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2009
Honda CRF450R
OWNER'S MANUAL & COMPETITION HANDBOOK

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   Summary of Contents for Honda CRF450R 2009

  • Page 1

    2009 Honda CRF450R OWNER’S MANUAL & COMPETITION HANDBOOK...

  • Page 2

    Please report any change of address or ownership keeping your CRF well maintained. Scheduled to your Honda dealer so we will be able to service is a must, of course. But it’s just as contact you concerning important product important to observe the break-in guidelines, and information.

  • 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

    Contents Chassis MOTORCYCLE SAFETY.......1 SERVICING YOUR HONDA......21 Suspension............83 Important Safety Information......2 Before You Service Your Honda Brakes..............87 Important Safety Precautions......2 The Importance of Maintenance .......22 Wheels...............91 Accessories & Modifications ......3 Maintenance Safety...........23 Tires & Tubes ............92 Safety Labels............4 Important Safety Precautions......23 Maintenance Schedule ........24...

  • Page 5

    Wiring Diagram..........154 Gearing ............134 Tire Selection for Track Conditions....135 CONSUMER INFORMATION ....155 Personal Fit Adjustments ........136 Authorized Manuals ........156 Control Positioning ........136 Contacting Honda..........157 Handlebar Position, Width & Shape...136 Your Honda Dealer..........158 The Honda Rider’s Club (USA only) .....159 Contents...

  • Page 7: Table Of Contents

    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 safety labels on your CRF.

  • Page 8: 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 9: 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 10: Safety Labels

    Safety Labels Read these labels carefully and don’t remove them. If a label comes off or becomes hard to read, contact your Honda dealer for replacement. (For Canada) Motorcycle Safety...

  • Page 11: Instruments & Controls

    Instruments & Controls Read this section carefully before you ride. It Operation Component Locations ......6 presents the location of the basic controls on your Indicator ...............7 CRF. MIL Blink Pattern ..........7 Current DTC/Freeze DTC .......7 Circuit Inspection..........8 DTC Index ............9 Instruments &...

  • Page 12: Operation Component Locations

    Operation Component Locations front brake lever clutch lever throttle grip engine stop button fast idle knob kickstarter (engine idle speed) rear brake pedal shift lever Instruments & Controls...

  • Page 13: Indicator

    If the MIL comes on at any other time, reduce speed and refer to an official Honda Service Manual available for purchase from your Honda dealer (page 156). If the MIL does not come on when it should, have your Honda dealer check it for problems.

  • Page 14: Circuit Inspection

    Indicator Circuit Inspection Always clean around the ECM and keep debris away from the connectors before disconnecting them. A faulty PGM-FI system is often related to poorly connected or corroded connections. Check the following connections. (1) MAP sensor connector (2) ECT sensor connector (3) TP sensor connector (4) IAT sensor connector (5) Injector connector...

  • Page 15: Dtc Index

    The series of 12, 19, and 69 MIL blinks cannot be checked because the engine cannot be started. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 156) for troubleshooting of the PGM-FI symptom.

  • Page 16

    Instruments & Controls...

  • Page 17: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........12 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?....13 you prepared, this section discusses how to Pre-ride Inspection........13...

  • Page 18: 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 19: 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 20

    Before Riding...

  • Page 21: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions........16 start and stop your engine as well as break-in Starting & Stopping the Engine ......17 guidelines. Preparation ............17 Starting Procedure ........17 How to Stop the Engine........18 Break-in Guidelines ...........19 Basic Operating Instructions Basic Operating Instructions...

  • Page 22: Safe Riding Precautions

    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.

  • Page 23: Starting & Stopping The Engine

    Starting & Stopping the Engine Warm Engine Starting Always follow the proper starting procedure Starting Procedure 1. Shift the transmission into neutral. described below. 2. Kick-start the engine. (Do not open the throttle.) Your CRF can be kickstarted with the Always follow the proper starting procedure transmission in gear by pulling in the clutch lever described as follow.

  • Page 24: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Lightly open the throttle (1) two or three times, and then close it. 3. Depress and hold the engine stop button (2) until the engine stops completely.

  • Page 25: 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 26

    Basic Operating Instructions...

  • Page 27

    You’ll also find Drive Chain ............94 important safety precautions, information on oils, Service Preparations Exhaust Pipe/Muffler .........97 and tips for keeping your Honda looking good. Maintenance Component Locations....32 Steering Damper..........100 Seat ..............33 Additional Maintenance Procedures ....103 An ECM system is used on this motorcycle;...

