Honda CRF250R 2006 Owner's Manual
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Honda CRF250R 2006 Owner's Manual

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2006
Honda CRF250R
OWNER'S MANUAL & COMPETITION HANDBOOK

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Summary of Contents for Honda CRF250R 2006

  • Page 1 2006 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

    Is Your Motorcycle Ready to Ride?....9 Contacting Honda..........155 Pre-ride Inspection..........9 Chassis Your Honda Dealer..........156 Suspension............72 The Honda Rider’s Club (USA only) .....157 BASIC OPERATING INSTRUCTIONS ..11 Brakes..............77 Safe Riding Precautions........12 Wheels...............81 TABLE OF CONTENTS ......158 Starting & Stopping the Engine ......13 Tires &...

  • 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 Information

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

  • Page 7: Accessories & Modifications

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

  • Page 8: Safety Labels

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

  • Page 9: Operating Controls

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

  • Page 10: Operation Component Locations

    Operation Component Locations hot start lever clutch lever front brake lever throttle grip engine stop button 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 .........87 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....91 and tips for keeping your Honda looking good. Maintenance Component Locations....28 Seat Removal .............29 Appearance Care ..........93 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 CRF or use cleaners, refer to Appearance Care (page 93). Servicing Your Honda...

  • Page 32: Maintenance Component Locations

    Servicing Your Honda...

  • Page 33: Seat Removal

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

  • Page 34: Fuel Tank Removal

    3. Remove the shroud A bolts/collars (2). (7) air cleaner cover rubber 4. Remove the shroud B bolts (3) and shrouds (4). (8) fuel tank bolt (9) fuel line (10) fuel valve bolt (2) shroud A bolts/collars (3) shroud B bolts (4) shroud Servicing Your Honda...
  • Page 35 7. Put the breather tube (7) in the steering stem (11) nut. (10) (12) (10) shroud (11) shroud B bolts (12) shrouds A bolts/collars (4) fuel tank bolt (5) air cleaner cover rubber 12. Install the seat (page 29). (6) fuel tank band (7) breather tube Servicing Your Honda...

  • Page 36: Subframe Removal

    3. Remove the seat (page 29). (6) lower mounting bolts (1) crankcase breather tube (7) upper mounting bolt (8) subframe (2) fuel tank band (3) air cleaner cover rubber (4) screw (5) air cleaner connecting tube clamp Servicing Your Honda...
  • Page 37 36 lbf·ft (49 N·m, 5.0 kgf·m) (4) screw (5) air cleaner connecting tube clamp (6) air cleaner cover rubber (7) fuel tank band (8) crankcase breather tube (1) subframe (2) upper mounting bolt (3) lower mounting bolts Servicing Your Honda...

  • Page 38: Fuel System

    (2) fuel filter of gasoline. If pinging or spark knock persists, WARNING consult your Honda dealer. 1. Check the fuel valve (1) and fuel filter (2) for Gasoline is highly flammable and contamination.
  • Page 39 5. Install the fuel joint in the fuel tank. 6. Install the fuel tank (page 31) and refill the fuel. Turn the fuel valve to ON; check for leaks. (1) fuel joint (3) fuel filter (2) bolts (4) O-ring Servicing Your Honda...

  • Page 40: Engine Oil

    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 6 races or about every 15.0 hours. Repeat steps 1–5. However, if you replace only the oil before 6. Reinsert the engine oil filler cap/dipstick. the recommended interval, see page 21. 7. Check for oil leaks. (cont’d) Servicing Your Honda...
  • Page 42 (11) facing out, away from the engine. You should see the “OUT-SIDE” mark (12) on the filter body, near the seal. Use a new genuine Honda oil filter or a filter of equal quality specified for your model. NOTICE If the oil filter is not installed properly, it will cause serious engine damage.

  • Page 43: Transmission Oil

    Other viscosities shown in the following chart suggested oil* Pro Honda HP Trans oil, may be used when the average temperature in Pro Honda GN4 or HP4 your riding area is within the indicated range.
  • 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 the water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.

