Honda CRF250R 2005 Owner's Manual
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Honda CRF250R 2005 Owner's Manual

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2005
Honda CRF250R
OWNER'S MANUAL & COMPETITION HANDBOOK

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Summary of Contents for Honda CRF250R 2005

  • Page 1 2005 Honda CRF250R OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take to your Honda dealer so we will be able to responsibility for keeping your CRF well contact you concerning important production maintained.
  • Page 3 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 4: Table Of Contents

    Contacting Honda..........153 The Importance of Maintenance .......18 Brakes..............76 Your Honda Dealer..........154 Maintenance Safety...........19 Wheels...............80 The Honda Rider’s Club (USA only) .....155 Important Safety Precautions......19 Tires & Tubes ............81 Maintenance Schedule ........20 Drive Chain ............83 Table of Contents...........156 General Competition Maintenance ....22 Exhaust Pipe/Muffler ........86...

  • Page 5: Motorcycle Safety

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

  • Page 6: Important Safety Precautions

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

  • Page 7: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 8: Safety Labels

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

  • Page 9: Operating Controls

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

  • Page 10: Component Locations

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

  • Page 11: Before Riding

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

  • Page 12: Are You Ready To Ride

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

  • Page 13: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the following items (page numbers are at the Check the following before each ride: right): •...
  • Page 14 Before Riding...

  • Page 15: Basic Operating Instructions

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

  • Page 16: Safe Riding Precautions

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

  • Page 17: Starting & Stopping The Engine

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

  • Page 19: Break-In Guidelines

    Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...
  • Page 20 Basic Operating Instructions...

  • Page 21: Servicing Your Honda

    You’ll also find Exhaust Pipe/Muffler .........86 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....89 and tips for keeping your Honda looking good. Component Locations ........28 Seat Removal .............29 Appearance Care ..........91 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...

  • Page 22: The Importance Of Maintenance

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

  • Page 23: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 24: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your own maintenance, use only genuine...
  • Page 25 NOTE: 1.Clean after every heat for dusty riding conditions. 2.Replace every 2 years. Replacement requires mechanical skill. 3.Replace after the first break-in ride. 4.Inspect after the first break-in ride. 5.Replace the transmission oil, if the clutch discs and plates are replaced. Servicing Your Honda...

  • Page 26: General Competition Maintenance

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

  • Page 30: Before & After Competition Maintenance

    (1) are in the same position on each side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...
  • Page 31 If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your motorcycle or use cleaners, refer to Appearance Care (page 91). Servicing Your Honda...

  • Page 32: Component Locations

    Servicing Your Honda...

  • Page 33: Seat Removal

    2. Install the collars and tighten the seat bolts. 19 lbf·ft (26 N·m, 2.7 kgf·m) (1) seat bolts (3) seat (2) collars (4) seat front prong (5) seat bracket (6) seat rear prong (7) tab Servicing Your Honda...

  • Page 34: Fuel Tank Removal

    (7) fuel tank bolt 3. Remove the shroud A bolts (2). 4. Remove the shroud B bolts/collars (3) and shrouds (4). (8) fuel line (9) fuel valve bolt (2) shroud A bolts (3) shroud B bolts/collars (4) shrouds Servicing Your Honda...
  • Page 35 5. Hook the air cleaner cover rubber (5). 6. Install the fuel tank band (6). (8) shrouds (9) shroud B bolts (10) shrouds A bolts 10. Install the seat (page 29). (4) fuel tank bolt (5) air cleaner cover rubber (6) fuel tank band Servicing Your Honda...

  • Page 36: Subframe Removal

    (14) by pulling it straight backward. (13) (14) (12) (3) muffler clamp bolt (4) muffler A bolt (12) subframe mounting A bolts (5) muffler B bolt/washer (13) subframe mounting B bolt (6) muffler (14) subframe Servicing Your Honda...
  • Page 37 (10) of the muffler clamp with the cut-out (14) (11) of the muffler (12). (11) (10) (15) (16) (12) (12) muffler (12) (14) muffler B bolt/washer (15) muffler A bolt (16) muffler clamp bolt (9) muffler clamp (11) cut-out (10) tab (12) muffler Servicing Your Honda...

