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Related Manuals for Honda CRF450RL 2021
Summary of Contents for Honda CRF450RL 2021
- Page 1 2021 OFF-ROAD HANDBOOK CRF450RL...
- Page 2 If you plan to do any service on your CRF beyond the standard maintenance procedures in this manual, you will find an official Honda Service Manual a valuable reference. If you have any questions, or if you ever need a special service or repairs, remember that your Honda dealer knows your CRF best and is dedicated to your complete satisfaction.
- Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
- Page 4 Example: • Molykote® G-n Paste manufactured by Dow Corning U.S.A. • Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Moly Paste 500 manufactured by Sumico Lubricant, Japan Use silicone grease.
- Page 5 dummyhead dummyhead CONTENTS Frame/ Body Panels Maintenance Setting Information INDEX...
- Page 6 dummyhead dummyhead MEMO...
- Page 7 dummytext 1. Frame/ Body Panels SERVICE INFORMATION ·····························1-2 ENGINE GUARD ··········································· 1-7 TROUBLESHOOTING···································1-2 LEFT CRANKCASE OVER COVER ············· 1-7 BODY PANEL LOCATIONS ·························1-2 RIGHT CRANKCASE OVER COVER··········· 1-9 SEAT······························································1-3 MUD GUARD ················································ 1-9 SEAT SUPPORT BASE ································1-3 TOP SHELTER············································ 1-10 RADIATOR SHROUD····································1-4 REAR FENDER A ·······································...
- Page 8 dummyhead dummyhead Frame/ Body Panels Frame/ Body Panels SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels, rear frame and exhaust system. • Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. •...
- Page 9 Frame/ Body Panels SEAT SUPPORT BASE SEAT HANGING/INSTALLATION REMOVAL/INSTALLATION Remove the side covers 1-4. Remove the seat mounting bolts [1]. Remove the seat [2] by pulling it backward. Remove the bolts [1] and flange collars [2]. Installation is in the reverse order of removal. Disconnect the relay box 8P connector [3].
- Page 10 Frame/ Body Panels SIDE COVER RADIATOR SHROUD REMOVAL/INSTALLATION REMOVAL/INSTALLATION Remove the radiator shroud 1-4. Remove the seat 1-3. Remove the side cover bolts [1]. Remove the following: Remove the side cover [2] by releasing the tab [3] from – Radiator shroud bolt A [1] the slot [4] of the seat support base [5].
- Page 11 dummyhead dummyhead Frame/ Body Panels FRONT VISOR REMOVAL/INSTALLATION Remove the bolt/washers [1]. Release the front visor bosses [2] from the front fender. Release the turn signal relay [3] from the stay [4]. Release the wire clip [5] from the front visor [6]. Remove the wire clamp [7].
- Page 12 Frame/ Body Panels FRONT BRAKE DISC COVER FRONT FENDER REMOVAL/INSTALLATION REMOVAL/INSTALLATION Remove the front brake disc cover bolts [1] and front Remove the following: brake disc cover [2]. – Front fender bolt/washers [1] Installation is in the reverse order of removal. –...
- Page 13 Frame/ Body Panels ENGINE GUARD Release the radiator grill tabs [1] from the radiator [2]. Remove the radiator grill [3]. REMOVAL/INSTALLATION Installation is in the reverse order of removal. Remove the engine guard bolt (long)/washer [1], engine TORQUE: guard bolts (short)/washers [2] and engine guard [3]. Horn bolt: Installation is in the reverse order of removal.
- Page 14 Install and tighten the gearshift pedal pinch bolt [2] to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Check the dimension between the gearshift pedal end and "HONDA" logo as shown. Move the gearshift pedal and check the shift mechanism for smooth operation. Install the engine guard 1-7.
- Page 15 Frame/ Body Panels Remove the bolt A [1], bolts B [2], bolts C [3], and right RIGHT CRANKCASE OVER crankcase over cover [4]. COVER Installation is in the reverse order of removal. REMOVAL/INSTALLATION TORQUE: Brake pedal pivot bolt: Remove the lock pin [1] from brake pedal pivot bolt [2]. 36 N·m (3.7 kgf·m, 27 lbf·ft) •...
- Page 16 Frame/ Body Panels TOP SHELTER REAR FENDER A REMOVAL/INSTALLATION REMOVAL/INSTALLATION Remove the radiator shrouds 1-4. Remove the side covers 1-4. Remove the fuel tank cap [1]. Remove the rear fender screws [1] and rear fender A [2]. Release the fuel tank breather hose A [2] from the guide Installation is in the reverse order of removal.