  • Page 47: Air Cleaner

    Service the air cleaner more frequently if you ride in unusually wet or dusty areas. Your Honda dealer can help you determine the correct service interval for your riding conditions.
  • Page 48 Install and tighten the retaining bolt (1) securely. (10) (1) air cleaner retaining bolt (2) two access top tabs (3) air cleaner assembly (4) “ ” mark (10) groove Servicing Your Honda...

  • Page 49: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 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

    Refer to Safety Precautions on page 19. Idle Speed Adjustment The best way to assure proper carburetion is to see your Honda dealer for regularly scheduled 1. Turn the pilot screw (1) in until it is lightly servicing, including carburetor adjustment.

  • Page 53: Clutch System

    To position the brake lever closer to the handgrip, turn the adjuster clockwise. 3. Tighten the lock nut. (4) lock nut (5) integral cable adjuster (+) increase freeplay (–) decrease freeplay 6. Adjust the cable end adjuster for minor adjustement. (cont’d) Servicing Your Honda...
  • Page 54 If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the Honda Service Manual (page 154). Servicing Your Honda...
  • Page 55 4. Remove the five clutch spring bolts and clutch (9) clutch lifter (11) clutch discs and plates springs (7). (10) clutch lifter rod (2) clutch plate Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps. (cont’d) Servicing Your Honda...
  • Page 56 7 lbf·ft (10 N·m, 1.0 kgf·m) 5. Apply engine oil to the needle bearing of the clutch lifter. 6. Install the clutch lifter (4) onto the rod. (7) O-ring (8) clutch cover (3) clutch lifter rod (4) clutch lifter Servicing Your Honda...
  • Page 57 Clutch System 12. Lubricate the dust seals (9), rear brake pedal (10) pivot and pivot bolt (11) with Honda Lithium Grease or equivalent. 13. Install the dust seals, washer (12) and pivot bolt and tighten the pivot bolt to the specified torque: 27 lbf·ft (36 N·m, 3.7 kgf·m)

  • Page 58: Hot Start Lever

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

  • Page 59: 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 60: Valve Clearance

    2. Remove the spark plug (page 55). (1) breather tube (2) direct ignition coil 3. Remove the cylinder head cover bolts (3), and cylinder head cover (4). (3) cylinder head cover bolts (4) cylinder head cover 4. Remove the plug hole packing. Servicing Your Honda...

  • Page 61: Valve Clearance Inspection

    If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 58) 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 62 (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. (1) cam chain tensioner lifter cover bolt (2) sealing washer (3) stopper tool Servicing Your Honda...
  • Page 63 Do not let the valve lifters and shims fall into the Be careful to not let the set rings of the camshaft crankcase. holders fall into the crankcase. (8) shims (7) valve lifters (4) camshaft holder bolts (6) camshaft (5) camshaft holders Servicing Your Honda...
  • Page 64 (1) valve lifter 2. Measure the shim thickness and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...
  • Page 65 (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 (cont’d) Servicing Your Honda...
  • Page 66 Tighten the camshaft holder bolts in a criss-cross pattern in 2 or 3 steps. (14) (12) (16) (16) sealing washer (17) cam chain tensioner lifter cover bolt (13) (14) (13) intake cam lobes (14) camshaft holder bolts Servicing Your Honda...
  • Page 67 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) direct ignition coil (8) breather tube 5. Install the fuel tank and the seat (page 31). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 68: Piston/Piston Rings/Piston Pin

