Honda CRF250X Owner's Manual & Competition Handbook
  1. Manuals
  2. Brands
  3. Honda Manuals
  4. Motorcycle
  5. CRF250X
  6. Owner's manual & competition handbook

Honda CRF250X Owner's Manual & Competition Handbook

Owner's manual & competition handbook
Hide thumbs Also See for CRF250X:
Table of Contents

Advertisement

Quick Links

HONDA
CRF250X
OWNER'S MANUAL &
COMPETITION HANDBOOK

Advertisement

Table of Contents
loading

Related Manuals for Honda CRF250X

Summary of Contents for Honda CRF250X

  • Page 1 HONDA CRF250X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 3 2005 Honda CRF250X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 Honda Motorcycle Warranties Booklet conditions with high engine load and low vehicle responsibility for keeping your motorcycle well given to you by your Honda dealer at the line of speed. maintained. Scheduled service is a must, of purchase. Be sure to keep your Honda owner’s course.
  • Page 5 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, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 6: Table Of Contents

    Before & After Competition Maintenance..33 Headlight & Taillight ........100 Your Honda Dealer..........166 Between Motos & Practice Maintenance ..33 Appearance Care ..........101 The Honda Rider’s Club (USA only) .....167 After Competition Maintenance ....33 ADJUSTMENTS FOR COMPETITION ...103 TABLE OF CONTENTS ......168 Service Preparations Front Suspension Adjustments......104...

  • Page 7: Motorcycle Safety

    Motorcycle Safety This section presents some of the most important Important Safety Precautions .......2 information and recommendations to help you Loading..............3 ride your motorcycle safely. Please take a few Accessories & Modifications .......4 moments to read these pages. This section also Safety Labels ............5 includes information about the location of safety labels on your motorcycle.

  • Page 8: Important Safety Precautions

    Important Safety Information exhaust system. Wear clothing that fully covers Keep Your Honda In Safe Condition. It’s Important Safety Precautions your legs. important to keep your motorcycle properly Do not wear loose clothing which could catch on maintained and in safe riding condition. Having a...

  • Page 9: Loading

    Loading Your Honda was designed as a rider-only Loading Guidelines motorcycle. It was not designed to carry a As discussed on page 4, we recommended that passenger or cargo. A passenger or cargo could you do not carry any cargo on this motorcycle.

  • Page 10: Accessories & Modifications

    Modifying your motorcycle or using non-Honda motorcycle. Because Honda cannot test all other operation. Such changes could seriously impair accessories can make your motorcycle unsafe. accessories, you must be personally responsible your motorcycle’s handling, stability, and...

  • Page 11: Safety Labels

    This page shows the locations of safety labels on your motorcycle. Some labels warn you of potential hazards that could cause serious injury. Othere provide important safety information. Read these labels carefully and don’t remove them. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. Motorcycle Safety...
  • Page 12 Motorcycle Safety...

  • Page 13: Operating Controls

    Operating Controls Read this section carefully before you ride. It Component Locations ..........8 presents the location of the basic controls on your motorcycle. Operating Controls...

  • Page 14: Component Locations

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

  • Page 15: Before Riding

    Before Riding Before each ride, you need to make sure you and Are You Ready to Ride?........10 your Honda are both ready to ride. To help get Is Your Motorcycle Ready to Ride?....11 you prepared, this section discusses how to Pre-ride Inspection ...........11...

  • Page 16: Are You Ready To Ride

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

  • Page 17: 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 18 Before Riding...

  • Page 19: Basic Operating Instructions

    Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions ........14 start and stop your engine as well as break-in Starting & Stopping the Engine ......15 guidelines. Preparation ............15 Fuel Valve .............15 Starting Procedure ........15 Flooded Engine ..........16 How to Stop the Engine........16 Shifting Gears.............17 Braking ...............18...

