Honda CRF450X 2020 Owner's Manual & Competition Handbook
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Honda CRF450X 2020 Owner's Manual & Competition Handbook

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2020
2020
CRF450X

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Summary of Contents for Honda CRF450X 2020

  • Page 1 2020 2020 CRF450X...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 3 2020 Honda CRF450X OWNER’S MANUAL & COMPETITION HANDBOOK FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. It conforms to US EPA Noise Emission regulations, but does not conform to Federal Motor Vehicle Safety Standards or US EPA On Highway Exhaust Emission regulations, and operation on public streets, roads, or highways is illegal.
  • Page 4 Throughout this manual, the following protect your new Honda and are aware of your abbreviations are used to identify the respective When you own a Honda, you’re part of a rights and responsibilities.
  • Page 5 A Few Words About Safety A Few Words About Safety Your safety, and the safety of others, is very important. Operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 6: Table Of Contents

    Contents MOTORCYCLE SAFETY......1 SERVICING YOUR HONDA ......29 Chassis Important Safety Information ......2 Before You Service Your Honda Suspension ............99 Important Safety Precautions ......2 The Importance of Maintenance .....30 Brakes ............116 Loading ............. 3 Maintenance Safety .........31 Wheels ............
  • Page 7 INDEX ............188 COMPETITION.......... 139 Transporting Your Motorcycle .....158 QUICK REFERENCE Front Suspension Adjustments ..... 140 Storing Your Honda ........159 Front Suspension Air Pressure ....140 Preparation for Storage ......159 Front Suspension Damping ....... 141 Removal from Storage .......159 Fork Springs ..........141 You &...

  • Page 9: Motorcycle Safety

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

  • Page 10: Important Safety Information

    Important Safety Information Important Safety Information Do not wear loose clothing which could catch on Keep Your Honda In Safe Condition. It’s Important Safety Precautions the control levers, kickstarter, footpegs, drive important to keep your CRF properly maintained chain, or wheels.

  • Page 11: Loading

    Loading Loading Your CRF was designed as a rider-only Loading Guidelines motorcycle. It was not designed to carry a As discussed on page 2, we recommended that you passenger or cargo. A passenger or cargo could do not carry any cargo on this motorcycle. interfere with your ability to move around to However, if you decide to carry cargo, ride at maintain your balance and control of the CRF.

  • Page 12: Accessories & Modifications

    Accessories & Modifications Accessories Modifications Accessories & Modifications We strongly recommend that you use only Honda We strongly advise you not to remove any original Genuine accessories that have been specifically equipment or modify your CRF in any way that Modifying your CRF or using non-Honda designed or approved and tested for your CRF.

  • Page 13: Safety Labels

    Safety Labels Safety Labels This page shows the locations of safety labels on your CRF. Some labels warn you of potential hazards that could cause serious injury. Others provide important safety information. Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your dealer for replacement.
  • Page 14 Safety Labels Motorcycle Safety...

  • Page 15: Instruments & Controls

    Instruments & Controls Instruments & Controls Read this section carefully before you ride. It Operation Component Locations .......8 presents the location of the basic controls on your Indicators & Displays ........9 CRF. Multi-function Display ........10 Speedometer..........12 Odometer/Tripmeter A & B......12 Fuel Mileage Meter........12 Digital Clock Setting ........13 Backlight Brightness Adjustment ....13...

  • Page 16: Operation Component Locations

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

  • Page 17: Indicators & Displays

    Indicators & Displays Indicators & Displays The indicators and display on your motorcycle Lamp Check Display Check keep you informed, alert you to possible problems, The PGM-FI (Programmed Fuel Injection) When starting the engine, the multi-function and make your riding safer and more enjoyable. malfunction indicator lamp (MIL) comes on display (1) will temporarily show all the Refer to the indicators and display frequently.

  • Page 18: Multi-Function Display

    Indicators & Displays Multi-function Display SEL button Uses this button for the following purposes. • To change the 12/24 hour The multi-function display includes the following • To adjust time • To adjust display illumination functions: • To select and reset the fuel mileage meter speedometer •...
  • Page 19 Indicators & Displays Normal MODE Setting MODE Press the SEL button to select the Odometer, TRIP A, TRIP B, Current fuel mileage, Average fuel Press and hold the SEL button while odometer mileage (TRIP A/TRIP B) or Fuel consumption (TRIP A/TRIP B). or current fuel mileage is displayed, the display turn into the setting mode.

  • Page 20: Speedometer

    Indicators & Displays To Reset the Tripmeter, Average Fuel Mileage and Speedometer Fuel Mileage Meter Fuel Consumption Press the SEL button (1) to select the TRIP A (2), The speedometer shows riding speed in miles or The fuel mileage meter includes the following average fuel mileage A (3), fuel consumption A kilometers per hour.

  • Page 21: Digital Clock Setting

    Indicators & Displays 6. Press SEL button until the desired hour is Digital Clock Setting Backlight Brightness Adjustment displayed. The digital clock shows the hour and minute. To To adjust the backlight brightness, proceed as adjust the time format and clock, proceed as follows: follows: 1.

  • Page 22: Changing The Speed And Mileage Unit

    Indicators & Displays Changing the Speed and Mileage Unit Changing the Fuel Mileage Unit To adjust the Speed and Mileage Unit proceed as If the “mph” for speed and “mile” for mileage are follows: selected, the fuel mileage unit cannot be select. To adjust the Fuel Mileage Unit proceed as 1.

  • Page 23: Before Riding

    Before Riding Before Riding Before each ride, you need to make sure you and Are You Ready to Ride? ........16 your CRF are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ....17 prepared, this section discusses how to evaluate Pre-ride Inspection........17 your riding readiness, and what items you should check on your CRF.

  • Page 24: Are You Ready To Ride

    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.

  • Page 25: Is Your Motorcycle Ready To Ride

    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 Check the following before each ride: following items (page numbers are at the right): •...
  • Page 26 Before Riding...