    4. Remove the seat and fuel tank (page 30). 5. Remove the subframe (page 32). 6. Remove the carburetor (page 119). 7. Remove the exhaust pipe (page 90). (3) engine hanger nuts (4) engine hanger plates (1) water hose clamp (2) water hose Servicing Your Honda...
  • Page 69 Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (10) (5) cylinder head bolts (6) cylinder bolt (11) (9) dowel pins (11) cam chain guide (10) cylinder head gasket (7) cylinder head nuts/washers (8) cylinder head Servicing Your Honda...
  • Page 70 2. Remove the dowel pins (3) and cylinder (1) piston ring gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin (4) piston rings Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 71 1. Clean the piston ring thoroughly. oil ring We recommend you consult the Service Manual 2. Apply engine oil to piston rings and install or your authorized Honda dealer for correct them. Service Limit measurements. NOTICE Do not damage the piston ring by spreading the ends too far.
  • Page 72 Do not align the piston pin clip end gap with the piston cut-out. (1) dowel pins (2) cylinder gasket 5. Clean the any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses (6) cut-out Servicing Your Honda...
  • Page 73 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 (cont’d) Servicing Your Honda...
  • Page 74 Do not let the washers and nuts fall into the crankcase. (7) engine hanger plates (8) engine hanger nuts/bolts of the frame side (9) engine hanger nut/bolt of the engine side (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 75 – abnormal engine noise (page 29). – secondary air leaks – coolant leaks (10) (9) radiator hose (10) radiator hose clamp 7. Install the shims, valve lifters and camshaft (page 61). 8. Install the spark plug (page 55). Servicing Your Honda...

  • Page 76: Suspension

    • Use Pro Honda HP Fork Oil 5W or an equivalent which contains special additives to assure maximum performance of your CRF's (1) fork protector (2) dust seal front suspension.

  • Page 77: Rear Suspension Inspection

    (page 113). 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 78: 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 79 12.4 US oz capacity (366 cm Maximum oil 13.9 US oz Slightly stiffer as capacity (410 cm it nears full compression. Minimum oil 10.6 US oz Slightly softer as capacity (314 cm it nears full compression. (cont’d) Servicing Your Honda...
  • Page 80 (10) (2) fork damper (10) O-ring 7. Temporarily install the fork damper to the outer tube. After installing the fork leg (page 106) tighten the fork damper to the specified torque: 25 lb·ft (34 N·m, 3.5 kgf·m) Servicing Your Honda...

  • Page 81: Brakes

    (3) piston 80), there is probably air in the brake system. (2) adjuster (–) Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the 1. Loosen the lock nut (1). system. 2. To position the brake lever farther away from the handgrip, turn the adjuster (2) clockwise.
  • Page 82 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 dealer for If the brake lever freeplay exceeds 0.8 in...
  • Page 83 Brakes Adding Front Brake Fluid Adding Rear Brake Fluid 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. When adding brake fluid be sure the reservoir is...
  • Page 84 0.04 in (1 mm) Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. replace (1) front brake caliper (3) brake disc (2) brake pads Servicing Your Honda...

  • Page 85: Wheels

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

  • Page 86: Tires & Tubes

    Overinflated tires make your CRF ride harshly, are more prone to damage from surface hazards, and wear unevenly. (1) tire tread depth Make sure the valve stem caps are secure. If necessary, install a new cap. Servicing Your Honda...
  • Page 87 • 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 88: Drive Chain

    Lubricate the drive chain (page 85) if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work them free. Adjust chain slack if needed. (2) chain guide slider (3) wear limit Servicing Your Honda...
  • Page 89 2. Measure the diameter of the drive chain decrease slack or clockwise to increase slack. Honda Chain Lube or an equivalent, or SAE 80 rollers and replace them if below the service Align the index marks (4) of the axle plates or 90 gear oil is recommended.
  • Page 90 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 91: Exhaust Pipe/Muffler

    1. Remove the seat mounting bolts (1), side cover bolts (2) and side covers (3). (4) muffler clamp bolt (5) muffler (6) muffler mounting bolt (7) washer (1) seat mounting bolt (3) side cover (2) side cover bolt Servicing Your Honda...
  • Page 92 (7) muffler mounting bolt (8) washer (9) muffler clamp bolt 3. Install the new gaskets (5) to the exhaust joint pipe (6). 4. Install each muffler to the exhaust joint pipe. (5) gasket (6) exhaust joint pipe Servicing Your Honda...
  • Page 93 (3) joint pipe clamp bolt (4) exhaust joint pipe mounting bolt (5) exhaust joint pipe (4) exhaust joint pipe (5) gasket (6) exhaust pipe Servicing Your Honda...
  • Page 94 6. Tighten the joint pipe clamp bolt and exhaust joint pipe mounting bolt (page 89). 7. Tighten the muffler clamp bolts and muffler mounting bolts (page 88). 8. Installation can be done in the reverse order of removal. Servicing Your Honda Servicing Your Honda...