  • Page 38: Fuel System

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

  • Page 40: Engine Oil

    (weight) the engine. JASO T 903 MA or MB NOT RECOMMENDED suggested oil* Pro Honda GN4, HP4 (without molybdenum additives) or HP4M (with Other viscosities shown in the following chart molybdenum additives) may be used when the average temperature in 4-stroke oil, or an equivalent* your riding area is within the indicated range.
  • Page 41 However, if you replace only the oil before the upper level mark. (Do not overfill) the recommended interval, see page 21. Reinstall the engine oil filler cap/dipstick. Repeat steps 1–5. 6. Reinsert the engine oil filler cap/dipstick. (cont’d) 7. Check for oil leaks. Servicing Your Honda...
  • Page 42 (11) facing out, away from the engine. You should see the ”OUT-SIDE” mark (12) on the filter body, near the seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 43: Transmission Oil

    Other viscosities shown in the following chart may be used when the average temperature in suggested oil* Pro Honda HP Trans oil, Pro Honda GN4 or HP4 your riding area is within the indicated range. (without molybdenum additives) 4-stroke engine...
  • Page 44 5. After inspection the oil level or adding oil, (3) sealing washer tighten the oil check bolt to the specified torque:. Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m) 6. Install the transmission oil filler cap securely. Servicing Your Honda...

  • Page 45: Coolant

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

  • Page 47: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.
  • Page 48 Air Cleaner 9. Apply a thin coat of Honda White Lithium 11.Install the assembly into the air cleaner NOTICE Grease to the sealing surface. housing keeping the two access top tabs (2) 10. Assemble the air cleaner (3) and holder (5).

  • Page 49: Crankcase Breather

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

  • Page 50: Throttle

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

  • Page 52: Engine Idle Speed

    The best way to assure proper carburetion is to 2. If the engine is cold, start it and warm it up Idle Speed Adjustment see your Honda dealer for regularly scheduled three minutes. Then shut it off. servicing, including carburetor adjustment.

  • Page 53: Clutch System

    1. Turn the cable end adjuster (2) to obtain the or worn, or the clutch discs may be worn. See specified freeplay. your Honda dealer or refer to the official Honda 2. Check the freeplay again. Service Manual (page 152).
  • Page 54 (4) clutch cover (7) clutch lifter (9) clutch discs and plates 4. Remove the five clutch spring bolts (5) and (8) clutch lifter rod clutch springs. Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps. Servicing Your Honda...
  • Page 55 Measure the free length of each spring. Service Limit: 1.46 in (37.2 mm) If one or more springs are beyond the service (7) O-ring (8) clutch cover limit, replace the springs as a set. (3) clutch lifter rod (4) clutch lifter (cont’d) Servicing Your Honda...
  • Page 56 Clutch System 11. Lubricate the O-ring (9), rear brake pedal (10) pivot and pivot bolt (11) with Honda Lithium Grease and tighten the pivot bolt to the specified torque: 27 lbf·ft (37 N·m, 3.8 kgf·m) Connect the brake pedal return spring (12) if it was removed.

  • Page 57: Hot Start Lever

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

  • Page 58: Spark Plug

    “leaf-type feeler gauge’’. • Do not adjust the spark plug gap. If the gap is out of specification, replace the spark plug with a new one. (3) sealing gasket (4) spark plug gap Servicing Your Honda...