- Page 17 Frame/ Body Panels REAR FENDER B LICENSE LIGHT COVER REMOVAL/INSTALLATION REMOVAL/INSTALLATION Remove the following: Remove the license light cover bolts [1] and trim clip [2]. – Rear fender A 1-10 Release the license light wire grommet [3] from the – License light cover 1-11 license light cover [4].
- Page 18 Frame/ Body Panels Disconnect the following connectors: Disconnect the license light 2P connector [1]. – Brake/taillight 3P [1] Remove the license light screw/washers [2] and nuts [3]. – License light 2P [2] Release the wire clip [4]. – Left turn signal light 2P (Orange) [3] remove the license light unit [5].
- Page 19 Frame/ Body Panels Remove the wire bands [1]. REAR FRAME Remove the bolts A [2], bolts B [3], and flange collars [4]. REMOVAL/INSTALLATION Remove the seat 1-3. Remove the battery terminal bolt [1]. Disconnect the battery negative (–) cable [2]. Release the terminal cover [3].
- Page 20 Frame/ Body Panels Disconnect the IAT sensor 2P (Black) connector [1]. Installation is in the reverse order of removal. Remove the nut [2] and release the wire stay [3]. TORQUE: Rear frame upper bolt: Release the open air hose [4] from the guide [5]. 32 N·m (3.3 kgf·m, 24 lbf·ft) Rear frame lower bolt: 49 N·m (5.0 kgf·m, 36 lbf·ft)
- Page 21 Frame/ Body Panels MUFFLER REMOVAL/INSTALLATION MUFFLER Remove the right side cover 1-4. MUFFLER COVER REMOVAL/ Loosen the exhaust pipe band bolt [1]. INSTALLATION Remove the muffler front mounting bolt [2], rear mounting Remove the right side cover 1-4. bolt [3], washer [4], and muffler [5]. Remove the gasket [6].
- Page 22 dummyhead dummyhead Frame/ Body Panels MUFFLER DISASSEMBLY/ASSEMBLY Remove the following: – Muffler cover 1-15 – Muffler 1-15 Assembly is in the reverse order of disassembly. SPARK ARRESTER HEAT GUARD SPARK ARRESTER BOLTS 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) SOCKET BOLTS WASHERS TAIL CAP BOLTS 5.25 N·m...
- Page 23 Frame/ Body Panels INSTALLATION EXHAUST PIPE Install a new gasket [1] to the exhaust port of the cylinder REMOVAL head. Remove the muffler 1-15. Install the exhaust pipe [2]. Remove the exhaust pipe joint nuts [1], exhaust pipe [2] Install the exhaust pipe joint nuts [3] but do not tighten and gasket [3].
- Page 24 Frame/ Body Panels CYLINDER HEAD EXHAUST PIPE Remove the sidestand switch bolt [1] and sidestand switch [2]. STUD BOLT REPLACEMENT Remove the exhaust pipe 1-17. Thread two nuts onto the stud and tighten them together, then use a wrench on them to turn the stud bolt out. Install new stud bolts into the cylinder head as shown.
- Page 25 Frame/ Body Panels INSTALLATION Install the sidestand switch [1] and new sidestand switch bolt [2]. Apply molybdenum disulfide grease to the sidestand Tighten the sidestand switch bolt to the specified torque. sliding surface 2-6. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the sidestand [1].
- Page 26 MEMO...
- Page 27 dummytext 2. Maintenance SERVICE INFORMATION ·····························2-2 DRIVE CHAIN SLIDER ······························· 2-50 MAINTENANCE SCHEDULE - OFF-ROAD DRIVE CHAIN ROLLER······························ 2-51 USE································································2-8 DRIVE/DRIVEN SPROCKET ······················ 2-51 MAINTENANCE SCHEDULE - ON-ROAD USE································································2-9 BRAKE FLUID ············································ 2-52 FUEL LINE···················································2-10 BRAKE PADS WEAR ································· 2-53 FUEL FILTER ··············································2-13 BRAKE SYSTEM ········································...
- Page 28 dummyhead dummyhead Maintenance Maintenance SERVICE INFORMATION GENERAL • Place the motorcycle on a level surface before starting any work. • The CRF450RL is equipped with a titanium fuel tank. Since the fuel tank has not been painted, it might become discolored with mud and dust.
- Page 29 dummyhead dummyhead Maintenance TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6) (Includes SH flange bolt)
- Page 30 dummyhead dummyhead Maintenance MAINTENANCE THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Fuel pump mounting nut 11 (1.1, 8) For tightening sequence; 2-13 Fuel pump mounting cap nut 11 (1.1, 8) Throttle cable adjuster lock nut 4.0 (0.4, 3.0) Air cleaner element set bolt 2.4 (0.2, 1.8) Left cylinder head hanger bolt...