  • Page 28: 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 29: 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 30: 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 Honda...

  • Page 31

    91-93 STEERING HEAD BEARINGS WE RECOMMENDED THESE ITEMS BE SERVICED BY REFERRING TO AN OFFICIAL HONDA SERVICE MANUAL. This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every moto for dusty riding condition.

  • Page 32: General Competition Maintenance

    Use Honda Genuine Parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.

  • Page 33

    Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White...

  • Page 34

    Always use new gaskets when reassembling components. Refer to Fuel System on page 40. handgrips. Check the fuel line for deterioration, damage, or leakage. Refer to an official Honda Service Manual (page 156) for Cylinder head/Cylinder Replace the fuel line every year. installation instructions.

  • Page 35

    Remove the nuts, clean seal. Both seals should be replaced at the same time. the threads of both the nuts and bolts, apply Pro Honda Hondalock or an equivalent and tighten to the specified torque.

  • Page 36: Before & After Competition Maintenance

    (2) fork air 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 37

    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 105). Servicing Your Honda...

  • Page 38: Maintenance Component Locations

    Servicing Your Honda...

  • Page 39: Seat

    2. Install and tighten the seat mounting bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (1) seat front prong (2) seat bracket (3) seat rear prong (4) ECM bracket Servicing Your Honda...

  • Page 40: Fuel Tank

    Do not support the fuel tank by the fuel feed 5. Pull the breather tube (5) out of steering stem hose (8). nut. (12) cushion rubbers 6. Unhook the fuel tank band (6). Servicing Your Honda...

  • Page 41

    (10) with the air cleaner housing cover tabs (13) collars and shroud A bolts (11). (11) (10) (3) fuel tank (5) fuel tank band (4) collar and fuel tank bolt (9) shrouds (11) air cleaner housing cover tabs (10) shroud tabs Servicing Your Honda...

  • Page 42: Subframe

    (2) seat mounting bolts (4) seat connecting tube clamp (15). 3. Loosen the muffler clamp bolt (5). (15) (10) (14) (10) IAT sensor connector (14) socket bolt (15) air cleaner connecting tube clamp (5) muffler clamp bolt Servicing Your Honda...

  • Page 43

    (9) left subframe lower bolt (10) right subframe lower bolt (19) (20) (19) subframe (20) crankcase breather tube (2) ECM (5) air cleaner housing cover tabs (3) bracket (6) air cleaner connecting tube (cont’d) (4) shroud tabs (7) throttle body Servicing Your Honda...

  • Page 44

    0.18 ± 0.06 in (4.5 ± 1.5 mm). (23) (18) (13) (21) (17) (17) IAT sensor connector 0.18 ± 0.06 in (22) (4.5 ± 1.5 mm) (18) muffler clamp (22) tab (21) muffler (23) cutout (13) socket bolt Servicing Your Honda...

  • Page 45

    16. Tighten the muffler clamp bolt (27) to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) (26) (31) (25) muffler mounting B bolt (26) muffler mounting A bolt (28) seat (29) side covers (30) seat mounting bolts (31) bolts (27) (27) muffler clamp bolt Servicing Your Honda...

  • Page 46: Fuel System

    If pinging or spark knock persists, consult your Honda dealer. Never use stale or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank.

  • Page 47

    (2) fuel pump (3) fuel quick connect fitting 4. Remove the bolt (4), clamp and setting rubber (5). (8) shop towel (cont’d) (4) bolt (5) clamp and setting rubber Servicing Your Honda...

  • Page 48

    • Handle fuel only outdoors. • Wipe up spills immediately. Injector side: Fuel Pump side: Align (1) retainer (new) (3) locking pawls (2) connector (4) connector grooves (10) (10) (9) retainer tabs (10) locking pawls Servicing Your Honda...

  • Page 49

    (11) with the groove (16) rubber cover (12) of the stay. 7. Increase the fuel pressure (page 44). (10) (11) (12) (8) rubber (11) clamp tab (9) clamp (12) groove (10) bolt Servicing Your Honda...

  • Page 50

    3. Connect the battery harness (2) between the main and sub-harness as shown. Connect the battery harness positive (+) cable first, then connect the battery harness negative (–) cable to a 12V battery terminals. 070MZ-MEN0100 • Battery harness Servicing Your Honda...

  • Page 51: Engine Oil

    SAE 10W-30 (2) oil classification (weight) JASO T 903 standard MA suggested oil * Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil (Canada only), or an equivalent motorcycle oil * * Suggested 4-stroke engine oils are equal...