  • Page 27: Basic Operating Instructions

    Basic Operating Instructions Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions.......20 start and stop your engine as well as break-in Side Stand ............20 guidelines. Starting & Stopping the Engine .......21 Fast Idle Knob..........21 Preparation ...........21 Starting Procedure........21 How to Stop the Engine .......22 Shifting Gears ..........23...

  • Page 28: Safe Riding Precautions

    Basic Operating Instructions Basic Operating Instructions Safe Riding Precautions Side Stand The side stand (1) is used to support your CRF Before riding your CRF for the first time, please while parked (page 25). To operate, push the side review the Important Safety Precautions stand down.

  • Page 29: Starting & Stopping The Engine

    Starting & Stopping the Engine Starting & Stopping the Engine Always follow the proper starting procedure 3. With the throttle closed. Starting Procedure described below. Pull the clutch lever all the way in, and depress the start button (2). Always follow the proper starting procedure Your CRF can be started with the transmission in described as follows.

  • Page 30: How To Stop The Engine

    Starting & Stopping the Engine Warm Engine Starting When starting the engine, the MIL (amber) will How to Stop the Engine 1. Shift the transmission into neutral. stay on for 2 seconds, then go off. If the MIL 2. Pull the clutch lever and depress the start indicator (1) does not come on or go off when it button.

  • Page 31: Shifting Gears

    Shifting Gears Shifting Gears Remember to close the throttle and pull the clutch lever in completely before shifting. NOTICE Improper shifting may damage the engine, transmission, and drive train. Learning when to shift gears comes with experience. Upshift to a higher gear or reduce throttle before engine rpm (speed) gets too high.

  • Page 32: Braking

    Braking Braking To slow or stop, apply the front brake lever and When descending a long, steep grade, use engine rear brake pedal smoothly, while downshifting to compression braking by downshifting, with match your speed. Gradually increase braking as intermittent use of both brakes. you feel the brakes slowing your speed.

  • Page 33: Parking

    Parking Parking Lower the side stand to support your CRF. Always choose a level surface to park. Basic Operating Instructions...

  • Page 34: Post-Ride Inspection

    Post-ride Inspection Post-ride Inspection When you return home after riding, thoroughly clean your CRF and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your CRF for leaks or damage. Be sure to lubricate the drive chain (page 125) to prevent rusting.

  • Page 35: Break-In Guidelines

    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 36 Basic Operating Instructions...

  • Page 37: Servicing Your Honda

    Fuel Tank ............45 Battery ............133 unnecessary. If you want to check the ignition Subframe ............49 Headlight & Taillight ........135 timing, refer to an official Honda Service Manual (page 182). Service Procedures Appearance Care ........... 136 Fluids & Filters For information about the exhaust emission and Fuel System............54...

  • Page 38: The Importance Of Maintenance

    If your CRF overturns or is involved in a crash, be sure your dealer inspects all major parts, even if you are able to make some repairs. Servicing Your Honda...

  • Page 39: 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 40: Maintenance Schedule

    Procedures for items in this schedule are provided in an official Honda Service Manual available for purchase from your dealer (page 182). Service intervals in the maintenance schedule for competition use are expressed in terms of motos and riding hours.
  • Page 41 STEERING HEAD BEARINGS *Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the official Honda Service Manual (page 182). **In the interest of safety, we recommended these items be serviced only by your dealer.
  • Page 42 All items should be checked before each off-road event. See your dealer unless you are mechanically qualified and have the proper tools. Damage from Competition use is not covered by the Distributor’s Limited Warranty on your Honda. Perform the Pre-ride Inspection (page 17) at each scheduled maintenance period.

  • Page 43: Maintenance Record

    2,400 (4,000) or 16 3,000 (5,000) or 20 3,600 (6,000) or 24 4,200 (7,000) or 28 4,800 (8,000) or 32 5,400 (9,000) or 36 6,000 (10,000) or 40 6,600 (11,000) or 44 7,200 (12,000) or 48 7,800 (13,000) or 52 Servicing Your Honda...

  • Page 44: General Competition Maintenance

    Use Honda Genuine Parts or their equivalents when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 45 Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Air Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda Foam...
  • Page 46 Refer to an official Honda Service Manual to the proper torque specification. (page 182). Use only Pro Honda HP Fork Oil, SS-19 or an equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.
  • Page 47 A small amount of coolant offers added assurance and security. Remove the nuts, weeping from the bleed hole is normal. See an official Honda clean the threads of both the nuts and bolts, apply Pro Service Manual or consult your dealer for replacing the Honda Hondalock or an equivalent and tighten to the mechanical seal or oil seal.

  • Page 48: Before & After Competition Maintenance

    • Clean the sides of the drive chain with a stiff, nylon parts-cleaning brush. Lubricate and adjust the chain as necessary. Do not perform maintenance while engine is running. Injury to your fingers or hands may result. Servicing Your Honda...

  • Page 49: After Competition Maintenance

    Take care to prevent catching your fingers between and apply a spray lubricant to all metal parts. the chain and sprocket. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 136). Servicing Your Honda...

  • Page 50: Maintenance Component Locations

    (both left and right) Servicing Your Honda...

  • Page 51: Seat

    2. Install and tighten the seat mounting bolts (5) to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat mounting bolts (2) seat (1) seat front prong (4) seat support base slots (2) slot (5) seat mounting bolts (3) seat center prongs Servicing Your Honda...

  • Page 52: Side Cover

    The right and left side covers can be installed in the same manner. The right and left side covers can be removed in the same manner. (1) side cover (2) bolts 2. Install the seat (page 43). (1) side cover (2) bolts Servicing Your Honda...