  • Page 20: Safe Riding Precautions

    Basic Operating Instructions Side Stand Safe Riding Precautions Tripmeter The side stand (1) is used to support your Before riding your motorcycle for the first time, The tripmeter (1) is used to record the distance motorcycle while parked (page 19). To operate, please review the Important Safety Precaution traveled (USA: miles, Canada: kilometers) per use your foot to lower the side stand until it is...

  • Page 21: Starting & Stopping The Engine

    Starting & Stopping the Engine Always follow the proper starting procedure 4. Warm up the engine; don’t operate the Starting Procedure throttle. described below. 5. About 15 seconds after the engine startes, push the choke knob back all the way to fully Your motorcycle can be kickstarted wirh the Always follow the proper starting procedure OFF.

  • Page 22: Flooded Engine

    Starting & Stopping the Engine. Flooded Engine How to Stop the Engine Starting the engine after a stall during riding or after a fall: 1. Shift the transmission into neutral. 2. Pull the hot start lever and start the engine. (Do not open the throttle).

  • Page 23: Shifting Gears

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

  • Page 24: Braking

    Braking To slow or stop, apply the front brake and rear brake smoothly, while down shifting to match your speed. Gradually increase braking as you feel the brakes slowing your speed. To prevent stalling the engine, pull the clutch lever in before coming to a complete stop.

  • Page 25: Parking

    Parking Lower the side stand to support your motorcycle. If you’re through riding for the day, also turn the fuel valve OFF. Always choose a level place to park. Basic Operating Instructions...

  • Page 26: Post-Ride Inspection

    Post-ride Inspection When you return home after riding thoroughly clean your motorcycle and remove any dirt, mud, brush, rocks or other objects you may have picked up along the way. After cleaning, carefully inspect your motorcycle for leaks or damage. Be sure to lubricate the drive chain (page 96) to prevent rusting.

  • Page 27: 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 28 Basic Operating Instructions...

  • Page 29: Servicing Your Honda

    You’ll also find Side Stand............93 important safety precautions, information on oils, Service Preparations Drive Chain ............94 and tips for keeping your Honda looking good. Component Locations ........35 Additional Maintenance Procedures ....97 Seat Removal .............36 A CDI (Capacitive Discharge Ignition) system is Fuel Tank Removal ..........37...

  • Page 30: The Importance Of Maintenance

    If your motorcycle overturns or is involved in a crash, be sure your Honda dealer inspects all major parts, even if you are able to make some repairs. Remember, proper maintenance is your responsibility.

  • Page 31: 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 32: Maintenance Schedule

    Honda dealer. performed with basic mechanical skills and hand tools. Procedures for these items are provided in * Should be serviced by your Honda dealer, this manual. unless the ower has the proper tools and service date and is mechanically qualified.
  • Page 33 90,91 STEERING HEAD BEARINGS Should be serviced by your Honda dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the official Honda Service Manual (page 164). In the interest of safety, we recommended these items be serviced only by your Honda dealer.
  • Page 34 MAINTENANCE SCHEDULE – COMPETITION USE All items should be checked before each competition event. See your Honda dealer unless you are mechanically qualified and have the proper tools. Damage from competition use is not covered by the Distributor’s Limited Warranty on your Honda.

  • Page 35: General Competition Maintenance

    General Competition Maintenance Perform maintenance on firm, level ground using the side stand, a workstand, or equivalent support. Use genuine Honda parts or their equivalent when servicing your motorcycle. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.

  • Page 36: General Competition Maintenance

    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 37 For added peace of mind, any way. Move the handlebar from lock to lock to be sure remove the nuts, clean the threads, and apply Honda Thread there is no cable interference. Check to be sure the top of the Lock or an equivalent prior to torquing the nuts.
  • Page 38 (containing more than 40% the suspension. Refer to the Honda Service Manual (page molybdenum disulfide additive). 164). Use only Pro Honda HP Fork Oil 5W (U.S.A. only) or equivalent which contains special additives to assure maximum performance of your CRF’s front suspension.