  • Page 52

    Improper disposal of drained fluids is harmful to the environment. (1) engine oil filler cap/dipstick (1) engine oil filler cap/dipstick (2) upper level mark (2) engine oil drain bolt (3) lower level mark (3) sealing washer (new) Servicing Your Honda...

  • Page 53

    (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. Servicing Your Honda...

  • Page 54: Transmission Oil

    JASO T903 transmission. standard others without friction modifiers as molybdenum additives Pro Honda GN4 4-stroke oil suggested oil* (USA & Canada), or Honda 4-stroke oil (Canada only), JASO T 903 standard or an equivalent motorcycle The JASO T 903 standard is an index for engine oil * oils for 4-stroke motorcycle engines.

  • Page 55

    (1) transmission oil filler cap (3) sealing washer (new) (2) oil check bolt 5. After inspecting the oil level or adding oil, tighten the oil check bolt with a new sealing washer to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) Servicing Your Honda...

  • Page 56: Coolant

    Coolant Recommendation Checking & Adding Coolant 1.10 US qt (1.04R) after draining 3. Install the radiator cap securely. Use Pro Honda HP Coolant or an equivalent high Refer to Safety Precautions on page 23. quality ethylene glycol antifreeze containing NOTICE corrosion protection inhibitors specifically 1.

  • Page 57

    “coolant weeping” from the bleed hole is troubleshooting of leaks). normal. If water leaks through the bleed hole, Coolant should be replaced by your Honda the mechanical seal is damaged. If oil leaks 2. Check the water hoses (1) for cracks,...

  • Page 58: 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.

  • Page 59

    Install the holder tab (5) in the hole (6) of the air cleaner element. NOTICE 8. Apply 0.1 – 0.2 oz (3 – 5 g) of Pro Honda (3) air cleaner element (5) holder tab White Lithium Grease or equivalent to the air...

  • Page 60: Crankcase Breather

    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 Servicing Your Honda...

  • Page 61: Throttle

    6. Install the fuel tank (page 35). (+) will increase freeplay. If you can’t get the freeplay within the specified range, contact your Honda dealer. Servicing Your Honda...

  • Page 62

    (1) throttle housing (2) paint mark 2. Check for smooth rotation of the throttle (3) from fully open to fully closed in all steering positions. If there is a problem, see your Honda dealer. (3) throttle Servicing Your Honda...

  • Page 63: Engine Idle Speed

    3. Shift the transmission into neutral. Start the engine. 4. Keep the motorcycle in an upright position. 5. Adjust idle speed with the fast idle knob (1). Idle speed: 1,750 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 64: Clutch System

    Make sure to adjust the clutch lever freeplay after the clutch cable is disconnected. (–) (1) lock nut (2) adjuster (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustment (page 59). Servicing Your Honda...

  • Page 65

    2. Check the clutch cable for deterioration, Inspect the clutch discs and plates (page 61). kinks, or damage. Servicing Your Honda...

  • Page 66

    Replace the needle bearing and washer if the needle bearing does 4. Remove the four clutch spring bolts and not turn smoothly. springs (6). Loosen the bolts in a crisscross pattern in two or three progressive steps. Servicing Your Honda...

  • Page 67

    9 lbf·ft (12 N·m, 1.2 kgf·m) Service Limit: 0.006 in (0.15 mm) Replace the clutch discs and plates as a set. (7) clutch pressure plate (cont’d) (8) clutch springs and bolts (2) clutch plate Servicing Your Honda...

  • Page 68

    15. Fill the crankcase with transmission oil (page 49). pedal pivot bolt (12) with urea based multi- purpose grease or equivalent. 12. Apply locking agent to the brake pedal pivot bolt threads. 13. Install the dust seals into the rear brake pedal (13). Servicing Your Honda...

  • Page 69: Spark Plug

    • Do not adjust the spark plug gap. If the gap is 11. Install the fuel tank and seat (pages 33, 35). out of specification, replace the spark plug with a new one. (3) sealing gasket (4) spark plug gap Servicing Your Honda...

  • Page 70: Valve Clearance

    (2) spark plug cap 3. Remove the cylinder head cover socket bolts (3), rubber seals (4) and cylinder head cover (5). (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover Servicing Your Honda...

  • Page 71

    360° and realign the punch mark with the index mark. (1) feeler gauge (2) valve lifters and cam lobes (2) primary drive gear bolt (4) index mark (3) punch mark (cont’d) Servicing Your Honda...

  • Page 72

    EX: 0.011 ± 0.001 in (0.28 ± 0.03 mm) (1) cam chain tensioner lifter cover bolt (2) sealing washer If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (this page) and select the correct shim for each valve. Servicing Your Honda...

