc/Plate Installation 7. Install the clutch pressure plate (7). specified torque: 8.

  • Page 57: Hot Start Lever

    (1) hot start lever (2) hot start lever freeplay (–) Inspection (3) lock nut (+) increase Check freeplay: (4) cable adjuster (–) decrease 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...

  • Page 58: Spark Plug

    “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. (3) sealing gasket (4) spark plug gap Servicing Your Honda...

  • Page 59: Valve Clearance

    4. Remove the cylinder head cover A bolt (3), cylinder head cover B bolts (4) and cylinder head cover (5). (2) spark plug (3) cylinder head cover A bolt (4) cylinder head cover B bolts (cont’d) (5) cylinder head cover Servicing Your Honda...
  • Page 60 If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Holder Assembly Removal (page 57) and select the correct shim for each valve. (3) primary drive gear bolt (5) index mark (4) “punch” mark (6) exhaust rocker arm Servicing Your Honda...
  • Page 61 = 0.025 in (0.63 mm) If only decompressor arm clearance needs adjustment, see Decompressor Arm Clearance Adjustment (page 63). If intake valve clearance, exhaust valve Clearance and decompressor arm clearance don’t need adjustment, see Spark Plug Installation (page 64). (cont’d) Servicing Your Honda...
  • Page 62 (4) cam sprocket bolts (5) cam sprocket (6) cam chain (10) (8) camshaft holder assembly (7) camshaft holder assembly bolts (9) intake valve lifters (8) camshaft holder assembly (10) shims 6. Remove the valve shims. Servicing Your Honda...
  • Page 63 • Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2.450 Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 3.000 mm. (1) valve lifter (2) shim Servicing Your Honda...
  • Page 64 1/2 engine oil and 1/2 molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive)) to the camshaft and outer surface of the each valve lifters (3). (4) camshaft holder assembly (5) intake cam lobes (6) camshaft holder assembly bolts Servicing Your Honda...
  • Page 65 Do not let the bolts and sprocket fall into the (10) cam sprocket (8) “punch” mark crankcase. (11) timing mark (9) index mark (12) “∆” mark (13) cam chain (14) (10) (10) cam sprocket (14) cam sprocket bolts (cont’d) Servicing Your Honda...
  • Page 66 “∆” mark (12) on the camshaft holder assembly. If the timing mark doesn’t align with the “∆” mark, remove the cam sprocket. Then realign the valve timing. (11) (12) (8) “punch” mark (9) index mark (11) timing marks (12) “∆” mark Servicing Your Honda...
  • Page 67 (19) decompressor arm adjusting screw (20) right side rocker arm (1) feeler gauge (4) lock nut (5) decompressor arm adjusting screw (6) right side rocker arm Recheck the clearance between the adjusting screw and right side rocker arm. Servicing Your Honda...
  • Page 68 (2) spark plug hole (1) O-ring (2) crankshaft hole cap 2. Install the cylinder head cover packing (3) into the groove of the cylinder head cover (4). (1) spark plug (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...
  • Page 69 B bolts (7) to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) (8) spark plug cap (9) breather tube (5) cylinder head cover (6) cylinder head cover A bolt (7) cylinder head cover B bolts Servicing Your Honda...