  • Page 39: Before & After Competition Maintenance

    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 40 If you decide to wash your motorcycle or use cleaners, refer to Appearance Care (page 101). Servicing Your Honda...

  • Page 41: Component Locations

    Servicing Your Honda...

  • Page 42: 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 43: Fuel Tank Removal

    (4) breather tube (5) fuel tank band (10) (6) air cleaner cover rubber (7) fuel tank bolt (1) shroud A bolts/collars (2) shroud B bolts/collars (3) shrouds (8) fuel line (10) fuel valve bolt (9) fuel valve Servicing Your Honda...
  • Page 44 6. Install the fuel tank band (6). (10) (8) shrouds (9) shroud B bolts/collars (10) shroud A bolts/collars (4) fuel tank bolt (6) fuel tank band 10. Install the seat (page 36). (5) air cleaner cover rubber Servicing Your Honda...

  • Page 45: Subframe Upright Position

    3. Remove the seat (10) (page 36). (14) (10) (14) screw (18) subframe (15) air cleaner connecting tube clamp (5) quick fastener (8) collars (6) left side cover bolt (9) left side cover (7) seat bolt (10) seat Servicing Your Honda...
  • Page 46 (18) and right side cover bolt (19). (3) subframe mounting A bolt (16) (17) (18) (6) rear suspension upper mounting bolt (19) (17) (7) nut (8) band (16) right side cover (17) collars (18) seat bolt (19) right side cover bolt Servicing Your Honda...

  • Page 47: Fuel System

    WARNING (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. seriously injured when handling fuel.
  • Page 48 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 or RES; check for leaks. (1) fuel filter (3) O-ring (2) screws Servicing Your Honda...

  • Page 49: 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 • Oil is a major factor affecting the peformance molybdenum additives) and service life of the engine.
  • Page 50 • If the oil is below or near the lower level mark and add the recommended oil until the upper level mark. (Do not overfill) Reinstall the engine oil filler cap/dipstick. Repeat steps 1–5. 6. Reinsert the engine oil filler cap/dipstick. 7. Check for oil leaks. Servicing Your Honda...
  • Page 51 (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 52: Transmission Oil

    • Oil is a major factor affecting the performance additives and service life of the transmission and clutch. suggested oil* Pro Honda HP Trans oil, Do not use non-detergent, vegetable, or castor Pro Honda GN4 or HP4 based racing oils.

  • Page 53: Checking And Adding Oil

    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 54: Coolant

    Coolant Recommendation Checking & Adding Coolant Use Pro Honda HP coolant or an equivalent high Refer to Safety Precautions on page 2. quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically 1. With the engine at normal operating recommended for use in aluminum engines.
  • Page 55 If oil leaks through the check hole, the engine oil seal is damaged. See the Honda Service Manual or consult your Honda dealer for replacing the water pump seal or the engine oil seal.
  • Page 56 Coolant should be replaced by your Honda (8). dealer, unless you have the proper tools and service data and are mechanically qualified. Refer to the Honda Service Manual (page 164). WARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.

  • Page 57: 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 58 Air Cleaner 7. Apply a thin coat of Honda White Lithium NOTICE Grease to the sealing surface. 8. Assemble the air cleaner and holder. Improper installation of the air cleaner assembly Install the tab (7) of the holder in the hole (8) may allow dirt and dust to enter the engine and of the air cleaner tab (9).

  • Page 59: Crankcase Breather

    1. Remove the crankcase breather tube plug (1) from the tube (2) and drain the deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 60: Throttle