  • Page 53: Fuel Tank

    (4) shroud (5) side cover (11) (13) (10) fuel tank bolts (11) washers 7. Lift the fuel tank (12) out of the frame to the (12) fuel tank left of the frame. (13) fuel feed hose (cont’d) Servicing Your Honda...
  • Page 54 (16) from the fuel pump (17). (17) (20) (21) (12) fuel tank (21) fuel joint (18) fuel quick connect fitting (22) connector housing (20) slide retainer (12) (16) (12) fuel tank (16) fuel quick connect fitting cover (17) fuel pump Servicing Your Honda...
  • Page 55 • Do not use gloves or a shop towel while It may cause the fuel tank cracking. installing the quick connect fitting. (3) slide retainer (cont’d) Servicing Your Honda...
  • Page 56 (22) shroud A bolt (19) side cover (7) harness band clip (9) fuel pump connector (8) stopper cable guide 12. Install the seat (page 43). (12) breather tube (14) tube guide (13) tube joint (15) top shelter Servicing Your Honda...

  • Page 57: Subframe

    (10) (12) (20) from the subframe (13). (13) (19) (11) (20) (13) (19) (20) (4) seat support base (12) hooks (10) bolts (13) subframe (13) subframe (11) collars (19) cable bands (20) negative (-) battery cable (cont’d) Servicing Your Honda...
  • Page 58 (25) (28) flange nut (30) canister air tube (29) harness guide (31) boss (13) sub frame (23) taillight connectors (35) upper mounting bolts (24) fuse box assembly mounting bolt/washer (36) lower mounting bolts (25) regulator/rectifier mounting bolts Servicing Your Honda...
  • Page 59 A (7), collars (8) and air cleaner housing mounting bolts B (9). (3) subframe (4) main frame (5) upper mounting bolts (6) lower mounting bolts (7) air cleaner housing mounting bolts A (8) collars (9) air cleaner housing mounting bolts B (cont’d) Servicing Your Honda...
  • Page 60 (18) fuse box assembly mounting bolt/washer 7 lbf·ft (10 N·m, 1.0 kgf·m) (19) regulator/rectifier mounting bolts (15) (22) (23) (22) (22) negative (-) battery cable (23) cable bands (14) (14) rear fender (15) rear fender mounting bolt Servicing Your Honda...
  • Page 61 (27) connecting tube band screw (36) (33) (31) (32) (35) (34) (28) (28) seat support base (34) collars A (31) bank angle sensor assembly (35) ECM stay (32) washers (36) bolts (33) collars B Servicing Your Honda...

  • Page 62: Fuel System

    “pinging” or “spark knock” (a louder rapping rotary joint to correct. noise) which, if severe, can lead to engine damage. • If you replace the fuel cap, use a Honda (Light pinging experienced while operating under Genuine replacement part or equivalent.
  • Page 63 4. Place a shop towel (4) over the fuel quick 4. Install the fuel quick connect fitting cover. connect fitting. 5. Install the fuel tank (page 47). (5) slide retainer (6) fuel joint (7) connector housing (4) shop towel (cont’d) Servicing Your Honda...
  • Page 64 • Do not use gloves or a shop towel while installing the quick connect fitting. (6) fuel joint (9) disconnected connector (10) plastic bags (3) slide retainer Servicing Your Honda...
  • Page 65 6. Install the fuel tank (page 47). 7. Increase the fuel pressure (page 62). (1) fuel pump mounting nuts (2) fuel pump mounting cap nut (3) stopper cable guide (4) washer (5) collars (6) conical spring washers (7) fuel pump plate (cont’d) Servicing Your Honda...
  • Page 66 (15) tabs terminals and fuel pump wire terminals. (20) (13) (19) fuel pump stopper (20) damper rubber (11) (12) (11) fuel pump wire terminals (12) fuel reserve sensor wire terminals (13) fuel pump base Servicing Your Honda...
  • Page 67 (6) while routing the fuel pump yellow (7) and green (8) wires through the holder grooves (9) as shown. (24) (10) damper rubber (new) (11) fuel pump stopper (21) fuel pump assembly (24) fuel pump filter (cont’d) Servicing Your Honda...
  • Page 68 Push the wire terminals until (23) dust seal (new) (26) dust seal lug (24) tabs (27) index mark they stop as shown. (31) fuel pump unit Be careful not to damage the wires. (32) fuel tank Servicing Your Honda...
  • Page 69 (35) fuel pump unit lug (36) Fuel tank side (33) (42) (33) fuel pump plate (36) conical spring washers (37) collars (38) washer (39) stopper cable guide (40) fuel pump mounting nuts (41) fuel pump mounting cap nut (42) identification mark Servicing Your Honda...
  • Page 70 The engine will start up by increasing the fuel pressure. If the engine does not start, check all connector connections and/or refer to an official Honda Service Manual (page 182) for troubleshooting of the PGM-FI symptom. Servicing Your Honda...

  • Page 71: Engine Oil

    JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke Oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil Suggested 4-stroke engine oils are equal performance to SJ oils that are not labeled as energy conserving or resource conserving on the circular API service label.
  • Page 72 3. Support the CRF in an upright position on a level surface. 4. Remove the engine oil fill cap/dipstick (4) from the left crankcase cover. (1) engine oil fill cap/dipstick (2) upper level mark (3) lower level mark Servicing Your Honda...
  • Page 73 (15) on the filter body, near the seal. the drain bolt threads, seating surface and a Use a new Honda Genuine oil filter or a filter new O-ring, then install the O-ring on the drain of equal quality specified for your model.

  • Page 74: Coolant

    Checking & Adding Coolant Coolant Recommendation Refer to Important Safety Precautions on page 31. Use Pro Honda HP Coolant or an equivalent high 1. With the engine at normal operating quality ethylene glycol antifreeze containing temperature, check the coolant level in the...
  • Page 75 3. Check the radiator mount for looseness. A small amount of coolant weeping from the 4. Make sure the siphon hose (2) is connected and bleed hole is normal. See an official Honda not clogged. (6) fins Service Manual or consult your dealer for 5.
  • Page 76 If the radiator cap is not installed properly, it will cause excessive coolant loss and may result in (3) reserve tank cap (4) UPPER level line overheating and engine damage. 5. Install the reserve tank cap. (1) radiator cap (2) filler neck Servicing Your Honda...

