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CRF and how it works. To protect your Please report any change of address or ownership investment, we urge you to take responsibility for to your Honda dealer so we will be able to keeping your CRF well maintained. Scheduled contact you concerning important production service is a must, of course.
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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.
Contacting Honda..........157 Before You Service Your Honda Brakes..............79 Your Honda Dealer..........158 The Importance of Maintenance .......18 Wheels...............83 The Honda Rider’s Club (USA only) .....159 Maintenance Safety...........19 Tires & Tubes ............84 Important Safety Precautions......19 Drive Chain ............86 TABLE OF CONTENTS ......160 Maintenance Schedule ........20...
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.
Keep your Honda in Safe Condition. As an experienced rider, you know there is much Maintaining your CRF properly is critical to your you can do to protect yourself when you ride.
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.
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...
Operating Controls Read this section carefully before you ride. It Component Locations ..........6 presents the location of the basic controls on your CRF. Operating Controls...
Component Locations hot start lever front brake lever clutch lever engine stop button throttle grip fuel fill cap choke knob kickstarter shift lever fuel valve rear brake pedal Operating Controls...
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...
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.
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): •...
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...
Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precaution beginning on page 7 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.
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.
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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.
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: •...
You’ll also find Exhaust Pipe/Muffler .........89 important safety precautions, information on oils, Service Preparations Additional Maintenance Procedures ....92 and tips for keeping your Honda looking good. Component Locations ........28 Seat Removal .............29 Appearance Care ..........94 An ICM (Ignition Control Module) system is Fuel Tank Removal ..........30...
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...
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...
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...
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This maintenance schedule is based upon average riding condition. Machine subjected to severe use require more frequent servicing. NOTE: 1.Clean after every moto for dusty riding condition. 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. Servicing Your Honda...
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.
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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...
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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.
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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...
(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...
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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 94). Servicing Your Honda...
(4) breather tube (5) fuel tank band (6) air cleaner case cover (7) fuel tank bolt (10) (1) shroud A bolts/collars (2) shroud B bolts (3) shrouds (8) fuel line (10) fuel valve bolt (9) fuel valve Servicing Your Honda...
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6. Install and hook the fuel tank band (6). (10) (8) shrouds (9) shroud B bolts (10) shroud A bolts/collars (4) fuel tank bolt 10. Install the seat (page 29). (5) air cleaner case cover (6) fuel tank band Servicing Your Honda...
(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.
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Install the fuel filter in the fuel tank. Refill the fuel tank. Attach the fuel valve and fuel line, and turn the fuel valve to ON; check for leaks. (1) fuel filter (3) O-ring (2) bolts Servicing Your Honda...
JASO T 903 MA or MB NOT RECOMMENDED suggested oil* Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke engine oil Other viscosities shown in the following chart or an equivalent* may be used when the average temperature in your riding area is within the indicated range.
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6 races or about every 15.0 hours. Repeat steps 1–4. However, if you replace only the oil before 6. Reinsert the engine oil filler cap. the recommended interval, see page 21. 7. Check for oil leaks. (cont’d) Servicing Your Honda...
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(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.
Other viscosities shown in the following chart may be used when the average temperature in suggested oil* Pro Honda HP Trans oil, Pro Honda GN4 or HP4 your riding area is within the indicated range. (without molybdenum additives) 4-stroke engine...
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(2) transmission oil drain bolt 5. After inspection the oil level or adding oil, (3) sealing washer tighten the oil check bolt and transmission oil filler cap to the specified torque:. Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m) Servicing Your Honda...
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.
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Refer to Safety Precautions on page 19. Honda Service Manual for troubleshooting of leaks). Coolant should be replaced by your Honda 2. Check water hoses (1) for cracks, dealer, unless you have the proper tools and deterioration, and clamp bands for looseness.
NOTICE Service the air cleaner more frequently if you Improper or lack of proper air cleaner ride in unusually wet or dusty areas. Your Honda maintenance can cause poor performance and dealer can help you determine the correct service premature engine wear.
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Air Cleaner 4. Remove the air cleaner with the retaining bolt, 9. Apply a thin coat of Honda White Lithium NOTICE keeping the two access top tabs up. Grease to the sealing surface. 5. Remove the air cleaner from the air cleaner 10.
Service the breather if you can see deposits in the transparent section of the drain tube. Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...
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) rubber dust cover (+)increase (3) lock nut (–)decrease...