- Page 31 NLGI #2) Brake lever pivot bolt sliding surface Brake pedal pivot bolt sliding surface Drive chain Steering head bearing rolling (Honda HP Chain area (Upper/lower), Lube or an equivalent) Steering head dust seal lips (Urea based multi-purpose extreme pressure grease...
- Page 32 Engine oil Fuel pump unit O-ring Fuel pump assembly O-ring (at joint) Fuel pump base O-ring (at joint) Honda DOT 4 brake fluid Brake caliper piston seal lips Brake caliper piston sliding surface Front master cylinder inner surface Apply 0.04 – 0.16 g (0.001 –...
- Page 33 Maintenance MATERIAL LOCATION REMARKS Pro Honda HP Fork Oil Fork bolt O-rings SS-19 Fork plug bolt O-ring Fork bolt assembly bushings Fork bolt assembly piston rings Fork bolt assembly O-rings Fork spring seat collar bushing Fork damper O-rings...
- Page 34 dummyhead dummyhead Maintenance MAINTENANCE SCHEDULE - OFF-ROAD USE Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. FREQUENCY Each race or about Every 4 race or Every 8 race or...
- Page 35 dummyhead dummyhead Maintenance MAINTENANCE SCHEDULE - ON-ROAD USE Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools.
- Page 36 Maintenance Check the rubber cushions [1] for proper installation as FUEL LINE shown. Installation is in the reverse order of removal. Gasoline is highly flammable and explosive. • Do not ride the motorcycle in state which the rubber You can be burned or seriously injured when cushions have been removed.
- Page 37 Maintenance INSPECTION QUICK CONNECT FITTING REMOVAL Lift the fuel tank 2-10. • Before disconnecting the fuel feed hose, relieve Check the quick connect fitting cover [1] for proper pressure from the system as follows. installation. Remove the quick connect fitting cover. 1.
- Page 38 Maintenance QUICK CONNECT FITTING 8. Unlock the slide retainer [1] of the quick connect fitting [2] by completely pulling it up. INSTALLATION 1. Fuel pump unit side: Install the rubber cover [1]. 2. Install the wire clip [2]. 9. Release the quick connect fittings from the fuel joints while holding the connector housing.
- Page 39 Maintenance 5. Lock the slide retainer [1] by pushing it until you hear 8. Connect the fuel pump 5P connector [1]. the "CLICK". Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector housing [2].
- Page 40 Maintenance Remove the fuel pump unit [1]. Check the terminal for loose connection or damage. Disconnect the following wires from the fuel pump base terminals. • Be careful not to damage the fuel pump unit. • Wipe up any spilled fuel immediately. –...
- Page 41 Maintenance Remove the fuel pump stopper [1] and damper rubber [2] Install the fuel filter [1] onto the fuel pump assembly [2] by from the fuel unit holder assembly [3]. aligning its hook with the joint boss securely. Align Remove the fuel pump assembly [1] with the fuel filter [2] Apply engine oil to a new O-ring.
- Page 42 Maintenance Apply engine oil to a new O-ring. Install a new dust seal [1] onto the fuel pump unit [2]. Install the O-ring [1] to the fuel pump base [2]. Install the fuel pump unit holder assembly [3] into the fuel •...
- Page 43 Maintenance Install the fuel pump unit [1] into the fuel tank [2] with the Install the following: fuel joint [3] facing forward. – Conical spring washers [1] – Collars [2] – Washers [3] • Be careful not to damage the fuel pump unit. –...
- Page 44 Maintenance Major adjustment is made with the throttle body side THROTTLE OPERATION adjuster [1]. Check for smooth operation of the throttle and that it Adjust the freeplay by loosening the throttle cable returns automatically to the fully closed position from any adjuster lock nut [2] and turning the throttle body side open position and from any steering position.
- Page 45 Wash in non- flammable solvent Apply 55 cm (1.9 US oz) of Pro Honda Foam Air Filter Oil or equivalent oil to the inside of the element. Place the air cleaner element [1] into a plastic bag [2] and spread the oil evenly by hand.
- Page 46 Maintenance Assemble the air cleaner element [1] and element holder Install the air cleaner lid [1]. [2]. Hook the air cleaner lid spring [2]. Hook the element hole [3] onto the holder tab [4]. Install the bolts [3] and tighten them securely. CRANKCASE BREATHER Apply 1.5 –...
- Page 47 Maintenance Remove the drain plug [1], then drain any fluid or dirt into Release the rear brake light switch 2P connector [1] from a proper container from the breather catch tank drain the connector clip (without disconnecting connector). hose [2]. Disconnect the following: Reinstall the drain plug.