  • Page 73

    (7) set rings (8) camshaft holder NOTICE Do not let the set rings fall into the crankcase. If the set rings are remained on the camshaft holder, remove the set rings carefully. (12) (12) intake valve lifters Servicing Your Honda...

  • Page 74

    • 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 75

    (6) decompressor weight If the operation is not smooth, refer to an official (4) cylinder head (10) cam sproket Honda Service Manual (page 156) for (7) camshaft (11) left camshaft bearing (9) cam chain decompressor disassembly or see your Honda dealer (cont’d)

  • Page 76

    (17). (18) camshaft holder (20) camshaft holder bolts (long) (19) “∆” mark (21) camshaft holder bolts (short) (12) timing mark NOTICE (13) camshaft holder mating surface Do not let the set rings fall into the crankcase. Servicing Your Honda...

  • Page 77

    (25). (1) O-ring (new) (25) (2) crankshaft hole cap (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (24) (24) sealing washer (new) (25) cam chain tensioner lifter cover bolt (cont’d) Servicing Your Honda...

  • Page 78

    6. Install the fuel tank and seat (pages 33, 35). (5) “UP” marks 4. Install and tighten the cylinder head cover socket bolts (6) to the specified torqie: 7 lbf·ft (10 N·m, 1.0 kgf·m) (6) cylinder head cover socket bolts Servicing Your Honda...

  • Page 79: Piston/piston Rings/piston Pin

    9. Remove the camshaft holder, camshaft, valve lifters and shims (page 66). 11. Remove the bolt (4), ground wire (5) and ignition coil/stay (6). (8) radiator hose clamp screw (9) radiator hose (4) bolt (6) ignition coil/stay (5) wire (cont’d) Servicing Your Honda...

  • Page 80

    (21) cylinder head (13) (15) (15) cylinder head hanger bolts (16) cylinder head hanger plate bolts (17) left cylinder head hanger plate (18) right cylinder head hanger plate (12) (12) insulator band screw (13) throttle body (14) insulator Servicing Your Honda...

  • Page 81

    20. Remove the cam chain guide (24) from the cylinder (25). NOTICE Do not let the cam chain fall into the crankcase. Do not pry on or strike the cylinder. (24) (25) (24) cam chain guide (25) cylinder (4) cylinder (5) piston Servicing Your Honda...

  • Page 82

    We recommend you consult an official Honda keep the piston pin clips, or other parts, from it up at a point just opposite the gap. Service Manual or your Honda dealer for correct falling into the crankcase. Service Limit measurements.

  • Page 83

    (6) side facing up. NOTICE Do not damage the piston ring by spreading the (2) spacer (5) top ring ends too far. (3) side rails (6) “R” mark Do not damage the piston during piston ring (4) piston installation. (cont’d) Servicing Your Honda...

  • Page 84

    (1) cylinder gasket (2) dowel pins 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). Servicing Your Honda...

  • Page 85

    2. Install the dowel pins (4) and a new cylinder head gasket (5). (3) cylinder (5) cam chain (4) piston rings NOTICE Do not let the dowel pins fall into the crankcase. (4) dowel pins (5) cylinder head gasket (cont’d) Servicing Your Honda...

  • Page 86

    (10) (12) (6) cylinder head (7) washers and cylinder head bolts (9) left cylinder head hanger plate (8) cylinder bolt (10) right cylinder head hanger plate (11) cylinder head hanger plate bolts (12) cylinder head hanger bolts Servicing Your Honda...

  • Page 87

    Push the ignition coil/stay against the frame. (17) rear shock absorber upper bolt (21) Push (25) (24) 0 – 0.04 in (0 – 1.0 mm) (23) (21) radiator hose clamp screw (23) ignition coil/stay (24) ground wire (25) bolt (cont’d) Servicing Your Honda...

  • Page 88

    17. Install the cylinder head cover (page 71). 18. Install the spark plug (page 63). 19. Install the exhaust pipe (page 99). 20. Install the subframe (page 35) and muffler (page 98). 21. Install the fuel tank and seat (pages 33, 35). Servicing Your Honda...

  • Page 89: Suspension

    (Adjusting two or more your CRF. If any suspension components appear clicks at a time may cause you to pass over worn or damaged, see your Honda dealer for the best adjustment.) Test ride after each further inspection. Your dealer is qualified to adjustment.

  • Page 90: Rear Suspension Inspection

    (pages 124, 129). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the muffler (page 97) and subframe The instructions found in this owner’s manual are (page 36).