  • Page 77: Air Cleaner

    (5) air cleaner assembly Your CRF’s air cleaner has very specific the retainer (2) and remove the air cleaner lid performance requirements. Use a new Honda (3). 4. Remove the air cleaner element (6) from the air Genuine air cleaner specified for your model or an cleaner holder (7) by releasing the hole (8) of air cleaner of equal quality.
  • Page 78 8. Assemble the air cleaner element and holder. Install the holder tab in the hole of the air cleaner element. 9. Apply 0.05 – 0.19 oz (1.5 – 5.5 g) of Pro Honda Foam Air Filter Sealer or equivalent to the air (4) air cleaner retaining bolt cleaner element contact area of the air cleaner housing.

  • Page 79: Crankcase Breather

    2. Reinstall the crankcase breather tube plugs. If the breather tube overflows, the air filter may become contaminated with engine oil causing poor engine performance. (1) crankcase breather tube plugs (2) crankcase breather tubes Servicing Your Honda...

  • Page 80: Throttle

    If you can’t get the freeplay within the specified Tighten the lock nut securely. range, contact your dealer. Make the adjustment with the lower adjuster. Servicing Your Honda...
  • Page 81 6. Install the dust cover reverse order. If the throttle operation is not smooth, replace the (3) throttle throttle cable. Be sure the throttle returns freely from fully open to fully closed automatically, in all steering positions. Servicing Your Honda...

  • Page 82: Engine Idle Speed

    2. Connect a tachometer to the engine. 3. Shift the transmission into neutral. Start the engine. 4. Adjust idle speed with the fast idle knob (1). Idle speed: 1,800 ± 100 rpm (–) (1) fast idle knob (+) increase (–) decrease Servicing Your Honda...

  • Page 83: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. Inspect the clutch discs and plates (page 78). Servicing Your Honda...
  • Page 84 5. Connect the clutch cable end to the lever. with commercially available cable lubricant. 6. Install the clutch cable and turn the adjuster. 2. Check the clutch cable for deterioration, kinks, or damage. Servicing Your Honda...
  • Page 85 If the operation is not smooth, refer to an official (1) bolts (2) over cover Honda Service Manual (page 182) for bearing (5) clutch spring bolts and springs disassembly or see your dealer. 3. Remove the six clutch cover bolts (3) and (6) clutch pressure plate clutch cover (4).
  • Page 86 B disc A (1) spring seat (6) lugs (2) judder spring (7) groove (3) clutch disc A (8) clutch disc C (4) clutch plates (9) tabs (5) clutch discs B (10) shallow slots (2) clutch plates Servicing Your Honda...
  • Page 87 (18). (17) (18) (14) (13) (13) clutch pressure plate (14) clutch spring bolts and springs (17) over cover (18) bolts 11. Pour recommended engine oil to the specified level (page 64). Servicing Your Honda...

  • Page 88: Spark Plug

    11. Install the fuel tank and seat (pages 43, 47). Press and hold the engine stop button and disengage the clutch by pulling the lever in. Servicing Your Honda...

  • Page 89: Valve Clearance

    The valve clearance will change as engine temperature rises. (3) cylinder head cover socket bolts (4) cylinder head cover rubber seals (5) cylinder head cover (6) spark plug hole packing (1) breather tube (2) spark plug cap Servicing Your Honda...
  • Page 90 (2) primary drive gear bolt (3) “T” mark (4) index mark (5) decompressor weight 6. Check the timing marks (6) on the cam sprocket aligns with the camshaft holder mating surface (7) of the cylinder head. (8) rocker arms Servicing Your Honda...
  • Page 91 Camshaft Removal (this page) and select the correct shim for each (1) feeler gauge (3) camshaft cam lobes (2) intake rocker arms valve. Valve Clearance: IN: 0.004 ± 0.001 in (0.11 ± 0.03 mm) (cont’d) Servicing Your Honda...
  • Page 92 (8) set rings (9) left camshaft bearing (10) camshaft (11) cam chain 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. Servicing Your Honda...
  • Page 93 Do not let the shims fall into the crankcase. If a calculated dimension is out of specifications, Do not clean the intake rocker arms using a have your motorcycle inspected by your dealer. commercially available compound cleaner. 1.80 mm 1.825 mm 1.85 mm 1.875 mm Servicing Your Honda...
  • Page 94 (5) decompressor weight (10) If the operation is not smooth, refer to an official Honda Service Manual (page 182) for decompressor disassembly or see your dealer. (1) rocker arms (3) valve spring retainers (2) shims...
  • Page 95 (12) (17) camshaft holder (19) camshaft holder bolts (long) (20) camshaft holder bolts (short) (18) “ ” mark (11) timing mark Do not let the set rings fall into the crankcase. (12) camshaft holder mating surface (cont’d) Servicing Your Honda...
  • Page 96 (27). (1) O-ring (new) (2) crankshaft hole cap (27) 3. Install the right crankcase over cover (page 79). (26) (26) sealing washer (new) (27) cam chain tensioner lifter cover bolt Servicing Your Honda...
  • Page 97 7 lbf·ft (10 N·m, 1.0 kgf·m) (1) spark plug hole packing (2) cylinder head cover (3) cylinder head cover packing (4) cylinder head cover groove (2) cylinder head cover (7) cylinder head cover socket bolts Servicing Your Honda...