  • Page 59: Valve Clearance

    2. Remove the spark plug (2). (1) breather tube (2) spark plug cap 4. Remove the cylinder head cover bolts (3), and cylinder head cover (4). (2) spark plug (3) cylinder head cover bolts (4) cylinder head cover (cont’d) Servicing Your Honda...
  • Page 60 If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 57) and select the correct shim for each valve. (3) primary drive gear lock bolt (5) index mark (4) “punch” mark (6) exhaust rocker arm Servicing Your Honda...
  • Page 61 4. Turn the tensioner shaft clockwise with the stopper tool (3) until it stops, in order to retract the tensioner fully. Then insert the stopper tool fully to hold the stopper in the fully retracted position. (3) stopper tool (cont’d) Servicing Your Honda...
  • Page 62 Do not let the valve lifters and shims fall into the crankcase. Be careful to not let the set rings of the camshaft holders fall into the crankcase. (8) shims (7) valve lifters (4) camshaft holder bolts (6) camshaft (5) camshaft holders Servicing Your Honda...
  • Page 63 (1) valve lifter 2. Measure the shim thickness and record it. Seventy-three different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (3.000 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...
  • Page 64 (2) valve retainers 4. Rotate the primary drive gear lock bolt (4) (crankshaft) clockwise and align the “punch” mark (5) with the index mark (6). (4) primary drive gear lock bolt (5) “punch” mark (6) index mark Servicing Your Honda...
  • Page 65 8. Install the new sealing washer (14) and cam chain tensioner lifter cover bolt (15). (15) (11) (16) feeler gauge (12) (14) (14) sealing washer (15) cam chain tensioner lifter cover bolt (10) camshaft holders (11) camshaft holder bolts (12) intake cam lobes (cont’d) Servicing Your Honda...
  • Page 66 (4). (19) (7) spark plug cap (8) breather tube (18) O-ring (19) crankshaft hole cap 5. Install the fuel tank and the seat (page 31). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 67: Piston/Piston Rings/Piston Pin

    (page 88). 10. Remove the cylinder head cover (page 55). Remove the spark plug (5). (6) radiator hose clamp (7) radiator hose (1) exhaust pipe joint nuts (2) exhaust pipe (3) exhaust pipe gasket (5) spark plug (cont’d) Servicing Your Honda...
  • Page 68 (15) cylinder head gasket Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. 16.Remove the cylinder head nuts, washers (12) and cylinder head (13). (12) (13) (12) cylinder head nuts/washers (13) cylinder head Servicing Your Honda...
  • Page 69 (2) piston pin (4) piston rings 4. Spread each piston rings (4) and remove by lifting it up at a point just opposite the gap. NOTICE Do not damage the piston ring by spreading the ends too far. Servicing Your Honda...
  • Page 70 2. Apply engine oil to the piston rings and install We recommend you consult the Service Manual them. or your authorized Honda dealer for correct Service Limit measurements. NOTICE Do not damage the piston ring by spreading the ends too far.
  • Page 71 Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 4. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out (cont’d) Servicing Your Honda...
  • Page 72 Do not let the dowel pins fall into the crankcase. Do not damage the piston rings and cylinder walls. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (4) cylinder (5) piston rings Servicing Your Honda...
  • Page 73 (8) engine hanger nuts of the frame side Tighten the cylinder head nuts in a criss-cross (9) engine hanger nut of the engine side pattern in 2 or 3 steps. (3) cylinder head (4) cylinder head nuts/washers (cont’d) Servicing Your Honda...
  • Page 74 (13) exhaust pipe gasket (14) exhaust pipe (15) exhaust pipe joint nuts 12. Install the carburetor (page 121) . 13. Install the subframe and muffler (page 32). 14. Install the fuel tank (page 31) and the seat (page 29). Servicing Your Honda...

  • Page 75: Suspension

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's front suspension.

  • Page 76: Rear Suspension Inspection

    (page 111). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Remove the subframe (page 32). The instructions found in this owner’s manual are 3.

  • Page 77: Fork Oil Change

    (weight) 5 W when the fork damper is removed. To avoid suggested oil Pro Honda HP Fork Oil or damage, hold both the outer tube and slider equivalent when removing the fork damper.
  • Page 78 Standard oil 12.4 US oz capacity (368 cm Maximum oil 14.0 US oz Slightly stiffer as capacity (414 cm it nears full compression. Minimum oil 10.8 US oz Slightly stiffer as capacity (318 cm it nears full compression. Servicing Your Honda...
  • Page 79 (2) is in good condition. Apply the recommended fork oil to the O-ring. (10) (2) fork damper (10) o-ring 7. Tighten the fork damper using the special tool, to the specified torque: 25 lb·ft (34 N·m, 3.5 kgf·m) Servicing Your Honda...