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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...
3. Connect a tachometer to the engine. 4. Shift into neutral. Start the engine. 5. Keep the motorcycle in an upright position. 6. Adjust idle speed with the throttle stop screw (2). Idle speed: 1,700 ± 100 rpm Servicing Your Honda...
3. Tighten the lock nut. (–) (4) lock nut (5) integral cable adjuster (+) increase free play (–) decrease free play 6. Adjust the cable end adjuster for minor adjustement. (cont’d) Servicing Your Honda...
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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 156). Servicing Your Honda...
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4. Remove the six clutch spring bolts and limit, replace the springs as a set. (7) clutch lifter (9) clutch discs and plates springs (5). (8) clutch lifter rod Loosen the bolts in a crisscross pattern in 2 or 3 progressive steps. (cont’d) Servicing Your Honda...
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11. Lubricate the O-ring (11), rear brake pedal 6. Install the clutch pressure plate (7). Clutch Disc/Plate Installation (12) pivot and pivot bolt (13) with Honda 7. Install the six clutch springs and bolts (8). Lithium Grease and tighten the pivot bolt to 8.
(1) hot start lever (2) hot start lever freeplay (–) Inspection (3) lock nut (+) increase Check freeplay: (4) cable adjuster (–) decrease 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...
“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...
4. Remove the cylinder head cover A bolt (3), cylinder head cover B bolts (4) and cylinder head cover (5). (2) spark plug (3) cylinder head cover A bolt (4) cylinder head cover B bolts (cont’d) (5) cylinder head cover Servicing Your Honda...
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If intake valve clearance and exhaust valve clearance need adjustment, see Camshaft Holder Assembly Removal (page 57) and select the correct shim for each valve. (3) primary drive gear lock bolt (5) index mark (4) “punch” mark (6) exhaust rocker arm Servicing Your Honda...
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Decompressor Arm clearance Adjustment (page 63). If intake valve clearance, exhaust valve clearance and decompressor arm clearance don’t need adjustment, see Spark Plug Installation (page 64). (2) cam chain tensioner lifter cover bolt (3) sealing washer (cont’d) Servicing Your Honda...
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• 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 3.000 mm. (1) valve lifter (2) shim Servicing Your Honda...
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1/2 engine oil and 1/2 molybdenum disulfide grease (containing more than 3% molybdenum disulfide additive)) to the camshaft and outer surface of the each valve lifters (3). (4) camshaft holder assembly (5) intake cam lobes (6) camshaft holder assembly bolts Servicing Your Honda...
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Do not let the bolts and sprocket fall into the crankcase. (14) (12) (11) (10) cam sprocket (11) timing mark (12) “∆” mark (13) cam chain (7) primary drive gear lock bolt (8) “punch” mark (10) (9) index mark (10) cam sprocket (14) cam sprocket bolts Servicing Your Honda...
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(19) (11) (18) (18) sealing washer (19) cam chain tensioner lifter cover bolt (16) (12) (8) “punch” mark (9) index nark (8) “punch” mark (16) exhaust rocker arm (9) index mark (11) timing marks (12) “∆” mark Servicing Your Honda...
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RIGHT EXHAUST VALVE CLEARANCE 0.014 IN (0.35 mm) Example: If measured right exhaust valve clearance is 0.011 in (0.28 mm), decompressor clearance is; 0.011 in (0.28 mm) + 0.014 in (0.35 mm) = 0.025 in (0.63 mm) Servicing Your Honda...
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(2) spark plug hole (1) O-ring (2) crankshaft hole cap 2. Install the cylinder head cover packing (3) into the groove of the cylinder head cover (4). (1) spark plug (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...
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B bolts (7) to the specified torque: 7 lbf·ft (10 N·m, 1.0 kgf·m) (8) spark plug cap (9) breather tube (5) cylinder head cover (6) cylinder head cover A bolt (7) cylinder head cover B bolts Servicing Your Honda...
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(11) engine hanger nut (12) engine hanger A bolt (13) fuel hose guide (19) (14) engine hanger B bolts (15) left engine hanger plate (16) right engine hanger plate (19) (20) (19) cylinder head nuts/washers (20) cylinder head Servicing Your Honda...
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(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...
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2. Apply engine oil to the piston rings and install We recommend you consult the Service Manual the piston rings. or your authorized Honda dealer for correct Service Limit measurements. NOTICE Do not damage the piston ring by spreading the ends too far.