- Page 48 Maintenance Disconnect the crankcase breather hose A [1]. Open the terminal cap [1]. Remove the terminal nut [2] and release the starter motor cable [3]. Remove the bolt [4] and release the battery negative (–) cable [5]. [2]/[3] Disconnect the crankcase breather hose B [1]. Contact [4]/[5] Remove the following:...
- Page 49 Maintenance SPARK PLUG Remove the bolt/washer [1]. Remove the following: REMOVAL/INSTALLATION – Crankcase breather catch tank [2] Remove the fuel tank 2-10. – Grommet A [3] – Flange collar [4] Disconnect the spark plug cap [1]. – Stay [5] – Grommet B [6] •...
- Page 50 Maintenance INSPECTION Check the gap between the center and side electrodes with a wire type feeler gauge [1]. Check the following and replace the spark plug if necessary. • To prevent damaging the iridium center electrode, use – Insulator [1] for damage a wire type feeler gauge to check the spark plug gap.
- Page 51 Maintenance Remove the spark plug hole seal ring [1] and cylinder Turn the crankshaft clockwise to align the "T" mark [1] on head cover packing [2]. the primary drive gear with the index mark [2] on the right crankcase cover. Check the decompressor weight [3] position.
- Page 52 Maintenance Check the valve clearance for the intake valves using a Check the valve clearance for the exhaust valves using a feeler gauge [1]. feeler gauge [1]. Insert a feeler gauge between the intake rocker arms [2] Insert a feeler gauge between the exhaust rocker arms and camshaft cam lobes [3].
- Page 53 Maintenance Apply engine oil to a new O-ring. Install the cylinder head cover [1]. Install the O-ring [1] to the crankshaft hole cap [2]. Make sure that the spark plug hole seal ring [2] is Apply grease to the crankshaft hole cap threads. installed properly.
- Page 54 Maintenance ADJUSTMENT Remove the cam chain tensioner lifter bolt [1] and sealing washer [2]. Remove the following: Insert the special tool into the cam chain tensioner lifter – Crankshaft hole cap 2-24 hole. – Cylinder head cover 2-24 TOOL: – Spark plug 2-23 Cam chain tensioner holder [3] 070MG-0010100 or Turn the crankshaft clockwise to align the "T"...
- Page 55 Maintenance Remove the camshaft holder bolts (long) [1], camshaft Lift the exhaust rocker arms [1] up. holder bolts (short) [2], camshaft holder [3] and set rings Remove the exhaust side shims [2]. [4]. Lift the intake rocker arms [3] up. Remove the intake side shims [4].
- Page 56 • Inspect the valve and valve seat if carbon deposits result in a calculated dimension of over 3.000 mm. Refer to an official Honda Service Manual or see your dealer to inspect the valve and valve seat. Apply molybdenum oil solution to the camshaft cam lobes.
- Page 57 Maintenance Make sure that the index line on the cam sprocket aligns Install the set rings [1] into the camshaft bearing grooves. with the camshaft holder mating surface. • Be careful not to drop the set rings into the crankcase. Install the camshaft holder [2] by aligning their grooves with the set rings and dowel pins with the camshaft holder base holes [3].
- Page 58 [3] through the oil filler hole. RECOMMENDED ENGINE OIL: [2]/[3] Pro Honda GN4 4-stroke oil (U.S.A. & Canada) or equivalent motorcycle oil API service classification: SG or higher JASO T903 standard: MA Viscosity: SAE 10W-30 •...
- Page 59 Maintenance ENGINE OIL CHANGE ENGINE OIL FILLING Apply engine oil to the engine oil drain bolt threads and a ENGINE OIL DRAINING new O-ring whole surface. Remove the engine guard 1-7. Install a new O-ring [1] to the oil drain bolt [2]. Start the engine and let it idle for 3 minutes.
- Page 60 Install the spring into a new oil filter. disassemble and inspect the decompressor system. Install the oil filter with the "OUT-SIDE" mark [7] facing Refer to an official Honda Service Manual or see your out. dealer to disassemble and inspect the decompressor system.
- Page 61 IDLE SPEED: 1,800 ± 100 rpm If engine idle speed can not adjust, check the fast idle knob. Refer to an official Honda Service Manual or see your dealer to check the fast idle knob. Disconnect the ignition coil primary wire connector (Green terminal side) [1] and primary wire connector (Black terminal side) [2].
- Page 62 Maintenance Remove the right radiator mounting bolts [1] and washers Remove the right cylinder head hanger bolt [1]. [2]. Remove the right cylinder head hanger plate bolts [2] and right cylinder head hanger plate [3]. [1]/[2] [1]/[2] Remove the bolt (long) [1] and bolt (short) [2]. Remove the thermostat housing [3] (with the PAIR check Loosen the insulator band screw [1] and pull the throttle valve cover, radiator hoses, and ECT sensor connector).