  • Page 95: 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 Control Cables Honda Service Manual for replacement or adjustment procedures, or see your Honda Periodically, disconnect the throttle, clutch and dealer.
  • Page 96 (9) cylinder head bolts (10) drive sproket bolt (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cover bolts (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda Servicing Your Honda...

  • Page 97: 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 98 #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 Servicing Your Honda...

  • Page 99: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......96 for maximum competition performance. Rear Suspension Adjustments ......109 Suspension Adjustments for Track Initial suspension adjustments should be Conditions ...........113 performed after a minimum of two hours of easy Suspension Adjustment Guidelines....114 break-in time.

  • Page 100: Front Suspension Adjustments

    Front Suspension Adjustments The front suspension can be adjusted for the Front Suspension Air Pressure Front Suspension Damping rider’s weight and riding conditions by using one or more of the following methods: Air is an unstable gas which builds up pressure Rebound Damping Adjustment as it is worked (such as in a fork).
  • Page 101 See the Service Manual or adjusters are firmly located in a detent, and not the fork is too hard on big bumps, turn the your Honda dealer for this service. between positions. damping adjuster counterclockwise 1-turn and lower the oil level in increments of 0.2 oz (5 cc)
  • Page 102 Front Suspension Adjustments 4. Remove the washers/handlebar holder nuts (4), 7. Remove the disc cover (8) by removing the Do not support the brake caliper by the brake mounting rubbers and handlebar (5). disc cover bolts (9). hose. Do not operate the brake lever after the front wheel is removed.
  • Page 103 Front Suspension Adjustments 12.Clean the fork assembly, especially the sliding 17.Temporarily install the fork damper to the NOTICE surface of the slider (19) and dust seal (20). outer tube. 13.Record the rebound damping adjuster position 18.Set the axle holder (28) in a vise with a piece of The outer tube can drop on the slider and and turn the adjuster counterclockwise until it damage the fork dust seal and guide bushing...
  • Page 104 Front Suspension Adjustments 22.Apply pressure to the fork damper and insert a Damper Oil Change special tool or mechanic’s stopper tool (30) (see below) between the axle holder (28) and lock nut (31) 1. Set the fork damper (1) in a vise with a piece 23.Hold the lock nut and remove the center bolt (32) of wood or soft jaws to avoid damage.
  • Page 105 (1) as shown. 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 5W or equivalent (4). Recommended Amount: Do not disassemble the fork cap assembly.
  • Page 106 Front Suspension Adjustments 9. Tighten the fork cap assembly (2) while 11.Screw in the lock nut (7) to the fork damper 13.Drain the extra oil from the fork damper oil piston rod (5) fully. holding the fork damper (1) using the lock nut hole (9).
  • Page 107 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider (1) by placing it upside down. (About 7 cc of fork oil will be left in the outer Wipe the oil completely off the fork damper.
  • Page 108 Front Suspension Adjustments 4. Set the axle holder in a vise with a piece of 8. Measure the length of the lock nut (2) and 10.Apply fork oil to the center bolt (8) O-ring. wood or soft jaws to avoid to damage. center bolt (8) clearance.
  • Page 109 (1). No mark 1 scribe mark and (factory products) Recommended Oil: 3 scribe mark 75 degrees apart Pro Honda HP Fork Oil 5 W or equivalent. 1 scribe mark (aftermarket parts) Standard oil 12.6 US oz Standard oil 12.5 US oz...
  • Page 110 Front Suspension Adjustments 15.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper assembly (4) to the assembly (4) is in good condition. Apply the specified torque using the lock nut wrench recommended fork oil to the O-ring. (14).
  • Page 111 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Clean the surfaces where the axle and axle Fit the brake caliper over the disc, taking care (18) and axle holder thoroughly. clamps contact each other. not to damage the brake pads. Apply locking agent to the bolt threads.
  • Page 112 Front Suspension Adjustments 25.Install the handlebar (25), mounting rubbers 27.Install and tighten the number plate bolt (31). (33) (26), washers and handlebar holder nuts (27) Install the handlebar pad (32). and tighten the handlebar holder nuts to the (32) specified torque: 32 Ibf·ft (44 N·m, 4.5 kgf·m) (31) (25)