    4. Tighten the lock nut. 5. Operate the throttle grip to ensure that it functions smoothly and returns completely. If you can’t get the freeplay within the specified range, contact your Honda dealer. (–) (2) dust cover (+)increase (3) upper lock nut (–)decrease...
  • Page 61 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 62: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your Honda dealer or refer to the official Honda Service Manual (page 164). Servicing Your Honda...
  • Page 63 4. Remove the five clutch spring bolts and clutch (8) clutch lifter springs (6). (9) clutch lifter rod (10) clutch discs, clutch plates, judder spring and Loosen the bolts in a crisscross pattern in 2 or 3 spring seat progressive steps Servicing Your Honda...
  • Page 64 Measure the free length of each spring. Service Limit: 1.50 in (38.0 mm) (10) If one or more springs are beyond the service (10) O-ring (11) clutch cover limit, replace the springs as a set. (6) clutch lifter rod (7) clutch lifter Servicing Your Honda...
  • Page 65 Clutch System 11. Lubricate the O-rings (12), rear brake pedal (13) pivot and pivot bolt (14) with Honda Lithium Grease. Tighten the pivot bolt to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) Connect the brake pedal return spring (15) if it was removed.

  • Page 66: Hot Start Lever

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

  • Page 67: 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 68: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (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 69 15 lbf·ft (21 N·m, 2.1 kgf·m) (6) right side cover (8) side cover bolt (7) collars (9) seat bolt (1) gasket (2) muffler (3) muffler B bolt (5) muffler clamp bolt (4) muffler A bolt Servicing Your Honda...
  • Page 70 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 63). Servicing Your Honda...

  • Page 71: Spark Arrester

    4. Install the spark arrester and gasket in the muffler (1) and tighten the four bolts (2) to the specified torque: 9 lbf·ft (12 N·m, 1.2 kgf·m) (1) muffler (2) bolts (1) muffler (3) spark arrester (2) bolts (4) gasket Servicing Your Honda...

  • Page 72: Valve Clearance

    The clearance will change as engine temperature rises. (1) crankshaft hole cap (1) breather tube (2) spark plug cap 4. Remove the cylinder head cover bolts (3), and cylinder head cover (4). (3) cylinder head cover bolts (4) cylinder head cover Servicing Your Honda...
  • Page 73 If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Removal (page 68) 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 74 (3) until it stops, in order to valve clearance. 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 75 Do not let the valve lifters and shims fall into the crankcase. Be careful 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 76 • Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2.450 Reface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2.900 mm. (1) valve lifter (2) shim Servicing Your Honda...
  • Page 77 3% molybdenum disulfide additive) to outer surface of the each valve (10) lifters. Install the valve lifters (3). (7) cam sprocket (9) cylinder head (8) timing marks (10) cam chain (cont’d) (3) valve lifters Servicing Your Honda...
  • Page 78 VALVE CLEARANCES: IN: 0.005 ± 0.001 in (0.12 ± 0.03 mm) EX:0.011 ± 0.001 in (0.28 ± 0.03 mm) (15) (14) stopper tool (15) sealing washer (16) camchain tensioner lifter caver bolt (13) (13) (13) feeler gauge Servicing Your Honda...
  • Page 79 2. Install the cylinder head cover packing (3) into the groove of the cylinder head cover (4). (7) spark plug cap (8) breather tube (3) cylinder head cover packing (4) cylinder head cover 5. Install the fuel tank and the seat (page 38). Servicing Your Honda...

  • Page 80: Piston/Piston Rings/Piston Pin

    (4) spark plug cap (6) radiator hose clamp 10.Remove the cylinder head cover (page 66). (7) radiator hose 11.Remove the spark plug (5). (1) exhaust pipe joint nuts (2) exhaust pipe (3) exhaust pipe gasket (5) spark plug Servicing Your Honda...
  • Page 81 (14) dowel pins (16) cam chain guide steps. (15) cylinder head gasket NOTICE Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (13) (12) (12) cylinder head nuts/washers (13) cylinder head Servicing Your Honda...
  • Page 82 (2) piston pin (4) piston rings 4. Spread each piston ring (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 83 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 84 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 Servicing Your Honda...
  • Page 85 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 (5) piston rings (4) cylinder (cont’d) Servicing Your Honda...
  • Page 86 (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 Servicing Your Honda...
  • Page 87 14.Fill the cooling system with the recommended radiator coolant (page 48). (11) (10) (12) spark plug cap (10) radiator hose (11) radiator hose clamp 7. Install the shims and cam shaft (page 71). 8. Install the spark plug (page 61). Servicing Your Honda...