- Page 63 Maintenance Remove the cylinder head 6 mm bolt [1]. Remove the cam chain guide [1]. Loosen the cylinder head bolts [2] in a crisscross pattern Inspect the cam chain guide for excessive wear or in two or three steps. damage, replace it if necessary. Remove the cylinder head bolts and washers [3].
- Page 64 Maintenance Place a clean shop towel over the crankcase. Remove the piston pin clips [1] with pliers. • Prevent the piston pin clip from dropping into the crankcase. Press the piston pin [2] out of the piston [3] and remove the piston.
- Page 65 dummyhead dummyhead Maintenance INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. – Cylinder – Piston – Piston rings – Piston pin – Connecting rod small end Measure each part and calculate the clearance according to CYLINDER/PISTON SPECIFICATIONS. Replace any part if it is out of service limit.
- Page 66 Maintenance ASSEMBLY Place a shop towel over the cylinder opening. Clean the piston ring grooves thoroughly. • Prevent dust or dirt from entering the crankcase. Apply molybdenum oil solution to the connecting rod • Be careful not to damage the piston when cleaning the small end [1] inner surface.
- Page 67 Maintenance Apply engine oil to the piston [1] outer surface and piston Clean any gasket material from the cylinder mating pin hole. surfaces of the crankcase. Apply molybdenum oil solution to the piston pin [2] outer Apply liquid sealant (TB1141G manufactured surface.
- Page 68 Maintenance Apply engine oil to the cylinder bore, piston outer surface, Install the dowel pins [1] and a new gasket [2]. and piston rings. Route the cam chain [1] and cam chain tensioner [2] • Be careful not to drop the cam chain [3] and dowel through the cylinder [3] and install the cylinder while pins into the crankcase.
- Page 69 Maintenance Install the throttle body by aligning its tab with the Install a new O-ring (large) [1] and O-ring (small) [2] to insulator groove. the thermostat housing [3]. Align the insulator band hole with the insulator tab. Install the thermostat housing to the cylinder head. Tighten the insulator band screw [1] to the specified range as shown.
- Page 70 The level should be between the "UPPER" [1] and terminal side) [5]. "LOWER" [2] level lines. If necessary, add the recommended coolant. RECOMMENDED ANTIFREEZE: Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors STANDARD COOLANT CONCENTRATION: 1:1 mixture with distilled water Install the cooling fan assembly [1] and fan motor shroud bolts [2].
- Page 71 Maintenance COOLANT REPLACEMENT Fill the system with the recommended coolant through the filler opening up to filler neck [1]. Remove the engine guard 1-7. Fill the radiator reserve tank to the upper level line 2- Support the motorcycle in an upright position on a level surface.
- Page 72 – Bypass hose [6] mechanical seal. – Siphon hose [7] Refer to an official Honda Service Manual or see your Check the tightness of all the hose band screws. dealer to replace the mechanical seal. If oil leaks through the bleed hole, replace the oil seal.
- Page 73 Maintenance SLACK ADJUSTMENT DRIVE CHAIN If the chain needs adjustment, loosen the rear axle nut [1] and drive chain adjuster lock nuts [2], then turn the adjusting bolts [3]. Amputation hazard. Never inspect or adjust Check that the adjusting block index marks [4] are in the the drive chain while the engine is running.
- Page 74 Lubricate the drive chain with drive chain lubricant [2]. STANDARD LINKS: 116 LINKS RECOMMENDED LUBRICANT: REPLACEMENT CHAIN Honda HP Chain Lube or an equivalent RK: 520EXU-120LJFZ Do not use a chain lubricant NOT designed specifically for use with O-ring chains to lubricate the drive chain.
- Page 75 Maintenance Insert a new master link [1] with new O-rings [2] from the Make sure that the pins are staked properly by inside of the drive chain, and install a new master link measuring the diameter of the staked area using a slide plate [3] and O-rings with the identification mark facing caliper [1].
- Page 76 Replace the drive chain guide slider if it is worn to the bottom of the wear limit indicator [3]. SERVICE LIMITS: Refer to an official Honda Service Manual or see your Upper side: 10 mm (0.4 in) dealer to replace the drive chain guide slider.
- Page 77 Maintenance DRIVE/DRIVEN SPROCKET DRIVE CHAIN ROLLER WEAR INSPECTION INSPECTION Inspect the drive and driven sprocket teeth for wear or Inspect the drive chain rollers for excessive wear or damage, replace them if necessary. binding. Never use a new drive chain on worn sprockets. Measure the upper drive chain roller (Green) [1] and Both chain and sprockets must be in good condition or lower drive chain roller (Black) [2] O.D.