  • Page 98: Piston/Piston Rings/Piston Pin

    Do not hang the throttle body and support it with a ignition coil bolts (4). suitable strap. (10) (1) ignition coil A connector (3) ignition coil (2) ignition coil B connector (4) ignition coil bolts (7) insulator band screw (8) throttle body (9) insulator (10) vacuum tube Servicing Your Honda...
  • Page 99 (15) cylinder head hanger plate bolts (16) left cylinder head hanger plate (17) right cylinder head hanger plate (28) (27) cam chain guide (28) cylinder (22) (22) cylinder bolt (23) cylinder head bolts and washers (24) cylinder head Servicing Your Honda...
  • Page 100 Do not let the cam chain fall into the crankcase. Do not let the dowel pins fall into the crankcase. (1) shop towels (3) piston pin (2) piston pin clips (4) piston (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 101 Piston Ring Installation rotate freely, without sticking. Space the ring end gaps 120 degrees apart between top ring, We recommend you consult an official Honda 1. Remove the carbon deposits from the piston second ring and spacer. Space each ring end Service Manual or your dealer for correct Service head and piston ring grooves.
  • Page 102 Be careful not to damage or shock the piston pin. Use new pin clips. Never reuse old clips. Do not let the clips fall into the crankcase. Do not align the piston pin clip end gap with the piston cutout (8). Servicing Your Honda...
  • Page 103 Do not let the cam chain fall into the crankcase. 0.2 – 0.4 in (5 – 10 mm) 0.2 – 0.4 in (2) dowel pins (3) cylinder gasket (new) (5 – 10 mm) (1) cylinder mating surface (4) cylinder bore (6) cam chain (5) piston rings Servicing Your Honda...
  • Page 104 (6) cylinder head (11) oil catch tank 37 lbf·ft (50 N·m, 5.1 kgf·m) (9) oil catch tank stay (12) mounting bolt (10) collar NOTICE Do not let the washers fall into the crankcase. Servicing Your Honda...
  • Page 105 (26) cylinder head (27) bolts (13) left cylinder head hanger plate (14) right cylinder head hanger plate (15) cylinder head hanger plate bolts (22) (21) (16) cylinder head hanger bolts (21) right radiator lower mounting bolt (22) washer (cont’d) Servicing Your Honda...
  • Page 106 – abnormal engine noise – secondary air leaks – exhaust gas leaks – coolant leaks (29) – oil leaks (31) (28) ignition coil (29) ignition coil bolts (30) ignition coil A connector (31) ignition coil B connector Servicing Your Honda...

  • Page 107: Suspension

    • Replace the damper oil every 6 races or 22.5 hours of running. See page 109 for damper fork oil replacement. • Use Pro Honda HP Fork Oil, SS-19 or an equivalent which contains special additives to assure maximum performance of your CRF’s...
  • Page 108 (3) handlebar lower holder nuts, washers and mounting (1) compression damping adjuster rubbers (2) rebound damping adjuster (4) handlebar 3. Loosen the fork bridge upper pinch bolts (5). 4. Loosen the fork bolts assembly (6), but do not remove them yet. Servicing Your Honda...
  • Page 109 • Do not operate the brake lever after the front wheel is removed. To do so will cause difficulty in fitting the brake disc between the brake pads. (9) disc cover (10) disc cover socket bolts (cont’d) Servicing Your Honda...
  • Page 110 The outer tube (1) can drop on the axle holder (4) suggested oil Pro Honda HP Fork Oil, SS-19 and damage the fork dust seal (5). To avoid damage, hold both the outer tube and slider when removing the fork damper.
  • Page 111 07WMA-KZ30100 • Lock nut wrench Improper disposal of drained oil is harmful to the Recommended Oil: environment. Pro Honda HP Fork Oil, SS-19 Recommended Standard Amount: Amount of fork oil left in the fork (within damper and spring) unit: cm 12.2 US oz (361 cm...
  • Page 112 5. Align the groove (7) in the outer tube with the top surface of the upper fork bridge (8). Align (2) fork damper assembly (3) lock nut wrench (4) fork bolt assembly (7) groove (8) upper fork bridge Servicing Your Honda...
  • Page 113 (14) with the lower ends of the stay A (15) and stay B (16), and assemble them. Install and tighten them to the left fork protector using the brake hose/speed sensor wire clamp bolts (17). (cont’d) Servicing Your Honda...
  • Page 114 15. Route the speed sensor wire (24) properly and holder nuts install the speed sensor (25) to the left fork bracket. Install and tighten the speed sensor mounting bolt (26). Install the speed sensor wire guide plate (27) and tighten the guide plate screw (28). Servicing Your Honda...
  • Page 115 (3) is fully exposed and install the piston base (4) or mechanic’s stopper tool between the axle holder (1) and fork center bolt lock nut. • Piston base 07958-2500001 (35) (34) compression damping adjuster (35) rebound damping adjuster (cont’d) Servicing Your Honda...
  • Page 116 (9) and back-up ring/seat stopper (10) from the fork assembly. (6) fork damper assembly (7) fork assembly (8) fork spring (9) spring seat collar (10) back-up ring/seat stopper (1) axle holder (3) fork center bolt lock nut (2) fork center bolt (4) piston base Servicing Your Honda...
  • Page 117 Pour the recommended fork oil into the fork damper assembly (4). Recommended Oil: Pro Honda HP Fork Oil, SS-19 (2) fork damper piston rod (3) fork bolt assembly Recommended Amount: 8.4 US oz (248 cm (1) fork center bolt lock nut 5.
  • Page 118 (1) fork center bolt lock nut (2) fork damper piston rod (7) (8) 13. Check the fork damper piston rod sliding (3) fork bolt assembly (7) O-rings (new) (6) fork bolt bushings (8) piston ring (new) surface and threads for damage. Servicing Your Honda...
  • Page 119 (2) fork damper piston rod (4) fork damper assembly Pour the drained oil into a suitable container and dispose of it in an approved manner (page 160). NOTICE Improper disposal of drained fluids is harmful to the environment. (cont’d) Servicing Your Honda...
  • Page 120 (4) fork damper assembly (9) oil hole Amount of fork oil left in the fork (11) air pressure release screws (without damper and spring) unit: cm (12) O-rings (new) minute °C/°F 30/86 20/68 10/50 0/32 Servicing Your Honda...
  • Page 121 Measure the thread length again. Standard: 0.43 – 0.47 in (11 – 12 mm) 07958-2500001 • Piston base (3) slider bushing (6) spring seat collar (4) seat stopper (7) fork damper (5) back-up ring (cont’d) Servicing Your Honda...
  • Page 122 Align 51 lbf·ft (69 N·m, 7.0 kgf·m) (17) (16) (15) (14) (17) (14) push rod (16) O-ring (new) (15) piston rod (17) fork center bolt (17) fork center bolt Servicing Your Honda...