  • Page 70: Piston/Piston Rings/Piston Pin

    (9) radiator hose clamp screw (10) radiator hose 9. Remove the cylinder head cover (page 55). 10. Remove the spark plug (8). (1) exhaust pipe joint nuts (2) exhaust pipe (3) exhaust pipe gasket (8) spark plug Servicing Your Honda...
  • Page 71 (11) engine hanger nut (12) engine hanger A bolt (13) fuel hose guide (19) (14) engine hanger B bolts (15) left engine hanger plate (16) right engine hanger plate (19) (20) (19) cylinder head nuts/washers (20) cylinder head Servicing Your Honda...
  • Page 72 2. Remove the A dowel pins (3), B dowel pin (4) and cylinder gasket (5). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) A dowel pins (5) cylinder gasket (4) B dowel pin Servicing Your Honda...
  • Page 73 1. Remove the carbon deposits from the piston oil ring We recommend you consult the Service Manual head and piston ring grooves with the or your authorized Honda dealer for correct removed ring. Service Limit measurements. 2. Apply engine oil to the piston rings and install the piston rings.
  • Page 74 (1) cylinder gasket (3) B dowel pin (2) A dowel pins 4. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out Servicing Your Honda...
  • Page 75 Do not damage the piston rings and cylinder walls. (7) cam chain guide (8) cam chain guide tab (9) cylinder cut-out (1) dowel pins (2) cylinder head gasket (4) cam chain (6) piston rings (5) cylinder (cont’d) Servicing Your Honda...
  • Page 76 (11) fuel hose guide 19 lbf·ft (26 N·m, 2.7 kgf·m) (12) engine hanger nut Tighten the engine hanger nut to the specified torque: 40 lbf·ft (54 N·m, 5.5 kgf·m) (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 77 (17) ignition coil bolts (18) ignition coil nut (page 32). (19) primary wire 15. Install the fuel tank and the seat (page 31). (20) spark plug cap 16. Add the coolant up to the filler neck (page 41). Servicing Your Honda...

  • Page 78: Suspension

    See page 102 for damper locking the front brake and pushing down on fork oil replacement. the handlebar several times. • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension.

  • Page 79: Rear Suspension Inspection

    (page 115). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the subframe (page 32). The instructions found in this owner’s manual are 3.

  • Page 80: Recommended Fork Oil

    (weight) 5 W when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage hold both the outer tube and slider when equivalent removing the fork damper.
  • Page 81 12.9 US oz capacity (380 cm Maximum oil 13.9 US oz Slightly stiffer as capacity (412 cm it nears full compression. Minimum oil 10.7 US oz Slightly softer as capacity (316 cm it nears full compression. (cont’d) Servicing Your Honda...
  • Page 82 Temporarily install the fork damper (2) to the outer tube (1). After installing the fork leg (page 119) tighten the fork damper to the specified torque: 25 lbf·ft (34 N·m, 3.5 kgf·m) (10) (1) outer tube (2) fork damper (10) O-ring Servicing Your Honda...

  • Page 83: Brakes

    (1) lock nut (3) piston 82), there is probably air in the brake system. (2) adjuster Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the 1. Loosen the lock nut (1). system.
  • Page 84 Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda motorcycle If the front brake lever freeplay exceeds 0.8 in...
  • Page 85 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 • Make sure there are no fluid leaks. brake fluid or an equivalent.
  • Page 86 Make sure there are no fluid leaks. Check for grooves deterioration or cracks in the hoses and fittings. (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 87: Wheels

    Excessively loose spokes may result in 3. Check wheel rim runout. If runout is instability at high speeds and the possible loss of noticeable, see the Honda Service Manual for control. It’s also important that the rim locks are inspection instructions.

  • Page 88: Tires & Tubes

    Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 89 • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 90: Drive Chain

    Adjust chain slack if needed. upper roller: 1.5 in (39 mm) lower roller: 1.4 in (35 mm) 5. Check the chain slider (4) for wear. If the wear is 0.2 in (5 mm) or more, replace it. Servicing Your Honda...
  • Page 91 Pro Align the index marks (4) of the axle plates otherwise appears unserviceable. Honda Chain Lube or an equivalent, or SAE 80 (5) with the same reference marks (6) on both or 90 gear oil is recommended.
  • Page 92 Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. 8. Recheck chain slack and adjust as necessary. Servicing Your Honda...