  • Page 88: 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 89: Rear Suspension Inspection

    (page 122). Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. 2. Lift the subframe to the upright position (page The instructions found in this owner’s manual are 39).

  • Page 90: Recommended Fork Oil

    (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 when equivalent removing the fork damper.
  • Page 91 10.4 US oz Slightly stiffer as capacity (308 cm it nears full compression. (2) fork damper (10) O-ring 7. Tighten the fork damper using the lock nut wrench to the specified torque: 25 lb·ft (34 N·m, 3.5 kgf·m) Servicing Your Honda...

  • Page 92: Brakes

    (page adjuster and piston (3). 89), 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 93 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 level freeplay exceeds 0.8 in...
  • Page 94 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 95 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 pads (3) brake disc (2) front brake caliper Servicing Your Honda...

  • Page 96: Wheels

    During the first 100 miles (150 km), 3. Check wheel rim runout. If runout is spokes will loosen more rapidly due to the initial noticeable, see the Honda Service Manual for seating of the parts. Excessively loose spokes inspection instructions.

  • Page 97: 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 98 • 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 99: Side Stand

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

  • Page 100: Drive Chain

    5. Turn the adjusting bolt counterclockwise lightly until it touches the axle plate. Then, tighten the lock nut to the specified torque by holding the adjusting bolt with a wrench. 20 lbf·ft (27 N·m, 2.8 kgf·m) Servicing Your Honda...
  • Page 101 It should only be rapidly. removed or replaced by your Honda dealer. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any The O-rings can be damaged by steam cleaning, sprocket, which is damaged or excessively high pressure washers, and certain solvents.
  • Page 102 Pro SERVICE LIMIT: Honda Chain Lube or an equivalent, or SAE 80 UPPER ROLLER: 1.1 in (29 mm) or 90 gear oil is recommended. LOWER ROLLER: 1.5 in (39 mm)

  • Page 103: 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 104 (8) oil filter cover (9) cylinder head bolts RIGHT SIDE (10) drive sprocket (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 105: Battery

    (negative cable (3) first). If your battery seems weak and/or is leaking electrolyte (cause slow starting or other electrical problems), see your Honda dealer. WARING: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

  • Page 106: Headlight & Taillight

    The taillight uses LED illumination. If the taillight does not function properly, see 1. Remove the two front visor bolts (1) and pull your Honda dealer for service. out the front visor (2). This model is equipped with an electric starter and battery for easy engine starting.

  • Page 107: Appearance Care

    CRF. The force of water under extreme dry the brakes and restore normal braking pressure can penetrate the dust seals of the You may use Pro Honda Hondabrite, a performance. suspension pivot points and steering head multi-surface cleaner/degreaser, to remove both...
  • Page 108 #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 109: Adjustments For Competition

    Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......104 for maximum competition performance. Rear Suspension Adjustments ......118 Suspension Adjustments for Track Conditions Initial suspension adjustments should be ..............122 performed after a minimum of two hours of easy Suspension Adjustments Guidelines ....123 break-in time.