  • Page 80: Brakes

    (page adjuster and piston (3). 79), there is probably air in the brake system. (–) Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system. Front Brake Lever Adjustment...
  • Page 81 Worn brake pads should be replaced. If the pads (20 mm), there is probably air in the brake are not worn, have your brake system inspected system and it must be bled. Refer to the Honda for leaks. Service Manual or see your Honda motorcycle If the brake lever freeplay exceeds 0.8 in...
  • Page 82 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid Other Inspection The recommended brake fluid is Honda DOT 4 The recommended brake fluid is Honda DOT 4 • Make sure there are not fluid leaks. brake fluid or an equivalent.
  • Page 83 0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 84: Wheels

    3. Check wheel rim runout. If runout is possible loss of control. It’s also important that noticeable, see the Honda Service Manual for the rim locks are secure to prevent tire slippage. inspection instructions.

  • Page 85: Tires & Tubes

    Overinflated tires make your motorcycle ride more harshly, are more prone to damage from surface hazards, and wear (1) tire tread depth unevenly. Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 86 • Use a replacement tire equivalent to the original. • Replace the tube any time you replace a tire. The old tube will probably be stretched and, if installed in a new tire, could fail. Servicing Your Honda...

  • Page 87: Drive Chain

    Lubricate the drive chain (page 84) if it appears dry or shows signs of rust. Lubricate (5) chain guide slider (6) wear limit groove any kinked or binding links and work them free. Adjust chain slack if needed. (cont’d) Servicing Your Honda...
  • Page 88 Pro decrease slack or clockwise to increase slack. Honda Chain Lube or an equivalent, or SAE 80 Align the index marks (4) of the axle plates or 90 gear oil is recommended.
  • Page 89 17 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 90: Exhaust Pipe/Muffler

    1. Remove the seat bolt (1), collars (2), side cover bolt (3) and right side cover (4). (5) muffler clamp bolt (7) muffler B bolt/washer (6) muffler A bolt (8) muffler (1) seat bolt (3) side cover bolt (2) collars (4) right side cover Servicing Your Honda...
  • Page 91 (3) cut-out (4) muffler (7) muffler B bolt/washer (2) tab (4) muffler (6) muffler A bolt (8) muffler clamp bolt 2. Remove the old gasket. 3. Install the new gasket (5). (5) gasket 4. Install the muffler. Servicing Your Honda...
  • Page 92 15 lbf·ft (21 N·m, 2.1 kgf·m) (1) exhaust pipe joint nuts (2) exhaust pipe (1) exhaust pipe gasket (3) exhaust pipe gasket (2) exhaust pipe (3) exhaust pipe joint nuts 2. Install the muffler (page 87). Servicing Your Honda...

  • Page 93: 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 the Honda Service Manual for replacement or adjustment procedures, or see your Honda dealer.
  • Page 94 (8) oil filter cover RIGHT SIDE (9) cylinder head bolt (10) drive sproket (1) cylinder head cover (2) exhaust pipe joint nuts (3) water pump cover (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover Servicing Your Honda...

  • Page 95: Appearance Care

    You may use Pro Honda Hondabrite, a performance. and steering head bearings-driving dirt inside multi-surface cleaner/degreaser, to remove both and needed lubrication out.
  • Page 96 #7447-maroon) is for removing stains on the non-coated aluminum frame only. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda...

  • Page 97: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......94 for maximum competition performance. Rear Suspension Adjustments ......107 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ...........111 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....112 break-in time.

