Honda CRF250X 2006 Owner's Manual & Competition Handbook
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Honda CRF250X 2006 Owner's Manual & Competition Handbook

Honda crf250x 2006
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2006
Honda CRF250X
OWNER'S MANUAL & COMPETITION HANDBOOK

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Summary of Contents for Honda CRF250X 2006

  • Page 1 2006 Honda CRF250X OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 2 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 3 A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, 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 4: 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 5: 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 6: 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 7: 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 8: 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 9: 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 10 Motorcycle Safety...

  • Page 11: Operating Controls

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

  • Page 12: Operation Component Locations

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

  • Page 13: 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 14: 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 15: 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 16 Before Riding...

  • Page 17: 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 18: 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 beginning on page 2 and the previous section,...

  • Page 19: 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 starts, push the choke knob back all the way to fully OFF. Your motorcycle can be started with the Always follow the proper starting procedure If idling is unstable, open the throttle slightly.

  • Page 20: 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 all the way in and start the engine.

  • Page 21: 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 22: 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 23: 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 24: 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 25: 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 26 Basic Operating Instructions...

  • Page 27: 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. Maintenance Component Locations....35 Additional Maintenance Procedures ....97 Seat Removal .............36 The ICM (Ignition Control Module) system is Fuel Tank Removal ..........37...

  • Page 28: 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 29: 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 30: 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 owner has the proper tools and service date and is mechanically qualified.
  • Page 31 90,91 STEERING HEAD BEARINGS Should be serviced by your Honda dealer, unless the owner has 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 32 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 33: 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 34: 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 35 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 36 (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 37: Before & After Competition Maintenance

    (2) pressure release screws side. This will ensure that the rear wheel is in proper alignment and allow maximum performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...
  • Page 38 If you decide to wash your motorcycle or use cleaners, refer to Appearance Care (page 101). Servicing Your Honda...

  • Page 39: Maintenance Component Locations

    Servicing Your Honda...

  • Page 40: Seat Removal

    2. Install the collars and tighten the seat bolts to the specified torque: 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 41: Fuel Tank Removal

    (4) breather tube (5) fuel tank band (6) air cleaner cover rubber (7) fuel tank bolt (10) (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 42 6. Install the fuel tank band (6). 7. Put the breather tube (7) in the steering stem 10. Install the seat (page 36). nut. (4) fuel tank bolt (6) fuel tank band (5) air cleaner cover rubber (7) breather tube Servicing Your Honda...

  • Page 43: Subframe Upright Position

    (11) (15) (15) screw (16) air cleaner connecting tube clamp (10) (19) subframe (5) air cleaner box cover (9) collars (6) quick fastener (10) left side cover (7) left side cover bolt (11) seat (8) seat bolt Servicing Your Honda...
  • Page 44 (16) right side cover (8) wire band (17) collars (18) seat bolt 5. Install the muffler (page 63). (19) right side cover bolt 9. Tighten the seat bolts to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) Servicing Your Honda...

  • Page 45: Fuel System

    (2) fuel filter of gasoline. If pinging or spark knock persists, WARNING consult your Honda dealer. 1. Check the fuel valve (1) and fuel filter (2) for contamination. Gasoline is highly flammable and Never use stale or contaminated gasoline.
  • Page 46 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) bolts Servicing Your Honda...

  • Page 47: Engine Oil

    JASO T 903 standard 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 48 • 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 49 (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 50: Transmission Oil

    NOT RECOMMENDED suggested oil* Pro Honda HP Trans oil, • Oil is a major factor affecting the performance Pro Honda GN4 or HP4 and service life of the transmission and clutch. (without molybdenum...
  • Page 51 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 52: Coolant

    Coolant Recommendation Checking & Adding Coolant Use Pro Honda HP Coolant or an equivalent high Refer to Safety Precautions on page 25. quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically 1. With the engine at normal operating recommended for use in aluminum engines.
  • Page 53 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 seal or the engine oil seal.
  • Page 54 Coolant should be replaced by your Honda 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 55: 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 56 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 57: 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 58: 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 59 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 60: 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 and plates may be worn. See your Honda dealer or refer to the Honda Service Manual (page 164). Servicing Your Honda...
  • Page 61 4. Remove the five clutch spring bolts and clutch (8) clutch lifter assembly 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 62 Replace the clutch discs and plates as a set. 4. Insert the clutch lifter rod into the mainshaft. 5. Install the clutch lifter (7) onto the rod. (2) clutch plate (6) clutch lifter rod (7) clutch lifter Servicing Your Honda...
  • Page 63 Clutch System 6. Install the clutch pressure plate (8). 11.Lubricate the dust seals (12), rear brake pedal (13) pivot and pivot bolt (14) with Honda 7. Install the five clutch springs and bolts (9). Lithium Grease or equivalent. 8. Tighten the bolts in a crisscross pattern in 2 or 12.