  • Page 110: 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 111 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 112 Front Suspension Adjustments 3. Disconnect the head light connector (3). 5. Loosen the upper pinch bolts (6). 9. Pull the front axle shaft (13) out of the wheel 6. Loosen the fork damper (7), using the lock hub and remove the front wheel. nut wrench but do not remove it yet.
  • Page 113 Front Suspension Adjustments 15.Hold the outer tube (23), then remove the fork 12.Clean the fork assembly, especially the sliding NOTICE damper (24) from the outer tube using the surface of the slider (21) and dust seal (22). Do not support the brake caliper by the brake lock nut wrench (25).
  • Page 114 Front Suspension Adjustments 17.Temporarily install the fork damper to the 22.Apply pressure to the fork damper and insert a (28) outer tube. special tool or mechanic's stopper tool (30) 18.Set the lower end (axle holder) (28) of the (see below) between the axle holder (28) and slider in a vise with a piece of wood or soft lock nut (31).
  • Page 115 Recommended Oil: Be careful not to damage the fork cap bushing. 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 6.6 US oz (195 cc, 6.9 Imp oz)
  • Page 116 Front Suspension Adjustments 11.Screw in the lock nut (7) to the fork damper 7. Extend the fork damper piston rod to 9. Tighten the fork cap (1) while holding the cut piston rod (6) fully. maximum. Adjust the oil level of the fork out of the fork damper (2) using the lock nut damper as shown.
  • Page 117 Front Suspension Adjustments 14.Blow out the oil from the fork damper spring 12.Blow the extra oil off to the fork damper (2) 13.Drain the extra oil from the fork damper chamber using compressed air to the oil hole. spring chamber (8) by pumping the fork spring chamber (8) oil hole (9).
  • Page 118 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 119 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 center bolt (8) O-ring. a vise with a piece of wood or soft jaws to center bolt (8) clearance.
  • Page 120 Fork Oil Capacity: outer tube/slider (1). Standard (0.42 kgf/mm) Fork Spring No mark Recommended Oil: 1 scribe mark (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 2 scribe mark (aftermarket parts) (11) Standard oil 11.8 US oz Standard oil 11.7 US oz...
  • Page 121 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. Insert both fork legs into the specified torque: recommended fork oil to the O-ring.
  • Page 122 Front Suspension Adjustments 19.Clean the threads of the fork protector bolts 20.Clean the surfaces where the axle and axle 21.Align the brake caliper (20) and hose with the (15) 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 123 Front Suspension Adjustments 23.Install the handlebar (22), mounting rubbers 25.Install and tighten the front visor bolts (27). NOTICE (23), washers and handlebar holder nuts (24) Install the handlebar pad (28). and tighten the handlebar holder nuts to the To avoid damage when torquing the axle pinch specified torque: bolts, be sure the axle is seated firmly onto the 33 Ibf·ft (44 N·m, 4.5 kgf·m)

  • Page 124: Rear Suspension Adjustments

    Min. : 9.6 in (243 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring pre-load length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 4.55 kgf/mm): 9.7 in (246 mm) limited to adjustments of the shock assembly Min.
  • Page 125 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 To adjust to the standard position: stages with separate adjusters.
  • Page 126 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 127 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 motorcycle’s suspension is dimension (step 2).

  • Page 128: 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 129: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 104 - 119. 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 130 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 131 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 132: Carburetor Adjustments & Turning Tips

    Carburetor Adjustments & Tuning Tips The carburetor used on your CRF will seldom Hot Start Circuit Carburetor Components experience trouble with the standard settings A lean mixture must be delivered to the cylinder under average load, and average climatic and when a hot engine is being started.
  • Page 133 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 134 Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 37). 8. Disconnect the throttle sensor connector (6). Carburetor Removal 5. Remove the band (2) and rear suspension Remove the carburetor. upper mounting nut (3), and pull out the rear suspension upper mounting bolt (4).
  • Page 135 Carburetor Adjustments & Tuning Tips 10. Remove the throttle drum cover bolt (8) and 3. Remove the link arm set screw (7). Carburetor Disassembly throttle drum cover (9). When installing the link arm set screw, apply a locking agent to the link arm set screw threads.
  • Page 136 Carburetor Adjustments & Tuning Tips When installing the floating valve (10) onto 5. Remove the accelerator pump cover screws 7. Remove the holder screw (19), throttle stop the throttle valve (8) make sure the floating (12) and accelerator pump cover (13). screw holder (20), float bowl screws (21), valve’s flat side faces out and the hole (11) tube guides (22) and float bowl (18).
  • Page 137 Carburetor Adjustments & Tuning Tips 9. Measure the float level (26) with the float Carburetor Assembly level gauge (27) during float tab just contacting the float valve and the carburetor intake (28) facing up. The float level should To assemble, reverse the disassembly procedures. be 0.31 in (8.0 mm).
  • Page 138 Carburetor Adjustments & Tuning Tips Adjustment Procedure Pre-Adjustment Checks 1. Turn the pilot screw in until it is lightly seated Before adjusting carburetor settings, check the and record the number of turns. Turn the pilot following: screw (1) out the same number of turns. •...