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(1) cylinder gasket (3) B dowel pin (2) A dowel pins 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...
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Do not damage the piston rings and cylinder walls. (7) cam chain guide (8) cam chain guide tab (9) cylinder cut-out (1) dowel pins (2) cylinder head gasket (4) cam chain (6) piston rings (5) cylinder (cont’d) Servicing Your Honda...
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(11) fuel hose guide 19 lbf·ft (26 N·m, 2.7 kgf·m) (12) engine hanger nut Tighten the engine hanger nut to the specified torque: 44 lbf·ft (59 N·m, 6.0 kgf·m) (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
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8. Install the spark plug (page 64). 14. Install the subframe and muffler (page 32). (17) ignition coil bolts (18) ignition coil nut 15. Install the fuel tank and the seat (page 31). (19) primary wire (20) spark plug cap Servicing Your Honda...
See page 102 for damper locking the front brake and pushing down on fork oil replacement. the handlebar several times. • 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 115). 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.
(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.
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Standard oil 13.1 US oz capacity (387 cm Maximum oil 14.4 US oz Slightly stiffer as capacity (426 cm it nears full compression. Minimum oil 11.1 US oz Slightly softer as capacity (327 cm it nears full compression. Servicing Your Honda...
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(2) is in good condition. Apply the recommended fork oil to the O-ring. (10) (1) outer tube (2) fork damper (10) O-ring 8. 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 adjuster and piston (3). 82), 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...
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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...
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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.
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Make sure there are no fluid leaks. Check for wear indicator grooves deterioration or cracks in the hoses and fittings. (1) brake pads (3) brake disc (2) front brake caliper Servicing Your Honda...
Excessively loose spokes 3. Check wheel rim runout. If runout is may result in instability at high speeds and the noticeable, see the Honda Service Manual for possible loss of control. It’s also important that inspection instructions.
Overinflated tires make your CRF 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...
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• 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...
Lower Roller: 1.4 in (35 mm) Adjust chain slack if needed. 5. Check the chain slider (4) for wear. If the wear is 3/16 in (5 mm) or more, replace Servicing Your Honda...
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(5) with the same reference marks (6) on both should be used in preference to motor oil. Pro otherwise appears unserviceable. sides of the swingarm. Honda Chain Lube or an equivalent, or SAE 80 Replacement chain: or 90 gear oil is recommended. D.I.D.520DMA2...
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Install the master link retaining clip so that the closed end of the clip will face the direction of forward wheel rotation. 8. Recheck chain slack and adjust as necessary. Servicing Your Honda...
1. Remove the seat bolt (1), side cover bolt (2) and right side cover (3). (4) muffler clamp bolt (6) muffler B bolt/washer (5) muffler A bolt (7) muffler (1) seat bolt (3) right side cover (2) side cover bolt Servicing Your Honda...
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(12) side cover bolt 3. Install the muffler (4). 4. Install the muffler clamp (5) by aligning the tab (6) of the muffler clamp with the cut-out (7) of the muffler. (4) muffler (6) tab (5) muffler clamp (7) cut-out Servicing Your Honda...
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.
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(6) oil filter cover (7) cylinder bolt (8) cylinder head bolts (1) cylinder head cover bolts (2) clutch cover bolts (3) water pump cover bolts (4) transmission oil check bolt (5) crankshaft hole cap (9) exhaust pipe joint nuts Servicing Your Honda...
You may use Pro Honda Hondabrite, a and steering head bearings-driving dirt inside multi-surface cleaner/degreaser, to remove both and needed lubrication out.
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#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...
Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments......98 for maximum competition performance. Front Suspension Air Pressure......98 Front Suspension Damping ......98 Initial suspension adjustments should be Fork Springs..........99 performed after a minimum of two hours of easy Front Suspension Disassembly .....99 break-in time.
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).
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)
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Front Suspension Adjustments 3. Remove the handlebar pad. 6. Remove the disc cover (7) by removing the NOTICE Remove the handlebar holder nuts (3), two bolts (8). washers, mounting rubbers and handlebar (4). Do not support the brake caliper by the brake hose.
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Front Suspension Adjustments 11.Clean the fork assembly, especially the sliding 14.Hold the outer tube, then remove the fork 16.Temporarily install the fork damper to the surface of the slider (18) and dust seal (19). damper (23) from the outer tube using a lock outer tube.