  • Page 64: Hot Start Lever

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

  • Page 65: 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 66: Exhaust Pipe/Muffler

    A damaged exhaust pipe and muffler may reduce engine performance. (5) muffler clamp bolt (7) muffler B bolt (6) muffler A bolt/washer (8) muffler (1) seat bolt (3) side cover bolt (2) collars (4) right side cover Servicing Your Honda...
  • Page 67 (11) (9) right side cover (11) side cover bolt (10) collars (12) seat bolt (6) muffler B bolt (8) muffler clamp bolt (7) muffler A bolt/washer (1) gasket (4) tab (2) muffler clamp (5) cut-out (3) muffler Servicing Your Honda...
  • Page 68 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 69: 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 70: Valve Clearance

    The clearance will change as engine temperature rises. (1) crankshaft hole cap (1) breather tube (2) direct ignition coil 4. Remove the cylinder head cover bolts (3), and cylinder head cover (4). (3) cylinder head cover bolts (5) packing (4) cylinder head cover Servicing Your Honda...
  • Page 71 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 bolt (5) index mark (4) “punch” mark (6) exhaust rocker arm Servicing Your Honda...
  • Page 72 (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 73 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 74 • 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 75 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 76 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) cam chain tensioner lifter caver bolt (13) (13) (13) feeler gauge Servicing Your Honda...
  • Page 77 Install the cylinder head cover packing into the groove of the cylinder head cover (4). (7) direct ignition coil (8) breather tube 5. Install the fuel tank and the seat (page 36, 38). (3) cylinder head cover packing (4) cylinder head cover Servicing Your Honda...

  • Page 78: Piston/Piston Rings/Piston Pin

    (7) radiator hose clamp 13.Remove the spark plug (6). valve (5) (california only). (8) radiator hose (1) air suction hose (4) PAIR control valve bolts/nuts (6) spark plug (2) vacuum hose (5) PAIR control valve (3) air supply pipe bolt Servicing Your Honda...
  • Page 79 (15) dowel pins (17) cam chain guide steps. (16) cylinder head gasket NOTICE Do not let the nuts, washers, valve lifters, shims, and cam chain fall into the crankcase. (14) (13) (13) cylinder head nuts/washers (14) cylinder head Servicing Your Honda...
  • Page 80 (2) cylinder 2. Remove the dowel pins (3) and cylinder gasket (4). NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 81 Piston Ring Installation We recommend you consult the Service Manual 1. Remove the carbon deposits from the piston oil ring or your authorized Honda dealer for correct crown and piston ring grooves with the Service Limit measurements. removed ring. 2. Apply engine oil to the piston rings and install them.
  • Page 82 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 83 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 84 (8) engine hanger nuts/bolts of the frame side Tighten the cylinder head nuts in a criss-cross (9) engine hanger nut/bolts of the engine side pattern in 2 or 3 steps. (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 85 12.Connect the vacuum (16) and air suction (17) hoses (california only). (17) (14) (16) (13) (15) (13) PAIR control valve (14) PAIR control valve bolts/nuts (15) air supply pipe bolt (16) vacuum hose (17) air suction hose Servicing Your Honda...

  • Page 86: 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 87: 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 88: 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 89 (10) O-ring (2) fork damper 7. Temporarily install the fork damper (2) to the outer tube (1). After installing the fork leg (page 115) tighten the fork damper to the specified torque: 23 lbf·ft (31 N·m, 3.2 kgf·m) Servicing Your Honda...