  • Page 98: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure •...
  • Page 99 See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your authorized Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2 oz (5 cc)
  • Page 100 Front Suspension Adjustments 3. Remove the handlebar pad. 6. Remove the disc cover (7) by removing the 8. Remove the fork protector (12) and brake Remove the washers/handlebar holder nuts (3), disc cover bolts (8). caliper (13). mounting rubbers and handlebar (4). NOTICE NOTICE Keep the master cylinder upright to prevent air...
  • Page 101 Front Suspension Adjustments 10.Clean the fork assembly, especially the sliding 13.Hold the outer tube (18), then remove the fork 15.Temporarily install the fork damper to the surface of the slider (15) and dust seal (16). damper (19) from the outer tube using a lock outer tube.
  • Page 102 Front Suspension Adjustments 20.Apply pressure to the fork damper and insert a (23) Damper Oil Change special tool or mechanic's stopper tool (25) (see below) between the axle holder (23) and (25) lock nut (26). 21.Hold the lock nut and remove the fork center bolt (24) from the fork damper.
  • Page 103 Recommended Oil: Be careful not to damage the fork cap bushing. Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5 W or equivalent Do not disassemble the fork cap assembly. Recommended Amount: Replace the fork cap as an assembly if it is 6.0 US oz (178 cc)
  • Page 104 Front Suspension Adjustments 9. Tighten the fork cap (1) while holding the cut 11.Screw in the lock nut (7) to the fork damper 13.Drain the extra oil from the fork damper piston rod (6) fully. out of the fork damper (2) using the lock nut spring chamber (8) oil hole (9).
  • Page 105 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Amount of fork oil left in the fork Fork Assembly (without damper and spring) unit: cc thread length (A) as shown. minute Standard: 0.43 – 0.51 in (11 – 13 mm) 1.
  • Page 106 Front Suspension Adjustments 4. Set the lower end (axle holder) of the slider in 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the fork center bolt (8) O- a vise with a piece of wood or soft jaws to center bolt (8) clearance.
  • Page 107 Standard (0.45 kgf/mm) Fork Spring No mark Recommended Oil: 1 scribe mark and (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 3 scribe mark 75 degrees apart 1 scribe mark (aftermarket parts) Standard oil 12.6 US oz...
  • Page 108 Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 16.Temporarily thread the fork damper (4) into 17.Tighten the fork lower pinch bolts (13) to the assembly (4) is in good condition. Apply the the outer tube (1). Insert both fork legs into specified torque: recommended fork oil to the O-ring.
  • Page 109 Front Suspension Adjustments 19.Clean the threads of the fork protector (15) 20.Clean the surfaces where the axle and axle 21.Align the brake caliper (17) and hose with the bolts and axle holder thoroughly. clamps contact each other. left fork leg, making sure that the brake hose Apply locking agent to the bolt threads.
  • Page 110 Front Suspension Adjustments 23.Install the handlebar (19), mounting rubbers 25.Install and tighten the number plate bolt (24). (26) (26) (20), washers and handlebar holder nuts (21) Install the handlebar pad (25). and tighten the handlebar holder nuts to the specified torque: (25) 33 Ibf·ft (44 N·m, 4.5 kgf·m) (20)

  • Page 111: Rear Suspension Adjustments

    Min. : 9.88 in (251 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) Min. (Softer, 5.1 kgf/mm): 9.92 in (252 mm) The instructions found in this owner’s manual are limited to adjustments of the shock assembly Min.
  • Page 112 Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping Compression damping may be adjusted in two stages with separate adjusters. To adjust to the standard position: 1.
  • Page 113 Rear Suspension Adjustments 4. Calculate the race sag dimension. Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very Standard Race Sag: 3.9 in (100 mm) important for competition use.
  • Page 114 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you dimension (step 5) from the unloaded to notice when your CRF’s suspension is dimension (step 2).

  • Page 115: 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 116: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 94 - 108. Remember to make all adjustments in one-click increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 117 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 118 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring preload). Example: –...