  • Page 93: Exhaust Pipe/Muffler

    1. Remove the seat bolt (1), side cover bolt (2) and right side cover (3). (4) muffler clamp bolt (6) muffler B bolt/washers (5) muffler A bolt (7) muffler (1) seat bolt (3) right side cover (2) side cover bolt Servicing Your Honda...
  • Page 94 (9) muffler A bolt 3. Install the muffler (4). 4. Install the muffler clamp (5) by aligning the tab (6) of the muffler clamp with the cut-out (7) of the muffler. (4) muffler (6) tab (5) muffler clamp (7) cut-out Servicing Your Honda...
  • Page 95 15 lbf·ft (21 N·m, 2.1 kgf·m) (1) exhaust pipe joint nuts (2) exhaust pipe (1) exhaust pipe gasket (3) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 2. Install the muffler (page 90). Servicing Your Honda...

  • Page 96: Additional Maintenance Procedures

    Refer to the Periodically, disconnect the throttle, clutch and Honda Service Manual for replacement or hot start cables at their upper ends. Thoroughly adjustment procedures, or see your Honda lubricate the cable pivot points with a dealer.
  • Page 97 (6) oil filter cover bolts (7) cylinder bolt (8) cylinder head bolts (1) cylinder head cover bolts (2) clutch cover bolts (3) water pump cover bolts (4) transmission oil check bolt (5) crankshaft hole cap (9) exhaust pipe joint nuts Servicing Your Honda...

  • Page 98: Appearance Care

    You may use Pro Honda Hondabrite, a and steering head bearings-driving dirt inside multi-surface cleaner/degreaser, to remove both and needed lubrication out.
  • Page 99 #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda...
  • Page 100 Servicing Your Honda...

  • Page 101: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......98 for maximum competition performance. Front Suspension Air Pressure......98 Front Suspension Damping ......98 Initial suspension adjustments should be Fork Springs..........99 performed after a minimum of two hours of easy Front Suspension Disassembly .....99 break-in time.

  • Page 102: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).

  • Page 103: Fork Springs

    See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2 oz (5 cc)
  • Page 104 Front Suspension Adjustments 4. Remove the handlebar holder nuts (3), 7. Remove the disc cover (7) by removing the Do not support the brake caliper by the brake washers, mounting rubbers and handlebar (4). two bolts (8). hose. Do not operate the brake lever after the front wheel is removed.
  • Page 105 Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (18) and dust seal (19). outer tube. 13.Record the rebound damping adjuster position The outer tube can drop on the slider and 18.Set the lower end (axle holder) (27) of the and turn the adjuster counterclockwise until it slider in a vise with a piece of wood or soft...

  • Page 106: Damper Oil Change

    Front Suspension Adjustments 22.Apply pressure to the fork damper and insert a Damper Oil Change (27) special tool or mechanic's stopper tool (29) (see below) between the axle holder (27) and (29) lock nut (30). 1. Set the fork damper (1) in a vise with a piece 23.Hold the lock nut and remove the fork center of wood or soft jaws to avoid damage.
  • Page 107 Recommended Oil: Be careful not to damage the fork cap bushing. Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5 W or equivalent Do not disassemble the fork cap assembly. Recommended Amount: Replace the fork cap as an assembly if it is 6.4 US oz (190 cc, 6.7 Imp oz)
  • Page 108 Front Suspension Adjustments 10. Tighten the fork cap (1) while holding the cut 12. Screw in the lock nut (9) to the fork damper 14. Drain the extra oil from the fork damper piston rod (6) fully. out of the fork damper (2) using the lock nut spring chamber (11) oil hole (5).