  • Page 90: Brakes

    6. Apply grease to the contacting faces of the 89), there is probably air in the brake system. adjuster and piston (3). (–) Refer to the Honda Service Manual or see your Honda dealer to have the air bled from the system. Front Brake Lever Adjustment...
  • Page 91 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 front brake lever freeplay exceeds 0.8 in...
  • Page 92 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 93 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 94: 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 95: Tires & Tubes

    Overinflated tires make your motorcycle ride 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 96 – ply, tube type Type • 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 97: 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 grease. Servicing Your Honda...

  • Page 98: 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 99 It should only be replacement chain or sprocket(s) will wear removed or replaced by your Honda dealer. rapidly. Excessively worn sprocket teeth have a hooked, worn appearance. Replace any...
  • Page 100 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: 1.2 in (31 mm) 2.

  • Page 101: Additional Maintenance Procedures

    Control Cables the fork bushings may be worn. Refer to the Honda Service Manual for replacement or Periodically, disconnect the throttle, clutch and adjustment procedures, or see your Honda hot start cables at their upper ends. Thoroughly dealer.
  • Page 102 RIGHT SIDE (9) cylinder head bolts (10) drive sprocket (1) cylinder head cover bolts (2) exhaust pipe joint nuts (3) water pump cove boltsr (4) crankshaft hole cap (5) transmission oil check bolt (6) clutch cover bolts Servicing Your Honda...

  • Page 103: Battery

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

  • Page 104: 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 105: 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 106 #7447-maroon) is for removing stains on the the chain lube. 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 107: 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 108: 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 109 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 110 Front Suspension Adjustments 3. Disconnect the head light connector (3). 5. Loosen the upper pinch bolts (6). 8. Remove the tripmeter cable (10) and front 6. Loosen the fork damper (7), using the lock axle nut (11) and loosen the axle pinch bolts nut wrench but do not remove it yet.
  • Page 111 Front Suspension Adjustments Do not support the brake caliper by the brake 12.Clean the fork assembly, especially the sliding NOTICE hose. Do not operate the front brake lever after surface of the slider (21) and dust seal (22). the front wheel is removed. To do so will cause The outer tube can drop on the slider and 13.Record the rebound damping adjuster position difficulty in fitting the brake disc between the...
  • Page 112 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 113 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 114 Front Suspension Adjustments 12.Screw in the lock nut (9) to the fork damper 8. Extend the fork damper piston rod to 10.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 115 Front Suspension Adjustments 15.Blow out the oil from the fork damper spring 13.Blow the extra oil off to the fork damper 14.Drain the extra oil from the fork damper chamber using compressed air to the oil hole. spring chamber (10) by pumping the fork spring chamber (10) oil hole (11).
  • Page 116 Front Suspension Adjustments 2. Tighten the lock nut (2) fully and measure the Fork Assembly thread length (A) as shown. Standard: 0.43 – 0.51 in (11 – 13 mm) 1. Drain the fork oil from the outer tube/slider by placing it upside down. Wipe the oil completely off the fork damper.
  • Page 117 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 118 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 marks (aftermarket parts) Standard oil 11.6 US oz (11) Standard oil 11.5 US oz...
  • Page 119 Front Suspension Adjustments 14.Check that the O-ring (12) on the fork damper 17.Tighten the fork damper (4) to the specified 19.Tighten the fork lower pinch bolts (13) to the assembly (4) is in good condition. Apply the torque using the lock nut wrench (14). specified torque: recommended fork oil to the O-ring.
  • Page 120 Front Suspension Adjustments 21.Clean the threads of the fork protector bolts 24.Check the left side collar (24) and tripmeter (18) and axle holder thoroughly. gear box (25) for wear or damage. (30) Apply locking agent to the fork protector bolt Install the left side collar (24) to the left wheel threads.
  • Page 121 Front Suspension Adjustments 27.Install the handlebar (34), mounting rubbers 29.Install and tighten the front visor bolts (39). NOTICE (35), washers and handlebar holder nuts (36) Install the handlebar pad (40). 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 32 Ibf·ft (44 N·m, 4.5 kgf·m)