  • Page 119: Carburetor Adjustments & Tuning Tips

    (2) and is mixed with air from your CRF. See your Honda dealer. the air passage (3) (located above the throttle valve (4)) to provide a rich mixture for starting.
  • Page 120 Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.
  • Page 121 3. Install the float bowl plug. Honda carburetor jet sizes are numbered in increments of 2 or 3. When changing the main jet The minimum to maximum range of pilot screw...
  • Page 122 Carburetor Adjustments & Tuning Tips 4. Disconnect the fuel line (2) from the fuel 10.Remove the hot start cable holder (6). 12.Remove the throttle drum cover bolt (9) and valve (3). throttle drum cover (10). 5. Remove the fuel tank (page 30). 6.
  • Page 123 Carburetor Adjustments & Tuning Tips 3. Remove the link arm set screw (7). When installing the floating valve (10) onto Carburetor Disassembly When installing the link arm set screw, apply the throttle valve (8) make sure the floating a locking agent to the link arm set screw valve’s flat side faces out and the hole (11) threads.
  • Page 124 Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop 9. Measure the float level (26) with the float (12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), level gauge (27) during float tab just tube guides (22) and float bowl (18).
  • Page 125 Carburetor Adjustments & Tuning Tips Carburetor Assembly To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • After installing the carburetor, adjust the throttle cable (1) free play and hot start cable (2) free play. •...
  • Page 126 Carburetor Adjustments & Tuning Tips All jetting is based on Standard Tuning Recommendations • Standard jetting • Unmodified Engine For the following recommendations to be accurate, you must use the standard settings as a TEMPERATURE FAHR. -21°~ 0° -1°~ 20° 19°~ 40°...
  • Page 127 Carburetor Adjustments & Tuning Tips Onece you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the situations that may require additional atmospheric conditions or race day situations that...
  • Page 128 Carburetor Adjustments & Tuning Tips 5. Change carburetor settings or select suitable Carburetor Minor Adjustments carburetor jets, taking into consideration the engine conditions and factors for temperature and altitude (page 122). The standard carburetor settings are ideal for the following conditions: sea level altitude, and 20°C 6.
  • Page 129 Carburetor Adjustments & Tuning Tips 11.Change the main jet (3) and slow jet (4) as 14.Remove the fuel tank (page 30). 18.Reinstall the jet needle, jet needle holder required. 15.Rotate the carburetor to the left and remove the carburetor top and carburetor top bolts. carburetor top bolts (5) and carburetor top (6).
  • Page 130 Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range Improperly tightened spark plugs can damage the or incorrect reach can cause engine damage. engine. If a plug is too loose, a piston may be Refer to Spark Plug on page 54.

  • Page 131: Chassis Adjustments

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

  • Page 132: Gearing

    Unless you have the required mechanical down, and avoid unwanted wheelspin. The feelings can’t be trusted. Eliminating wheelspin knowhow, tools, and an official Honda Service engine may bog in certain corners so you’ll with a gearing change can make you feel like Manual, sprocket changing should be done by need to slip the clutch to compensate;...

  • Page 133: Tire Selection For Track Conditions

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

  • Page 134: Personal Fit Adjustments

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

  • Page 135: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......132 Storing Your Honda..........133 You & the Environment ........134 Troubleshooting..........135 Tips...

  • Page 136: Transporting Your Motorcycle

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

  • Page 137: Storing Your Honda

    Removal from Storage such as during the winter, thoroughly inspect (1) at the water pump (2) to drain coolant. your Honda and correct any problem before After the coolant has been completely storing it. That way, needed repairs won’t be drained, ensure that the drain bolt sealing 1.

  • Page 138: You & The Environment

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

  • Page 139: Troubleshooting

    POSSIBLE CAUSES parenthesis. The items that require use of the • Lack of fuel in tank 1. Disconnect fuel FUEL FLOW Honda Service Manual are followed by an (P-34) line at carburetor RESTRICTED • Clogged fuel line and check for asterisk.
  • Page 140 Tips...

  • Page 141: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........138 other technical data. Specifications ...........139 Torque Specifications........140 High Altitude Carburetor Adjustment ....143 Oxygenated Fuels..........144 Competition Logbook ........145 Optional Parts List ...........147 Spare Parts & Equipment.........148 Wiring Diagram..........149 Technical Information...

  • Page 142: Vehicle Identification

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

  • Page 143: Specifications

    Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.5 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,172 mm Single 10˚ inclined from Overall width 32.6 in Transmission 5-speed, constant mesh 827 mm Cylinder arrangement vertical...