  • Page 123: Rear Suspension Inspection

    There • If you have a problem finding an acceptable adjustment, return to the standard position and should be no movement. If there is, have the begin again. bearings replaced by your dealer. Servicing Your Honda...

  • Page 124: Brakes

    (page 119), there is probably air in the brake system. Refer to an official Honda Service Manual or see your dealer to have the air bled from the system. (2) lock nut...
  • Page 125 If the travel for the rear brake pedal feels leaks. excessive, there is probably air in the brake system and it must be bled. Refer to an official Honda If the pulling distance for the front brake lever Service Manual or see your dealer for brake feels excessive, there is probably air in the brake bleeding.
  • Page 126 Do not mix different types of fluid, they may not be compatible. not be compatible. •The recommended brake fluid is Honda DOT 4 •The recommended brake fluid is Honda DOT 4 Brake Fluid or an equivalent. Brake Fluid or an equivalent.
  • Page 127 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 128: Wheels

    Wheel Rims & Spokes Axles & Wheel Bearings Keeping the wheels true (round) and maintaining 1. Inspect the wheel rims (1) and spokes (2) for See an official Honda Service Manual for correct spoke tension are critical to safe damage. inspection information: motorcycle operation.

  • Page 129: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...
  • Page 130 • 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 131: Side Stand

    2. Check the side stand assembly for freedom of movement. (1) side stand spring If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with molybdenum grease. Servicing Your Honda...

  • Page 132: Drive Chain

    Lubricate the drive chain (page 125) 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 125). (3) chain guide slider (4) wear limit Servicing Your Honda...
  • Page 133 Drive Chain Drive Chain Rollers Adjustment Lubrication Lubricate the drive chain with Pro Honda HP Check the upper drive chain roller (1) and lower 1. Loosen the rear axle nut (1). Chain Lube or an equivalent chain lubricant or drive chain roller (2) for wear or damage.
  • Page 134 1. Clean the side surfaces of the chain with a dry Teeth Teeth cloth. Use a high flash point solvent such as kerosene or Pro Honda chain cleaner – not gasoline. Do not brush the rubber O-rings. Brushing will damage them. Use of a solvent REPLACE REPLACE may also damage the O-rings.

  • Page 135: Exhaust Pipe/Muffler

    5. Install the washer (7), muffler mounting B bolt (8) and A bolt (9). (2) muffler mounting A bolt (3) muffler mounting B bolt (4) washer (5) muffler (7) washer (8) muffler mounting B bolt (9) muffler mounting A bolt (cont’d) Servicing Your Honda...
  • Page 136 5. Tighten the muffler clamp bolt, muffler mounting A bolt and B bolt (page 127). (8) muffler mounting B bolt (9) muffler mounting A bolt 8. Install the right side cover (page 44). 9. Install the seat (page 43). Servicing Your Honda...

  • Page 137: Spark Arrester

    (1) muffler (2) tail cap cover bolts (6) spark arrester mounting bolts (3) washers (7) spark arrester (4) tail cap cover (8) gasket (1) muffler (6) spark arrester mounting bolts (7) spark arrester (8) gasket (new) (cont’d) Servicing Your Honda...
  • Page 138 8. Install the tail cap cover (4), washers (3) and tighten the tail cap cover bolts (2) to the specified torque: 3.9 lbf·ft (5.25 N·m, 0.5 kgf·m) (1) muffler (2) tail cap cover bolts (3) washers (4) tail cap cover Servicing Your Honda...

  • Page 139: 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 dealer.
  • Page 140 (5) oil filter cover bolts (3) water pump cover bolts (6) cylinder head bolts (4) crankshaft hole cap (8) drive sprocket bolt (6) cylinder head bolts (9) engine oil drain bolt (7) exhaust pipe joint nuts (10) coolant drain bolt Servicing Your Honda...

  • Page 141: Battery

    The lithium-ion (li-ion) battery contains a fuse inside. If the fuse blows, the battery needs replacement. The voltage may read above 12V even with a blown battery fuse when the battery is unmounted (page 165). (cont’d) Servicing Your Honda...
  • Page 142 Using a battery charger that is not recommended can cause permanent damage to your battery. (1) battery (3) negative (–) terminal bolt (2) positive (+) terminal bolt (4) battery band 4. Install the seat (page 43). Servicing Your Honda...

  • Page 143: Headlight & Taillight

    (6) “TOP” mark (2) front visor (4) dust cover (3) headlight connector 6. To install the headlight, reverse the removal 3. To pull the headlight bulb out, push and turn procedure. the headlight bulb socket (5) counterclockwise. Servicing Your Honda...

  • Page 144: Appearance Care

    Muffler stain remover (Scotch Brite Hand Pad penetrate the dust seals of the suspension pivot #7447-maroon) is for removing stains on the non- You may use Pro Honda Hondabrite, a multi- points and steering head bearings-driving dirt coated aluminum frame only.
  • Page 145 After washing, rinse with plenty of water and dry with a clean cloth. Servicing Your Honda...
  • Page 146 Servicing Your Honda...

  • Page 147: Adjustments For Competition

    Adjustments for Competition Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments ......140 for maximum competition performance. Front Suspension Air Pressure....140 Front Suspension Damping......141 Initial suspension adjustments should be Fork Springs..........141 performed after a minimum of 2 hours of easy Fork Oil Adjustment ........142 break-in time.

  • Page 148: Front Suspension Adjustments

    Front Suspension Adjustments Front Suspension Adjustments The front suspension can be adjusted for the rider's 4. Install and tighten the pressure release screw to Front Suspension Air Pressure weight and riding conditions by using one or more the specified torque: of the following methods: 1.0 lbf·ft (1.3 N·m, 0.1 kgf·m) Air is an unstable gas which builds up pressure as it...