  • Page 91: Recommended Fork Oil

    4. Drain the fork oil by turning the outer tube (1) upside down. (About 0.5 US oz (15.8 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.) (cont’d) Servicing Your Honda...

  • Page 92

    Slightly softer as capacity (305 cm it nears full capacity (300 cm it nears full compression. compression. Be sure the oil capacity is the same in both fork legs. (1) outer tube (2) fork damper (8) O-ring Servicing Your Honda...

  • Page 93: Brakes

    90), there is probably air in the brake system. (2) adjuster Refer to an official Honda Service Manual or see your Honda dealer to have the air bled from the 1. Loosen the lock nut (1). system. 2. To position the front brake lever farther away (–)

  • Page 94

    Refer to an official for leaks. Honda Service Manual or see your Honda dealer If the front brake lever freeplay exceeds 0.8 in for brake bleeding.

  • Page 95

    • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent. DOT 4 brake fluid or an equivalent.

  • Page 96

    0.04 in (1.0 mm) (1) brake pads (3) brake disc (2) rear brake caliper replace 0.04 in (1.0 mm) wear indicator grooves (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 97: Wheels

    Keeping the wheels true (round) and maintaining correct spoke tension is critical to safe 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for motorcycle operation. During the first few rides, damage. inspection information: spokes will loosen more rapidly due to the initial 2.

  • Page 98: Tires & Tubes

    CRF ride harshly, are more prone to damage inside the tire or the tire is slipping on the from surface hazards, and wear unevenly. rim. Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...

  • Page 99

    • 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 100: Drive Chain

    Lubricate the drive chain (page 95) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed (page 95). (2) chain guide slider (3) wear limit Servicing Your Honda...

  • Page 101

    Pro SERVICE LIMIT: 1.4 in (35 mm) to decrease slack or clockwise to increase Honda HP Chain Lube or an equivalent, or SAE slack. 80 or 90 gear oil is recommended. Replace the roller if beyond the service limit.

  • Page 102

    17 pins, from pin center to pin center. position the new chain on the sprockets. RK520TXZ/116 If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 103: Exhaust Pipe/muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (4) muffler clamp bolt (5) muffler mounting A bolt (6) muffler mounting B bolt (7) washers (8) muffler (1) seat mounting bolt (3) right side cover (2) side cover bolt Servicing Your Honda...

  • Page 104

    3. Install the muffler (4). 4. Install the muffler clamp (2) by aligning the tab (5) of the muffler clamp with the cutout (6) of the muffler. (10) (10) muffler clamp bolt (2) muffler clamp (5) tab (4) muffler (6) cutout Servicing Your Honda...

  • Page 105

    4. Tighten the exhaust pipe joint nuts to the specified torque: 15 lbf·ft (21 N·m, 2.1 kgf·m) 5. Tighten the muffler clamp bolt, muffler mounting A bolt and B bolt (page 98). 6. Installation can be done in the reverse order of removal. Servicing Your Honda...

  • Page 106: Steering Damper

    1 hour to ensure that the there is any abnormaliy. components appear worn or damaged, see your Refer to an official Honda Service Manual or steering damper has worked in (page 19). Honda dealer for further inspection. Your dealer see your Honda dealer for steering damper •...

  • Page 107

    Release the damper rod, then check that it extends to its maximum length. If the damper rod does not extend to its maximum length, refer to an official Honda Service Manual for disassembly and inspection instructions or see your Honda dealer.

  • Page 108

    (2) facing up and forward. Turn the move smoothly and quietly. damper rod and its stopper ring (3) facing Refer to an official Honda Service Manual or toward the front side. see your Honda dealer. 3. Install the collar (4) and steering damper mounting bolts (5).

  • Page 109: Additional Maintenance Procedures

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

  • Page 110

    Coolant drain bolt (5) crankshaft hole cap (9) drive sprocket bolt Water hose joint bolts (7) cylinder head bolts (11) transmission oil drain bolt (10) engine oil drain bolt (12) coolant drain bolt (13) water hose joint bolts Servicing Your Honda...

  • Page 111: Appearance Care

    Wet any heavy deposits with water first. Then spray on the Pro Honda Hondabrite and rinse with a garden hose at full pressure. Stubborn deposits may require a quick wipe with a sponge. Servicing Your Honda...

  • Page 112

    #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 113: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......108 for maximum competition performance. Front Suspension Air Pressure....108 Front Suspension Damping ......109 Initial suspension adjustments should be Fork Springs..........109 performed after a minimum of 2 hours of easy Front Suspension Disassembly ....110 break-in time.