  • Page 109: Fork Assembly

    Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider by placing it upside down. (About 7 cc of fork oil will be left in the outer Wipe the oil completely off the fork damper.
  • Page 110 Front Suspension Adjustments 4. Set the lower end (axle holder) of the slider in 8. Measure the length of the lock nut (2) and 10. Apply fork oil to the center bolt (8) O-ring. a vise with a piece of wood or soft jaws to center bolt (8) clearance.
  • Page 111 Fork Oil Capacity: outer tube/slider (1). Standard (0.46 kgf/mm) Fork Spring No mark Recommended Oil: 4 scribe marks (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 2 scribe marks (aftermarket parts) Standard oil 12.5 US oz (11) capacity...
  • Page 112 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper (4) to the specified assembly (4) is in good condition. Apply the torque using the lock nut wrench (14). (16) recommended fork oil to the O-ring. Actual: 15.Pull up the outer tube (1) slowly and install 25 lbf·ft (34 N·m, 3.5 kgf·m)
  • Page 113 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle 25.Install the handlebar (25), mounting rubbers (18) and axle holder thoroughly. clamps contact each other. (26), washers and handlebar holder nuts (27) Apply locking agent to the bolt threads.
  • Page 114 Front Suspension Adjustments 27.Install and tighten the number plate bolt (30). Install the handlebar pad (31). (32) (31) (30) (32) axle pinch bolts NOTICE (30) number plate bolt (31) handlebar pad To avoid damage when torquing the axle pinch bolts, be sure the axle is seated firmly onto the 28.With the front brake applied, pump the fork left fork leg clamp inner surface.

  • Page 115: Rear Suspension Adjustments

    Min. gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring preload length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 5.3 kgf/mm): 9.88 in (251 mm) limited to adjustments of the shock assembly Min.

  • Page 116: Rear Suspension Damping

    Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping Compression damping may be adjusted in two stages with separate adjusters. To adjust to the standard position: 1.

  • Page 117: Rear Suspension Race Sag

    Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.
  • Page 118 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 119: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 120: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 98 - 115. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 121 Suspension Adjustment Guidelines Symptom Action Stiff Initial travel too stiff: – Test softer compression damping adjustments in one-click increments. suspension • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in one-click increments. •...
  • Page 122 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring preload). Example: –...

  • Page 123: Carburetor Adjustments & Tuning Tips

    (2) and is mixed with air from your CRF. See your Honda dealer. the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for starting.

  • Page 124: Accelerator Pump/Slow Circuit

    Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.

  • Page 125: Carburetor Circuit Functions

    3. Tighten the drain screw. Honda carburetor jet sizes are numbered in The minimum to maximum range of pilot screw increments of 2 or 3. When changing the main jet adjustment is 1 3/8 to 2 1/8 turns out from the size, increase or decrease it gradually until the lightly seated position.
  • Page 126 Carburetor Adjustments & Tuning Tips 4. Disconnect the fuel line (2) from the fuel 10. Remove the hot start cable holder (6). 12. Remove the throttle cables (9) by loosening valve (3). the throttle cable lock nut (10). 5. Remove the fuel tank (page 30). 6.

  • Page 127: Carburetor Disassembly

    Carburetor Adjustments & Tuning Tips 3. Remove the link arm set screw (6). When installing the floating valve (8) onto the Carburetor Disassembly When installing the link arm set screw, apply a throttle valve (5) make sure the floating locking agent to the link arm set screw threads. valve’s flat side faces out and the hole (9) 4.
  • Page 128 Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (15), throttle stop 9. Measure the float level (23) with the float (10) and accelerator pump cover (11). screw holder (16), float bowl screws (17), level gauge (24) during float tab just tube guides (18) and float bowl (19).

  • Page 129: Carburetor Assembly

    Carburetor Adjustments & Tuning Tips Carburetor Assembly To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. Tighten the following parts to the specified torque. float bowl screws: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m) accelerator pump cover screws: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m) top cover bolts: 1.5 lbf·ft (2.1 N·m, 0.2 kgf·m)

  • Page 130: Standard Tuning Recommendations

    Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary. Adjustment Standard settings Pilot screw opening 1 1/2 turns out Slow jet...

  • Page 131: Special Tuning Conditions

    Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the atmospheric conditions or race day situations that situations that may require additional...