- Page 78 Support the motorcycle upright on a level surface and RECOMMENDED BRAKE FLUID: check the brake fluid level. Honda DOT 4 brake fluid If the level is near the lower level line [1], check the brake Install the diaphragm, set plate, and reservoir cover.
- Page 79 [5]. Replace the brake pad if it is wear to the service limit. RECOMMENDED BRAKE FLUID: Refer to an official Honda Service Manual or see your dealer to replace the brake pads. Honda DOT 4 brake fluid Install the diaphragm, set plate, and reservoir cover.
- Page 80 Refer to an official Honda Service Manual or see your To position the front brake lever closer to the throttle grip, dealer to have the air bled from the system.
- Page 81 Front: 0.3 mm (0.01 in) Rear: 0.3 mm (0.01 in) Refer to an official Honda Service Manual or see your dealer to replace the brake disc. BRAKE LIGHT SWITCH Adjust the rear brake light switch so that the brake light comes on just prior to the brake actually being engaged.
- Page 82 Maintenance CLUTCH INSPECTION Minor adjustments can be made at the cable end adjuster [1]. Drain the engine oil 2-32. Turning the cable end adjuster in direction (+) will Remove the right crankcase over cover 1-9. increase freeplay and turning it in direction (–) will Loosen the clutch cover bolt (long) [1] and clutch cover decrease freeplay.
- Page 83 Maintenance Remove the following: – Clutch lifter piece [1] – Clutch lifter rod [2] Remove the following: – Clutch disc C [1] – Six clutch plates [2] – Five clutch discs B [3] – Clutch disc A [4] – Judder spring [5] –...
- Page 84 dummyhead dummyhead Maintenance Inspect the following parts for scratch, damage, abnormal wear and deformation. – Clutch springs – Clutch pressure plate – Clutch lifter peace – Clutch lifter rod – Clutch discs/plates – Judder spring – Spring seat Replace if necessary. Measure each part according to CLUTCH SPECIFICATIONS.
- Page 85 Maintenance Install the spring seat [1] and judder spring [2] as shown. Insert the clutch lifter rod [1] into the mainshaft. Coat the clutch disc lining surfaces with clean engine oil. • Check the lifter rod installation by turning the clutch Install the clutch disc A (larger I.D.
- Page 86 Maintenance CONTROL CABLES Apply engine oil to a new O-ring [1] and install it onto the clutch cover [2]. THROTTLE CABLE LUBRICATION Install the clutch cover with the O-ring onto the right crankcase cover. Remove the dust cover [1]. Remove the bolts [2] and separate the throttle housing [3].
- Page 87 Maintenance Apply specified grease to the throttle cable ends and Align the throttle housings [1] end with the paint mark on throttle pipe flange groove 2-6. the handlebar. Put the throttle pipe on the handlebar. Tighten the upper bolt [2] first, then the lower bolt [3]. Connect the throttle cables [1] to the throttle pipe [2].
- Page 88 – Move the sidestand full down. – The engine should stop as the sidestand is lowered. If there is a problem with the system, check the sidestand switch. Refer to an official Honda Service Manual or see your dealer to check the sidestand switch. 2-62...
- Page 89 Replace the bearings if excessively worn. Check the cushion linkage and replace any damaged needle bearings. HANDLEBAR REMOVAL Refer to an official Honda Service Manual or see your dealer to replace the bearings. Remove the handlebar pad [1]. Install the engine guard 1-7.
- Page 90 Maintenance Loosen the handlebar lower holder nuts [1]. Release the wire clip [1]. Remove the rear handlebar upper holder bolts [2], front Remove the bolt [2] and wheel speed sensor [3]. handlebar upper holder bolts [3], handlebar upper Remove the front brake caliper mounting bolts [4] and holders [4] and handlebar [5].
- Page 91 Maintenance Remove the fork protector mounting bolts [1] and fork 2. Pull the fork leg [1] up and align the fork outer tube protectors [2]. lower index line with the top bridge upper surface. Position the fork leg in the direction as shown. Left side shown: Left side shown: Align...
- Page 92 Maintenance Loosen the fork bottom bridge pinch bolts [1] and pull the Hold the outer tube [1] and remove the fork damper [2] fork leg [2] down and out. using the special tool from the outer tube. TOOL: Lock nut wrench, 50 mm [3] 07WMA-KZ30100 Slide the outer tube down onto the axle holder.
- Page 93 Maintenance FORK SPRING REPLACEMENT If only change the fork tube oil, perform the following procedure: If you plan to only fork oil exchange, skip the following Place the fork [1] upside down and drain the fork oil from procedures. the fork inside. Set the axle holder of the slide pipe in a vise with a piece By standing time and temperature, the amount of of wood or soft jaws to avoid damage.