  • Page 114: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the 4. Install and tighten the fork air pressure release Front Suspension Air Pressure rider’s weight and riding conditions by using one screw to the specified torque: 0.9 lbf·ft (1.2 N·m, 0.1 kgf·m) or more of the following methods: Air is an unstable gas which builds up pressure •...

  • Page 115: Front Suspension Damping

    Front Suspension Adjustments Both compression and rebound damping can be Front Suspension Damping Fork Springs increased by turning the adjuster clockwise. Compression Damping Adjustment The fork springs in CRF’s are about right for NOTICE This adjustment affects how quickly the fork riders weighing between 150 lbs (68 kg) and 160 compresses.

  • Page 116: Front Suspension Disassembly

    3 hours of riding. See an official Honda Keep the master cylinder upright to prevent air Service Manual or your Honda dealer for this from entering system. service. • When disassembling the fork, turn the...

  • Page 117

    Front Suspension Adjustments 7. Remove the front axle nut (9) and loosen the 11. Loosen the fork bridge lower pinch bolts (19), (14) axle pinch bolts (10) on both forks. then pull the fork legs down and out. (15) Pull the front axle shaft (11) out of the wheel hub and remove the front wheel with disc cover/collar.

  • Page 118

    Front Suspension Adjustments 14. Hold the outer tube, then remove the fork 15. Drain the fork oil from the outer tube/slider 18. Make the mechanic's stopper tool out of a thin damper (6) from the outer tube using a lock (26) and oil holes (27) of the fork damper.

  • Page 119: Damper Oil Change

    Front Suspension Adjustments 23. Remove the fork damper assembly (32) from Damper Oil Change (23) the fork assembly (33). (29) Remove the fork from the vise. Remove the fork spring (34) and spring 1. Place the fork damper (1) in a vise with a retainer (35) from the fork assembly.

  • Page 120

    Front Suspension Adjustments 3. Remove the fork cap assembly (5) from the 6. Clean the fork cap and fork damper threads 8. Pump the fork damper piston rod (6) slowly several times to bleed the air from the fork fork damper threads and then pop it out by (9).

  • Page 121

    Front Suspension Adjustments 10. Extend the fork damper piston rod (6) to 11. Place the fork damper (1) in a vise with a 13. Check the fork damper piston rod sliding maximum length, holding it, install the fork piece of wood or soft jaws to avoid damage. surface for damage.

  • Page 122: Fork Assembly

    Front Suspension Adjustments 15. Drain the extra oil from the oil holes (7) of 2. Tighten the fork center bolt lock nut (2) fully Fork Assembly the fork damper oil chamber (8). and measure the thread length (A) as shown. Standard: 0.6 –...

  • Page 123

    Front Suspension Adjustments 4. Place the lower end (axle holder) of the slider 8. Measure the length of the fork center bolt lock 10. Remove the piston base or mechanic's stopper in a vise with a piece of wood or soft jaws to nut (2) and fork center bolt (10) clearance.

  • Page 124

    Front Suspension Adjustments 13. Pour the recommended fork oil (12) into the Fork Oil Capacity: Optional Stiffer 27.41 lbf/in (4.8 N/mm) Fork Spring fork assembly (1). Standard 26.27 lbf/in (4.6 N/mm) Fork Spring No mark Recommended Oil: 6 scribe marks (factory products) KHL15-11 (KYB).

  • Page 125

    Front Suspension Adjustments 14. Install a new O-ring (13) on the fork damper 17. Tighten the fork damper (15) to the specified assembly (4). Apply the recommended fork torque using the lock nut wrench (16). oil to the O-ring. Actual: 15.

  • Page 126

    Front Suspension Adjustments 21. Clean the threads of the fork protector socket 24. Clean the threads of the brake caliper bolts (20) and axle holder thoroughly. mounting bolts (27) and brake caliper (28) (29) Apply locking agent to the bolt threads. thoroughly.

  • Page 127

    Front Suspension Adjustments 28. Install the handlebar (32), mounting rubbers, 30. With the front brake applied, pump the fork 32. Clean the threads of the disc cover socket bolt washers and handlebar lower holder nuts (33) up and down several times to seat the axle and (35) and apply locking agent to the bolt and tighten the handlebar holder nuts to the check front brake operation.

  • Page 128: Rear Suspension Adjustments

    4. After adjustment, hold the adjusting nut and Each turn of the adjuster changes spring length the damper; see your Honda dealer. The tighten the shock spring lock nut to the and spring pre-load. One turn equals: spring instructions found in this owner’s manual are...