  • Page 144: Torque Specifications

    Torque Specifications Nuts, Bolts, Fasteners Torque Check and tighten nuts, bolts, and fasteners before every outing. Remarks Item lbf•ft N•m kgf•m ENGINE Engine Cylinder head cover Exhaust pipe joint nut Water pump cover RIGHT SIDE Crankshaft hole cap Transmission oil check bolt Clutch cover Cylinder bolt...
  • Page 145 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME 11.0 Steering stem nut Fork bridge upper pinch (19) (13) (14) bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.0 NOTE 1...
  • Page 146 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m FRAME Front brake master (29) cylinder holder bolts Brake hose bolts Caliper mounting bolts NOTE 4 NOTE 1 Front brake disc nuts Rear brake disc nuts NOTE 1 Brake pedal pivot bolt (36) 0.38 Front spoke...

  • Page 147: High Altitude Carburetor Adjustment

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

  • Page 148: Oxygenated Fuels

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

  • Page 149: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from Keep track of the settings and adjustments that Information worth recording for this section of previous racing events. The best way to organize worked best at a particular location.
  • Page 150 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Consumer Information...

  • Page 151: Optional Parts List

    Optional Parts List These parts and tools may be ordered from your FRAME Remarks FRAME Remarks authorized Honda dealer. Driven sprocket < >: Drive chain links Shock spring 296.8 lbf/in (5.30 kgf/mm) Standard 51 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...

  • Page 152: Spare Parts & Equipment

    Spare Parts & Equipment There are numerous spare parts you can take to ignition components Pro Honda HP Trans Oil or Pro Honda GN4 or an event to help ensure you get in a full day of top end-complete HP4 (without molybdenum additives only) riding.

  • Page 153: Wiring Diagram

    Wiring Diagram SPARK THROTTLE POSITION PLUG SENSOR Technical Information...
  • Page 154 Technical Information...

  • Page 155: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........152 contacting Honda and how to get an official Contacting Honda..........153 Honda service manual. Your Honda Dealer...........154 The Honda Rider’s Club (USA only) ....155 Consumer Information...

  • Page 156: Authorized Manuals

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

  • Page 157: Contacting Honda

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

  • Page 158: Your Honda Dealer

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

  • Page 159: The Honda Rider's Club (Usa Only)

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

  • Page 160: Service Preparations Component Locations

    General Competition Maintenance ....22 Drive Chain ............83 Your Honda Dealer..........154 Before & After Competition Maintenance..26 Exhaust Pipe/Muffler ........86 The Honda Rider’s Club (USA only) .....155 Between Motos & Practice Maintenance ..26 Additional Maintenance Procedures ....89 After Competition Maintenance ....26 Appearance Care ..........91...

  • Page 161: Index

    ............34 fluid level .............77 damping adjustments, system............34 lever, front adjustment .........76 front ..............94 oxygenated ..........144 pad wear ............79 rear..............108 tank capacity ..........34 pedal height ..........76 dealer, your Honda ..........154 valve .............13 break-in guidelines ..........15 diagram, wiring ..........149 drive chain............83 Index...
  • Page 162 Index gap, spark plug ..........54 maintenance, rear suspension maintenance......72 gasohol ............144 additional procedures ........89 Rider’s Club Honda.........155 gasoline..............34 after competition ..........26 riding, gearing.............128 before & after competition......26 basic operation ..........11 guidelines, suspension adjustment ....112 between motos & practice......26 before..............7 general competition........22 important safety information......2...
  • Page 163 Index suspension, front ............71,94 rear............72,107 suspension adjustment, front ..............94 rear..............107 for track conditions ........111 guidelines ...........112 transmission oil ..........39 tuning tips ............115 throttle, freeplay............46 inspection .............47 tires, air pressure ...........81 flat ..............81 selection............129 tools ...............148 torque specifications........140 transporting............132 troubleshooting..........135 tubes, replacing ..........81 valve, fuel............34 vehicle identification........138 washing your motorcycle ........91...

  • Page 164: Quick Reference

    Pro Honda GN4 or HP4 (without molybdenum additives) or HP4M (with molybdenum additives) 4-stroke oil, or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke oil, or an equivalent. Tires Front: 80/100-21 51M, Rear: 100/90-19 57M...

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