  • Page 113: 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 114 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 The high speed damping adjuster has 2 turn or stages with separate adjusters.
  • Page 115 Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded dimension (step 2). Setting the proper race sag (ride height) is very UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.
  • Page 116 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 117: 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 118: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 96 - 110. 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 119 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 120 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 121: 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 122: Accelerator Pump/Slow Circuit

    Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed Fuel is metered by the main jet (1), jet needle (2) throttle is opened.
  • Page 123 3. Tighten the drain screw. richen the mixture. 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 size, increase or decrease it gradually until the adjustment is 1 to 1 3/4 turns out from the lightly desired jetting is obtained.
  • Page 124 Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 30). 9. Remove the hot start cable holder (4). 11.Remove the throttle drum cover bolt (7) and 5. Remove the sub-frame (page 32). throttle drum cover (8). 6. Loosen the insulator band screw (2). (4) hot start cable holder (7) throttle drum cover bolt 10.Disconnect the rear suspension (5) upper...
  • Page 125 Carburetor Adjustments & Tuning Tips 3. Remove the link arm set screw (7). When installing the floating valve (10) onto Carburetor Disassembly/Assembly 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 126 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 127 Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • Route the throttle cables (1), hot start cable (2) and throttle sensor wire correctly. • After installing the carburetor, adjust the throttle grip free play and hot start lever free play.
  • Page 128 Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary. Adjustment Standard settings Pilot screw opening 1–3/4 turns out Slow jet...
  • Page 129 Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change drastically. However, there are some unique There are some unique atmospheric conditions or Before adjusting carburetor settings, check the situations that may require additional atmospheric conditions or race day situations that...
  • Page 130 Carburetor Adjustments & Tuning Tips 6. Adjust the pilot screw as required. Carburetor Minor Adjustments WARNING The standard carburetor settings are ideal for the Gasoline is highly flammable and following conditions: sea level altitude, and 20°C explosive. You can be burned or (68 °F) air temperature.
  • Page 131 Carburetor Adjustments & Tuning Tips 12.Change the main jet (4) and slow jet (5) as 15.Remove the fuel tank (page 30). 19.Reinstall the jet needle, jet needle holder required. 16.Rotate the carburetor to the left and remove the carburetor top and carburetor top bolts. carburetor top bolts (6) and carburetor top (7).
  • Page 132 Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range An improperly tightened spark plug can damage or incorrect reach can cause engine damage. the engine. If a plug is too loose, a piston may Refer to Spark Plug on page 55.

  • Page 133: 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 134: Gearing

    Honda Service Manual, engine may bog in certain corners so you’ll wheelspin with a gearing change can make you sprocket changing should be done by your Honda need to slip the clutch to compensate; feel like you’re going slower when, in reality, dealer.

  • Page 135: 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 136: 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 137: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......134 Storing Your Honda..........135 You & the Environment ........136 Troubleshooting..........137 Tips...

  • Page 138: 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 139: Storing Your Honda

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

  • Page 140: 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 141: 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 line at carburetor RESTRICTED (P-34) • Clogged fuel line and check for asterisk.
  • Page 142 Tips...

  • Page 143: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........140 other technical data. Specifications ...........141 Torque Specifications........142 High Altitude Carburetor Adjustment ....145 Oxygenated Fuels..........146 Competition Logbook ........147 Optional Parts List ...........149 Spare Parts & Equipment.........150 Wiring Diagram..........151 Technical Information...