  • Page 132: Carburetor Minor Adjustments

    Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments Gasoline is highly flammable and explosive. You can be burned or The standard carburetor settings are ideal for the seriously injured when handing fuel. following conditions: sea level altitude, and 68°F (20°C ) air temperature.
  • Page 133 Carburetor Adjustments & Tuning Tips 7. Change the main jet (4) and slow jet (5) as 9. Rotate the carburetor and align the lug (6) on 13. Remove the jet needle holder (10) and jet required. the carburetor with the slot (7) on the needle (11) from the throttle valve (12).

  • Page 134: Spark Plug Reading

    Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 54.

  • Page 135: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is Adjusting your CRF’s wheelbase can offer subtle adjustable. changes in overall handling.

  • Page 136: Gearing

    Unless you have the required mechanical down, and avoid unwanted wheelspin. The appraisal of the change. “Seat-of-the-pants” knowhow, tools, and an official Honda Service engine may bog in certain corners so you’ll feelings can’t be trusted. Eliminating wheelspin Manual, sprocket changing should be done by need to slip the clutch to compensate;...

  • Page 137: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium” additional loads to the transmission because it for the variety of soil conditions the majority of grips so well, especially when riding in situations...

  • Page 138: Personal Fit Adjustments

    Handlebar Position, Width & Shape Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained.

  • Page 139: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......136 Storing Your Honda..........137 Preparation for Storage ........137 Removal from Storage.........137 You & the Environment ........138 Troubleshooting..........139 Tips...

  • Page 140: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your CRF, brace the front wheel transport your Honda, we recommend that against the front of the truck bed or trailer rail. you follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 141: Storing Your Honda

    Drain gasoline into an approved If the coolant level lowers, add coolant and 9. Place your CRF on the optional Honda container. Retighten the drain screw. repeat the above procedure. workstand or equivalent to raise both tires off Install the radiator cap securely.

  • Page 142: You & The Environment

    You & the Environment Owning and riding a motorcycle can be NOTICE enjoyable, but you must do your part to protect nature. When you show respect for the land, Improper disposal of drained fluids is harmful to wildlife, and other people, you also help preserve the environment.

  • Page 143: Troubleshooting

    POSSIBLE CAUSES parenthesis. The items that require use of the FUEL FLOW • Lack of fuel in tank 1. Disconnect fuel Honda Service Manual are followed by an line at carburetor RESTRICTED (P-34) and check for • Clogged fuel line asterisk.
  • Page 144 Tips...

  • Page 145: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........142 other technical data. Specifications ...........143 Torque Specifications........144 High Altitude Carburetor Adjustment ....147 Oxygenated Fuels..........148 Competition Logbook ........149 Optional Parts List ...........151 Spare Parts & Equipment.........152 Wiring Diagram..........153 Technical Information...

  • Page 146: Vehicle Identification

    Vehicle Identification The frame number (2) is stamped on the right Serial Numbers side of the steering head. RIGHT SIDE The frame, VIN, and engine serial numbers are required when you register your CRF. They may also be required when ordering replacement parts.

  • Page 147: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 86.3 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,191 mm Overall width Single 8˚ inclined from Transmission 5-speed, constant mesh 32.5 in 825 mm Cylinder arrangement vertical...

  • Page 148: Torque Specifications

    Torque Specifications Nuts, Bolts, Fasteners Torque Check and tighten nuts, bolts, and fasteners before every outing. Remarks Item lbf•ft N•m kgf•m ENGINE Engine Cylinder head cover bolts Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolts...
  • Page 149 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME 11.0 Steering stem nut Fork bridge upper pinch bolts (12) (13) Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...
  • Page 150 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (40) FRAME Front brake master cylinder holder bolts (37) Brake hose bolts (29) Front brake caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 (32) Brake pedal pivot bolt (36)

  • Page 151: High Altitude Carburetor Adjustment

    However, the carburetor must be returned to standard factory specifications when lower altitude riding is desired. See your Honda dealer for high altitude modification. NOTICE Sustained operation at altitudes below 5,000 feet...