- Page 94 Maintenance Push the outer tube until the fork center bolt lock nut [1] is Remove the push rod [1] from the piston rod [2]. fully exposed and install the special tool between the axle Remove the special tool [3] while pushing the outer tube. holder [2] and fork center bolt lock nut.
- Page 95 Maintenance Remove the following from the fork assembly [1]: Place the fork [1] upside down and drain the fork oil from the inside of the outer tube and slide pipe. – Fork damper assembly [2] – Fork spring [3] By standing time and temperature, the amount of remaining oil in the fork is varied.
- Page 96 Maintenance Install the seat stopper [1], back-up ring [2] and spring Hold the outer tube [1] and temporarily tighten the fork seat collar [3] to the fork damper in the shown direction. damper [2] using the special tool. TOOL: • Install the back-up ring with its black coated side Lock nut wrench, 50 mm [3] 07WMA-KZ30100 facing the seat stopper.
- Page 97 Maintenance Recheck the length between the fork center bolt lock nut Tighten the fork center bolt lock nut [1] by hand until it [1] end and piston rod [2] end is in the standard value. touches the fork center bolt [2]. Tighten the lock nut to the specified torque.
- Page 98 Fill the recommended fork oil into the fork tube [1]. tube. RECOMMENDED FORK OIL: Compare the length at assembly and disassembly; they Pro Honda HP Fork Oil SS-19 should be same length. STANDARD FORK OIL CAPACITY: STANDARD: 311 ± 2 mm (12.2 ± 0.1 in) 355 cm (12.0 US oz, 12.5 Imp oz)
- Page 99 Maintenance Pull up the outer tube [1] slowly and temporarily tighten 2. Tighten the fork bottom bridge pinch bolts [1]. the fork damper [2] using the special tool. TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) TOOL: Lock nut wrench, 50 mm [3] 07WMA-KZ30100 Install the front fork 2-73.
- Page 100 Maintenance 4. When the fork bolt is removed, tighten the fork bolt [1] Tighten the fork bottom bridge pinch bolts [1] to the to the specified torque. specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) Over-tightening the fork bottom bridge pinch bolts can deform the outer tube.
- Page 101 Maintenance HANDLEBAR INSTALLATION Clamp the brake hose and wheel speed sensor wire with the brake hose clamps [1]. Temporarily install the bushings [1], handlebar lower Install the clamps and brake hose clamp bolts [2]. holders [2], washers [3] and handlebar lower holder nuts Tighten the brake hose clamp bolts to the specified [4].
- Page 102 Maintenance FRONT WHEEL INSTALLATION Tighten the left axle holder bolts [1] to the specified torque. Clean the clamping surface of the front axle and axle TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) holders. Install the left side collar [1] and right side collar [2] onto With the front brake applied, pump the front suspension the front wheel.
- Page 103 Maintenance Check the fork center bolt lock nut [1] is installed on the Remove the piston ring [1] and O-rings [2] from the fork fork damper piston rod [2] properly. bolt assembly. • If the lock nut was removed, the piston rod will fall into •...
- Page 104 Apply recommended fork oil to the slider bushings [1], RECOMMENDED FORK OIL: new O-rings [2] and a new piston ring [3]. Pro Honda HP Fork Oil SS-19 Install new O-rings and piston ring to the fork bolt FILLING OIL CAPACITY: assembly [4].
- Page 105 Maintenance After assembling the fork damper, perform following Drain the extra fork oil from the oil holes [1] of the fork procedure to breed the air from the fork damper: damper [2]. Make sure that the compression damping adjuster is in the full soft position.
- Page 106 Maintenance If your cannot use compressed air, perform the following FORK DAMPER OPERATION INSPECTION procedure: After air bleeding, perform following procedure to inspect Remove the fork plug bolt [1] from the fork bolt assembly. the fork damper operation: Hold the fork damper upside down for 10 minutes for Make sure that the compression damping adjuster is in drain the oil from the fork damper spring chamber.
- Page 107 Maintenance Wipe off any oil completely from the fork damper [1]. Apply recommended fork oil to the slider bushing [1]. Compress the piston rod [2] 200 – 250 mm (7.9 – 9.8 in) Install the seat stopper [2], back-up ring [3] and spring from fully extended and hold the fork damper in an seat collar [4] to the fork damper in the shown direction.
- Page 108 Check that all chassis nuts and bolts are tightened to the spoke wrench [1]. their correct torque values 2-3. TOOLS: Refer to an official Honda Service Manual or see your FRONT: dealer to torque values. Spoke wrench, 6.1 mm 07JMA-MR60100...