Front Suspension Adjustments 21.Apply pressure to the fork damper and insert a Damper Oil Change (27) special tool or mechanic's stopper tool (29) (see below) between the axle holder (27) and (29) lock nut (30). 1. Loosen the fork cap (1) by turning the fork 22.Hold the lock nut and remove the fork center damper (2) using the lock nut wrench (3).
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Recommended Oil: Be careful not to damage the fork cap bushing. Oil Level: 1.65 – 1.85 in (42 – 47 mm) Pro Honda HP Fork Oil 5 W or equivalent Do not disassemble the fork cap assembly. Recommended Amount: Replace the fork cap as an assembly if it is 6.6 US oz (195 cc, 6.9 Imp oz)
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Front Suspension Adjustments 9. Tighten the fork cap (1) while holding the cut 11. Screw in the lock nut (7) to the fork damper 13. Drain the extra oil from the fork damper piston rod (6) fully. out of the fork damper (2) using the lock nut spring chamber (9) oil hole (5).
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.
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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.
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Fork Oil Capacity: outer tube/slider (1). Standard (0.46 kgf/mm) Fork Spring No mark Recommended Oil: 4 scribe marks (factory products) Pro Honda HP Fork Oil 5 W or equivalent. 2 scribe marks (aftermarket parts) (11) Standard oil 12.7 US oz capacity...
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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.
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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 (19) 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.
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Front Suspension Adjustments 23.Install the handlebar (21), mounting rubbers 25.Install and tighten the number plate bolt (26). (28) (22), washers and handlebar holder nuts (23) Install the handlebar pad (27). (28) and tighten the handlebar holder nuts to the specified torque: (27) 32 Ibf·ft (44 N·m, 4.5 kgf·m) (22)
Min. 9.8 in (249.0 mm) gas. Do not attempt to disassemble, service, or dispose of the damper; see your Honda dealer. Spring preload length (Optional spring) The instructions found in this owner’s manual are Min. (Softer, 5.3 kgf/mm): 9.88 in (251 mm) limited to adjustments of the shock assembly Min.
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.
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 UNLOADED MEASUREMENT Standard Race Sag: 3.9 in (100 mm) important for competition use.
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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).
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.
Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 98 - 115. 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.
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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. •...
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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: –...
(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.
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.
3. Install the float bowl plug. Honda carburetor jet sizes are numbered in The minimum to maximum range of pilot screw increments of 2 or 3. When changing the main jet adjustment is 1 3/8 to 2 1/8 turns out from the size, increase or decrease it gradually until the lightly seated position.
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Carburetor Adjustments & Tuning Tips 4. Disconnect the fuel line (2) from the fuel 10. Remove the hot start cable holder (6). 12. Remove the throttle cables (9) by loosening valve (3). the throttle cable lock nut (10). 5. Remove the fuel tank (page 30). 6.
Carburetor Adjustments & Tuning Tips 3. Remove the link arm set screw (6). When installing the floating valve (8) onto the Carburetor Disassembly When installing the link arm set screw, apply throttle valve (5) make sure the floating a locking agent to the link arm set screw valve’s flat side faces out and the hole (9) threads.
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Carburetor Adjustments & Tuning Tips 5. Remove the accelerator pump cover screws 7. Remove the holder screw (15), throttle stop 9. Measure the float level (23) with the float (10) and accelerator pump cover (11). screw holder (16), float bowl screws (17), level gauge (24) during float tab just tube guides (18) and float bowl (19).
Carburetor Adjustments & Tuning Tips Carburetor Assembly To assemble, reverse the disassembly procedures. To install the carburetor, reverse the removal procedures. • After installing the carburetor, adjust the throttle cable (1) free play and hot start cable (2) free play. •...
Carburetor Adjustments & Tuning Tips All jetting is based on Standard Tuning Recommendations • Standard jetting • Unmodified Engine For the following recommendations to be accurate, you must use the standard settings as a TEMPERATURE CENT –30°~ –17° –18°~ –6° –7°~ 5°...
Carburetor Adjustments & Tuning Tips One 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 atmospheric conditions or race day situations that situations that may require additional...
Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments Gasoline is highly flammable and explosive. You can be burned or The standard carburetor settings are ideal for the seriously injured when handing fuel. following conditions: sea level altitude, and 68°F (20°C ) air temperature.