  • Page 122: 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 123 Rear Suspension Adjustments High Speed Damping: Rear Suspension Damping The high speed damping can be adjusted by turning the hexagonal portion of the compression adjuster. Compression Damping Compression damping may be adjusted in two stages with separate adjusters. To adjust to the standard position: 1.
  • Page 124 Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded UNLOADED MEASUREMENT dimension (step 2). Setting the proper race sag (ride height) is very (without rider) EXAMPLE: 23.6 in (600 mm) Standard Race Sag: 3.9 in (100 mm)
  • Page 125 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 126: 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 127: 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 128 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 129 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 130: 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 131 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 132 Carburetor Adjustments & Tuning Tips 4. Remove the fuel tank (page 37). 8. Disconnect the throttle position sensor Carburetor Removal 5. Remove the band (2) and rear suspension connector (6). Remove the carburetor. upper mounting nut (3), and pull out the rear suspension upper mounting bolt (4).
  • Page 133 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. 4.
  • Page 134 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 135 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 136 Carburetor Adjustments & Tuning Tips Idle Speed Adjustment 1. If the engine is cold, start it and warm it up three minutes. Then shut it off. 2. Connect a tachometer to the engine. 3. Shift into neutral. Start the engine. 4.

  • Page 137: 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 138: Gearing

    (before and after the change) to get an accurate knowhow, tools, and a Honda Service Manual, appraisal of the change. “Seat-of-the-pants” sprocket changing should be done by your Honda For tight tracks, consider lower gearing to avoid feelings can’t be trusted. Eliminating wheelspin dealer.

  • Page 139: 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 140: 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 141: 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 142: 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 143: Storing Your Honda

    Honda and correct any problem before After the coolant has been completely 10.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 144 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 145: You & The Environment

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

  • Page 146: 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 147: 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 148: 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 149: 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 150 Taking Care of Unexpected...

  • Page 151: 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 152: 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 153: Specifications

    Specifications For USA (except California) & CANADA Item English Metric Item English Metric Item English Metric Dimension Engine Drive train Overall length 85.5 in Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type 2,172 mm Overall width Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement...
  • Page 154 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 85.5 in 2,172 mm Overall width Transmission 5-speed, constant mesh 32.6 in 827 mm Cylinder arrangement Overall height 49.6 in...

  • Page 155: 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 156 Rear shock link nuts NOTE 2, 4 Shock spring lock nut Kickstarter arm bolt (12) NOTES: 1. Apply Honda Thread Lock or an equivalent to the threads. 2. Apply oil to the threads and flange surface. (18) 3. Stake. 4. U-nut. (17) 5.
  • Page 157 0.12 Side stand mounting bolts (upper) (lower) (27) NOTES: 1. Apply Honda Thread Lock or an equivalent to the threads. (28) 2. Apply oil to the threads and flange surfaces. (26) 3. Stake. (27) 4. U-nut. (30) (31) 5. UBS nut.

  • Page 158: 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 159: 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 160: 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 161: 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 162 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) Technical Information...

  • Page 163: 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 <116>...

  • Page 164: Spare Parts & Equipment

    (front & rear) additives) 4-stroke Oil Spare Parts (Engine Oil) Pro Honda HP Trans Oil or Pro Honda GN4 or General Tools spark plugs HP4 (without molybdenum additives only) 4- air cleaner (clean & oiled, sealed in a plastic bag) stroke Oil (Engine Oil) chain &...

  • Page 165: Wiring Diagram

    Wiring Diagram Technical Information...
  • Page 166 Technical Information...

  • Page 167: 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 168: 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 169: 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 170: 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 171: 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 172: Table Of Contents

    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......2...
  • Page 173 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 ......168 INDEX ............170 QUICK REFERENCE........174 Table of Contents...

  • Page 174: Index

    ........101 installation ............64 tire selection..........91 clutch system, adjustment........56 after competition maintenance......33 consumer information........163 air cleaner............51 competition logbook ........157 air pressure, contacting Honda ..........165 filter, front suspension..........104 controls, operating ..........8 air ..............51 tires ...............91 coolant..............48 oil ..............44 apparel, protective..........2 cylinder removal ..........76...
  • Page 175 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 component locations ........35 basic operation..........13...
  • Page 176 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 inspection............91 selection ............92 tools..............160 torque specifications.........151-153 transporting ............138 tripmeter.............14 troubleshooting ..........142 tubes, replacing ..........91 valve, fuel ............15 valve clearance...........66 vehicle identification ........148...
  • Page 177 Memo...
  • Page 178 Memo...
  • 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 80/100 – 21 51 M 100/100 –...

Table of Contents