- Page 109 dummytext 3. Setting Information SERVICE INFORMATION ·····························3-2 SUSPENSION ADJUSTMENT GUIDELINE ··················································· 3-9 HANDLE POSITION ······································3-3 WIRING DIAGRAM ····································· 3-12 SUSPENSION SETTING ·······························3-4...
- Page 110 dummyhead dummyhead Setting Information SERVICE INFORMATION Setting Information TOOL Pin spanner (2 required) 07702-0020001 or Pin spanner A (2 required) 89201-KS6-810...
- Page 111 Setting Information Loosen the handlebar lower holder nuts [1]. HANDLE POSITION Remove the rear handlebar upper holder bolts [2], front HANDLEBAR LOWER HOLDER handlebar upper holder bolts [3], handlebar upper POSITION ADJUSTMENT holders [4] and handlebar [5]. Remove the handlebar lower holder nuts and washers The position of the handlebar can be changed by [6].
- Page 112 Setting Information Install the handlebar pad [1]. FRONT FORK ADJUST TO ATMOSPHERIC PRESSURE Air pressure acts as a progressive spring and affects the entire range of fork travel. Air is an unstable gas; it increases in pressure as it is worked (such as in a fork), so the fork action on this motorcycle will get stiffer as the race progresses.
- Page 113 Setting Information HOW TO USE THE COMPRESSION ADJUSTER HOW TO USE THE REBOUND ADJUSTER The compression damping force can be adjusted from The rebound damping force can be adjusted from the the softest to the stiffest with 16 clicks (4 clicks / 1 softest to the stiffest with 16 clicks (4 clicks / 1 rotation) or rotation) or more by the compression adjuster [1] of the more by the rebound adjuster [1] of the fork center bolt.
- Page 114 Setting Information REAR SUSPENSION HOW TO SET THE STANDARD POSITION 1. Turn the adjuster clockwise (H) until it stops (stiffest position). 2. Turn counterclockwise (S) direction from the stiffest The shock absorber contains nitrogen under high pressure. Be sure to observe the following. position and align the adjuster punch mark [2] with the –...
- Page 115 Setting Information HOW TO USE THE REBOUND ADJUSTER DAMPER UNIT NITROGEN RELEASE (WHEN DISCARD THE DAMPER UNIT) The rebound damping force can be adjusted from the softest to the stiffest with 17 clicks (8 clicks / 1 rotation) or The shock absorber contains nitrogen under high more by the rebound adjuster [1] on the lower left side of pressure.
- Page 116 Setting Information Remove the lower shock absorber mounting nut [1], and bolt [2]. Remove the upper shock absorber mounting nut [3], bolt [4] and shock absorber. [1]/[2] [3]/[4] Remove the valve cap [1]. Depress the valve core [2] to release the nitrogen from the reservoir completely.
- Page 117 dummyhead dummyhead Setting Information SUSPENSION ADJUSTMENT GUIDELINE FRONT FORK SETTING • Adjustments for type of track Hard-surfaced Begin with the standard setting. If the suspension is too stiff/soft, adjust according to the chart below. track Sand track Adjust to a stiffer position. Example: –...
- Page 118 dummyhead dummyhead Setting Information REAR SUSPENSION SETTING • Adjustments for type of track Hard-surfaced Begin with the standard settings. track If the suspension is too stiff/soft, adjust according to the chart below. Mud track Adjust to a stiffer position because mud build-up increases your CRF’s weight. Example: –...
- Page 119 dummyhead dummyhead Setting Information SETTING RECORD SHEET In order to setting the suspension faster and more accurately, record, save and reference the settings in the race and practice. Copy this page if necessary and use it. Day/Month/Year Event/Course Race Course Temperature/Humidity Weather/Course condition Soil condition...
- Page 120 dummyhead dummyhead Setting Information WIRING DIAGRAM 3-12...
- Page 121 INDEX dummytext INDEX AIR CLEANER ······························································2-18 MUFFLER····································································· 1-15 BODY PANEL LOCATIONS ···········································1-2 NUTS, BOLTS, FASTENERS······································· 2-82 BRAKE FLUID·······························································2-52 PISTON/PISTON RINGS/PISTON PIN ························ 2-35 BRAKE LIGHT SWITCH ···············································2-55 RADIATOR COOLANT················································· 2-44 BRAKE PADS WEAR ···················································2-53 RADIATOR GRILL·························································· 1-6 BRAKE SYSTEM ··························································2-54 RADIATOR SHROUD·····················································...
- Page 122 61MKEY00 XXXX.2020.03 00X61-MKE-Y000 PRINTED IN JAPAN...