  • Page 144: Vehicle Identification

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

  • Page 145: Specifications

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

  • Page 146: Torque Specifications

    Torque Specifications Torque Nuts, Bolts, Fasteners Remarks Item lbf•ft N•m kgf•m ENGINE Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Water pump cover bolts Crankshaft hole cap Transmission oil check bolt Clutch cover bolts...
  • Page 147 Torque Specifications Frame Torque Item Remarks lbf•ft N•m kgf•m FRAME Steering stem nut 11.0 Fork bridge upper pinch (13) bolts (12) Fork bridge lower pinch bolts Handlebar upper holder bolts Handlebar holder nuts Front axle nut Front axle pinch bolts Rear axle nut 13.1 NOTE 1...
  • Page 148 Torque Specifications Frame Torque Remarks Item lbf•ft N•m kgf•m (38) FRAME (34) (33) Front brake master (28) cylinder holder bolts Brake hose bolts Caliper mounting bolts NOTE 4 Front brake disc nuts NOTE 1 (37) Rear brake disc nuts NOTE 1 Brake pedal pivot bolt (23) Spoke...

  • Page 149: 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 150: 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 151: 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 152 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 153: 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 154: Spare Parts & Equipment

    (front & rear) additives) or HP4M (with molybdenum additives) 4-stroke Oil (Engine Oil) Spare Parts Pro Honda HP Trans Oil or Pro Honda GN4 or General Tools HP4 (without molybdenum additives only) spark plugs 4-stroke Oil (Transmission Oil) air cleaner (clean &...

  • Page 155: Wiring Diagram

    Wiring Diagram SPARK THROTTLE POSITION PLUG SENSOR Technical Information...
  • Page 156 Technical Information...

  • Page 157: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........154 contacting Honda and how to get an official Contacting Honda..........155 Honda service manual. Your Honda Dealer...........156 The Honda Rider’s Club (USA only) ....157 Consumer Information...

  • Page 158: Authorized Manuals

    The Service Manual used by your authorized Honda dealer is available from NOTE: Dealers and Companies, please provide dealer or company name, and also Helm, Inc. (USA only, Canada: See your Honda dealer to order authorized manuals) the name of the person to whose attention the shipment should be sent. For purchases outside U.S.A., please write to the address shown below for a quotation.

  • Page 159: 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 160: 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 161: The Honda Rider's Club (Usa Only)

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

  • Page 162: Service Preparations Maintenance Component Locations

    General Competition Maintenance ....22 Drive Chain ............84 Your Honda Dealer..........156 Before & After Competition Maintenance..26 Exhaust Pipe/Muffler ........87 The Honda Rider’s Club (USA only) .....157 Between Motos & Practice Maintenance ..26 Additional Maintenance Procedures ....91 After Competition Maintenance ....26 TABLE OF CONTENTS ......158 Appearance Care ..........93...

  • Page 163: Index

    ..............96 recommendation...........34 fluid level .............78 rear..............110 refueling ............34 lever, front adjustment .........77 dealer, your Honda ..........156 system............34 pad wear ............80 diagram, wiring ..........151 oxygenated ..........146 pedal height ..........77 drive chain............84 tank capacity ..........34 break-in guidelines ..........15 valve .............13...
  • Page 164 Index gap, spark plug ..........55 maintenance, rear suspension maintenance......72 gasohol ............146 additional procedures ........91 Rider’s Club Honda.........157 gasoline..............34 after competition ..........26 riding, gearing.............130 before & after competition......26 basic operation ..........11 guidelines, suspension adjustment ....114 between motos & practice......26 before..............7 component locations ........28 important safety information......2...
  • Page 165 Index suspension, front ............72,96 rear............73,109 suspension adjustment, front ..............96 rear..............109 for track conditions ........113 guidelines ...........114 transmission oil ..........39 tuning tips ............117 throttle, freeplay............46 inspection .............47 tires, air pressure ...........82 flat ..............82 selection............83 tools ...............150 torque specifications........142 transporting............134 troubleshooting..........137 tubes, replacing ..........82 valve, fuel............34 vehicle identification........140 washing your motorcycle ........93...
  • Page 166 Memo...
  • Page 167 Memo...

  • Page 168: 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. 80/100 – 21 51M 100/90 –...

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