  • Page 129: 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 Compression Damping adjuster. Compression damping may be adjusted in two To adjust to the standard position: stages with separate adjusters.

  • Page 130: Rear Suspension Race Sag

    Rear Suspension Adjustments unloaded: motorcycle on an optional workstand Ask the other helper to measure the loaded Rear Suspension Race Sag with rear suspension fully extended, no rider. with rider dimension. loaded with rider: motorcycle on ground, with REAR FENDER MOUNTING BOLT Setting the proper race sag (ride height) is very rider.

  • Page 131

    Rear Suspension Adjustments 5. Measure the loaded without rider dimension. Spring Rates A spring that is too stiff for your weight will not Do this with your CRF set at the standard race If you are lighter or heavier than the average allow the rear tire to hook up under acceleration sag.

  • Page 132: 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 133: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 108 – 126. Remember to make all adjustments in one-click or 1/12 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.

  • Page 134

    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 135

    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 pre-load). Example: –...

  • Page 136: Tuning Tips

    Tuning Tips An optional PGM-FI setting tool can change the NOTICE NOTICE ignition timing and amount of the fuel injection (page 153). Using spark plugs with an improper heat range An improperly tightened spark plug can damage Be sure to observe the PGM-FI setting by or incorrect reach can cause engine damage.

  • Page 137: Steering Damper Adjustment

    Steering Damper Adjustment The steering damper can be adjusted for riding Steering Damper Damping conditions by using following method: • Damping – Turning the steering damper adjuster adjusts how quickly the steering The steering damper adjuster (1) has 13 positions damper compress or extend.

  • Page 138: Steering Damper Adjustment Guidelines

    Steering Damper Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on this page. Symptoms and Adjustment • Always begin with the standard settings. • Turn the steering damper adjuster in one-click increments at a time. Adjusting two or more clicks at a time may cause you to pass over the best adjustment. Test ride after each adjustment.

  • Page 139: 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 tube in the clamp is not Adjusting your CRF’s wheelbase can offer subtle adjustable.

  • Page 140: Gearing

    Unless you have the required mechanical • Wet and slippery or sandy conditions: use a (before and after the change) to get an accurate know-how, tools, and an official Honda Service higher gear (less teeth) to keep engine rpm appraisal of the change. “Seat-of-the-pants”...

  • Page 141: 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 142: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.

  • Page 143: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle ......138 Storing Your Honda..........139 Preparation for Storage ........139 Removal from Storage.........139 You & the Environment ........140 Troubleshooting..........141 Tips...

  • Page 144: 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 you against the front of the truck bed or trailer rail. follow these guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 145: Storing Your Honda

    If you won’t be riding for an extended period, Removal from Storage such as during the winter, thoroughly inspect your Honda and correct any problem before storing it. That way, needed repairs won’t be 1. Uncover and clean your CRF.

  • Page 146: 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 147: Troubleshooting

    The items that require use of an CORRECT • Worn cylinder and • Brake dragging 1. Check the wheel INCORRECT official Honda Service Manual are followed by piston ring • Worn or damaged spin smoothly • Damaged cylinder head wheel bearings an asterisk (*).

  • Page 148

    Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy • Incorrect spark plug • Faulty ECM 1. Check the spark INCORRECT 1. Check the ignition INCORRECT •...

  • Page 149: Technical Information

    Specifications ...........145 Torque Specifications........146 Nuts, Bolts, Fasteners .........146 Oxygenated Fuels..........149 Competition Logbook ........150 Optional Parts List ...........152 Spare Parts & Equipment.........153 Spare Parts ..........153 General Tools ..........153 Honda Special Tools ........153 Chemical Products ........153 Other Products ..........153 Wiring Diagram..........154 Technical Information...

  • Page 150: Vehicle Identification

    Vehicle Identification The engine number (2) is stamped on the left Serial Numbers crankcase. The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts. You may record these numbers in the Quick Reference section at the rear of this manual.

  • Page 151: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 86.3 in 2,193 mm Single 6˚30’ inclined from Overall width Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement vertical...

  • Page 152: Torque Specifications

    Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Remarks Item lbf•ft N•m kgf•m Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover socket bolts LEFT SIDE Clutch cover bolts Water pump cover bolts Transmission oil check bolt Crankshaft hole cap NOTE 1 Oil filter cover bolts...