  • Page 152: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating with alcohol or an ether compound. These symptoms, try another service station or switch gasolines are collectively referred to as to another brand of gasoline. oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use Fuel system damage or performance problems oxygenated fuels to help reduce emissions.

  • Page 153: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 154 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 155: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 308.0 lbf/in (5.50 kgf/mm) Standard 48 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...

  • Page 156: Spare Parts & Equipment

    Spare Parts & Equipment There are numerous spare parts you can take to radiator hoses Pro Honda HP Trans Oil or Pro Honda GN4 or an event to help ensure you get in a full day of radiator shrouds (L & R) HP4 (without molybdenum additives only) 4- riding.

  • Page 157: Wiring Diagram

    Wiring Diagram Technical Information...
  • Page 158 Technical Information...

  • Page 159: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........156 contacting Honda and how to get an official Contacting Honda..........157 Honda service manual. Your Honda Dealer...........158 The Honda Rider’s Club (USA only) ....159 Consumer Information...

  • Page 160: Authorized Manuals

    For purchases outside U.S.A., please write to the address shown below for a quotation. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service...

  • Page 161: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address (USA only): Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 162: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so events in your area. You’ll also find that your you can utilize the full range of services dealer is a source of information (USA only) the available.

  • Page 163: The Honda Rider's Club (Usa Only)

    Safety Foundation training. Separate free training from the Specialty Vehicle Institute of America for ATV owners. • One full year of the Honda Red Rider magazine or Honda Red Rider ATV (for ATV purchasers). • Discounts from HRCA partners for experienced rider courses.

  • Page 164: Table Of Contents

    Table of Contents The following presents the contents of each SERVICING YOUR Honda ......17 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............74 The Importance of Maintenance .......18 Front Suspension Inspection......74 MOTORCYCLE SAFETY.......1 Maintenance Safety...........19 Rear Suspension Inspection......75 Important Safety Information......2...
  • Page 165 Standard Tuning Recommendation ....126 Contacting Honda..........157 Adjustments for Altitude & Temperature ...126 Your Honda Dealer..........158 Special Tuning Conditions......127 The Honda Rider’s Club (USA only) .....159 Pre-Adjustment Checks ......127 Carburetor Minor Adjustments ....128 Spark Plug Reading ........130 Chassis Adjustments........131 Rear End .............131 Fork Height/Angle ........131...

  • Page 166: Index

    ..............98 refueling ............34 fluid level .............80 rear..............112 system............34 lever, front adjustment .........79 dealer, your Honda ..........158 oxygenated ..........148 pad wear ............82 diagram, wiring ..........153 tank capacity ..........34 pedal height ..........79 drive chain............86 valve .............13 break-in guidelines ..........15...
  • Page 167 Index gap, spark plug ..........54 maintenance, rear suspension maintenance ......111 gasohol ............148 after competition ..........26 Rider’s Club Honda.........159 gasoline..............34 before & after competition......26 riding, gearing.............132 between motos & practice......26 apparel ............2 guidelines, suspension adjustment ....116 component locations ........28 basic operation ..........11 general competition........22...
  • Page 168 Index suspension, front ..............74 rear..............75 suspension adjustment, front ..............98 rear..............111 for track conditions ........115 guidelines ...........116 transmission oil ..........39 tuning tips ............119 throttle, freeplay............46 inspection .............47 tires, air pressure ...........84 flat ..............84 selection............85 tools ...............152 torque specifications ........144-146 transporting............136 troubleshooting..........139 tubes, replacing ..........84 valve, fuel............13 vehicle identification........142...
  • Page 169 Memo...
  • Page 170 Memo...
  • Page 171 Memo...

  • Page 172: Quick Reference

    Pro Honda GN4, HP4 (without molybdenum additives), or HP4M (with molybdenum additives) 4-stroke engine oil or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke engine oil, or an equivalent. Tires 80/100 –...

Table of Contents