  • Page 149: Front Suspension Damping

    Front Suspension Adjustments NOTICE Front Suspension Damping Fork Springs Always start with full hard when adjusting Compression Damping Adjustment The fork springs in CRF’s are about right for riders damping. This adjustment affects how quickly the fork weighing between 170 lb (77 kg) and 200 lb (91 Do not turn the adjuster screw more than the given compresses.

  • Page 150: Fork Oil Adjustment

    Front Suspension Adjustments Optional Soft 27.4 Ibf/in (4.8 N/mm) Fork Spring Fork Oil Adjustment 1. Remove the front suspension (page 100). No mark 2. Disassemble the fork outer tube (page 102). 3. Disassemble the fork damper (page 107). Fork Oil Capacity: Standard 28.6 Ibf/in (5.0 N/mm) Fork Spring 12.1 US oz Standard oil capacity...

  • Page 151: Rear Suspension Adjustments

    9.07 in (230.5 mm) Each complete turn of the adjusting nut Honda Service Manual. changes the spring length by 0.06 in (1.5 mm). If your CRF is new, put enough part-throttle break- After adjustment, hold the adjusting nut and...

  • Page 152: Rear Suspension Damping

    Rear Suspension Adjustments To decrease spring pre-load High Speed Damping: Rear Suspension Damping Loosen the shock spring lock nut with the optional The high speed damping can be adjusted by pin spanners (3) and turn the adjusting nut to turning the hexagonal portion of the compression Compression Damping increase the spring length (4).
  • Page 153 Rear Suspension Adjustments Low Speed Damping: The low speed damping can be adjusted by turning the center screw of the compression damping adjuster. The low speed compression damping adjuster has 13 clicks or more. Turning the adjuster one full turn clockwise advances the adjuster 4 clicks.

  • Page 154: 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 SEAT MOUNTING BOLT Setting the proper race sag (ride height) is very rider.
  • Page 155 Rear Suspension Adjustments Spring Rates A spring that is too stiff for your weight will not If you are lighter or heavier than the average rider allow the rear tire to hook up under acceleration and cannot set the proper ride height without and will pass more bumps on to you.

  • Page 156: Suspension Adjustments For Track Conditions

    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 157: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 140 – 148. 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...
  • Page 158 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 159 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 160: Tuning Tips

    Tuning Tips Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range or An improperly tightened spark plug can damage Refer to Spark Plug on page 80. incorrect reach can cause engine damage. the engine. If a plug is too loose, the piston may be damaged.

  • Page 161: Chassis Adjustments

    Chassis Adjustments Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle Wheelbase concern. Subtle changes in overall handling may also be noted. The position of the fork in the clamp is not Adjusting your CRF’s wheelbase can offer subtle adjustable.

  • Page 162: Tire Selection For Track Conditions

    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”...

  • Page 163: 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 164 Adjustments for Competition...

  • Page 165: Tips

    Here’s helpful advice on how to transport and store your CRF, as well as three troubleshooting flow charts. Transporting Your Motorcycle...... 158 Storing Your Honda ........159 Preparation for Storage......159 Removal from Storage ......159 You & the Environment ........ 160 Troubleshooting..........

  • Page 166: Transporting Your Motorcycle

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

  • Page 167: Storing Your Honda

    Storing Your Honda Storing Your Honda If you won’t be riding for an extended period, such 4. Remove the radiator cap and coolant drain bolt 11. Stuff a rag into the muffler outlet. Then tie a as during the winter, thoroughly inspect your CRF...

  • Page 168: You & The Environment

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

  • Page 169: Troubleshooting

    • Excessive carbon build- parenthesis. The items that require use of an the engine at high up in combustion CORRECT official Honda Service Manual are followed by an speed chamber • Ignition timing too asterisk (*). advance (Faulty ECM)* 8.
  • Page 170 Troubleshooting POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH SPEED CHECK POSSIBLE CAUSES CHECK POSSIBLE CAUSES Steering is heavy 1. Check the spark INCORRECT • Incorrect spark plug heat 1. Check the ignition INCORRECT • Faulty ECM* •...

  • Page 171: Taking Care Of The Unexpected

    Taking Care of the Unexpected Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........164 solve problems. If Your Battery Is Low (or Dead) ....165 If You Crash...........166 Taking Care of the Unexpected...

  • Page 172: If A Fuse Blows

    If a Fuse Blows If a Fuse Blows All of the electrical circuits on your CRF have a fuse to protect them from damage caused by excess current flow (short circuit or overload). If something electrical on your CRF stops working, the first thing you should check for is a blown fuse (1).

  • Page 173: If Your Battery Is Low (Or Dead)

    If Your Battery Is Low (or Dead) If Your Battery Is Low (or Dead) If an overvoltage, overcurrent, or short circuit is applied, the battery fuse may blow. Do not jump-start as this can damage your CRF’s electrical system and battery. Bump starting is not recommended.

  • Page 174: If You Crash

    If You Crash If You Crash Personal safety is your first priority after a crash. If you or anyone else has been injured, take time to assess the severity of the injuries and whether it is safe to continue riding. If you cannot ride safely, send someone for help.

  • Page 175: Technical Information

    Nuts, Bolts, Fasteners ........170 Emission Control Systems ......173 Oxygenated Fuels...........175 Competition Logbook ........176 Optional Parts List .........178 Spare Parts & Equipment.......179 Spare Parts ..........179 General Tools..........179 Honda Special Tools........179 Chemical Products ........179 Other Products ...........179 Wiring Diagram ..........180 Technical Information...

  • Page 176: Vehicle Identification

    Vehicle Identification Vehicle Identification The engine number (2) is stamped on the right 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 177: Specifications

    Specifications Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 86.3 in 2,191 mm Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall width 32.2 in 818 mm Cylinder Single 10° inclined Transmission 6-speed, constant mesh arrangement...