  • Page 153

    Torque Specifications FRAME LEFT SIDE Torque Remarks Item (16) lbf•ft N•m kgf•m Steering stem nut 11.0 Fork bridge upper pinch (14) bolts (13) Fork bridge lower pinch (12) bolts Handlebar upper holder bolts Handlebar lower holder nuts Front axle nut Axle pinch bolts Rear axle nut NOTE 1...

  • Page 154

    Torque Specifications FRAME LEFT SIDE Torque Remarks Item lbf•ft N•m kgf•m (40) (45) Front brake master (42) (37) cylinder holder bolts (30) (46) Brake hose oil bolts Front brake caliper mounting bolts NOTE 6 (34) Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 Brake pedal pivot bolt...

  • Page 155: 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 156: 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 157

    Competition Logbook Date Running Location/Event Comments (Suspension Settings, Steering Damper Settings, Gearing, Chassis Adjustments, Time Maintenance Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 158: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks authorized Honda dealer. Shock spring 308.3 lbf/in (54 N/mm) Standard FRAME Remarks Pink Driven sprocket < >: Drive chain links Standard 48 Teeth, Aluminum. <116> Optional...

  • Page 159: Spare Parts & Equipment

    Spare Parts screwdrivers: blade & Phillips No. 1, 2, 3 KHL15-11 (KYB) wrench, large adjustable Pro Honda DOT 4 Brake Fluid spark plugs wrenches: open end & box Pro Honda HP Chain Lube air cleaner (clean & oiled, sealed in a plastic bag)

  • Page 160: Wiring Diagram

    Wiring Diagram Technical Information...

  • Page 161: 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 162: Authorized Manuals

    For manuals.) 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 Customer Name information for various systems common to all Honda motorcycles, motor scooters and ATVs.

  • Page 163: 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 164: Your Honda Dealer

    Parts, Pro Honda products, Honda Genuine Accessories (USA only), and Honda accessories and products (Canada only). The same quality that went into your Honda can be found in Honda Genuine replacement parts. You’ll also find comparable quality in the accessories and products available from the parts department.

  • Page 165: The Honda Rider's Club (usa Only)

    The Honda Rider’s Club (USA only) You may be eligible for a Honda Rider’s Club of America (HRCA) membership with the purchase of your new Honda. You can log on to the HRCA Clubhouse website for details at www.hrca.honda.com. Consumer Information...

  • Page 166: Table Of Contents

    Table of Contents The following presents the contents of each SERVICING YOUR HONDA......21 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............83 The Importance of Maintenance .......22 Front Suspension Inspection......83 MOTORCYCLE SAFETY.......1 Maintenance Safety...........23 Rear Suspension Inspection......84 Important Safety Information......2...

  • Page 167

    Gearing ............134 Tire Selection for Track Conditions....135 CONSUMER INFORMATION ....155 Personal Fit Adjustments ........136 Authorized Manuals ........156 Control Positioning ........136 Contacting Honda..........157 Handlebar Position, Width & Shape...136 Your Honda Dealer..........158 The Honda Rider’s Club (USA only) .....159 Table of contents...

  • Page 168: Index

    ............108 flooded engine, starting........17 authorized manuals..........156 rear..............122 fork, steering damper ..........131 front suspension adjustment.......108 dealer, your Honda ..........158 front suspension inspection......83 diagram, wiring ..........154 oil recommendation........85 basic operation ..........15 drive chain............94 front brake lever adjustment ......87 before riding ............11 front suspension maintenance ......108...

  • Page 169

    Index gap, spark plug ..........63 maintenance, rear suspension maintenance......122 gasohol ............149 after competition ..........30 Rider’s Club Honda (USA only).....159 gasoline..............40 before & after competition......30 riding, gearing.............134 between motos & practice......30 apparel ............2 guidelines, component locations ........32 basic operation ..........15 steering damper ..........132 general competition........26...

  • Page 170

    Index stopping engine ..........18 storage .............139 subframe ............36 suspension, front ..............83 rear..............84 suspension adjustment, front ............108 rear..............122 for track conditions ........126 guidelines ...........127 transmission oil ..........48 tuning tips............130 throttle, freeplay............55 inspection .............56 tires, air pressure ...........92 flat ..............92 selection............93 tools ...............153 torque specifications engine ............146 frame ...........147-148...

  • Page 171

    Memo...

  • Page 172: Quick Reference

    Fuel/Tank Capacity unleaded gasoline, pump octane number of 91 or higher tank: 1.5 US gal (5.7R) Engine oil Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil. Transmission oil Pro Honda GN4 4-stroke oil or an equivalent motorcycle oil. Tires 80/100 –...

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