  • Page 139: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a Fork Height/Angle Wheelbase specific concern. Subtle changes in overall handling may also be noted. Standard Position Adjusting your motorcycle’s wheelbase can offer The position of the outer tubes in the clamps is subtle changes in overall handling.

  • Page 140: Gearing

    Honda Service Manual, certain sections or perhaps you can just rev it with a gearing change can make you feel like sprocket changing should be done by your Honda out a bit longer. you’re going slower when, in reality, you’ve dealer.

  • Page 141: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your motorcycle offer a “happy additional loads to the transmission because it medium”...

  • Page 142: 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 143: Tips

    Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......138 Storing Your Motorcycle........139 You & the Environment ........141 Troubleshooting..........142 Tips...

  • Page 144: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to To secure your motorcycle, 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- •...

  • Page 145: Storing Your Honda

    Honda and correct any problem before After the coolant has been completely 11.Place your CRF on the optional Honda work- storing it. That way, needed repairs won’t be drained, ensure that the drain bolt sealing stand or equivalent to raise both tires off the...
  • Page 146 Storing Your Honda Removal from Storage 1. Uncover and clean your CRF. Change the engine and transmission oil if more than 4 months have passed since the start of storage. 2. Uncover the end of the muffler and remove the rag from the muffler outlet.

  • Page 147: You & The Envionment

    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 148: 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-41) line at carburetor RESTRICTED • Clogged fuel line and check for asterisk.

  • Page 149: Taking Care Of The Unexpected

    Taking Care of the Unexpected This section gives practical advice to help you If a Fuse Blows ..........144 problems. If Your Battery is Low (or Dead).....145 Taking Care of the Unexpected...

  • Page 150: If A Fuse Blows

    Leave the blown fuse in that circuit and have your motorcycle checked by your Honda dealer. Recommended Main Fuse: 15A 1. To prevent an accidental short circuit, stop the engine.

  • Page 151: If Your Battery Is Low (Or Dead)

    Bump starting is also not recommended. If you can’t charge the battery or it appears unable to hold a charge, contact your Honda dealer. Taking Care of the Unexpected...
  • Page 152 Taking Care of Unexpected...

  • Page 153: Technical Information

    Technical Information This section contains dimensions, capacities, and Vehicle Identification ........148 other technical data. Specifications ...........149 Torque Specifications........151 High Altitude Carburetor Adjustment ....154 Emission Control Systems .......155 Oxygenated Fuels..........156 Competition Logbook ........157 Optional Parts List ...........159 Spare Parts & Equipment.........160 Wiring Diagram..........161 Technical Information...

  • Page 154: Vehicle Identification

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

  • Page 155: Electrical Battery

    Specifications For USA (except California) & CANADA 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 85.6 in 2,174 mm Overall width Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement...
  • Page 156 Specifications For California 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 85.6 in 2,174 mm Overall width 32.6 in Transmission 5-speed, constant mesh 827 mm Cylinder arrangement Overall height Primary reduction...

  • Page 157: 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 Clutch cover Water pump cover Transmission oil check bolt Crankshaft hole cap Oil filter cover Cylinder bolt Cylinder head bolt Exhaust pipe joint nut...
  • Page 158 Rear shock link nuts NOTE 2, 4 Shock spring lock nut Kickstarter arm bolt NOTES: 1. Apply Honda Thread Lock or an equivalent to the threads. 2. Apply oil to the threads and flange surface. 3. Stake. 4. U-nut. 5. UBS nut.
  • Page 159 0.12 Side stand mounting bolts (upper) (lower) (33) NOTES: 1. Apply Honda Thread Lock or an equivalent to the threads. (22) 2. Apply oil to the threads and flange surfaces. (28) 3. Stake. 4. U-nut. (25) 5. UBS nut.