  • Page 178: Torque Specifications

    Torque Specifications Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Item Remarks Check and tighten nuts, bolts, and fasteners before every outing. lbf·ft N·m kgf·m LEFT SIDE Cylinder head cover socket bolts Clutch cover bolts Water pump cover bolts Crankshaft hole cap NOTE 1 Oil filter cover bolts Cylinder head bolts...
  • Page 179 Torque Specifications LEFT SIDE FRAME (16) (21) (13) Torque Item Remarks lbf·ft N·m kgf·m Steering stem nut 11.0 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar lower holder nuts NOTE 1 Front axle nut Axle pinch bolts Rear axle nut 13.1...
  • Page 180 Torque Specifications FRAME LEFT SIDE (42) (49) (48) (54) (32) (52) (39) Torque Item Remarks lbf·ft N·m kgf·m Brake hose oil bolts (36) Front brake caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 Rear brake disc nuts NOTE 1 Brake pedal pivot bolt Spokes...

  • Page 181: Emission Control Systems

    Compliance with the terms of the Distributor’s repair or replacement, of any device or element of engine’s emission performance unless your CRF Warranties for Honda Motorcycle Emission design incorporated into any new vehicle for the will be used exclusively in competition. If you...
  • Page 182 Tampering with the fuel tank, fuel hoses, or fuel riding. Honda Motor Co., Ltd. utilizes various systems to vapor charge hoses to reduce or defeat the reduce carbon monoxide, oxides of nitrogen and...

  • Page 183: Oxygenated Fuels

    Oxygenated Fuels Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating symptoms, with alcohol or an ether compound. These try another service station or switch to another gasolines are collectively referred to as oxygenated brand of gasoline. fuels.

  • Page 184: Competition Logbook

    Competition Logbook Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of racing events. The best way to organize the many worked best at a particular location.
  • Page 185 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Chassis Adjustments, Maintenance Performed, etc.) Time (Make several photocopies of this page for future use) Technical Information...

  • Page 186: Optional Parts List

    Optional Parts List Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized dealer. Fork spring 28.6 Ibf/in (5.0 N/mm) Shock spring 296.9 lbf/in (52 N/mm) Standard Standard 2 scribe marks or No mark FRAME Remarks (Medium)

  • Page 187: Spare Parts & Equipment

    Pro Honda GN4 4-stroke Oil following: screwdrivers: blade & Phillips No. 1, 2, 3 (Engine Oil) wrench, large adjustable Pro Honda HP Fork Oil, SS-19 Spare Parts wrenches: open end & box Honda DOT 4 Brake Fluid wrenches: hex (Allen)

  • Page 188: Wiring Diagram

    Wiring Diagram Wiring Diagram STARTER FRONT WHEEL BANK ANGLE SWITCH SPEED SENSOR SENSOR FUSE A 10A FI PURGE B 10A ILLUMI CONTROL SOLENOID C 10A HEADLIGHT VALVE FUEL D 10A METER PUMP (Bl) E 10A STARTER COMBINATION METER (Bl) (Bl) FUEL THERMISTOR FUSE BOX...

  • Page 189: Consumer Information

    Consumer Information Consumer Information This section contains information about contacting Authorized Manuals........182 Honda and how to get an official Honda Service Warranty Coverage ........183 Manual. Warranty Service ...........184 Contacting Honda ..........185 Your Honda Dealer ........186 Consumer Information...

  • Page 190: Authorized Manuals

    The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles, scooters and ATV.

  • Page 191: Warranty Coverage

    • Noise Control Warranty Your new Honda is covered by certain warranties as described in the Honda Motorcycle Warranties Booklet that was provided to you by your Honda dealer. Please read this booklet and be aware of the responsibilities, restrictions, and exclusions which apply.

  • Page 192: Warranty Service

    (such as brakes, tires etc.). If you believe you have a problem with your Honda, call the service department of your Honda dealer. Make an appointment for an inspection and diagnosis. Remember, as the owner of the motorcycle, you will be asked to authorize that inspection.

  • Page 193: Contacting Honda

    If you wish to comment on your experiences with your CRF or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O. Box 2200, Torrance CA 90509- 2200, Mailstop: 100-4C-7B, Telephone: (866) 784-1870.

  • Page 194: Your Honda Dealer

    Honda. The parts department offers Honda Genuine Parts, Pro Honda products, Honda Genuine Accessories. 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 195 Consumer Information...

  • Page 196: Index

    ............ 141 ..........57 front fuel pump ............144 ............64 rear ........186 ........ 22 dealer, your Honda flooded engine, starting ....13 ......... 180 backlight brightness adjustment diagram, wiring fork, ..........19 ........13 ....140...
  • Page 197 .......... 2 importance protective apparel ........131 handlebar inspection ............. 31 safety ........135 headlight & taillight ..........32 schedule Honda, ......... 182 manual, service ........182 service manual ..........4 modifications ........... 186 ......143 your dealer rear suspension adjustment ........
  • Page 198 Index safety, throttle, ........5 ..........72 a few words about freeplay ....... 2 ..........73 important information inspection ........ 2 ..........73 important precautions lubrication ........... 31 maintenance tires, ........20 ........... 121 riding precautions air pressure ......... 32 ............
  • Page 199 Memo...
  • Page 200 Memo...
  • Page 201 91 or higher tank: 2.01 US gal (7.6 ℓ) Engine Oil/Capacity Pro Honda GN4 4-stroke Oil or an equivalent motorcycle oil. 1.22 US qt (1.15 ℓ) after draining and filter change 1.16 US qt (1.10 ℓ) after draining...
  • Page 202 Quick Reference These symbols are used in Operating Controls and Basic Operating Instructions sections: SYMBOL COMPONENT SEE PAGE fast idle knob 8, 21 START button 8, 21 Quick Reference...
  • Page 203 California Proposition 65 Warning Warning: Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your hands frequently when servicing your vehicle.
  • Page 204 31MKE710 XXXX.2019.XX.L 00X31-MKE-7100 PRINTED IN XXXX...

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