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Carburetor Adjustments & Tuning Tips 6. Change the main jet (3) and slow jet (4) as 8. Remove the carburetor and align the lug (5) 12. Remove the jet needle holder (9) and jet required. on the carburetor with the slot (6) on the needle (10) from the throttle valve (11).
Carburetor Adjustments & Tuning Tips NOTICE NOTICE Spark Plug Reading Using spark plugs with an improper heat range Improperly tightened spark plugs can damage the or incorrect reach can cause engine damage. engine. If a plug is too loose, a piston may be Refer to Spark Plug on page 54.
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 adjustable. changes in overall handling.
Unless you have the required mechanical down, and avoid unwanted wheelspin. The feelings can’t be trusted. Eliminating wheelspin knowhow, tools, and an official Honda Service engine may bog in certain corners so you’ll with a gearing change can make you feel like Manual, sprocket changing should be done by need to slip the clutch to compensate;...
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...
Handlebar Position, Width & Shape Apply Honda Thread Lock or an equivalent to the threads of these bolts prior to adjustment to help ensure the correct torque is retained.
Tips Here’s helpful advice on how to transport and store your Honda, as well as two troubleshooting flow charts. Transporting Your Motorcycle ......136 Storing Your Honda..........137 Preparation for Storage ........137 Removal from Storage.........137 You & the Environment ........138 Troubleshooting..........139 Tips...
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 against the front of the truck bed or trailer rail. you follow these guidelines: Attach the lower ends of two straps to the tie-down •...
9. Inflate the tires to their recommended Gasoline is highly flammable and pressures. explosive. You can be burned or 10. Place your CRF on the optional Honda seriously injured when handling fuel. workstand or equivalent to raise both tires off the ground.
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.
POSSIBLE CAUSES parenthesis. The items that require use of the FUEL FLOW • Lack of fuel in tank 1. Disconnect fuel Honda Service Manual are followed by an line at carburetor RESTRICTED (P-34) and check for • Clogged fuel line asterisk.
Technical Information This section contains dimensions, capacities, and Vehicle Identification ........142 other technical data. Specifications ...........143 Torque Specifications........144 High Altitude Carburetor Adjustment ....147 Oxygenated Fuels..........148 Competition Logbook ........149 Optional Parts List ...........151 Spare Parts & Equipment.........152 Wiring Diagram..........153 Technical Information...
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.
Specifications Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 86.3 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,191 mm Overall width Single 6˚ inclined from Transmission 5-speed, constant mesh 32.3 in 821 mm Cylinder arrangement vertical...
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...
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.
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.
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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...
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 308.0 lbf/in (5.50 kgf/mm) Standard 48 Teeth, Aluminum. Standard CARBURETOR Remarks <114>...
Spare Parts & Equipment There are numerous spare parts you can take to top end-complete Pro Honda HP Trans Oil or Pro Honda GN4 or an event to help ensure you get in a full day of radiator hoses HP4 (without molybdenum additives only) 4- riding.
Consumer Information This section contains information about Authorized Manuals .........156 contacting Honda and how to get an official Contacting Honda..........157 Honda service manual. Your Honda Dealer...........158 The Honda Rider’s Club (USA only) ....159 Consumer Information...
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...
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.
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.
Safety Foundation training. Separate free training from the Speciality 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.
Table of Contents The following presents the contents of each SERVICING YOUR HONDA......17 Chassis section of your owner’s manual. Before You Service Your Honda Suspension............74 The Importance of Maintenance .......18 Front Suspension Inspection......74 MOTORCYCLE SAFETY.......1 Maintenance Safety...........19 Rear Suspension Inspection......75 Important Safety Information......2...
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Standard Tuning Recommendation ....126 Contacting Honda..........157 Adjustments for Altitude & Temperature ...126 Your Honda Dealer..........158 Special Tuning Conditions......127 The Honda Rider’s Club (USA only) .....159 Pre-Adjustment Checks ......128 Carburetor Minor Adjustments ....128 Spark Plug Reading ........130 Chassis Adjustments........131 Rear End .............131 Fork Height/Angle ........131...
91 or higher tank: 1.90 US gal (7.2R) Engine oil Pro Honda GN4 or HP4 (without molybdenum additives) 4-stroke engine oil or an equivalent. Transmission oil Pro Honda HP Trans oil, Pro Honda GN4 or HP4 (without molybdem additives) 4-stroke engine oil, or an equivalent.