  • Page 160: 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 161: Emission Control Systems

    The vehicle Emission Control Information label of design incorporated into any new vehicle for Honda Motor Co., Ltd. Utilizes lean carburetor (1) is attached to the frame below the seat. the purpose of noise control prior to its sale or...

  • Page 162: 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 163: 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 164 Competition Logbook Date Running Location/Event Comments (Suspension Settings, Gearing, Chassis Adjustments, Maintenance Time Performed, etc.) (Make several photocopies of this page for future use) Consumer Information...

  • Page 165: 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 268.8 lbf/in (4.80 kgf/mm) Standard 53 Teeth, Aluminum. Standard ENGINE Remarks <114>...

  • Page 166: Spare Parts & Equipment

    In addition to the usual nuts and bolts, top end-complete (Engine Oil) consider the following: radiator hoses Pro Honda HP Trans Oil or Pro Honda GN4 or radiator shrouds (L & R) HP4 (without molybdenum additives only) 4- brake hoses (front & rear) stroke Oil (Transmission Oil)

  • Page 167: Wiring Diagram

    Wiring Diagram Technical Information...
  • Page 168 Technical Information...

  • Page 169: Consumer Information

    Consumer Information This section contains information about Authorized Manuals .........164 contacting Honda and how to get an official Contacting Honda..........165 Honda service manual. Your Honda Dealer...........166 The Honda Rider’s Club (USA only) ....167 Consumer Information...

  • Page 170: 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 171: 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 172: 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 173: 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 174: Service Preparations Component Locations

    Table of Contents The following presents the contents of each SERVICING YOUR HONDA......23 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............82 The Importance of Maintenance .......24 Front Suspension Inspection......82 MOTORCYCLE SAFETY.......1 Maintenance Safety...........25 Rear Suspension Inspection......83 Important Safety Precautions..
  • Page 175 Emission Control Systems ......155 Oxygenated Fuels..........156 Competition Logbook ........157 Optional Parts List ..........159 Spare Parts & Equipment........160 Wiring Diagram..........161 CONSUMER INFORMATION ....163 Authorized Manuals ........164 Contacting Honda..........165 Your Honda Dealer..........166 The Honda Rider’s Club (USA only) .....167 Table of Contents...

  • Page 176: Index

    ........16 front suspension..........104 component locations, fork, tires ...............91 maintenance ..........35 front suspension adjustment .......104 American Honda, contacting ......165 operating controls ...........8 front suspension inspection ......82 apparel, protective..........2 competition logbook ........157 oil recommendation ........84 coolant..............48 contacting Honda ..........165 frame number...........148...
  • Page 177 Index gap, spark plug...........61 maintenance, rear suspension maintenance ......83 gasohol ...............41 after competition...........33 Rider’s Club Honda .........167 gasoline ..............41 before & after competition ......34 riding, gearing .............134 between motos & practice ......33 apparel ............2 guidelines, suspension adjustment....123 general competition ........29 basic operation..........13...
  • Page 178 Index suspension, front ..............82 rear ..............83 suspension adjustment, front ............104 rear ..............118 for track conditions........135 guidelines............123 transmission oil..........46 tuning tips ............126 throttle, freeplay ............54 inspection............55 tires, air pressure............91 flat ..............91 selection ............92 tools..............160 torque specifications.........151-153 transporting ............138 troubleshooting ..........142 tubes, replacing ..........91 valve, fuel ............15 vehicle identification ........148 washing your motorcycle.........101...
  • Page 179 Memo...

  • Page 180: 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: 100/100-18 59M...

Table of Contents